Honda - Civic (02-03) Service Manual OCRed

INTRODUCTION
General Info
How to Use This M a n u a l - - - - - - - - - - - ,
This manual is divided into 23 sections. The first page of each section is marked with a black tab that lines up with its corresponding thumb index tab on this page and the back cover. 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 a quick reference system. Each section includes: 1. A table of contents, or an exploded view index showing: Parts disassembly sequence . Bolt torques and thread sizes. Page references to descriptions in text. 2. Disassembly/assembly procedures and tools. 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments.
Specifications Maintenance Engine Electrical Engine Cooling Fuel and Emissions
Safety Messages-----------------,
Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgment.
I
You will find important safety information in a variety of forms including: Safety Labels - on the vehicle. Safety Messages - preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean:
1-*TransaXle
m"'jW@fj
"tt"IIt.)~1
You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be HURT if you don't follow instructions.
~========~ *Steering
Suspension *Brakes (Including ABS) *Body *Heating, Ventilation and Air Conditionin *Body Electrical *Restraints
B1
Instructions - how to service this vehicle correctly and safely.
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 publication may be reproduced, or stored in a retrieval system, or 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. As you read this manual, you will find information that is preceded by a INOTICEI symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.
First Edition 8/2002 1,168 pages HONDA MOTOR CO., LTD. All Rights Reserved Service Publication Office Specifications apply to U.S.A. and Canada
As sections with *inclode SRS components; special precautions are required when servicing.

General Information
Chassis and Paint Codes -2002 Model ....................................... 1-2 Chassis and Paint Codes -2003 Model....................................... 1-3 Identification Number Locations ........ 1-4 Warning/Caution Label Locations 1-5
Under-hood Emission Control Label .................... ................. 1-7
Lift and Support Points ........................ 1-8

Towing .................................................. 1-9 Parts Marking Locations ...................... 1-10
General Information
Chassis and Paint Codes - 2002 Model
Vehicle Identification Number
SHH EP3 3 5 2 U 300001
Engine Number
K20A3 - 1700001
IIITiITTb cdefgh
I Ib
a. Manufacturer, Make and Type of Vehicle SHH: HONDA OF THE U.K. MFG., LTD. U.K. HONDA Passenger vehicle b. Line, Body and Engine Type EP3: CIVIC/K20A3 c. Body Type and Transmission Type 3: 2-door Hatchback/5-speed Manual d. Vehicle Grade (Series) 5: Si (U.S.) 5: SiR (Canada) 6: Si with side airbag system (U.S.) 6: SiR with side airbag system (Canada) e. Check Digit f. Model Year 2:2002 g. Factory Code U: Honda of U.K. Manufacturing in Swindon, England h. Serial Number U.S.: 300001Canada: 600001-
a. Engine Type K20A3: 2.0 ~ DOHC VTEC Sequential Multiport Fuel-injected engine b. Serial Number
Transmission Number
NRH3
- 1000001
I Ib
8. Transmission Type
NRH3: 5-speed Manual b. Serial Number
Paint Code
Code B-92P NH-57B NH-623M R-B1 Y-62P Color Black Pearl Taffeta White Satin Silver Metallic Milano Red Euro Yellow Pearl
Ni~hthawk
U.S.
Canada
I
--!
---
Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification! Color label.
1-2
Chassis and Paint Codes - 2003 Model

Vehicle Identification Number Engine Number
SHH EP3 3 5 3
U 400001
K20A3
- 2700001
IIITrTTTb cdefgh
I Ib
a. Manufacturer, Make and Type of Vehicle SHH: HONDA OF THE U.K. MFG., LTD. U.K. HONDA Passenger vehicle b. Line, Body and Engine Type EP3: CIVIC/K20A3 c. Body Type and Transmission Type 3: 2-door Hatchback/5-speed Manual d. Vehicle Grade (Series) 5: Si (U.S.) 5: SiR (Canada) 6: Si with side airbag system (U.S.) 6: SiR with side airbag system (Canada) e. Check Digit f. Model Year 3:2003 g. Factory Code U: Honda of U.K. Manufacturing in Swindon, England h. Serial Number U.S.: 400001Canada: 700001-
a. Engine Type K20A3: 2.0 e DOHC VTEC Sequential Multipart Fuel-injected engine b. Serial Number
Transmission Number
NRH3
- 2000001
I Ib
a. Transmission Type NRH3: 5-speed Manual b. Serial Number
Paint Code
Code B-92P B-520P NH-578 NH-623M R-81 Y-62P Color NiQhthawk Black Pearl Vivid Blue Pearl Taffeta Wh ite Satin Silver Metallic Milano Red Euro Yellow Pearl U.S. Canada
0-
..
.
Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification! Color Label.
L
1-3
..
Generallnformation
Identification Number Locations
Vehicle Identification Number IVIN)
Vehicle Identification Number (VIN)
------------------
~_:7
-------- ---------- ---- -- - --- - - - - - ---------
Engine Number Transmission Number
1-4
Warning/Caution Label Locations

NOTE: FRONT PASSENGER AIRBAG WARNING TAG (CHILD SEAT) is installed on the glove box on the U.S. model.
Steering Wheel:
DRIVER MODULE DANGER CABLE REEL CAUTION
Passenger's Compartment:
SRS INFORMATION
U.S. model
SRSWARNING INFORMATION FRONT PASSENGER MOOULE OANGER MONITOR NOTICE
SlOE MOOULE DANGER SIDE AIRBAG CAUTION

Located on driver's and passenger's doorjamb (not shown}
(cont'd)
1-5
Generallnformation
Warning/Caution Label Locations (cont'd)
SERVICE INFORMATION LABEL SRS WARNING LABEL Information label I and ENGINE COOLANT INFORMATION
(Underhood Emission Control
i/~;;-, ~i~
_f
- - L __
~-
______
----~
TIRE INFORMATION
---- -------
RADIATOR CAP CAUTION
AIR CONDITIONING INFORMATION
BATTERY CAUTION
1-6
Under-hood Emission Control Label

Emission Group Identification
Example: 2002 model
Engine and Evaporative Families:

Engine Family:
2 HNX V 02.0
VBP
abc d
I I I Ie I
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5 AND NLEV LEV REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV II LEV PASSENGER CARS. Example: 2003 model
a. Model Year 2: 2002 3:2003 b. Manufacturer Subcode HNX: HONDA c. Family Type V: LDV d. Displacement e. Sequence Characters VBP: 2002 XKC: 2003
THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5 AND NLEV LEV REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW LEV II LEV PASSENGER CARS.
Evaporative Family:
2 HNX R 0099
AAH
abc d
I I I Ie I
a. Model Year 2: 2002 3:2003 b. Manufacturer Subcode HNX: HONDA c. Family Type R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters AAH: 2002 AAA: 2003
1-7
General Information
Lift and Support Points
NOTE: If you are going to remove heavy components
such as suspension or the fuel tank from the rear of the
Floor Jack
1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform Ie), and jack up the vehicle high enough to fit the safety stands under it.
vehicle, first support the front of the vehicle with tali

safety stands. When substantial weight is removed
from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist.
Frame Hoist
1. Position the hoist lift blocks (A), or safety stands,
under the vehicle's front support points (8) and rear support points (e).
2. Raise the hoist a few inches, and rock the vehicle
gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspectthe lift points for solid contact with the lift blocks.
c
5. Position the safety stands underthe support points and adjust them so the vehicle will level.
6. Lower the vehicle onto the stands.
Safety Stands
To support the vehicle on safety stands, use the same support points (B and e) as for a frame hoist. Always
use safety stands when working on or under any
vehicle that is supported only by a jack.
1-8
Towing
If the vehicle needs to be towed, call a professional
towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment - The operator loads the vehicle Wheel Lift Equipment - The tow truck uses two pivoting arms that go under the tires (front or rear) and
lifts them off the ground. The other two wheels remain on the ground. This is an acceptable way of towing the vehicle.
Sling-type Equipment - The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted.
on the back of a truck. This is the best way of

transporting the vehicle.
To accommodate flat-bed equipment, the vehicle is equipped with towing hooks (A) and tie down hooks (B). The towing hook can be used with a winch to pull the
vehicle onto the truck, and the tie down hooks slots can be used to secure the vehicle to truck.
If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following: Release the parking brake. Shift the transmission in Neutral. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h).
iNOTICEi
Improper towing preparation will damage the transmission. Follow the above procedure exactly. If
you cannot shift the transmission, the vehicle must
be transported on a flat-bed . Trying to lift or tow the vehicle by the bumpers will
cause serious damage, The bumpers are not
designed to support the vehicle's weight.
1-9
Generallnformation
Parts Marking
To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original
parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engine or
transmission VIN plate is transferred to a replacement engine or transmission and attached with break-off bolts.
NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.
1-10
I.
Specifications
Standards and Service Limits
Engine Electrical .................................................... Engine Assembly .................................................. Cylinder Head ........................................................ Engine Block .......................................................... Engine Lubrication ................................................ Cooling ................................................................... Fuel and Emissions ............................................... Clutch ..................................................................... Manual Transmission and Differential ................ Steering .................................................................. Suspension ............................................................ Brakes ..................................................................... Air Conditioning .................................................... 2-2 2-2 2-3 2-4 2-5 2-5 2-6 2-6 2-7 2-9 2-9 2-10 2-10
specs
Design Specifications
Dimensions ............................................................ Weight (U.S.A.) ...................................................... Weight (CANADA) ................................................. Engine .................................................................... Starter .................................................................... Clutch ..................................................................... Manual Transmission ........................................... Steering .................................................................. Suspension ............................................................ Wheel Alignment .................................................. Brakes ..................................................................... Tires ........................................................................ Air Conditioning .................................................... Electrical Ratings ................................................... 2-11 2-11 2-11 2-11 2-11 2-11 2-11 2-12 2-12 2-12 2-12 2-12 2-12 2-13
Body Specifications
Illustration .............................................................. 2-14

Engme EI ectrlca
Item Ignition coil
Measurement Rated voltage
-~
Qualification
Standard or New
---
Service Limit
.Ev_________ ----1-3-4-2 NGK: IZFR6Kll DEN SO: SKJ20DR-Mll
Firing order Spark plug
--
Type Gap
'1.0-1.1 mm (0.039-0.043 in.)

At idle (check the red mark) in neutral: 82 BTDC at 65050 rpm
I 1.3 mm (0.051 in,)
Ignition timing Alternator
Output
At 13.5 V and
normal engine
80A
1
temperature Coif (rotorl resistance

Slip ring 0.0.
At 68"F 120"CI
2.2-3.0
14.4 mm (D.S7 in.)

10.5 mm (0,41 in.)
, '4.0 mm (0,55 in.!
Brush length
Brush spring tension
I 1.5 mm 10.06 in.1

0.20 mm (0.008 in.)
2.9-3.5 N (0,30-0.36 kgf, O.7-0.Blbs)
Starter
Output
Commutator mica depth
1.1 kW 0.50-0.80 mm (0.020-0.031 in.) 0.02 mm (0.001 in.) max.

2S.0 mm (1.10 in.)
14.0-14.5 mm (0.55-0.57 in.)
Commutator run cut Commutator O.D.

Brush length
0.05 mm 10.002 in.1

27.0 mm (1.06 in.) 9.0 mm (0.35 in.)
,Iy Ename Assem bl

Hem Compression
Measurement
Pressure check at 250 rpm with wide open throttle. (See Design Specs for ratio)
Qualification
Minimum Maximum variation
Standard or New
930 kPa (9.5 kgf/cml, 135 psi)
I
i
Service Limit
200 kPa 12.0 kgf/em', 28 psi I
2-2
;ylln c r d er Hea d
Item
Head
Measurement
Qualification
Standard or New
Service Limit
Warpage Height
0.05 mm (a.D02 in.)
103.95- 104.05 mm
. (4.093-4.096 in.1 0.05-0.20 mm (0.002-0.008 in.)
No.1 journal No.2, 3, 4, 5 journals
Camshaft
End play
Camshaft-to-holder oil clearance
0.4 mm (0.02 in.)
0.030-0.069 mm (O.OOl-0.003 in.) ' 0.060-0.099 mm (0.002- 0.004 in.)

0.03 mm (0.001 in.) max.
0.15 mm W,006 in.) 0.'5 mm (0.006 in.)

0.04 mm (a.D02 in.)
Total runout
Cam lobe height
Intake, primary Intake, secondary

.
,
33.925 mm (1.3356 in.) 29.638 mm 11.1668 in.) 34.092 mm (1.3422 in.) 0.21-0.25 mm (0.008-0.010 in.) 0.28-0.32 mm (0.01' -0.013 in.)
5.475-5.485 mm (0.2156-0.2159 in.) 5.450-5.460 mm (0.2146-0.2150 in.) 0.030-0.055 mm (0.0012-0.0022 in.) 0.055-0.080 mm (0.0022-0.0031 in.) 1.25-1.55 mm (0.049-0.061 in.) 1.25-1.55 mm (0.049- 0.061 in.) 40.8-- 41.0 mm (1.606-1.614 in.) 54.6-54.8 mm (2.150-2.157 in.) 47.61 mm (1.874 in.) 49.64 mm (1.954 in.) 5.515-5.530 mm (0.2171-0.2177 in.) 5.515 '-5.530 mm (0.2171-0.2177 in.) 15.2--16.2 mm (0.598-0.638 in.) 15.5- 16.5 mm (0.610-0.650 in.) 0.025- 0.052 mm (0.0010-0.0020 in.) 0.018-0.056 mm (0.0007 -0.0022 in.) 0.08 mm (0.003 in.) 0.08 mm (0.003 in.) 5.55 mm (0.219 in.) 5.55 mm (0.219 in.) 5.445 mm (0.214 in.) 5.42 mm (0.213 in.) 0.08 mm (0.003 in.) 0.11 mm (0.004 in.) 2.00 mm (0.079 in.) 2.00 mm (0.079 in.)
Exhaust
Intake Exhaust
Valves
Clearance (cold)
Stem D.D.
Stem-ta-guide clearance Valve seats Width Stem installed height Valve springs Valve guides Free length
I
Intake
Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
1.0.
Installed height Rocker arms Arm-to-shaft clearance
Intake Exhaust Intake Exhaust
2-3

Engme 81 ock
nem
Block
Measurement
Warpage of deck Bore diameter
Qualification
Standard or New
Service limit
0.10 mm (0.004 in.)
I 0.07 mm (0.003 in.) max.

86.010- 86.020 mm
113.3862- 3.3866 in.1 B or II
IAorl
I!
186.070 mm (3.3886 in.)

186.070 mm 13.38S""6ir0
186.000-86.010 mm (3.3858- 3.3862 in,)
Bore taper Rebaring limit

Piston
0.05 mm (O.OO~_~ 0.25 mm (0.01 in.)

No letter or A 85.980 -85.990 mm 13.3850-3.3854 in.I' 85.930 mm 13.3831 in.1 85.970-85.980 mm 13.3846- 3.3850 in.1 85.920 mm (3.3827 in.)
Skirt 0.0. at 11 mm (0.4 in.) from
bottom of skirt
Clearance in cylinder Ring groove width
I Letter B
. Top Second
0.020-0.040 mm (O.Og08-0.0016 in.) 1.220-1.230 mm (0.0481-0.0484 in.) 1.220-1.230 mm {Q.0481-Q.0484 in.}
0.05 mm (C.D02 in,) ,,_ '1.25 mm (0,049 in.) 1.25 mm (O.049 in,)
r-Pi~ton ring
--+
i
. I
Ri~g-to-groove clear~~---'~'--
Oil
2.005 -2.025 mm (0.0789

-
~r:nm (D.OSl in.) o.6~-.~-io~0.0~) I 0.13 ~m (0.005 j~'.)

0.0797 in.).
0.13 mm (0.005 in.) 0.13 mm (0.005 in.) 0.60 mm (0.024 in.) 0.70 mm (0.028 in.)
Second (REKEN) , Second (FEDERAL MOGULI Top Second

I'
0.030 -0.055 mm (0.0012-0.0022 in.) 0.025" 0.060 mm (0.0010-0.0024 in.) 0.20' -0.35 mm (0.008- 0.014 in.) 0.40-0.55 mm (0.016-0.022 in.)
Ring end gap
1-0c-iC--::IR"E"K"E"N"c-_--j-'0.25 -0.65 mm (0.0_~_0_0_.0_2_6_in_.I_ _ . . 0.75 mm (0.030 in.) 0.80 mm (0.031 in.) Oil (FEDERAL ! 0.20-0.70 mm (0.008-0.028 in.)
MOGULI Piston pin 1-::..:.::.".~-c---------Pin-to-piston clearance
-+--.___..__ .~:-_2_1._96_5mm 1O.8646_0_._86_48",i",n:'j.1..:2,-,1:.::.95_3_m_m_IO,8_64_3_in_.1

-0.005- --+- 0.002 mm (-0.00020- + 0.005 mm (0.0002 in.)
I
Pin-to-rod clearance
I 0.00008 in.1
0.005--0.015 mm 10.0002-0.0006 in.1 1.02 mm 10.0008 in.1 21.976 mm (0.8~50 - 0.865,,2."in."''11_ _ _ _ _ _ _ _--j _--'-'_ _ _ _ _ _ _ _--j 0.40 mm (0.016 in.) __ _
Connecting rod
, S_m~a~II-_e_n_d~b~o~re~d_i_am~e-,-te~r_ _ _ _-,-___ ~_ _ _--+,_2_1_.970 fEnd play installed on crankshaft Crankshaft Main journal diameter , No.1 journal No.2 journal
f--La_r~g~e-_e_n_d_b_o_re_d_i_am_e_te_r_IN_o_r_m_a_I~1--l________+-4_8_.0_m m_I_1_.8~9in.) __
0.15-0.30 mm (0.006 -0.012 in.) , 54.984-55.008 mm (2.1648-2.1657 in.)1

I '
No.4 journal No.5 journal I-N"o':.-=3'"'j"O"u"rn"'a"-1--+5-4-.976- 55.000 mm (2.1644 - 2. 1654 in.) Rod journal diameter
1-'
i'
44.976
45.000 mm (1.7707 --'.7717 in.) 0.010 mm (0.0004 in.) 0.010 mm (0.0004 in.) 0.45 mm (0.018 in.) '0.050 mm (0.0020 in.)
I'
"Ro::.d::i."m"a",in."I,, o:.::u:.:rn"ac.l"ta"p:.::e."r_ _ _ _--l_______+0-'-.0:..:0:.::5-'m"m l.::.O:.::.O.::.00:::2=in .) max. ccc
I-R"o::.d::.i"m"a",in.",,,o:.::u:.:rn,,ac.I_"o,,ut:..-o,:i,,-r:.::o:.::u:..n,,d_ _ End play
+ ______--+-'0=.005 mm (0.0002 in.) max.

0.10- 0.35 mm (0.004-0.014 in.) No.1 journal No.2 journal No.4 journal . No.5journal 10.017 -0.041 mm (0.0007 --- 0.0016 in.)
~~~---------+------~+------
I Runout Crankshaft bearings Main bearing-to-journal oil clearance
' 0.03 mm (0.0012 in.) .. m",a"x:..._____--+-"0::-.0-:4-'m=m"I,,0:.:-.0,,0"'16 in"'.I--j ....
I
i \
_._~
0.021
" -::Ro-d-:-:-be-a-r-;-in-g-cC"le-a-r-an-c-e------+-~~-~-
No.3 journal
~~0.049
mm (o.0~10-0.0019 in.) 0.049 mm (0.0008 0.0019 in.)
0.055 mm (0.0022 in.) 0.060 mm (0.0024 in.)
2-4
Engme Lb u neatlon
Item
Engine oil
Measurement Qualification
Standard or New
5.32 (5.6 US qt) for engine overhaul
Service Limit
Capacity
4.2 Q (4.4 US qt) for oil change, including filter

4.0 ij (4.2 US qtl for oil change, without filter Oil pump Inner-ta-outer rotor clearance Pump housing-ta-outer rotor clearance
i Pump housing-ta-rotor axial
0.02-0.16 mm (0.001 -0.006 in.)
0.20 mm (0.008 in,) 0.23 mm (0.009 in.)
! 0.15-0.21 mm (D,006-0.00B in.)

0.02-0.07 mm (0.001-0.003 in.)
NO.1 journal, front
0.12 mm (0.005 in.)
clearance Balancer shafts, journal diameter
19.938-19.950 mm 10.7850-0.7854 in.1 19.92 mm (0.784 in.)

23.938--23.950 mm (0,9424-0.9429 in.) 23.92 mm (0.942 in.)
I shaft
No.1 journal, rear shaft No.2 journal, front and : 32.949-32.961 mm (1.2972-1.2977 in.) 32.93 mm (1.296 in.)
e::--:---- ...
rear shaft 0.005 mm (0.0002 in.) max. Front Rear . No.1 journal, front shaft No.1 journal. rear shaft No.2 journal, front and rear shaft 0.070-0.135 mm (0.0028-0.0053 in.) 0.070-0.135 mm (0.0028-0.0053 in.) 0.050-0.082 mm (0.0020-0.0032 in.)
Balancer shafts, journal taper Balancer shafts, end play
0.15 mm (0.006 in.) 0.15 mm (0.006 in.) 0.10 mm (0.004 in.) 0.10 mm (0.004 in.) 0.15 mm (0.006 in.)
Balancer shafts, shaft-to-bearing clearance
1
0.050-0.082 mm (0.0020-0.0032 in.) 0.060--0.120 mm (0.0024-0.0047 in.)
,
Balancer shaft bearings, 1.0.
i
No.1 journal, front shaft
20.000-20.020 mm (0.7874-0.7882 in.) 20.03 mm (0.789 in.)
. . NO.1 Journal, rear shaft : 24.000-24.020 mm (0.9449- 0.9457 in.) 24.03 mm (0.946 in.)
33.021 -33.069 mm (1.3000-1.3019 in.) 33.09 mm (1.303 in.) 70 kPa (0.7 kgf/cm', 10 psi) min. 300 kPa (3.1 kgf/cm', 44 psi) min. rear shaft
No.2 journal, front and Reliefvalve, oil pressure with oil temperature at 176F (SoOe) At idle At 3,000 rpm
coomg r
Item Radiator Reservoir Radiator cap Thermostat
Measurement Coolant capacity {includes engine, heater, hoses, and reservoir} Coolant capacity Opening pressure Opening temperature Valve lift at fully open
Oualification Engine overhaul Coolant change
Standard or New
Service Limit
6.7L 17.1 US qtl 5.0 L (5.3 US qt) 0.53 L (0.56 US qtl

,93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi)
Begins to open Fully open
169-176'F (76-80'CI 194'F (90'CI

8.0 mm W.31 in.) min.
Radiator fan switch
Switching temperature
Turns ON Turns OFF
196-203'F (91-95'CI
Subtract 5-- 15F (3-8"C) from actual ON temperature
2-5

Fuel and Emissions
kern
Fuel pressure regulator Fuel tank Engine idle Measurement Pressure with fuel pressure gauge
Qualification
Standard or New I 320-370 kPa 13.3" 3.8 kgf/cm', 47 -52 psi I

50~113.2USgall
Service Limit
connected
Capacity Idle speed with headlights and radiator fan off Fast idle
Neutral
Neutral
750=50 rpm 1,600+50 rpm
Clutch
kern
Measurement
Qualification
Standard or New
193 mm (7.60 in.)
Service Limit
Clutch pedal
Height from the floor
Stroke
Play
Disengagement height from the floor
.
130-140 mm (5.1-5.5 in.)

10- 16 mm (0.39-0.63 in,)
115 mm (4.53 in.) min.
.-
Flywheel Clutch disc Pressure plate
Runcut on clutch mating surface
0.05 mm (0.002 in.) max.
0.15 mm (0.006 in.)
Rivet head depth

Thickness Warpage Height of diaphragm spring fingers Measured with special tool and feeler gauge
1.65-2.25 mm (0.065-0.089 in.)

8.3-8.9 mm (0.33-0.35 in.) 0.03 mm (0.001 in.) max. 0.6 mm (0.02 in.) max.
0.7 mm (O.03 in.)

6.0 mm (0.24 in.) 0.15 mm (0.001 in.) 0.8 mm (0.03 in.)
2-6
Manual Transmission and MIT Differential

Item
Transmission Measurement
Oualification
I
Standard or New For fluid change: 1.52 (1.6 US qt)

, For overhaul: 1.7 Q. (l.B US qt)
Service limit
Capacity
End play
Diameter of bushing surface
fluid
Mainshaft
0.11 --0.17 mm (0.004-0.007 in.)
Adjust
20.75 mm (0.817 in.) 31.93 mm (1.257 in.)
20.80-20.85 mm (O.alS-D.a2l in.) 31.984-32.000 mm (1.2594-1.2598 in.) 27.977-- 27.990 mm (1.1015-" 1.1020 in.)
Diameter of distance collar Diameter of ball bearing contact area

(clutch housing side)
27.92 mm (1.099 in.)
Diameter of needle bearing contact

area
38.984-39.000 mm 11.5348 -1.5354 in.) 27.987-28.000 mm (1.1019

0.02 mm (0.001 in.) max. 44.009-44.025 mm 0.7326 0.06-0.16 mm (0.002-0.006 in.) 23.92-23.97 mm (0.941-0.944 in,) 35.000-35.015 mm (1.37S0-1.3785 in.) 39.937-39.950 mm (1.5723-1.5728 in.) 30.020-30.033 mm (1.1819--1.1824 in.) 0.02 mm (0.001 in.) max. 0.04-0.10 mm (0.0016-0.0039 in.) 52.010- 52.029 mm (2.0476-2.0484 in.) 0.06--0.16 mm (0.002-0.006 in.) 22.92-22.97 mm (0.902'-0.904 in.) 52.010-52.029 mm (2.0476-2.0484 in.) 0.06-0.16 mm (0.002-0.006 in.) 27.92- 27.97 mm (1.099-1.101 in.) 39.95-39.96 mm (1.5728-1.5732 in.) 46.989--47.000 mm (1.8499-1.8504 in.) 23.03 -'-23.08 mm (0.907-0.909 in.) 39.95-39.96 mm (1.5728-1.5732 in.) 46.989-47.000 mm (1.8499---1.S504 in.) 28.03-28.08 mm (1.104 1.106 in.)
38.93 mm (1.533 in.)

27.93 mm (1,100 in.)
0.05 mm (0.002 in.)
Diameter of ball bearing contact area (transmission housing side) Runout Mainshaft 3rd, 4th and 5th gears Countershaft
1.1024 in.)
1.0.
End play Thickness Diameter of needle bearing contact area (clutch housing side) Diameter of distance collar contact area Diameter of ball bearing contact area (transmission housing side) Runout 35 mm shim-to~bearing inner race clearance
1.7333 in.}
44.0S mm (1.735 in.) 0.25 mm (0.010 in.) 23.S0 mm (0.937 in.) 34.95 mm (1.376 in.) 39.88 mm (1.570 in.) 29.97 mm (1.180 in.) 0.05 mm (0.002 in.) Adjust 52.0S mm (2.050 in.) 0.25 mm (0.010 in.) 22.S7 mm (0.900 in.) 52.08 mm (2.050 in.) 0.25 mm (0.010 in.) 27.87 mm (1.097 in.) 39.97 mm (1.574 in.) 46.94 mm (1.848 in.)
.
Countershaft 1st gear Countershaft 2nd gear Countershaft 1st gear distance collar Countershaft 2nd gear distance collar
1.0 .
End play Thickness
1.0.
End play Thickness
1.0. 0.0.
Length
1.0. 0.0.
Length
39.97 mm (1.574 in.) 46.94 mm (1.848 in.)
2-7

Manual Transmission and Differential (cont'd)
Item
Mainshaft 4th
I.D. D.D.
Length A
Measurement
Qualification
32.00~32.01
Standard or New
mm (1.2598--1.2602 in.)
Service Limit
32.02 mm (1.261 in.)
and 5th gears

distance collar

MBS distance
collar Reverse idler gear Synchro ring Triple cone synchro
--

28.00-28.01 mm (1.102-1.103 in.) 23.95-24.05 mm (0.943-0.947 in.)
0.036 - 0.084 mm (0.0014
38.989-39.000 mm (1.5350 1.5354 in.) 51.95-52.05 mm (2.045-2.049 in.) 24.03-24.08 mm 10.946-0.947 in.)
38.94 mm (1.533 in.)
I.D.
Length
28.02 mm (1.103 in.)

20.90 mm {O.832 in.}
I.D.
Gear-to-reverse gear shaft clearance
Ring-ta-gear clearance
20.016-20.043 mm (0.7880-0.7891 in.) 0.0033 in.)
0.16 mm (D.OOS in.) 0.4 mm (0.016 in.)

0.3 mm (0.012 in.) 0.3 mm W.012 in.) 0.6 mm (0.024 in.)
Ring pushed against gear Ring pushed against gear Ring pushed against gear Ring pushed against gear
0.70 - 1.49 mm (0.028-0.059 in.) 0.70 - 1.19 mm W.028 -0.047 in.)

'0.50-1.04 mm (0.020-0.041 in.) 0.95-1.68 mm (0.037-0.066 in.) 7.4-7.6 mm W.29-0.30 in.) 0.35-0.65 mm (0.014-0.026 in.)
Outer synchro ring-to-synchro cane clearance Synchra cone-to-gear clearance Outer synchra ring-ta-gear cone clearance Finger thickness Fork-to-synchro sleeve clearance Finger thin~_~_~~s Fark-ta-reverse idler gear clearance
Shift fork Reverse shift fork Shift arm
1.0 mm (0.039 in.)

~-
_.
13.4-13.7 mm W.527-0.539 in.) 0.20-0.59 mm (0.007-0.024 in.) 13.973-14.000 mm W.5501-0.5512 in.) 16.9 -17.0mm(0.665 0.669 in.) 0.62 mm (0.024 in.) 0.50 mm (0.020 in.) 0.1 mm (0.004 in.) 0.1 mm (0.004 in.) 1.3 mm (0.051 in.)
J.D.
Shift fork diameter at contact area Shift arm-to-shift lever clearance
, 0.2
0.5 mm (0.008- 0.020 in.)
Select lever Shift lever
Finger width Shaft-ta-select lever clearance Groave (to select lever) Shaft-ta-shift arm clearance
14.85-14.95 mm (0.585-0.589 in.) 0.05-0.25 mm (0.002-0.010 in.) 15.00- -15.10 mm W.591---0.594 in.) 0.013-0.07 mm (0.0005-0.003 in.) 18.010-18.028 mm (0.7091-0.7098 in.) 0.027-0.057 mm (0.0011-0.0022 in.) 28.025-28.045 mm (1.1033- 1.1041 in.) 0.05-0.15 mm(O.002-0.006 in.) 18.042-18.066 mm (0.7103- 0.7113 in.) 0.059-0.095 mm (0.0023-0.0037 in.) 0-0.10 mm (0 0.0039 in.) 0.15 mm W.OOG in.) Adjust
MIT
differential carrier
Pinion shaft contact area I.D. Carrier-to-pinion shaft clearance Driveshaft contact area I.D. Backlash
MIT
differential pinion gear 80mmshim
I.D.
Pinion gear-to-pinion shaft clearance 80 mm shim-to-bearing outer race clearance in transmission housing
2-8
5 teermg
~em
Measurement
Rotational play measured at outside
edge with engine running Starting load measured at outside
edge with engine running
Qualification
Steering wheel
Standard or New 0- 10 mm (0-0.39 in.)

29 N (3.0 kgf, 6.6 Ibsl
Service Limit
Gearbox
Angle of rack guide screw loosened from locked position
5 Max.
5 uspenslon
Item
Wheel alignment Camber
Measurement
Qualification
Front
Rear
Standard or New
-0"00' _45'
Service limit
-045' __ 45' 1 33'1

Q
Caster Total Toe

I Front wheel turning angle
Front
I Front
Rear
O_3mmW -:0.12 in.)

IN 2
2 ,
mm (0.08 ooe
Oll<
in.)
Inside wheel
3J040':::!::2
29"50' (Reference)
Outside wheel Wheel

Wheel bearing
Aluminum wheel run out End play
Axial
Radial
0-0.7 mm (O-O.03 in.)

0-" 0.7 mm (0-0.03 in.) 0---0.05 mm (0-0.002 in.) 0-0.05 mm (0-0.002 in.)
1 2.0 mm (0.08 in.1 11.5 mm (0.06 in.1
Front
Rear
2-9

Brakes
Hem
Parking brake
Measurement Qualification
Standard or New
Service Limit
Distance traveled when lever pulled with 196 N (20 k9f, 441bsl of force
7 -8 clicks
184 mm (7 4/16 in.)
lever
Brake pedal Master cylinder Brake disc
Pedal height (carpet removed) Free play

Piston-to-pushrod clearance Thickness Runout
0.4
3.0 mm (0.016-0.118 in.)

19.00 mm (0.75 in.) 8.0 mm (0.31 in.) 0.10 mm (0.004 in,) 0.10 mm (0.004 in.) 0.015 mm (0.0006 in.)
0-0.4 mm (0-0.02 in.)
Front
Rear
i 21.0 mm (0.83 in.)

9.0 mm (O.35 in.)
Front
Rear
Parallelism
Brake pads Thickness
Front and rear
Front
10.0 mm (0.39 in,) 9.0 mm (0.35 in.)
1.6 mm (0.06 in,) 1.6 mm (0.06 in.)
Rear
A"Ir Con d"" Itlonma

Hem
Refrigerant Refrigerant oil Type Capacity of system Type Capacity of components Condenser Evaporator Each line and hose Compressor Compressor Drive belt Starter coil resistance Pulley-to-pressure plate clearance Tension 130- 150 mQ (41/3-5 fl oz)
Measurement Qualification Standard or New
I
Service Limit ..-
HFC-134 a (R-134 a) 500-550 g (17.6- 19.4 oz)
SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01) 25 m (5/6 II ozl

45 mQ (1 1/2 fl oz)
10 mQ (1/3fl oz)
At 68'F (20'C)
3.05-3.35 Q
0.35-0.6 mm (0.014-0.024 in.) Auto tensioner (needs no adjustment)
2-10
Item
DIMENSIONS
Measurement Overall length
Qualification
Specification
4,210 mm (16S.8 in.)
Overall width
Overall height
1.695 mm (S6.7 in.)

1,440 mm (56.7 in.)
Wheelbase
Track
Ground clearance
2,570 mm (101.2 in.)

' Front
Rear
1,470 mm (57.9 in.)
1,470 mm {57.S in.} 152 mm (5.98 in.)

four (4)
Seating capacity
WEIGHT {U.S.A.I WEIGHT {CANADAI ENGINE Gross Vehicle Weight Rating {GVWRI Gross Vehicle Weight Rating {GVWRI
3,6601bs
1,660 kg Water cooled, 4-stroke DOHC VTEC engine
Type
Cylinder a~~r~angement
Bore and stroke Displacement Compression ratio
_.
Intine 4-cylinder, transverse
86 x 86 mm (3.39 x 3.39 in.)

1,998 em' (122 cu in.)
9.8 Chain drive, DOHC VTEC 4 valves per cylinder
i,
Valve train
Lubrication system Oil pump displacement Water pump displacement Fuel required At 6,000 engine
Forced, wet sump, with trochoid pump
54.3
82
Q (57.4
US qt)/minute
'pm
At 3.400 engine
a(87 US qt)/minute
gasoline with 86 pump octane number or higher
'pm
UNLEAD~D
STARTER
Type Normal output Nominal voltage Hour rating Direction of rotation
Gear reduction 1.1 kW 12V , 30 seconds Clockwise as viewed from gear end
,
CLUTCH
I
Clutch type Clutch friction material surface area Type Primary reduction Gear ratio
Single plate dry, diaphragm spring 174 cm' {26.97 sq in.) Synchronized, 5-speed forward, 1 reverse Direct 1:1 1st 2nd 3,d 3.062 . 1.769 1.212 0.921 0.738 3.583 Single helical gear 4.764
MANUAL TRANSMISSION
,4th
,
Final reduction
5th Reverse Type Gear ratio
2-11
(cont'd)
Item
STEERING Type Overall ratio Turns,lock-ta-lock
Measurement
Qualification
15.1 2.835
360 mm (14.2 in)
Specification
Electric, Power-assisted rack and pinion
Steering wheel diameter

SUSPENSION Type Shock absorber WHEEL ALIGNMENT Camber Front
Rear
Independent strut with stabilizer, coil spring Double wishbone Telescopic, hydraulic, nitrogen gas-filled Telescopic, hydraulic, nitrogen gas-filled
i
Front
Rear
: Front
Rear
-000'
-0"45'
Caster Total toe

BRAKES Type of service brake Type of parking brake Pad friction surface area TIRES AIR CONDITIONING Size of front and rear tires Size of spare tire Compressor
Front Front
Rear
133'
o mm (Din.)
In 2 mm (1/16 in.) Power-assisted self-adjusting ventilated disc Power-assisted self-adjusting solid disc Mechanical actuating, rear wheels 45 em" (7.0 sq in.) x 2 28 em' (4.3 sq in.) x 2 P195/60 R15 B8V T125!70 D15 95M
.-
Front
Rear
Front Rear
Type Number of cylinders Capacity Maximum speed Lubricant capacity Lubricant type
Scroll
85.7
rna (5.23 cu in.}/rev.
12,000 rpm 130ml!.(41/3f1oz) SP-l0 (PIN 38897-P13-A01AH or 38899-P13-A011 Corrugated fin Corrugated fin Sirocco fan 220W/12 V 4 speed 480 m' (16.900 cu ft)/h Air-mix type Dry, single plate, poly-V belt drive 42 W maximum at 12 V
Condenser Evaporator Blower
Type Type Type Motor type Speed control Maximum capacity
,
Temperature control Compressor clutch
Type Electrical power consumption at 68'F 120'CI
Refrigerant
Type Capacity
HFC-134a (R-134al 500-550g (17.S-19.4ozl
2-12
Hem
Measurement
Qualification
,
Specification
12 V-36AH/5 hours
12V-1.1 kW, 1.2kW 12 V-95A, 90A
ELECTRICAL RATINGS
Battery
Starter
Alternator
Fuses
Under-hood fuse
relay box Under-dash fuse relay box
BOA, BOA, 50A, 40A, 30A, 20A, 15 A, 10 A, 7.5 A
30 A, 20 A, 15A, lOA, 7.5A

12V-BOW 12 V-55 W
12 V-21 W
Light bulbs
Headlight high beam Headlight low

beam
Front turn signal lights Front parking lights Rear turn signal
12 V
5W
--
12V-21W 12 V-5 W 12 V-21/5 W

12 V-5 W
lights Front/rear side marker lights

Brake/taillights High mount brake light
Back-up lights License plate light Ceiling light

Cargo area light
Spotlights
12V-21 W 12 V-5 W 12V--BW 12V-5W 12V-5W 14V-l.4W LED 12V-5W
Gauge lights
Indicator lights Side turn signal
light
2-13
Body Specifications
Unit: mm (in.)
..
..-
1,565161.61
.
_._-------+
I
1
1.440156.71
0;-
!!!
~
~
" = ...
..
~
;::
~
"' ~
__ t
i~
.
0;-
!!!
...
" =' ...

.:
-y
~" i
l
, I
I,
-,-
._-_.!...
r
2-14

Maintenance
Lubricants and Fluids ....................................... 3-2 Maintenance Schedule for Normal Conditions
Listed by DistancefTime ............................................... 3-4
Maintenance Schedule for Severe Conditions
Listed by DistancefTime ............................................... 3-6
Maintenance Schedule
Listed by Maintenance Item for Normal Conditions ....................................................................... 3-8 Listed by Maintenance Item for Severe Conditions ....................................................................... 3-9
Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work IIR . procedures (such as Assembly/ eassembly, Replacement, averhau I Insta II' atlan, etc.) contained . eac h section. In LUBRICATION POINTS LUBRICANT NO. Honda Motor Oil (PIN 08798-9023). The oil container 1 Engine
I
must display the API Certification seal shown below. ; Make sure it says "For Gasoline Engines." SAE
I
2 3 4 5 6 7
I
Transmission Brake system (includes ABS line) Clutch line Release fork (manual transmission) Throttle cable end (throttle link) Shift and select cable ends (manual
transmission)
Viscosity: See chart below. Honda MTF*' (PIN 08798-9016) Honda DOT 3 Brake Fluid*' (PIN 08798-9008) Super High Temp Urea Grease (PIN 08798-9002)
Silicone grease
8 , Throttle cable end (dashboard lower panel hole) Brake booster clevis 9 10 Clutch booster clevis Shift lever pivot 11 12 Pedal linkage 13 Battery terminals 14 Fuel fill door 15 Hood hinges and hood latch 16 Hatch hinges Door hinges, upper and lower 17 18 Caliper piston boot, caliper pins and boots 19 Air conditioning compressor
I Multi-purpose grease
,
Honda Caliper Grease (PIN 08C30-B0234M) Compressor oil: SP-1 0 (PIN 38897-P13-A01AH or . 38899-P1 3-A01) , For refriqerant: HFC-134 a (R-134 a)
API CERTIFICATION SEAL
Recommended Engine Oil Engine oil viscosity for ambient temperature ranges
fHfH+
-20 0 20 40 60 80 100'F -30 -20 -10 0 10 20 30 40'C
*1: Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. *2: Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2
.....
(jj)
(D)
(~)
(J)
CD
1])
3-3
Listed by Distance/Time for Normal Conditions
This two-page Manitenance Schedule outlines the minimun required maintenance. Service at the indicated distance or time, whichever comes first. Use the Maintenance Schedule for Severe conditions if the vehicle meets any of the qualifiers in the Severe Conditions schedule or if the vehicle is normally driven in Canada.
....
"
10,000 mil 16,000 km/ 1 year 20,000 mil 32,000 km/ 1 year 30,000 mil 48,000 km/2 years 30,QOO mi/48,QOO km 40,000 mil 64,000 km/2 years 50,000 mil 80,000 km/ 3 years / /3years 60,000 mil 96,000 km/ 3 years 60,000 mil 96,000 km 70,000 mil 112,000 kml 4 years 80,000 mil 128,000 kml 4 years 90,000 mil 144,000 kml 5 years
~o,ooo
mil 144,000 km 100,000 mi/160,000 km/5 years 110,000 mi/176,000 km/ Inspect valve clearance. (cold) (see page 6-32): Intake: 0.21 -0.25 mm (0.008-0.010 in.) Exhaust 0.28-0.32 mm (0.011-0.013 in.) Replace spark plugs. Use IZFR6Kl1 (NGK) or SKJ20DR-Ml1 (DEN SO). Gap: 1.0-1.1 mm (0.039-0.043 in.) Do items in A. '10,000 mi/176,000 km/6 years Do item in E. / 16years 120,000 mil 192,000 kml 6 years Replace transmission fluid. Use Honda MTF (see page 13-3). :. . .. Do items in A,B, and C. 120,000 mil 192,000 km Do item in D. -/-/9 years Do item in E. 120,000 mil 192,000 kml 10 years, then every 60,000 mil 96,000 kml 5 years ! Replace coolant (see page 10-6), Capacity: 5,0 L! (5,3 US qt). Use Honda All Season Antifreeze/Coolant Type 2. According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void the customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.
I I Do I I Do I Do 1 Do Do r- 1 Do Do Do Do Do Do Do Do Do
items in A. items in A and B. items in A and C. item in D. items in A and B. items in A. item in E. items in A, B, and C. item in D. items inA. items in A and B. items in A. and C. item in D. items in A and B.
3-4
Do the items in parts A, Bt C, D, and E as required for mileage/time interval listed.
A
Replace engine oil (see page 8-5), -Capacity without filter change: 4.0 Q, (4.2 US qt, 3.5 Imp qt) Rotate tires. Follow the pattern shown in the Owner's Manual --Check tire information and condition.
B
Replace engine oil filter (see page 8-6), -Capacity with filter change: 4.2ft {4.4 US qt, 3.7 Imp qt} Inspect front and rear brakes (see page 19-3), Check pads and discs for wear (thickness), damage, and cracks. Check calipers for damage, leaks, and tightness of mount bolts. Check parking brake adjustment. Should be fully applied within 7 to 9 clicks. Inspect tie-rod ends, steering gearbox, and boots (see page 17-5), Check rack grease and steering linkage. Check boots for damage and leaking grease. Check fluid line for damage and leaks. Inspect suspension components. Check bolts for tightness. Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3). Inspect brake hoses and lines {including ABS}. -Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage. Check all fluid levels and condition of fluids; check for leaks. If necessary, add MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. L I Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9-8). I I Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page' 1-146).
C
I
Inspect and adjust drive belt. Look for cracks and damage, and inspect auto tensioner (needs no adjustment). Replace the dust and pollen filter (see page 21-39) . Replace the dust and pollen filter whenever airilow from the heating and cooling system is less than normal.
o
I Replace air cleaner element every 30,000 miles (48,000 km) (independent of time).
E
J
Replace brake fluid every 3 years (independent of mileage).
According to state and federal regulations, failure to do the maintenance items marked with asterisk{ *) will not void customer's emissions warranties. However, Honda recommends that all maintenance service be done atthe recommended interval to ensure long-term reliability .
3-5
Listed by Distance/Time for Severe Conditions
Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of the following conditions; if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-4). Severe Driving Conditions Driving less than 5 miles {8 km) per trip or, in freezing temperatures, driving less than 10 miles (16 km) per trip Driving in extremely hot (over 90F/32C) conditions Extensive idling or long periods of stop-and-go driving, such as a taxi or a commercial delivery vehicle. Trailer towing, driving with a car-top carrier, or driving in mountainous conditions. Driving on muddy, dusty, or de-iced roads 5,000 mil 8,000 km/6 months 10,000 mil 16,000 km/l year Do Do Do Do Do Do Do Do Do Do Do Do Do Do Do Do item in A. items in A and B. items in E and H. item in A. items in A, B, and C. item in A. item in F. items in A, B, and D. item in A. items in A, B, and C. items in E and H. item in A, item in G, items in A and B, item in A. item in F.
15,000 mil 24,000 km/-15,000 mi/24,000 km/ 1-1/2 years 20,000 mi/32,000 km/ 1 year 25,000 mi/40,000 km/2 years
30,000 mil 48,000 km/-' 30,000 mi/48,000 km/2 years 35,000 mil 56,000 km/2-1/2 years 40,000 mi/64,000 kml 2 years
45,000 mi/72,OOO km/-
45,000 mil 72,000 km/3 years
-/-/3 years
50,000 55,000 60,000 60,000
mi/80,000 km/3 years mil 88,000 kml 3- 112 years mil 96,000 kml mil 96,000 km/3 year Replace transmission fluid. Use Honda MTF (see page 133). i Do items in A, B, C, and D. Do item in A. 65,000 mil 104,000 km/4 years Do items in A and B. 70,OOOmii 112,000 km/4 years Do items in E and H. 75,000 mil 120,000 kml 75,000 miJ 120,000 km/4 1/2 years Do item in A. Do items in A~-B,-ancrc: 80,000 miJ 128,000 km/4 years Do item in A. 85,000 mil 136,000 km/5 years 90,000 mil 144,000 km/ Do item in F. Do items in A, B, and D. 90,000 mil 144,000 km/ 5 years 95,000 mil 152,000 km/5-1/2 years Do item in A. items in--A, and C.- 100,000 mil 160,000 kml 5 years 105,000 mi/168,000 km/Do items in A, E, and H. -1-/6years Do item in G.
Do
S';
110,000 mil 176,000 km/-Inspect valve clearance. (cold) (see page 6-32): Intake: 0.21 -0.25 mm (0.008-- 0.010 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) Replace spark plugs.Use IZFR6K 11 (NGK) or SKJ20DR-M 11 (DENSQ) Gap: 1.0~1.1 mm (0.039-0.043 in.) Do items in A and S. 110,000 mil 176,000 kml 6 years ! Do item in A. 115,000 mil 184,000 km/6 1/2 years Do item in F. 120,000 mil 192,000 kml 120,000 mil 192,000 km/6 years Replace transmission fluid. Use Honda MTF (see page 13-3). Do items in A, B, C, and D. / 19 years Do item in G. 120,000 mil 192,000 km/ 10 years, then every 60,000 mil 96,000 km/5 years Replace coolant (see page 10-6). Capacity: 5.0 Q. (5.3 US qt) Use Honda All Season Antifreeze/coolant Type 2.
3-6
Do the items in parts A B, C, 0, E, F, and G as required for mileage/time interval listed.
A
Replace engine oil (see page 8-5), -Capacity without filter change: 4.0.n (4.2 US qt, 3.5 Imp qt)
B
I I Replace engine oil filter (see page 8-6), -Capacity with filter change: 4.2 Q (4.4 US qt, 3.7 Imp qtl I I Inspect front and rear brakes . Check pads and discs for wear (thickness), damage, and cracks . Check calipers for damage, leaks, and tightness of mount bolts. Lubricate door locks, latches and hinges with Honda white lithium grease. i Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual-Check tire inflation and
condition.
I I Inspecttie-rod ends, steering gearbox, and boots (see page 17-5). o Check rack grease and steering linkage. o Check boots for damage and leaking grease. o Check fluid line for damage and leaks. I I Inspect suspension components o Check bolts for tightness. o Check condition of ball joint boots for deterioration and damage. r I Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).
c
Check parking brake adjustment. Should be fully applied within 7 to 9 clicks. Inspect brake hoses and lines. (including ABS). -Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage (see page 19-24). Check al[ fluid leve[s and condition of fluids; check for leaks. [f necessary, add MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9-8). Inspect fuel lines and connections"'. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-146). Check all lights. Check function of all interior and exterior lights, and the position of the headlights (see page 22-68). Inspect the vehicle underbody. Check the paint for damage, scratches, stone chipping, and dents.
o
Inspect and adjust drive belt. o Look for cracks and damage, and inspect auto tensioner (needs no adjustment). I I Replace dust and pollen filter.
E
I Replace air cleaner element every 15,000 miles (24,000 km) in dusty condition (independent of time) otherwise use Normal Conditions scredule (see page 11-162).
F
j Replace air cleaner element every 30,000 miles (48,000 km) (independent of time) (see page 11-162).
G Replace brake fluid every 3 years (independent of mileage).
H
Replace the dust and pollen filter every 15,000 miles if vehicle is driven mostly where air has high concentration of soot from industry and diesel-powered vehicles; also replace the dust and pollen filter anytime airflow is less than usual (see page 21-39). According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.
3-7
Listed by Maintenance Item for Normal Conditions
Follow the Normal Schedule if the severe driving conditions specified in the Maintenance Schedule for Severe Conditions on the next page do not apply, and if only OCCASIONALLY driven in severe driving conditions. Follow the Severe Conditions schedule if the vehicle is driven MAINLY in Canada. Service at the indicated distance or time, whichever comes first.
60 96
!
miles x 1,000
km x 1,000
10 16 12
I
20 32
30 48 24
I
40 64
50 80 36
70 112
I
80 128
90
144
i
100
160
110 176 72
120 192
months
Replace engine oil Rotate tires (Check tire inflation and condition at least once per month)
48
60
1
!
!
,
I I
Replace engine oil filter

Inspect front and rear brakes Check parking brake adjustment Visually inspect the following items: Tie-rod ends, steering gearbox and boots Suspension components Driveshaft boots Brake hoses and lines (including ABS) Ali fluid levels and condition of fluids Exhaust system Fuel lines and connections Inspect and adjust drive belt Replace dust and pollen filter Replace transmission fluid Service the following items at the recommended intervals Replace air cleaner element Replace spark plugs Inspect valve clearance Inspect idle speed* Replace engine coolant
,
,
,
, ,
I
,
I
I
Every 30,000 miles (48,000 kmJ Every 110,000 miles (176,000 km) Inspect every 110,000 miles (176,000 km), otherwise adjust only if noisy. Every 160,000 miles (256,000 km) or 8 years At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Every 3 years
Replace brake fluid
: According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long-term reliability.
3-8
Listed by Maintenance Item for Severe Conditions

Use this schedule if the vehicle is driven MAINLY in Canada or in any of the following conditions. NOTE: if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule.
Severe Driving Conditions

Driving less than 5 miles (8 km) pertrip or, in freezing temperatures, driving less than 10 miles (16 km) per trip. Driving in extremely hot over 90 of (32C) conditions. Extensive idling, or long periods of stop-and-go-driving, such as a taxi or a commercial delivery vehicle. Trailer towing, driving with a car-top carrier, or driving in mountainous conditions. Driving on muddy, dusty, or de-iced roads.
Service at the ind'ieated distance or time, whichever comes first.
miles x ',000 km x 1,000 months
'0
20 32 12
30
4S
40 64 24
50 80 36
60 96
70 112 48
80 128
90 144 60
100 160
110 176 72
120 192
16
Replace engine oil
Replace every 5,000 miles ~8,OOO km) or 6 months
Rotate tires
(Check tire inflation and condition at least once per month)
I 1
,
Replace engine oil filter Inspect front and rear brakes Lubricate all locks, hinges, and latches Visually inspect the following items: Tie-rod ends, steering gearbox and boots Suspension components
I
I
Driveshaft boots
Check parking brake adjustment Visually inspect the following items: Brake hoses and lines (including ASS) All fluid levels and condition offluids Exhaust system* Fuel lines and connections*
lights and controls, vehicle underbody

Inspect and adjust drive belt Replace dust and pollen filterNOT< 1 Replace transmission fluid Service the following items at the recommended intervals Replace air cleaner element Replace spark plugs Inspect valve clearance Inspect idle speed* Replace engine coolant Every 15,000 miles (24,000 km) in dusty conditions, otherwise use normal schedule. Every 110,000 miles (176,000 km) Inspect every 110,000 miles (176.000 km), otherwise adjust only if noisy_ Every 160,000 miles (256,000 km) or 8 years At 120,000 miles (192.000 kml or 10years. then every 60,000 miles (96.000 kml or 5 years Every 3 years
Replace brake fluid
*: According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance service be done at the recommended interval to ensure long~term reliability.
NOTE 1: Replace the dust and pollen filter at 15,000 miles/24,OOO km if the vehicle is driven mostly in urban areas that have high concentrations of soot in the air from industry and diesel-powered vehicles.
3-9
Engine Electrical
Engine Electrical
Special Tools ......................................................... 4-2
Starting System
Component Location Index .................................. Circuit Diagram ..................................................... Starter Circuit Troubleshooting ........................... Clutch Interlock Switch Test ................................. Starter Solenoid Test ............................................ Starter Performance Test ..................................... Starter Replacement ............................................. Starter Overhaul .................................................... 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-26 4-26 4-27 4-28 4-29 4-30 4-36 4-37 4-38 4-40 4-42 4-42 4-43 4-44 4-45 4-45
Ignition System
Component Location Index .................................. Circuit Diagram ..................................................... Ignition Timing Inspection ................................... Ignition Coil Removal/Installation ....................... Spark Plug Inspection ...........................................
Charging System
Component Location Index .................................. Circuit Diagram ..................................................... Charging Circuit Troubleshooting ....................... Drive Belt Inspection ............................................. Drive Belt Replacement ........................................ Drive Belt Auto-tensioner Inspection .................. Drive Belt Auto-tensioner Replacement .............. Alternator Replacement ....................................... Alternator Overhaul ..............................................
Cruise Control
Component Location Index .................................. Circuit Diagram ..................................................... Symptom Troubleshooting Index ....................... Cruise Control Unit Input Test ............................. Main Switch Test/Replacement ........................... Set/Resume/Cancel Switch Test/Replacement .. Cruise Control Actuator Test ................................ Cruise Control Actuator/Cable Replacement ...... Actuator Cable Adjustment .................................. Clutch Pedal Position Switch Test .......................
Engine Electrical
Special Tools
Number I Tool Number
,
Description Attachment, 52 x 55 mm Driver
I
I
CD
I 07746-0010400
077 49-0010000
Qty 1 1
I
CD
4-2
Starting System
Component Location Index
--~~~'= D:~ _ '[--I

C] c~
UNDER-DASH FUSE/RELAY BOX
c:::::: I
CLUTCH INTERLOCK SWITCH
Test, page 4-6

STARTER CUT RELAY
Test, page 22-51
---------
L_.
STARTER
Starter Circuit Troubleshooting, page 4-5

Solenoid Test, page 4-7
Performance Test, page 4-8 Replacement page 4-9

Overhaul, page 4-10
-..e
4-3
Starting System
Circuit Diagram
No.20 I40A) : USA model
No.20 ISOA) : Canada model

UNDER-HOOD fUSE/RELAY BOX
ATTERY
IGNITION SWITCH
WHT
NO.19 (80A)
No.20
1ST BLK/WHT
5T HOT in START 1111
I
W
S -------------------;g
STARTfR
CUT
RELAY
FUSE/RflAY .OX
UNDER DASli
.U( r'HT
LTGRN
SWITCH
IW
;S M
i8
'
SOLENOID
Q
STARTER
CLUTCH INTER LOCK

ION: Pedal pr
.....,
BlK
1
G50'
,~
4-4
Starter Circuit Troubleshooting

NOTE: Airtemperature must be between 59 and 100F 115 and 38C I during this procedure. After this test, or any subsequent repair, reset the engine controle module IECMI to clear any diagnostic trouble codes IDTCsiisee page 11-41. The battery must be in good condition and fully charged. If you disconnect the battery, do the ECM idle learn procedure Isee page 11-1391. Recommended Procedure: Use a starter system tester.
Connect and operate the equipment in accordance
4. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables and the starter for looseness and corrosion. Then try starting the engine again.
Did the starter crank the engine?
YES-Repairing the loose connection fixed the problem. The starting system is now OK. NO-If starter will not crank the engine at all, go to step 5. If it cranks the engine erratically or too slowly, go to step 7. If it won't disengage from the flywheel ring gear when you release the key, check for the following until you find the cause. Solenoid plunger and switch malfunction Dirty drive gear or damaged overrunning clutch
5. Make sure the transmission is in neutral, then disconnect the starter subharness 1 P connector (A)
with the manufacturer's instructions. Alternate Procedure
1. Hook up the following equipment: Ammeter, 0-400 A Voltmeter, 0-20 V laccurate within 0.1 voltl Tachometer, 0-1200 rpm
2. Remove the No. 17 115AI fuse from the under-dash fuse/relay box. 3. With the clutch pedal pressed, turn the ignition switch to start (III).
Did the starter crank the engine normally?
from the engine wire harness 1P connector IBI. Connect a jumper wire from the battery positive terminal to the starter subharness 1P connector.
n.'.J'iO-\:,----A
Did the starter crank the engine?
YES- The starting system is OK . YES-Go to step 6. NO-Go to step 4. NO-Check the BLK/WHT wire between the starter
~.
subharness 1 P connector and the starter. If wire is OK, remove the starter, and repair or replace as necessary.
Iconl'd)
4-5
Starting System
Starter Circuit Troubleshooting (cont'd)
6. Check the following items in the order listed until you find the open circuit. 1. Disconnect the clutch interlock switch 2P connector. Check the BLK/WHT wire and connectors between the under-dash fuse/relay box and the
ignition switch, and between the under-dash
Clutch Interlock Switch Test
fuse/relay box and the starter. Check the ignition switch (see page 22-531. Check the clutch interlock switch and connector. Check the starter cut relay (see page 22-51 I. Check LT GRN wire between the starter cut relay/ under-dash fuse/relay box and the clutch
interlock switch.
Check the BLK wire between the clutch interlock switch and G501. 7. Check the cranking voltage and current draw. Is cranking voltage greater than or equal to 8.7 V and current draw less than or equal to 230 A? YES-Go to step 8. NO-Replace the starter, or remove and disassemble it, and check these items until you find the cause.
Starter armature dragging Shorted armature winding
2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals
according to the table.
Excessive drag in engine 8. Check the engine speed while cranking the engine. Is the engine speed above 100 rpm? YES-Go to step 9. NO-Replace the starter, or remove and disassemble it, and check for the following until you find the cause.
Excessively worn starter brushes Open circuit in commutator brushes Open circuit in starter armature commutator
If the continuity is not as specified, replace the clutch interlock switch . If OK, install clutch interlock switch and adjust the pedal height (see page 12-41.
\
-PRESSED
Terminal
2
~
Clutch Interlock Switch \
RELEASED
segments
Dirty or damaged helical splines or drive gear Faulty drive gear clutch
9. Remove the starter, and inspect its drive gear and the flywheel ring gear for damage. Replace any
damaged parts .
4-6
Starter Solenoid Test

1. Disconnect the Sand M connectors from the starter solenoid.
2. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity . If there is continuity, go to step 3 . If there is no continuity, replace the solenoid . 3. Check the pull-in coil for continuity between the S terminal and M terminal. There should be
continuity,
If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid.
,-e
4-7
Starting System
Starter Performance Test
1. Disconnect the wires from the S terminal and the M terminal.
2. Make a connection as described below using as
5. Disconnect the battery from the starter body. If the pinion retracts 'Immediately, it is working properly.
heavy a wire as possible (preferably equivalent to the wire used forthe vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds. 3. Connect the battery as shown. Be sure to
disconnect the starter motor wire from the solenoid. Ifthe starter pinion moves out, it is working
A (B
I
;:;,--,
BATTERY
12V
l
BODY (GROUND)
properly.
(B
12V
BATTERY
r
!
6. Clamp the starter firmly in a vise. 7. Connect the starter to the battery as described in the diagram below, and confirm thatthe motor starts and keeps rotating.
4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly.
n".1
12V
~
BATTERY
(B
12V
BATTERY
8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V,
BODY (GROUND)
the starter is working properly. Specifications:
4-8
Starter Replacement
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery first, then disconnect the positive cable. 3. Disconnect the knock sensor connector.
4. Remove the bolt (A) securing the harness bracket, then remove the intake manifold bracket (B).
A 6x1.0mm 12 Nm 11.2 kgfm, S.7Ibflt)
5. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal.
8x1.25mm 9Nm (0.9 kgf.m, 7 Ib'ttl
~'25mm
64Nm
(S.S kgf.m, 47 Ibf.ft)
B 8 x 1.25 mm 22 Nm 12.2 kgfm, 16lbfltl
6. Remove the two bolts holding the starter, then remove the starter.
7. Install the starter in the reverse order of removal. Make sure the crimped side of the ring terminal (A) is facing out.
8. Connect the positive cable and negative cable to
the battery. 9. Start the engine to make sure the starter operates properly. 10. Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
11. Selthe clock . 12. Perform the engine control module (ECM) idle learn procedure (see page 11-139).
4-9
Starting System
Starter Overhaul
Disassembly/Reassembly
STARTER SOLENOID
/
"
/(MOIYbdenUm
Disulfide)
';(', G;'
,)
:/-
<\ ,: " ",
@@f;/C
OVERRUNNING CLUTCH ASSEMBLY
~~ ~~~' ~~:o~
I
~
'
',~/ Y
'I
SOLENOID LEVER GEAR HOUSING
lW@ j;J
'(O.'~
I ~~"
//
_ '
IC&
C' @)
BRUSH
('0 -- \
ARMATURE HOUSING ARMATURE
/~II~
/" "
Ii (C
(Molybdenum Disulfide)
(Molybdenum Disulfide)
END COVER BRUSH HOLDER
4-10
r:-:'I I.!:!.I
Armature Inspection and Test
5. Check the commutator diameter. If the diameter is

below the service limit, replace the armature.
1. Remove the starter (see page 4-9).

Commutator Diameter
2. Disassemble the starter as shown althe beginning of this procedure. 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear
or damage, replace the armature.
Standard (New): 28.0 mm (1.10 in.) Service Limit: 27.0 mm (1.06 in.)
6. Measure the commutator (A) runout.
4. Check the commutator (A) surface. If the surface is

dirty or burnt, resurface with emery cloth or a lathe within the specifications in step 5, or recondition
If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. If the commutator runout is not within the service limit, replace the armature.
with # 500 or # 600 sandpaper (8). Commutator Runout Standard (New): 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)
~.
(conl'd)
4-11
Starting System
Starter Overhaul (cont'd)
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth Standard (New): 0.50-0.80 mm (0.020-0.031 in.) 0.20 mm (0.008 in.) Service Limit:
,
9. Place the armature IA) on an armature tester IB). Hold a hacksaw blade IC) on the armature core. If the blade is attracted to the core or vibrates while
the core is turned, the armature is shorted. Replace the armature.
A
10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coli
core IB), and between the commutator and armature shaft (C). If continuity exists, replace the 8. Check for continuity between the segments of the commutator. If an open circuit exists between any
segments, replace the armature. armature.
4-12
Starter Brush Inspection 11. Measure the brush length. II it is not within the service limit, replace the brush holder assembly. Brush Length Standard (New): 14.0~14.5 mm (0.55~0.57 in.) Service Limit: 9.0 mm (0.35 in.)
Starter Brush Holder Test 14. Check that there is no continuity between the (+) brush holder (A) and (~) brush holder (8). Iithere is continuity, replace the brush holder assembly.
__
~-B
Brush Spring Inspection
Starter Field Winding Test

12. Check lor continuity between the brushes (A). II there is no continuity, replace the armature housing (8).
15. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then
attach a spring scale (8) to the spring (C). Measure

the spring tension at the moment the spring lifts off the brush. If the spring tension is not within specification, replace the spring.
Spring Tension:
13.7~17.7
3.09~3.97
N (1.40~1.80 kgt, Ibt)
~B
13. Check lor continuity between each brush (A) and
the armature housing (B). If there is continuity, replace the armature housing.
(cont'd)
4-13
Starting System
Starter Overhaul (cant'd)
Planetary Gear Inspection Starter Reassembly
I~
16. Check the planetary gears IAI and ring gear IBI. Replace them if they are worn or damaged.
B
20. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. NOTE: To seatthe new brushes, slip a strip of # 500 or # 600 sandpaper, with the grit side out, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the
commutator.
o
A Overrunning Clutch Inspection
17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. 18. Rotate the overrunning clutch IAI both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it
"
21. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats
against the commutator, then release the spring
--
locks in both directions, replace it.
-t
againstthe end of the brush.
~A
D.
19. If the starter drive gear IBI is worn or damaged,
replace the overrunning clutch assembly; the gear is not available separately. 22. Install the starter end cover to retain the brush
holder.
Check the condition of the flywheel ring gear. Replace it if the starter drive gear teeth are damaged.
4-14
Ignition System
\;----;
_J--
~,
"
----
------------
---- ---
.SPARK PLUG
Inspection, page 4-19
IGNITION COIL
Ignition Timing Inspection, page 4-17

Removal/Installation, page 4-18
4-15
Ignition System
Circuit Diagram
No.20 I411A) : USA model No.20 ISOA) : Canada model
(
IGNITION SWITCH
UNDER-- HOOD FUse/RELAY BOX BAnERY ~
~)---+-~:-+--WHT
No.19IBOA)
No.ZO
~
!AT (
~,
BL.K/YEL
1G1 HOT in ON In) and START 1111)

UNDER-DASH FUSE/RELAY
No.1 115AI
BOX
r r r r
-BRN
ECM '-
BLKIWHT
WH T BLU
BLU RED
YEL/GRN
BlJWH.
BlKL.
BlKWHY
BLK{WHT
<M
<M
eM
0
10M
IGNITION
00<"
loo
, cv
--
J"""
l
sr
or
-uv
NoJ
l."
V.
--
~
No.1
loo~
No.4
No,2
BLK
r
~
r
SP ARK PL UGS
~
"
-' L
G101
ICM: Ignition ControlModule
4-16
Ignition Timing Inspection

1. Connect the Honda PGM Tester to the data link connector (DTC), and check for DTC's. If a DTC is
present, diagnose and repair the cause before inspecting the ignition timing.
6. Point the light toward the pointer (Alan the cam chain case. Check the ignition timing under no load conditions: headlights, blower fan, rear window defogger, and air conditioner are not operating. If
the ignition timing differs from the specification,
2. Start the engine. Hold the engine at 3,000 rpm with no load (in Neutral) until the radiator fan comes on, then let it idle. 3. Check the idle speed (see page "-1381. 4. Follow the tester's prompts in the "SCS" menu
(see the tester operator's manual),
and there are no engine control module (ECM)DTCs, replace the ECM (see page 11-4). Ignition Timing: 82 BTDC (RED mark (B)) during idling in neutral
5. Connect the timing light to the service loop.
7. Turn the ignition switch OFF. 8. Disconnectthe Honda PGM Tester and the timing light.
~.
4-17
Ignition System
Ignition Coil Removal/Installation
1. Remove the ignition coil cover (A), then remove the ignition coils (8).
6x 1.0 mm 9.8 Nm 11.0 kgfm, 7.2Ibfftl
~~ ~
/'
6 x 1.0 mm 12Nm 11.2 kgf.m, 8.7Ibfft)
W4F
r-" '"
~---~~
2. Install the ignition coils in the reverse order of removal.
4-18
Spark Plug Inspection

1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: Advanced ignition timing Loose spark plug Plug heat range too hot
Insufficient cooling
3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed below . Spark Plugs: IZFR6Kll (NGK) SKJ20DR-Mll (DEN SO)
Fouled plug may be caused by: Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too cold
Excessive idling/low speed running
Clogged air cleaner element Deteriorated ignition coils

Worn or deformed electrodes
Damaged
gasket
L I
~ ~~~~~
'==-~~~_
Carbon deposits { Cracked center electrode insulator
. Oil-fouling
Improper gap
Cracked insulator ~"~J
4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 18 Nm (1.8 kgf.m, 13Ibfft).
2. Do not adjust the gap of iridium tip plugs (A); replace the spark plug if the gap is out of
specification.
Electrode Gap: Standard (New):

Service Limit:
1.0-1.1 mm (0.039-0.043 in.) 1.3 mm (0.051 in. I

A
4-19
Charging System
,
CHARGING SYSTEM INDICATOR (In the gauge assembly) UNDERHOOD FUSE/RELAY BOX (Has built-in ELECTRICAL LOAD DETECTOR IELDI UNITI
----;---
AUTO TENSIONER Inspection, page 4-27 Replacement, page 4-28
BATTERY
Test, page 22-50
DRIVE BELT Inspection, page 4-26 Replacement, page 4-26
ALTERNATOR Troubleshooting, page 4-22 Replacement, page 4-29 Overhaul, page 4-30
(
4-20
Circuit Diagram
UNDER-HOODFUS/RELAYBOX BATTERY
No 20 (40A) : USA model No 20 150AI :Canada model

~,
No.1SI80Aj
No.20
_W
ELOUNIT
WHT
1
---'
~,,1G1
SWITCH
BLKtyEL
~
IG1 HOT in ON (II) and START (1111
No.4
I UNDER-DASH
FUSE/RELAY
(lOA)
BOX
GRN RED
BLK ORN
BLK ORN
VV
,eM
EeM
CM
'-BJ. BlJ(
WHT GRN
BLKrEl
WHTBLU L
I I
L
-.l
FR
WHT RED
ALTERNATOR
IG
H
RECTIAER
VOLTAGE REGULATOR
NJ..J
FIELD WINDING
t:
i- I-
r~
I- ~I- ..
-'-
-'
"'"
4-21
Charging System
Charging Circuit Troubleshooting
If the charging system indicator does not come on or
6. Measure the voltage at the No.3 terminal of the

engine wire harness 6P connector with the ignition
does not go off, or the battery is dead or low, test these items in the order listed below: Battery Isee page 22-50)
Charging system indicator Alternator and regulator circuit
switch ON III).
ENGINE WIRE HARNESS 6P CONNECTOR
Alternator control system
.-+-+-,
2 3
5 6
(BlK/YEll
Charging System Indicator Test

1. Turn the ignition switch ON (II).
Does the charging system indicator come on?
=
Wire side of female terminals
YES-Go to step 2. NO-Go to step 3.
Is there battery voltage? 2. Start the engine. YES-Go to step 7. Does the charging system indicator go off? YES-Charging system indicator circuit is OK. Go to the Alternator and Regulator circuit Test.. NO-Go to step 3. 7. Turn the ignition switch OFF.
3. Turn the ignition switch OFF. 8. Disconnect engine control module (ECM) connector
NO-Check for a blown No.4110A) fuse in the under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the alternator and the under-dash fuse/relay box .
4. Troubleshoot the multiplex control system Isee page 22-172). Is the multiplex control system OK? YES-Go to step 5. NO-Check the multiplex control system as indicated by the diagnostic trouble code IDTC) Isee step 8 on page 22-172) .
5. Disconnect the engine wire harness 6P connector from the starter sub harness 6P connector.
B 124P). 9. Check continuity between the ECM connector

terminal B 10 and engine wire harness 6P connector
terminal No.6.
ECM CONNECTOR B (24P)
6 7
15 1718
23
ACGl (WHT/BlUj
ENGINE WIRE HARNESS 6P CONNECTOR L....L....L..J
Is there continuity?
YES-Go to step 10.

NO-Repair open in the wire between the alternator and the ECM .
4-22
e
10. Check continuity between the ECM connector terminal 810 and body ground.
ECM CONNECTOR B 124PI
r:-:'I I..!=.I
Alternator and Regulator Circuit Test
1. Be sure the battery is sufficiently charged and in good condition (see page 22-50), and the
connections at the fuse box and alternator are
1 2 3 8 9 10 1718
6 7
13 21 15 23
clean and tight. 2. Raise the hoist to full height. 3. Hook up the ammeter, 0-400 A, to the starter
sub harness.
1- _ _ _ _
ACGL IWHT/BLUI
_-_9--;;;;
YES-Repair short to ground in the wire between
the ECM and the engine wire harness 6P connector .
",e
NO-Go to alternator and regulator test.
4. Lowerthe hoist.
5. Hook up the voltmeter, 0-20 V (accurate within
0.1 V),to Tl0l.
L:.
(conl'd)
4-23
Charging System
Charging Circuit Troubleshooting (cont'd)
6. Start the engine. Hold the engine at 3,000 rpm with no load (in Neutrall until the radiator fan comes on, then let it idle.
Alternator Control System Test

NOTE: After troubleshooting, perform the engine control module IECM) idle learn procedure Isee page 11-139).
, -.
7. Raise the engine speed to 2,000 rpm, and hold it there.
8. Turn the headlights Ihigh beaml on, and measure

voltage at the under-hood fuse/relay box terminal. Is the voltage between 13.9 and 15.1 V?
VES~Go
1. Check for proper operation of the electrical load detector IELD) by checking the malfunction indicator lamp IMIL) Isee page 11-3). If a DTC is present, diagnose and repair the cause before continuing with this test.
2. Disconnect the engine wire harness 6P connector from the starter sub harness 6P connector.
to step 9.
NO~Repair
or replace the alternator components Isee page 4-30) .
3. Start the engine, and turn the headlights Ihigh

beam) ON.
9. Read the amperage at 13.5 V.
NOTE: Adjust the voltage by turning the blower motor, rear window defogger, brake lights, etc. ON. Is the amperage 60A or more?
VES~Alternator/regulator
4. Measure voltage between the engine wire harness 6P connector terminal No.2 and the positive terminal of the battery.
BATTERY
operation is OK .
NO~Repair or replace the alternator components Isee page 4-30),.
C IWHT/GRN)

Is there 1 V or less?
VES~Go
to step 8.
NO~Go
to step 5.
5. Turn the headlights and ignition switch OFF. 6. Disconnect ECM connector B 124P).
4-24
7. Check for continuity between ECM connector terminal B18 and body ground.
10. Check for continuity between ECM connector terminal 818 and engine wire harness 6P connector terminal No.2.
8
ACGC IWHT IGRNI

Is there continuity? Is there continuity?
YES-Repair short to ground in the wire between the alternator and the ECM . NO-Check that the terminals are firmly seated at the ECM connector B. If OK, substitute a known good ECM, and recheck (see page 1161. If prescribed voltage is now available, replace the original ECM . 8. Turn the headlights and ignition switch OFF. 9. Disconnect ECM connector B (24PI.
YES-Repair or replace the starter subharness or the alternator (see page 4301 .
Le
NO-Repair open in the wire between the alternator and the ECM .
4-25
Charging System
Drive Belt Inspection
Check that the auto-tensioner indicator (A) is within the standard range (8) as shown. If it is out of the standard range, replace the drive belt (see page 4-26).
Drive Belt Replacement

1. Move the auto-tensioner (A) to relieve tension from the drive belt (8), and remove the drive belt.
/~
~-,
.\\\fJ..,'f'M.w.)i!rl(
2. Install the new belt in the reverse order of removal.
~.
" '-, I
4-26
'-.
..
Drive Belt Auto-tensioner Inspection

1. Check whether there is a change in the position of
the auto-tensioner indicator before starting the
5. Remove the auto-tensioner Isee page 4-281. 6. Install the tensioner pulley. 7. Clamp the auto-tensioner IAI by using two 8 mm bolts (8) and a vise IC) as shown. Do not clamp the
auto-tensioner itself.
engine and after starting the engine. If there is a

change in the position, replace the auto-tensioner.
2. Check for abnormal noise from the tensioner pulley.

If abnormal noise is heard, replace the tensioner
pulley.
L.
3. Remove the drive belt Isee page 4-261. 8. Set the torque wrench ID) on the pulley bolt.
4. Move the auto-tensioner within its limit with the belt tension release tool in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. If the tensioner does not move smoothly or there is abnormal noise, replace the auto-tensioner.
9. Align the indicator IE) on the tensioner base with center mark (F) on the tensioner arm by using the
torque wrench, and measure the torque. If the torque value is out of specification, replace the auto-tensioner.
NOTE: If the indicator exceeds the center mark,

recheck the torque. Auto-tensioner spring torque:
26.5-36.3 Nm 12.7-3.7 kg.m, 19.5-26.8Ibfft)
4-27
Charging System
Drive Belt Auto-tensioner Replacement
1. Remove the drive belt Isee page 4-26). 2. Remove the idler pulley.
4. Remove the auto-tensioner.
6x 1,Omm 12Nm 11.2 kgfm, 8,7 Ibfftl
x 1.25 mm 22Nm 12.2 kgfm, 16 Ibf,ftl

8 x 1.25 mm 22 Nm 12.2 kgfm, 16Ibf,ft)
3. Remove the tensioner pulley.
5. Install in the reverse order of removal.
55 N,m 15.6 kgfm, 41Ibf,ft)
4-28
\.-.
Alternator Replacement
1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's 9. Remove the alternator.
preset buttons. 2. Disconnect the negative cable from the battery first,
then disconnect the positive cable.
10. Install the alternator and drive belt in the reverse

order of removal.
11. Connect the positive cable and negative cable to the battery. 12. Enter the anti-theft code for the radio, then enter
3. Remove the front bumper (see page 20-85), 4. Remove the right side headlight (see page 22-791. 5. Remove the reserve tank from the bracket 6. Remove the drive belt (see page 4-261. 7. Remove the three bolts securing the alternator.
13. Setthe clock. 14. Perform the engine control module (ECMI idle learn procedure (see page 11-1391.
L.
8. Disconnect the alternator connector (AI and BLK wire (BI from the alternator.
4-29
Charging System
Alternator Overhaul
Exploded View
--
FRONT BEARING STATOR THROUGH BOLT DRIVE-END HOUSING /
SEAL RING
,",\~/",@
I
~ ~~
RECTIFIER ASSEMBLY
REAR HOUSING ASSEMBLY INSULATOR BUSHING
4-30
r--:'I l!::!.I
~.
Special Tools Required
Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 NOTE: Refer to the Exploded View as needed during this procedure. 1. Test the alternator and regulator before you remove them (see page 4-221. 2. Remove the alternator (see page 4-29). 3. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact
wrench.
B
4. Remove the harness bracket (A), insulator (B), three flange nuts (C), and the screw (D), then remove the plate terminal (E).
6. Remove the brush holder (A), voltage regulator (B), and the rubber seal (C) .
(conl'd)
4-31
Charging System
Alternator Overhaul (cont'd)
7. Remove the four screws, then remove the rectifier (A) and four insulators (8).
9. If you are not replacing the front bearing and/or rear bearing, go to step 16. Remove the rotor from the stator drive end housing.
10. Inspect the rotor shaft for scoring, and inspect the
bearing journal surface in the stator housing for seizure marks.
8. Remove the four flange nuts, then remove the rear
housing (A) and washer (8).
If either the rotor or stator housing is damaged, replace the alternator. If both the rotor and the stator housing are OK, go to step 11.
11. Remove the rear bearing using a puller as shown.
4-32
12. With a hammer and commercially available tools

shown, install a new rear bearing on the rotor shaft.
14. Support the stator housing in a vise, and drive out the front bearing with a brass drift and hammer.
NOTE: Install the bearing using the inner race.
15. With a hammer and the special tools, install a new

front bearing in the stator housing.
13. Remove the front bearing retainer plate.
f \
,
07749-0010000
.,. e4 @. - - -----
G." .
07746-0010400
(conl'd)
4-33
Charging System
Alternator Overhaul (cont'd)
Rectifier Test
16. Check for continuity in each direction, between the B terminal and P terminals, and between the E terminal and P terminals of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of eight diodes Ifour pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 16 checks. If any diode is faulty, replace the rectifier assembly. IDiodes are not available separately.1 If all the diodes are OK, go to step 17.
E
Alternator Brush Inspection
17. Measure the length of both brushes IAI with a vernier caliper IBI. If either brush is shorter than the service limit, replace the brush assembly. If brush length is OK, go to step 18.
Alternator Brush Length: Standard INewl: 10.5 mm 10.41 in. I Service Limit: 1.5 mm 10.06 in. I
.. /
p.
p,
p,
Rotor Slip Ring Test
18. Check that there is continuity between the slip rings IAI.
BP',
,-l
If there is continuity, go to step 19. If there is no continuity, replace the alternator.

C
t
p, p, p,
+---+--~l
P.
19. Check that there is no continuity between each slip ring and the rotor IBI and the rotor shaft ICI.
If there is no continuity, go to step 20. If there is continuity, replace the alternator.
"'-".
4-34
~.
Stator Test
20. Check that there is continuity between each pair of leads IAI. If there is continuity, go to step 21. If there is no continuity, replace the alternator.
A
21. Check for no continuity between each lead and the coil core IBI. If there is no continuity, go to step 22. If there is continuity, replace the alternator.
22. Assemble the alternator in reverse order of
disassembly, and note these items: Be careful not to get any grease or oil on the slip rings. If you removed the pulley, tighten its locknut to 111 Nm 111.3 kgfm, 81.7 Ibfftl when you install it.
4-35
Cruise Control
CRUISE CONTROL INOICATOR (Built into gauge assembly)
~~~'- ~
..
~-
00\. -,'(",
---
'./
.
--,~
\
\,
_i
~-'-
CRUISE CONTROL SET/RESUME/CANCEL SWITCH
Test/Replacement, page 4-42
CLUTCH PEDAL POSITION SWITCH
Test, page 445

Clutch Pedal Adjustment, page 12-4
CRUISE CONTROL UNIT Input Test, page 4-40 BRAKE PEDAL POSITION SWITCH
CRUISE CONTROL MAIN SWITCH
Test/Replacement, page 4-42
Test, page 22-84

Pedal Height Adjustment, page 19-6
""I.
-------------------
CRUISE CONTROL ACTUATOR

Test, page 4-43 Replacement, page 4-44
ACTUATOR CABLE
Adjustment, page 4-45
4-36
Circuit Diagram
UNDER-DASH FUSE/RElA VBOX
No.20 14OA) USA model
UNOER- HOOD FUSE/RELAY BOX BA TTERY
IGNITION SWITCH WHT
No.20 ISM) :Canada model
No.19180AI
NolO'
11SAI
No.7
., -&1G1 HOT in ON 1111 .nd START 11111
No.l017.5AI
BLK/YEL
~ No.4
(1OAI
COMBINATION
LIGHTSWrrCH
HORN RELAY
......
~
'",I
po'
BLK/ AN
RED/BLK
0..
~
HORN BRAKEJleDAL PDSITKlN
SWITCH
WHT GRN
cD~'~
REEL
,
1
CRUISE CONlllOL SETI
CANCf:l
REDI"'
CRUISE CONTROL
YL
HOR~~
6
RESUME/
MAIN SWITCH _ INDICATOR UGHT
~
~
2
6,84WI
UGHT (O.UW)
(~
I~
,
SET
L
I 1~
g:- 1, :~ME
2
LTGRN
5
RD
REOrL!(
SWITCH
f
WHT
.......
LTGRN
f-'u< -
CPU
'K~ ~mE ~
GRY RED LTGt'u<
7
CRUISE CONTROL UNIT
CRUISE CONTROL INDICATOR 11.26WI

GAUGE ASSEMBLY
Bl'
au
2
BLKrN
IT RN
BlU El
5 9
,
,
OR' :>V HT
2
3
"
OR' VEL
12
,.
LJLU
13 10 3
t.
SLULHT
CRUISE CONTROL
ACTUATOR
I
G34l'
I'
, VSS GAUGE ASSEMBLY
'lLK
CLUTCH PEDAL POsmoN SWITCH ON : PItd.1 released
I
G501
I
G~'
4-37
Cruise Control
Symptom Troubleshooting Index
NOTE: The numbers in the table show the troubleshooting sequence . Belore troubleshooting. - check the No. 10 (7.5A) and No.4 (lOA) luses in the under-dash luse/relay box, and the No.7 (15A) luse in the under-hood luse/relay box. - check that the horn sounds. - check the tachometerto see il it works properly. - check the speedometer to see il it works properly.
Symptom
Cruise control cannot be
I
set
1. 2. 3. 4. 5. 6.
Diagnostic procedure Check main switch (see page 4-42) Check SET/RESUME/CANCEL switch (see page 4-42) Test brake pedal position switch (see page 22-84) and check its adjustment (see page 19-6) Test clutch pedal position switch (see page 4-45) and check its adjustment (see page 12-4) Check cruise control unit (see page 4-40) Check vehicle speed sensor (VSS) (see page 22-65)
Also check for Poor ground: G501 Open circuit,

loose or
disconnected terminals: LTGRN, BLK/ORN, GRY/RED, BLU, LT BLU, BLU/WHT

Poor ground:
Cruise control can be set but indicator light does not go on
1. 2.
Check cruise control indicator bulb in gauge assembly (see page 22-63) Check cruise control unit (see page 4-40)
G501 Open circuit, loose or disconnected terminals: YEL, BLU/yEL
Cruise speed is
1. 2. 3. 1. 2. 3. 1. 2. 3. 1. 2.
noticeably higher or lower than what was set

Excessive overshooting or undershooting when trying to set speed
Speed fluctuation on a
Check vehicle speed sensor (VSS) (see page 22-65) Check cruise control actuator (see page 4-43) Check cruise control unit (see page 4-40) Check cruise control actuator (see page 4-43) Check vehicle speed sensor (VSS) (see page 22-65) Check cruise control unit (see page 4-40) Check vehicle speed sensor (VSS) (see page 22-65) Check cruise control actuator (see page 4-43) Check cruise control unit (see page 4-40) Check SET/RESUME/CANCEL switch (see page 4-42) Check cruise control unit (see page 4-40)
Open circuit, loose or disconnected
terminals:
Ilat road with cruise control set Vehicle does not decelerate or accelerate accordingly when SET/ RESUME/CANCEL bunon is pushed Set speed does not
cancel (engine rpm stays
1. 2.
high) when clutch pedal

~_Shed
Test clutch pedal position switch (see page 4-45) and check its adjustment (see page 12-4) Check cruise control unit (see page 4-40) Test brake pedal position switch (see page 22-84) and check its adjustment (see page 19-6)
Check cruise control unit (see page 4-40)
GRY/RED, LT GRN/BLK Short to ground in the LT BLU wire
Set speed does not

cancel when brake pedal is pushed
1. 2.
Open circuit, loose or disconnected terminals:
--
WHT/BLK
4-38
Symptom Set speed does not cancel when main switch is pushed OFF Set speed does not cancel when CANCEL button is pushed
1. 2. 1. 2.
Diagnostic procedure Check main switch (see page 4-42) Check cruise control unit (see page 4-40)
Also check for Short to power in the l T GRN wire. Open circuit, loose or disconnected terminals: GRY/RED, l T GRN/BlK Open circuit, loose or disconnected terminals: l T GRN/BlK
Check SET/RESUME/CANCEL switch (see page 4-42) Check cruise control unit (see page 4-40)
Set speed will not resume when RESUME button is pushed (with
main switch on, and set
I
1. 2.
Check SET/RESUME/CANCEL switch (see page 4-42) Check cruise control unit (see page 4-40)
i
speed temporarily : cancelled by pressing the brake pedal)
4-39
Cruise Control
Cruise Control Unit Input Test
SRS components are located in this area. Review the SRS component locations (see page 23-13) and precautions and procedures (see page 23-14) in the SRS section before performing repairs or service. 1. Disconnect the 14P connector from the control unit. 2. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. If the terminals look OK, go to step 3.
14P CONNECTOR
3. With the 14P connector disconnected, make these input tests. Cavity 1
Wire BRN/WHT
Test condition Connect battery

power
Test: Desired result Check the operation of the magnetic clutch: Clutch should click and output link should be locked. Check for voltage to ground: There should be 0 V with the pedal pressed and battery voltage with the pedal released.
BLU
Ignition switch ON (II), main switch ON and brake pedal pressed, then released
BLK
Under all conditions
Check for continuity to

ground:
Possible cause if result is not obtained Faulty actuator I Poor ground (G301) ' An open in the wire Short to ground (arcs when I power is connected) Faulty brake pedal position switch An open in the wire Open in cruise control main switch Blown No.4 (10 A) fuse in the under/dash fuse/relay box Poor ground (G501) An open in the wire
BLKJORN
Ignition switch ON
(II) 5 WHT/BLK Brake pedal pressed, then released
There should be continuity. Check for voltage to ground: There should be battery voltage. Check for voltage to ground: There should be battery voltage with the pedal pressed, and 0 V with the pedal released.
Blown No.4 (10 A) fuse in the under-dash fuse/relay box An open in the wire Blown No.7 (15 A) fuse in the under-hood fuse/relay box Faulty brake pedal position
switch An open in the wire
4-40
Cavity
6
Wire GRY/RED
Test condition Set button pushed
Test: Desired result Check for voltage to ground: There should be battery voltage.
When testing terminal No.6,
LT GRN/ BLK
Resume button
pushed
9 11
BRN BRN/yEL
Connect battery
there should be no voltage an terminal No.7. Check for voltage to ground: There should be battery voltage. , When testing terminal No.7, there should be no voltage on terminal No.6. Check the operation of the
actuator motor: You should
Possible cause if resuH is not obtained Blown Na. 7 (15 A) fuse in the under-hood fuse/relay box Faulty horn relay Faulty set/resume/cancel
switch An open in the wire
Faulty cable reel Short to ground (horn sounds when buttan is pressed)
10
BLU/YEL
power to the BRN terminal and ground to the BRN/YEL terminal Ignition switch ON (II)
Faulty actuator
An open in the wire
be able to hear the motor.
Attach to ground:
Cruise indicator light in the
Blown No. 10 (7.5 A) fuse in the under-dash fuse/relay box
gauge assembly should come on. 12 BLU/wHT Ignition switch ON (II) and main switch ON; raise the front of the vehicle, and
rotate one wheel
Blown cruise indicator bulb
Check for voltage between the BLU/WHT (+) and BLK (-) terminals: There should be 0-5 V or
more repeatedly.
Faulty gauge assembly An open in the wire Faulty VSS

An open in the wire
Short to graund
13
LTGRN
slowly while holding the other wheel Ignition switch ON (II) and main switch ON Clutch pedal
Check far voltage to ground: There should be battery voltage. Check for continuity to
ground:
Blown No.4 (10 A) fuse in the under-dash fuse/relay box Faulty main switch
14
LT BLU
released
I
properly, replace the cruise control unit.
There should be continuity. NOTE: There should be na continuity when the clutch pedal is pressed.
Faulty clutch pedal position Poor ground (G501) Incorrect cl utch switch
switch
An open in the wire
adjustment An open in the wire
4. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK,
the cruise control unit may be faulty. Substitute a known-good cruise control unit and retest. Ifthe system works
4-41
Cruise Control
Main Switch Test/Replacement
1. Remove the driver's dashboard lower cover (see page 20-591.
1. Remove the two screws, then remove the switch.
Set/Resume/Cancel Switch Test/ Replacement
'--'
2. Release the clips of the main switch and push the main switch (A) out of the panel, then disconnect the 5P connector (8) from the main switch.
Terminal side of mate terminals
-----
E~
Terminal side of male terminals
-""'I')
-~
2. Check for continuity between the terminals in each switch position according to the table .
If there is continuity, and it matches the table, but 3. Check for continuity between the terminals in each switch position according to the table. If the
continuity is not as specified, replace illumination
bulbs (C) or the switch.
switch failure occurred on the cruise control unit input test, check and repair the switch circuit. If there is no continuity in one or both positions, replace the switch.
..
_.
\
Position
Terminal
\
OFF ON
1\
Position
Terminal
10 ~ ~ 10 ~ rO 10 ~ fO ~ 10 ~ rO
SET ION) f---'li;SUME ION)

;
CANCEL ION)
4-42
Cruise Control Actuator Test

1. Disconnect the 4P connector (A) from the cruise control actuator (8). 6. Check the operation of the actuator motor in each output linkage position according to the table. You should be able to hear thE> motor.
Battery power
Output linkage position
~'
~olarities
MIDDLE FULL , CLOSE POSITION , The No.3 The No.4 I motor Terminal Terminal motor runs, runs. The No.3 No.4 The motor Terminal I Terminal motor runs. staas.
'(-)
FUL~
OPEN The motor stops. The motor runs.
OUTPUT LINKAGE
2. Remove the cover (A), and check the output linkage (8) for smooth movement.
FULL OPEN
,
-'
",
,.
'.
.'
FULL CLOSE
7. If the actuator motor does not operate as specified, replace the cruise control actuator assembly.
3. Connect battery power to the No.2 terminal and ground to the NO.1 terminal. 4. Check for a clicking sound from the magnetic clutch. The output linkage should be locked. 5. If the output linkage is not locked, replace the
cruise control actuator assembly.
4-43
Cruise Control
Cruise Control Actuator/Cable Replacement
1. Fully open the cruise control link by hand, then remove the cruise control cable (AI from link. Loosen the locknut (8), and remove the cable from the bracket. 3. Remove the actuator cover (Ai, then remove the actuator cable (81 from the cruise control actuator.
4. Install in the reverse order of removal, and adjust
the free play at the throttle linkage after connecting

2. Disconnect the 4P connector, and remove the three bolts securing the cruise control actuator. the actuator cable.
6x1.0mm 12 Nm 11.2 kgfm,8.7Ibfftl
4-44
Actuator Cable Adjustment

1. Check that the actuator cable (AI moves smoothly with no binding or sticking.
Clutch Pedal Position Switch Test

1. Disconnect the 2P connector from the clutch pedal position switch (AI.
CLUTCH PEDAL POSITION SWITCH 2P CONNECTOR
~,
~
A
I
~"r /~f.
""
2. Start the engine.

3. Measure the amount of movement of the output linkage (81 until the engine speed starts to increase. At first, the output linkage should be located at the fully closed position (CI. The free play (DI should be 3.75O.5 mm (O.15O.02 in.l.
2. Remove the clutch pedal position switch.
3. Check for continuity between the terminals

according to the table .
If the continuity is not as specified, replace the
4. If the free play is not within specs, loosen the locknut (EI, and turn the adjusting nut (FI until the free play is as specified, then retighten the locknut.
clutch pedal position switch. If OK, install the clutch pedal position switch and adjust the pedal height (see page 12-41.
1\
Terminal
Clutch Pedal \ Position Switch PRESSED RELEASED
1
I
4-45
Engine Mechanical
Engine Assembly
Engine Removal .................................................... 5-2 Engine Installation ................................................ 5-9
Cylinder Head ............................................. 6-1 Engine Block ............................................... 7-1 Engine Lubrication ..................................... 8-1 Intake Manifold/Exhaust System ........., ... 9-1
Engine Assembly
Engine Removal
Front subframe adapter EQS02C000011 NOTE:

Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors
6. Disconnect the intake air temperature (IAT) sensor connector (A), remove the breather hose (B) and vacuum hose (el, then remove the air cleaner housing cover/intake air duct assembly (D).
carefully while holding the connector portion.

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 in the wide open position (support rod in the lower hole). 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's
preset buttons. 3. Disconnect the negative cable from the battery first, then disconnect the positive cable.
4. Remove the battery.

5. Remove the intake manifold cover.
7. Remove the air cleaner housing.
5-2
8. Remove the intake air duct.
10. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control cable (8) from the links. Loosen the locknuts (C), and remove the cables from the bracket.
9. Remove the battery cables (A) from the under-hood fuse/relay box, then remove the harness clamp (8) and ground cable (C).
11. Relieve fuel pressure (see page 11-144). 12. Remove the fuel line (see page 11-149).
13. Remove the evaporative emission (EVAP) canister
hose (A) and brake booster vacuum hose (8).
B~
B
(cont'd)
5-3
Engine Assembly
Engine Removal (cont'd)
14. Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (8). 16. Disconnect the engine control module (EeM)
connectors (A) and main wire harness connector
(8).
~ ...........j
15. Remove the shift cable (A) and select cable (8).
B
17. Remove the harness clamps (A) and grommet (8). then pull the engine wire harness through the bulkhead.
--------- ----~
5-4
18. Remove the drive belt Isee page 4-26). 19. Remove the A/e line mounting bolt.
30. Disconnect the air fuel ratio (A/F) sensor connector IA) and secondary heated oxygen sensor Isecondary H02S) connector (8), then remove the three way catalytic converter ITWC) assembly (C).
20. Remove the radiator cap. 21. Raise the hoist to full height. 22. Remove the front tires/wheels. 23. Remove the splash shield.
A
"":;..--_-8
31. Remove the lower hose.
----~~~
--
T'::~--- __
-----
----
24. Loosen the drain plug in the radiator to drain the engine coolant Isee page 10-6). 25. Drain the transmission fluid (see page 13-3). 26. Drain the engine oil (see page 8-5). 27. Disconnect the stabilizer links Isee page 18-18).
28. Disconnect the suspension lower arm ball joints (see step 3 on page 18-19).
29. Remove the driveshafts (see page 16-3). Coat all

precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
(cont'd)
5-5
Engine Assembly
32. Lower the hoist. 33. Remove the upper hose (A) and heater hoses (8). 36. Remove the transmission mount bracket support bolt and nuts.
37. Remove the upper bracket mounting bolt and nut. 34. Remove the radiator (see page 10-10). 35. Attach the chain hoist to the engine as shown.
5-6
38. Make sure the hoist brackets are positioned properly. Raise the hoist to full height. 39. Remove the rear mount mounting bolts.
41. Attach the subframe adapter to front of the subframe, then tighten the knurled knob.
EQS02COOOOll
42. Raise the jack. Line up the slots in the arms with the bolt holes on the corner of the jack base, then attach the adapter to the jack base with the bolts. 40. Remove the front mount bracket mounting bolt.
(conl'dl
5-7
Engine Assembly
43. Use a marker to make alignment marks on the reference lines (A) that align with the centers of the rear subframe mounting bolts (8). 45. Disconnect the compressor clutch connector (A), then remove the NC compressor (8) without disconnecting the NC hoses.
46. Check that the engine/transmission is completely

free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
47. Slowly lower the engine about 150 mm (6 in.1. Check once again that all hoses and wires are
disconnected from the engine/transmission.
48. Lowerthe engine all the way. Remove the chain

hoist from the engine.
B B
49. Remove the engine from under the vehicle. 44. Remove the lront sublrame (C).
J.
5-8
Engine Installation
Front subframe adapter EQS02C000011 1. Install the accessory brackets, and tighten their bolts and nuts to the specified torques.
ENGINE MOUNT BRACKET
10x 1.25 mm 44 Nm 14.5 kglm, 331bf.itl
l.
AIC COMPRESSOR BRACKET
10 x 1.25 mm
44 Nm 14.5 kgl.m, 331bl1t1
(cont'd)
5-9
Engine Assembly
Engine Installation (cont'd)
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into
position in the vehicle.
5. Install the subframe (A). Align the reference marks (B) on the subframe with the center of the bolt heads, then tighten the bolts.
INOTICEI
Reinstall the mounting bolts/support nuts in
the sequence given. Failure to follow this sequence may cause excessive noise and
vibration, and reduce bushing life. 3. Install the NC compressor (A), and connect the
compressor clutch connector (8).
{:".,c'- '- _~ - ' ,: -. t':, ,'I
:Y
'-""'
i,ll,
,/ '
Replace.
/--:"'---7B
6. Tighten the rear mount mounting bolts.

8x 1.25 mm 22 Nm (2.2 kgl.m, 161blttl
4. Support the subframe with the subframe adapter and a jack.
.=:==~--
., .,
EQS02C000011
10 x 1.25 mm 59 Nm (6.0 kgl-m, 43 Iblttl
5-10
7. Loosely tighten the front mount bracket mounting bolt.

\:::--
10. Tighten the transmission mount bracket support bolt and nuts.
12 x 1.25 mm
vO
54 Nm 15.5 kgfm, 40 Ibl,ft)
. /" \ .
--'--<.. (
.....'/ .::,
1'04'/'"
i / },
! / ...
.-------,
1;;jj- /
Replace.
8. Lower the hoist. 9. Tighten the upper bracket mounting bolt and nut.
11. Raise the hoist to full height. 12. Tighten the front engine mount bracket mounting bolt,
12 x 1.25 mm 64 N,m (6,5 kglm, 47Iblft)
, ,e
13. Lower the hoist.

14. Remove the chain hoist from the engine.
15. Install the radiator {see page 10101.

16. Raise the hoist to full height. 17. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring "clicks" into place in the differential and intermediate shaft.
(cont'dl
5-11
Engine Assembly
18. Connect the suspension lower arm ball joints (see step 6 on page 18-19). 19. Connectthe stabilizer links (see page 18-18). 20. Install the three way catalytic converter (TWC) assembly (A); use new gaskets (B) and new selflocking nuts (C).
C
23. Install the splash shield.
-
~-::::..---
--T----__ -~\
ft----
10x1.25mm
33 Nm (3.4 kgfm, 25Ibflt)
~~ ....... '"""''''
24. Lower the hoist. 25. Install the drive belt. 26. Install the A/C line mounting bolt.
6x 1.0mm
9.8 Nm 11.0 kgfm, 7.2Ibfltl
~~
8x1.25mm
,--.
22 Nm (2.2 kgfm, 16Ibflt)

D
21. Connectthe air fuel ratio (A/F) sensor connector (D) and secondary heated oxygen sensor (secondary H02S) connector (E). 22. Install the lower radiator hose.
5-12
27. Install the upper radiator hose (AI and heater hoses IBI.
30. Connect the ECM connectors IAI and main wire

harness connector (B).
28. Push the engine control module IECMI connectors through the bulkhead, then install the grommet IAI.
-- -
-::::.;::;-
31. Install the throttle cable Isee page 11-1641, then adjust the cable (see page 11-1631. 32. Install the cruise control cable Isee page 4-441, then adjust the cable (see page 4-451 . 33. Install the brake booster vacuum hose IAI and the evaporative emission (EVAPI canister hose IBI.
--=-==:-::---=
29. Install the harness clamps IBI.
34. Install the fuel line Isee page 11-1501.
Icont'dl
5-13
Engine Assembly
35. Install the select cable (A) and shift cable (B) using the plastic washers (C), washers (D), and new cotter pins (E).
6x 1.0mm
37. Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamp (B).
9.8 Nm 11.0 kgl.m, 7.2Ibllt)
D______
C
E~
~
~
---------...~
---....CV
'e
~
!
@
~
38. Install the ground cable (C). 39. Install the intake air duct.
36. Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B).
B 6X1.0mm
x 1.0 mm 12 Nm 11.2 kglm, 8.7Ibllt)
!a/ 'ff
" ::c::
9.8Nm 11.0 kglm, 7.2 Ibllt)
5-14
40. Install the air cleaner housing.
43. Install the intake manifold cover.
,
/
6x,.omm
12 Nm (1.2 kgfm, 8.7Ibflt)
41. Install the air cleaner housing cover IAI and connect the intake air temperature IIATI sensor connector IBI.
44. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
45. Check that the transmission shifts into gear smoothly. 46. Inspect for fuel leaks. Turn the ignition switch ON 1IIIIdo not operate the starterl so that the fuel pump runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line.

47. Refill the engine with engine oillsee page 8-51. 48. Refill the transmission with fluid Isee page 13-31.
49. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open Isee page 10-61.
B
42. Install the breather hose ICI and vacuum hose IDI.
50. Perform the engine control module IECMI idle learn procedure Isee page 11-1391. 51. Inspectthe idle speed Isee page 11-1381.
52. Inspect the ignition timing Isee page 4-171.

53. Check the wheel alignment Isee page 18-41.
54. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
55. Set the clock.
5-15
Engine Mechanical
Cylinder Head
Special Tools ................................................................. Component Location Index ........................................ Engine Compression Inspection ................................ VTEC Rocker Arm Test ................................................. VTC Actuator Inspection .............................................. Valve Clearance Adjustment ....................................... Crankshaft Pulley Removal and Installation .............. Cam Chain Removal ..................................................... Cam Chain Installation ................................................. Auto-Tensioner Removal/Installation ......................... Chain Case Oil Seal Installation .................................. Cylinder Head Cover Removal .................................... Cylinder Head Removal ............................................... VTC Actuator, Exhaust Camshaft Sprocket Replacement ............................................................. Cylinder Head Inspection for Warpage ...................... Rocker Arm Assembly Removal ................................. Rocker Arms and Shafts Disassembly/Reassembly ........................................ Rocker Arms and Shafts Inspection ............................ Camshaft Inspection .................................................... Valves, Springs, and Valve Seals Removal ................ Valve Inspection ........................................................... Valve Stem-to-Guide Clearance Inspection ............... Valve Guide Replacement ........................................... Valve Seat Reconditioning .......................................... Valves, Springs, and Valve Seals Installation ............ Rocker Arm Assembly Installation .............................. Cylinder Head Installation ........................................... Cylinder Head Cover Installation ................................ 6-2 6-3 6-6 6-7 6-8 6-9 6-11 6-12 6-15 6-19 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-31 6-32 6-32 6-33 6-35 6-37 6-38 6-39 6-41
Cylinder Head
Special Tools
Ref. No.
CD
':l)
CD
CD
(J)
@J @ @
Tool Number 07 AAJ-PNAA 100 07HAH-PJ7010B 07 JAA-OO 1020A 07 JAB-OO 1020A 07NAB-00 1040A 07VAE-001010A 07ZAJ-PNAA 100 07ZAJ-PNAA200 07ZAJ-PNAA300 07742-0010100 077 46-00 10400 077 49-00 10000
Description Air Pressure Regulator Valve Guide Reamer, 5.5 mm Socket, 19 mm Holder Handle Holder Attachment, 50 mm Valve Spring Compressor Attachment VTEC Air Adapter VTEC Air Stopper Air Joint Adapter Valve Guide Driver, 5.5 mm Attachment, 52 x 55 mm
Driver
Oty 1 1 1 1 1 1 2 1 1 1 1 1
~_---
-1
CD
/
cI:.
,--,
'\
,,//
~.
/-------\/
I '-_oj

lEi
1\
-" ,---~-j
~"
"
@
6-2
IGNITION COIL COVER
CYLINDER HEAD COVER Removal, page 6-22 Installation, page 6-41
CAM CHAIN Removal, page 6-12 Installation, page 6-15
ff /
~
~ ~. 0<>
CAM CHAIN GUIDE B
CAM CHAIN GUIDE A
O-RING
JL
Q
O~~
)"-71
'VARIABLE VALVE TIMING CONTROL (VTC) OIL SOLENOID VALVE
,
/
~
TENSIONER ARM CRANKSHAFT PULLEY Replacement, page 6 11
CRANKSHAFT POSITION (CKP) SENSOR AUTO-TENSIONER Replacement, page 6-19
CHAIN CASE
4!U . ~~
\
"lll. .
1
CRANKSHAFT PULLEY BOLT
Replacement, page 6- l'
O-RING
CHAIN CASE COVER
(conl'd)
6-3
Cylinder Head
. Comp O nent Locatio n Index (cont'd)
CAMSHAFT HOLDER CAM CHAIN GUIDE B DOWEL PIN
PULSE PLATES
MSHAFT POSITION ftMP} SENSOR
o
Cl
,
, --------INTAKE InspectIOn,
CAMp~~1);29
FT
VTC ACTUATO~_24 Remova.l, pa g: 6-25 Installation, p ge / /
-
EXH AUST CAMSHAFT
TOP OEADCENTER OR (TDC) SENS
DOWEL PIN
ROCKER ARM ASSEMBLY e 6-27 Overha.ul, pa~ e 6-28 Inspection, p 9
6-4

SPRING RETAINER VALVE KEEPERS EXHAUST VALVE SPRING
~
~e
CYLINDER HEAD BOLT

Inspectton, page 6-39
EXHAUST VALVE SEAL
EXHAUST VALVE GUIDE
~~j
~
"
VALVE SPRING SEAT
0
,:
e,
~ &
~ ~INTAKEVALVE
SEAL ______
"'" ~ INTAKE VALVE """~ SPRING
_____
Replacement, page 6-31
INTAKE VALVE GUIDE

HEAT SHIELD
VTEC SOLENOID VALVE
VTEC SOLENOID VALVE FILTER
6-5
Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating temperature (cooling fan comes on).
9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure Above 930 kpa (9.5 kgf/cm', 135 psi)
10. Measure the compression on the remaining cylinders.
2. Turn the ignition switch OFF.

3. Remove the intake manifold cover (see step 1 on page 6-22).
4. Disconnect all four injector connectors. 5. Start the engine, and let it run until it stalls. 6. Remove the four ignition coils (see page 4-18). 7. Remove the four spark plugs. 8. Attach the compression gauge to the spark plug hole. Maximum variation Within 200 kPa (2.0 kgf/cm', 28 psi) 11. If the compression is not within specifications, check these items, then remeasure the compression. Damaged Damaged Damaged Damaged or worn valves and seats cylinder head gasket or worn piston rings or worn piston and cylinder bore
6-6
VTEC Rocker Arms Test

Special Tools Required Air pressure regulator 07 AAJ-PNAA 100 VTEC air adapter 07ZAJ-PNAA 100 VTEC air stopper 07ZAJ-PNAA200 Air joint adapter 07ZAJ-PNAA300 1. Remove the cylinder head cover (see page 6-22). 2. Set the No.1 piston at top dead center (TDC) (see step 1 on page 6-12). 3. Verify that the intake primary rocker arm (A) moves independently of the intake secondary rocker arm
(8).
4. Repeat step 3 on the remaining intake primary rocker arms with each piston at TDC. When all the primary rocker arms pass the test, go to step 5. 5. Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgf/cm', 57 psi). 6. Inspect the valve clearance (see page 6-9). 7. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (8).
E 07 AAJPNAA 100
07ZAJ-PNAA300
If the intake primary rocker arm does not move,

remove the primary and secondary rocker arms
as an assembly and check that the pistons in the

secondary and primary rocker arms move
smoothly. If any rocker arm needs replacing,

replace the primary and secondary rocker arms
as an assembly, and test. If the intake primary rocker arm moves freely, go to step 4.
B 07ZAJ-PNAA200 C 07ZAJ-PNAA 100
8. Remove the No.2 and No.3 camshaft holder bolts, and install the VTEC air adapters (C) finger-tight. 9. Connect the air joint adapter (D), and air pressure regulator with a 0-100 psi gauge (E).
(cont'd)
6-7
8. Punch a hole through the tape over one of the advance holes.
12. Remove the special tools.

13. Tighten the camshaft holder mounting bolts to 22 Nm (2.2 kgfm, 16Ibfft). 14. Tighten the sealing boltto 20 Nm (2.0 kgf.m, 14Ibfft). 15. Install the cylinder head cover (see page 6-41).
6-8
Valve Clearance Adjustment

9. Apply air to the advance hole to release the lock. NOTE: Adjust the valves only when the cylinder head temperature is less than 100F 138C). 1. Remove the cylinder head cover Isee page 6-22). 2. Set the No.1 piston at top dead center ITOCI. The punch mark IA) on the variable valve timing control IVTC) actuator and the punch mark (8) on the exhaust camshaft sprocket should be at the top. Align the TOC marks IC) on the VTC actuator and
exhaust camshaft sprocket.
B
A
10. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator.
Icont'd)
6-9
Cylinder Head
Valve Clearance Adjustment (cont'd)
3. Select the correct thickness feeler gauge for the valves you're going to check. Intake: Exhaust: 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (8) until the drag on the feeler gauge is correct. .
0.21-0.25 mm (0.008-0.D10 in.) 0.28-0.32 mm (0.011-0.013 in.)
Adjusting screw locations:

B
',-= I
T?~fl~ SJ
No.1
' i '
No.2
__
:~_.~!
'I
I,
@5i>'l''fdv fJi_.
No.3
NO.4
' ,
I'
A INTAKE: 20 Nm 12.0 kgfm, 14Ibfft) EXHAUST: 14 Nm 11.4 kgfm, 10 Ibfft) 6. Tighten the locknut, and recheck the clearance. Repeat the adjustment if necessary.
INTAKE 4. Insert the feeler gauge (A) between the adjusting screw (8) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag.
7. Rotate the crankshaft 180 clockwise (camshaft pulley turns 90).
8. Check and, if necessary, adjust the valve clearance on No.3 cylinder.
6-10
Crankshaft Pulley Removal and Installation

9. Rotate the crankshaft 180' clockwise (camshaft pulley turns 90').
Special Tools Required Holder handle 07 JAB-OO 1020A Holder attachment, 50 mm 07NAB-00l 040A Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
Removal
1. Remove front tires/wheels.
"-o--c~~~r=--,
/ <JcO'
. . --0.'...
2. Remove the splash shield (see step 23 on page 5-5). 3. Hold the pulley with holder handle (A) and holder attachment (B).
B 07NAB001040A
10. Check and, if necessary, adjust the valve clearance on NO.4 cylinder. 11. Rotate the crankshaft 180' clockwise (camshaft pulley turns 90').
c~;t;
A
07JAB001020A
C
07JAA001020A (or commercially available)
12. Check and, if necessary, adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover (see page 6-41) .
4. Remove the bolt with a 19 mm socket (C) and breaker bar.
(conl'd)
6-11
Cylinder Head
Crankshaft Pulley Removal and Installation (cont'd)
Installation
1. Clean the crankshaft pulley (A), crankshaft (8), bolt (C), and washer (D). Lubricate as shown below.
~_~: Clean
Cam Chain Removal

NOTE: Keep the cam chain away from magnetic fields.
1. Turn the crankshaft pulley so its top dead center (TDC) mark (A) lines up with the pointer (B).
B
.: lubricate
2. Remove the front tires/wheels. 2. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B). 3. Remove the splash shield.
A
07JAB-001020A
07JAA-001020A for commercially available)
4. Remove the drive belt (see page 4-26). 5. Remove the cylinder head cover (see page 6-22). 6. Remove the crankshaft pulley (see page 6- 11).
I
_"'---- ___
o""--~
3. Tighten the bolt to 245 Nm (25.0 kgfm, 181 Ibfft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench. 4. Install the splash shield (see step 20 on page 5-12). 5. Install front tires/wheels.
6-12
7. Disconnectthe crankshaft position (CKP) sensor connector (A) and variable valve timing control (VTC) oil control solenoid valve connector (8).
11. Remove the side engi ne mount bracket.
12. Remove the chain case.
8. Remove the VTC oil control solenoid valve (see step 1 on page 11-127) . 9. Support the engine with a jack and wood block under the oil pan. 10. Remove the ground cable (A), and remove the upper bracket (8).
(cont'd)
6-13
Cylinder Head
Cam Chain Removal (cont'd)
13. Loosely install the crankshaft pulley.
14. Turn the crankshaft counterclockwise to compress the auto-tensioner. 16. Remove the auto-tensioner.
I
17. Remove the cam chain guide 8.
15. Align the holes on the lock (AI and the autotensioner (81, then insert a 1.5 mm (0.06 in.1 diameter pin (el into the holes. Turn the crankshaft
clockwise to secure the pin.
6-14
Cam Chain Installation

18. Remove the cam chain guide A (A) and tensioner arm (8). NOTE: Keep the cam chain away from magnetic fields. 1. Set the crankshaft to top dead center (TOe). Align the TOe mark (A) on the crankshaft sprocket with the pointer (8) on the cylinder block.
19. Remove the cam chain.
2. Setthe camshafts to TOe. The punch mark (A) on the variable valve timing control (VTe) actuator and the punch mark (8) on the exhaust camshaft sprocket should be at the top. Align the TOe marks (e) on the VTe actuator and exhaust camshaft
sprocket.
B
(cont"d)
6-15
Cylinder Head
Cam Chain Installation (cont'd)
3. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the punch mark (8) on the crankshaft sprocket. 5. Install the cam chain guide A (A) and tensioner arm
(8).
6x 1.0mm
12Nm (1.2 kglm, 8.7Iblft)
j
!~
A B
1iIJ)
!~
-~
8 x , .25 mm
22Nm
4. Install the cam chain on the VTC actuator and

exhaust camshaft sprocket with the punch marks
12.2 kglm, 16 Iblftl
(A) aligned with the two colored pieces (8).

B
6. Install the auto-tensioner.
6x 1,0 mm 12Nm
11.2 kglm, 8.7Iblft)
"'.
6-16
7, Install the cam chain guide B,

_~8X1.25mm
10, Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes, 11, Clean and dry the chain case mating surfaces, 12, Apply liquid gasket, PIN 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes,
22N,m 12,2 kgf,m, 16lbf,ftl
8. Remove the pin from the auto-tensioner.
9, Check the chain case oil seal for damage, If the oil seal is damaged, replace the chain case oil seal (see page 6-21),
Apply liquid gasket along the broken line.
13, Apply liquid gasket to the cylinder block upper surface contact areas (A) on the chain case. 14, Apply liquid gasket, PIN 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes, NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket, Instead, reapply liquid gasket after removing old residue,
~~~
(conrd)
6-17
Cylinder Head
Cam Chain Installation (cont'd)
15. Install the new O-ring (A) on the chain case. Set the edge of the chain case (8) to the edge of the oil pan (e), then install the chain case on the cylinder block
(D).
16. Install the side engine mount.braeket.
NOTE: When installing the chain case, do not slide

the bottom surface on the oil pan mounting surface.
--
10xl.25mm
44Nm
14.5 kgfm, 33 Ibf,ltl

--: I
N
.~
17. Install the upper bracket (AI. then tighten the bolt!
nuts in the numbered sequence shown.
A
6x 1.0 mm 12Nm 11.2 kgfm, 8.7 Ibfltl
-~J
6x 1.0 mm 12Nm 11.2 kgfm, 8.7 Ibfltl
I "..
A B
D----....
18. Install the ground cable (8).
~c
6-18
Auto-Tensioner Removal! Installation

19. Install the variable valve timing control (VTC) oil control solenoid valve (see step 1 on page 11-127).
Removal:
20. Connect the crankshaft position (CKP) sensor connector (A) and VTC oil control solenoid valve connector (B).
1. Remove the chain case cover.
)
B
/,.~.1,;./,.,'. /~.<.,
':. ..
, ,
.. :
'
'.
-,"',
';
-~~~~'- ,~',/
~.-
21. Install the crankshaft pulley (see page 6-12). 22. Install the cylinder head cover (see page 6-41). 23. Install the drive belt. 24. Install the splash shield.
2. Turn the crankshaft counterclockwise to compress the autotensioner.
"
'." ,
R:>.....', , g
~
CfftJ'
~
{1;~
(conl'd)
6-19
Cylinder Head
Auto-Tensioner Removal/Installation (cont'd)
3. Align the holes on the lock IAI and the autotensioner IB), then insert a 1.5 mm 10.06 in.1 diameter pin lei into the holes. Turn the crankshaft clockwise to secure the pin.
Installation:
1. Install the auto-tensioner.
-- ----
;;;/
j~~
4. Remove the auto-tensioner.
6x 1.0 mm 12 Nm 11.2 kgf.m, 8.7Ibf1t1
----------
2. Remove the pin from the auto-tensioner.
./C
6-20
Chain Case Oil Seal Installation

3. Remove old liquid gasket from the chain case cover mating surfaces, bolts, and bolt holes.
4. Clean and dry the chain case cover mating surfaces.
Special Tool. Required Driver 0774S-00 I 0000 Attachment, 52 x 55 mm 07746-0010400

1. Use the special tools to drive a new oil seal squarely into the chain case to the specified
5. Apply liquid gasket, PIN 08718-000S, evenly to the

chain case mating surface of the chain case cover
installed height.
and to the inner threads of the holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
07746-0010400
2. Measure the distance between the chain case
surface (AI and oil seal (B).
6. Install the chain case cover.

Oil Sealln.talled Height:
33.0-33.7 mm (1.30-1.33 in.)
33.0 33.7 mm 11.30 - 1.33 in.1
6-21
Cylinder Head
Cylinder Head Cover Removal
4. Remove the cylinder head cover.
2. Remove the four ignition coils (see page 4-18). 3. Remove the dipstick (A) and breather hose (6).
,',
'\\
,1--><',
<'--B
6-22
Cylinder Head Removal

NOTE: Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100F (38C) before loosening the cylinder head bolts. 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. Drain the engine coolant (see page 10-6). 2. Remove the drive belt (see page 4-26). 3. Remove the intake manifold (see page 9-3). 4. Remove the air cleaner housing (see step 7 on page
5-2).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head. Engine coolant temperature (ECT) sensor connector Camshaft position (CMP) (top dead center (TDC)) sensor B connector Camshaft position (CMP) sensor A connector 9. Remove the upper radiator hose (A) and heater hose (8).
5. Remove the water bypass hose (A).
10. Remove the harness holder (A) from the bracket, then remove the connecting pipe mounting bolt (8)
and brake booster vacuum line mounting bolts (C).
6. Remove the exhaust manifold (see page 9-7). 7. Remove the cam chain (see page 6-12).
~\ ,~ c ~
11. Remove the water bypass hose (D).
(cont'd)
6-23
Cylinder Head
Cylinder Head Removal (cont'd)
12. Remove the rocker arm assembly (see page 6-261. 13. Remove the cylinder head bolts. To prevent
warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are
VTC Actuator, Exhaust Camshaft Sprocket Replacement

Removal:
1. Remove the cam chain (see page 6-121. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTCI actuator mounting bolt and exhaust camshaft sprocket mounting bolt.
'-
loosened.
CYLINDER HEAD BOLTS LOOSENING SEQUENCE:
14. Remove the cylinder head.
3. Remove the VTC actuator and exhaust camshaft sprocket.
I
6-24
Cylinder Head Inspection for Warpage

Installation:
1. Install the VTC actuator and exhaust camshaft
sprocket.
1. Remove the cylinder head jsee page 6-23). 2. Inspect the camshaft (see page 6-29).
2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt, then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgfm, B3Ibflt) Exhaust camshalt sprocket mounting bolt: 72 Nm (7.3 kgf.m, 53Ibflt)
3. Check the cylinder head for warpage. Measure along the edges, and three ways across the center . If warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacing is not required.
If warpage is between 0.05 mm (0.002 in.) and 0.2 mm (0.008 in.), resurface the cylinder head. Maximum resurface limit is 0.2 mm (0.008 in.) based on a height of 104 mm (4.09 in.). Cylinder Head Height: Standard (New): 103.95- 104.05 mm (4.093-4.096 in.)
4. Install the cam chain (see page 6-15).
PRECISION STRAIGHT EDGE
6-25
Cylinder Head
Rocker Arm Assembly Removal
1. Remove the cam chain (see page 6-12). 2. Loosen the rocker arm adjusting screws (A). 5. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B). 4. Remove the cam chain guide B, camshaft holders, and camshafts.
3. Remove the camshaft holder bolts. To prevent

damaging the camshafts, unscrew the bolts two turns at a time, in a crisscross pattern.
CAMSHAFT HOLDER BOLTS LOOSENING SEQUENCE:
"'--
6-26
Rocker Arms and Shafts Disassembly/Reassembly

NOTE:
Identify parts as they are removed to ensure reinstallation in original location.
o
Inspect the rocker shafts and rocker arms (see page 628) . When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. Bundle the rocker arms with rubber bands to keep them together as a set.
The rocker arms must be installed in the same positions if reused.

o
I ln~ _ _ _--1,,~
____ ____
~,,~
~n~
_ _---,-~nJ
1...____ SHAFT ROCKER EXHAUST
No. t CAMSHAFT
HOLDER RUBBER BAND
o
I
-~
'[
I
o
--
I ----------- '-6j
,
---,
No.5 CAMSHAFT
HOLDER
.............. .
----------'
----
'"
""
No.2
CAMSHAFT HOLDER
NO.3
CAMSHAFT HOLDER
No.4 CAMSHAFT HOLDER
INTAKE ROCKER ARM ASSEMBLY
h~__-,,,~__
--.J
L----~rJ~KEROCKERSHAFT
6-27
Cylinder Head
Rocker Arms and Shafts Inspection
1. Remove the rocker arm assembly (see page 6-261.
4. Measure the inside diameter of the rocker arm, and check it for an out-af-round condition.
2. Measure the diameter of the shaft at the first rocker

location. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.025-0.052 mm (0.0010-0.0020 in.) Exhaust: 0.018-0.056 mm (0.0007 - 0.0022 in.) Service Limit: 0.08 mm (0.003 in.)
3. Zero the gauge (A) to the shaft diameter.
5. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all overtolerance rocker arms. If any VTEC
rocker arm needs replacement, replace the rocker arms (primary and secondary) as a set.
',-
6. Inspect the rocker arm pistons (A). Push each piston manually. If it does not move smoothly, replace the rocker
arm set.
NOTE: Apply oil to the pistons when reassembling.
I
6-28
Camshaft Inspection
NOTE: Do not rotate the camshaft during inspection. 1. Remove the rocker arm assembly (see page 6-26L and disassemble it (see page 6-271. 2. Put the rocker shaft holders, camshaft, and camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 8mm bolts: 22 Nm (2.2 kgf.m, 16lbfftl 6 mm bolts: 12 Nm (1.2 kgfm, 8.7Ibfftl 6 mm bolts: 11]), @, @ 3. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head. 4. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth and read the end play. If the end play is beyond the service limit, replace the camshaft head and recheck. If it is still beyond the service limit, replace the cylinder. Camshaft End Play: Standard (Newl: 0.05-0.20 mm (0.002-0.008 in. I Service Limit: 0.4 mm (0.02 in.)
(cont'dl
6-29
Cylinder Head
Camshaft Inspection (cont'd)
5. Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the
10. Check the total runout with the camshaft supported on V-blocks.
camshaft holders from the cylinder head. 6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pined, scored, or
excessively worn.
If the total runout of the camshaft is within the service limit, replace the cylinder head.
If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-
7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a
plastigage strip across each journal.
to-holder oil clearance. If the oil clearance is still beyond the service limit, replace the cylinder head.
Camshaft Total Runout: Standard (Newl: 0.03 mm (0.001 in. I max. 0.04 mm (0.002 in. I Service Limit:
8. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 2. 9. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. If the camshaft-to-holder clearance is within limits, go to step 11. If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head.
If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been
replaced, go to step 10.

Camshaft-to-Holder Oil Clearance: Standard (New): No.1 Journal: 0.030-0.069 mm (0.001-0.003 in.) No.2, 3, 4, 5 Journals: 0.060-0.099 mm (0.002-0.004 in.) 0.15 mm (0.006 in.1 Service Limit:
11. Measure cam lobe height.
Cam L0 b e Helgl t Stan d ard (N ew: . h INTAKE EXHAUST PRI 33.925 mm 34.092 mm (1.3356 in.) (1.3422 in.) SEC 29.638 mm (1.1668 in.) PRI: Primary SEC: Secondary C/C: Cam Chain
INTAKE SEC PRI
6-30
.. _ " "
Valves, Springs, and Valve Seals Removal

Special Tools Required Valve spring compressor attachment 07VAE-0010l0A
4. Install the valve guide seal remover.
Identify the valves and valve springs as they are

removed so that each item can be reinstalled in its original position.
1. Remove the cylinder head Isee page 6-231.
2. Using an appropriate-sized socket IAI and plastic mallet (6). lightly tap the valve retainer to loosen the valve keepers.
5. Remove the valve seal.
3. Install the spring compressor. Compress the spring, and remove the valve keepers.
6-31
Cylinder Head
Valve Inspection
1. Remove the valves Isee page 6-311.
Valve Stem-to-Guide Clearance Inspection

1. Remove the valves Isee page 6-311.
2. Measure the valve in these areas.

Intake Valve Dimensions
2. Slide the valve out of its guide about 10 mm, then

measure the guide-ta-stem clearance with a dial indicator while rocking the stem in the direction of
A Standard INew): 34.85-35.15 mm 11.372-1.384 in.) B Standard INew): 108.7-109.5 mm 14.280-4.311 in.) C Standard INew): 5.475-5.485 mm 10.2156-0.2159 in.) C Service Limit: 5.445 mm 10.214 in.)
Exhaust Valve Dimensions
normal thrust Iwobble methodl.

If the measurement exceeds the service limit, recheck it using a new valve. If the measurement is now within the service limit, reassemble using a new valve. If the measurement with a new valve still exceeds the service limit, go to step 3.
A Standard INew): 29.85-30.15 mm 11.175-1.187 in.) B Standard INew): 108.3-109.1 mm 14.264-4.295 in.) C Standard INew): 5.450-5.460 mm 10.2146-0.2150 in.) C Service Limit: 5.42 mm 10.213 in.)
Intake Valve Stem-to-Guide Clearance: Standard INew): 0.06-0.11 mm 10.002-0.004 in.) Service Limit: 0.16 mm (0.006 in.)
Exhaust Valve Stem-to-Guide Clearance:
---
Standard INew): 0.1 1 -~o. 16 mm 10.004-0.006 in.) Service Limit: 0.22 mm 10.009 in.)
;p-------.-----:-[]
3. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. ofthe valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit.
Intake Valve Stem-to-Guide Clearance: Standard INew): 0.030-0.055 mm 10.0012-0.0022 in.) Service Limit: 0.08 mm 10.003 in.)
Exhaust Valve
Stem4o~Guide
Clearance:
Standard INew): 0.055-0.080 mm 10.0022-0.0031 in.) Service Limit: 0.11 mm 10.004 in.)
; ,4
6-32
Valve Guide Replacement

Valve guide driver, 5.5 mm 07742-0010100 Valve guide reamer, 5.5 mm 07HAH-PJ7010B 1. Inspect valve stem-to-guide clearance (see page 632). 2. As illustrated below, use a commercially available air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer.
5. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 in.) towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the

valve guide to prevent damaging the driver.
6. Turn the head over, and drive the guide out toward the camshaft side of the head.
[~_~D
5.3mm (0.21 in.)
I-:L~
87mm 57mm ~ 13.43 in.}---r--- 12.24 in.} -
Tr
10.8 mm {0.42 in.}
3. Select the proper replacement guides, and chill

them in the freezer section of a refrigerator for about an hour.
4. Use a hot plate or oven to even}y heat the cylinder head to 300"F (150"C). Monitor the temperature with a cooki ng thermometer. Do not get the head hotterthan 30D"F (15D"C); excessive heat may
loosen the valve seats.
7. If a valve guide won't move, dri}l it out with a 8 mm (5/16 inch) bit. then try again. Drill guides only in
extreme cases; you could damage the cylinder
head if the guide breaks. 8. Remove the new guide(s) from the freezer, one at a
time, as you need them.
Icont'd}
6-33
Cylinder Head
Valve Guide Replacement (cont'd)
9. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (B). If you have all 16 guides to do, you may have to rehealthe head. 10. Coat both reamer and valve guide with cutting oil. 11. Rotate the reamer clockwise the full length of the
valve guide bore.
07HAH-PJ7010B
Valve Guide Installed Height: Intake: 15.2-16.2 mm (0.598-0.638 in.) Exhaust: 15.5-16.5 mm (0.610-0.650 in.)
07742-0010100
~.
12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water

to remove any cutting residue.
14. Check the clearances with a valve (see page 6-32).

Verify that a valve slides in the intake and exhaust valve guides without exerting pressure.
6-34
Valve Seat Reconditioning

,. Inspect valve stem-to-guide clearance (see page 632). If the valve guides are worn, replace them (see page 6-33) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a valve seat cutter.
5. Make one more very light pass with the 45' cutter to remove any possible burrs caused by the other
cutters.
Valve Seat Width: Standard (New): 1.25-1.55 mm (0.049-0.061 in.) Service Limit: 2.00 mm (0.079 in.)
6. After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue compound (A) to the

valve face. Insert the valve in its original location in
the head, then lift it and snap it closed against the

seat several times.
3. Carefully cut a 45 seat, removing only enough material to ensure a smooth and concentric seat.
4. Bevel the upper and lower edges at the angles

shown in the illustration.
Check the width of the seat and adjust accordingly.
INTAKE: 35 EXHAUST: 30
7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. If it is too high (closer to the valve stem), you
must make a second cut with the 67.5 cutter to move it down, then one more cut with the 45 cutter to restore seat width.
If it is too low (close to the valve edge), you must

make a second cut with the 35 cutter (intake
sidel or the 30' cutter (exhaust sidel to move it up,

then make one more cut with the 45 cutter to restore seat width.
NOTE: The final cut should always be made with

the 45 cutter.
(cont'dl
6-35
Cylinder Head
Valve Seat Reconditioning (cont'd)
8, Insert the intake and exhaust valves in the head, and measure valve stem installed height (A),
Intake Valve Stem Installed Height: Standard (New): 40,8-41,0 mm (1,606-1,614 in.) Exhaust Valve Stem Installed Height: Standard (New): 54.6-54,8 mm (2,150-2.157 in.)
9. If valve stem installed height is over the standard,
replace the valve and recheck, If it is still over the standard, replace the cylinder head; the valve seat in the head is too deep,
6-36
Valves, Springs, and Valve Seals Installation

Special Tools Required Valve spring compressor attachment 07VAE-00101 OA 1. Coatthe valve stems with engine oil. Install the
valves in the valve guides. 6. Install the valve retainer.
5. Install the valve spring. Place the end of the valve

spring with closely wound coils toward the cylinder
head.
2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F). They are not interchangeable.
F
7. Install the valve spring compressor. Compress the spring, and install the valve keepers. Remove the valve spring compressor.
~
f--
c
B
8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem.
6-37
Cylinder Head
Rocker Arm Assembly Installation
:.ean and dry the No.5 rocker shaft holder mating surfaces.
~eassemble
5. Remove the bolts from the rocker shaft holder.
the rocker arm assembly Isee page 6-
27 !.
_ .l.pply liquid gasket, PIN 08718-0009, evenly to the :ylinder head mating surface of the No.5 rocker shaft holder. '.OTE: Do not install the parts if 5 minutes or more cave elapsed since applying liquid gasket. Instead, 'eapply liquid gasket after removing old residue.
6. Make sure the punch marks on the variable valve timing control IVTCI actuator and exhaust camshaft sprocket are facing up, then set the camshafts IAI in the holder.
4. Insert the bolts IAI into the rocker shaft holder, then install the rocker arm assembly IBI on the cylinder head.
7. Set the camshaft holders (BI and cam chain guide B ICI in place. 8. Tighten the bolts to the specified torque.
Specified torque:
8 mm bolts: 6 mm bolts: 6 mm bolts: 22 Nm (2.2 kgf.m, 16lbfftl 12 Nm (1.2 kgfm, 8.7Ibfftl @, @, @
9. Install the cam chain (see page 6-151, and adjust the valve clearance Isee page 6-91.
6-38
Cylinder Head Installation

Install the cylinder head in the reverse order of
removal:
5. Measure the diameter of each cylinder head bolt at point A and paint B.
B 50 mm (2.0 in.1
~----
1. Clean the cylinder head and block surface. 2. Install the new cylinder head gasket (AI and dowel pins (BI on the cylinder block. Always use a new cylinder head gasket.
.
:..---~
A 45 mm It.B in.1
...
.m1lI.~ .~ .. ~~.- ..
.'
6. If either diameter is less than 10.6 mm (0.42 in.l, replace the cylinder head bolt.
3. Set the crankshaft to top dead center (TDCI. Align

the TDC mark (Alan the crankshaft sprocket with the pointer (BI on the cylinder block.
4. Install the cylinder head on the block.
(conrdl
6-39
Cylinder Head
Cylinder Head Installation (cont'd)
7. Apply engine oil to the bolt threads and under the bolt heads of all the cylinder head bolts. 8. Tighten the cylinder head bolts in sequence to 39 Nom (4.0 kgf.m, 29Ibf.ft). Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step. 10. Install the rocker arm assembly (see page 6-38). 11. Install the water bypass hose (A).
B 6x 1.0mm
C 6x 1.0 mm
12Nm (1.2 kgfm, 8.7Ibfftl
12 Nm (1.2 kgfm, 8.7Ibfftl
9. After torquing, tighten all cylinder head bolts in two steps (90' per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90'.
12. Tighten the connecting pipe mounting bolt (8) and brake booster vacuum line mounting bolts (e), then install the harness holder (D) on the bracket. 13. Install the upper radiator hose (A) and heater hose
(8).
~g.
A
6-40
Cylinder Head Cover Installation

14. Install the water bypass hose. 1. Thoroughly clean the head cover gasket and the groove. 2. Install the head cover gasket (A) in the groove of the cylinder head cover (BI.
15. Install the air cleaner housing (see step 37 on page 5-151. 16. Install the intake manifold (see page 9-51. 17. Install the exhaust manifold (see page 9-71. 3. Check that the mating surfaces are clean and dry. 4. Apply liquid gasket, PIN 08718-0009, on the chain case and the No.5 rocker shaft holder mating areas. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
18. Install the cam chain (see page 6-151 . 19. Adjust the valve clearance (see page 6-91. 20. Install the drive belt (see page 4-261. 21. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease
to prevent corrosion.
-T~-\-""
22. After installation, check that all tubes, hoses and

connectors are installed correctly.
, -;j/~'
\, ---"' L-...-.J>--"
23. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starterl so that the fuel pump runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
T~!
,.1
\- f---=--
check for fuel leakage at any point in the fuel line. 24. Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
Apply liquid gasket to these points. Apply liquid gasket to these points.
open (see page 10-61. 25. Inspectthe idle speed (see page 11-1381. 26. Inspect the ignition timing (see page 4-17) .
(cont'd)
6-41
Cylinder Head
Cylinder Head Cover Installation (cont'd)
5. Set the spark plug seals (A) on the spark plug tubes. Once the cylinder head cover (8) is on the cylinder head, slide the cover slightly back and larth to seat the head cover gasket. 7. Tighten the bolts in two or three steps. In the linal step, tighten all bolts, in sequence, to 9.8 Nm 11.0 kglm, 7.2 Iblft).
rf:'
________________~O,
-@
.00_ ~,@L_ @
oo~
8. Install the dipstick IA) and breather hose IBI.
6. Inspect the cover washers Ie). Replace any washer that is damaged or deteriorated.
~.' \~'
.... ' "
6-42
9. Install the four ignition coils (see page 4-18).
10. Check that all tubes, hoses, and connectors are installed correctly.
11. Install the intake manifold cover.
,
/
6Xl.0mm 12 Nm 11.2 kglm,
8.7Ibl1t1
12. After assembly, wait at least 30 minutes before lilling the engine with oil.
6-43

Engine Mechanical
Engine Block
Special Tools ................................................................. Component Location Index ......................................... Connecting Rod and Crankshaft End Play Inspection .................................................................. Crankshaft Main Bearing Replacement ...................... Connecting Rod Bearing Replacement ...................... Oil Pan Removal ........................................................... Crankshaft and Piston Removal .................................. Crankshaft Inspection .................................................. Block and Piston Inspection ........................................ Cylinder Honing ............................................................ Piston, Pin and Connecting Rod Replacement .......... Piston Ring Replacement ............................................. Piston Installation ......................................................... Connecting Rod Bolt Inspection .................................. Crankshaft Installation ................................................. Oil Pan Installation ....................................................... Transmission End Crankshaft Seal Installation-In Car ...................................................... 7-2 7-3 7-5 7-6 7-8 7-11 7-12 7-14 7-15 7-17 7-18 7-21 7-23 7-24 7-24 7-27 7-28
Engine Block
Special Tools
Ref. No.
Tool Number Description
I
I
Qty
CD
@ @
07ZADPNAA 100 077460010700 077490010000
\ Oil Seal Driver Attachment 96 Attachment, 24 x 26 mm Driver
1 1 1
~
CD CD
7-2
Compo nent Location Index

BAFFLE PLATE
~AI IN BEARINGS I I C earan Selection , page 7-6 7-6 ee, page

FLYWHEEL CRANKSH lRANSMI:~21~NSDEAL'
nstaliation , st ep 21 on page 7-26
THRUST WASHERS
CRANKSHAFT End pi Runou~Y, page 7-5 Out-of R' page7-14 emovalound ,page 7-14 R lnstallati~ n, page-12 page 7 7-24
(conl'd)
7-3
Engine Block
Component Location Index (cont'd)
~~o ~~ Q 't=~=> ~PISTONPIN

PISTON Removal, page 7-12 Measurement, page 7-15 Removal, page 7-18 Inspection, page 7-19 Installation, page 7-20
CONNECTING ROD End play, page 7-5 Small end measurement page 7-19
~
CONNECTING ROD BEARINGS clearance, page Selection page 7-9 ,
~.~ f B
-,
ENGINE BLOCK Cylinder bore inspection, page 7-15 Warpage inspection, page 7 -15 Cylinder bore honing, page 7-17 Ridge removal, step 13 on page 7-13
Oil
7-8!.
If\ . ~____ ~
~
______
CONNECTING ROD
BEARING CAP
/c
CONNECTING ROD BOLT Inspection, page 7-24
7-4
Connecting Rod and Crankshaft End Play Inspection

1. Remove the oil pump (see page 8-91.
2. Remove the baffle plates (see step 6 on page 7-121. 5. Install a dial indicator as shown. Push the crankshaft lirmly away Irom the dial indicator, and zero the dial against the end 01 the crankshaft. Then pull the crankshaft lirmly back toward the indicator;
the dial reading should not exceed the service limit. Crankshaft End Play Standard (Newl: 0.10-0.35 mm Service Limit:
3. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft.
Connecting Rod End Play Standard (New): 0.15-0.30 mm Service Limit:
(0.006-0.012 in.1 0.40 mm (0.016 in.)
(0.004-0.014 in.) 0.45 mm (0.018 in.)
4. If the connecting rod end play is out-of-tolerance,

install a new connecting rod, and recheck. If it is
6. II the end play is out-aI-tolerance, replace the thrust washers and recheck. II it is still out-aI-tolerance, replace the crankshaft.
still out-aI-tolerance, replace the crankshaft (see page 7-121 .
7-5
Engine Block
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection
1. To check main bearing-ta-journal oil clearance, remove the lower block and bearing halves (see page 7-12). 2. Clean each main journal and bearing hall with a clean shop towel. 3. Place one strip of plastigage across each main journal. 6. If the plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper hall olthe bearing. Install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. II the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
\..
4. Reinstall the bearings and lower block, then torque the bolts to 29 Nm (3.0 kglm, 22 Iblft) + 56.
NOTE: Do not rotate the crankshaft during inspection.
5. Remove the lower block and bearings again, and measure the widest part 01 the plastigage.
Main 8earing-to-Journal Oil Clearance No. 1,2, 4, 5 Journals: Standard (New): 0.017 - 0.041 mm (0.0007 - 0.0016 in.) Service Limit: 0.050 mm (0.0020 in.) No.3 Journal: Standard (New): 0.025 - 0.049 mm (0.0010 - 0.0019 in.) Service Limit: 0.055 mm (0.0022 in.)
7-6
Main Bearing Selection

Crankshaft Bore Code Location
1. Numbers or letters or bars have been stamped on
Main Journal Code Location 2. The main journal codes afe stamped on the crankshaft.
the end of the block as a code for the size of each of

the five main journal bores. Write down the crank
bore codes. If you can't read the codes because of accumulated dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
NO.5 JOURNAL (FLYWHEEL ENOl No.1 JOURNAL (PULLEY END)
f2J~
. . ..
/~~
No.1 JOURNAL NO.5 JOURNAL
AAA A
Icont'd)
7-7
Engine Block
Crankshaft Main Bearing Replacement (cont'd)
3. Use the crank bore codes and crank journal codes
to select the appropriate replacement bearings
Connecting Rod Bearing Replacement

Rod Bearing Clearance Inspection
1. Remove the oil pump Isee page 8-9). 2. Remove the baffle plates Isee step 6 on page 7-12).
from the following table. NOTE: Color code is on the edge of the bearing . When using bearing halves of different colors, it
does not matter which color is used in the top or
3. Remove the connecting rod cap and bearing half.

4. Clean the crankshaft rod journal and bearing half
with a clean shop towel.
bottom.
.,. Larger crank bore 2 or
Main journal
Crank bore
5. Place plastigage across the rod journal. 6. Reinstall the bearing half and cap, and torque the bolts to 20 Nm 12.0 kgf.m, 14Ibfft) -j 90 '.
NOTE: Do not rotate the crankshaft during
inspection.
code
B or"
,3 or : C or III
4 or
D or 1111
code
1
---
... Smaller bearing (Thicker) Pink
Pink!
Yellow
Yellow: Green Green

I I
1--Pink!
Yellow
2
3
Yellow
Green!
Brown
I-----r----r----- --Yellow
7. Remove the rod cap and bearing half, and measure
f-----4
I----+_
Green
Gr.en
Green! Brown Brown

Brown
I
i
the widest part of the plastigage. Connecling Rod Bearing-la-Journal Oil

Clearance:
--
i Brown
'Greenl
Black
1-----+--5
Green! Brown
Brown Smaller
"--------t
Black Black! Blue
Blue
Brown Black
II
Black!
Standard (New):
Service Limit:
0.020-0.050 mm 10.0008-"0.0020 in.) 0.060 mm 10.0024 in.)
6
Smaller
Blue
main
journal
bearing
(Thicker!
7-8
8. 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(s), and
recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.
Rod Bearing Selection

1. Inspect each connecting rod for cracks and heat damage. Connecting Rod Big End Bore Code Locations
9. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearing, replace the crankshaft and start over.
2. Each rod has a tolerance range from 0-0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3 or 4/1, II, III, or 1111) indicating the range. You may find any
combination of numbers and bars in any engine.
(Half the number or bar is stamped on the bearing cap, the other half on the rod.) If you can't read the code because of an
accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent.
Normal Bore Size: 48.0 mm 11.89 in.)
'-".' 0
,
~;--<
(cont'd)
7-9
Engine Block
Connecting Rod Bearing Replacement (cont'd)
Connecting Rod Journal Code Location 4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table.
NOTE: Color code is on the edge of the bearing. When using bearing halves of different colors, it does not matter which color is used in the top or bottom.
Big end
bore
.. Larger big end bore
\..
3. The connecting rod journal codes are stamped on the crankshaft.

Connecting Rod Journal Code Location (Letters or Bars)
code
Rod
journal
~
code
A
B
~
Smaller bearing (Thicker)
Pink
Pink!
Yellow Green
Yellowl Green
Yellow Yellow/ Green Green
Greenl
Brown
Brown
Greenl Brown!
Brown Black
Black
D
/
Brown
Brown! Black
Blackl Blue
Blue
Smaller
rod
journal
Smaller bearing (Thicker)
No.1 JOURNAL
No.4 JOURNAL
7-10
Oil Pan Removal

1. Drain the engine oil (see page 8-51.
2. If the engine is stili in the vehicle, remove the subframe. -1 Attach the chain hoist to the engine (see step 35 on page 5-61. -2 Disconnect the suspension lower arm ball joints (see step 3 on page 18-191. -3 Remove the rear mount mounting bolts (see step 39 on page 5-71. -4 Remove the front mount mounting bolt (see step 40 on page 5-71. -5 Use a marker to make alignment marks on the reference lines that align with the centers of the rear subframe mounting bolts. Remove the front subframe (see step 43 on page 5-81. 6. Remove the oil pan. 3. Remove the bolts/nuts securing the oil pan. 4. Drive an oil pan seal cutter between the oil pan and cylinder block. 5. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan.
7-11
Engine Block
Crankshaft and Piston Removal
1. Remove the engine assembly Isee page 5-21. 2. Remove the transmission Isee page 13-41. 3. Remove the oil pan Isee page 7-111. 4. Remove the oil pump Isee page 8-91. 5. Remove the cylinder head Isee page 6-231. 6. Remove the baffle plates.
,~
8. Remove the bearing cap bolts. To prevent warpage,

unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all bolts are loosened.
(j;.
..
0
'
"
()
10
,
0
'
1.0
.,
;'
J
.
~
(~: 0"
{)
j
~~
10
I
9. Remove the lower block and bearings. Keep all 7. Remove the 8 mm bolts.
bearings in order.
I -
'I))
'J.!'
:1:
7-12
10. Remove the rod caps/bearings. Keep all caps/

bearings in order.
14. Use the wooden handle of a hammer (A) to drive out the pistons (B).
11. Lift the crankshaft out of the engine, being careful

not to damage the journals.
15. Reinstall the lower block and bearings on the

engine in the proper order. 16. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod
assembly. 17. To avoid mixup on reassembly, mark each piston/

connecting rod assembly with its cylinder number.
12. Remove the upper bearing halves from the
NOTE: The existing number on the connecting rod
connecting rods, and set them aside with their respective caps. 13. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a
ridge reamer (A). Followthe reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.
does not indicate its position in the engine, it indicates the rod bore size.
7-13
Engine Block
Crankshaft Inspection
Out-ol-Round and Taper 1. Remove the crankshaft from the cylinder block (see page 7-121. 2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 3. Clean the keyway and threads. 4. Measure out-of round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-ol-Round Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.) 9. Measure runout on all main journals. Rotate the crankshaft two complete revolutions. The Straightness 6. Place the cylinder block on the surface plate. 7. Clean and install the bearigns on the No.1 and No.5 journal of the cylinder block. 8. Lower the crankshaft into the block.
difference between measurements on each journal

must not be more than the service limit. Crankshaft Total Runout Standard (New): 0.03 mm (0.0012 in.1 max. Service Limit: 0.04 mm (0.0016 in.1
EB
5. Measure taper at the edges of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.)
7-14
Block and Piston Inspection

1. Remove the crankshaft and pistons Isee page 7-12).
4. Measure wear and taper in direction X and Y at
three levels in each cylinder as shown. If 2. Check the piston for distortion or cracks.
measurements in any cylinder are beyond the oversize bore service limit, replace the block. If the
3. Measure the piston diameter at a point 11 mm 10.4 in.) from the bottom of the skirt. There are two standard-size pistons INa Letter or A, and B). The letter is stamped on the top of the piston. Letters are also stamped on the block as cylinder bore
sizes.
Piston Diameter:
block is to be rebored, refer to step 7 after reboring. Cylinder Bore Size Standard INew): A or I: 86.010-86.020 mm 13.3862-3.3866 in.) B or II: 86.000-86.010 mm 13.3858-3.3862 in.) Service Limit: 86.070 mm 13.3886 in.)
Oversize:
Standard INew): No Letter lor A): 85.980-85.990 mm 13.3850-3.3854 in.) B: 85.970-85.980 mm 13.3846-3.3850 in.)
Service Limit:
0.25: 86.250-86.260 mm 13.3957-3.3961 in.)

Reboring limit:
0.25 mm 10.01 in.) max.
No Letter lor A): 85.930 mm 13.3831 in.! B: 85.920 mm 13.3827 in.)
Bore Taper: Limit: IDifference between first and third measurement) 0.05 mm 10.002 in.)
11 mm
10.4 in.J
PISTON DIAMETER
First
Measurement
Second
'--~O
Measurement
Third
Measurement
6 mm (O.2 in.)
No.4
Oversize Piston Diameter:
0.25: 86.230-86.240 mm 13.3949 -3.3953 in.)
Iconl'd)
7-15
Engine Block
Block and Piston Inspection (cont'd)
5. Scored or scratched cylinder bores must be honed. 6. Check the top of the block for warpage. Measure
along the edges and across the center as shown.
7. Calculate the difference between the cylinder bore

diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear.
Engine Block Warpage Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0.004 in.)
Piston-to-Cylinder Clearance Standard (New): 0.020-0.040 mm (0.0008-0.0016 in.) Service Limit: 0.05 mm (0.002 in.)
_ _ _ _ PISTON-TO-CYLINDER CLEARANCE
PRECISION STRAIGHT EDGE
':---1
7-16
Cylinder Honing
Only a scored or scratched cylinder bore should be honed. 1. Measure the cylinder bores (see page 7-151. If the block is to be reused, hone the cylinders and
remeasure the bores.
2. Hone the cylinder bores with honing oil and a fine (400 gritl stone in a 60 degree cross-hatch pattern (A). Use only a rigid hone with 400 grit or finer
stone such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or broken.
3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and
oil them immediately to prevent rusting. Never use
solvent, it will only redistribute the grit on the cylinder walls.

4. If scoring or scratches are still present in the cylinder bores after honing to the service limit,
rebore the cylinder block. Some light vertical scoring and scratching is acceptable if it is not deep
enough to catch your fingernail and does not run
the full length of the bore.
7-17
Engine Block
Piston, Pin, and Connecting Rod Replacement
Disassembly
1. Remove the piston from the cylinder block (see
page 7-12). 2. Apply engine oil to the piston pin snap rings (A),
and turn them in the ring grooves until the end
4. Heat the piston and connecting rod assembly to about 158F 170C), then remove the piston pin.
gaps are lined up with the cutouts in the piston pin bores (8). NOTE: Take care not to damage the ring grooves.
A
iL
I~
3. Remove both snap rings (A). Start at the cutout in

the piston pin bore. Remove the snap rings
carefully so they do not go flying or get lost. Wear

eye protection .
=_--:0.
~... ...
____ --
-::
7-18
Inspection
NOTE: Inspect the piston, piston pin, and connecting
rod when they are at room temperature.
3. Check the difference between the piston pin

diameter and piston pin hole diameter in the piston.
1. Measure the diameter of the piston pin.

Piston Pin Diameter
Piston Pin-to-Piston Clearance Standard (New): -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) Service Limit: 0.005 mm (0.0002 in.)
Standard (New): 21.961-21.965 mm (0.8646-0.8648 in.) Service Limit: 21.953 mm (0.8643 in.)
4. Measure the piston pin-to-connecting rod clearance.

Piston Pin-to-Connecting Rod Clearance Standard (New): 0.005-0.015 mm (0.0002-0.0006 in.) Service Limit: 0.02 mm (0.0008 in.)
2. Zero the dial indicator to the piston pin diameter.
o--_~---=-~_--~
~<--
=' =-==--= ----
(conl'd)
7-19
Engine Block
Piston, Pin, and Connecting Rod Replacement (cont'd)
Reassembly
1. Install a piston pin snap ring (A). 4. Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D) and the
embossed mark (E) on the same side. _
2. Coat the piston pin bore in the piston, the bore in

the connecting rod, and the piston pin with engine oil.
3. Heat the piston to about 158'F (70'C).
5. Install the remaining snap ring (F).

6. Turn the snap rings in the ring grooves until the
end gaps are positioned at the bottom of the piston.
......
7-20
Piston Ring Replacement

1. Remove the piston from the cylinder block (see page 7-121. 2. Using a ring expander (AI, remove the old piston rings (BI. 4. Using a piston, push a new ring (AI into the cylinder bore 15-20 mm 10.6-0.8 in.1 from the bottom.
15--20 mm (0.6-0.8 in.1
3. Clean all ring grooves thoroughly with a squaredoff broken ring or ring groove cleaner with a blade to fit the piston grooves. The top and 2nd ring grooves are 1.2 mm (0.05 in.1 wide. The oil ring groove is 2.0 mm (0.08 in.1 wide. File down a blade if necessary. Do not use a wi re brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools. NOTE: lithe piston is to be separated from the connecting rod, do not install new rings yet.
5. Measure the piston ring end-gap (BI with a feeler gauge: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits (see step 4 on page 7-151. If the bore is over the service limit, the cylinder block must be rebored. Piston Ring End-Gap Top Ring Standard (Newl: 0.20-0.35 mm (0.008-0.014 in.1 Service Limit: 0.60 mm (0.024 in.1 Second Ring Standard (Newl: 0.40-0.55 mm (0.016-0.022 in.1 Service Limit: 0.70 mm (0.028 in. 1 Oil Ring REKEN manufactured ring Standard (Newl: 0.25-0.65 mm (0.010-0.026 in.1 Service Limit: 0.75 mm (0.030 in.1 FEDERAL MOGUL manufactured ring Standard (Newl: 0.20-0.70 mm (0.008-0.028 in. 1 Service Limit: 0.80 mm (0.031 in. 1
(cont'dl
7-21
Engine Block
Piston Ring Replacement (cont'd)
6. Install the top ring and second ring as shown.The top ring (A) has a 1R mark or no mark and the second ring (8) has a 2R mark or 2ND mark. The marks must be facing upward.
A
8. Position the ring end gaps as shown:
OIL RING GAP
About 90
SECOND RING GAP
TOP RING GAP and SPACER RING GAP
OIL RING GAP PISTON PIN
9. After installing a new set of rings, measure the ring-ta-groove clearances:

Top Ring Clearance Standard (New): 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.) Service Limit: Second Ring Clearance Standard (New): REKEN manufactured ring 0.030-0.055 mm (0.0012-0.0022 in.) FEDERAL MOGUL manufactured ring 0.025-0.060 mm (0.0010-0.0024 in.) 0.13 mm (0.005 in.) Service Limit:
Piston Ring Dimensions:
Top Ring (Standard): A:3.1 mm (0.12 in.) B: 1.2 mm (0.05 in.) Second Ring (Standardl: A: 3.4 mm (0.13 in.) B: 1.2 mm (0.05 in.)
--:----
7, Rotate the rings in their grooves to make sure they do not bind.
7-22
Piston Installation
If the crankshaft is already installed
1. Set the crankshaft to bottom dead center 18DCI for
each cylinder. 2. Remove the connecting rod caps, then install the
If the crankshaft is not installed

1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
ring compressor, and check that the bearing is securely in place. 3. Position the arrow IAI facing the cam chain side of the engine.
2. Position the arrow IAI facing the cam chain side of the engine.
~~~q
---=-~:
A
A
4. Position the piston in the cylinder, and tap it in
3. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer IAI.
Maintain downward force on the ring compressor
using the wooden handle of a hammer IAI.

Maintain downward force on the ring compressor
181 to prevent the rings from expanding before

entering the cylinder bore.
B . . . 'i _____ A
181 to preventthe rings from expanding before

entering the cylinder bore.
B ...
~A
5. Stop after the ring compressor pops free, and check the connecting rod-ta-crank journal alignment before pushing the piston into place.
6. Check the connecting rod bearing clearance with
4. Position all pistons attop dead center.
plastigage Isee page 7-81. 7. Inspectthe connecting rod bolts Isee page 7-241.
8. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 20 Nm 12.0 kgf.m, 14lbfftl + 90.
7-23
Engine Block
Connecting Rod Bolt Inspection
1. Measure the diameter of each connecting rod bolt at point A and point B.
35mm 11.38 in.1
Crankshaft Installation
Special Tools Required Driver 077 49-00 10000 Attachment, 24 x 26 mm 077 46-0010700 Oil seal driver attachment 96 07ZAD-PNAA 100 1. Install the crankshaft end bushing with the special tools when replacing the crankshaft. Drive in the crankshaft end bushing until the special tools
bottom against the crankshaft.
07749-0010000
/
2. Calculate the difference in diameter between point A and point B.
Point A - Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.1 mm (0-0.004 in.)
3. If the difference in diameter is out of tolerance,
replace the connecting rod bolt. 2. Check the connecting rod bearing clearance with plastigage (see page 7-81.
3. Check the main bearing clearance with plastigage
(see page 7-61. 4. Inspect the connecting rod bolts Isee page 7-24).
7-24
5. Install the bearing halves in the cylinder block and connecting rods. 6. Apply a coat of engine oil to the main bearings and rod bearings. 7. Hold the crankshaft so rod journal No.2 and rod journal No.3 are straight up, and lower the crankshaft into the block. 8. Install the thrust washers (AI in the No.4 journal of the cylinder block.
B
12. Tighten the connecting rod bolts to 20 Nm (2.0 kgfm, 14 Ibfftl. 13. Tighten the connecting rod bolts an additional SO'. 14. Remove old liquid gasket from the lower block mating surfaces, bolts and bolt holes. 15. Clean and dry the lower block mating surfaces. 16. Apply liquid gasket, PIN 08718-000S, evenly to the cylinder block mating surface of the lower block and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
,~
c-" ,
__ ~'
- , ',>c,;ii
,\\ '3 / ; ) --',
r-~-~---0---~":-&--:~~:C"l
'-'
','::
'-'
S. Apply engine oil to the threads of the connecting rod bolts. 10. Seat the rod journals into connecting rod No.1 and connecting rod NO.4. Line up the mark (81 on the
connecting rod and cap, then install the caps and
bolts finger-tight. 11. Rotate the crankshaft clockwise, and seat the
journals into connecting rod No.2 and connecting
rod No.3. Line up the mark on the connecting rod and cap, then install the caps and bolts finger-tight.
(cont'dl
7-25
Engine Block
Crankshaft Installation (cont'd)
17. Putthe lower block on the cylinder block. 18. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf.m, 22 Ibfft).
'C!)
21. Use the special tools to drive a new oil seal squarely into the block to the specified installed height.
1,0
I
o
.!
,-.
1.0
- -,
1"}1,
V,
id iCy,
'\
07ZAD-PNAA 100
22. Measure the distance between the crankshaft (A) and oil seal (S).
1::[1
Oil Seal Installed Height:
5.5-6.5 mm
(0.22-0.26 in.)
19. Tighten the bearing cap bolts an additional 56. 20. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf.m, 16Ibfft).
___ 5.5-6.5 mm
10.22-0.26 in.1
',,--
"
',' - '
7-26
Oil Pan Installation

23. Install the baffle plates.
1. Remove old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes. 2. Clean and dry the oil pan mating surfaces.
9
,
3. Apply liquid gasket, PIN 08718-0009, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes.
NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
24. Install the oil pump (see page 8-14).
25 . Install the oil pan (see page 7-27). 26. Install the cylinder head Isee page 6-39), 27. Install the transmission (see page 13-8), 28. Install the engine assembly (see page 5-9).
4. Install the oil pan. 5. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 Nm 11.2 kgf.m, 8.7 Ibfft).
@@ @
@ @ @
\..--tAr~~~~Ifi'iJr--fi'--ri"lt---f
(])
\.
.~~
\
11
15
Icont'd)
7-27
Engine Block
Oil Pan Installation (cont'd)
6. II the engine is still in the vehicle, install the sublrame.
Transmission End Crankshaft Seal Installation - In Car
-1 Install the sublrame. Align the relerence lines on the sublrame with the bolt head center, then tighten the bolts (see step 5 on page 5-10). -2 Tighten the lront mounting bolt (see step 6 on page 5-10). -3 Tighten the rear mount mounting bolts (see step 7 on page 5-11).
-4 Connect the suspension lower arm ball joints
Driver 077 49-00 10000 Oil seal driver attachment 96 07ZAD-PNAA 100 1. Dry the crankshaft oil seal housing.
2. Use the special tools to drive a new oil seal squarely into the block to the specilied installed height.
(see step 6 on page 18-19). 7. After assembly, wait at least 30 minutes belore lilling the engine with oil.
07ZAD-PNAA 100
\...".
3. Measure the distance between the crankshaft (A) and oil seal (8).
Oil Seal Installed Height:
5.5-6.5 mm 10.22-0.26 in.)

-...-- 5.5-6.5 mm 10.22-0.26 in.!
~i
7-28

Engine Mechanical
Engine Lubrication
Special Tools ................................................................. Component Location Index ......................................... Oil Pressure Switch Test .............................................. Oil Pressure Test ........................................................... Engine Oil Replacement .............................................. Engine Oil Filter Replacement ..................................... Oil Filter Feed Pipe Replacement ................................ Oil Pump Overhaul ....................................................... Oil Pressure Switch Replacement ............................... 8-2 8-3 8-4 8-4 8-5 8-6 8-7 8-8 8-16
Engine Lubrication
Special Tools
Tool Number 07HAA-PJ70100
Descri tion
Oil Filter Wrench
\.- I 4
'-
41
8-2

WASHER
.~ ~ ~/"oo"
it'~~7!Jll~ .4~----~~y'?~ I~ ~ :g7~ 127
@ ~~FFLEPLATE
OIL PUMP CHAIN TENSIONER
"
_~~''-y--,
~OILCONTROL
.....
"
ORIFICE
CRANKSHAFT SPROCKET
OIL PRESSURE SWITCH Switch Test, page 8-4
OIL PUMP CHAIN GUIDE
Oil Pressure test, page 8-4 Replacement, page 8-16
8-3
Engine Lubrication
Oil Pressure Switch Test
1. Remove the YEURED wire (AI from the engine oil pressure switch (BI.
Oil Pressure Test

If the oil pressure indicator stays on with the engine
running, check the engine oil level. If the oil level is

correct: 1. Connect a tachometer.
2. Remove the engine oil pressure switch, and install
an oil pressure gauge (AI .
~
''.. '.'."
'.
-----------
.............
-'...
2. Check for continuity between the positive terminal (CI and the engine (groundl. There should be continuity with the engine stopped. There should
be no continuity with the engine running.
3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil
pressure switch.
3. Start the engine. Shut it off immediately if the

gauge registers no oil pressure. Repair the problem before continuing.
4. Allow the engine to reach operating temperature

(fan comes on at least twice). The pressure should
be: Engine Oil Temperature: 176F (80CI At Idle:

Engine Oil Pressure: 70 kPa (0.7 kgf/cm', 10 psi)
minimum
At 3,000 rpm: 300 kPa (3.1 kgf/cm', 44 psi)
minimum
5. If the oil pressure is NOT within specifications, inspect these items:
Check the oil screen for clogging. Check the oil pump (see page 8-81.
Check crankshaft and connecting rod bearing clearances.
8-4
Engine Oil Replacement

1. Warm up the engine.
2. Remove the drain bolt IAI, and drain the engine oil.
A
44 Nm t4.5 kgfm, 33 Ibf!t)
Do not overtighten.
3. Reinstall the drain bolt with a new washer 181. 4. Refill with the recommended oillsee page 3-21.
Capacity 4.04 14.2 US qtl at oil change . 4.2414.4 US qtl at oil change including filter. 5.3 4 15.6 US qtl after engine overhaul.
5. Run the engine for more than 3 minutes, then check
for oil leakage .
8-5
Engine Lubrication
Engine Oil Filter Replacement
Special Tool Required Oil filter wrench 07HAA-PJ70100 5. If 4 numbers or marks (1 to 4 or'" to ............ 1are printed around the outside of the filter, use the following procedure to tighten the filte,. Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom . Tighten the filter by turning it clockwise 3 numbers or marks from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom.
Engine Oil Filter (3/4-turn type)

1. Remove the oil filter with the special tool.
2. Inspect the threads (AI and rubber seal (81 on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system.
B
Number when rubber A

seal is seated.
Number after tightening.
3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: Tightening torque: 3/4 turn clockwise. 12 Nm (1.2 kgf.m, 8.7 Ibfftl
Number or Mark when rubber seal is seated Number or Mark after tightening
1
,
2
or
I I
,
...
4 or
or
...... .........
,
3 or
4 or
TTTT
I
1
:
1
or
2
or
TTTT
... ......
3 or
I .........
6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage.
07HAA-PJ70100
I
8-6
14
Oil Filter Feed Pipe Replacement

1. Remove the oil filter (see page 8-61. 2. Remove the oil filter feed pipe.
3. Install the two 20 x 1.5 mm nuts (AI onto the new oil filter feed pipe. Hold the nut with a wrench, then tighten the other nut.
4. Tighten the oil filter feed pipe to the block to 49 N m (5.0 kgfm, 36Ibfftl, then remove the nuts from the oil filter feed pipe .
8-7
Engine Lubrication
Oil Pump Overhaul
Exploded View
BAFFLE PLATE
~
6x1.0mm 12Nm 11.2 kgfm, 8.7 Ibfft)
.:'"-'"
~=~~~~=~~~=:_:~)
-
/6Xl.0mm 12Nm 11.2 kgfm, 8.7 Ibfft)
/~7x ~:~ mm
12.8 kgfm, 20 Ibfft)
~m
DOWEL PIN PUMP HOUSING
6x 1.0 mm
12Nm
vV V~
/ 11-..
", ."'",'''
Apply engine oil to
/UPPER BALANCER ,.. SHAFT HOLDER
- . . . . ) .' ", ~BALANCERSHAFT BEARINGS W.

I ______ REAR
11.2 kgfm, 8.71bfft)
~~d'A
~~~
"
~El
-Q
,c
:---
BALANCER SHAFT
f:'~k~f.m,
10xl.25mm
~ ~~~ -;1
33 Ibfft) Apply engone od to
~ "crisP' ~
SEALING BOLT
39Nm
~
SPRING
RELIEF VALVE
Valve must slide freely OUTER ROTOR In housing bore Replace If scored. INNER ROTOR
LOWER BALANCER SHAFT HOLDER
14.0 kgfm, 29Ibfft)
8-8
Oil Pump Removal

1. Set the No.1 piston attop dead center (TDe) (see step 1 on page 6-12). 2. Remove the oil pan (see page 7-11). 3. Remove and discard the oil pump chain tensioner.
6. Remove the oil pump sprocket (A), then remove the oil pump (8).
4. To hold the rear balancer shaft, insert a 6 mm pin driver (A) into the maintenance hole in the lower balancer shaft holder and through the rear balancer shaft.
5. Loosen the oil pump sprocket mounting bolt.
(cont'd)
8-9
Engine Lubrication
Oil Pump Overhaul (cant'd)
Oil Pump Inspection
1. Remove the pump housing. 3. Check the housing-ta-rotor axial clearance between the rotor (AI and pump housing (BI. If the housingto-rotor axial clearance exceeds the service limit, replace the oil pump. Housing-to-Rotor Axial Clearance Standard (New): 0.02-0.07 mm (0.001-0.003 in.) Service Limit: 0.12 mm (0.005 in. I
B
2. Check the inner-ta-outer rotor radial clearance between the inner rotor (AI and outer rotor (BI. If the inner-ta-outer rotor radial clearance exceeds the service limit, replace the oil pump. Inner Rotor-to-Outer Rotor Radial Clearance Standard (New): 0.02-0.16 mm (0.001-0.006 in.) 0.20 mm (0.008 in.) Service Limit:
4. Check the housing-to-outer rotor radial clearance between the outer rotor (AI and pump housing (BI. It the housing-ta-outer rotor radial clearance exceeds the service limit, replace the oil pump. Housing-to-Outer Rotor Radial Clearance Standard (Newl: 0.15-0.21 mm (0.006-0.008 in. I Service Limit: 0.23 mm (0.009 in.)
5. Inspect both rotors and the pump housing for scoring or other damage. Replace parts if necessary.
8-10
Balancer Shaft Inspection

1. Seatthe balancer shaft by pushing it away from the
oil pump sprocket end of the oil pump.
3. Remove the baffle plate (A) and upper balancer shaft holder (with bearings) IB), then remove the front balancer shaft Ie) and rear balancer shaft ID).
2. Zero the dial indicator against the end of the

balancer shaft, then push the balancer shaft back and forth and read the end play. Balancer Shaft End Play: Front Balancer Shaft: Standard (New): 0.070-0.135 mm (0.0028-0.0053 in.) Service Limit: 0.15 mm (0.006 in.) Rear Balancer Shaft: Standard (New): 0.070-0.135 mm (0.0028-0.0053 in.) Service Limit: 0.15 mm (0.006 in.)
___-
~\
~
(conl'd)
8-11
Engine Lubrication
Oil Pump Overhaul (cont'd)
4. Measure the inner diameter of the No.1 bearing for the front balancer shaft hole and the rear balancer shaft hole. Bearing Inner Diameter: Front: Standard (New): 20.000-20.020 mm (0.7874-0.7882 in.) Service Limit: 20.03 mm (0.789 in.) Rear: Standard (New): 24.000-24.020 mm (0.9449-0.9457 in.) Service Limit: 24.03 mm (0.946 in.) Front: 5. Measure the diameters of the No.1 journals on the
front balancer shaft and rear balancer shaft.
NO.1 Journal Diameter: Front: Standard (New): 19.938-19.950 mm (0.7850-0.7854 in.) Service Limit: 19.92 mm (0.784 in.!
Rear:
Standard (New): 23.938-23.950 mm (0.9424-0.9429 in.! Service Limit: 23.92 mm (0.942 in.!
Front:
Rear:
Rear:
8-12
6. Clean both balancer shaft No.2 journals and bearing halves with a clean shop towel.
7. Place one strip at plastigage across each No.2
journal.
10. Align the punch mark on the rear balancer shaft with the center at the two punch marks on the tront balancer shaft, then install the balancer shafts in the lower balancer shaft holder.
8. Reinstall the bearings and upper balancer shaft holder, then torque the bolts.
NOTE: Do not rotate the balancer shaft during inspection.
9. Remove the upper balancer shaft holder and bearings again, and measure the widest part at the plastigage. It the balancer shaft No.2 journal oil
clearance is out-of-tolerance, install the new
bearings, and recheck. It it is still out-at-tolerance, replace the balancer shafts. No.2 Journal Oil Clearance: Standard (New): 0.060-0.120 mm (0.0024-0.0047 in. I Service Limit: 0.15 mm (0.006 in. I
11. Apply engine oil to the threads at the 8 mm bolts (AI.

6x 1.0 mm
12Nm 11.2 kgfm, 8.7Ibfltl
~
~~
.,
t..~/
c
A
rr ~ ~
~8X1.25mm
27Nm
12.8 kgfm, 201blltl
----B
12. Install the upper balancer shalt holder IBI and baffle plate ICI.
Iconl'dl
8-13
Engine Lubrication
Oil Pump Overhaul (cont'd)
13. Install the pump housing.
Oil Pump Installation

1. Make sure the No.1 piston is at TOC {see step 1 on page 6-121. 2. Align the dowel pin (Alan the rear balancer shaft with the mark {BI on the oil pump.
6x1,Omm 12Nm
(1.2 kgfm. 8.7Ibfft)
3. To hold the rear balancer shaft. insert a 6 mm pin driver (AI into the maintenance hole in the lower balancer shaft holder and through the rear balancer shaft.
8-14
4. Apply engine oil to the threads of the oil pump sprocket mounting bolt (AI.
8. Squeeze the new oil pump chain tensioner (AI. then install the set clip (81 on it as shown. NOTE: The set clip is supplied with the oil pump
chain tensioner.
10x 1.25mm
~
10x 1.25 mm
\ t,
o
44Nm 14.5 kgfm. 331blltl
I
8.7Iblltl
9. Install the oil pump chain tensioner.

6x1.0mm 12 Nm 11.2 kglm.
8x 1.2Smm
161blltl
44 Nm 14.5 kglm. 331blltl
8x 1.2Smm 22 Nm 12.2 kglm. 161blltl
I &,~,~(''il'S
1\
.
/
./
5. Loosely install the oil pump (81. then install the oil pump sprocket (el. 6. Remove the pin driver (DI. 7. Tighten the oil pump mounting bolts .
(cont'dl
8-15
Engine Lubrication
Ojl Pump Overhaul (cont'd)
10. Remove the set clip from the oil pump chain tensioner.
Ojl Pressure Swjtch Replacement

1. Disconnect the oil pressure switch connector, then remove the oil pressure switch.
18Nm 11.8 kgfm, 13lbfftJ 2. Apply liquid gasket to the oil pressure switch 11. Install the oil pan (see page 7-27J.
threads, then install the oil pressure switch.
8-16

Engine Mechanical
Intake Manifold and Exhaust System
Intake Manifold Removal and Installation ................. 9-2 Exhaust Manifold Removal and Installation .............. 9-7 Exhaust Pipe and Muffler Replacement ..................... 9-8

Intake Manifold Removal and Installation
Exploded View:
ax 1.2Smm 22N'm 12.2 kgfm, 16Ibfft}
ax 1.25mm 22 Nm 12.2 kgfm, 16Ibfft}
~~.~ I ~-A<~.
..
~,'"
"":.
INTAKE MANIFOLD Replace if cracked or
if mating surface is
O.~.' ~ damaged.~ ~ ~~
.... .. " '"
~""
"'..... "
GASKET
Replace.
~ !~
~
!~
Q
fj
GASKET Replace.
INTAKE MANIFOLD PLATE Replace if cracked or if mating surface is damaged. 6x 1.0 mm 12Nm 11.2 kgfm, 8.7Ibfft}
, 8
8x1.2Smm 22Nm 12,2 kgfm, 16Ibfft) THROTTLE BODY
INTAKE MANIFOLD BRACKET ax 1.25mm 22Nm 12.2 kgf.m, 16Ibfft}
9-2
Removal:
3. Disconnectthe intake air temperature (IAT) sensor connector (A), and remove the breather hose (B),
then remove the air cleaner housing cover!intake
air duct assembly (e).
2. Remove the evaporative emission (EVAP) canister hose (A), brake booster vacuum hose (B), and vacuum hoses (e).
4. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control cable (B) from the links. Loosen the locknuts (e), and remove the cables from the bracket.
A
C
B~~
B
c~
."""cc(,~ ~
,
. ,.. , . .,"
(cont'd)
9-3

Intake Manifold Removal and Installation (cont'd)
5. Be prepared to catch and clean up spilled coolant. Remove the water bypass hoses, then plug the water bypass hoses.
9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
Four injector connectors Idle air control (lAC) valve connector Throttle position (TP) sensor connector Manifold absolute pressure (MAP) sensor
connector
Evaporative emission (EVAP) canister purge

valve connector
10. Remove the bolt securing the intake manifold and
bracket.
\
6. Relievefuel pressure (see page 11-144). 7. Remove the fuel line (see page 11-149). 8. Remove the positive crankcase ventilation (PCV) hose (A), harness holder mounting bolt (B) and harness clamp mounting bolt (C).
\
11. Remove all the intake manifold mounting bolts!
nuts.
12. Remove the two stud bolts (A), then remove the intake manifold (B).
9-4
Installation:
1. Install the intake manifold IA) with a new gasket (8), then install and tighten the two stud bolts Ie).
4. Install the pev hose IA}, harness holder mounting bolt 18}, and harness clamp mounting bolt Ie}.
~ .. ..~~ /
..
'"
22Nm 12.2 kgfm, 16 Ibfftl
2. Tighten all intake manifold mounting bolts/nuts in a

crisscross pattern in two or three steps, beginning
with the inner bolt.
5. Install the fuel line Isee page 11150). 6. Install the water bypass hoses.
3. Tighten the bolt securing the intake manifold and bracket.
\
8x1.25mm 22 Nm 12.2 kg/m, 16Ib/.ft}
,--------
7. Install the throttle cable Isee page 11164), then adjust the cable Isee page 11163). 8. Install the cruise control cable Isee page 444), then adjust the cable Isee page 445) .
Icont'd}
9-5

Intake Manifold Removal and Installation (cont'd)
9. Install the air cleaner housing cover (A), and connect the IAT sensor connector (B). 12. Install the intake manifold cover.
...___6)( '.0 mm ___ 12Nm 11.2 kgfm,
,
~--
__':
a.7Ibfft)
13. Clean up any spilled engine coolant. 14. After installation, check that all tubes, hoses, and
10. Install the breather hose (C). 11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).
connectors are installed correctly.
15. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line. 16. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see page 10-6).
B A
9-6
Exhaust Manifold Removal and Installation

1. Remove the VTEC solenoid valve (see page 11-128). 2. Remove the driveshaft heat shield (see page 16-19). 3. Remove the cover and exhaust manifold bracket, then remove the exhaust manifold.
8x1.25mm
~f~k~f.m.
16Ibftt)
CO~~ ._!~-:(a cr :??~~f":";-"""--" ~ ~

/
GASKET Replace.
..
EXHAUST MANIFOLD
'
...
"-
EXHAUST MANIFOLD BRACKET
~.
o~:--".
:
". - -.... ~ 10 x '.25 mm
SELFLOCKING NUT
%1' ~~ Replace.
44 Nm (4.5 kgf.m, 33 fbfttl
10x1.25mm 44Nm 14.5 kgfm. 33Ibftt) Replace
10 x 1.25 mm
44Nm (4.5 kgfm, 33 fbftt)
, I 4{3' ~\ ,~ V
WASHER
8x1.25mm 22 Nm (2.2 kgfm, 16Ibfft) Replace. Tighten the bolts in steps. alternating side-to-side.
4. Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. 5. Install the other parts in the reverse order of removal.
9-7

Exhaust Pipe and Muffler Replacement
NOTE: Use new gaskets and selflocking nuts when reassembling .
GASKET
.........................
Replace.
~
ax 1.25mm
22 Nm 12.2 kgfm. 16Ibfft)
Replace.
"
Tighten the bolts in steps, alternating sidetoside. EXHAUST PIPE B
_ _ _ _ 6 x 1.0 mm _________ 9.8 Nm ~ 11.0 kgfm, 7.2 Ibfft)
@?'
SELFLOCKING NUT 10 x 1.25 mm 33 Nm 13.4 kgfm, 25Ibfft) Replace.
(J) U
J','
c "":,,,
,/
"0 _______ SECONDARy HEATED ...----OXYGEN SENSOR
/
Replace
~'
8 x 1.25 mm 22 N.m 12.2 kgf.m, 16Ibf.ft) Replace. Tighten the bolts in steps, alternating side-ta-side.
J.}i]
~
THREE WAY CATALYTIC CONVERTER ITWC)
AIR FUEL RATIO lA/F) SENSOR 44 Nm (4.5 kgfm, 33Ibfft)
9-8

Engine Cooling
Cooling System
Component Location Index ........................................ . Radiator Cap Test ........................................................ . Radiator Test ................................................................ . Fan Motor Test ............................................................. . Thermostat Test ........................................................... Water Pump Inspection .............................................. . Water Pump Replacement .......................................... . Coolant Check ............................................................... Coolant Replacement .................................................. . Thermostat Replacement ........................................... . Water Passage Installation ......................................... . Water Outlet Installation ............................................. . Radiator and Fan Replacement 10-2 10-3 10-3 10-4 10-4 10-5 10-5 10-6 10-6 10-8 10-9 10-9 10-10
Fan Controls
Component Location Index ......................................... Symptom Troubleshooting Index ............................... Circuit Diagram ............................................................. Radiator Fan Circuit Troubleshooting ........................ Radiator Fan Switch Circuit Troubleshooting (Open) ........................................................................ Radiator Fan Switch Circuit Troubleshooting (Short) ........................................................................ Radiator Fan Switch Test ............................................. Radiator Fan Switch Replacement .............................. 10-11 10-12 10-13 10-14 10-16 10-16 10-17 10-17
Cooling System
WATER OUTLET. Installation, page 10-9
I
WATER PUMP Inspection, page 10-5 Replacement, page 10-5 RESERVE TANK
~~".-
!~
,
. !'.21."'' ,.
.... ,
"
-~,j
CONNECTING PIPE
WATER PASSAGE Installation, page 10-9
RADIATOR CAP
THERMOSTAT Test, page 10-4 Replacement, page 10-8
RADIATOR FAN SWITCH
Test, page 10-17

Replacement, page 10-17 RADIATOR FAN ASSEMBLY Replacement, page 10-10 Fan Motor Test, page 10-4
AIC CONDENSER FAN ASSEMBLY Replacement, page 10-10 Fan Motor Test, page 10-4
10-2
Radiator Cap Test

1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on the pressure tester (8) (commercially available).
B
Radiator Test
1. Wait until the engine is cool, then carefully remove
the radiator cap and fill the radiator with engine coolant to the top of the filler neck. 2. Attach the pressure tester (A) (commercially available) to the radiator.
2. Apply a pressure of 93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi). 3. Check for a drop in pressure.
-~---
-- ( <::::::::
---.
',~
---
-------~-
4. If the pressure drops, replace the cap. 3. Applya pressure of 93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi).
4. Inspect for engine coolant leaks and a drop in pressure. 5. Remove the tester, and reinstall the radiator cap.
10-3
Cooling System
Fan Motor Test
,. Disconnect the 2P connectors from the radiator fan motor and condenser fan motor.
Thermostat Test
Replace the thermostat if it is open at room temperature.
To test a closed thermostat:

1. Suspend the thermostat (A) in a container of water.
Do not let the thermometer (B) touch the bottom of the hot container.
B~
2. Test the motor by connecting battery power to the B terminal and ground to the A terminal. 3. If the motor fails to run or does not run smoothly, replace it.
A
2. Heat the water, and check the temperature with a

thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open.
3. Measure the lift height of the thermostat when it is fully open.

STANDARD THERMOSTAT above S.O mm (0.31 in.) Lift height: Starts opening: 169-176F (76-S0C) 194F (90C) Fully open:
10-4
Water Pump Inspection

1. Remove the drive belt (see page 4-261. 2. Turn the water pump pulley counterclockwise. Check that it turns freely. 3. Check for signs of seal leakage. A small amount of "weeping" from the bleed holes (AI is normal.
Water Pump Replacement

1. Remove the drive belt (see page 4-261. 2. Drain the engine coolant (see page 10-61. 3. Remove the crankshaft pulley (see page 6-11 I. 4. Remove the six bolts securing the water pump, then remove the water pump (AI.
A~
6x 1.0mm 12 Nm (1.2 kg!m,
a.7Ib!It)
5. Inspect and clean the O-ring groove and mating

surface with the water passage. 6. Install the water pump with new O-rings in the reverse order of removal.
7. Clean up any spilled engine coolant. 8. Install the crankshaft pulley (see page 6-121. 9. Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-61.
10-5
Cooling System
Coolant Check
1. Look at the coolant level in the reserve tank. Make sure it is between the MAX mark (A) and MIN mark
(B).
Coolant Replacement
1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the ignition
switch. Make sure the engine and radiator are cool
to the touch. 2. Remove the radiator cap. 3. Remove the splash shield (see step 23 on page 5-5). 4. Loosen the drain plug (A), and drain the coolant.
=
2. If the coolant level in the reserve tank is at or below the MIN mark, add coolant to bring it up to the MAX mark, and inspect the cooling system for leaks.
o
A
5. Remove the reserve tank drain cap (A), and drain the coolant.
10-6
6. After the coolant has drained, tighten the radiator

drain plug securely, and install the reserve tank
drain cap securely,
8. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2 (P/N OL999-90011. Using a non-Honda
coolant can result in corrosion, causing the
7. Fill the reserve tank to the MAX mark (AI with Honda All Season Antifreeze/Coolant Type 2 IP/N OL999-90011.
cooling system to malfunction or fail. Honda All Season Antifreeze/Coolant Type 2 is a

mixture of 50% antifreeze and 50% water. Premixing is not required.
Engine Coolant Refill Capacity [including the reserve tank capacity of 0.53 ~ 10.56 US qtl: 5.0 15.3 US qt)
9. Install the radiator cap loosely. 10. Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
11. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2 if needed.
12. Putthe radiator cap on tightly, then run the engine
again and check for leaks.

13. Install the splash shield Isee step 22 on page 5-121 .
10-7
Cooling System
Thermostat Replacement
1. Drain the engine coolant (see page 10-61. 2. Remove the splash shield (see step 23 on page 5-51.
3. Remove the lower hose, then remove the thermostat.
6x 1.0 mm
9.8Nm 11.0 kgf.m. 7.2Ibfftl
~--
O-RING
Replace.
THERMOSTAT
4. Install the thermostat with a new O-ring, then install the lower hose.
5. Install the splash shield (see step 22 on page 5-121. 6. Refill the radiator with engine coolant. and bleed air from the cooling system with the heater valve open (see page 10-61.
10-8
Water Passage Installation

1. Clean and dry the water passage mating surfaces. 2. Apply liquid gasket PIN 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
Water Outlet Installation

Install the water outlet IAI with a new O-ring (BI.
~
',.
~6X1.0mm
12 Nm 11.2 kgfm, a.7Ibfftl
3. Install the water passage IAI with a new O-ring IBI.

B
......... .
44 Nm 14.5 kgfm, 33 Ibfftl
10 x 1.25 mm
4. After assembly, wait at least 30 minutes before
filling the engine with oil.
10-9
Cooling System
Radiator and Fans Replacement
1. Drain the engine coolant (see page 10-6). 2. Remove the front bumper (see page 20-85). 3. Remove the bulkhead. 4. Remove the upper radiator hose and lower radiator hose.
DRAIN PLUG
a.RING.
UPPER RADIATOR HOSE Replace
/RADIATORCAP RADIATOR
RADIATOR FAN
ASSEMBLY
~
/
/tl
6xl.0mm
7Nm (0.7 kgf.m,
5lbfftj
D-RING Replace.
)'L~'K.''':
~ ~~ERCUSHION
RADIATOR FAN SWITCH 24Nm (24 kgf m, 17 Ibf ttl \
~
~:<.?),
!O>
LOWER RADIATOR HOSE
~'\Q~
,~
FAN MOTOR
CONNECTORS
RESERVE TANK
Ale CONDENSER
FAN ASSEMBLY
6xl.0mm 9.8 Nm (1.0 kgf.m, 7.2Ibfft)
RADIATOR FAN SWITCH CONNECTOR
5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out. 6. Remove the fan shroud assemblies and other parts from the radiator. 7. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely. 8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts. 9. Fill the radiator with engine coolant and bleed the air (see page 10-61.
10-10
Fan Controls
UNDER-HOOD FUSE/RELAY BOX
RADIATOR FAN RELAY Test, page 22-51
_---i(}:!D-l:~ .~ -~ ,= ;'--{J ----.'~[ =-l J

CONDENSER FAN RELAY
D-
C~
-=c --"'1
1
I 7"-1= ~ r- I ~~~--~~->.
Test, page 22-51
RADIATOR FAN SWITCH Test, page 10-17
RADIATOR FAN ASSEMBLY

CONDENSER FAN ASSEMBLY Motor Test, page 10-4
Motor Test, page 10-4
10-11
Fan Controls
Before performing any troubleshooting procedures check: Fuses
Grounds Cleanliness and tightness of all connectors
SYMPTOM
Radiator fan does not run at all
Radiator fan does not run for engine cooling, but it runs
PROCEDURE
Radiator Fan Circuit Troubleshooting (see page 10-14), Radiator Fan Switch Circuit Troubleshooting (Open) (see page 10-16), Radiator Fan Switch Circuit Troubleshooting (Short) (see page 10-16),
with AlC ON Radiator fan runs with ignition switch ON (II), AlC OFF, and engine temperature below 199'F (93'C)
10-12
Circuit Diagram
No.20 (40A) 1',10.20 (SOA)
: USA model : Canada model
UNDER HOOD RJ SE/RELAV BOX
IGNITION SWITCH
No.20
AmRY
-'-
NO.'91~~1
WHT~
IG2 HOT in ACC III ON Ulland START'1I1Il
~BlK/RED
NO.4120A)
No,' (20A)
BlK/Y
BLK/YEl
f~
1
= = b
RADIATOR
FAN
RELAY
il
~~DENSER
RELAY
CONDITIOMNG SYSTEM
AIR
BLU BLK
h
GRNWHT RADIATOR FAN
BLU/YEL
ECM
.'
1
D
'.
1
MOTOR
FANSWfTCH [Closed: Above '1

199'F (93'e)
RADIATOR
M ~X~DENSER MOTOR
1
.'
BlK
BLK
BlK
1
GJ"
G301
G301
10-13
Fan Controls
Radiator Fan Circuit Troubleshooting
1. Check the NO.4 (20A) fuse in the under-hood fuse/relay box, and the No. 14 (10A) fuse in the under-dash fuse/relay box. 4. Connect the No.1 and No.2 terminals of the
radiator fan relay 4P socket with a jumper wire.
Is the fuse (s) OK?

YES-Go to step 2.
RADIATOR FAN RELAY 4P SOCKET
NO- Replace the fuse (s) and recheck .

2. Remove the radiator fan relay from the under-hood fuse/relay box, and test it (see page 22-51).
Is the relay OK?

YES-Go to step 3. NO-Replace the radiator fan relay .
r
2
YES-Go to step 5. NO-Go to step 6. body ground.
JUMPER WIRE
4 3
Terminal side of female terminals
Does the radiator fan run?
3. Measure the voltage between the No.2 terminal of the radiator fan relay 4P socket and body ground.
5. Disconnect the jumper, and turn the ignition switch
ON (II). Check for voltage between the No.3

terminal of the radiator fan relay 4P socket and
Is there battery voltage?

YES-Go to step 4.
NO-Replace the under-hood fuse/relay box .
Is there battery vOltage?

YES-Go to step 9.
NO-Check for an open in the wire between the under-hood fuse/relay box and under-dash fuse/ relay box .
10-14
6. Disconnect the radiator fan motor 2P connector. 7. Check for continuity between the No.1 terminal of the radiator fan relay 4P socket and the No.2
terminal of the radiator fan motor 2P connector.
9. Reinstall the radiator fan relay. 10. Disconnect the radiator fan switch 2P connector. 11. Connect the No.1 and No.2 terminals, of the
radiator fan switch 2P connector with a jumper wire.
RADIATOR FAN SWITCH 2P CONNECTOR
1
Terminal side of
female terminals
~JUMPER Q7--------J WIRE

Wire side of
female terminals
RADIATOR FAN MOTOR 2P CONNECTOR
Does the radiator fan run? Is there continuity?
YES- Replace the radiator fan switch .
YES-Go to step 8. NO-Go to step 12 .

NO-Repair open in the wire between the underhood fuse/relay box and the radiator fan motor 2P connector terminal No.2 .
12. Remove the jumper wire, and measure the voltage
between the No.2 terminal of the radiator fan

switch connector and body ground.
8. Check for continuity between the No.1 terminal of the radiator fan motor 2P connector and body ground.
RADIATOR FAN MOTOR 2P CONNECTOR
BlK
= =
Is there battery voltage? YES-Check for an open in the wire between
Is there continuity? YES-Replace the radiator fan motor.
radiator fan switch 2P connector terminal No.1 and
body ground. If the wire is OK, check for a poor ground at G301 .
NO-Repair open in the wire between the radiator fan switch terminal No.2 and the underhood
NO-Check for an open in the wire between

radiator fan motor 2P connector terminal No.1 and
body ground. If the wire is OK, check for a poor ground at G301 .
fuse/relay box .
10-15
Fan Controls
Radiator Fan Switch Circuit Troubleshooting (Open)
1. Disconnect the radiator fan switch 2P connector. 2. Turn the ignition switch ON (II). 3. Measure voltage between the No.2 terminal of the radiator fan switch 2P connector and body ground.
RADIATOR FAN SWITCH 2P
Radiator Fan Switch Circuit Troubleshooting (Short)

NOTE: After troubleshooting, perform the e"gine control module IECM) idle learn procedure Isee page
11-139).
1. Remove the radiator fan relay from the under-hood fuse/relay box, and test it Isee page 22-51). Is the relay OK? YES-Go to step 2. NO-Replace the radiator fan relay . 2. Remove the radiator fan switch, and test it Isee page 10-17). Is the radiator fan switch OK? YES-Go to step 3.
CONNECTOR
Is there battery voltage? YES-Go to step 4.

NO~Repair open in the wire between the radiator fan switch 2P connector terminal No.2 and underhood fuse/relay box .
NO- Replace the radiator fan switch .

3. Disconnect the battery negative cable from the battery. 4. Disconnect engine control module (ECM) connector B 124P) and the under-hood fuse relay box 14P
connector.
4. Turn the ignition switch OFF, and check for continuity between the No.1 terminal of the radiator fan switch 2P connector and body ground.
5. Check for continuity between the No.2 terminal of the radiator fan switch 2P connector and body ground.
BLK
Is there continuity? YES-Replace the radiator fan switch .

NO-Check for an open in the wire between the radiator fan switch 2P connector terminal No.1 and body ground. If the wire is OK, check for a poor ground at G301 .
YES-Repair short in the wire between the radiator fan switch 2P connector terminal No.2 and underhood fuse/relay box .
NO-Replace the under-hood fuse/relay box .
10-16
Radiator Fan Switch Test

NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-6).
1. Remove the radiator fan switch from the radiator
Radiator Fan Switch Replacement

1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A).
A 24 Nm 12.4 kgfm, 17 Ibftt)
(see page 10-17). 2. Suspend the radiator fan switch (A) in a container of water as shown.
~O
B~
B
/h
./c-.'
"-iq
2. Install the radiator fan switch with a new O-ring (B).
3. Heat the water, and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container.
4. Measure the continuity between terminal No.1 and
terminal No.2 according to the table.

Terminal Operation Temperature
'96'-203'F 19,'-9S'C) SWITCH f---Es -_-o'=S,"'Fc'13=',c-_"C'""C"')"'I-Ow-er+--+---j ",' a
ON
OFF
than the temperature when it goes on
10-17
Fuel and Emissions
Fuel and Emissions Systems

Special Tools ............................ General Troubleshooting Information ........................... DTC Troubleshooting Index .... Symptom Troubleshooting Index ...................................... System Descriptions ................ How to Set Readiness Codes .. 11-2 11-3 11-7 11-10 11-12 11-46
PGM-FI System
Component Location Index DTC Troubleshooting ............. . MIL Circuit Troubleshooting .. . DLC Circuit Troubleshooting .. Injector Replacement .............. . AlF Sensor Replacement ........ . Secondary H02S Replacement ........................ . ECT Sensor Replacement ...... . CMP Sensor B (TDC Sensor) Replacement ........................ . IAT Sensor Replacement ........ . Knock Sensor Replacement ... . CKP Sensor Replacement 11-49 11-52 11-97 11-109 11-111 11-113 11-113 11-114 11-114 11-115 11-115 11-116
FuelPressureTest ................... Fuel Lines Inspection ............... Fuel Line/Quick-Connect Fittings Precautions ............. Fuel Line/Quick-Connect Fittings Removal .................. Fuel Line/Quick-Connect Fittings Installation ............... Fuel Pressure Regulator Replacement ......................... Fuel Filter Replacement ........... Fuel Pump/Fuel Gauge Sending Unit Replacement ................. Fuel Pulsation Damper Replacement ......................... Fuel Tank Replacement ........... Fuel Gauge Sending Unit Test ....... Low Fuel Indicator Test .................
11-145 11-146 11-148 11-149 11-150 11-152 11-152 11-153 11-154 11-155 11-156 11-158
Intake Air System

Component Location Index Throttle Body Test ................... Intake Air Bypass Control Thermal Valve Test .............. Air Cleaner Replacement ........ Air Cleaner Element Replacement ........................ . Throttle Cable Adjustment ..... . Throttle Cable Removal/Installation ........... . Th rottle Body Removal/ Installation ........................... . Throttle Body Disassembly/ Reassembly ......................... . 11-159 11-160 11-161 11-162 11-162 11-163 11-164 11-165 11-166
VTEC/VTC
Component Location Index DTC Troubleshooting ............. . VTC Oil Control Solenoid Valve RemovallTest ............ . CMP Sensor A Replacement .. . VTEC Solenoid Valve Removal/Inspection 11-117 11-118 11-127 11-128 11-128
Idle Control System

Component Location Index DTC Troubleshooting ............. . AlC Signal Circuit Troubleshooting .................. . Alternator FR Signal Circuit Troubleshooting .................. . EPS Signal Circuit Troubleshooting .................. . Brake Pedal Position Switch Signal Circuit Troubleshooting ............ . Idle Speed Inspection ............. . ECM Idle learn Procedure 11-129 11-130 11-133 11-134 11-135
Catalytic Converter System

DTC Troubleshooting ............. . 11-167
PCV System
DTC Troubleshooting ............. . 11-168 PCV Valve Inspection and Test .............................. .. 11-169 11-169 PCV Valve Replacement
EVAPSystem
11-137 11-138 11-139 Component Location Index DTC Troubleshooting ............. . EVAP Two Way Valve Test ..... . Fuel Tank Vapor Control Valve Test ............................ . EVAP Canister Replacement .. . Fuel Tank Vapor Control Valve Replacement ............. . 11-170 11-171 11-186 11-187 11-189 11-189
Fuel Supply System

Component Location Index 11-140 Fuel Pump Circuit Troubleshooting .... . 11-141 Fuel Pressure Relieving .......... . 11-144

Special Tools
Ref. No.
CD
@
8)
CD
CD
1 2 3 4 Ijj)
Tool Number A973X041XXXXX 07JAZ001000B 07SAZ001000A 07VAJ0040100 07NAJP070 1OA 07XAA001010A 07ZAJS5AA200 074060020201 074060070300 07MAJPV4011A 07MAJPV40120 07406004000A 07ZAJS5A0100
Descri~tion
...
_--
...
_...Qty_
1 1 2 1 1 1 1 1 1 1 1 1 1
Vacuum Pump/Gauge, 0-30 in.Hg VacuumlPressure Gauge, 0-4 in.Hg Backprobe Set Fuel Pressure Gauge Adapter Pressure Gauge Adapter Fuel Sender Wrench Hose, Oil Pressure AfT Pressure Hose AfT Low Pressure Gauge WlPanel AfT Pressure Hose, 2,210 mm AfT Pressure Hose Adapter Fuel Pressure Gauge Fuel Pressure Gauge Set
CD
11)
CD
1, 2, 3, 4
11-2
General Troubleshooting Information

Intermittent Failures
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the Malfunction Indicator Lamp (MILian the dash does not come on, check for poor connections or loose terminals at all connectors related to the circuit that you are troubleshooting. 2. If the MIL stays on, connect the Honda PGM Tester (Alar an OBD II scan tool to the Data Link Connector (DLCI IBI located under the driver's side of the dashboard.
Opens and Shorts

"Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something won't work at all. With complex electronics (such as ECMsl this can sometimes mean something works, but not the way it's supposed to.
B
How to Use the PGM Tester or a Scan Tool

3. Turn the ignition switch ON (III. If the MIL (Malfunction Indicator Lampl has come on 4. Check the Diagnostic Trouble Code (DTCI and note it. Also check the freeze data. Refer to the DTC Troubleshooting Index, and begin the appropriate troubleshooting procedure. 5. If you do not find any DTCs, go to MIL circuit troubleshooting (see page 11-971. NOTE: Freeze data indicates the engine conditions when the first malfunction, misfire, or fuel trim malfunction
1. Start the engine and check the MIL (AI. NOTE: If the ignition switch is turned ON (II). and the engine is not started, the MIL will stay on for 15-20 seconds (see page 11-461.
was detected .
The scan tool and the Honda PGM Tester can read the DTe, freeze data, current data, and other Engine Control Module (ECMI data. For specific operations, refer to the user's manual that came with the scan tool or Honda PGM Tester. If the MIL did not stay If the MIL did not come on but there is a driveability problem, refer to the Symptom Troubleshooting Index in this section. If you can't duplicate the DTC Some of the troubleshooting in this section requires you to reset the ECM and try to duplicate the DTC. If the problem is intermittent and you can't duplicate the code, do not continue through the procedure. To do so will only result in confusion and, possibly, a needlessly replaced ECM.
(cont'dl
11-3

General Troubleshooting Information (cont'd)
How to Reset the ECM
You can reset the ECM in either of two ways:
How to Remove the ECM for Testing

1. Remove the passenger's dashboard lower cover
Use the OBD II scan tool or Honda PGM Tester to reset the ECM memory, See the OBD II scan tool or Honda PGM Tester user's
manuals for specific instructions .
(see page 20-63), the passenger's kick panel (see page 20-63), and the glove box (see page 20-63), 2, Remove the ECM mounting bolts (B) and the ECM
(C),
Turn the ignition switch OFF, and remove the No, 6 ECU (ECMI (15A) fuse (A) from the under-hood fuse/ relay box (B) for 10 seconds,
9,8N,m (1,0 kgf,m, 7,2Ibf,ftl
3, Remove the ECM (B),
How to End a Troubleshooting Session (required after any troubleshooting)

1, Reset the ECM as described above, 2, Do the ECM idle learn procedure (see page 11-139) 3, Turn the ignition switch OFF, 4, Disconnect the OBD II scan tool or Honda PGM Tester from the DLC, NOTE: The ECM is part of the immobilizer system, If you replace the ECM, it will have a different
immobilizer code. In order for the engine to start, you must rewrite the immobilizer code with the
4, Install the ECM in the reverse order of removal.
Honda PGM Tester,
11-4
How to Troubleshoot Circuits at the ECM

2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it
touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector
Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multi meter Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multi meter (C).
or the wire side is sealed (A). disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the
connector.
INOTICEI
Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections.
c
A
(cont'd)
11-5

ECM Updating and Substitution for Testing
Special Tools Required Honda Interface Module (HIM) EQS05A35570
Use this procedure when you have to substitute a
How to Substitute the ECM
,. Remove the ECM from the vehicle. 2. Install a known-good ECM in the vehicle.
known-good ECM in a troubleshooting procedure. Update the ECM only if the ECM does not already have the latest software loaded.
3. Rewrite the immobilizer code with the ECM replacement procedure from the Honda PGM Tester. It allows you to start the engine.
4. After completing your tests, reinstall the original ECM and rewrite the immobilizer code with the
NOTE:
Make sure the battery is fully charged before you update the ECM . To prevent ECM damage during the update, do not turn the ignition switch OFF, and do not use any of the vehicle's electrical devices (light, horn, radio, etc. ). How to Update the ECM ,. Turn the ignition switch ON (II). Do not start the
engine.
ECM replacement procedure on the Honda PGM

Tester again.
2. Connect the Honda Interface Module (HIM) to the Data Link Connector (DLC) (A) located under the
driver's side of dashboard.
---',,-
EQS05A35570
3. Do the ECM update procedure as described on the HIM label and in the ECM update system.
11-6
DTC Troubleshooting Index

DTe IMIL indication')
,
Temporary DTe
----
Detection Item
Note
P0010 156)
,
P0011 156) P010713) P010813)
POO11
- -
--------------,
POl12110)
!
POl13110) POl16 (86)

,
-----
POl16
-- - ,
POl1716) POl1816) P0122 17) P0123 (7) P0128 187) P0134 (41) P0137 163) P0138 163) P0139 163) P0141 165)
- - ----
--- -
P0128
Variable Valve Timing ControllVTC) Oil Control Solenoid Valve Malfunction Variable Valve Timing ControllVTC) System Malfunction Manifold Absolute Pressure IMAP) Sensor Circuit LowVoltaae Manifold Absolute Pressure (MAP) Sensor Circuit Hiah Voltaae Intake Air Temperature IIAT) Sensor Circuit Low Voltaae Intake Air Temperature IIAT) Sensor Circuit High Voltaae , Engine Coolant Temperature (ECT) Sensor Rangel , Performance Problem : Engine Coolant Temperature IECT) Sensor Circuit , Low Voltaae ' Engine Coolant Temperature IECT) Sensor Circuit Hiah Voltaae Throttle Position ITP) Sensor Circuit Low Voltage Throttle Position (TP) Sensor Circuit Hiah Voltaae Coolina SYstem Malfunction Air Fuel Ratio lA/F) Sensor ISensor 1) No Activity
'I
' Isee page 11-118)

---
Iseepage 11-1191
--- - - - -
Isee page 11-521 (see page 11-53) (see page 11-55) Isee page 11-56) , (see page 11-57) (see page 11-58) , (see page 11-59) (see page (see oaae (see oaae Isee page 11-60) 11-62) 11-64) 11-65)
Detected
Secondary Heated Oxygen Sensor ISecondary H02S) ISensor 2) Circuit Low Voltaae Secondary Heated Oxygen Sensor ISecondary H02S) ISensor 2) Circuit Hiah Voltaae Secondary Heated Oxygen Sensor ISecondary H02S) ISensor 2) Slow Resoonse Secondary Heated Oxygen Sensor (Secondary H02S) ISensor 2) Heater Circuit Malfunction Fuel SYstem Too Lean Fuel S~m Too Rich Random Misfire Isee page 11-65) Isee page 11-66) Isee page 11-67) Isee page 11-68) Isee oaae 11-70) Isee paQe 11-70) Isee page 11-71)
P0137 P0138 P0139

- -
P0171 145) P0171 POl72 145) POl72 P0300 and any P0300 and any of of P0301 171) ! P0301 P0302 (72) P0302 P0303173) P0303 P0304174) P0304 , P0301 P0301 171) LNo.l Cvlinder Misfire P0302 172) P0302 : No.2 Cvlinder Misfire P0303173) No.3 Cvlinder Misfire I P0303 ' P0304(74) i P0304 i I No.4 Cylinder Misfire *: These DTCs are indicated by a blinking malfunctIOn indicator lamp IMIL) when the SCS jumped with the Honda PGM Tester.
Isee paQe 11-72) Isee page 11-72) Isee paae 11-72) Isee page 11-72) service signal line
IS
Icont'd)
11-7

DTe Troubleshooting Index (cont'd)
DTe IMIL indication) P0325 (23) P0335 (4) P0336 (4) Temporary OTe
------
Detection Item
Knock Sensor Circuit Malfunction- - - -_.. - - -----"-"
Note
Cra nksh aft Po.s.ili<Jn[CKf'! _Sensa r...N.Q. i9."8l Crankshaft Position ICKP) Sensor Intermittent
Interru~tion
Isee page 11-77) Isee paqe 11-78) Isee page 11-78)
P0340 1571 P0344 (57) P0341 (57) P0420 (67) P0451 (91) P0452 (91) P0453 (91) P0500 (17) P0505(14) P0563 (34) P0600 (39)
-----
I
I
P0420 P0451
.
P0452 .-._",I P0453 , P0505

-
_I
---- -----
Pll06(13) Pll07 (13) Pll08(13) Pl121 (7) Pl122(7) Pl128(5) Pl129(5) Pl157 (48) Pl158 (48)
I
Pll06
--
Camshaft Position ICMP) Sensor A No Signal Isee page 11-121) Camshaft Position ICMP) Sensor A Intermittent ! Isee page 11-1211 , i Interruption Isee page 11-122) Va~i.a_ble VaiveTimingC;ontrolllin;) Phase Gap Isee page 11-167) _' Catalyst Syst"rnE:tficiency Below Threshold -, Fuel Tank Pressure IFTP) Sensor Range/Performance Isee page 11-171) I Problem ii Fuel Tank Pressure (FTP) Sensor Circuit Low Voltage : Isee page 11-1721._ Fuel Tank Pressure IFTP) Sensor Circuit High Voltaqe . Isee paqe 11-173) . Vehicle Speed Sensor IVSS) Circuit Malfunction cls"e_paQe 11-80) Isee page 11-130) _ _ Idle Control System Malfunction Engine Control Module IECM) Power Source Circuit Isee page 11-81) Unexpected Voltage Refer to the Multiplex Serial Communication Link Malfunction Control System Troubleshooting Isee page 22-172). Isee page 11-83) Barometric Pressure IBARO) Sensor Range/
-~-
Performance Problem Barometric Pressure (BARO) Sensor Circuit Low
--
Isee page 11-83) Isee page 11-83) Isee page 11-63) Isee page 11-63)
----
Voltage
, Barometric Pressure (BARO) Sensor Circuit High
Pl121 I P1122 . Pl128 P1129
--
- -
-+
. Throttle Position ITP) Sensor Signal Lower Than E><jJected ___ Throttle Position ITP) Sensor Signal Higher Than ...;.!><Jl ect ed -----Manifold Absolute Pressure IMAP) Sensor Signal ____ .. _ ; LOWer ThanExpected _ Manifold Absolute Pressure IMAP) Sensor Signal Higher Than Expected Air Fuel Ratio INF) Sensor ISensor 1) Range/
Rerformance Problem
-----
~Y~I!~--
----- --.-
----------------
Isee page 11-54) I Isee page 11-54)

,
- -
Isee page 11-84) Isee page 11-85)

--
P1159 (48) Pl163161 ) Pl164(61) P,-i66 (41) Pl167(41)'
----
Air Fuel Ratio INF) Sensor ISensor 1) AFS Terminal LowVoltaQe Air Fuel Ratio INF) Sensor ISensor 1) AFS+ Terminal
LowVol~e
- - - - - - - - - - -- - - - - -
Isee page 11-86) isee paQe 11-88) Isee page 11-88)
_._IPl163 I Pl164
I
Air Fuel Ratio INF) Sensor ISensorl) Slow Response I Air Fuel Ratio IA/F) Sensor ISensor 1) Range/
J_,e_~fQ!_t"!1ance Problem
Air Fuel Ratio INF) Sensor ISensor 1) Heater Circuit
, Malfunction
Iisee page 11-89)

----
I ,
----
Air Fuel Ratio INF) Sensor ISensor 1) Heater System

Malfunction
IS
Isee page 11-91)
. These DTCs are indicated by a blinking MIL when the SCS service signal line
Tester.
Jumped With the Honda PGM
1: '02 model
11-8
DTC
(MIL indication')
Temporary DTC
Detection Item
Page
a e11-123) a e11-92) (see a e11-93) (see page 11-95) (see page 11-95) (see page 11-175) (see page 11-180) (see a e 11-168) (see a e 11-1311 (see page 11-96) with the Honda PGM
P1259 P1297 P1298 P1361
VTEC S stem Malfunction Electrical Load Detector (ELD) Circuit Low Volta e Electrical Load Detector (ELD) Circuit Hi h Volta e Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) Intermittent Si nallnterru tion P1362 (8) , Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) No Si nal P1456 (90) P1456 Evaporative Emissions (EVAP) Control System Leaka e (Fuel Tank S stem) P1457 (90) P1457 Evaporative Emissions (EVAP) Control System Leaka e (EVAP Canister S stem) P1505 (109) P1505 Positive Crankcase Ventilation (PCV) Air Leaka e PJ_519 (14) Idle Air Control (IAC)Valve Circuit Malfunction P1607 (-) Engine Control Module (ECM) Internal Circuit Malfunction *: These DTCs are indicated by a blinking MIL when the SCS service signal line is jumped
(22) (20) (20) (8)
Tester .
11-9

When the vehicle has one of these symptoms, check the diagnostic trouble code (DTCI with the scan tool. If there is no DTC, do the diagnostic procedure for the symptom, in the sequence listed, until you find the cause. Symptom Engine will not start IMIL works OK, no DTCs set I
I
~ 1. 2. 3.
Diagnostic procedure Test the battery (see page 22-501. Test the starter Isee page 4-81. Troubleshoot the fuel pump circuit Isee page 11141).
,
Also check for Low compression No ignition spark

Intake air leaks
Locked up engine Broken timing chain Contaminated fuel
Engine will not start IMIL comes on and stays on, or

never comes on at all, no
, ,
Troubleshoot the MIL circuit Isee page 11-971.
DTCs setl Engine will not start (immobilizer indicator stays on or flashsl Hard starting (MIL works OK, no DTCs setl Cold fast idle too low IMIL works OK, no DTCs set I Cold fast idle too high (MIL works OK, no DTCs setl
Troubleshootthe immobilizer system Isee page 22-1651. '
,
Low compression Intake air leaks Contaminated fuel
1. 2. 1.
! 2.
Test the battery (see page 22-50). Check the fuel pressure Isee page 11-1451. Do the ECM idle learn procedure Isee page 11-1391. Check the idle speed Isee page 11-1381. Do the ECM idle learn procedure (see page 11-1391. Check the idle speed (see page 11-1381. Inspect/adjust the throttle cable Isee page 11-1631. Inspect andtestthe throttle body (see page 11-1601. Do the ECM idle learn procedure (see page 11-1391. Check the idle speed Isee page 11-1381. Inspect/adjust the throttle cable (see page 11-1631. Inspect and test the throttle body Isee page 11-1601 Do the ECM idle learn procedure Isee page 11-1391. Troubleshootthe alternator FR signal circuit (see page 11-1341. Inspect and test the throttle body Isee page 11-1601. Do the ECM idle learn procedure Isee page 11-1391. Troubleshoot the alternator FR signal circuit (see page 11-1341. Check the fuel pressure (see page 11-1451. Inspect and testthe throttle body Isee page 11-1601. Inspect/adjust the throttle cable Isee page 11-1631.
Idle speed fluctuates IMIL works OK, no DTCs setl
After warming up, idle speed is below specifications with no load IMIL works OK, no DTCs setl After warming up, idle speed
is above specifications with
1. 2. 3. 4. 1. 2. 3. 4. 1. 2. 3. 1. 2.
Intake air leaks
Vacuum hose clogged/ cracked/poor

connection
no load IMIL works OK, no DTCs set I Low power IMIL works OK, no DTCs setl
1. 2. 3.
Engine stalls IMIL works OK, no DTCs setl
, ,
1. 2. 3. 4.
Do the ECM idle learn procedure Isee page 11-1391. Check the fuel pressure Isee page 11-1451. Check the idle speed (see page 11-1381. Troubleshootthe brake pedal position switch signal circuit Isee page 11-137).
Low compression Camshaft timing problem Engine oil level problem Intake air leaks
Faulty harness and sensor connections
I
11-10
S m tom Difficult to refuel (MIL works OK, no DTCs set)
1.
Also check for Malfunctioning gas

station filling nozzle.
2.
3. 4. Inspect the fuel tank vapor control signal tube between the fuel pipe and the fuel tank vapor control valve. Inspect the fuel tank vapor vent tube between the EVAP canister and the fuel tank vapor control valve.
~~__~~__~~______-t~-oC,~h~e~c~k~th~e~E~V~A~P~ca~n~i~st~e~r.~~~~~------~--t7~~~--~------~
Fuel overflows during refueling (No DTCs set) Replace the fuel tank vapor control valve (see page 11189). Malfunctioning gas station filling nozzle.
11-11

System Descriptions
Electronic Control System
The functions of the fuel and emission control systems are managed by the engine control module (ECM). Fail-safe Function
When an abnormality occurs in the signal from a sensor, the ECM ignores that signal and assumes a pre-programmed value far that sensor that allows the engine to continue to run.
Back-up Function When an abnormality occurs in the ECM, the injectors are controlled by a back-up circuit independent of the system to
permit minimal driving.
Self-diagnosis
When an abnormality occurs in the signal from a sensor, the ECM supplies ground for the malfunction indicator lamp
(MIL) and stores the diagnostic trouble code (OTC) in erasable memory. When the ignition is first turned on, the ECM supplies ground to the MIL for 15 to 20 seconds to check the MIL bulb condition. Two Driving Cycle Detection Method To prevent false indications, the "two driving cycle detection method" is used for some self-diagnostic functions.
When an abnormality occurs, the ECM stores it in its memory. When the same abnormality recurs after the ignition
switch is turned OFF and ON (II) again, the ECM turns on the MIl.
11-12
ECM Data
You can retrieve data from the ECM by connecting the OBD II scan tool or the Honda PGM Tester to the data link connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE to help you find the causes of intermittent problems. NOTE: The "operating values" listed are approximate and may vary depending on the environment and the individual vehicle. Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up in the neutral position, and the A/C and all accessories turned off
Data Description Operatin!l Value
I
Freeze Data
Diagnostic Trouble Code (DTC)
If the ECM detects a problem, it will store it as a code

consisting of one letter and four numbers. Depending on
r:'--' Speed Engine
the problem, an SAEdefined code (POxxx) or a Honda defined code 1P1 xxx) will be gu.t!,ut to the tester. The ECM computes engine speed from the signals sent from the crankshaft position (CKP) sensor. This data is used for determining the time and amount of injected fuel. The ECM converts pulse signals from the vehicle speed sensor (VSS). The absolute pressure caused in the intake manifold by engine load and speed.
If no problem is detected, there is no output.

...
YES
I
Nearly the same as tachometer indication
YES
Vehicle Speed
At idle speed: 750:!: 50 rpm Nearly the same as speedometer

indication
YES
Manifold Absolute
Pressure
With engine stopped:

Nearly the same as atmospheric pressure.
YES
(MAP)
!
Engine Coolant Temperature (ECT)
The ECT sensor converts coolant temperature into voltage
and signals the ECM. The sensor is a thermistor whose

internal resistance changes with coolanttemperature. The
ECM uses the voltage signals from the ECT sensor to

determine the amount of injected fuel.
Air Fuel Ratio (A/F) Sensor, (Sensor 1)
The A/F sensor detects the oxygen content in the exhaust
gas and sends voltage signals to the ECM. Based on these signals, the ECM controls the air/fuel ratio. When the
oxygen content is high (that is, when the ratio is leaner than the stoichiometric ratio), the voltage signal is lower. When the oxygen content is low (that is, when the ratio is richer than the stoichiometric ratio), the voltage signal is higher. The AJF sensor signals are electrical current that
At idle speed: about 20-41 kPa (150-310 mmHg, 6-12 in.Hg), 0.7-1.3 V With cold engine: Same as ambient temperature and IAT With engine warmed up: about 176-212F (SO-100C), 0.5-0.S V 0.0 1.25 V -S.0-11.0 mA (PGM Tester) At idle speed: about 0.1-0.9 V
YES
NO
Secondary
Heated Oxygen
Sensor
I are indicated as voltage on the scan tool. I The H02S detects the oxygen content in the exhaust gas and sends voltage signals to the ECM. Based on these I signals, the ECM controls the air/fuel ratio. When the
oxygen content is high (that is, when the ratio is leaner than the stoichiometric ratio), the voltage signal is lower. When the oxygen content is low (that is, when the ratio is richer than the stoichiometric ratio), the voltage signal is
0.0-1.25 V At idle speed: about 0.1-0.9 V
NO
(Secondary H02S, Sensor2)
higher.
(cont'd)
11-13

System Descriptions (cont'd)
ECM Data (cont'd)
Data Fuel System Status DescriPtion Fuel system status is indicated as "open" or "closed". OperatinllValue At idle speed: closed
Freeze Data YES
Closed: Based on the NF Sensor output, the ECM

determines the air/fuel ratio and controls the amount of
injected fuel. Open: Ignoring NF Sensor output, the ECM refers to signals from the throttle position (TP), manifold absolute pressure (MAP), intake air temperature (lAT), barometric pressure (BARD), and engine coolant temperature (ECT)) Short Term Fuel Trim
sensors to control the amount of iniected fuel. The air/fuel ratio correction coefficient for correcting the ' 0.7-1.5 amount of injected fuel when the fuel system status , is "closed." When the ratio is leaner than the stoichiometric ratio, the ECM increases short term fuel trim gradually, and the amount of injected fuel increases. The air/fuel ratio gradually gets richer, causing a lower oxygen content in the exhaust gas. Consequently, the short term fuel trim is lowered, and the ECM reduces the amount of injected fuel. , , This cycle keeps the air/fuel ratio close to the stoichiometric ratio when in ctosed loop status. Long term fuel trim is computed from short term fuel trim 0.8-1.2 and indicates changes occurring in the fuel supply system over a long period . . If long term fuel trim is higher than 1.00, the amount of injected fuel must be increased. If it is lower than 1.00, the amount of injected fuel must be reduced. The IAT sensor converts intake air temperature into With cold engine: voltage and signals the ECM. When intake air Same as ambient temperature is low, the internal resistance ofthe sensor temperature and ECT increases, and the voltage signal is higher. Based on the accelerator pedal position, the opening At idle speed: angle of the throttle valve is indicated. about10% Ignition timing is the ignition advance angle set by the At idle speed: 8' 5' ECM. The ECM matches ignition timing to driving BTDC when the SCS conditions. service signal line is jumped with the Honda I PGM Tester . CLV is the engine load calculated from MAP data. At idle speed: ' 12-34% . At 2,500 rpm with no load: , 14--34%
YES
Long Term Fuel Trim
YES
Intake Air
Temperature
YES
(IAT) Throttle
Position Ignition
YES ND
Timing
Calculated Load Value (CLV)
is
c;:--
11-14
ECM Electrical Connections

FUEL PUM p
ElO
-b -
0
PGM-AMAIN RELAY 2
1c;J
~ I~
-b -
PGM-FIMAIN RELAV 1
io..l
LoTo(jJ
CD
Ale CLUTCH RELAY
---'-
IOAITERV
RADIATOR
C!:'
~
"31~
IG2
@ @
iil
1. -
FAN RELAY
LoTo-
IGNITION SWITCH
No.6 ECU (ECM) No. 20 )G (40A)

(Canada: 50A)
CD No. 19 BATIERY (BOA)
U NDER-HOOD FUSE/RELAY BOX:
(15A)
No. 14 OPTION (40A)
No.9 BACK UP (7.5A) No.7 HORN, STOP (15A)
UNOER-OASH FUSE/RELAY BOX:

(]) No. 17 FUEL PUMP 7 15A) 8 No.4 ACG (10A) , No.1 IGN COIL (15A) @ No. 10 METER (7.5A) 1 No. 14 A/C CLUTCH RELAY (10A) @ No.2 +B LAF (A/F) HEATER (20A)
10
,
'CM
r'-
AJIGP1
A21GP2
91G1
IMOFPREl PGl AS PG2A.
MRLYE7
E15 flO
E18 Ace 86 FANe
;--
-~
(cont'd)
11-15

A
NO.1 INJECTOR
MAP SENSOR
veel A2l
B51NJl
MAPA19
5Gl All
* J=
TPSENSOR
No.2 INJECTOR
841NJ2
VCC2 A20
No.3 INJECTOR
B31NJ3
TPS A15
SG2 A10
No. 4 INJECTOR
B21NJ4 IATSENSOR
lAC VALVE
IATB17
H~
A1ZIACV
ECTSENSQR
EeTB8
~-
,-,.
KS
BAROSENSOR
(Built into
the ECM)
K$A9
----_. __ ._--------_ ...... _--_ .. _-_ .. __ .....
... _-----
DlTI. =
l
J
CMP SENSORS
A26
fT~~~
(TOC SENSOR)
A7CKP
CKPSENSOR
RVSB7
I
REVERSE LOCK
SOLENOID VALVE
11-16
I~;"
~SSs=~~
__
J~----~ I
I-_ A18VSS AFSHTCRE8
AFSHTC~
1
EVAP CANISTER
A/FSENSOR RELAY
Al2
EVAP CANISTER
V_l~ErN~T~S~H~UT~ V;AL~V~E: : : ~
l[~
" EVAP BVPASS
~
PURGE VALVE
________________
r~:~~~~~~~~r-------~-1
821 PCS
{==A~F~S~A~'~6i--'=:~~~~~f~~~~~~~~~~~
"'1
AFS+ A6
AFSHTCAl
.,
A/F SENSOR ISENSOR 11
E21 VSV
SOLENOID VALVE
SH02S E2
I ~ lALT
E202WBS
SH02SHTC E6
SECONDARY HOZS
{SENSOR 2)
E
SPARK
Bl0ALTL
813 ALTF
LGl A24
LG2A23
LG3 E3
B18ALTC
1
L
CMPSENSQR A
To~~.~------k~l=CMP~AA25-+~:on 1 === .. ,
I
PLUG
I~I
ICM
A30lGPlSl
_ _ _ _----l<>---VTC-+- 81
No.1 IGNITION COIL VTC

To~
823
SPARKI~II PLUG I I leM

No.2 IGNITION COIL
A291GPLS2
VTECQIL PRESSURE SWITCH
VTPSW 89
~~ARKI~~ PLUG II 'I
t~l
VTEC SOLENOID VAL.VE
I TO~~~~~[J~~::1=f:::~~-!------1~~::~--r-----~
No.3 IGNITION COIL
PLUG
ICM
"""'L
A28IGPL.S3
SPARKI~ II 'I
ICM
A271GPlS4
VTS 815
No. 4 IGNITION COIL
(cont'd)
11-17

N
FTPSENSOR
I( t
GAUGE ASSEMBLY
E5 vee3
e14 FTP
E4SG3
BKSWE22
r
SEFMJE24
POSITION SWIT CH
BRAKE PEDAL
~I
I r;:::::.,
T
E31 MIL
To MULTIPLEX
CONTROL UNIT
7c
CPU
IMoeD E27
To
IMMOBILIZER UN IT
"',.
r::-
I
DATA LINK CONNECTOR
~
E30WEN
r-
E29SCS
E23 K-LINE
1
E26 NEP
EPSLD E16
To EPS CONTROL UNIT
TEST
TACHOMETER
CONNECTOR
/~----------------------------------------------------------------~
ECMB
ECME
124 PI
4 5
21 23
131 PI
1234567
8 9
TERMINAL LOCATIONS
11-18
ECM Inputs and Outputs at Connector A (31P)
I
1 AF9-1TC 10 002 22 AFS HTC+ 2 IGP2 11 001 23 LG2 3 IGP1 12 IACV
4 PG2
5 PG1 15 TPS
6 AFS+ 16 AFS-
7 CKP
/ /
24 LG1
26 25 CMPB CMPA (TOC)
1/
18 VSS
9 KS
19 20 21 MAP VCC2 VCC1
27 28 29 30 IGPLS4 IGPLS3 IGPLS2 IGPLS1

NOTE: Standard battery voltage is 12 V.
sensor heater
voltage
voltage
(cont'd)
11-19

ECM Inputs and Outputs at Connector A (31 P)
I
1 AFSYTC 10 SG2 22 AFS HTC+ 2 IGP2 11 SG1 23 LG2 3 IGP1 4 PG2 5 PG1 15 TPS 6 AFS+ 16 AFS7 CKP 18 VSS 12 IACV 24 LG1
1/ /
26 25 CMPB CMPA (TOC)
1/
9 KS
21 19 20 MAP VCC2 VCC1
27 28 29 30 IGPLS4 IGPLS3 IGPLS2 IGPLS1
1/
Signal

Terminal number 19
Wire color GRN/RED
Terminal name
Description
20 21 22
YELJBLU YELJRED WHT
MAP {MANIFOLD ABSOLUTE PRESSURE SENSORI VCC2{SENSOR VOLTAGEI VCC1 {SENSOR VOLTAGEI
Detects MAP sensor signal
With ignition switch ON (II): about 3 V At idle: about 1.0 V (depending on engine speed)
!
Provides sensor voltage
With ignition switch ON (II): about 5 V With ian it ion switch OFF: about 0 V
Provides sensor voltage

Detects A/F sensor heater voltage Ground for the ECM circuit Ground for the ECM circuit Detects CMP sensor A sinnal Detects CMP sensor B (TDC sensor}
I RATIO {NFl SENSOR
'AFSHTC
{AIR FUEL
' With ignition switch ON (II): about 5 V With ianition switch OFF: about 0 V With ignition switch ON (II): battery voltage
23 24 25 26
BRN/YEL BRN/YEL BLU/WHT GRN
27 28 29 30
BRN WHT/BLU BLU/RED YELJGRN
HEATER CONTROL + SIDEI LG2{LOGIC GROUNDI LG1{LOGIC GROUNDI CMP A {CAMSHAFT POSITION SENSOR AI CMP B CAMSHAFT POSITION {CMPI SENSOR B {TDC (TDP DEAD CENTER SENSORI) IGPLS4{No.4IGNITION COIL PULSEI IGPLS3{No.3IGNITION COIL PULSEI IGPLS2{No.2 IGNITION , COIL PULSEI IGPLS1 (No. 1 IGNITION COIL PULSEI
Less than 1.0 V at all times less than 1.0 V at all times With engine running: pulses With engine running: pulses
Drives No.4 ignition coil Drives No.3 ignition coil Drives No.2 ignition coil Drives NO.1 ignition coil
I
With ignition switch ON (II): about 0 V With engine running: pulses
11-20
ECM Inputs and Outputs at Connector B (24P)
I
1 VTC+ 2 INJ4 3 INJ3 4 INJ2 5 INJ1 13 ALTF 21 PCS 6 FANC
7
RVS
8 9 10 ECT VTPSW ALTL 17 IAT 18 ALTC
1/ /
L/
15 VTS
23
VTC-
~
Signal
Terminal
number
Wire color
BLU/WHT VEL BLU RED BRN GRN GRN/WHT
Terminal name
VTC+ (VTC OIL CONTROL SOLENOID VALVE +SIDE) INJ4(No.4INJECTOR) INJ3 (No. 3 INJECTOR) INJ2(No. 2 INJECTOR) INJ1 (No. 1 INJECTOR) FANC (RADIATOR FAN CONTROL) RVS (REVERSE LOCK SOLENOID VALVEI ECT (ENGINE COOLANT TEMPERATURE SENSOR) VTPSW (VTEC OIL PRESSURE SWITCH) ALTL (ALTERNATOR L SIGNALI ALTF (ALTERNATOR FR SIGNAL) VTS (VTEC SOLENOID VALVE) IAT !INTAKE AIR TEMPERATURE SENSOR) ALTC (ALTERNATOR CONTROL) PCS (EVAPORATIVE EMISSION CANISTER PURGE VALVE) VTC (VTC OIL CONTROL SOLENOID VALVE -SIDE)
Description
Drives VTC oil control solenoid valve Drives No.4 iniector Drives No.3 iniector
1 2 3 4 5
With ignition switch ON (II): 0 V
At idle: duty controlled
Drives No.2 in'ector

Drives NO.1 injector Drives radiator fan relay Drives reverse lock solenoid valve With radiator fan running: about 0 V
6
7
With radiator fan staDoed: batter voltaae

With vehicle speed below 9.4 mph (15 km/h):
battery voltage
RED/WHT BLU/BLK WHT/BLU WHT/RED GRN/YEL RED/YEL WHT/GRN VELJBLU
9
10 13 15 17 18 21
With vehicle sneed above 12.5 mph (20 km/h): 0 V Detects ECT sensor signal With the ignition switch ON (II): about 0.' 4.8V (deoendinq on enaine coolanttemoerature) With engine at low engine speed: about 0 V Detects VTEC oil pressure With enQine at hiah enaine soeed: battery voltaqe switch sianal " With ignition switch ON (II): about 0 V Detects alternator L signal With enaine runnina: batter voltaqe Detects alternator FR signal With engine running: about 0 V 5V (deoendina on electrical load) Drives VTEC solenoid valve At idle: about 0 V Detects IAT sensor signal Sends alternator control siqnal , Drives EVAPcanister purge
1
valve
Drives VTC oil control solenoid valve
23
BLK/WHT
With ignition switch ON (II): about 0.1 V 4.8V (dependinq on intake air temperature) With engine running: about 0 V 5 V (dependinq on electrical load) With engine running, engine" coolant below" 49F (65C): battery voltage With engine running, engine coolant above' 4goF (65C): duty controlled With the ignition switch ON (II): 0 V
(cont'd)
11-21

ECM Inputs and Outputs at Connector E (31P)
1 IMO FPR
2
9-IJ2S
LG3
SG3
V/ / V
22 23 24 BKSW K-UNE SEFMJ
/
15 ELD 26 NEP
SH02S
I
7 MRLY 18 ACC
14 FTP
HTC 16 EPS LD
1/ /
27 IMO
CD
8 AFS HTCR 20
2WBS
9 IG1 21 VSV 31 MIL
29 30 SCS WEN
Terminal
number 1
2
Wire color
Terminal name
Description
Drives PGM FI main relay 2 Detects secondary H02S (sensor 2) signal
Signal
GRN/YEL WHT/RED
3 4
BRN/YEL PNK YELJBLU BLK/WHT
IMO FPR (IMMOBILIZER FUEL PUMP RELAY) SH02S ISECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S)' SENSOR 2) LG3(LOGIC GROUND) SG3(SENSOR GROUNDI VCC3(SENSOR VOLTAGE) S02SHTC ISECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) HEATER CONTROL) MRLY IPGM-FI MAIN RELAY) AFSHTCR (AIR FUEL RATIO lA/F) SENSOR HEATER CONTROL RELAY} IG1 (IGNITION SIGNAL} FTP(FUEL TANK PRESSURE (FTP)SENSOR) ELD (ELECTRICAL LOAD DETECTOR) EPSLD (ELECTRICAL POWER STEERING LOAD DETECT} ACC (A/C CLUTCH RELAY)
oV for 2 seconds after turning ignition switch ON

(II) then battery voltage With throttle fully opened from idle with fully warmed up engine: above 0.6 V
With throttle quickly closed: below 0.4 V

Ground far the ECM/PCM control circuit Sensor ground Provides sensor voltage Drives secondary H02S heater Less than 1.0 V at all times Less than 1.0 V at all times With ignition switch ON (II): about 5 V With ignition switch OFF: about 0 V With ignition switch ON (II): battery voltage With fully warmed up engine running: duty controlled With ignition switch ON (II): about 0 V With ignition switch OFF: battery voltage With ignition switch ON (II): 0 V
5
6
RED/YEL
ORN
Drives PGM-FI main relay 1 Power source for the DTC memorv Drives air fuel ratio sensor heater relay Detects ignition signal Detects FTP sensor signal Detects ELD signal
9
14 15 16
YElJBLK LTGRN GRN/RED LT GRN/BLK
Detects Power steering load signal
18
RED
Drives AlC clutch relay
With ignition switch ON (It): battery voltage With ianition switch OFF: about 0 V With ignition switch ON (II) and fuel fill cap open: about 2.5 V With ig-nition switch ON ill): about 0.' V 4.8 V (deDendina on electrical load) At idle with steering wheel in straight ahead position: about 0 V At idle with steering wheel at full lock: momentary batter voltaae With compressor ON: about 0 V With compressor OFF: battery voltaae
,11-22
ECM Inputs and Outputs at Connector E (31 PI
1 IMO FPR
I
2
SHJ2S
3 LG3
sm
14 FTP
l( /
22 24 23 BKSW K-LiNE SEFMJ
V 1/
/
15 ELD 26 NEP
6 SH02S HTC 16 EPS LD
MRLY
8 AFS HTCR 18 ACC
9
IG1 21 VSV 31 MIL
1/
27 IMO CD
/
I
V
29
SCS
20
2'Nffi
30 WEN
NOTE: Standard battery voltage is 12 v.

Terminal number 20
Wire color
Terminal name
Description
Signal
21
22 23 24 26 27 29
30 31
2WBS (EVAPORATIVE With ignition switch ON (II): battery voltage Drives EVAP bypass solenoid valve EMISSION (EVAPI BYPASS SOLENOID VALVEI I LTGRN/RED VSV (EVAPORATIVE ! With ignition switch ON (II): battery voltage Drives EVAP canister vent EMISSION (EVAPI shut valve I I CANISTER VENT SHUT VALVEI WHT/BLK BKSW (BRAKE PEDAL With brake pedal released: about 0 V : Detects brake pedal oosition switch sianal With brake oedal Dressed: battery voltaae POSITION SWITCH I LT BLU K-LiNE Sends and receives scan With ignition switch ON (II): pulses or battery tool sianals voltaoe With ignition switch ON (II): about 5 V YEL SEFMJ Communicates with multiplex control unit With enqine runninq under load: pulses NEP (ENGINE SPEED BLU Outputs engine speed pulse With engine running: pulses I PULSEI RED/BLU i IMOCD (IMMOBILIZER Detects immobilizer signal i CODE) Detects service check signal With the service check signal shorted with the PGM BRN i SCS (SERVICE CHECK , SIGNAl( Tester: about 0 V With the service check sianal opened: about 5 V RED/WHT WEN (WRITE ENABLE Detects write enable signal , With ignition switch ON (II): about 0 V SIGNAl( Drives MIL With MIL turned ON: about 0 V GRN/ORN . MIL (MALFUNCTION i INDICATOR LAMPI With MIL turned OFF: battery voltage BLU/RED
(cont'd)
11-23

Vacuum Hose Routing
To
EVAPORATIVE EMISSION IEVAP) CANISTER INTAKE AIR BYPASS CONTROL THERMAL VALVE
FRONT OF VEHICLE EVAPORATIVE EMISSION IEVAP) CANISTER PURGE VALVE
11-24
Vacuum Hose Routing
----
I.,~
~~ltJ=-ri~~=~
:~~
='1
ATMOSPHERE
====-:./
CD AIR FUEL RATIO lA/F) SENSOR ISENSOR 1) (j) SECONDARY HEATED OXYGEN SENSOR ISECONDARY H02S) ISENSOR 2) @ MANIFOLD ABSOLUTE PRESSURE IMAP) SENSOR (j) ENGINE COOLANT TEMPERATURE IECT) SENSOR INTAKE AIR TEMPERATURE IIAT) SENSOR CRANKSHAFT POSITION ICKP) SENSOR (j) KNOCK SENSOR CAMSHAFT POSITION ICMP) SENSOR B ITOP DEAD CENTER ITDC) SENSOR) CAMSHAFT POSITION ICMP) SENSOR A @lIDLEAIRCONTROLIIAC)VALVE THROTTLE BODY @INJECTOR @ FUEL PULSATION DAMPER FUEL FILTER .:llJ FUEL PRESSURE REGULATOR @FUELPUMP FUEL TANK
@RESONATOR @ AIR CLEANER @ POSITIVE CRANKCASE VENTILATION IPCV) VALVE THREE WAY CATALYTIC CONVERTER EVAPORATIVE EMISSION IEVAP) CANISTER @EVAPORATIVEEMISSIONIEVAP)CANISTER PURGE VALVE EVAPORATIVE EMISSION IEVAP) CANISTER VENT SHUT VALVE @ EVAPORATIVE EMISSION IEVAP) TWO WAY VALVE EVAPORATIVE EMISSION IEVAP) BYPASS SOLENOID VALVE FUEL TANK PRESSURE IFTP) SENSOR EVAPORATIVE EMISSION IEVAP) VALVE FUEL TANK VAPOR CONTROL VALVE FUEL TANK VAPOR RECIRCULATION VALVE INTAKE AIR BYPASS CONTROL THERMAL VALVE
(cont'd)
11-25

PGM-FI System
The Programmed Fuel Injection (PGM-FI) system is a
sequential multipart fuel injection system.
Camshaft Position (CMP) Sensor B (Top Dead Center (TOC) Sensor) The CMP sensor B (TOC sensor) detects the position of
the No.1 cylinder as a reference for sequential fuel injection to each cylinder.
Air Conditioning (AlC) Compressor Clutch Relay When the ECM receives a demand for cooling from the AlC system, it delays the compressor from being
energized, and enriches the mixture to assure smooth
transition to the AlC mode. Air Fuel Ratio (A/F) Sensor The AlF Sensor operates over a wide air/fuel range. The AlF Sensor is installed upstream of the TWC, and sends signals to the ECM which varies the duration of fuel
injection accordingly,
SENSOR TERMINALS
MAGNET
Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and
determines ignition timing and timing for fuel injection
of each cylinder as well as detecting engine misfire.

MAGNET
HEATER TERMINALS
Barometric Pressure (BARO) Sensor The BARD sensor is inside the ECM. It converts atmospheric pressure into a voltage signal that the ECM
uses to modify the basic duration of the fuel injection
discharge.
Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor
(thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases.
THERMISTOR
11-26
Ignition Timing Control The ECM contains the memory for basic ignition timing
at various engine speeds and manifold absolute pressure. It also adjusts the timing according to engine coolant temperature.
Malfunction Indicator Lamp IMIL) Indication (In relation to Readiness Codes)

The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems.
lithe vehicle's battery has been disconnected or gone dead, if the DTes have been cleared, or if the ECM has
been reset, these codes are set to incomplete. In some states, part of the emissions testing is to make sure
Injector Timing and Duration The ECM contains the memory for basic discharge
duration at various engine speeds and manifold pressures. The basic discharge duration, after being
these codes are set to complete. II all of them are not set to complete, the vehicle may fail the test and the
test cannot be finished. To check if the readiness codes are set to complete,
read out from the memory, is further modified by

signals sent from various sensors to obtain the final
discharge duration. By monitoring long term fuel trim, the ECM detects long
term malfunctions in the fuel system and sets a
Diagnostic Trouble Code (DTC). Intake Air Temperature (lAT) Sensor

The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases.
TERMINAL
turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. II it then goes off, the readiness codes are set to complete.
If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the
procedures to set them in this section (see page 11-46). Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM.
SENSOR UNIT
Knock Sensor minimize knock.
THERMISTOR
The knock control system adjusts the ignition timing to
TERMINAL
PIEZO
CERAMIC
Icont'd)
11-27

Secondary Heated Oxygen Sensor (Secondary H02S1 Vehicle Speed Sensor (VSSI
The secondary H02S detects the oxygen content in the

exhaust gas downstream of the three way catalytic
The VSS is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of
pulses per minute increases/decreases with the speed
converter (TWC) and sends signals to the ECM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary H02S is installed in the TWC.
of the vehicle.
BEARING
TERMINALS ZIRCONIA ELEMENT SENSOR TERMINALS
GEAR
SHAFT CIRCUIT BOARD HEATER HEATER TERMINALS
Starting Control
When the engine is started, the ECM provides a rich mixture by increasing injector duration.
Throttle Position (TPI Sensor The TP sensor is a potentiometer connected to the
throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body.
ELEMENT
BRUSH HOLOER
TERMINAL BRUSH
11-28
VTEC/VTC
The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load. The VTEC mechanism changes the valve lift and timing by using more than one cam profile. The VTC changes the phase of the intake camshaft via oil pressure. It changes the intake valve timing continuously.
~i
<.-_LO_W_S_P_E_E_D_C_A_M _ _
HIGH SPEED CAM
'>
ENGINE LOAD
CD Light-load
QfHi-gh speed
LOW
!L:::==:::.___________________
ENGINE SPEED HIGH
LOW--
Drivin Condition
VTC Control Base Position
Descri tion Cam angle is retarded to reduce the entry of exhaust
gas into the intake port and to achieve stable fuel

consurn tion durin lean burn.
@ Medium/high-load
Cam angle is advanced for EGR effect and to reduce this pumping loss. The intake valve is closed quickly to help reduce the entry of air/fuel mixture into the ______.____-+-;-;___-;o-_-;;---cc-_ _-+-oin-:'t~a~k~e_f'_'0~rt~a~n~d~im~=rove th_e~h'!rgi"n=e'_'ff"e"c"'t.~~_ __I
Advance-Base Position Cam phase angle is controlled for optimum valve timin and maximum en ine ower .
Advance Control
(cont'd)
11-29

VTCsystem The VTC system makes continuous intake valve timing changes based on operating conditions. Intake valve timing is optimized to allow the engine to produce maximum power. Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry afthe air/fuel mixture into the intake port and improve the charging effect. Cam angle is reduced at idle to stabilize combustion and reduces engine speed. If a malfunction occurs, the VTC system control is disabled and the valve timing is fixed at the fully retarded position.
TDC MAXIMUM VTC ADVANCE 50 0_ . _ - . MAXIMUM VTC ADVANCE 50
0
EX
",' ,4t---1~~' SHORT OVERLAP

, ,
.. ' 4t-----1.~' LONG OVERLAP

VTEC system The VTEC system changes the cam profile to correspond to engine speed. It maximizes torque at low engine speed and output at high engine speed. The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds.
LOW SPEED VALVE TIMING
HIGH SPEED VALVE TIMING
IN
11-30
System Diagram
CMP SENSOR A "
____________ _ _ _ _ _ _ _ _..... From No.4 ~ ACC (lOA) fuse
INTA-K-E--~~
CAMSHAFT VTC RETARD CHAMBER
BLK/VEL
BAN/VEL
~
BLU/WHT~
r - - - BLU/WHT , - - - BLK/WHT GRN/VEL BLU/BLK
/ _ VARIOUS "~ SENSORS ECM
-"~r---.J
BLK
VANE
l
\ {QJR1..-- VTEC OIL PISTON , PRESSU~RE BRN/
SWITCH VEL
VTEC SOLENOID VALVE
';';~,iiu:M~W
SPOOL VALVE '-
!-
~Io.
~ROCKER ARMS
Camshaft Position (CMP) Sensor The CMP sensor detects camshaft angle position for the VTC system.
TERMINAL
(cont'd)
11-31

Idle Control System
When the engine is cold, the AlC compressor is on, the
transmission is in gear, the brake pedal is pressed, the power steering load is high, or the alternator is
Fuel Supply System

Fuel Cutoff Control During deceleration with the throttle valve closed,
current to the injectors is cut off to improve fuel economy at engine speeds over 1,030 rpm. Fuel cut-off action also occurs when engine speed exceeds
charging, the ECM controls current to the Idle Air Control (lAC) valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Electrical Power Steering (EPS) Senser The EPS sensor signals the ECM when the power steering load is high. Idle Air Control (lAC) Valve To maintain the proper idle speed, the lAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM.
From AIR CLEANER To INTAKE MANIFOLD
6,900 rpm, regardless of the position of the throttle

valve, to protect the engine from over-revving. When
the vehicle is stopped, the ECM cuts the fuel at engine speeds over 6,500 rpm. Fuel Pump Control When the ignition is turned on, the ECM grounds the PGMFI main relay which feeds current to the fuel pump for 2 seconds to pressurize the fuel system. With the engine running, the ECM grounds the PGMFI main relay and feeds current to the fuel pump. When the
engine is not running and the jgnition is on, the ECM
cuts ground to the PGMFI main relay which cuts current to the fuel pump. PGMA Main Relay 1 and 2 The PGMFI main relay consists of two separate relays.
Relay 1 is energized whenever the ignition switch is ON
(II) to supply battery voltage to the ECM power to the

injectors, and power for relay. Relay 2 is energized to
supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is
running.
lAC VALVE
11-32
Intake Air System

Refer to the System Diagram to see the functional layout of the system.
Intake Air Bypass Control Thermal Valve When the engine is running, the intake air bypass
control thermal valve sends air to the injectors.
Throttle Body The throttle body is a single-barrel side draft type. It houses the TP senser and the lAC valve. The lower portion of the lAC valve is heated by engine coolant from the cylinder head.
VALVE
WAX ELEMENT
lAC VALVE
INJECTOR
INTAKE AIR BYPASS CONTROL THERMAL VALVE
(conl'd)
11-33

Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon
Positive Crankcase Ventilation (PCV) System

The PCV valve prevents blow-by gasses from escaping into the atmosphere by venting them into the intake manifold.
BREATHER PIPE
monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (C02). dinitrogen (N2), and water vapor.
HOUSING
rr=-'===~=;'/
THREE WAY CATALYST
PCV HOSE
FRONT OF
VEHICLE . . : BLOW-BY VAPOR ::l: FRESH AIR
11-34
Evaporative Emission (EVAP) Control System

Refer to the System Diagram to see the functional layout of the system. EVAP Canister The EVAP canister temporarily stores fuel vapor from the fuel tank until it can be purged back into the engine and burned. EVAP Canister Purge Valve When the engine coolanttemperature is below 149F (65C), the ECM turns off the EVAP canister purge valve which cuts vacuum to the EVAP canister. Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM during the EVAP leak check.
SENSOR UNIT
EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP
canister corresponding to the pressure inside the fuel tank. It also relieves excess vacuum in the tank by
allowing fresh air to be drawn into the tank through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve during the EVAP leak check.
EVAP BYPASS SOLENOID VALVE
To FTP SENSOR
~~r~~~j;;=i3
AJI,:.'Jt_ _ _ VALVE
To EVAP CANISTER
TERMINAL
L~.~~
ASSEMBLY DIAPHRAGM VALVE
(conl'd)
11-35

Idle Control System Diagram
The idle speed of the engine is controlled by the Idle Air ControlllAC) valve:
After the engine starts, the lAC valve opens for a certain amount of time. The amount of air is increased to raise the
idle speed . When the engine coolant temperature is low, the lAC valve is opened to obtain the proper fast idle speed. The
amount of bypassed air is controlled in relation to engine coolant temperature.
INTAKE MANIFOLD
lAC VALVE
INTAKE AIR DUCT
AIR CLEANER
YEL/BlK
--I11III
BLK/ RED
From PGMFI
MAIN RELAY
THROTTLE BODY
ECM/PCM
~ VARIOUS y--- SENSORS
BlK
1
Intake Air System Diagram
This system supplies air for engine needs. A resonator in the intake air pipe provides additional silencing as air is
drawn into the system.

INTAKE MANIFOLD
,,::.>1
V
: J-_\ r7""9.i!iiii!
'~'''~[(~~ _--.-,Y---=~:'-""
- F"l
I
AIR CLEANER
~ '2'
RESONATOR
BLK
YEl/BlK
---<l1lI From
PGM-FI
BLK/ RED
MAIN RELAY
THROTTLE BODY
ECM/PCM
VARIOUS SENSORS
BlK
11-36
Evaporative Emission (EVAP) Control Diagram

The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the canister into the engine and burned. The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold. The purging vacuum is controlled by the EVAP canister purge valve, which operates whenever engine coolant temperature is above 149F (65C). When vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and regulates the flow of fuel vapor to the EVAP canister. During refueling, the fuel tank vapor control valve opens with the pressure in the fuel tank, and feeds the fuel vapor to the EVAP canister.
VA~LVE t / I ~
FUEL TANK VAPOR RECIRCULATION
FUEL TANK VAPOR SIGNAL TUBE __ /
,..------YEL/BLU FTP SENSOR

LTGRN----~
I,..-----PNK---{ ECM LTGRN/REO
= --"1' ill
'1"'
-11 EVAP VALVE
~I:l
/'----: VARIOUS
"~SENSOR
!I'---
.i!
___________
FUEL FILL CAP
'r!-F't:J----,
Ii
YELl BLU
BLK
FUEL TANK VAPOR RECIRCULATION TUBE FUEL TANK VAPOR CONTROL VALVE
From r;==:::=~-BLK/YEL ~No. 4 ACG
EVAP CANISTER = VENT SHUT VALVE
1
110 Allus.
EVAP CANISTER PURGE VALVE EVAPTWOWAY VALVE
(conl'd)
11-37

ECM Circuit Diagram
JUNCTION
CONNECTOR
III" I
I
I
VEL/BLK
...r.;
r- YEL/BLK
INJ1
---.J
~5
BR
J
No.1 INJECTOR
YEL{BLK
....fE
~4
INJ2
RE
I
NO.~ INJECTOR
VEl/BLK
v-
...(.3
INJ3
BLU
I
NO.3 INJECTOR
"
YEL{BlK
INJ4
~2
VE L
I
NO.4 INJECTOR
I. CVALVE
-:':-
YEL/BlK
+ ~
IACV
BLK/RED BLK
~
-,
-!=G101
T t:2>
.2
VEL/BlK -
CMPB IToCI
GR
BRN/YEL-
-,
CMPSE NSORB (TOe SE NSOR)
-,
YElfBLK -
'7
CKP
BLU
BRN/YEL-
CKPSEN SOR
,-
r
11-38
SENSOR
BRN/YEl-
(Built into the ECM)
JUNCTION CONNECTOR
G101

,~,
MAP
----r
OIL PRESSURE
VTEC
SWITCH
BLU/BLK -----------------------------------------;::::::::::------------
=iQJ
MAP SENSOR
1}-':":'--GRN/WHT
SGI
VCC2
'" TPS
-,-,~__ YEL/BLU ~==J==:::================== -.J

RED/BLK
VEL/BLU RED/BLK
rGRNIVEL
TP~
E::1l
______- fAg KS
__ REO/BI.U
==---=r-_J;=n==---=nn[}--REDIBLU----{ _Cl02
~_____
II
-----.f.,,,J----~=J===='= - - - - - [ g ]
i-----'A6 AFS+
ro~~~~fJ>~l~$~
t---- r. A1 AFS
RED----------;:======C;'Og~~~,~cr~ l REDIVEL I
WHT------------
BL~~~D) ~~~i8J~J
~
A/FSENSOR tSENSOR1)
BLK/WHT _____________
..J
(cont'd)
11-39

ECM Circuit Diagram (cont'd)
GRNI
<j-='=---GRNfYEl
SG2
GRN/VEL~
VEL
GRN/YEL-r~
1-----<'-(18,i!"IA:.;T--RED/VEL
RED/VEL IAT5ENSOR
---U=~J
1-----<'-(B8r"--IREDfWHT - - - - - - - - - - - - - - - - - - - - - - - R E D / W H T --{~
Eel SENSOR
EeT
GRNjVEl
-r~
LG, LG2
T
1
Gl01
BLK/VEL
BRN/VEl
BRN/VEL BRNfVEL BRN/VEL
CONNECTOR
JUNCTION
CMPA
'2
BLU/WHT
BRN/VEL
~
CMP5ENSORA
K
r-BRNfYEL
CONNECTOR
JUNCTION
Gl01
81
RVS
GRN/WHT
r--",,:j~
REVERSE SOLENOID
LOCK
VALVE
11-40
VSS
wHT/GRN-r----1---+----~
~!!T/
~
BlK/VEL BlK/VEL
BLK/VEL
=1~
.BLK~~
~BLK/VEL
~~~~WfOR
Gl01
PCS
B211j-'---VEL/BLU
--~t~------r~============~~~-===J ~ I o
BlK/VEL
~I
BLKI
C102
EVAP CANISTER PURGE VALVE
WHT/BLU
---------------============
13)--"''-- WHT/RED _ _--J
BLK/VEL
WHT/BLU WHT/RED
WHT/GRN
ALT
.........-----81
ALTC
WHT/GRN - - - - -
VEl/GRN
_---1+++=~BLK/W~HT~ r::::=;~~
,..-----BLK:---No.1 IGNITION COIL BLK/WHT
~ ~J ~rc~K
No. 21GNrTlON COIL
BLU/RED
~ -----------t_t+~4====~~~~=---f 1==::;=: ;~1irC~K ~ 44=:; :

.----BLK'---.J
WHT/BLU
----------~t_~==t4===~~~~= ~
BLK/WHT
BLK----
~irC~K
No.3 IGNITION COIL
"-_
'A2
IGPLS4
~ BR---_----1~=++=~r--:::::~
BLK/WHT BLK:---BlK! WHT
~ ~irC~K
No. 4 IGNITION COIL
6 --,-
C101
BLK!
.,:""BLK<--Gl01
Icont'dl
11-41

ECM Circuit Diagram Icont'dl
rpG""2-:~:==========================--J)--'
A
Gl01
IGPl
PG,
VEL/BLK
IGP2
VEL{BLK
------1,---------1
----------------+
1- r
Cl01
-G551
YEl/GRN:3:
IMOFPR
VEl/BLK
r-._-i;;,El
GRN/YEL
GRN/YEl
VEL/BlK
PG M-FI
MAIN RELAV2
T
VEL/BLK
MRLY
r-.--1;;,E7 RED/VEL
WHT/BLK WHT/BLK
PG M-A MA IN RELAY 1
AFSHTCR
r-._-i;;,E8 OR
_-----+==~~WH~~:~D- EV
r-'.'.
RELAY
A/F SENSOR
IMoeD
r-.-t4E27
RED/BLU
------------------------+~ To IMMOBILIZER UNIT
11-42

}="--BRN /YEL
C451
LG'
TIReD'
..... --- ....... _------- ........... _-_ ..
BRN/YEL
)-'-SG::;''-__ PNK
PNK elK/WHT -BlK/CRN
[
--.---~53
-PNK.~--
BLK/WHT
:R;~~~
BlK/CRN
. .~
SECONDARY
H02S
!SeNSOR 2)
S02SHTC
E6
BLK (WHT
' -_ _-(ES)-:.VC::;C::;':...._VEL/BLU
LTGRN-
VEl/~LU ~ LTGRN
PNK
FTPSENSQR
PNK-
i)'-''---- LTG RN
E2,i}-'.VS:;,V'-_LT GR N/RED
-BLK/ORN -
LTGRN/RED
-----{~
EVAP
CANISTER VENT SHUT VALVE
BlK/DRN
----{~
2WBS
E2
BLUI RED
BLU/REO
VEL
BRNI
BLK/
ORN
- ,BLK/DRN ----{~
EVAP BYPASS
SOLENOID
--fnl
VALVE
rfJ
f -....----(ie16
EP5LD
LTGRN/BLK
------------------------------------------------------~,. ~~~~~OLUNIT
MIL ,--y--",E3';';;;::"--'GRN/ORN
-1J
C453
....--+---_,::~3WHT ~;:;:;::::J I
MIL
GAUGE ASSEMBLY
------t--+-----'GRN/ORN
(conl'd)
11-43

ECM Circuit Diagram Icont'd)
11-44

f--____--{E9).::'G:,;1----------~
~ffJ
ORN
BLK!
BLKI
DRN
BlK!
MULTIPlEX CONTROL UNIT
ORN
BLKIWHT { --
CO NNECTORG
coNNECTORD L--<I---4---+--~+--BLK
WHTIRED L---------------------______ VEL

L - -_ _
IBlK
-1
-
W
CV
(~)
,.B=K~SW~_______________________1----~-----, f--r------~E22r WHT/BLK
L---------------~----t_-----'VEL IBlK
coNNECTOR E_
@'
SEFMJ
r---------------f----+------VEL ,-------------1----4------BLU
'-----1WHTIRED ,----WHT/BLK { WHl/GRN

co NNECTORO
--
NEP
'-----------BLUIWHT-
coNNECTOR K
IGNITION SWITCH
L--f---+--+---VEL '----+--+---BLU
>"''-+---1 1---------------+4---BLK
'8'("
.~
~ NNECTORA
d
/VEL -
BLK (YEL ~C---~I~G~l4_--~~==================t::t==: WHT
'~
-J1)
TEST TACHOMETER CONNECTOR
I r_...:+~~~~========t::t==:BLK I '--
'-----+--f---WH
L--++-WHl/GRN TIRED -
CON NECTORJ
BLU
UNDER-HOOD FUSE/RELAY BOX: (DNo, 20 IG (40A) (Canada: 50A) WNo, 14 OPTION (40A) @No, 6 ECU (ECM) (15A) (ilNo, 9 BACK UP (10A) CllNo, 7 HORN, STOP (15A) @No, 19 BATTERY (BOA) UNDER-DASH FUSE/RELAY BOX: WNo, 4 ACG (10AI @No,1 IGN COIL (15A) No, 2 A/F HEATER (20A) @No, 17 FUEL PUMP (15A) @No, 10 METER (7.5A) @No, 14 A/CCLUTCH RELAY 110A)
===:t::t:==WHT~ -WH
TIRED
CON NECTOR H
BRAKE PEDAL
POSITION SWITCH
'-----------'WHT/GRN ~~ L-------------1WHT/BLK -l~-.-
..-
Brake pedal pressed: closed Brake pedal released: open
11-45

How to Set Readiness Codes
Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes)
The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. Ifthe vehicle's battery has been disconnected or gone
Catalytic Converter Monitor and Readiness Code

NOTE:
Do not turn the ignition switch off during the procedure.
dead, if the DTCs have been cleared, or if the ECM has

been reset, these codes are set to incomplete. In some
states, part of the emission testing is to make sure these codes are set to complete. If all of them are not set to
complete, the vehicle may fail the emission test, or the test cannot be finished. To check ifthe readiness codes are complete, turn the
All readiness codes are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester.
Low ambient temperatures or excessive stop-and-go traffic may increase the drive time needed to switch the readiness code from incomplete to complete . The readiness code will not switch to complete until all the enable criteria are met.
ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are complete. If it blinks several
times, one or more readiness codes are not complete. To set readiness codes from incomplete to complete,
If a fault in the secondary H02S system caused the MIL to come on, the readiness code cannot be set to complete until you correct the fault.
Enable Criteria
ECT at 158F (70C) or higher. Intake air temperature (IAT) at 20F (- rC) or higher.
Vehicle speed is steady, and vehicle speed sensor
do the procedure for the appropriate code.
(VSS) reads more then 25 mph (13km/h).
Procedure
1. Connect the scan tool to the vehicle's data link
connector (DLC), and bring up the tool's generic OBD II mode. 2. Start the engine.
3. Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise. After about
5 miles (3 km), the readiness code should switch

from incomplete to complete. 4. If the readiness code is still set to incomplete, check
for a temporary DTC. If there is no DTC, one or

more of the enable criteria were probably not met; repeat the procedure.
11-46
Evaporative Emissions (EVAP) Control System Monitor and Readiness code

NOTE: All readiness code are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester, The enable criteria must be repeated if the intake air temperature (lAT) drops lower than 36F (20C) from
its value at engine start up.
Air Fuel Ratio (A/F) Sensor Monitor and Readiness Code

NOTE: Do not turn the ignition switch off during the
procedure.
All readiness codes are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester.
Enable Criteria Enable Criteria

At engine start up, ECT and IAT are higher than 32F (DoC) , but lower than 95F (35C), At engine start up, the ECT and IAT are within 12F (rC) of each other. ECT at 140F (60C) or higher.
Procedure
1, Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode, 2, Start the engine,
3. Test-drive the vehicle under stop-and-go conditions
Procedure
1, Connect the scan tool to the vehicle's data link connector (DLC), and bring up the tool's generic OBD II mode, 2, Start the engine,
with short periods of steady cruise, During the drive, decelerate (wirh the throttle fully closed) for 5 seconds, After about3,5 miles (2,2 km), the
readiness code should switch from incomplete to complete.
3, Test-drive the vehicle under stop-and-go conditions with short periods of steady cruise, After about 2,5 miles (1,6 km), the readiness code should
switch from incomplete to complete.
4, If the readiness code is still set to incomplete, check for a temporary DTC, If there is no DTC, the enable
criteria was probably not met; repeat the procedure.
4, If the readiness code is still setto incomplete, check for a temporary DTC, If there is no DTC, one or more of the enable criteria were probably not met; repeat the procedure,
Air/Fuel Ratio (A/F) Sensor Heater Monitor Readiness Code

NOTE: All readiness codes are cleared when the battery is disconnected or when the ECM is cleared with the OBD II scan tool or Honda PGM Tester.
Procedure
1, Connect the scan tool to the vehicle's data link connector (DLC)' and bring up the tool's generic OBD II mode, 2, Start the engine, and let it idle for 1 minute, The
readiness code should switch from incomplete to
complete, 3, If the readiness code is still set to incomplete, check for a temporary DTC, If there is no DTC, repeat the
procedure .
(conl'd)
11-47

How to Set Readiness Codes (cont'd)
Misfire Monitor and Readiness Code
This readiness code is always set to available because misfiring is continuously monitored. Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road.
Monitoring also pauses, and the misfire counter holds at its current value, if the throttle position changes more than a predetermined value, or if driving conditions fall outside the range of any
related enable criteria.
Fuel System Monitor and Readiness Code

This readiness code is always set to available because the fuel system is continuously monitored during closed loop operation.
Monitoring pauses when the catalytic converter, EVAP control system, and A/F sensor monitors are active.
Monitoring also pauses when any related enable

criteria are not being met. Monitoring resumes when the enable criteria is again being met.
Comprehensive Component Monitor and Readiness Code

This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the engine is cranking or running.
11-48
PGM-FI System
CAMSHAFT POSITION ICMP) SENSOR B ITOP DEAD CENTER ITDC) SENSOR) Troubleshooting, page 11-95 Replacement. page 11-' 14
',>
,t " _, ", _ _",
:-,
17i"~'E'.'\()~!/CJ:/~?n\i .
ELECTRICAL LOAD DETECTOR IELD) Troubleshooting, page 11-92 INTAKE AIR TEMPERATURE IIAT) SENSOR
Troubleshooting, page 11-55

ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-57 Replacement, page 11-114 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 11-52 THROTTLE POSITION (TP) SENSOR Troubleshooting, page 11-60 KNOCK SENSOR Troubleshooting, page 11-77 Replacement, page 11-115
'.\ )
------~-
CRANKSHAFT POSITION ICKP) SENSOR Troubleshooting, page 11-78 Replacement, page 11-116
AIR FUEL RATIO (A/F) SENSOR (SENSOR 1) Troubleshooting, page 11-84 Replacement, page 11-113
SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) (SENSOR 2) Troubleshooting, page 11-65 Replacement page 11-113
(cont'd)
11-49
PGM-FI System
INJECTORS
11-50
DATA LINK CONNECTOR IDLC) General Troubleshooting Information, page 11-3
PGM-FI MAIN RELAY 1

'"
"
I I
ENGINE CONTROL MODULE

General Troubleshooting Information, page "-3 Troubleshooting, page 11-96
11-51
PGM-FI System
OTC Troubleshooting
OTe P0107: MAP Sensor Circuit Low Voltage
1. Turn the ignition switch ON (II). 2. Check the MAP with the scan tool. Is about 101 kPa (760 mmHg, 30 in.Hg) or 2.9 V indicated? YES-Intermittent failure, system is OK a!this time.
Check for poor connections or loose terminals at
Is there about 5 V? YES-Repair open in the wire between the ECM (A211 and the MAP sensor. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . 8. Check the MAP with the scan tool. Is 2 kPa (15 mmHg, 0.6 in.Hg) or less or 0 V indicated? YES-Go to step 9.
the MAP sensor and at the ECM . NO-Go to step 3. 3. Turn the ignition switch OFF. 4. Disconnect the MAP sensor 3P connector.
NO-Replace the MAP sensor . 5. Turn the ignition switch ON (II). 9. Turn the ignition switch OFF. 6. Measure voltage between MAP sensor 3P connector terminals No.1 and No.3.
MAPSENSOR3PCONNECTOR
10. Disconnect ECM connector A (31PI. 11. Check for continuity between MAP sensor connector terminal No.2 and body ground.
MAPSENSOR3PCONNECTOR
MAP
(GRN/RED)
Is there about 5 V? YES-Go to step 8.
Wire side offemale terminals
Is there continuity? NO-Go to step 7. 7. Measure voltage between ECM connector terminals All and A21.
ECM CONNECTOR A (31P)
YES-Repair short in the wire between the ECM (A191 and the MAP sensor.. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
SGl
(GRN/WHT) '-----(,.,[r-----~
11-52
DTe P0108: MAP Sensor Circuit High Voltage

1. Start the engine. Hold the engine at 3,000 rpm with no load (in neutrall until the radiator fan comes on, then let it idle. 2. Check the MAP with the scan tool. Is about 101 kPa (780 mmHg, 30 in.Hg) or higher, or about 2.9 V or higher indicated? YES-Go to step 3.
9. Measure voltage between MAP sensor 3P connectorterminals No.1 and No.3.

MAP SENSOR 3P CONNECTOR
NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the MAP sensor and atthe ECM . 3. Turn the ignition switch OFF. 4. Disconnect the MAP sensor 3P connector. 5. Connect MAP sensor 3P connector terminals No.2 and No.3 with a jumper wire.
Is there about 5 V? YES-Go to step 10. NO-Repair open in the wire between the ECM (A 111 and the MAP sensor.. 10. Turn the ignition switch OFF. 11. Connect ECM connector terminals A 11 and A 19 with a jumper wire.
ECM CONNECTOR A {31 PI
MAP SENSOR 3P CONNECTOR
MAP IGRN/REDI
SGt IGRN/WHTI
1 234 5 6 7 9 101112 1516 18192021 22 24 2526 2728 30

MAP SG1 (GRN/WHT) L---:;====----.JIGRN/REDI JUMPER WIRE
JUMPER WIRE
6. Turn the ignition switch ON (III. 12. Turn the ignition switch ON (III. 7. Check the MAP with the scan tool. 13. Check the MAP with the scan tool.
/s about 101 kPa (760 mmHg, 30 in.Hg) or higher.
or about 2.9 V or higher indicated? YES-Go to step 8. NO-Replace the MAP sensor.
8. Remove the jumper wire.
Is about 101 kPa (760 mmHg, 30 in.Hg) or higher. or about 2.9 V or higher indicated? YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptomlindication goes away with a known-good ECM, replace the original ECM .
NO-Repair open in the wire between the ECM (A 191 and the MAP sensor .
11-53
PGM-FI System
OTe Troubleshooting (cont'd)
OTC P1128: MAP Sensor Signal Lower Than
Expected
OTC P1129: MAP Sensor Signal Higher Than

Expected
1. Start the engine. Hold the engine at 3,000 rpm with
no load (in neutral) until the radiator fan comes on, then let it idle.
2. Check the MAP with the scan tool.

Is 54. 1 kPa (406 mmHg, 16.0 in.Hg), 1.6 V, or higher indicated? YES-Intermittent failure, system is OK at this time . NO-Replace the MAP sensor.
2. Check the MAP with the scan tool.

Is 36.9 kPa (277 mmHg, 10.9 in. Hg), 1.1 V, or less indicated? YES-Intermittent failure, system is OK at this time . NO-Replace the MAP sensor.
11-54
OTe POl12: IAT Sensor Circuit Low Voltage

2. Check the IAT with the scan tool.
8. Check the temperature reading on the scan tool. Be aware that if the engine is warm, the reading will be higher than ambient temperature. If the engine is cold, the IAT and ECTwili have the same value.
Is 302F (150'C) or higher (or H-Umit in Honda mode of PGM Tester), or 0 V indicated?
Is the correct ambient temperature indicated?

YES-Intermittent failure, system is OK at this time.
the IAT sensor and at the ECM . NO-Replace the IAT sensor.. 3. Disconnect the IAT sensor 2P connector. 4. Check the IAT with the scan tool.
Is 302F(150'C) or higher (or H-Umit in Honda mode of PGM Tester), or 0 V indicated?

YES-Go to step 5. NO-Replace the IAT sensor..
5. Turn the ignition switch OFF . 6. Disconnect ECM connector B (24P). 7. Check for continuity between IAT sensor 2P connector terminal No.2 and body ground.
IAT SENSOR 2P CONNECTOR
YES-Repair short in the wire between the ECM (BI7) and the IAT sensor. NO- Update the ECM if it does not have the latest
software, or substitute a known-good ECM, then
recheck (see page 11-6). If the symptom/indication
goes away with a known-good ECM, replace the
original ECM .
11-55
PGM-FI System
DTC Troubleshooting (cont'd)
OTC P0113: IAT Sensor Circuit High Voltage
1. Turn the ignition switch ON (II). 2. Check the IAT with the scan tool. YES-Go to step 8. Is -4'F (-20'C) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated? YES-Go to step 3. NO-Intermitent failure, system is OK at this time.
7. Check the IATwith the scan tool. Is - 4'F (- 20'C) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated?
NO-Replace the IAT sensor..

the IAT sensor and at the ECM .
10. Connect ECM connector terminals A10 and 817 with a jumper wire.
ECM CONNECTORS

4. Disconnect the IAT sensor 2P connector.
5. Connect IAT sensor 2P connector terminals No.1 and No.2 with a jumper wire.
IAT SENSOR 2P CONNECTOR
A 131 PI
B 124 PI
JUMPER WIRE
SG2 IGRN/YELI
IAT IRED/YELl
JUMPER WIRE
11. Turn the ignition switch ON (II). 12. Check the IAT with the scan tool.
Is - 4"F (-20'C) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated? 6. Turn the ignition switch ON (II). YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the ECM (A1O, 817) and the IAT sensor .
11-56
OTe P0116: ECT Sensor Range/Performance Problem

NOTE: If DTC P0117 and/or P0118 are stored at the same time as DTC P0116, troubleshoot those DTCs first, then recheck for DTC P0116. 1. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle.
2. Check the ECT with the scan tool.

Is 176-212F (80-100C) or 0.5-0.8 V indicated? YES-Intermittent failure, system is OK at this time. Check the thermostat and the cooling system._ NO-Check the thermostat and the cooling system. If they are OK, replace the ECT sensor._
11-57
PGM-FI System
OTe P0117: ECT Sensor Circuit Low Voltage
1. Turn the ignition switch ON (II). 7. Check for continuity between the ECT sensor 2P connector terminal No.1 and body ground.
ECT SENSOR 2P CONNECTOR

Is 150'C (302'F) or higher (or H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES-Go to step 3. NO-Intermittent failure, system is OK at this time.
the ECT sensor and a!the ECM .

3. Disconnect the ECT sensor 2P connector.

Is there continuity? YES-Repair short in the wire between the ECM (88) and the ECT sensor. NO-Update the ECM if it does not have the latest software,or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
Is 150'C (302 'F) or higher (or H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES-Go to step 5. NO-Replace the ECT sensor. 5. Turn the ignition switch OFF. 6. Disconnect ECM connector 8 (24P).
11-58
OTe P0118: ECT Sensor Circuit High Voltage

1. Turn the ignition switch ON (III.
7. Check the ECTwith the scan tool.
Is -20"C (-4F) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated?
YES-Go to step 8.
Is -20C (-4F) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated? YES-Go to step 3. NO-Intermittent failure, system is OK at this time.
NO-Replace the ECT sensor..

the ECT sensor and atthe ECM .
10. Connect ECM connector terminals A 10 and B8 with a jumper wire.

ECM CONNECTORS

4. Disconnect the EeT sensor 2P connector. 5. Connect the EeT sensor 2P connector terminals
A (31 PI
B (24 PI
No.1 and No.2 with a jumper wire.

ECT SENSOR 2P CONNECTOR
JUMPER WIRE
ECT IRED/WHTI
SG2 (GRN/VELI
JUMPER WIRE
11. Turn the ignition switch ON (III. 12. Check the ECT with the scan tool.
Is -20"C (-4"F) or less (or L-Limit in Honda mode of PGM Tester) or 5 V indicated?
6. Turn the ignition switch ON (II). YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the ECM (A 10, B81 and the ECT sensor.
11-59
PGM-FI System
OTe P0122: TP Sensor Circuit Low Voltage
1. Turn the ignition switch ON (II). 2. Check the throttle position with the scan tool.
8. At the sensor side, measure resistance between the
TP sensor 3P connector terminals No.1 and No.2 with the throttle fully closed.
TP SENSOR 3P CONNECTOR
Is there about 10% or 0.5 V when the throttle is fully closed and about 90% or 4.5 V when the throttle is fully opened?
the TP sensor and at the ECM . NO-Go to step 3.


4. Disconnect the TP sensor 3P connector.
Is there about 0.5-0.9 kQ?

YES-Go to step 9. NO-Replace the throttle body (the TP sensor is not available separately) .
9. Measure resistance between the TP sensor 3P connector terminals No.2 and No.3 with the throttle fully closed.
5. Turn the ignition switch ON (II). 6. Measure voltage between the TP sensor 3P connector terminals No.1 and NO.3.
SG2 IGRN/VEL) VCC2 IVEL/BLU)
Is there about 5 V?
YES-Go to step 7. NO-Go to step 14. 7. Turn the ignition switch OFF.
Is there about 4.5k Q

YES-Gotostep 10.
NO-Replace the throttle body (the TP sensor is not available separately) . 10. Disconnect ECM connector A (31 PI.
11-60
11. At the wire harness side, check lor continuity between TP sensor 3P connector terminal No.2 and body ground.
13. At the wire harness side, check lor continuity between TP sensor 3P connector terminal No.2 and body ground.
=
Is there continuity? Is there continuity?

YES-Repair short in the wire between the ECM (A 151 and the TP sensor.. YES-Update the ECM il it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. II the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO-Go to step 12. 12. Connect ECM connector terminal A15 to body ground with a jumper wire.
ECM CONNECTOR A 131P)
NO- Repair open in the wire between the ECM (A151 and the TP sensor..
14. Measure voltage between ECM connector terminals A10 and A20.
ECM CONNECTOR A (31PI
1 21 3 1 4 5 6 71 1/ 9 10 111121/1/ 1516 1/118119 20 21 22231241 ~ 27128129 30 1/

TPS
IRED/BlK)
JUMPER WIRE

Is there about 5 V?
YES-Repair open in the wire between the ECM (A201 and the TP sensor . NO-Update the ECM il it does not have the latest
software, or substitute a known-good ECM, then recheck (see page 11-6), If the symptom indication goes away with a known-good ECM. replace the
original ECM .
11-61
PGM-FI System
DTe P0123: TP Sensor Circuit High Voltage
7. Measure voltage between ECM connector terminals Al0 and A20.
2. Check the throttle position with the scan tool.
Is there about 10% or 0.5 V when the throttle is fully closed and about 90% or 4.5 V when the throttle is fully opened?
1 21 3 1 4 5 6 7 L V 9 10 11112VV 15 16 1/1181192o 21 27128129 1/ 231241 ~

SG 2 IG RN/YEL)
':L
the TP sensor and althe ECM . NO-Go to step 3. 3. Turn the ignition switch OFF.
VCC2 IYELI BLU)
Is there about 5 V?
4. Disconnect the TP sensor 3P connector.

6. At the wire harness side, measure voltage between
YES-Repair open in the wire between the ECM (Al0) and the TP sensor . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
the TP sensor 3P connector terminals No.1 and No.3.

SG2 IGRN/YEL)
VCC2 IYEL/BLU)
Is there about 5 V?
YES-Replace the throttle body (the TP sensor is not available separately) . NO-Gotostep7.
11-62
OTC P1121: TP Sensor Signal Lower Than Expected

1. Turn the ignition switch ON III). 2. Check the throttle position with the scan tool.
OTC P1122: TP Sensor Signal Higher Than Expected

1. Turn the ignition switch ON (II). 2. Check the throttle position with the scan tool.
Is 12.9 %, 0.6 V, or higher indicated when the throttle is fully opened?

YES-Intermittent failure, system is OK at this time . NO-Replace the TP sensor Ithe TP sensor is not available separately) .
Is 12.9 %, 0.6 V, or less indicated when the throttle is fully closed?

YES-Intermittent failure, system is OK at this time . NO-Replace the TP sensor Ithe TP sensor is not available separately) .
11-63
PGM-FI System
OTC Troubleshooting (cont'd)
Ole P0128: Cooling System Malfunction
NOTE: If the DTCs listed below are stored at the same time as DTC P0128, troubleshoot those DTCs first, then recheck for P0128. P0107, P0108, Pl128, Pl129: Manifold absolute pressure (MAP) sensor Pll06, Pll07, Pll08: Barometric pressure (BARO) sensor P1259: VTEC system POl16, POl17, P0118: Engine coolant temperature (ECT) sensor POl12, POl13: Intake air temperature (IAT) sensor P0500: Vehicle speed sensor (VSS) P0335, P0336: Crankshaft position (CKP) sensor P0300: Random misfire P0301, P0302, P0303, P0304: No.1, No.2, No.3 or No.4
cylinder misfire
3. Check the radiator fan. Does the radiator fan keep running? YES-Check the radiator fan circuit (see page 1014), the radiator fan switch circuit (Short) (see page 10-16), and the radiator fan switch (see page 10-17). Also, inspect the ECT and IAT circuits and terminal connections. If the Circuits, the switch, and the connections are OK, update the ECM if it does not have the latest software, or substitute a knowngood ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the thermostat (see page 10-8) .
P0505: Idle control system malfunction P1519: Idle air control (lAC) valve DTC P0128 can occasionally set when the hood is
opened while the engine is running.
1. Check the engine coolant level. Is the engine coolant level low? YES-Refill the engine coolant. If necessary, repair the coolant leakage . NO-Go to step 2. 2. Turn the ignition switch ON (II), and make sure the NC is off.
11-64
OTC P0134: NF Sensor (Sensor 1) No Activity Detected

1. Check the attachment state of the A/F sensor (Sensor 1).
OTC P0137: Secondary H02S (Sensor 2) Circuit Low Voltage

1. Resetthe ECM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on. 3. Check the secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.
Is it slacked from the exhaust pipe?

YES- Reinstall the A/F sensor (Seneor 1) (see page 11-113) . NO-Go to step 2. 2. Resetthe ECM (see page 11-4). 3. Start the engine. Hold the engine speed at 3,000rpm with no load (in neutral) until the radiator
fan comes on, then let it idle for 2 minute.
Is there 0.3 V or less?

YES-Go to step 4. NO-Intermittent failure, system is OK at this time.
the secondary H02S (Sensor 2) and at the ECM . 4. Turn the ignition switch OFF. 5. Disconnect the secondary H02S (Sensor 2) 4P
connector.
Is OTe P0134 indicated?

YES-Replace the A/F sensor (Seneor 1) (see page 11-113) .
NO-Intermittent failure, sistem is OK at this time, Check for poor connections or loose terminals at
6. Turn the ignition switch ON (II). 7. Check the secondary H02S (Sensor 2) output
voltage with the scan tool.
the A/F sensor (Seneor 1) and the ECM .

YES-Go to step 8. NO-Replace the secondary H02S (Sensor 2) . 8. Turn the ignition switch OFF. 9. Disconnect ECM connector E (31P) .
Iconl'dl
11-65
PGM-FI System
10. Check for continuity between the secondary H02S (Sensor 21 4P connector terminal No.2 and body ground.
SECONDARY H02S (SENSOR 2) 4P CONNECTOR
DTe P0138: Secondary H02S (Sensor 2) Circuit High Voltage

1. Resetthe ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in neutrall until the radiator fan comes on. 3. Check the secondary H02S (Sensor 21 output voltage at 3,000 rpm with the scan tool. Is there 1.0 V or more? YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the secondary H02S (Sensor 21 and at the ECM . 4. Turn the ignition switch OFF.
SH02S (WHTIRED)
Is there continuity? YES-Repair short in the wire between the ECM (E21 and the secondary H02S (Sensor 21 . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
5. Disconnect the secondary H02S (Sensor 21 4P connector. 6. Connect secondary H02S (Sensor 21 4P connector terminals No.1 and No.2 with a jumper wire.
SECONDARY H02S (SENSOR 2) 4P CONNECTOR JUMPER WIRE
-'-=<'SG3 (P NKI
2
4
t-SHO 2S (WHTIRED)
11-66
8. Check the secondary H02S (Sensor 21 output voltage with the SCan tool. Is there 1.0 V or more? YES-Go to step 9. NO-Replace the secondary H02S (Sensor 21 . 9. Turn the ignition switch OFF. 10. Connect ECM connector terminals E2 and E4 with a jumper wire.
ECM CONNECTOR E (31PI
OTe P0139: Secondary H02S (Sensor 2) Slow
Response
1. Resetthe ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with no load lin neutrall until the radiator fan comes on. 3. Check the secondary H02S (Sensor 21 output voltage at 3,000 rpm with the scan tool. Is there 0.3- O.B V, for 2 minutes? YES-Replace the secondary H02S (Sensor 21 . NO-Intermittent failure, system is OK at this time.
SH02S (WHT IRE~D~I"l",.,li~~~~
JUMPER WIRE SG3(PNKI
the secondary H02S (Sensor 2) and at the ECM .
11. Turn the ignition switch ON (III. 12. Check the secondary H02S (Sensor 21 output voltage with the scan tool. Is there 1.0 V or more? YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the ECM (E2, E41 and the secondary H02S (Sensor 21 .
11-67
PGM-FI System
DTe Troubleshooting (cont'd)
OTC P0141: Secondary H02S (Sensor 2) Heater Circuit Malfunction
1. Resetthe ECM (see page 11-4). 2. Start the engine. 6. Check for continuity between body ground and secondary H02S (Sensor 2) 4P connector terminals No.3 and NO.4 individually.
SECONDARY H02S ISENSOR 2} 4P CONNECTOR
Is DTC P0141 indicated?

the secondary H02S (Sensor 2) and at the ECM .

3. Turn the ignition switch OFF. 4. Disconnect the secondary H02S (Sensor 2) 4P
connector.
YES- Replace the secondary H02S (Sensor 2) .
5. At the secondary H02S (Sensor 2) side, measure resistance between H02S 4P connector terminals No.3 and No.4.
SECONDARY H02S ISENSOR 21 4P CONNECTOR
NO-Go to step 7. 7. Turn the ignition switch ON (II). 8. Measure voltage between secondary H02S 4P connector terminals No.3 and No.4.
SECONDARY H02S (SENSOR 2) 4P CONNECTOR
1 2
3 4
2
S02SHTC (BLK/WHTJ
3 4
IG1 (BLK/ORN)
Is there about 3.3
YES-Go to step 6. NO-Replace the secondary H02S (Sensor 2) .
Is there battery Voltage?

YES-Go to step 9. NO-Go to step 12. 9. Turn the ignition switch OFF. 10. Disconnect ECM connector E (31P).
11-68
11. Check for continuity between ECM connector terminal E6 and body ground. ECM CONNECTOR E {31 PI S02SHTC {BLK/WHTI
13. Turn the ignition switch OFF. 14. Reconnect the secondary H02S {Sensor 214P
connector.
15. Disconnect ECM connector E (31P). 16. Turn the ignition switch ON (III.
17. Measure voltage between ECM connector terminal E6 and A5.
ECM CONNECTORS
=
PGl {BLKI A {31 PI
/s there continuity?
YES-Repair short in the wire between the ECM (E61 and the secondary H02S (Sensor 21 . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . 12. Measure voltage between secondary H02S (Sensor 21 4P connector terminal No.4 and body ground. SECONDARY H02S {SENSOR 21 4P CONNECTOR
S02SHTC (BLK/WHT)
E (31 PI
1 234 5 6
8 9

YES-Repair open in the wire between the ECM (E61 and the secondary H02S (Sensor 2) . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
1 2 3 4
IGl {BLK/ORNI
':i.
=

YES-Gotostep 13. NO-Check the No.4 ACG (10AI fuse in the underdash fuse/relay box. If the fuse is OK, repair open in the wire between the secondary H02S (Sensor 21 and No.4 ACG (lOA) fuse .
11-69
PGM-FI System
OTC P0171: Fuel System Too Lean OTC P0172: Fuel System Too Rich
NOTE: If some of the DTCs listed below are stored at the same time as DTC P0171 and/or POl72, troubleshoot those DTCs first, then recheck for P0171 and/or POl72. P0107, P0108, Pl128, Pl129: Manifold absolute pressure (MAPI sensor Pl162, Pl166, Pl167: A/F sensor (Sensor 11 heater P0137, P0138: Secondary H02S (Sensor 21 P0141: Secondary H02S (Sensor 21 heater P1259: VTEC system 1. Check the fuel pressure (see page 11-1451.
Is fuel pressure OK?
3. Turn the ignition switch OFF. 4. With a vacuum pump, apply vacuum to the evaporative emission (EVAP) canister purge valve (AI from the evaporative emission (EVAPI canister
side.
YES-Go to step 2.
Does it hold vacuum?
NO-Check these items: If the pressure is too high, replace the fuel pressure regulator (see page 11-1521. If the pressure is too low, check the fuel pump, the fuel feed pipe, the fuel filter, and replace the fuel pressure regulator (see page 11-1521 . 2. Start the engine. Hold the engine at 3,000 rpm with no load lin neutrall until the radiator fan comes on. YES-Check the engine valve clearances and adjust if necessary. If the valve clearances are OK, replace the injectors (see page 11-111).. NO-Replace the EVAP canister purge valve .
11-70
DTC P0300: Random Misfire and Any Combination of the Following: DTC P0301: No.1 Cylinder Misfire DTC P0302: No.2 Cylinder Misfire DTC P0303: No.3 Cylinder Misfire DTC P0304: NO.4 Cylinder Misfire
NOTE: If the misfiring is frequent enough to trigger detection of increased emissions during two consecutive driving cycles, the MIL will come on, and DTC P0300 (and some combination of P0301 through P0304) will be stored. If the misfiring is frequent enough to damage the catalyst, the MIL will blink whenever the misfiring occurs, and DTC P0300 (and some combination of P0301 through P0304) will be stored. When the misfiring stops, the MIL will remain on.
1. Troubleshoot the following DTCs first if any of them were stored along with the random misfire DTC(s): P0107, P0108, P1128, P1129: Manifold absolute pressure (MAP) sensor P0171, P0172: Fuel system P0335, P0336: Crankshaft position (CKP) sensor P0505: Idle control system P1149, P1162, P1163, P1164, P1165: Air fuel ratio (NF) sensor P1259: VTEC system P1361, P1362: Camshaft position (CMP) sensor B (Top dead center (TDC) sensor) P1519: Idle air control (lAC) valve 2. Testdrive the vehicle to verify the symptom. 3. Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause.
S m tom
Random misfire only at low RPM and under load Random misfire only during acceleration
Procedure(s) Check fuel pressure (see page 11145).
Also check for: Low compression. Low quality fuel. Malfunction in the VTEC system (see page 11-123). Correct engine valve clearances (see page 6 9).
Check fuel pressure (see page 111451.
Random misfire at high RPM, under load, or under random conditions
Check fuel pressure (see page 11145).
11-71
PGMFI System
OTC P0301: No.1 Cylinder Misfire OTC P0302: No.2 Cylinder Misfire OTC P0303: No.3 Cylinder Misfire
YES-Replace the faulty ignition coil.. 7. Determine which cylinder(s) had the misfire.
Does the misfire occur in the cylinder where the

ignition coil was exchanged?
OTC P0304: No.4 Cylinder Misfire

NO-Go to step 8. 1. After checking and recording the freeze data. reset the ECM (see page 114). If there is no freeze data of the misfire, just clear the DTC. 2. Start the engine, and listen for a clicking sound from the injector at the problem cylinder. 8. Turn the ignition switch OFF. 9. Exchange the spark plug from the problem cylinder with one from another cylinder. 10. Testdrive the vehicle for several minutes in the
range of the freeze data or under various conditions if there was no freeze data.
Does the injector click?

YES-Go to step 3. NO-Go to step 30. 3. Turn the ignition switch OFF. YES-Go to step 12. 4. Exchange the ignition coil from the problem
cylinder with one from another cylinder.
11. Check for a DTC or Temporary DTC with the scan Tool.
Is OTe or Temporary OTe P0301, P0302, P0303 or P0304 indicated?
NO-Intermittent misfire due to spark plug fouling,

etc. (no misfire at this time) .
5. Test-drive the vehicle for several minutes in the range of the freeze data or under various conditions ifthere was no freeze data.
12. Determine which cylinder(s) had the misfire.
6. Check for a DTC or a Temporary DTC with the scan tool.
Does the misfire occur in the cylinder where the spark plug was exchanged?
YES-Replace the faulty spark plug .
Is OTe or Temporary OTe P0301, P0302, P0303 or P0304 indicated?

YES-Go to step 7. NO-Intermittent misfire due to poor contact at the
ignition coil connectors (no misfire at this time). Make sure the coil connections are secure .
NO-Go to step 13. 13. Turn the ignition switch OFF. 14. Exchange the iniector from the problem cylinder
with one from another cylinder.
15. Let the engine idle for 2 minutes.
"72
16. Test-drive the vehicle for several minutes in the range of the freeze data or under various conditions if there was no freeze data.
22. Measure voltage between ignition coil 3P connector terminal No.3 and body ground.
IGNITION COil 3P CONNECTOR
17. Check for a DTC or a Temporary DTC with the scan Tool.
Is OTC or Temporary OTC P0301, P0302, P0303 or P0304 indicated? YES-Go to step 18. NO-Intermittent misfire due to bad contact at the injector connector (no misfire at this time). Make sure the injector connection is secure. Check for poor connections or loose terminals at the injector. 18. Determine which cylinder(sl had the misfire. YES-Go to step 23. Does the misfire occur in the cylinder where the injector was exchanged? NO-Repair open in the wire between the No.1 IGN COIL (15AI fuse and the ignition coil.. 23. Turn the ignition switch OFF. NO-Go to step 19. 19. Turn the ignition switch OFF. 20. Disconnect the ignition coil 3P connector from the problem cylinder. 21. Turn the ignition switch ON (III. 2 24. Check for continuity between ignition coil 3P connector terminal No.2 and body ground.
IGNITION COil 3P CONNECTOR
IG
I-'IB::.cl::cK::../W:..,HTI
=
YES-Replace the faulty injector..
GND
IBlKI
Is there continuity? YES-Go to step 25.

NO-Repair open in the wire between the ignition coil and Gl01 .
25. Disconnect ECM connector A (31PI.
Iconl'dl
11-73
PGM-FI System
26. Check for continuity between body ground and ECM connector terminal (see table).
ECM CONNECTOR A 131PI
28. Check for continuity between body ground and ECM connector terminal (see tablel.
.Q
=
.Q
=
IGPLS3
IWHT IBLU I
.Q
=
= =
.Q
=
IGPLS3
IWHTIBLUI
PROBLEM CYLINDER No.1 No.2 No.3 No.4
DTC P0301 P0302 P0303 P0304
ECM TERMINAL A30 A29 A28 A27
WIRE COLOR YEL/GRN BLU/RED WHT/BLU BRN
PROBLEM CYLINDER No.1 No.2 No.3 NO.4
DTC P0301 P0302 P0303 P0304
ECM TERMINAL A30 A29 A28 A27
WIRE COLOR YEL/GRN BLU/RED WHT/BLU BRN
Is there continuity? YES-Repair short in the wire between the ECM and the ignition coil.. NO-Go to step 27. 27. Connect ignition coil 3P connector terminal No.1 to body ground with a jumper wire (see table).
IGNITION COll3P CONNECTOR
Is there continuity? YES - Go to step 29. NO-Repair open in the wire between the ECM and the ignition coil.. 29. Check the engine compression.
Is the compression OK? YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair the engine . 30. Disconnect ECM connector B (24P).
JUMPER WIRE
2 3
DTC P0301 P0302 P0303 P0304
I
I I
WIRE COLOR 31. Turn the ignition switch ON (III. YEL/GRN BLU/RED WHT/BLU BRN
11-74
32. Measure voltage between body ground and ECM connector terminal (see table).
ECM CONNECTOR B (24PI
36. Exchange the injector from the problem cylinder

with one from another cylinder.
37. Lelthe engine idle for 2 minutes.

INJ2 (REDI
INJ3 (BLUI
INJl (BRNI
5 13
17 18
6 7 15
23
38. Test-drive the vehicle for several minutes in the range of the freeze data or under various conditions ifthere was no freeze data.
21
39. Check for a DTC or Temporary DTC with the scan tool.
=
fs DTC or Temporary DTC P0301. P0302, P0303, or P0304 indicated?

YES~Go
to step 40.
DTC P0301 P0302 P0303 P0304
ECM TERMINAL B5 B4 B3 B2
WIRE COLOR BRN RED BLU VEL
NO-Intermittent misfire due to injector

malfunction, etc. Make sure the injector connections are secure. Check for poor connections or loose terminals at the injector connector..
40. Determine which cylinder(s) had the misfire.
fs there battery voftage?

YES~Go
NO~Go
to step 33.
Does the misfire occur in the cylinder where the injector was exchanged?
YES - Replace the faulty injector.
to step 41.
33. Turn the ignition switch OFF, and remove the engine cover. 34. Disconnect the injector 2P connector from the
problem cylinder.
35. Measure the resistance between injector 2P connector terminals No.1 and No.2.
INJECTOR 2P CONNECTOR
NO Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
41. Turn the ignition switch OFF. 42. Remove the engine cover.
43. Disconnect the injector 2P connector from the
,~
problem cylinder. 44. Turn the ignition switch ON (II).
fs there 10 12
1312 ?
YES~Go
to step 36 . the injector (see page 11-111) . (conl'd)
NO~Replace
11-75
PGM-FI System
45. Measure voltage between injector 2P connector terminal No.1 and body ground.
48. Connect injector 2P connector terminal No.2 to body ground with a jumper wire Isee table).
IGP (VEL/BLK) ~
~
'
2
INJ JUMPER WIRE
/s there battery voltage?

YES~Go
to step 46.
open in the wire between the injector and the PGM-FI main relay 1. 46. Turn the ignition switch OFF. 47. Check for continuity between body ground and ECM connector terminallsee table).
NO~Repair
DTC P0301 P0302 P0303 P0304
WIRE COLOR BRN RED BLU YEL
49. Check for continuity between body ground and ECM connector terminal (see table).
ECM CONNECTOR B 124P)
INJ3 IBLU)
INJ1(BRNI
INJ2 IRED)
INJ3 IBLUI
INJ1IBRN)
INJ2 IREDI
6 7 6 7
17 18 15 23 15 23
.Q
.Q
.Q
.Q
.Q
.Q
.Q
.Q
= =
PROBLEM CYLINDER No.1 No.2 No.3 No.4 DTC P0301 P0302 P0303 P0304
= =
!
ECM : TERMINAL I B5 B4 B3 B2 WIRE COLOR BRN RED BLU YEL
= =
PROBLEM CYLINDER No.1 No.2 No.3 No.4 DTC P0301 P0302 P0303 P0304
= =
I
! TERMINAL
B5 B4 B3 B2 ECM , I WIRE COLOR BRN RED BLU YEL
YES~Replace
the injector, then recheck .
short in the wire between the ECM and the injector .

NO~Go
YES~Repair
NO~Repair open in the wire between the ECM and the injector .
to step 48.
11-76
Ole P0325: Malfunction in Knock Sensor

Circuit
1. Reselthe ECM Isee page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load lin neutral) until the radiator fan comes on, then let ',t idle. 3. Hold the engine at 3,000-4,000 rpm for at least
60 seconds.
7. Connect starter subharness 6P connector terminal

No.5 to body ground with a jumper wire.
STARTER SUBHARNESS 6P CONNECTOR
KS (RED/BlU)
JUMPER W)RE
Is DTC P0325 indicated? YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the knock sensor and althe ECM . 4. Turn the ignition switch OFF. 5. Disconnect the starter subharness 6P connector.
=
8. Check for continuity between body ground and ECM connector terminal AS.
ECM CONNECTOR A (3IP)
6. Check for continuity between ECM connector terminal A9 and body ground.
ECM CONNECTOR A 131 Pl
Is there continuity? YES-Go to step 9. NO-Repair open in the wire between the ECM lAS)
and the starter subharness 6P connector .
9. Check the starter subharness between the 6P

connector and the knock sensor for an open or
Is there continuity? YES-Repair short in the wire between the ECM IA9) and the starter subharness 6P connector.. NO-Go to step 7.
short. If it's OK, substitute a known-good knock sensor and recheck. Is DTC P0325 indicated? YES-Update the ECM if it does not have the latest
recheck Isee page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO-Replace the original knock sensor and/or
starter subharness .
11-77
PGM-FI System
OlC P0335: CKP Sensor No Signal OlC P0336: CKP Sensor Intermittent Interruption
1. Reset the ECM (see page 11-41. 2. Start the engine. 7. Measure voltage between CKP sensor 3P connector terminal No.1 and body ground.
CKP SENSOR 3P CONNECTOR
Is OTC P0335 and/or P0336 indicated?

YES-Go to step 3.
NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the CKP sensor and at the ECM . 3. Turn the ignition switch OFF.
4. Disconnect the CKP sensor 3P connector.
Is there about 5 V?
YES-Go to step 8. NO-Goto step 10. 8. Measure voltage between CKP sensor 3P connector terminals No.2 and No.3.
CKPSENSOR3PCONNECTOR
5. Turn the ignition switch ON III). 6. Measure voltage between CKP sensor 3P connector terminal No.3 and body ground.
CKP SENSOR 3P CONNECTOR
=

YES-Go to step 9.

YES-Gotostep7. NO-Repair open in the wire between PGM-FI main relay 1 and the CKP sensor.. NO-Repair open in the wire between the CKP sensorandGl0l . 9. Substitute a known-good CKP sensor and recheck.

YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the original CKP sensor .
11-78
10. Measure voltage between ECM connector terminal A7 and body ground.
=
Is there about 5 V? YES-Repair open in the wire between the ECM (A7) and the CKP sensor. NO-Gotostep 11.
11. Turn the ignition switch OFF . 12. Disconnect ECM connector A (31P). 13. Check for continuity between ECM connector terminal A7 and body ground.
r.-",,,,,.r;:;:;;::;:;::;:~CKPIBLU)
7 9
.Q
=
Is there continuity? YES-Repair short in the wire between the ECM (A7) and the CKP sensor.. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-79
PGM-FI System
OTe P0500: VSS Circuit Malfunction
1. Test-drive the vehicle. 2. Check the vehicle speed with the scan tool. 9. Turn the ignition switch OFF.
10. Disconnect ECM connector A 131P). 11. Turn the ignition switch ON (II). 12. Block the right front wheel, and slowly rotate the left front wheel.
13. Measure voltage between ECM connector terminals A18 and A24. ECM CONNECTOR A 131 PI
Is the correct speed indicated?

the VSS and at the ECM . NO-Go to step 3. 3. Turn the ignition switch OFF. 4. Block the rear wheels, and set the parking brake.
5. Raise the front of the vehicle, and make sure it is
securely supported. 6. Turn the ignition switch ON (II). 7. Block the right front wheel. and slowly rotate the left front wheel.
8. Measure voltage between ECM connector
LG1,==--{ IBRN/YELI
vss IWHT/GRNI
terminals A18 and A24. ECM CONNECTOR A 131P)
Does the voltage pulse between 0 V and 5 Vor between OV and battery voltage?
YES-Update the ECM if it does not have the latest
1 21314 5 6 71 1/9 10 111121/1/ 15 16 1/118119 20 21 22 23L24) ~ 271: 312930 /

LG1i IBRN/YEL)
recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Check these items: A short or an open in the wire between the ECM (A18) and the VSS . If the wire is OK, testthe VSS Isee page 22-71) .
w---
vss IWHT/GRN)
Does the vOltage pulse between 0 V and 5 V or between OV and battery voltage?
YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Go to step 9.
11-80
OTe P0563: ECM Power Source Circuit Unexpected Voltage

1. Resetthe ECM (see page 11-41. 2. Turn the ignition switch OFF. 3. Wait 5 seconds. 4. Turn the ignition switch ON (II).
/5 OTe P0563 indicated?
9. Remove the glove box (see page 20-631. 10. Remove the PGM-FI main relay 1 (AI.
A

11. Check for continuity between ECM connector terminal E7 and body ground.
ECM CONNECTOR E 131 PI MRlY IRED/YEll
the No.6 ECU (ECMI (15 AI fuse in the under-hood fuse/relay box and atthe ECM . 5. Turn the ignition switch OFF. 6. Disconnect ECM connector E (31PI.

8. Measure voltage between ECM connector terminal E7 and body ground.
ECM CONNECTOR E 131 PI MRlY IRED/YEll
.Q
/5 there continuity?
YES-Repair short in the wire between the ECM (E7) and the PGM-FI main relay 1.
NO-Replace the PGM-FI main relay 1. 12. Turn the ignition suitch OFF.
/5 there battery voltage?
13. Reconnect ECM connector E (31PI. YES-Gotostep 12. NO-Go to step 9.
Icont'dl
11-81
PGM-FI System
ECM CONNECTOR E (31P)
18. Remove the glove box (see page 20-631. 19. Remove the PGM-FI main relay 1 (AI.
MRlY (REO/YELl
1 2
345 6 141516
7 18 ",27=-==,,-,
22 23 24
26

YES-Go to step 15. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . 15. Disconnect ECM connector A (31 PI. 16. Turn the ignition switch ON (III. 17. Measure voltage between body ground and ECM connector terminals A3 and A2 individually.
ECM CONNECTOR A (31 PI
-20. Measure voltage between body ground and ECM connector terminals A3 and A2 individually. ECM CONNECTOR A 131PI
IGP2 IGPI
IVEL/BLKI
IVEL/BLKI
':L
IGP2
(VEl/BlK)
(VEl/BlKI
IGP'

10 11 12
222324
2526
YES-Repair shortto power in the wire between

the ECM (A2.A31 and the PGM-FI main relay 1.
NO- Replace the PGM-FI main relay 1.

YES-Go to step 18. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM/PCM .
11-82
Ole P1106: BARO Sensor Range/Perfomance Problem

1. Reset the ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with no load lin neutral! until the radiator fan comes on, then let it idle. 3. Test-drive with the transmission in 4th gear. 4. Accelerate for 5 seconds using wide open throttle. 5. Check for a Temporary DTC with the scan tool.
Ole P1107: BARO Sensor Circuit Low Voltage Ole P1108: BARO Sensor Circuit High Voltage
1. Resetthe ECM (see page 11-41. 2. Turn the ignition switch ON 1111.
Is DTC PII07 or PI lOB indicated?

YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Intermittent failure, system is OK at this time .
Is Temporary DTC PII06 indicated?

YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO-Intermittent failure, system is OK at this time .
11-83
PGM-FI System
DTe P1157: A/F Sensor (Sensor 1) Rangel Performance Problem
1. Resetthe ECM (see page 11-4). 2. Start the engine. Is OTe Ptt57 indicated?
YES~Go
6. Check for continuity between ECM connector terminals A6 and A16.

ECM CONNECTOR A (31PI IAFS+ (REDI
to step 3.
~~
1 21314 5 6 7lv 9 10 11112VV 15 16 /118119 20 21 22231241 ~ 27128129 30 1/

AFS- (RED/YELl
failure, system is OK at this time. Check for poor connections or loose terminals at the A/F sensor (Sensor 1) and atthe ECM . 3. Turn the ignition switch OFF. 4. Disconnect the A/F sensor (Sensor 1) 4P connector and ECM connector A (31 PI. 5. Connect A/F sensor (Sensor 1) 4P connector terminals No.1 and No.2 with a jumper wire.
A/F SENSOR ISENSOR 1I 4P CONNECTOR
NO~lntermittent
YES~Go NO~Go
to step 9.
to step 7.
7. Connect A/F sensor (Sensor 1) 4P connector terminal No.1 to body ground with a jumper wire.
A/F SENSOR (SENSOR 1I 4P CONNECTOR
AFS+[t!jIBLUI (GRNI AFS-
1 2 3 4
AFS+ IBLUI JUMPER WIRE JUMPER WIRE
=
11-84
8. Check for continuity between ECM connector terminals A6 and body ground.
ECM CONNECTOR A (lIP)
AFS+ (RED)
DTe P1158: A/F Sensor (Sensor 1) AFS Terminal Low Voltage

1. Reset the ECM (see page l1-4).
@
=
~
1 21314 5 6 71 1/1 9 10 11112VV 15 16 /Mli9 20 21 27128129 30 V 22231241 ~
Is OTC PIIS8 indicated?

the A/F sensor (Sensor 1) and at the ECM.

YES-Repair open in the wire between the A/F sensor (Sensor 1) and the ECM (A16) . NO-Repair open in the wire between the A/F sensor (Sensor 1) and the ECM (A6) . 9. Substitute a known-good A/F sensor (Sensor 1) and recheck.
4. Disconnect the A/F sensor (Sensor 1) 4P connector, and ECM connector A (31P). 5. Check for continuity between ECM connector terminal A16 and body ground.
ECM CONNECTOR A (lIP)
Is OTC PIIS7 indicated?

YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). if the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the A/F sensor (Sensor 1) .
=
YES-Repair short in the wire between the A/F sensor (Sensor 1) and the ECM (A16) . NO-Go to step 6.
rcont'dl
11-85
PGM-FI System
6. Substitute a known-good A/F sensor (Sensor 1) and recheck.
OTe Pl159: A/F Sensor (Sensor 1) AFS Terminal Low Voltage

1. Reset the ECM (see page 11-4).

YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). if the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the A/F sensor (Sensor 1).

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the A/F sensor (Sensor 1) and at the ECM .

4. Disconnect the A/F sensor (Sensor 1) 4P connector and ECM connector A (31P).
5. Check for continuity between ECM connector

terminal A6 and body ground.
~
=
I AFS+ IRED)
1 21314 5 6 71 L 9 10 11112VV 15 16 VI18119 2021 22231241 ~ 27128129 30 V
YES-Repair short in the wire between the A/F sensor (Sensor 1) and the ECM (A6) . NO-Go to step 6.
11-86
6. Substitute a known-good AlF sensor (Sensor 11 and recheck.

Is OTe PI159 indicated?
the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. if the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO~Replace
YES~Update
the AlF sensor (Sensor 11 .
11-87
PGM-FI System
DIC P1163: A/F Sensor (Sensor 1) Slow Response
NOTE: If DTC Pl162 is stored at the same time as DTC Pl163, troubleshoot DTC Pl162 first, then recheck for DTC Pl163. 1. Resetthe ECM (see page 11-41. 3. Test-drive in 3rd gear. Starting at 1,600 rpm, 2. Start the engine. Hold the engine at 3,000 rpm with
no load (in neutral) until the radiator fan comes on. accelerate using wide open throttle for at least
DIC P1164: A/F Sensor (Sensor 1) Circuit Range/Performance Problem

1. Resetthe ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in neutrall until the radiator fan comes on.
5 seconds. Then decelerate for at least 5 seconds with the throttle completely closed until the NF
sensor readiness code is set to complete or
3. Test-drive under the following conditions: 55 mph (89 km/hl steady speed
Transmission in 5th gear Until the NF sensor readiness code or
Temporary DTC Pl164 comes on. 4. Check for a Temporary DTC with the scan tool.
Temporary DTC Pl163 comes on 4. Check for a Temporary DTC with the scan tool.
Is Temporary DTC Ptt64 indicated?

YES-Replace the NF sensor (Sensor 11 . NO-Intermittent failure, system is OK at this time.
Is Temporary DTC Ptt63 indicated?

YES-Replace the NF sensor (Sensor 11 .
NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the NF sensor (Sensor 11 and at the ECM .
the NF sensor relay, at the NF sensor (Sensor 11, and atthe ECM .
11-88
OTC P1166: NF Sensor (Sensor 1) Heater Circuit Malfunction

1. Reset the ECM (see page 11-41. 2. Start the engine. Is OTe P1166 indicated?
Is there battery voltage? YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Go to step 5.

5. Measure voltage between ECM connector terminals A22 and A24.

the NF sensor relay, the NF sensor (Sensor 1), and the ECM . 3. Check the following fuse: No. 14 OPTION (30A) fuse in under-hood fuse/ relay box. No. 2+8 LAF (NF) HEATER (20A) fuse in underdash fuse/relay box. No.4 ACG (lOA) in under-dash fuse/relay box .
Are any of the fuses blown? YES-Repair short in the wire between the NF
sensor relay and the fuses .
Is there battery voltage? YES-Go to step 6. NO-Go to step 10. 6. Turn the ignition switch OFF.
7. Disconnect ECM connector E (31P).
NO-Go to step 4. 4. Measure voltage between ECM connector terminals Aland A24, 30 seconds after the ignition switch is turned ON (II).
ECM CONNECTOR A 131 PI AFSHTC IBLK/WH~T~Ir-=-r-=-,..c;:;::;::::~
8. Turn the ignition switch ON (II). 1

9
lcont'dl
11-89
PGM-FI System
9. Connect ECM connector terminal E8 to body ground with a jumper wire, then measure voltage between ECM connector terminals AI and A24.
ECM CONNECTORS E 131 PI AFSHTCRIORNI
1234567 141516 18 2021
YES-Repair short in the wire between the NF sensor relay, NF sensor (Sensor 11 and ECM (A221 . NO-Go to step 13.
JUMPER WIRE
26
27
2930 31
=
AI31 PI
9
14. Measure voltage between ECM connector terminals E8 and A24.

ECM CONNECTORS
E 131 PI

YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the NF sensor (Sensor 11 and ECM (All . 10. Turn the ignition switch OFF.
A 131 PI

YES-Repair open in the wire between the ECM (A221 and the NF sensor (Sensor 11 . NO-Go to step 15.
15. Check for continuity in the wires between the NF sensor and the fuses.
11. Disconnect the ECM connector A (31 PI and the NF sensor (Sensor 11 4P connector. 12. Check for continuity between the NF sensor (Sensor 11 4P connector terminal NO.3 and body ground.
A/F SENSOR ISENSOR 11 4P CONNECTOR
YES- The wires are OK. Replacethe NF sensor relay . NO-Repair open in the wire between the NF sensor relay and the fuses .
AF2HTC+ IWHTI
=
11-90
OTe P1167: NF Sensor (Sensor 1) Heater Circuit Malfunction

NOTE: If DTC Pl162 is stored at the same time as DTC Pl167, troubleshoot DTC P1162 first, then troubleshoot DTC Pl167.
6. Check for continuity between ECM connector terminals A6 and A16.

1. Resetthe ECM (see page 11-41. 2. Start the engine. Wait for at least 80 seconds.
Is OTC P01167 indicated? YES-Go to step 3.
AFS-IREDI
1 21314 5 6 71 V 9 10 11[121/1/ 15 16 1/118119 2021 27128129 30 / 22231 24 1 ~

AFS- IRED/YELl
NO-Intermittent failure, system is OK at this time.

the NF sensor relay, at the NF sensor (Sensor 11, and at the ECM . 3. Turn the ignition switch OFF. 4. Disconnect the NF sensor 4P connector and ECM connector A (31 PI . 5. Connect the NF sensor (Sensor 11 4P connector terminals No.2 and No.1 with a jumper wire.
A/F SENSOR ISENSOR 11 4P CONNECTOR JUMPER WIRE
Is there continuity? YES-Replace the NF sensor (Sensor 11 . NO-Repair open in the wire between the NF sensor (Sensor 11 and the ECM (A6 or A161 .
AFS+~S IBLUI~RI\II
11-91
PGM-FI System
OTe P1297: ELD Circuit Low Voltage
1. Resetthe ECM (see page 11-4). 2. Start the engine. 3. Turn on the headlights.
ECM CONNECTOR E 131PI
8. Turn the ignition switch OFF. 9. Disconnect ECM connector E (31P). 10. Check for continuity between body ground and ECM connector terminal E15.

the ELD and at the ECM . 4. Turn the ignition switch and the headlights OFF. 5. Disconnect the ELD 3P connector. 6. Turn the ignition switch ON (II).
=
7. Measure voltage between body ground and ELD 3P connector terminal No.3.
ELD 3P CONNECTOR
YES-Repair short in the wire between the ECM IE151 and the ELD . NO- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
Is there about 5 V?
YES-Replace the ELD . NO-Go to step 8.
11-92
DTC P1298: ELD Circuit High Voltage

1. Reset the ECM (see page 11-4). 2. Start the engine.
8. Turn the ignition switch OFF. 9. Connect ELD 3P connector terminal No.3 to body ground with a jumper wire.
ELD 3P CONNECTOR
3. Turn on the headlights.
Is DTe P1298 indicated?

YES~Go
11
to step 4.
ELD (GRN/REDI
m31
iJ
iUMPERWIRE
I
failure, system is OK at this time. Check for poor connections or loose terminals at the ELD and at the ECM . 4. Turn the ignition switch and headlights OFF. 5. Disconnect the ELD 3P connector.
NO~lntermittent
10. Disconnect ECM connector E (31P). 6. Turn the ignition switch ON (II). 7. Measure voltage between body ground and ELD 3P connector terminal No.1 .
ELD 3P CONNECTOR
11. Check for continuity between body ground and ECM connector terminal E15.
ECM CONNECTOR E (31 PI
.Q (GRN/RED)
= =
Wire side of female terminals Wire side of female terminals
ELD
Is there continuity? Is there battery voltage?

YES~Go YES~Go
to step 12.
to step 8.
NO~Repair open in the wire between the ECM (E15) and the ELD.
the No.4 ACG (1 OA) fuse in the underdash fuse/relay box. If the fuse is OK, repair open in the wire between the No.4 ACG (10A) fuse and the ELD.
NO~Check
(cont'd)
11-93
PGM-FI System
12, Check for continuity between ELD 3P connector terminal No, 2 and body ground,
ElO 3P CONNECTOR
YES-Go to step 13, NO- Repair open in the wire between the ELD and G201,. 13, Reconnect the ELD 3P connector and ECM connector E (31 PI, 14, Start the engine and let it idle, 15, While measuring voltage between ECM connector terminals A24 and E1 5, turn the headlights on (high),
ECM CONNECTORS
Does the voltage drop?

YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6), If the symptom/indication goes away with a known-good ECM, replace the original ECM,. NO-Replace the ELD,.
11-94
DTC P1361: Camshaft Position (CMP) Sensor B (TDC Sensor) Intermittent Interruption DTC P1362: Camshaft Position (CMP) Sensor B (TDC Sensor) No Signal
1. Reset the ECM Isee page 11-4). 2. Start the engine.
7. Measure voltage between CMP sensor B ITDC sensorl 3P connector terminal No.1 and body ground.
eMP SENSOR B (TOe SENSOR! 3P CONNECTOR
YES-Go to step 3.
NO~lntermittent failure, system is OK at this time. Check for poor connections or loose terminals at the CMP sensor B ITDC sensor) and at the ECM .
Wire Side of female terminals
Is there about 5 V?
YES-Go to step 8. 3. Turn the ignition switch OFF. NO-Go to step 10. 4. Disconnect the CMP sensor B ITDC sensorl 3P connector. 8. Measure voltage between CMP sensor B ITDC sensorl 3P connector terminals No.2 and No.3.
eMP SENSOR B ITOC SENSORIJP CONNECTOR
5. Turn the ignition switch ON III) . 6. Measure voltage between CMP sensor B ITDC sensor) 3P connector terminal No.3 and body ground.
CMP SENSOR B (TOC SENSOR) 3P CONNECTOR
Wire side offemaleterminals
YES-Go to step 9. NO-Repair open in the wire between the CMP sensor B ITDC sensorl and Gl0l .
9. Substitute a known-good CMP sensor B ITDC

sensor) and recheck.
YES-Go to step 7. NO-Repair open in the wire between the PGM-FI main relay 1 and the CMP sensor B ITDC sensorl .
YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO- Replace the original CMP sensor B (TDC sensor) .
Icont'dl
11-95
PGM-FI System
10. Measure voltage between ECM connectorterminal A26 and body ground.
,
OTe P1607: Malfunction in ECM Internal
Circuit
1. Resetthe ECM (see page 11-4). 2. Turn the ignition switch ON (II), and wait for 40 seconds.
Is OTe PI6D7 indicated?

YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Intermittent failure, system is OK at this time. A low battery can cause this problem. Ask the customer if there has been any recent trouble
starting the engine .
Is there about 5 V?
YES-Repair open in the wire between the ECM (A26) and CMP sensor B (TDC sensor) . NO-Gotostep 11. 11. Turn the ignition switch OFF. 12. Disconnect ECM connector A (31P). 13. Check for continuity between ECM connector terminal A26 and body ground.
=
YES-Repair short in the wire between the ECM (A26) and the CMP sensor B (TDC sensor) . NO-Update the ECM if it does not have the latest
recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-96
MIL Circuit Troubleshooting

1. Connect an OBO II scan tool/Honda PGM Tester (see page 11-3). 2. Turn the ignition switch ON (II) and read the OBO II scan tool/Honda PGM Tester. Does the aBO /I scan tool/Honda PGM Tester communicate with the ECM? YES-Go to step 3. NO-Go to troubleshooting" OLC Circuit Troubleshooting" (see page 11-109). 3. Check the OBO II scan tool/Honda PGM Tester lor OTCs. Are any DTCs indicated? YES-Go to the OTC Troubleshooting Index. NO-Go to step 4. A loose No. 17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. A poor connection at ECM terminal E31. An intermittent open in the GRN/ORN wire between the ECM (E31) and the gauge assembly.
An intermittent short in the wire between the
ECM (A21) and the manilold absolute pressure (MAP) sensor.

ECM (A20) and the throttle position (TP) sensor.

ECM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES-Go to step 10. NO-Go to step 8. 8. Inspect the No.1 0 METER (7.5A) luse in the underdash luse/relay box . Is the fuse OK? YES-Go to step 9. NO-Repair short in the wire between No. 10 METER (7.5A) fuse and the gauge assembly. Also replace the No. 10 METER (7.5A) luse . 9. Inspect the No. 20 IGl (40A) (Canada: 50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES-Repair open in the wire between the No. 20 IG (40A) (Canada: 50A) fuse and the gauge
assembly_ If the wire is OK, test the ignition switch
4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the Mallunction Indicator Lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (l1)? YES-lithe MIL always comes on and stays on, go to step 76. But il the MIL sometimes works normally, lirst check for these problems.
ECM (E29) and the data link connector (OLC).

ECM (E31) and the gauge assembly. NO-II the MIL is always off, go to step 6. But il the
MIL sometimes works normally, first check for these problems.
(see page 22-53). NO-Repair short in the wire between No. 20 IG (40A) (Canada: 50A) luse and the under-dash fuse! relay box. Also replace the No. 20 IG (40A) (Canada: 50A) fuse .
A loose No. 10 METER (7.5A) luse in the underdash fuse/relay box. A loose No. 20 IG (40A) (Canada: 50A) fuse in the under-hood fuse/relay box. A loose No.6 ECU (ECM) (15A) fuse in the underhood fuse/relay box .
(cont'd)
11-97
PGM-FI System
MIL Circuit Troubleshooting (cont'd)
10. Try to start the engine.
Does the engine start?
16. Remove the blown No.6 ECU IECM) 115A) fuse from the under-hood fuse/relay box. 17. Remove the glove box Isee page 20-63) and the PGM-FI main relay 1.
A
YES-Go to step 11. NO-Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM connector terminal E31 to body ground with a jumper wire.
ECM CONNECTOR E 131 PI
JUMPER WIRE MIL IGRN/ORNI
=
18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually.
PGM-FI MAIN RELAY 1 4P CONNECTOR
1
13. Turn the ignition switch ON III).
Is the MIL on?
+B
IWHT/ BLKJ
YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Check for an open in the wire between the ECM IE31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly . 14. Turn the ignition switch OFF.
.Q
=
YES-Repair short in the wire between the No.6 ECU IECM) 115A) fuse and the PGM-FI main relay 1. Also replace the No.6 ECU IECM) 115A) fuse . NO-Go to step 19.
15. Inspect the NO.6 ECU IECM) 115A) fuse in the under-hood fuse/relay box.
Is the fuse OK?
11-98
19. Disconnect each of the components or the connectors below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 ECM connector A (31 P) Each injector 2P connector Idle air control (lAC) valve 3P connector Camshaft Position (CMP) sensor B ITop dead center (TDC) sensor) 3P connector Crankshaft position (CKP) sensor 3P connector
PGMFI MAIN RELAY 1 4P CONNECTOR
21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground.
m~
Is there continuity? Is the fuse OK?
,
1
PGM-FI MAIN RELAY 1 4P CONNECTOR IGPI lYE LIB LKI
131XJ41
Q
=
W ~
/
1
IGPI IYEL/B LKI
13[XJ41
Q
=
YES-Repair short in the wire between the PGM-FI main relay 1 and each item. Also replace the No.6 ECU IECM) (15A) fuse . NO-Replace the PGM-FI main relay 1. Also replace the No 6 ECU IECMI115AI fuse . 22. Inspect the No. 17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box.
YES-Go to step 20. NO- Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM, update the ECM if it does not have
YES-Go to step 34. NO-Go to step 23. 23. Remove the blown No. 17 FUEL PUMP (15A) fuse from the under-dash fuse/relay box. 24. Disconnect ECM connector E (31P).
the latest software, or substitute a known-good

ECM, then recheck Isee page 11-6). If the symptom/ indication goes away with a known-good ECM, replace the original ECM. Also replace the NO.6 ECU (ECM) (15 A) fuse. 20. Disconnect the connectors of all these components. PGM-FI main relay 2 ECM connector A 131 P) Injectors Idle air control (lAC) valve Camshaft Position (CMP) sensor B (Top dead center (TDC) sensor) Crankshaft position (CKP) sensor
lcont'dl
11-99
PGM-FI System
ECM CONNECTOR E (31 PI
Is there continuity? YES-Go to step 26. NO-Replace the No. 17 FUEL PUMP (15 AI fuse, and update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . 26. Remove the PGM-FI main relay 2 (A).
Is there continuity? YES-Repair short in the wire between the No. 17 FUEL PUMP (15A) fuse and the ECM (E91, or between the No. 17 FUEL PUMP (15 A) fuse and the PGM-FI main relay 2. Also replace the No. 17 FUEL PUMP (15A) fuse . NO-Go to step 28. 28. Remove the rear seat cushion (see page 20-80). 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector.
I,','
,
---
"
I,','
, , ,
1'-::',' "
" "
----::...-------~-----
11-100
31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground.
FUEL PUMP 5P CONNECTOR
33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground.
FUEl PUMP 5P CONNECTOR
YES-Replace the PGM-FI main relay 2. Also replace the No. 17 FUEL PUMP (1 5A) fuse . NO-Check the fuel pump, and replace it if necessary. Also replace the No. 17 FUEL PUMP (15A) fuse . 34. Disconnect ECM connector E 131 PI .
YES-Repair short in the wire between the fuel pump and the PGM-FI main relay 2. Also replace the No. 17 FUEL PUMP (15A) fuse .
NO-Go to step 32. 32. Reinstall the PGM-FI main relay 2 (A). 35. Turn the ignition switch ON 1111.
,
,. "
" "
"
,--"
"
"
c.J '
, ' , 1,'1
:,'
1 234
~,!
22 23 24
'5115 18 2021 26 27 2930 31
/s there battery voltage?
YES-Go to step 37. NO-Repair open in the wire between the No. 17 FUEL PUMP (15A) fuse and the ECM (E9) .
(conI' d)
11-101
PGM-FI System
37. Measure voltage between ECM/PCM connector terminal E7 and body ground.
ECM CONNECTOR E (3tP)
40. Measure voltage between PGMFI main relay 1 4P connector terminal No.4 and body ground.
(WHT/BlK)
-B
=
=

YES-Go to step 42. NO-Go to step 38. 38. Turn the ignition switch OFF. 39. Remove the PGMFI main relay 1 (A).
A

YES-Goto step 41. NO-Repair open in the wire between the NO.6 ECU (ECM) (15A) luse and the PGMFI main relay 1.
41. Check for continuity between PGMFI main relay 1 4P connector terminal NO.3 and ECM connector terminal E7.
PGM-FI MAIN RELAY 1 4P CQrjNECTOIR
--
ECM
CONNECTO~R~E;'~17;:;~M~~~E'D/"VEl)
YES- Test the PGM-FI main relay 1 (see page 2251). II the relay is OK, update the ECM il it does not have the latest software, or substitute a knowngood ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the PGM-FI main relay 1 and the ECM (E7) .
11-102
42, Reconnect ECM connector E (31P), 43, Turn the ignition switch ON (II), 44, Measure voltage between body ground and ECM connector terminals A2 and A3 individually,
ECM CONNECTOR A 131 PI IGP21YEL/BLKI IGP11YEL/BLKI
48, Measure voltage between PGMFI main relay 1 4P connector terminal No, 2 and body ground,
2
+B
IWHT/BLKI
=
=
=
YES~-~Go
to step 49,
YES-Go to step 51, NO-Go to step 45, 45, Turn the ignition switch OFF, 46, Remove the PGMFI main relay 1 (A),
A
NO-Repair open in the wire between the No, 6 ECU (ECM) (15A) fuse and the PGMFI main relay 1,. 49, Turn the ignition switch OFF, 50, Check for continuity between PGMFI main relay 1 4P connector terminal No.1 and ECM connector terminals A2 and A3 individually,
IGPl IYEL/BLKI
Wire side of female terminals IGP2 IYEL/BLKI ECM IGPl IYEL/BLK}
CONNECTOR~~J;~~~~~~~~
E131P} 8 9
47, Turn the ignition switch ON (II),
Is there continuity? YES-Replace the PGMFI main relay 1,. NO-Repair open in the wire between the PGMFI main relay 1 and the ECM (A2, A3),.
(cont'd)
11-103
PGM-FI System
51. Measure voltage between body ground and ECM connector terminals A4, A5, A23, and A24 individually.
ECM CONNECTOR A 131 PI PG21BlKI PG11BlKI
53. Turn the ignition switch OFF. 54. Disconnect the manifold absolute pressure (MAP) sensor 3P connector. 55. Turn the ignition switch ON (II). 56. Measure voltage between body ground and ECM connector terminal A21.
ECM CONNECTOR A 131 PI
'Y.
=
lG2 IBRNI YEll
'Y.
=
Is there more than 1.0 V? YES-Go to step 52. NO-Repair open in the wire(s) that had more than 1.0 V between G 101 and the ECM (A4, A5, A23, A24) . 52. Measure voltage between body ground and ECM connector terminal A21.
Is there about 5 V? YES-Replace the MAP sensor. NO-Go to step 57. 57. Turn the ignition switch OFF.
SS;S'--7r'tT-;~r.!:';~~9 RED I IYEll r;c
r-:"--;;,,VCC1
58. Disconnect ECM connector A (31P).
=
Is there about 5 V? YES-Go to step 60. NO - Go to step 53.
11-104
61. Turn the ignition switch OFF. 62. Disconnect the throttle position (TP) sensor 3P
connector.

r-"..-o-,VCCI
1--'+'T'--T-lrlrlhS-'-r.l4--'r"9-i (VElI REDI
64. Measure voltage between body ground and ECM connector terminal A20.
ECM CONNECTOR A 131 PI
VCC2
Is there continuity? YES-Repair short in the wire between the ECM (A21) and the MAP sensor. NO-Update the ECM il it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). lithe symptom/indication goes away with a known-good ECM, replace the original ECM . 60. Measure voltage between body ground and ECM
connector terminal A20.
(VEll
BLU)
Is there about 5 V? YES-Replace the throttle body (the TP sensor is not available separately) . NO-Go to step 65. 65. Turn the ignition switch OFF. 66. Disconnect ECM connector A (31P).
VCC2
(VEll
BLUI
=
Is there about 5 V? YES-Go to step 68. NO-Go to step 61 .
con! d
11-105
PGM-FI System
67. Check lor continuity between ECM connector terminal A20 and body ground.
ECM CONNECTOR A (31PI ECM CONNECTOR E (31 PI
68. Measure voltage between body ground and ECM

connector terminal E5.
=
=
Is there continuity? YES-Repair short in the wire between the ECM

(A20) and the TP sensor, or repair short in the wire
Is there about 5 V? YES- Update the ECM il it does not have the latest
between the ECM (A8) and the knock sensor. NO-Update the ECM il it does not have the latest
recheck (see page 11-6). II the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the luel tank pressure (FTP) sensor 3P
connector.
recheck (see page 11-6). II the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-106
72. Measure voltage between body ground and ECM

connector terminal E5.

ECM CONNECTOR E 131Pl
Is there about 5 V?
YES-Replace the FTPsensor.. NO-Go to step 73. Is there about 5 V (or battery voltage)? YES-Go to step 82. NO-Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM connector E (31P).
73. Turn the ignition switch OFF. 74. Disconnect ECM connector E (31 PI. 75. Check for continuity between ECM connector terminal E5 and body ground.
YES-Repair short in the wire between the ECM (E5) and the FTP sensor. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . (conl'd)
11-107
PGM-FI System
YES-Repair short in the wire between the data link connector (DLCI and the ECM (E291 . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . 82. Turn the ignition switch OFF. 83. Disconnect ECM connector E (31PI. 84. Turn the ignition switch ON (III.
Does the MIL stay on?
YES-Repair short in the wire between the gauge assembly and the ECM (E311. If the wire is OK, replace the gauge assembly . NO-Update the ECM if it does not have the latest
recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-108
OLC Circuit Troubleshooting

If the ECM does not communicate with the aBO II scan tool, Honda PGM Tester, or I/M test equipment, do this
troubleshooting procedure.
3. Measure voltage between OLe terminals No.5 and No. 16.

DATA LINK CONNECTOR (DlC}
1. Measure voltage between OLC terminal No. 16 and body ground.

DATA LINK CONNECTOR (DlCI
lG (BRN/YEll
r--"'-'''''''","",T""?c=T~ ~ B
4 5
(WHT IREDI
+ B (WHT IRED}
12
14
16
Terminal side offemale terminals

YES-Go to step 4. Is there battery voltage?

NO~ Repair
open in the wire between OLC terminal No.5 and the ECM (E3) .
YES-Go to step 2. 4. Turn the ignition switch ON (II). NO-Repair open in the wire between OLC terminal No. 16 and the No.9 BACK UP (7.5 A) fuse in the under-hood fuse/relay box .
2. Measure voltage between OLC terminals No.4 and No. 16.
5. Measure voltage between OLC terminals No.5 and No.7.

PG (BlKI
9
+B (WHT/RED}
Is there 8.5 V or more?

YES~Go
to step 10.
Is there battery voltage? NO-Go to step 6. YES-Go to step 3. 6. Turn the ignition switch OFF.
NO-Repair open in the wire between OLe terminal No.4 and body ground .
(cont'd)
11-109
PGM-FI System
OLC Circuit Troubleshooting (cont'd)
7. Disconnect ECM connector E 131PI. Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC. 8. Check for continuity between DLC terminal No.7 and body ground.
DATA LINK CONNECTOR IDLC)
YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between DLC terminal No.7 and the ECM IE231. After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester, and go to the DTC Troubleshooting index . 10. Turn the ignition switch OFF.
KLlNE ILT BLU)
=
11. Disconnect ECM connector E 131 PI. Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC. 12. Turn the ignition switch ON 1111.
YES-Repair short to ground in the wire between DLC terminal No.7 and the ECM IE23). After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester, and go to the DTC Troubleshooting index . NO-Go to step 9.
13. Measure voltage between DLC terminals No.5 and No.7.

DATA LINK CONNECTOR (DLC)
LG
(BRN/YEL)
9. Check for continuity between DLC terminal No.7

and ECM terminal E23.
4 12
1--7,L7i-'7i'--SC-'ctr-:;.-:':::,--';2d Wi re side of
t:::oct',-;-f-hEFcr;ct;2:;:0t;2",1 fema Ie term i nals
/s there
DATA LINK CONNECTOR (DLC)
a V?
4 5
YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO-Repair short to power in the wire between the DLC terminal No.7 and the ECM IE231. After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester, and go to the DTC Troubleshooting index .
11-110
Injector Replacement
1. Relieve fuel pressure Isee page 11-144). 2. Disconnect the connectors from the injectors IA), disconnect the ground cable (8), and remove the bracket Ie).
Nm
12.2 kglm, 16 (blltl
A
D
:>
3. Disconnect the quick-connect fittings ID). 4. Remove the fuel rail mounting nuts IE) from the fuel rail IF) then remove the fuel rail and injectors as an assembly. 5. Remove the injector clip IG) from the injector.
6. Remove the injector from the fuel rail.
Iconl'd)
11-111
PGM-FI System
Injector Replacement (cont'd)
7. Coat the new a-rings (A) with clean engine oil, and insert the injectors (8) into the fuel rail (C).
c
t=:==;~_-I_--,vA
8. Install the injector clip (D). 9. Coat the injector a-rings (E) with clean engine oil. 10. Install the injectors into the fuel rail, then install the fuel rail into the intake manifold IG). 11. Install the fuel rail mounting nuts, ground cable, and bracket.
12. Connect the connectors to the injectors.
13. Connect the quick-connect fittings. 14. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check for fuel leakage.
11-112
A/F Sensor Replacement

02 sensor wrench, Snap-on YA8875, SP Tools 93750 , or equivalent, commercially available 1. Disconnect the NF sensor 4P connector (A), then remove the NF sensor (8).
B 44Nm 14.5 kgfm, 33Ibfft)
Secondary H02S Replacement

02 sensor wrench, Snap-on YA8875, SP Tools 93750 , or equivalent, commercially available 1. Disconnect the secondary H02S 4P connector (A), then remove the secondary H02S (8).
2. Install the NF sensor in the reverse order of removal. 2. Install the secondary H02S in the reverse order of removal.
11-113
PGM-FI System
ECT Sensor Replacement
1. Remove the air cleaner (see page 11-1621. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (AI. 1. Remove the air cleaner (see page 11-1621. 2. Disconnect the CMP sensor B (TDC sensorl 3P
connector,
CMP Sensor B (TOC Sensor) Replacement
3. Remove the CMP sensor B (TDC sensorl (AI.
12Nm 11.2 kgfm. 8.7Ibf1t1
4. Install the sensor in the reverse order of removal
with a new a-ring (BI.
4. Install the sensor in the reverse order of removal
with a new a-ring (BI.
11-114
IAT Sensor Replacement

1. Disconnect the IAT sensor 2P connector. 2. Remove the clip IAI and the IAT sensor IBI.
Knock Sensor Replacement

1. Remove the intake manifold bracket IAI.
..
~.=-~
~/
/~ . rl
3. Install the sensor in the reverse order of removal.
31 B Nm 13.2 kgfm, 23lbfftl
/~ '~l
1!1.
24Nm 12.4 kgfm, 17lbfftl
2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor IBI.
11-115
PGM-FI System
CKP Sensor Replacement
1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor IAI.
12 Nm 11.2 kgfm,
8.7Ibfftl
\
/
/
3. Install the sensor in the reverse order of removal with a new a-ring IBI.
11-116
VTEC/VTC
\, ,\
-------------VTC OIL CONTROL SOLENOID VALVE Troubleshooting, page 11+'18
'--
------------
Test,page 1'-127
VTC SOLENOID VALVE Troubleshooting, page 11-123 Removal/Inspection, page 11-128
CAMSHAFT POSITION ICMP) SENSOR A Troubleshooting, page 11-121 Replacement, page 11-128
11-117
VTEC/VTC
DTC Troubleshooting
OTC P0010: VTC Oil Control Solenoid Valve Malfunction
1. Reset the ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with no load lin neutrall until the radiator fan comes on, then let it idle. 3. Test-drive at a steady speed between 20-40 mph (30-60 km/hl for 10 minutes.
Is OTC POOIO indicated?

the VTC oil control solenoid valve and at the ECM . 4. Turn the ignition switch OFF. 5. Disconnect the ECM connector 8 (24PI.
6. Measure resistance between ECM connector
terminals 81 and 823.

VTC~
IBLU /WHTI
).,Jr;=::;:::::;:::=1
13 1718 15
21
VTCIBLK/WHTI
23
Is there 6.75-8.25 Q ?
7. Disconnect the VTC oil control solenoid valve 2P connector.
YES-Go to step 11. NO-Repair open in the wire between the ECM (81, 8231 and the VTC oil control solenoid valve .
11-118
11. Check for continuity between ECM connector terminals 81 and 823 and body ground individually.
Ole POOll: VlC System Malfunction

1. Resetthe ECM (see page 11-41. 2. Start the engine. Hold the engine at 3,000 rpm with
VTC-(Bl.U/WHTj
12345
8 9 10 17 18 13
67
15
no load (in neutral) until the radiator fan comes on.
3. Test-drive at a steady speed between 20-40 mph (30-60 km/hl for 10 minutes. 4. Check for Temporary DTC POOll with the scan tool.
Is Temporary DTC POOII indicated?

Check for poor connections or loose wires at the
YES-Go to step 12. NO- Update the ECM if it does not have the latest
VTC oil control solenoid valve and at the ECM . 5. Watch the low oil pressure light with the engine running.
recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . 12. Disconnect the VTC oil control solenoid valve 2P
connector.
Is the low oil pressure light on?

YES-Check the oil pressure (see page 8-41 . NO-Go to step 6. 6. Turn the ignition switch OFF.
13. Check for continuity between ECM connector terminals 81 and 823 and body ground individually.
7. Remove the auto-tensioner (see page 4-281.
(BLK/WHT)
VTC
YES-Repair short in the wire between the ECM (81, 823) and the VTC oil control solenoid valve . NO-Replace the VTC oil control solenoid valve (see page 11-127) .
(cont'dl
11-119
VTEC/VTC
8. Remove the VTC strainer (A). Check the VTC strainer for clogging.
13. Connect ECM connector terminals A3 and Bl with a

jumper wire momentarily.
NOTE: Do not jump for more than 1 minute.

ECM CONNECTORS A (31PI
IGPI (VEL/BLKI
1 2 3 4
JUMPER WIRE
6 71
10 111121/1/ 15 16 1/118119 2021 22231241 ~ 27128129 3D 1/

B (24P)
- I 2314151 VTC8 9 101/1/1131/ 151/ (BLUI WHT)
f6'7
Is the strainer OK?

YES-Go to step 9. NO-Clean the VTC strainer, then replace the engine oil filter and the engine oil.. 9. Check the VTC oil control solenoid valve (see page
17 18 1/1
1/1211/ 23 1/
Did the engine stall or run rough?

YES- Test-drive at a steady speed between 20-40 mph (30-60 km/h) for 10 minutes. If temporary DTC POOll is indicated, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). )f the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Go to step 14.
11-127).
Is the VTC oil control solenoid valve OK?
YES-Go to step 10. NO-Clean the ports of the VTC oil control solenoid valve, or replace the VTC oil control solenoid valve (see page 11-127) .
14. Check the VTC actuator (see page 6-8). 10. Install the VTC oil control solenoid valve.
Is the VTC actuator OK?
11. Start the engine. Hold the engine at 700-1,000 rpm. YES-Remove the auto-tensioner (see page 4-28), and clean or replace the VTC oil strainer. Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
12. Connect ECM connectorterminal B23 to body

ground with a jumper wire.
17 18
VTCIBLK/WHTI
15 23
JUMPER WIRE
NO-Replace the VTC actuator .
=
11-120
OTC P0340: CMP Sensor A No Signal OTC P0344: CMP Sensor A Intermittent Interruption
1. Resetthe ECM (see page 11-4). 2. Start the engine.
7. Measure voltage between CMP sensor A 3P connector terminal NO.1 and body ground.
CMP SENSOR A 3P CONNECTOR
Is DTC P0340 andlor P0344 indicated?

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the CMP sensor A and atthe ECM . 3. Turn the ignition switch OFF. NO-Go to step 10. 4. Disconnect the CMP sensor A 3P connector. 5. Turn the ignition switch ON (II). 8. Measure voltage between CMP sensor A 3P connector terminals No.2 and No.3.
Is there about 5 V?
YES-Go to step 8.
6. Measure voltage between CMP sensor A 3P connector terminal NO.3 and body ground.
=
YES-Go to step 9.
NO-Repair open in the wire between the CMP sensor A and Gl0l .

YES-Go to step 7. NO-Check the NO.4 ACG (lOA) fuse in the underdash fuse/relay box. If the fuse is OK, repair open in the wire between the CMP sensor A and No.4 ACG (lOA) fuse . 9. Substitute a known-good CMP sensor A and recheck.
Is DTC P0340 andlor P0344 indicated?

YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the original CMP sensor A (see page 11-128) . (conI' d)
11-121
VTEC/VTC
10. Measure voltage between ECM connector terminal A25 and body ground.
Ole P0341: VTC Phase Gap

1. Reset the ECM (see page 11-41. 2. Start the engine.
1 234
679
Is OTC P0341 indicated? YES-Go to step 3. NO-Intermittent failure, system is OK at this time.
=
the CMP sensor A and at the ECM . 3. Check the VTC oil control solenoid valve (see page 11-127). Is the VTC oil control solenoid valve OK?
Is there about 5 V? YES-Repair open in the wire between the ECM IA251 and CMP sensor A.. NO-Go to step 11. 11. Turn the ignition switch OFF. 12. Disconnect ECM connector A 131PI. 13. Check for continuity between ECM connector terminal A25 and body ground.
YES-Go to step 4. NO-Clean the VTC oil control solenoid valve, or replace it (see page 11-1271. 4. Remove the head cover, and check the cam chain (see page 6-121. Is the cam chain OK? YES-Go to step 5. NO-Replace the cam chain Isee page 6-121 .
123 10 11 12 222324
5. Check the VTC actuator Isee page 6-81. Is the VTC actuator OK? YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO- Replace the VTC actuator .
=
Is there continuity? YES-Repair short in the wire between the ECM IA251 and the CMP sensor A . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-122
OTe P1259: VTEC System Malfunction

Special Tools Required Pressure gauge adapter 07NAJ-P07010A AfT low pressure gauge w/panel 07406-0070300 AfT pressure hose 07406-0020201 AfT pressure hose, 2,210 mm 07MAJ-PY4011A AfT pressure adapter 07MAJ-PY40120 Oil pressure hose 07ZAJ-S5AA200 1. Reset the ECM (see page 11-4). 2. Check the engine oil level, and refill if necessary. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on. 4. Road test the vehicle: Accelerate in the 15t gear to an engine speed over 4,000 rpm. Hold the speed for at least 2 seconds. If DTC P1259 is not repeated during the first road test,
6. Disconnect the VTEC oil pressure switch 2P
connector.
7. Check for continuity between VTEC oil pressure switch 2P connector terminals No.1 and NO.2.
VTEC OIL PRESSURE SWITCH 2P CONNECTOR
Q
YES-Go to step 8.
repeat the test two more times.

NO-Replace the VTEC oil pressure switch . YES-Go to step 5. 8. Turn the ignition switch ON (II). NO-Intermittent failure, system is OK at this time. Check the oil consumption if oil was added in step 2. Check for poor connections or loose terminals at the VTEC solenoid valve, the VTEC oil pressure switch, and at the ECM . 5. Turn the ignition switch OFF. 9. Measure voltage between VTEC oil pressure switch 2P connector terminal No.1 and body ground.
VTEC OIL PRESSURE SWITCH 2P CONNECTOR VTPSW IBLU/BLKI

YES-Gotostep 14. NO-Go to step 10 .
(conrdl
11-123
VTEC/VTC
10. Measure voltage between ECM connector terminal 89 and body ground.
ECM CONNECTOR B 124P) VTEC Oil PRESSURE SWITCH 2P CONNECTOR
14. Measure voltage between VTEC oil pressure switch 2P connector terminals No.1 and No.2.
1234567 8 9 10 13 15 17 1 LLJ",21:.JL.J!2",3JLj
VTPSW IBlU/BlK)
VTPSW IBLU/BlK)
LG1 IBRN/YEL)
'------{'i.. }-_...J
=
Is there battery voltage? Is there battery voltage?

YES-Repair open in the wire between the VTEC oil pressure switch and the ECM (89) . NO-Goto step 11. 11. Turn the ignition switch OFF. 15. Turn the ignition switch OFF. 12. Disconnect ECM connector 8 124P). 16. Disconnect the VTEC solenoid valve 2P connector. 13. Check for continuity between ECM connector terminal 89 and body ground.
YES-Go to step 15. NO-Repair open in the wire between the VTEC oil pressure switch and G101 .
17. Check for resistance between VTEC solenoid valve 2P connector terminals No.1 and NO.2.
VTEC SOLENOID VALVE 2P CONNECTOR
1234567 13 15 171 21 23
8 9 10
VTPSW IBLU/BlK)
Q
=
YES-Repair short in the wire between the VTEC oil pressure switch and the ECM (89) . NO- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
/sthere 14-30"?
YES-Go to step 18. NO-Replace the VTEC solenoid valve Isee page 1,.,28) .
11-124
18. Remove the VTEC oil pressure switch (A) and install the special tools as shown, then reinstall the VTEC oil pressure switch.
07406-002020t or 07MAJ-PY40llA and 07MAJ-PY40120
23. Turn the ignition switch OFF. 24. Disconnect the VTEC solenoid valve 2P connector. 25. Attach the battery positive terminal to VTEC
solenoid valve 2P connector terminal No.2.
07406-0070300
~,
A
22Nm
26. Start the engine, then connect the battery negative terminal to VTEC solenoid valve 2P connector
terminal No.1, and check the oil pressure at an
(2.2 kgf.m,
16lbfftl
07NAJ-P07010A 07ZAJ-S5AA200
engine speed of 3,000 rpm.
Is the oil pressure above 390 kPa (4.0 kgf/cni, 57 psi)?

YES-Go to step 27. NO-Inspectthe VTEC solenoid valve (see page 11128) .
19. Reconnect the VTEC solenoid valve 2P connector and VTEC oil pressure switch 2P connector. 20. Connect a tachometer or OBD II scan tool/Honda PGM Tester to the DLC. 21. Start the engine. Hold the engine at 3,000 rpm with
27. With the battery terminals still connected to the

VTEC solenoid valve connector, measure voltage
between ECM connector terminal B9 and body ground .

22. Check the oil pressure at engine speeds of 1,000 and 2,000 rpm. Keep the measuring time as short as possible (less than 1 minute) because the engine
is running with no load.
6 7
8 9 10
171
15 23
VTPSW IBLU/BLKI
Is the oil pressure below 49 kPa (0.5 kgf/cni, 7 psi)?

YES-Go to step 23. NO-Inspectthe VTEC solenoid valve (see page 11128).
=
Is there battery voltage above 4,000 rpm?

YES-Go to step 28. NO-Replace the VTEC oil pressure switch (see page 11-128). 28. Turn the ignition switch OFF. 29. Disconnect the battery terminals from the VTEC
solenoid valve terminal connector.
Iconl'd)
11-125
VTEC/VTC
30. Disconnect ECM connector B (24P). 31. Check for continuity between ECM connector terminal B15 and body ground.
32. Connect VTEC solenoid valve 2P connector terminal No.2 to body ground with a jumper wire.
VTEC SOLE NOlO VALVE 2P CONNECTOR
VTS IGRN/YEL) JUMPER

WIRE
8 9 10 1718
VTS IGRN/YEL)
Q
=
33. Check for continuity between ECM connector terminal B15 and body ground.
ECM CONNECTOR B 124P) VTS IGRN/YEL)
YES~Repair short in the wire between the VTEC solenoid valve and the ECM (B15) .
NO~Go
to step 32.
6 7
8
1718 15
23
YES~Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO~Repair open in the wire between the VTEC solenoid valve and the ECM (B15) .
11-126
VTC Oil Control Solenoid Valve Removal/Test

1. Remove the VTC oil control solenoid valve (A).
4. Connect the battery positive terminal to VTC oil

control solenoid valve 2P connector terminal No.2.
NOTE: Install the valve in the reverse order of removal with a new a-ring (B), then check these
items:
VTC OIL CONTROL SOLENOID VALVE 2P CONNECTOR
Clean and dry the VTC oil control solenoid valve mating surface. Coat the O-ring with engine oil. Do not install the VTC oil control solenoid valve
while wearing fibrous gloves,
Be careful not to contaminate the cylinder head

opening.
BATTERY
5. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1, then make sure the valve (A) opens fully.
12Nm 11.2 kgfm,
8.7Ibfftl
2. Check the VTC oil control solenoid valve filter for clogging. If it is clogged, replace the VTC oil control solenoid valve. 3. Check the clearance between the port (advance side) and the valve. The clearance (A) should be at least 2.8 mm (1/8 in.).
11-127
VTEC/VTC
CMP Sensor A Replacement
1. Remove the air cleaner (see page 11-162). 2. Disconnect the CMP sensor A 3P connector. 3. Remove the CMP sensor A (A). 1. Disconnect the VTEC solenoid valve 2P connector.
2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2.
VTEC Solenoid Valve Removall Inspection
Resistance: 14-30 Q
/ ,r>.-'---- -,
4. Install the sensor in the reverse order of removal with a new a-ring (8).
3. If the resistance is within specifications, remove the
VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (8) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the
engine oil.
6x 1.0mm 9.B Nm 11.0 kgfm, 7.2 Ibfttl
11-128
Idle Control System

:-
\,
"
~-
----,
-------------
IDLE AIR CONTROL (lAC) VALVE

-,
11-129
Idle Control System

OTC Troubleshooting
OTe P0505: Idle Control System Malfunction
NOTE: If DTC P1519 is stored althe same time as DTC P0505, troubleshoot DTC P1519 first, then recheck for DTC P0505. 1. Start the engine. Hold the engine at 3,000 rpm with no load lin neutral) until the radiator fan comes on, then let it idle. 2. Check the engine speed at idle with no-load conditions: headlights, blower fan, rear defogger,
radiator fan, and air conditioner off.
7. Put your fingers on the lower port (A) in the throttle body.
Is the engine running at 750 50 rpm?

YES-Intermittent failure, system is OK at this time . NO-If the idle speed is less than 700 rpm, go to step 3; if it's 800 rpm or higher, go to step 4. 3. Disconnect the idle air control (lAC) valve 3P
connector.
Does the engine stall?

YES-Check the idle speed (see page 11-138). If it's out of specification, replace the lAC valve . NO-With the throttle valve completely closed,
check for vacuum leaks, and repair as necessary .
Does the engine speed increase or fluctuate?

YES-Check the idle speed (see page 11-138). If the idle will not adjust properly, clean the passage in the throttle body, and then adjust the idle . NO-Replace the lAC valve . 4. Turn the ignition switch OFF. 5. Remove the intake air duct from the throttle body. 6. Start the engine, and let it idle.
11-130
DTC P1519: lAC Valve Circuit Malfunction

1. Resetthe ECM (see page 11-41. 2. Turn the ignition switch ON (II). Is DTC P1519 indicated? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the lAC valve and at the ECM . 3. Turn the ignition switch OFF. 4. Disconnect the lAC valve 3P connector.
8. Check for continuity between body ground and lAC valve 3P connector terminal No.1.
lAC VALVE 3P CONNECTOR
5. Turn the ignition switch ON 1111.

YES-Go to step 9.
6. Measure voltage between lAC valve 3P connector terminal No.2 and body ground.
NO-Repair open in the wire between the lAC valve and Gl0l . 9. Disconnect ECM connector A (31PI. 10. Check for continuity between body ground and ECM connector terminal A 12.
Is there battery voltage? YES-Go to step 7. NO-Repair open in the wire between the lAC valve and the PGM-FI main relay 1. 7. Turn the ignition switch OFF. YES-Repair short in the wire between the lAC valve and the ECM (A 121 . NO-Go to step 11.
Icont'dl
11-131
Idle Control System

11. Connect lAC valve 3P connector terminal No.3 to body ground with a jumper wire.
15. Measure voltage between body ground and ECM connector terminal A 12.
9
IACV IBLK/REDI JUMPER WIRE
2223
=
Is there battery voltage? YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Replace the lAC valve .
Is there continuity? YES-Go to step 13. NO-Repair open in the wire between the lAC valve and the ECM (A121 . 13. Reconnect the lAC valve 3P connector. 14. Turn the ignition switch ON (III.
11-132
AIC Signal Circuit Troubleshooting

1. Turn the ignition switch ON (II). 2. Momentarily connect ECM connector terminals A24
and E18 with a jumper wire several times.
ECM CONNECTOR A (31PI UNDERHOOD FUSE/RELAY BOX 14P CONNECTOR
6. Momentarily connect under-hood fuse/relay box 14P connector terminal No. 10 to body ground with
a jumper wire several times.
1 21314 5671 10 111121/1/1516/118192021 22231241 2712829 30V
171""9
ILGI (BRN/YEL)
2 7 8
5 6 1314
ACC (RED) JUMPER WIRE
JUMPER WIRE E (31PI ACC (RED)
1 21314 22 231241
VVVVI14
5 6 7 18 9 1516VI181VI20 21 ~ 271VI29130 31
=
Is there a clicking noise from the Ale compressor clutch? YES-Go to step 3.
Is there a clicking noise from the Ale compressor clutch? YES- Repair open in the wire between the ECM (E1S) and the AlC clutch relay . NO-Check the AlC system for other symptoms.
NO-Go to step 6. 3. Start the engine. 4. Turn the blower switch ON. 5. Turn the AlC switch ON. Does the
Ale operate?
YES- The air conditioning signal is OK . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-5). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-133
Idle Control System

Alternator FR Signal Circuit Troubleshooting
1. Disconnect the alternator 4P connector from the alternator. 2. Turn the ignition switch ON (III.
ALTERNATOR 4P CONNECTOR
11. Connect alternator 4P connector terminal No. 4to body ground with a jumper wire.
3. Measure voltage between ECM connector terminals A24 and B13.

ECM CONNECTORS A 131PI
,.----,
1
2
ALTFI WHT/REOI
4
JUMPER WIRE
1 2 I 3 I 4 5 6 7 J/l9 10 11112VV 15 16 VI18119 20 21 22 231241 ~ 2712812930V
ILG1 IBRN/YELI
':L
B 124PI ALTF IWHT/RE 01
-=
[6'7 213 4 5 8 9 1OIVIVI13 IV 15 V 17 18 1/1 IVI21 V 23 V

I
12. Check for continuity between body ground and ECM connector terminal B13.
/s there about 5 V?
YES-Go to step 4. NO-Go to step 13. 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 7. Measure voltage between ECM connector terminals A24 and B13.
,--------,ALTF IWHT/REOI
Q
=
YES- Test the alternator (see page 4-221 . NO-Repair open in the wire between the ECM (B131 and the alternator. 13. Turn the ignition switch OFF.
Does the voltage decrease when the headlights and rear window defogger are turned on?
YES- The alternator FR signal is OK.
14. Disconnect ECM connector B (24PI. NO-Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM connector B (24PI.
10. Disconnect the alternator 4P connector.
11-134

15. Check for continuity between body ground and ECM connector terminal 813. ECM CONNECTOR B (24PI ALTF (WHT/RED)
17 18
Electrical Power Steering (EPS) Signal Circuit Troubleshooting

2. Measure voltage between ECM connector terminals A24 and E16.
ECM CONNECTORS
A (31P)
21
6 7 15 23
1 2 I 314 5 6 7lJ/ 9 10 11112VV 15 16 VI18119 20 21 22 231241 ~ 2712812930V LG1 (BRN/YEL)

I
E (31P) 5 6 71 8 9 15 16 V118/120 21 ~ 271/129130 31 EPSLD (LT GRN/BLK)
YES-Repair short in the wire between the ECM (813) and the alternator.
2 1314
/ /VV114
22231241

YES-Go to step 6 . NO-Go to step 3. 3. Start the engine. 4. Turn the steering wheel to the full lock position.
5. Measure voltage between ECM connector terminals A24 and E16.
NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
Is there momentary battery voltage?

YES- The EPS signal is OK. NO-Goto step 10. 6. Turn the ignition switch OFF. 7. Disconnect the EPS control unit 20P connector. 8. Turn the ignition switch ON (II) .
(cont'd)
11-135
Idle Control System

Electrical Power Steering (EPS) Signal Circuit Troubleshooting (cont'd)
9. Measure voltage between EPS control unit terminal NO.17 and body ground. 13. Measure voltage between EPS control unitterminal No. 17 and the body ground.
EPS CONTROL UNIT 20P CONNECTOR EPS CONTROL UNIT 20P CONNECTOR
1 2 3 5 6 7 8 10 111315 1920
1 2 3 5 6 7 8 10 111315171920
=
Is there battery Voltage? Is there battery voltage?

YES-Substitute a known-good EPS control unit and recheck . NO- Repair open in the wire between the ECM IE16) and the EPS control unit.. YES-Substitute a known-good EPS control unit and recheck . NO-Go to step 14. 14. Turn the ignition switch OFF. 15. Disconnectthe ECM connector E 131P). 10. Turn the ignition switch OFF. 11. Disconnect the EPS control unit 20P connector.
16. Check for continuity between body ground and ECM connector terminal E16.
EPSLD ILT GRN/BLKI
Q
=
YES-Repair short in the wire between the ECM IEI6) and the EPS control unit.. NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-136
Brake Pedal Position Switch Signal Circuit Troubleshooting

1. Check the brake lights.
Are the brake lights on without pressing the brake pedal?
4. Inspect the NO.7 HORN, STOP (15AI fuse in the under-hood fuse/relay box.
Is the fuse OK?
YES-Inspect the brake pedal position switch (see page 19-61 . NO-Go to step 2. 2. Press the brake pedal.
Do the brake lights come on?
YES-Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15AI fuse. Inspect the brake pedal position switch (see page 19-101 . NO-Repair short in the wire between the ECM (E221 and the NO.7 HORN, STOP (15AI fuse. Replace the No.7 HORN, STOP (15AI fuse .
YES-Go to step 3. NO-Go to step 4. 3. Measure voltage between ECM connector terminals A24 and E22 with the brake pedal
pressed.
ECM CONNECTORS
A (31P)
1 2 314 5 6 71 V 9 10 111121/1/ 15 16 1/118119 20 21 27\28\29 30/ 2223\24\ ~

LGl (BRN/YEL) E (31P)
5 6 7 I \8 9 15 16 V118/120 21 / /VV114 22231241 ~ 271/129130 31 1 2 1 3 14

IBKSW (WHT/BLK)
YES- The brake pedal position switch signal is OK . NO-Repair open in the wire between the ECM (E221 and the brake pedal position switch .
11-137
Idle Control System

Idle Speed Inspection
NOTE: Leave the idle air control (lAC) valve connected . Before checking the idle speed, check these items: - The malfunction indicator lamp (MIl) has not been reported on.
- Ignition timing
3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions:
headlights, blower fan, radiator fan, and air
- Spark plugs - Air cleaner - PCV system Pull the parking brake lever up. Start the engine, and make sure the headlights are off. 1. Disconnect the evaporative emission (EVAP)
canister purge valve 2P connector.
conditioner off.
Idle speed should be: 750
50 rpm
5. Let the engine idle for 1 minute with the heater fan
switch on HI and air conditioner on, then check the
idle speed.
Idle speed should be: 750 50 rpm
2. Connect a tachometer (A) to the test tachometer connector (B), or connect the Honda PGM Tester (C) or an aBO II scan tool to the data link connector (DLC) (D) located under the driver's side of the dashboard.
A
NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting Index. 6. Reconnect the EVAP canister purge valve 2P
connector.
11-138
ECM Idle Learn Procedure

The idle learn procedure must be done so the ECM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: Disconnect the battery.
Replace the ECM or disconnect its connector.
Reset the ECM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. Remove the No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. Remove the No.19 battery (BOA) fuse from the underhood fuse/relay box. Remove PGM-FI main relay 1. Remove any of the wires from the under-hood fuse/ relay box.
Disconnect any of the connectors from the under-
hood fuse/relay box.

Disconnect the connector between the engine compartment wire harness and ECM wire harness. Disconnect the G2 terminal from the transmission
housing. Disconnect the G1 terminal from the body. Disconnect the G101 terminal from the cylinder head cover.
Procedure:
To complete the idle learn procedure, do this: 1. Make sure all electrical items (NC, audio, rear defogger, lights, etc.,) are off. 2. Start the engine, and hold it at 3,000 rpm with no
load (in neutral) until the radiator fan comes on, or until the engine coolanttemperature reaches 194F
(90C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its
running time in the 5 minutes.
11-139
Fuel Supply System

FUEL PUMP

FUEL FILTER Replacement, page 11-152 FUEL GAUGE SENDING UNIT
(
~,

FUEL PRESSUR REGULATOR
/<::,~ePlacement, page 11-152

~~!!il,UV,/'"j ~
FUEL FILL CAP
FUEL TANK Replacement. page 11-155 FUEL RAIL FUEL TUBE/QUICK-CONNECT FITTINGS Precautions, page 11-148 Removal, page 11-149 Installation, page 11-150 FUEL FEED LINE FUEL PULSATION DAMPER Replacement, page 11-154 FUEL VAPOR LINE
---- - --- - --- -
---
/
/
/
" /
!,:
, , , ,
PGM-FI MAIN RELAY 1
PGM-FI MAIN RELAY 2 Troubleshooting, page 11-141
11-140
Fuel Pump Circuit Troubleshooting

If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some noise if you listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the fuel pump does not make noise, check as follows: 1. Turn the ignition switch OFF. 2. Remove the glove box (see page 20-63), then remove the PGM-FI main relay 2 (A).
IG1 IYELI BLKI
5. Measure voltage between PGM-FI main relay 2 5P connector terminal No.1 and body ground.
=

-~-----~
--
YES-Go to step 6. NO-Repair open in the wire between the underdash fuse/relay box and PGM-FI main relay 2. 6. Turn the ignition switch OFF. 7. Disconnect ECM connector E (31P). 8. Check for continuity between PGM-FI main relay 2 5P connector terminal NO.3 and ECM connector terminal El.
3. Turn the ignition switch ON (II). 4. Measure voltage between PGM-FI main relay 2 5P connector terminal No.5 and body ground.
IGP1 IYEL/BLKI
IMOFPR IGRNI YELl IMOFPR IGRNI YELl
.Q
=
234567 89 141516 18 2021 222324 26 27 293031

Is there battery voltage? Is there continuity?

YES-Go to step 5. YES-Go to step 9. NO-Repair open in the wire between the PGM-FI main relay 1 and the PGM-FI main relay 2. NO-Repair open in the wire between the PGM-FI main relay 2 and the ECM (El)..
(cont'd)
11-141
Fuel Supply System

Fuel Pump Circuit Troubleshooting (cont'd)
9. Reinstall the PGM-FI main relay 2. 10. Turn the ignition switch ON (II). 11. Measure voltage between ECM/PCM connector terminal El and body ground.
ECM CONNECTOR E (31P) )MOFPR (GRN/YEl)
Is there battery voltage? YES- Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Goto step 15. 15. Turn the ignition switch OFF.
1 234 5 6 7 8 9 141516 18 2021 222324 26 ",27,-,,-,-=2::193::::0"-,3,,,1
16. Remove the rear seat cushion (see page 20-80). 17. Remove the access panel from the floor.
=
18. Measure voltage between fuel pump 5P connector terminal No.5 and body ground within the first 2 seconds after the ignition switch was turned ON (II).
Is there battery voltage? YES-Go to step 12. NO-Replace the PGM-F) main relay 2. 12. Turn the ignition switch OFF. 13. Reconnect ECM connector E (31P). 14. Turn the ignition switch ON (III, and measure voltage between ECM connector terminal El and body ground within the first 2 seconds after the ignition switch was turned ON (II).
ECM CONNECTOR E (31P) IMOFPR (GRN/YEl)
Is there battery voltage? YES-Go to step 24. NO-Go to step 19. 19. Turn the ignition switch OFF.
20. Remove the PGM-FI main relay 2.
=
11-142
21. Connect PGM-FI main relay 2 SP connector terminals No.1 and No.2 with a jumper wire.
PGM-FI MAIN RELAY 2 5P CONNECTOR FUEL PUMP IYEl/ GRNI JUMPER WIRE
25. Check for continuity between fuel pump SP connector terminal NO.4 and body ground.
~' ~
IG1 (YEl/BlKI
[2] [Z]
~
22. Turn the ignition switch ON 1111. 23. Measure voltage between fuel pump SP connector terminal No.5 and body ground.
YES-Replace the fuel pump . NO-Repair open in the wire between the fuel pump SP connector and G5S1 .
Is there battery voltage? YES-Replace the PGM-FI main relay 2 . NO-Repair open in the wire between the PGM-FI main relay 2 and the fuel pump SP connector.. 24. Turn the ignition switch OFF.
11-143
Fuel Supply System

Fuel Pressure Relieving
Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment.
1. Turn the ignition switch OFF. 2. Remove the PGM-FI main relay 2 IAI. 9. Place a rag or shop towel over the quick-connect fitting IAI.
10. Disconnect the quick-connect fitting IAI: Hold the connector IBI with one hand and squeeze the retainer tabs ICI with the other hand to release them from the locking pawls IDI. Pull the connector off. 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank.
6. Remove the engine cover.
NOTE:
Prevent the remaining fuel in the fuel feed line or
hose from flowing out with a rag or shop towel. Be careful not to damage the line lEI or other parts.
Do not use tools. If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push the connector until it comes off easily.
Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
7. Disconnect the negative cable from the battery.

8. Check the fuel quick-connect fitting for dirt, and clean it if necessary.
11. After disconnecting the quick-connect fitting, check it for dirt or damage Isee page 11-1491.
11-144
Fuel Pressure Test

o o
Fuel pressure gauge 07406-004000A Fuel pressure gauge set 07ZAJ-S5A0100 1. Relieve the fuel pressure (see page 11-144). 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge.
07406-004000A
07ZAJ-S5A0100
3. Start the engine and let it idle.

o o
lithe engine starts, go to step 5. lithe engine does not start, go to step 4.
4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on.
o o
If the pump runs, go to step 5. If the pump does not run, do the fuel pump circuit troubleshooting (see page 11-1411.
5. Read the pressure gauge. The pressure should be 320-370 kpa (3.3-3.8 kgf/cm', 47-52 psi)
o
If the pressure is OK, the test is complete. If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter (see page 11-152), then recheck the fuel pressure.
11-145
Fuel Supply System

Fuel Line Inspection
Check the fuel system lines, hoses, and fuel filter for damage, leaks, and deterioration. Replace any damaged parts.
Make sure the connection is secure and the quick-connect fitting cover is firmly locked into place.
11-146
Check all clamps and retighten if necessary . : Do not disconnect the hose from the line at these joints.
To
FUEL PULSATION
DAMPER
C
To EVAPORATIVE EMISSION IEVAPI
CANISTER PURGE VALVE
BASE GASKET Replace .
Clamp in the middle. Clamp in the middle. / There should be no
~40[~em"k
There should be no clearance. mark mark Setthis part
{ clea,.n,e.
~.
When installing the fuel fill tube, align the marks
@#J':~~. ~
90
There should be no clearance .
90
on the tube and

the line.
11-147
Fuel Supply System

Fuel Line/Quick-Connect Fittings Precaution
The fuel tube/quick-connect fittings connect the fuel rail (A) to fuel feed hose (8), the fuel feed hose (8) to the fuel line (C), and the fuel tube (D) to the fuel pump assembly (E). When removing or installing the fuel feed hose, fuel pump assembly, or fuel tank, it is necessary
to disconnect or connect the quick-connect fittings.
Pay attention to the following: The fuel feed hose (8), fuel tube (D), and quickconnect fittings (F) are not heat-resistant; be careful not to damage them during welding or other heatgenerating procedures.
The fuel feed hose (8), fuel tube (D) and quickconnect fittings (F) are not acid-proof; do not touch them with a shop towel which was used for wiping battery electrolyte. Replace them if they came into
contact with electrolyte or something similar.
When connecting or disconnecting the fuel feed hose (8), fuel tube (D), and quick-connect fittings (F), be careful not to bend or twist them excessively. Replace them it they are damaged.
A disconnected quick-connect fitting can be

reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line.
Replace the retainer when replacing the fuel rail. replacing the fuel line. replacing the fuel pump. replacing the fuel filter. replacing the fuel gauge sending unit. it has been removed from the line. it is damaged. PART MANUFACTURER RETAINER COLOR GREEN
ENGINE TOKAI COMPARTMENT (FUEL FEED HOSE: FUEL LINE SIDE) ENGINE TOKAI COMPARTMENT (FUEL FEED HOSE: FUEL RAIL SIDE) FUEL TANK SANOH I UNIT
8LU
WHITE
11-148
Fuel Line/Quick-Connect Fittings Removal

1. Relieve fuel pressure (see page 11-1441. 2. Check the fuel quick-connect fittings for dirt, and clean if necessary. 3. Hold the connector (AI with one hand and squeeze the retainer tabs (BI with the other hand to release them from the locking paws (CI. Pull the connector 4. Check the contact area (AI of the line (BI for dirt and damage.
o o
If the surface is dirty, clean it. if the surface is rusty or damaged, replace the fuel pump, fuel filter, fuel feed line.
off.
NOTE: o Be careful not to damage the line (DI or other parts. Do not use tools. If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
'I ~
A
..0"
(;
5. To prevent damaged and keep foreign matter out, cover the disconnected connector and line end with plastic bags (AI.
NOTE: The retainer cannot be reused once it has been removed from the line. Replaced the retainer when - replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged.
11-149
Fuel Supply System

Fuel Line/Quick-Connect Fittings Installation
1. Check the contact area (A) of the line (B) for dirt and damage, and clean if necessary. 3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer from the mating line.
2. Insert a new retainer (A) into the connector (B) if the

retainer is damaged, or after
replacing the fuel replacing the fuel replacing the fuel replacing the fuel replacing the fuel
rail. feed line. pump. filter. gauge sending unit
removing the retainer from the line.
~.
11-150
4. Align the quick-connect fittings with the line (A), and align the retainer (B) locking pawls with the connector (e) grooves. Then press the quickconnect fittings onto the line until both retainer
5. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector.
pawls lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end.
Connection with new retainer:
6. Reconnect the negative cable to the battery, and turn the ignition switch ON (II). The fuel pump will
run for about 2 seconds, and fuel pressure will rise.
Repeat 2 Or 3 times, and check that there are no fuel leaks.
Reconnection to existing retainer:
11-151
Fuel Supply System

Fuel Pressure Regulator Replacement
1. Remove the fuel pump (see page 11-153). 2. Remove the fuel pressure regulator (A). 1. Remove the fuel pump (see page 11-153). 2. Remove the fuel filter (AI.
Fuel Filter Replacement

The fuel filter should be replaced whenever the fuel pressure drops below the specified value (270-320 kPa, 2.8-3.3 kgf/cm', 40-47 psi), after making sure that the fuel pump and the fuel pressure regulator are OK.
3. Install the part in the reverse order of removal with
a new a-ring (8).
3. Install in the reverse order of removal with a new base gasket (8) and a new a-ring (e), then check
these items:
When connecting the wire harness, make sure the connection is secure and the terminal (0) is
firmly locked into place . When installing the fuel gauge sending unit (E),
make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively,
11-152
Fuel Pump/Fuel Gauge Sending Unit Replacement

8. Remove the locknut (A) and the fuel tank unit.
Fuel sender wrench 07XAA-001 010A
1. Relieve the fuel pressure (see page 11-144).

2. Remove the fuel fill cap. 3. Remove the seat cushion (see page 20-80). 4. Remove the access panel (A) from the floor.
5. Disconnect the fuel pump 5P connector (81. 6. Disconnect the quick-connect fining (CI from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (AI.
9. Remove the stopper (a). Release the hook (P) and remove the fuel filter (8), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F).
10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is
firmly connected to the fuel pump (H).
11. Install the fuel tank unit in the reverse order of /07XAA-001010A
removal with a new base gasket (I) and new a-rings (J), then check these items: When connecting the wire harness, make sure the connection is secure and the connector (K) is
=:v ~
'."', , .
"I' '__
------- ------- ~--~-~--------'
'~ ,','," .,:~," p;

A
firmly locked into the place. When installing the fuel gauge sending unit,
make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. When installing the fuel tank unit, align the marks
(L) on the fuel tank (M) and the fuel tank unit (NI.
11-153
Fuel Supply System

Fuel Pulsation Damper Replacement
1. Relieve the fuel pressure (see page 11-1441.
2. Remove the engine cover.
3. Remove the fuel rail mounting nuts from the fuel

rail.
4. Remove the ground cable (Gl01). 5. Raise the fuel rail. 6. Place a wrench (AI on the fuel rail (BI.
7. Place a wrench (el on the fuel pulsation damper (DI. 8. Remove the pulsation damper. 9. Install the fuel pulsation damper in the reverse order of removal with new washers.
NOTE:
Replace all washers whenever the fuel pulsation

damper is loosened or removed .
If the drain hole (AI of the fuel pulsation damper cover does not face bottom, reinstall it as shown.
11-154
Fuel Tank Replacement

,. Relieve the fuel pressure (see page "-'44). 2. Drain the fuel tank: Remove the fuel pump (see page"-' 53). Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank. 3. Jack up the vehicle, and support it with safety stands. 4. Remove the fuel pipe cover (A). Disconnect the fuel vapor hose and quick-connect fittings. Disconnect the hoses. Slide back the clamps (8), then twist the hoses as you pull to avoid damaging them.
---.::---
e;,
~~
A
38Nm (3.9 kgf.m, 28Ibfft)
5. Place a jack or other support under the tank. 6. Remove the strap bolts, and let the strap (e) hang free.
7. Remove the fuel tank (0). If it sticks to the undercoat on its mount, carefully pry it off the mount.
8. Install the parts in the reverse order of removal.
11-155
Fuel Supply System

Fuel Gauge Sending Unit Test
Fuel sender wrench 07XAA-00101 OA NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram (see page 22-S81. 1. Check the No. 10 METER (7.SAI fuse in the underdash fuse/relay box before testing. 2. Do the gauge drive circuit check (see page 22-S61. If the fuel gauge needle sweeps from minimuni
to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3 .
7. Measure voltage between fuel pump SP connector terminals No.1 and No.2 with the ignition switch ON (III. There should be battery voltage. If the voltage is as specified, go to step 8. If the voltage is not as specified, check for: - an open in the YEUBLK or BLK wire. - poor ground (GS511.
If the fuel gauge needle does not sweep from

minimum to maximum position position and then return to the minimum position, replace the
gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion (see page 20-801. S. Remove the access panel (AI from the floor.
(BLKI
8. Turn the ignition switch OFF. Remove the No.9 BACK UP (7.5AI fuse from the under-hood fuse/
relay box for at least 10 seconds, then reinstall it.
9. Install a 2 Q resistor between fuel pump 5P

connector terminals No.1 and No.2, then turn the
ignition switch ON (III.

6. Disconnect the fuel pump SP connector (BI.
11-156
10. Check that the pointer of the fuel gauge indicates "F" . If the pointer does not indicate "F", replace the gauge . If the pointer indicates "F", inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level.. 11. Relieve the fuel pressure (see page 11-144). 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). /07XAA-001010A
15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions . If you do not get the following readings, replace the fuel gauge sending unit (see page 11-163). Float
Position
F 11 to13
1/2 68.5 to 74.5
LOW 114.4 to 126.6
E 130 to 132
Resistance
(R)
NOTE: Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10
seconds after completing troubleshooting,
otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level.
A
93Nm
19.5 kglm, 69 Iblltl
("' '-.I~ j jI
I
1/2
11-157
Fuel Supply System

Low Fuel Indicator Test
1. Do the fuel gauge sending unit test Isee page 11156). If the system is OK, go to step 2. If the system has any malfunction, repair it. 2. Turn the ignition switch OFF. Remove the NO.9 BACK UP 11 OA) fuse from the under-hood fuse! relay box for at least 30 seconds, then reinstall it. 3. Turn the ignition switch ON 1111 with the float at the E IEMPTY) position. If the low fuel indicator is on, go to step 4. If the low fuel indicator is not on, refer to the low fuel indicator Circuit Diagram Isee page 22-58) and check the circuit. 4. Turn the ignition switch OFF. Remove the NO.9 BACK UP 110A) fuse from the under-hood fuse! relay box for at least 30 seconds, then reinstall it. 5. Lift the float above the LOW position. If the low fuel indicator goes off, the system is OK. If the low fuel indicator is still on, refer to the low fuel indicator Circuit Diagram Isee page 22-58), and check the circuit.
11-158
Intake Air System

Test, page 11-161
- --- __ ~I
INTAKE AIR BYPASS CONTROL THERMAL VALVE
AIR CLEANER Replacement. page 11-162 AIR CLEANER ELEMENT

THROTTLE CABLE Adjustment, page 11-163 Removal/Installation, page 11-164
THROTTLE BODY
Test, page 11-160 Removal/Installation, page 11-165 Disassembly/Reassembly, page 11-166
11-159
Intake Air System

Throttle Body Test
NOTE: Do not adjust the throttle stop screw. It is preset at the
factory .
If the malfunction indicator lamp IMILI has been

reported on, check for diagnostic trouble codes
IDLCsiisee page 11-31. 1. With the engine off, check the throttle cable movement. The cable should move without binding
or sticking.
If the cable moves OK, go to step 2. If the cable binds or sticks, check it and its routing. If the cable is faulty, reroute it or replace it and adjust it Isee page 11-1631, then go to step 2. 2. Move the throttle lever by hand to see if the throttle
valve and/or shaft are too loose or too tight. If there is excessive play in the throttle valve
shaft, or any binding in the throttle valve at the fully closed position, replace the throttle body. If the throttle valve and shaft are OK, go to step 3.
3. Connect the scan tool to the DLC.

5. Check the throttle position with the scan tool. The reading should be about 10% when the throttle is fully closed and about 90% when the throttle is fully opened.
lithe throttle position is correct, the throttle body is OK.

If the throttle position is not correct, replace the
throttle body.
11-160
Intake Air Bypass Control Thermal Valve Test

Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX 1. Start the engine. Then let it idle. NOTE: The engine coolant temperature must be below 149 of (65 C). 2. Remove the vacuum hose (A) from the intake air If the vacuum reading changes, check for these problems: Misrouted, leaking, broken, or clogged intake air
5. Raise and lower the engine speed, and make sure the vacuum gauge reading does not change as the rpm changes.
duct, and connect a vacuum pump/gauge to the

hose. A
A973X041XXXXX
bypass control system vacuum lines. A cracked or damaged intake air bypass control thermal valve.
3. Raise and lower the engine speed, and make sure the vacuum gauge reading changes as the engine
speed changes.
If the vacuum reading does not change, check for
these problems:
Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines .
A cracked or damaged intake air bypass control

thermal valve.
4. Hold the engine at 3,000 rpm with no load (in

neutral) until the radiator fan comes on, then let it
idle .
11-161
Intake Air System

Air Cleaner Replacement
1. Remove the nuts (A) and the stud (8).
Air Cleaner Element Replacement

1. Disconnect the PCV hose (A).
A
",....j~lt'--.-
~12N.m
11.2 kglm. 8.7 Iblft)
3Nm
10.3 kglm, 2 IblftJ
2. Remove the air cleaner (C). 3. Install in the reverse order of removal.
2. Open the air cJeaner housing cover (8).

3. Remove the air cleaner (e) from the air cleaner housing (D). 4. Install in the reverse order of removal.
11-162
Throttle Cable Adjustment

1. Check cable free play at the throttle linkage. Cable free play IAI should be 10-12 mm 13/8-1/2 in.l.
2. If the free play is not within spec 110-12 mm, 3/8-1/2 in.l, loosen the locknut IB), turn the adjusting nut ICI until the free play is as specified, then retighten the locknut . 3. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle
position whenever you release the accelerator
pedal.
11-163
Intake Air System

Throttle Cable Removal/Installation
1. Fully open the throttle valve, then remove the throttle cable (AI from the throttle link (81.
A
5. After installing, start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator
fan comes on, then let it idle.
6. Hold the cable, removing all slack from it.
7. Set the locknut on the cable bracket (AI.

Turn the adjusting nut (81 so that its free play is Omm.
The should be no clearance.
.r-'L"-<---' [
/./c
(PIN 08798-90021
-A
2. Remove the cable housing (CI from the cable bracket (DI. 3. Remove the throttle cable (AI from the accelerator pedal (81.
~. :.. ~
n/~.8N.m V 11.0 kgfm,

7.2Ibfhl
========I~[
[[ :::J
8. Remove the cable from the cable bracket (AI. Set the adjusting nut on the other side of the throttle bracket, then tighten the locknut (CI. 9. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle
position whenever you release the accelerator
pedal.
~.
SILICONE GREASE (PIN 08798-90021
11-164
Throttle Body Removal/Installation

NOTE:
Do not adjust the throttle stop screw. After reassembly, adjust!he throttle cable (see page 11-1631 and the cruise control cable (see page 4-451. The throttle position (TPI sensor is not removable.
THROITLE STOP SCREW (Do not adjust) THROITLE LEVER
There should be no clearance
GASKET Replace. EVAPORATIVE EMISSION IEVAP} CANISTER PURGE VALVE
THROITLE CABLE
~~"""~~\t~~---~.'....
MANIFOLD ABSOLUTE PRESSURE IMAP} SENSOR
,~,
/t@A,
~ ~-~~
~kgfm, 16Ibfft} 12.2
22Nm
~'~'~ ..
,.-----.
THROITLE POSITION ITP} SENSOR
IDLE AIR CONTROL (lAC) VALVE
11-165
Intake Air System

Throttle Body DisassemblyIReassembly
Nm
MAP SENSOR O-RING Replace.
(0.2 kgfm. 1 Ibfft)
~
I
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE
TPSENSOR
THROTTLE BODY
:~ . " ,>./. "t/,,'

/.//
...
~
GASKET Replace.
I~U ~
I
ii:---:~- ~"'~
..
-~
3.5 Nm
(0.35 kgfm, 2.5Ibfft)
11-166

DTe Troubleshooting
DTe P0420: Catalytic System Efficiency Below Threshold
NOTE: If some of the OTCs listed below are stored at the same time as OTC P0420, troubleshoot those OTCs first, then recheck for OTC P0420. P0137, P0138: Secondary Heated Oxygen Sensor (secondary H02S) (Sensor 2) P0141: Secondary H02S (Sensor 2) heater 1. Reset the ECM (see page 11-4), then continue to step 2 through 5 to reset the readiness code. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on.
3. Drive for about 10 minutes without stopping. Your speed can vary. 4. With the transmission in 4th gear, drive at a steady
speed between 50-62 mph (80-100 km/h) for

30 seconds.
5. Repeat step 4 three times. Between each repetition,
close the throttle completely for 1-2 seconds. If the engine is stopped during this part of the procedure, repeat steps 3, 4 and 5. 6. Check for a Temporary OTC with the scan tool. Does the scan tool indicate Temporary OTe
P0420?
YES-Check the TWC. If necessary, replace the
TWC .
NO-Check for readiness code completion. If the
readiness is complete, it was a intermittent failure,
and the system is OK at this time. If the readiness code is incomplete, repeat steps 2 through 5 .
11-167
PCVSystem
OTe Troubleshooting
Ole P1505: PCV Air Leakage
1. Reset the ECM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with
3. Let the engine idle for at least 40 seconds with the throttle fully closed. 4. Check for a DTC P1505 with the scan tool.

YES-Check these parts for vacuum leaks . PCV valve PCV hose EVAP canister purge valve Throttle body Brake booster hose NO-Intermittent failure, system is OK at this time .
11-168
PCV Valve Inspection and Test

1. Check the PCV valve (AI, hoses (B), and
connections for leaks or restrictions.
PCV Valve Replacement

1. Disconnect the PCV hose. 2. Remove the PCV valve (A).
rl ):;J
a@
------A
with a new gasket (B).
2. At idle, make sure there is a clicking sound from the
44Nm 14.5 kgfm, 33 IbfftJ
PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your
fingers or pliers.
3. Install the parts in the reverse order of removal
If there is no clicking sound, check the PCV valve
grommet for cracks or damage. If the grommet is
OK, replace the PCV valve and recheck.
11-169
EVAP System
=-
- -- -'"=-.:-
--
- -- -------- -----
EVAPORATIVE EMISSION IEVAPI CANISTER PURGE VALVE Troubleshooting, step 3 on page 11-175, step 1 on page 11-180
FUEL TANK VAPOR CONTROL VALVE Test, page 11-187 Replacement. page 11-189 EVAPORATIVE EMISSION (EVAPI CANISTER
Troubleshooting, step 28 on page 11-183

FUEL TANK PRESSURE SENSOR Troubleshooting, page 11-171 EVAPORATIVE EMISSION IEVAPI BYPASS SOLENOID VALVE Troubleshooting,
EVAPORATIVE EMISSION (EVAP) CANISTER VENT SHUT VALVE Troubleshooting, step 23 on page 11-178, step 19 on page 11-182
--~
step 12 on page 11-176, step lOon page 11-181
EVAPORATIVE EMISSON (EVAP) TWO WAY VALVE
Test, page 11-186
11-170
OTe Troubleshooting
OTe P0451: FTPSensorRange/Performance
Problem
Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX 1. Remove the fuel fill cap. 2. Turn the ignition switch ON (II). 3. Monitor fuel tank pressure (FTP) sensor voltage with the Honda PGM Tester, or me~sure voltage between ECM connector terminals E4 and E14.
ECM CONNECTOR E 131 PI SG31PNKI
6. Connect a vacuum pump to the open end of the hose.
7. Turn the ignition switch ON (II). 8. Monitor FTP sensor voltage with the Honda PGM Tester, or measure voltage between ECM connector terminals E4 and E14, and carefully squeeze the vacuum pump a little.
'Y
1 213 4 5 6 7 I 18 9 1/11/1/1,11 415 16 1/118V120 21 22231241 l ~ 27VI29130 31

FTPILTGRNI

SG31PNKI
Is there about 2.SV? YES-Go to step 4. NO-Replace the FTPsensor . 4. Turn the ignition switch OFF.
'Y
1 213 4 5 6 7 I 18 9 /1/1. '11 415 16 1/1181/120 21 22231241 L ~ 271/129130 31

FTPILTGRNI
5. Disconnect the hose between the EVAP two way valve and the FTPsensoralthe EVAP two way valve end.
9. The voltage should smoothly drop from about 2.5 V to about 1.5 V. Stop applying vacuum when the voltage drops to about 1.5 V or damage to the FTP sensor may occu r. Does the voltage drop 10 about 1.5 V and hold? YES-Check for misrouted, leaking, or broken FTP sensor vacuum lines. If the vacuum lines are OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO- Replace the FTP sensor .
11-171
EVAPSystem
OTe P0452: FTP Sensor Circuit Low Voltage
1. Check the vacuum lines at the FTP sensor for misrouting, leakage, breakage, or clogging. Are the vacuum lines OK? 9. Turn the ignition switch ON III). YES-Go to step 2.
NO-Repair or replace vacuum lines as necessary .
,
6. Turn the ignition switch OFF. 7. Reinstall the fuel fill cap. 8. Disconnect the FTP sensor 3P connector. 10. Measure voltage between FTPsensor3Pconnector terminals No.1 and No.2.
FUEL TANK PRESSURE SENSOR 3P CONNECTOR
2. Resetthe ECM (see page 11-41. 3. Remove the fuel fill cap. 4. Turn the ignition switch ON (III. 5. Monitor FTPsensorvoltagewiththe Honda PGM Tester, or measure voltage between body ground and ECM connector terminal E14.
ECM CONNECTOR E 13lPI
SG3IPNK}
Is there about 5 V? YES-Go to step 11. NO-Repair open in the wire between the FTP sensor and the ECM (E51 .
=
Is there about 2.5 V? YES-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the FTP sensor and at the ECM . NO-Go to step 6.
11-172
11. Measure voltage between FTP sensor 3P connector terminals No.2 and No.3.
FUEL TANK PRESSURE SENSOR 3P CONNECTOR
DTC P0453: FTP Sensor Circuit High Voltage

1. Check the vacuum lines at the FTP sensor for misrouting, leakage, breakage, or clogging.
Are the vacuum lines OK?

YES-Go to step 2.
NO-Repair or replace vacuum lines as necessary .
2. Reset the ECM (see page 11-4).

3. Remove the fuel fill cap.
Is there about 5 V?
4. Turn the ignition switch ON (II). YES-Replace the FTPsensor. NO-Go to step 12. 12. Turn the ignition switch OFF. 5. Monitor FTP sensor voltage with the Honda PGM Tester, or measure voltage between body ground and ECM connector terminal E14.
13. Disconnect ECM connector E (31PI . 14. Check for continuity between FTPsensor3P connector terminal No.3 and body ground.
FTPSENSOR3PCONNECTOR
ECM CONNECTOR E 131 P)
Is there about 2.5 V?

YES-Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the FTP sensor and at the ECM . NO-Go to step 6.
YES-Repair short in the wire between the FTP sensor and the ECM (E14) . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
(cont'd)
11-173
EVAPSystem
6. Turn the ignition switch OFF. 7. Reinstall the fuel fill cap. 8. Disconnect the FTP sensor 3P connector. 9. Turn the ignition switch ON (II).
FTPILTGRN)
11. Measure voltage between FTP sensor 3P connector terminals No.2 and NO.3.
FTP SENSOR 3P CONNECTOR
10. Measure voltage between FTP sensor 3P connector terminals No.1 and No.2.
FTP SENSOR 3P CONNECTOR SG3IPNK)
Is there about 5 V?
SG3IPNK)
YES-Replace the FTP sensor . NO-Gotostep 12.
12. Measure voltage between ECM connector terminals E4 and E14.

ECM CONNECTOR E 131 P) SG3IPNK)
Is there about 5 V? YES-Go to step 11. NO-Repair open in the wire between the FTP sensor and the ECM (E4) .
1 213
'::L
/ /VVI1 415 16 VI18VI20

22231241
71J8T9
l: ~
21 271/129130 31
FTPILTGRN)
Is there about 5 V? YES-Repair open in the wire between the FTP sensor and the ECM (E14) . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
11-174
OTe P1456: EVAP Control System Leakage (Fuel Tank System)
EVAP Canister Purge Valve Test 3. Disconnect the vacuum hose from the EVAP
canister purge valve (A), and connect a vacuum
INOTICE I
The fuel system is designed to allow specified
maximum vacuum and pressure conditions. Do not deviate from the vacuum and pressure tests as indicated in these procedures. Excessive pressure/
pump to the hose.
vacuum would damage the EVAP components or cause eventual fuel tank failure. Special Tools Required Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX This is a two-trip code. Once cleared, it cannot be
reproduced in one trip. Also, certain specific driving
and ambient conditions must occur before the ECM will complete the system checks. Additional test drives may still not meet the specific conditions needed to reproduce the code. Follow these troubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code. NOTE: Fresh fuel has a higher volatility that creates
greater pressure/vacuum. The optimum condition for
A973X041-XXXXX 4. Turn the ignition switch ON (II). 5. Apply vacuum to the hose.
Does the valve hold vacuum?

YES- The EVAP canister purge valve is OK. Go to step 11. NO-Go to step 6. 6. Turn the ignition switch OFF. Fuel Fill Cap Check 7. Disconnect the EVAP canister purge valve 2P 1. Check the fuel fill cap (the cap must say "If not tightened 3 clicks check engine light may come on"),
connector.
testing is fresh fuel, and must be less than a full tank. If possible, to assist in leak detection, add 1 gallon of fresh fuel to the tank (as long as it will not fill the tank),
just before starting these procedures.
Is the proper fuel fill cap installed and properly tightened?

YES-Go to step 2. NO-Replace or tighten the cap . 2. Check the fuel fill cap seal.
Is the fuel fill cap seal missing or damaged?

YES- Replace the fuel fill cap .
NO-The fuel fill cap is OK. Go to step 3.
(cont'd)
11-175
EVAPSystem
8. Check for continuity between EVAP canister purge valve 2P connenctor terminal No.2 and body ground.
EVAP CANISTER PURGE VALVE 2P CONNECTOR
EVAP Bypass Solenoid Valve Test 11. Disconnect both vacuum hoses from the EVAP two way valve IAI, and connect a vacuum pump to the canister port on the EVAP two way valve.
A973X-041-XXXXX
YES-Go to step 9. NO-Replace the EVAP canister purge valve . 9. Disconnect ECM connector B 124PI. 10. Check for continuity between EVAP canister purge valve 2P connector terminal No.2 and body ground.
EVAP CANISTER PURGE VALVE 2P CONNECTOR JUMPER WIRE
12. Turn the EVAP bypass solenoid valve on with the Honda PGM Tester, or connect ECM connecter terminal E20 to body ground with a jumper wire.
ECM CONNECTOR E 131 P)
2WBS IBLU/RED}
=
=
14. Apply vacuum to the hose.
Does the valve hold vacuum? Is there continuity?

YES-Go to step 15. YES-Repair short in the wire between the EVAP canister purge valve and the ECM (B211 . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck Isee page 11-61. If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Go to step 20.
11-176
15. Turn the ignition switch OFF. 16. Disconnect the EVAP bypass solenoid valve 2P
connector.
19. Measure voltage between EVAP bypass solenoid valve 2P connector terminal No.1 and body ground.
EVAP BYPASS SOLENOID VALVE 2P CONNECTOR
17. Check for continuity between EVAP bypass solenoid valve 2P connector terminal No.2 and body ground.
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR
YES-Go to step 18. NO-Repair open in the wire between the EVAP bypass solenoid valve and the ECM (E201 . 18. Turn the ignition switch ON (II).
YES-Replace the EVAP two way/bypass solenoid valve (AI . NO-Repair open in the wire between the EVAP bypass solenoid valve and the No.4 ACG (10A) fuse .
(conl'd)
11-177
EVAPSystem
20. Plug the fuel tank port (AI of the EVAP two way
valve.
EVAP Canister Vent Shut Valve Test 22. Disconnect the vacuum hose from the EVAP
canister vent filter (A), and connect a vacuum pump to the hose.
A973X-041-XXXXX A
21. While monitoring FTPsensorvoltagewiththe

Honda PGM Tester, or measuring the voltage between ECM connector terminals E4 and E 14,
23. Turn the ignition switch ON 1111. 24. Apply vacuum to the hose with five strokes of the
pump.
slowly pump the vacuum pump until the voltage drops to about 1.5 volts.
ECM CONNECTOR E 131P) SG3IPNK)

YES-Go to step 25. NO-The EVAP canister vent shut valve is OK. Go to step 30.
':L
1 213 4 5 6 71 18 9 /1 /I/t /11 415 16 1/1181/120 21 22231 24 1 lc ~ 27VI 29 130 31

FTPILTGRN)

26. Disconnect the EVAP canister vent shut valve 2P connector. 27. Check for continuity between EVAP canister vent shut valve 2P connector terminal No.2 and body
Does the voltage drop to 1.5 V and hold for at least 20 seconds?
YES- The EVAP bypass solenoid valve/EVAP two way valve is OK. Go to step 22. NO-Repairthe leak from the EVAP bypass
solenoid valve, EVA? two way valve, or
ground.
EVAP CANISTER VENT SHUT VALVE 2P CONNECTOR
FTPsensor .
11-178

YES~Go
Vacuum Hoses and Connections Test 30. Do the fuel tank vapor control valve test (see page 11-187).
Is the fuel tank vapor control valve OK?

YES~Gotostep31.
NO~Replace
the fuel tank vapor control valve .
31. Tighten the fuel cap 3 "clicks", then monitor the FTPsensor readings with the Honda PGM Tester. 32. Start the engine, and let it idle for 5 minutes. 33. Check the FTP sensor readings. to step 28.
NO~Replace the EVAP canister vent shut valve (AI and o-ring (8) .
28. Disconnect ECM connector E (31 PI.
29. Check for continuity between EVAP canister vent solenoid valve 2P connector terminal No.2 and body ground.
Is the reading above 0.5 kpa (4 mm Hg, 0.16 in. Hg) pressure, or about 3 V?
YES~Update
=
the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO~Check
the following parts for leaks:.
short in the wire between the EVAP canister vent shut valve and the ECM (E21) .
NO~Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . YES~Repair
Fuel tank (A) Fuel fill cap (8) Fuel fill pipe (C) Fuel tank vapor control valve (D) Fuel tank vapor recirculation valve (E) Fuel tank vapor recirculation tube (F) Fuel tank vapor signal tube (G) Fuel tank vapor control vent tube (H) FTPsensor (J) - Repair or replace any leaking parts.
11-179
EVAPSystem
OTe P1457: EVAP Control System Leakage (EVAP Canister System) INOTICEI
The fuel system is designed to allow specified maximum vacuum and pressure conditions. Do not deviate from the vacuum and pressure tests as indicated in these procedures. Excessive pressure! vacuum would damage the EVAP components or cause eventual fuel tank system failure. Special Tools Required Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX This is a two-trip code. Once cleared, it cannot be reproduced in one trip. Also, certain specific driving and ambient conditions must occur before the ECM will complete the system checks. Additional test drives may still not meet the specific conditions needed to reproduce the code. Follow these troubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code. NOTE: Fresh fuel has a higher volatility that creates greater pressure/vacuum. The optimum condition for testing is fresh fuel, and there must be less than a full tank. If possible, to assist in leak detection, add 1 gallon of fresh fuel to the tank las long as it will not fill the tankl, just before starting these procedures. EVAP Canister Purge Valve Test 1. Disconnect the vacuum hose from the EVAP canister purge valve (A), and connect a vacuum pump to the hose. 2. Turn the EVAP canister purge valve on with the Honda PGM Tester, or connect ECM connector terminal B21 to body ground with a jumper wire.
ECM CONNECTOR B (24P) I 2 3 1415 '6'7 8 9 10 1/1/11 317 151/ 1718 1/ 1/1211/ 231/ pcs JUMPER WIRE
(VEl/BlU)
_L Wire side of female terminals

4. Apply vacuum to the hose.

YES-Go to step 5. NO- The EVAP canister purge valve is OK. Go to step 10.
6. Disconnect the EVAP canister purge valve 2P

connector. 7. Check for continuity between EVAP canister purge valve 2P connector terminal No.2 and body ground.
EVAPCANISTER PURGE
VALVE 2P CONNECTOR
1
2
pcs
~YELI.LUI
A
A973X-041-XXXXX
YES - Go to step 8. NO-Repair open in the wire between the EVAP canister purge valve and the ECM/PCM IB211 . 8. Turn the ignition switch ON 1111.
11-180
9. Measure voltage between EVAP canister purge valve 2P connector terminal No.1 and body ground.
EVAP CANISTER PURGE VALVE 2P CONNECTOR
EVAP Bypass Solenoid Valve Test 10. Disconnect both vacuum hoses from the EVAP two way valve (A), and connect a vacuum pump to the
canister port on the two way valve.
=
Wire side of female terminals A973X-041-XXXXX
Is there battery voltage? YES-Replace the EVAP canister purge valve . 11. Turn the ignition switch ON (II). NO-Repair open in the wire between the EVAP canister purge valve and the No.4 ACG (1 OA) fuse . 12. Apply vacuum to the hose. Does the valve hold vacuum? YES- The EVAP two way/bypass solenoid valve is OK. Go to step 18. NO-Go to step 13. 13. Turn the ignition switch OFF. 14. Disconnect the EVAP bypass solenoid valve 2P connector. 15. Check for continuity between EVAP bypass solenoid valve 2P connector terminal No.2 and body ground.
(cont'd)
11-181
EVAPSystem
EVAP Canister Vent Shut Valve Test 18. Disconnect the vacuum hose from the EVAP canister vent filter (A), and connect a vacuum pump to the hose.
Is there continuity? YES-Go to step 16. NO- Replace the EVAP two way/bypass solenoid valve (A) . 16. Disconnect ECM connector E (31P). 17. Check for continuity between EVAP bypass solenoid valve 2P connectorterminal No.2 and body ground.
19. Turn the EVAP canister vent shut valve on with the Honda PGM Tester, or connect ECM connector terminal E21 to body ground with a jumper wire.
5 6 71 18 9 VSV {LTG RN/REDI / /VVJ14 15 16 VJ18V120 2127VI29130 31 22231241 ~ 1 2 I3 I4

JUMPER WIRE
=
20. Turn the ignition switch ON (II) Is there continuity? 21. Apply vacuum to the hose. YES-Repair the short in the wire between the EVAP bypass solenoid valve and the ECM (E20) . NO-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . Does the valve hold vacuum? YES- The EVAP canister vent shut valve is OK. Go to step 27. NO-Go to step 22. 22. Turn the ignition switch OFF.
23. Disconnect the EVAP canister vent shut valve 2P connector.
11-182
24. Check for continuity between EVAP canister vent shut valve 2P connector terminal No.2 and body ground.
Canister System Leak Test 27. Turn the ignition switch OFF. 28. Connect two, three-way T-fittings (AI into the hose from the EVAP canister to the EVAP two way valve. Connect the FTP sensor to one of the T-fittings and the vacuum pump to the other.
~
2
@
~
v,v
Il T GRN/REDI
Is there continuity? YES-Go to step 25. NO-Repair open in the wire between the EVAP canister vent shut valve and the ECM (E21).. 25. Turn the ignition switch ON (III. 26. Measure voltage between EVAP canister vent shut
A973X-04l-XXXXX
A
valve 2P connector terminal No.1 and body ground.

EVAP CANISTER VENT SHUT VALVE 2PCONNECTOR
29. Remove the vent hose from the EVAP canister vent shut valve (AI. and cap the port (81 to seal the fresh
air vent of the EVAP canister.
A973X041XXXXX
A
B
Is there battery voltage? YES-Replace the EVAP canister vent shut valve (AI and the a-ring 181 .
NO-Repair open in the wire between the EVAP canister vent shut valve and the No.4 ACG (10AI fuse .
(conl'dl
11-183
EVAPSystem
31. While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring voltage between ECM connector terminals E4 and E14, slowly pump the vacuum pump.
ECM CONNECTOR E 131PI SG3 (PNK)
37. While monitoring FTPsensorvoltagewiththe Honda PGM Tester, or measuring voltage between ECM connectorterminals E4 and E14, slowly pump the vacuum pump.
ECM CONNECTOR E (31P) SG3IPNK)
121345671J89
':L VVVV1141516/118V120 21
22231241
L~
':L
271/129130 31
5 6 71 18 9 VVVVI14 1516 /118V120 21 22231241 L ~ 27VI29130 31

FTPILTGRN)
1 213 4
FTP{LTGRNI
32. Continue to pump vacuum until the voltage drops to about 1.5 V. Make sure the engine coolant temperature is still above 95F (35C) and your vacuum pump has no leak. 33. Monitor the voltage for 20 seconds. Does the voltage drop 1.5V and hold for at least 20 seconds? YES-Inspect the EVAP canister vent shut valve line and connections. NO-Go to step 34.
38. Continue to pump vacuum until the voltage drops to about 1.5V. Make sure the engine coolant temperature is still above 95F (35C) and your vacuum pump has no leak. 39. Monitor the voltage for 20 seconds. Does the voltage hold for at least 20 seconds? YES-Inspect the fuel tank vapor control line and connections . NO-Go to step 40. 40. Turn the ignition switch OFF.
34. Turn the ignition switch OFF. 35. Disconnect the quick-connect fitting IA) from the EVAP canister, and plug the canister port (B). 41. Disconnect the purge line hose (A) from the canister at the metal line and plug the hose (B).
A
~~~;J~===:::::~~~~ ~
T.,,.,..,._ xxxxx
A973X. 041-
~ :::::-=-=-------------~J._~'7/Ir- xxxxx
A973X
041-
11-184
43. While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring voltage between ECM connector terminals E4 and E14, slowly pump the vacuum pump.
ECM CONNECTOR E 131 PI SG3 (PNKI
'i.
1 1213 4 5 6r7l IS 9 1/1/1/1/11 415 16l71i sT/120 21 22231241 L ~ 1271/129130 31

FTP(LTGRNI
44. Continue to pump vacuum until the voltage drops to about 1.5V. Make sure the engine coolant temperature is still above 95F (35C) and your vacuum pump has no leak .
45. Monitor the voltage continuously for 20 seconds.
Does the voltage drop to 1.5 V and hold for at least 20 seconds?
YES-Inspect the EVAP canister purge valve line and connections. If they are OK, perform the EVAP two way valve test (see page 11-186) and the fuel tank vapor control valve test (see page 11-187) . NO-Replace the EVAP canister (see page 11-189) .
11-185
EVAPSystem
EVAP Two Way Valve Test
Special Tools Required Vacuum pump/Gauge, 0-30 in. Hg A973X-041-XXXXX Vacuum/Pressure Gauge, 0-4 in. Hg 07JAZ-0010008
4. Move the vacuum pump hose from the vacuum

fining to the pressure fitting, and move the vacuum gauge hose from the vacuum side to the pressure
side (A) as shown .
1. Remove the fuel fill cap. 2. Disconnect the vapor line from the EVAP two way valve (A). Connect it to aT-fitting (8) from the
vacuum gauge and the vacuum pump as shown.
A973X-041-XXXXX
(;:~~~~
A?
A973X-041-XXXXX \
"'!
B
~~~~~
5. Slowly pressurize the vapor line while watching the

gauge. The pressure should stabilize momentarily
above 1.0 kPa (8 mmHg, 0.3 in.Hg) .

Ifthe pressure momentarily stabilizes (valve
3. Apply vacuum slowly and continuously while watching the gauge. The vacuum should stabilize momentarily at 0.8-2.1 kPa (6-16 mmHg, 0.2-0.6 in.Hg). If the vacuum stabilizes (valve opens) below 0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa (16 mmHg, 0.6 in.Hg), install a new valve and retest.
opens) above 1.0 kPa (8 mmHg, 0.3 in.Hg), the valve is OK. If the pressure stabilizes below 1.0 kPa (8 mmHg, 0.3 in.Hg), install a new valve and retest.
11-186
Fuel Tank Vapor Control Valve Test

Valve Test
1. Make sure the fuel tank is less than half full.
Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX
Float Test
2. Remove the fuel fill cap. 1. Make sure the fuel tank is less than half full. 3. Disconnect the fuel tank vapor signal tube IA). 2. Remove the fuel fill cap to relieve fuel tank pressure, then reinstall the cap.
3. Disconnect the fuel tank vapor recirpulation tube (Al, and connect a vacuum pump to it.
4. Disconnect the vacuum hoses IA) from the EVAP canister IB), then plug the ports with plugs Ie).
A973X-041-XXXXX
4. Plug the line IB). 5. Apply vacuum to the fuel tank vapor recirculation tube . If the vacuum holds, replace the fuel tank vapor control valve Isee page 11-189) . If the vacuum does not hold, the float is OK. Do the valve test.
A973X-041-XXXXX
5. Disconnect the vacuum hose (0) from the EVAP

canister vent shut valve (E), and connect a vacuum pump to the vacuum hose.
6. Pump the vacuum pump 80 times .
If the vacuum holds, go to step 7 . If the vacuum does not hold, go to step 10.
Iconl'd)
11-187
EVAPSystem
Fuel Tank Vapor Control Valve Test (cont'd)
7. Connect a second vacuum pump to the fuel tank vapor signal tube (A). 9. Fill the fuel tank with fuel, then check for fuel in the EVAP two way valve (A), and fuel tank vapor
recirculation hose (8).
,
If fuel runs out of the hoses at either location, replace the fuel tank vapor control valve. If the fuel does not run out of the hoses, the fuel
tank vapor system function is normal.
NOTE: At either location, tiny droplets of fuel are

normaL
A973X041XXXXX
8. Apply vacuum (1 pump) to the fuel tank vapor signal tube (A), then check the vacuum on the pump in step 6.
A
If the vacuum holds, replace the fuel tank vapor control valve (see page 11-189). If the vacuum is released, go to step 9.
Check for fuel running out.
Check for fuel running out.
10. Disconnect the fuel tank vapor quick disconnect from the EVAP canister, then plug the port on the canister. Reapply vacuum (80 pumps). If the vacuum holds, replace the fuel tank control valve (see page 11-189). If the vacuum does not hold, inspect the EVAP
canister vent shut valve a-ring. If the a-ring is OK,
replace the EVAP canister, and repeat step 4.
,
11-188
EVAP Canister Replacement

1. Remove the vacuum hoses IAI.
Fuel Tank Vapor Control Valve Replacement

1. Remove the fuel tank Isee page 11-1551. 2. Remove the fuel tank vapor control valve IAI from the fuel tank IBI.
2. Remove the bolt IBI . 3. Remove the EVAP canister lei.

3. Install the fuel tank vapor control valve. 4. Install the fuel tank Isee page 11-1551.
11-189

Transaxle
Clutch ............................................................. 12-1
Manual Transmission .................................... 13-1 MIT Differential ............................................. 13-52 Driveline/Axle ................................................ 16-1

Clutch
Special Tools ............................................................. Component Location Index .................................... . Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment ................... . Clutch Master Cylinder Replacement .................... . Slave Cylinder Replacement ................................... . Clutch Replacement ................................................. .
12-2 12-3 12-4 12-5 12-7 12-9
Clutch
Special Tools
Ref. No.
CD CD CD
Tool Number 07JAF-PM7011A 07LAB-PV00100 or 07924-PD20003 07ZAF-PR8A 100 07936-3710100
Descri~tion
I I
Qk
1 1 1 1
Clutch Alignment Disc Ring Gear Holder Clutch Alignment Shaft Remover Handle
TI
12-2
RESERVOIR
~-~
LJ
RESERVOIR HOSE
\
RETAINING C/IP / _ Replace. '1 '"
,
~
(
________ CLUTCH INTERLOCK SWITCH Adjustment, page 12-4
8
~i
~-- CLUTCH PEDAL
---------~ f$ " /
O-RING Replace.
POSITION SWITCH Adjustment, page 12-4
CLUTCH MASTER CYLINDER Replacement, page 12-5 CLUTCH DISC Removal, page 12-9 Installation, page 12-12
/~llESiSLI,RE
FLYWHEI,L Inspection, page 12-11 Replacement, page 12-11
PLATE Removal, page 12-9 Installation, page 12-12 RELEASE BEARING Replacement, page 12-13
/'
O-RING ,t?,J/' RePla/ ROLL PINS
'// /m
,"
/,"'""
ccc
I( ,
~~,--.'
~
i,,'
Ii i8!d
V'------CLUTCH HOSE
-~
' ;,. .
/CLUTCH HOSE CLIP
SLAVE CYLINDER
12-3
Clutch
Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment
NOTE:
3. Tighten the clutch push-rod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C).
5. Turn the clutch pedal position switch (B) in an
To check the clutch pedal position switch (see page 4-45). To check the clutch interlock switch (see page 4-6).
Remove the driver's side floor mat before adjusting
the clutch pedal. The clutch is self-adjusting to compensate for wear. If there is no clearance between the master cylinder piston and push rod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.
additional 3/4 to 1 turn.
6. Tighten the clutch pedal position switch locknut (A).

7. Loosen locknut (J) and the clutch interlock switch
1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C).
J 9.SN.m (1.0 kglm, 7.2Iblltl
(K).
8. Press the clutch pedal to the floor.

9. Release the clutch pedal 10-16 mm (0.39-0.63 in.) from the fully pressed pOSition, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J).
.____K
18Nm (l.S kgfm. 13 Iblltl
,
I
2. Loosen the clutch push-rod locknut (D), and turn
the push rod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) atthe clutch pedal.
130-140 mm (5.12-5.51 in.) Clutch Pedal Free Play: 10-16 mm (0.39-0.63 in.) Clutch Pedal Height: 193 mm (7.60 in.) Disengagement Height: 115 mm (4.53 in.) Between Floor And Carpet Height (Approximate Value): 38 mm (1.50 in.) Clutch Pedal Stroke:
12-4
Clutch Master Cylinder Replacement

NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Pry out the lock pin IAI, and pull the pedal pin IBI out of the yoke. Remove the master cyli nder mounting nuts lei. 6. Disconnect the reservoir hose 101 from the clutch master cylinder reservoir. Plug the end of the
reservoir hose with a shop towel to prevent brake fluid from coming out.
7. Remove the O-ring lEI and the clutch master cylinder seallFI from the master cylinder. 8. Install the clutch master cylinder in the reverse
order of removal. Install a new O-ring.
/(???,.'
B / /
9. Make sure the hose clamps IAI are positioned on the master cylinder IBI and reservoir lei as shown.
/~---
2. Remove the air cleaner housing cover and the air
1-3mm 10.04-0.12 in.J
cleaner housing Isee step 6 on page 5-21. 3. Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
4. Remove the clutch line bracket from the frame rail, and remove the clutch line clip. 5. Remove the clutch master cylinder IAI, and pull it toward the middle of the engine compartment. Remove the retaining clip IBI. Disconnectthe clutch line lei. Plug the end of the clutch line with a shop
towel to prevent brake fluid from coming out.
__ --.L _ ---- ------
Iconl'dl
12-5
Clutch
Clutch Master Cylinder Replacement (cont'd)
10, To prevent the retaining clip (A) from coming off, pry open the tip of the retaining clip (B) with a screwdriver.
~B
11, Tighten the master cylinder mounting nuts to 13 N, m (1,3 kgf,m, 9.4lbf, ft), 12, Bleed the clutch master hydraulic system (see step 11 on page 12-8), NOTE: The reservoir filling is covered in the bleeding procedure, 13, Install the air cleaner housing (see step 37 on page
5- 15),
12-6
Slave Cylinder Replacement

NOTE: Use fender covers to avoid damaging painted surfaces. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
1. Write down the frequencies for the radio's preset buttons. Disconnectthe negative (-) cable first, then the positive (+) cable from the battery. Remove the battery.
6. Remove the mounting bolts (A) and the slave cylinder (B).
A 0
2. Remove the battery tray.
7. Remove the roll pins (C). Disconnect the clutch line (D), and remove the O~ring (E). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out.
3. Remove the air cleaner housing cover and the air cleaner housing (see step 6 on page 5~2).
8. Install the slave cylinder in the reverse order of removal. Install a new O~ring (A).
4. Remove the intake air duct (see step 8 on page 5. Remove the clutch line bracket (A).
5~3)
(Brake Assembly lube)
9. Pull the boot (B) back, and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot. 10. Apply super high temp urea grease (PIN 08798~ 9002) to the push rod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 N m 12.2 kgf.m, 16Ibfft) .
Icont'd)
12-7
Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system. Attach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.
Make sure there is an adequate supply of fluid in the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear althe bleeder hose. It may be necessary to limit the movement of the release fork (B) with a block of wood to remove all the air from the system. Tighten the bleed screw to 8 Nm (0.8 kgfm, 6 Ibf ttl; do not overtighten it. Refill the clutch master cylinder with fluid when done. Always use only Honda DOT 3 brake fluid.
12. Install the intake air duct (see step 36 on page 5-14). 13. Install the air cleaner housing (see step 37 on page 5-15). 14. Install the battery tray. 15. Install the battery, connect the positive (+) cable first, then the negative (~I cable.
16. Reset the frequencies for the radio station preset
buttons.
12-8
Clutch Replacement
Special Tools Required Clutch alignment disc 07JAFPM7011A Ring gear holder 07LABPV00100 or 07924PD20003 Clutch alignment shaft 07ZAFPR8A 100 Remover handle 079363710100
2. Install the special tools.
Pressure Plate and Clutch Disc Removal

1. Check the diaphragm spring fingers for height using the special tool and feeler gauge. If the height
is more than the service limit, replace the pressure
07ZAFPRBA 100 079363710100
plate. Standard INewl: Service Limit: 0.6 mm (0.02 in.1 max. 0.8 mm (0.03 in.1
07LABPV00100 or 07924PD20003
3. To prevent warping, unscrew the pressure plate

07ZAFPRBA 100 079363710100 07JAFPM7011A
mounting bolts (A) in a crisscross pattern in several
steps, then remove the pressure plate (BI.
4. Inspect the fingers of the diaphragm spring (AI for

wear at the release bearing contact area.
A
-----"
r ,
:fTil .lLlJ-----
,"--'.-'
'j-'
i.e.'
===c.--
5. Inspect the pressure plate (AI surface for wear,

cracks, and burning. A
(cont'd\
12-9
Clutch
Clutch Replacement (cont'd)
6, Inspect for warpage using a straight edge (A) and feeler gauge (8), Measure across the pressure plate (el, If the warpage is more than the service limit,
replace the pressure plate.
,
g, Measure the clutch disc thickness, If the thickness is less than the service limit, replace the clutch disc, Standard (New): Service Limit:
Standard (New): Service Limit:
0.03 mm (0,001 in.) max, 0,15 mm (0,006 in.)
8,3-8.9 mm (0,33 -0,35 in.) 6,0 mm (0,24 in.)
10, Measure the rivet depth from the clutch disc lining
7, Remove the clutch disc and special tools,
surface (A) to the rivets (8) on both sides, If the rivet depth is less than the service limit, replace the clutch disc, Standard (New): Service Limit:
1.65-2,25 mm (0,065-0,089 in,) 0,7 mm (0,03 in.)
8, Inspectthe lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or
oil soaked, replace it.
A
12-10
Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning. 3. Measure the flywheel (A) runout using a dial indicator (8) through at least two full turns. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the
runout is more than the service limit, replace the
Flywheel Replacement
1. Install the special tool.
07lAB-PV00100 or 07924-PD0003
flywheel and recheck the runout. Resurfacing the flywheel is not recommended. Standard (New): Service Limit: 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)
A
--:::::::::::::.;::=L
~
2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
4. Install the special tool, then torque the flywheel

mounting bolts in a crisscross pattern in several
steps.
12x1.0mm
103 Nm (10.5 kglm, 76 Iblftl 07LAB-PV00100 or 07924-PD20003
(conl'd)
12-11
Clutch
Clutch Replacement (cont'd)
Clutch Disc and Pressure Plate Installation
1. Temporarily install the clutch disc onto the splines of the transmission mains haft. Make sure the clutch disc slides freely on the mainshaft. 2. Install the ring gear holder.
07ZAF-PR8Al00
B
5. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TORQUE: 25 N-m (2_6 kgfm, 19Ibfft)
07936-3710100
IP/N 08798-90021 071AB-PV00100 or 07924-PD20003
3. Apply super high temp urea grease (PIN 087989002) to the splines (A) of the clutch disc (B), then
install the clutch disc using the special tools.
6. Remove the special tools. 4. Install the pressure plate (A) and the mounting bolts (B) finger-tight. 7. Make sure the diaphragm spring fingers are all the same height.
12-12
Release Bearing Replacement

1. Remove the release fork boot (AI from the clutch housing (81.
4. Apply super high temp urea grease (PIN 0879890021 to the release fork (AI. the release fork bolt (81, the release bearing (CI, and the release bearing guide (DI in the shaded areas.
B
1.0-1.69 10.04--0.060zl
C 0.4-1.09 (0.01- 0.04 ozl

D
0.4-1.09 (0.01-0.04 ozl
2. Remove the release fork (CI from the clutch housing (81 by squeezing the release fork set spring (DI with pliers. Remove the release bearing (EI.
5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through
3. Check the release bearing for play and noise by spinning it by hand. If there is excessive play or noise, replace the release bearing with a new one. NOTE: The release bearing is packed with grease.
Do not wash it in solvent.
the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the
release fork bolt squarely. Make sure the release
fork set spring (FI is properly set. 7. Install the release fork boot (EI. Make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (AI right and left to make
sure that it fits properly against the release bearing
(81 and that the release bearing slides smoothly.
12-13

Manual Transmission
Special Tools ................................ Transmission Fluid Inspection and Replacement ..................... Back-Up Light Switch Test .......... Transmission Removal ............... Transmission Installation ........... Transmission Disassembly ........ Reverse Shift Fork Clearance Inspection ................................. Change Lever Clearance Inspection ................................. Change Lever Assembly Disassembly/Reassembly ....... Shift Forks Clearance Inspection ................................. Shift Forks Disassembly/Reassembly ....... Mainshaft Assembly Clearance Inspection ............... Mainshaft Disassembly .............. Mainshaft Inspection ................... Mainshaft Reassembly ............... Countershaft Assembly Clearance Inspection ............... Countershaft Disassembly ......... Countershaft Inspection ............. Countershaft Reassembly .......... Synchro Sleeve and Hub Inspection and Reassembly .... 13-2 13-3 13-3 13-4 13-8 13-14 13-19 13-19 13-20 13-21 13-22 13-23 13-25 13-26 13-28 13-31 13-32 13-33 13-34 13-39 Synchro Ring and Gear Inspection ................................ . Mainshaft Bearing and Oil Seal Replacement ........................... . Countershaft Bearing Replacement ........................... . Mainshaft Thrust Clearance Adjustment .............................. . Transmission Reassembly ........ . Gearshift Mechanism Replacement ........................... . 13-39 13-41 13-42 13-43 13-46 13-51
MIT Differential
Component Location Index Backlash Inspection .................... . Final Driven Gear/Carrier Replacement ........................... . Carrier Bearings Replacement .. . Oil Seal Replacement ................. . Differential Thrust Clearance Adjustment .............................. . 13-52 13-53 13-53 13-54 13-55 13-56
Manual Transmission
Special Tools
Ref.No. Tool Number Deseri tion VSB02C000015 Engine Hanger Adapter, 2.0 to 2.4 Liter VSB02C000018 Engine Hanger 07GAJ-PG20110 Mainshaft Holder 07GAJ-PG20130 Mainshaft Base 07JAD-PL90100 Oil Seal Driver 07NAD-P20A100 Oil Seal Driver Attachment "'(1) 07736-A01000B Adjustable Bearing Puller, 20-40 mm CD 07746-0010300 Attachment, 42 x 47 mm CD 07746-0030100 Driver, 40 mm I.D. @ 07746-0030300 Driver, 30 mm I.D. @ 077 49-00 10000 Driver Part of Mainshaft Inspection Tool Set, 07GAJ-PG20102 . Must be used with commercially available 3/8" - 16 Slide Hammer.
at
CD CD "CD "CD CD CD
1 1 1 1
CD
I
I~
1' . .........
' I '
CD
I/~\I
.~\
~
CD
':[D
13-2
Transmission Fluid Inspection and Replacement

1. Park the vehicle on level ground, and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (BI. check the condition of the fluid, and make sure the fluid is at the proper level (C).
Back-Up Light Switch Test

1. Disconnect the back-up light switch (A) connector.
A 29Nm (3.0 kgfm, 22lbfltl
B~
2. Check for continuity between the back-up light

switch 2P connector No.1 and No.2 terminals. There should be continuity when the shift lever is in reverse.
3. If the transmission fluid is dirty, remove the drain plug (D) and drain the fluid.
3. If necessary, replace the back-up light switch. Apply liquid gasket (PIN 08718-0001), and install it
on the transmission housing .
39 NmI4.0 kgfm, 29lbfltl
A 44 NmI4.5 kgfm, 331b1ltl
4. Reinstall the drain plug with a new washer, and refill the transmission fluid to the proper level. Oil Capacity 1.5 a(1.6 us qt) atfluid change 1.7 a(1.8 us qt) at overhaul
Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting and noise because it does not contain the proper additives.
5. Reinstall the oil filler plug with a new washer .
13-3
Manual Transmission
Transmission Removal
Special Tools Required Engine hanger adapter, 2.0 to 2.4 liter VSB02C000015 Engine hanger VSB02C000018 Engine support hanger, A & Reds AAR-T-12566' Subframe adapter EQS02C000011' * Available through the Honda Tool and Equipment Program 888-424-6857
8. Remove the cable bracket (A), then disconnect the

cables (B) from the top of the transmission housing.
Carefully remove both cables and the bracket

together so as not to bend the cables.
NOTE: Use fender covers to avoid damaging painted surfaces. 1. Write down the frequencies for the radio's preset buttons. Disconnect the negative (-) cable first, then the positive (+) cable from the battery. Remove the battery. 2. Remove the intake manifold COver (see page 9-3). 3. Remove the air cleaner housing (see page 11-162). 4. Remove the intake air duct (see step 8 on page 5-3). 5. Remove the battery tray (A). 9. Remove the harness clip.
B
6. Disconnect the transmission ground cable (8). 7. Disconnect the back-up light switch connector (A) and vehicle speed sensor (VSS) connector (B).
13-4
10. Carefully remove the slave cylinder and clutch line bracket so as not to bend the clutch line. Do not operate the clutch pedal once the slave cylinder has
been removed.
12. Attach the special tool to the threaded hole in the cylinder head.
11. Remove the engine wire harness cover (A) by lifting up on the lock tab (8), then slide the harness forward off the air cleaner housing mounting bracket (C).
13. Install the engine hanger (A) and the engine support hanger (8) to the vehicle, then attach the hook to the special tool.
VSB02C000015
A
VSB02COOOOla
14. Remove the two upper transmission mounting bolts.
(cont'd)
13-5
Manual Transmission
Transmission Removal (cont'd)
15. Remove the transmission mount bracket IAI and transmission mounting bolt IBI. 20. Remove the three way catalytic converter ITWCI assembly Isee step 30 on page 5-51. 21. Remove the driveshafts Isee page 16-31. 22. Remove the intermediate shaft Isee page 16-191. 23. Remove the front engine mount bracket mounting bolt.
16. Remove the air cleaner bracket ICI.

17. Raise the vehicle, and make sure it is securely
supported. 18. Drain the transmission fluid. Reinstall the drain bolt with a new washer Isee page 13-31. 19. Remove the splash shield.
24. Remove the three bolts securing the transmission rear mount.
'
--~------
/~~~
~----:,.;c.~i,""~;:~:::r~fr~6:~ -~~
~ ~
."
13-6
25. Support the sublrame with the sublrame adapter and a jack.
27. Remove the clutch cover.
.
the front suspension subframe.
EQS02COOOOll
28. Remove the front engine mount.
26. Make relerence marks IAI on the lront suspension sublrame IBI and mounting bolts lei, then remove
29. Place the transmission jack under the transmission, and remove the transmission mounting bolts.
Icont'dl
13-7
Manual Transmission
Transmission Removal (cont'd)
30. Pull the transmission away from the engine until the transmission mainshaft clears the clutch
pressure plate, then lower the transmission on the
Transmission Installation
Special Tools Required Engine hanger adapter, 2.0 to 2.4 liter VSB02C000015 Engine hanger VSB02C000018 Engine support hanger, A & Reds AAR-T-12566' Subframe adapter EQS02C000011 Available through the Honda Tool and Equipment Program 888-424-6857 1. Check the two dowel pins are installed in the clutch housing. 2. Apply super high temp urea grease (PIN 087989002) to the release fork (A) and the release bearing (B). Install the release fork and the release bearing.
1.0-1.6 g (0.04-0.060z)
transmission jack.
31. Remove the transmission rear mount (A) and the
transmission rear mount bracket (B).
32. Remove the boot (Al, the release fork (B), and the release bearing (C) from the transmission (0).
//~'i,~
0.4-1.0 g 10.01-0.04 oz)
./
~A
3. Install the transmission rear mount bracket (A) and

the transmission rear mount (B).
12 x 1.25 mm 64 Nm (6.5 kgfm,
47
Ibf':.!.ft~I,--_ _ _ _~~
-"'_,
12 x 1.25 mm 64Nm (6.5 kgfm,
471bS
4. Place the transmission on the transmission jack, and raise it to the engine level.
13-8
5. Install the transmission mounting bolts.
8. Support the subframe with the subframe adapter

and a jack.
~-------~
'-""-
12 x 1.25
mm
~\ ~=r:
~--
EQS02C000011
6. Install the front engine mount. 9. Install the front suspension subframe (A) in its original position by aligning the marks (B) you made in the removal procedure.
..
---~
12 x 1.25 mm 64Nm (6.5 kgfm, 47 Ibfftl
--6-- -"I
12 x 1.25 mm 64Nm
(6.5 kgfm, 47 Ibfftl
7. Install the clutch cover.
14 x 1.5 mm
98 Nm (10.5 kgfm, 761blftl
~ / ~l \-\
B
r-1~ ~ .. ~o
".
14x1.5mm 98 Nm
110.5 kgfm, 76lbfftl
6 x 1,0 mm 12 Nm (1.2 kgfm, 9lbfftl
(conl'd)
13-9
Manual Transmission
Transmission Installation (cont'd)
10. Install the three rear mounting bolts for the
transmission rear mount.
15. Install the transmission mount bracket (AI and the transmission mounting bolt (BI.
6x 1.0 rnm
12Nm 11.2 kglm.
~
lll-(ffi.<"=:=
A
"
12 x 1.25 mm
54N'm
15.5 kglm. 40lblltl
16. Install the air cleaner bracket (CI.

10 x 1.25
rnm
59 Nm 16.0 kglm. 43 Iblltl
17. Install the two upper transmission mounting bolts.
11. Loosely tighten the front engine mount bracket mounting bolt.
,2'~. /
\!~~
c '-\/
o~o
12. Install the intermediate shaft (see page 16-241. 13. Install the drivershafts (see page 16-171. 14. Install the three way catalytic converter (TWCI assembly (see step 17 on page 5-121.
.~o0
12 x 1.25 mm 64 Nm 16.5 kglm. 47 Iblltl
18. Remove the engine hanger and special tool from

engine.
13-10
19. Tighten the front engine mount bracket mounting bolt.

12 x 1.25 mm 64 Nm 16.5 kgf.m, 47lbfttl
21. Install the brake booster and EVAP line bracket mounting bolts (A). and air cleaner housing bracket mounting bolt (6). Tighten the air cleaner housing bracket mounting bolt (e), and install the water pipe mounting bolt (D).
A
9.8Nm (1.0 kgfm, 7.2Ibftt)
----~'
IIE?~--c
20. Install the splash shield.
22Nm 12.2 kgfm, 16 IbfttJ
D
9.8Nm 11.0 kgfm, 7.2IbfttJ
/~-""
<
;f\'~
---
22Nm {2.2 kgfm, 16lbfttJ
=--,-:::,,-::
22. Install the engine harness cover .
~-.~~
'. \. ..';;"~
-~,
,- ',j
~~~-G
:~-
FfJ :ii
,~"
{cont'dJ
13-11
Manual Transmission
Transmission Installation (cont'd)
23. Apply super high temp urea grease (PIN 087989002) to the end of the slave cylinder rod. Install the slave cylinder and the clutch line bracket. Take care notto bend the clutch line.
____ 6xl.0mm 9.8Nm 11.0 kgfm,
25. Install the cable bracket (A) and cables (8).
7.2Ibfftl
24. Install the harness clip.
26. Apply a light coat of super high temp urea grease (PIN 08798 - 9002) to the cable ends.
27. Connect the back-up light switch connector (A) and the vehicle speed sensor (VSS) connector (8).
B
13-12
28. Connect the transmission ground cable (A).
6x 1.0 mm 9.8Nm 11.0 kgfm, 7lbfftl
--------------
i& . .
A
8 x 1.25 mm 22Nm 12.2 kgfm, 16lbfftl
29. Install the battery tray (B). 30. Install the intake air duct (see step 36 on page 514). 31. Install the air cleaner housing (see step 39 on page 515). 32. Install the intake manifold cover (see step 41 on page 515). 33. Install the battery. Connect the positive (+) cable first, then the negative (-) cable to the battery. 34. Refill the transmission fluid (see page 133). 35. Testdrive the vehicle. 36. Check the clutch operation. 37. Check the front wheel alignment (see page 184). 38. Enter the antitheft code for the radio, then enter the customer's radio station presets. 39. Do the engine control module (ECM) idle learn procedure (see page 11139) .
13-13
Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
-~ L' ---- ',',
CD
0-__ ,"
o .,_
--------------,U
_"'_ _<i'_
_1.
I
CD DIFFERENTIAL ASSEMBLY ':';, SHIFT FORK ASSEMBLY (3) 6 mm FLANGE BOLT 12 Nm 11.2 kgfm, 9lbfftl
1) BEARING SET PLATE (3) COUNTERSHAFT ASSEMBLY
.]; NEEDLE BEARING j) OIL GUIDE PLATE C
,~!; 14 x 20
@
@28mmSPRING WASHER @ BALL BEARING ([4) 28 x 43 x 7 mm OIL SEAL Replace . j~ REVERSE GEAR SHAFT )5) REVERSE IDLER GEAR JJ; 6 mm SPECIAL BOLT 15 Nm 11.5 kgfm, 11lbfftl
~]) BACK-UP LIGHT SWITCH
29 Nm 13.0 kgfm, 22lbfftl

l~ O-RING
- Replace.
.~~ VEHICLE SPEED SENSOR IVSSI
~-~ 8 mm FLANGE BOLT
22 Nm 12.2 kgfm, 16lbfftl
mm DOWEL PIN
@MAGNET @ MAINSHAFT ASSEMBLY 'J:D 28 mm WASHER
(1]1 REVERSE SHIFT FORK a_~ REVERSE LOCK CAM (J:~) 35 x 58 x 8 mm OIL SEAL
,:[$ CLUTCH HOUSING @ TRANSMISSION HANGER @ 10 mm FLANGE BOLT 44 Nm 14.5 kgfm, 33 Ibfftl
Replace.
13-14
Exploded View-Transmi sSlon Housing .
I
I
~
~
'\,
o \
" c';'
#-~
-'
I I I I I
\
@
~ ~:ANSMISSION HOUSING mmWASHER Replace.
QQ)
80 mm SHIM
if~ 20 mm WASHER
@ CHANGEm DOWEL PIN @6 LEVER ASSEMBL V

(jj) DETENT'
@8x14m
Replace.
ifD FILLER PLUG

~
!~ ~m FLANGE BOLT
.~
,m 14,5 kglm, 33 Iblhl
g7mNm FLANGE BOLT , m 12.8 kgl.m 20 Ibl hi TRAN " INTER~~~~S~~~ ~ANGER A ",.39 Nm 14.0 kglm, 291blhl ;:: OIL GUIDE PLATE M ~) 72 mm SHIM @OILGUTTER PLATE
,4)
glm, 9 Iblhl 22 N BOLT m 12.2 kglm, 161blh

)
12mNm,,:'\f~~E BOLT
44 Nm 14.5 kglm, 33 Iblhl
~~~I~~e~ 8 mm OIL SEAL

~~ ~~
@ 12 mm WASHER Replace.
14 mm WASHER
Replace.
@SPRING Ql) STEEL BALL @TRANSMISS @ CLUTCH lIN~OC~IHpANGER B BRACKET
Ill)
DRAIN PLUG 39 Nm 14 . 0 kglm, 29 Iblhl ~ ~~ ~m SEALING CAP m 13.5 kgl.m, 25 Iblhl
(conl'd)
13-15
Manual Transmission
Transmission Disassembly (cont'd)
NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench. 1. Remove the detent bolts (AI. springs, steel balls, and back-up light switch (8). 3. Remove the interlock bolt (AI. the change lever assembly (8), 8 x 14 mm dowel pins (C), and the clutch line clip bracket (D).
4. Remove the drain plug (AI. filler plug (81. and 10 mm flange bolt (C). 2. Remove the vehicle speed sensor (VSS) (A) and O-ring (8).
13-16
5. Remove the 8 mm flange bolts in a crisscross

pattern in several steps.
10. Remove the reverse lock cam.
i y
}"~". \,:,.
1,- ," _
'.'
'~ . 1
.:./
- 0i . n
-
'~/c~' .. . . . -..~ ..........0..0... . . .

..... I 9
,,. u
_' / / - c . ..
.-
'. \
,
II
,!
6. Remove the transmission hanger A, and transmission hanger B.
11. Remove the reverse idler gear (A) and reverse gear shaft (8).
7. Remove the 32 mm sealing cap (A).
___ B
8. Expand the 72 mm snap ring (8) on the countershaft ball bearing, and remove it from the
groove using a pair of snap ring pliers.
9. Remove the transmission housing (C) and
14 x 20 mm dowel pins (D).
(cont'd)
13-17
Manual Transmission
Transmission Disassembly (cont'd)
12. Remove the reverse shift fork. 15. Remove the differential assembly (A) and magnet
(8).
13. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (e) from the clutch housing (D).
16. Remove the oil gutter plate (AI, 72mm shim (B), and oil guide plate M.
A
14. Remove the 28 mm spring washer (E) and 28 mm washer (F).
13-18
Reverse Shift Fork Clearance Inspection

1. Measure the clearance between the reverse idler gear (A) and the reverse shift fork (8) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2. Standard: 0.20-0.59 mm (0.007-0.024 in.) Service Limit: 1.3 mm (0.051 in.)
B
Change Lever Clearance Inspection

1. Measure the clearance between change lever IAI and the select lever 18) with a feeler gauge ICI. If the clearance is more than the service limit, go to step 2. Standard: 0.05-0.25 mm (0.002-0.010 in.) Service Limit: 0.50 mm (0.020 in.)
B------J
L
2. Measure the groove of the change lever .
2. Measure the width of the reverse shift fork. If distance is not within the standard, replace the reverse shift fork with a new one. If distance is within the standard, replace the reverse gear with a new one. Standard: 13.4-13.7 mm (0.527-0.539 in.)
If distance is not within the standard, replace the change lever with a new one. If distance is within the standard, replace the select lever with a new one. Standard: 15.00-15.10 mm (0.591-0.594 in.)
13-19
Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
DUST SEAL SELECT LEVER
-f?O .-_-_-.
~
/RePlac. e /
... B. e careful notto damage the dust seal when installing it.
BREATHER CAP Turn the arrow toward the front of the vehicle, and install it.
-I
~.
." .,j
fiJ].~:. ru
.. __
DUST COVER
~
IPIN 08798-90021
~
IPIN 08798-9002)
~CHANGELEVER
WASHER
OIL SEAL
~
SCREW Replace.
Replace.
Stake the screw in place with a center punch. SELECT STOP PLATE
9.8N.m 11.0 kgfm, 7.2Ibfftl
13-20
Shift Forks Clearance Inspection

NOTE: The synchro sleeve and synchro hub should be replaced as a set. 1. Measure the clearance between each shift fork (AI and its matching synchro sleeve (B(. If the
clearance exceeds the service limit, go to step 2.
3. Measure the clearance between the shift fork (A) and the shift arm (B). If the clearance exceeds the
service limit, go to step 4.
Standard: 0.2-0.5 mm (0.007 -0.020 in.) Service Limit: 0.62 mm (0.024 in.)
Standard: 0.35-0.65 mm (0.014-0.026 in. I Service limit: 1.0 mm 10.039 in. I
4. Measure the width of the shift arm .
If the width af the shift arm is nat within the

A standard, replace the shift arm with a new one.
2. Measure the thickness of the shift fork fingers.

If the thickness of the shift fork finger is not within the standard, replace the shift fork with a new one . If the thickness of the shift fork finger is within the standard, replace the synchro sleeve with a new one. Standard: 7.4-7.6 mm (0.29-0.30 in.)
If the width af the shift arm is within the standard, replace the shift fark and shift piece with a new
one.
Standard: 16.9-17.0 mm (0.665-0.669 in.)
13-21
Manual Transmission
Shift Forks Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
34 SHIFT FORK
-------
-~!
..
_____ 5TH SHIFT FORK
-----.-
-c
~. REVERSE SHIFT PIECE
L:J.
!l9
5 x 25 mm SPRING PIN
Replace.
PIN DRIVER. 5 mm
13-22
Mainshaft Assembly Clearance Inspection

NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft
(B).
4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C).
If the clearance is more than the service limit, go
to step 5.
If the clearance is within the service limit, go to
step 7.
Standard: Service Limit:
0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.)
c
2. Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E) .
to step 3 . If the clearance is within the service limit, go to step 4.

5. Measure distance
CD on the distance collar.
0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.)
If distance 'T' is not within the standard, replace the distance collar with a new one.
If distance
3. Measure the thickness of 3rd gear.
T is within the standard, go to step 6.

24.03-24.08 mm (0.946-0.947 in.)
Standard:
If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new
one.
Standard: Service limit:
23.92-23.97 mm 10.941-0.944 in.) 23.80 mm (0.937 in.)
(cont'd)
13-23
Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
6, Measure the thickness 01 4th gear.
If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one. If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new 8, Measure distance@onthedistancecollar, If distance @ is not within the standard, replace the distance collar with a new one. II distance @ is within the standard, go to step 9, Standard:
one.
24,03-24,08 mm (0,946-0,947 in,)
r;? ... ... ... c/f~:'~t

/
23,92 - 23,97 mm (0,941-0,944 in,) 23,80 mm (0,937 in,)
---------
---.
~
--
,
9, Measure the thickness 01 5th gear, If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one. II the thickness 01 5th gear is within the service limit, replace the 5th synchro hub with a new one, Standard: Service Limit: 7. Measure the clearance between the distance collar (A) and 5th gear (8) with a dial indicator Ie), lithe clearance is more than the service limit, go to step 8. If the clearance is within the service limit, go to step 10, Standard: Service Limit:
0,06-0,16 mm (0,002-0,006 in,) 0,25 mm (0,010 in,)
23,92-23.97 mm (0.941-0,944 in,) 23,80 mm (0.937 in,)
...
c
\
B
13-24

10. Measure the thickness of the MBS distance collar.
If the thickness of MBS distance collar is less than the standard, replace the MBS distance
collar with a new one. Standard:
Mainshaft Disassembly
1. Remove the angular ball bearing (AI and the
tapered cone ring using a commercially available
bearing separator (BI and a commercially available

bearing puller (C). Be sure the bearing separator is underthe tapered cone ring.
23.95-24.05 mm (0.943-0.947 in.)
2. Support 5th gear (Alan steel blocks, and press the mainshaft out of the 5th synchro hub (BI. Use of a jaw-type puller can damage the gear teeth.
(conl'dl
13-25
Manual Transmission
Mainshaft Disassembly (cont'd)
3. Support the 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. If any part of the mainshaft is less than the service limit, replace it with a new
one.
Standard: A Ball bearing surface (transmission housing side): 27.987-28.000 mm (1.1019-1.1024 in.) B Distance collar surface: 31.984-32.000 mm (1.2594-1.2598 in.) C Needle bearing surface: 38.984-39.000 mm (1.5348-1.5354 in.) o Sail bearing surface (clutch housing side): 27.977-27.990 mm (1.1015-1.1020 in.) E Bushing surface: 20.80-20.85 mm (0.819-0.821 in.)
Service Limit:
A: B: C: 0: E:
27.93 31.93 38.93 27.92 20.75
mm mm mm mm
(1.100 in.) (1.257 in.) (1.533 in.) (1.099 in.) mm (0.817 in.)
13-26
2. Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete
revolutions when measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)
13-27
Manual Transmission
Mainshaft Reassembly
Exploded View
/~~!.c'~~AMBALL BEARING
3RD/4TH SYNCHRO SLEEVE
Check for wear and operation. Note the direction of installation.
TAPERED CONE RING

~-.v'D.,DISTANCE
COLLAR
"-"VN""Rn~,
GEAR
""-1" ~SYNCHRO RING

~SYr~CHIRO
SPRING
SYNCHRO SLEEVE
~'SY~~CHIROSPRING
~~~ _ _ _ SYNCHRO RING

NEEDLE BEARING Check for wear and operation. -----5TH GEAR
NEEDLE BEARING Check for wear and operation. GEAR 4TH/5TH GEAR DISTANCE COLLAR
~S;YN'CHFIO
RING
~;;~I:_ _ SYNCHRO SPRING
13-28
Special Tools Required Driver, 40 mm I.D. 07746-0030100 Anachment, 30 mm I.D. 077 46-0030300
6. Install the 3rd/4th synchro sleeve IA) by aligning the stops 18) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/ 4th synchro hub set.
NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th synchro hubs. 2. Install the needle bearing and 3rd gear on the mainshaft. 3. Install the synchro ring and the synchro spring. 4. Install the 3rd/4th synchro hub IAI by aligning the synchro ring fingers 181 with 3rd/4th synchro hub grooves ICI.
7. Install the synchro spring IA).

____ 8
5. Install the 3rd/4th synchro hub IA) using the special tool.
8. Install the synchro ring 18) by aliging the synchro cone fingers IC) with 3rd/4th synchro hub grooves ID).
9. Install the 4th gear, needle bearing, distance collar, needle bearing, and 5th gear .
Iconl'd)
13-29
Manual Transmission
Mainshaft Reassembly (cont'd)
10. Install the synchro ring and the synchro spring. 11. Install the 5th synchro hub (A) by aligning the synchro cone fingers (B) with 5th synchro hub grooves (C). 14. Install the synchro spring (AI.
15. Install the synchro ring (BI by aligning the synchro cone fingers (CI with 5th synchro hub grooves (01. 12. Install the 5th synchro hub (A) using the special tools. 16. Install the MBS distance collar and the tapered
cone ring.
17. Install the new ball bearing (AI using the special tools and a press (BI.
07746-0030100
07746-0030300
13. Install the 5th synchro sleeve.
13-30
Countershaft Assembly Clearance Inspection

1. Measure the clearance between the 1st gear (A) and the distance collar (8) with a feeler gauge (C).
3. Measure the thickness of the 1st gear.

If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one. If the thickness of 1st gear is within the service
to step 2. If the clearance is within the service limit, go to step 4.
limit, replace the 1st/2nd synchro hub with a new
one.
Standard: 22.92-22.97 mm (0.902-0.904 in.) Service Limit: 22.87 mm (0.900 in.)
I
4. Measure the clearance between the 2nd gear (A) and 3rd gear (8) with a feeler gauge (C). If the
clearance is more than the service limit, go to
2. Measure the thickness of the distance collar. If the thickness is not within the standard, replace the distance collar with a new one.
step 5.
If the thickness is within the standard, go to step 3.
0.06-0.16 mm (0.002-0.006 in.) Standard: Service Limit: 0.25 mm (0.010 in.)
Standard:
23.03-23.08 mm (0.907-0.909 in.)
1
c
(conl'd)
13-31
Manual Transmission
Countershaft Assembly Clearance Inspection (cont'd)
5. Measure the thickness of the distance collar. If the thickness is not within the standard, replace
the distance collar with a new one.
Countershaft Disassembly
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
If the thickness is within the standard, go to step 6.
Standard:
28.03-28.08 mm (1.104-1.106 in.)
--------------
-----....
--<:
2. Remove the special bolt (left-hand threads).

3. Support the ball bearing (A) on steel blocks, then use a press (8) and an attachment (e) to press the
counters haft out of the ball bearing.
6. Measure the thickness of the 2nd gear.
c
If the thickness of 2nd gear is less than the
service limit, replace 2nd gear with a new one.
If the thickness of 2nd gear is within the service limit, replace the 1st/2nd synchro hub with a new
one.
4. Remove the 35 mm shim and distance collar.
13-32
Countershaft Inspection
5. Support 4th gear (A) on steel blocks, then use a press and an attachment (8) to press the countershaft (e) out of the 5th gear. 1. Inspect the gear surface and bearing surface for
wear and damage, then measure the countershaft
at points A. 8, and
e. If any part of the countershaft
is less than the service limit, replace it with a new one. 8
Standard: A Ball bearing surface (transmission housing side): 30.020-30.033 mm (1.1819-1.1824 in.)
B Distance collar surface:
39.937"-39.950 mm (1.5723-1.5728 in.)
e Needle bearing surface (clutch housing side):

35.000-35.015 mm (1.3780-1.3785 in.)
Service limit:
A: 8: C: 6. Support 2nd gear (A) on steel blocks, then use a press and an attachment (8) to press the counters haft (e) out of the 3rd gear. 29.97 mm (1.180 in.) 39.88 mm (1.570 in.) 34.95 mm (1.376 in.)
2. Inspect the runout by supporting both ends of the

countershaft. Rotate the countershaft two complete revolutions when measuring the runout. If the runout exceeds the service limit, replace the counters haft with a new one.
Standard: Service limit:
0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
13-33
Manual Transmission
Countershaft Reassembly
Exploded View
__~SPE(:IAL BOLT Replace. 118 Nm 112 kgfm, 87Ibllt)
~~~"'~BALL BEARING
Check for wear and operation. Note the direction of installation. 1ST/2ND SVNCHRO HUB SPRING CONE SVNCHRO 1ST GEAR GEAR 35mmSHIM COLLAR
NEEDLE BEARING Check for wear and operation. DISTANCE COLLAR
NEEDLE BEARING Check for wear and operation.
~~~~~~.~~:11~~~ DAMPER damage. and

--3>TRIPLE CONE SVNCHRO
SVNCHRO SPRING
13-34
Special Tools Required Driver, 40 mm 1.0. 07746-0030100 Attachment, 30 mm 077 46-0030300

NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces. 2. Install the distance collar, needle bearing, and 1st gear onto the countershaft. 3. Install the triple cone synchro assembly IAI by aligning the synchro cone fingers 181 with 1st gear grooves ICI, then install the synchro spring 101.
6. Install the synchro spring IAI .
7. Install the triple cone synchro assembly 181 by aligning the synchro cone fingers ICI with the 1st/2nd synchro hub grooves 101. 8. Install the distance collar IAI and friction damper 181 by aligning the friction damper fingers ICI with the 1st/2nd synchro hub grooves 101.
c
4. Install the 1st/2nd synchro hub IAI by aligning the synchro cone fingers 181 with 1st/2nd synchro hub grooves ICI.
11'1'1" I' :. II,
5. Install the reverse gear.
Icont'dl
13-35
Manual Transmission
Countershaft Reassembly (cont'd)
9. Install the needle bearing. 10. Install the 2nd gear (A) by aligning the synchro cone fingers (8) with 2nd gear grooves (C). 12. Install the 4th gear (A) using the special tool and a
press (8). Do not exceed the maximum pressure.
r~,~_B
n".. __-A
14,700 N (1,500 kgt, 3,307 (bt) max. 07746-0030100
13. Install the 5th gear (A) using the special tool and a 11. Support the countershaft (A) on the steel blocks, then install the 3rd gear (8) using the special tool and a press (C). Do not exceed the maximum
pressure.
14,700 N (1,500 kgt, 3,307 (bl) max. 07746-0030100
press (8). Do not exceed the maximum pressure.

14,700 N (1,500 kgt,
3,307 Ibf) max.
07746-0030100
13-36
14. Install the distance collar (AI, 35 mm shim, and old ball bearing (S) using the special tools and a press
(e).
16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 15 is within the standard, replace only the ball bearing. 35 mm Shim Part Number -'A 23981-PPP-000 23981-PPP-900 S 23982-PPP-000 e 23982-PPP-900 D 23983-PPP-000 E 23983-PPP-900 F 23984-PPP-000 G H 23984-PPP-900 23985-PPP-000 J 23985-PPP-900 K 23986-PPP-000 L 23986-PPP-900 M 23987 -PPP-OOO N 23987 -PPP-900 P Q 23988-PPP-000 23988-PPP-900 R 23989-PPP-000 S 23989-PPP-900 T 23990-PPP-000 U 23990-PPP-900 W X 23991-PPP-000 y 23991PPP-900 23992-PPP-000 Z AA 23992-PPP-900 23993-PPP-000 AS 23993-PPP-900 Ae 23994-PPP-000 AD 23994-PPP-900 AE AF 23995-PPP-000
077 46-0030300
15. Measure the clearance between the old bearing (A) and the 35 mm shim (S) with a feeler gauge (e) . Standard:
0.04-0.10 mm 10.002-0.004 in.)

A
I~
Thickness 0.87 mm (0.0343 0.91 mm (0.0358 0.95 mm (0.0374 0.99 mm (0.0390 1.03 mm (0.0406 1.07 mm (0.0421 1.11 mm (0.0437 1.15 mm (0.0453 1.19 mm (0.0469 1.23 mm (0.0484 1.27 mm (0.0500 1.31 mm (0.0516 1.35 mm (0.0531 1.39 mm (0.0547 1.43 mm (0.0563 1.47 mm (0.0579 1.51 mm (0.0594 1.55 mm (0.0610 1.59 mm (0.0626 1.63 mm (0.0642 1.67 mm (0.0657 1.71 mm (0.0673 1.75 mm (0.0689 1.79 mm (0.0705 1.83 mm (0.0720 1.87 mm (0.0736 1.91_mm (0.0752 1.95 mm (0.0768 1.99 mm (0.0783
in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) .. in.) in.) in.) in.) in.) in.) in.) in.) in.) in.)
(conl'd)
13-37
Manual Transmission
Countershaft Reassembly (cont'd)
17. Support ball bearing (A) on steel blocks (8), then use a press (C) and an attachment (D) to press the counters haft (E) out of the ball bearing. 20. Tighten the new special bolt (A) (left-hand threads).
18. If necessary, install the 35 mm shim selected in step 16, then recheck the clearance. 19. Install the distance collar (AI. 35 mm shim, and new ball bearing (8) using the special tools and a press
(C).
13-38
Synchro Sleeve and Hub Inspection and Reassembly

1. Inspect the gearteeth on all synchro hubs and
synchro sleeves for rounded off corners, which indicate wear.
Synchro Ring and Gear Inspection

1. Inspect the inside of each synchro ring (A) for wear. Inspect the teeth (B) on each synchro ring for wear (rounded off).
2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for freedom of movement. Be sure to match the three sets of longer teeth (C) (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves (D) in the synchro hub. Do not install the synchro sleeve with its longer teeth in the 1st/2nd synchro hub slots (E) because it will damage the spring ring.
B----...
NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set.
B
Example of synchro ring teeth
c
E
o o
GOOD WORN
2. Inspect the teeth (C) on each synchro sleeve and matching teeth on each gear for wear (rounded off).
c
Example of synchro sleeve teeth and gear teeth
A--fl-~
o o
GOOD WORN
(cant' d)
13-39
Manual Transmission
Synchro Ring and Gear Inspection (cont'd)
3. Inspect the thrust surface (D) on each gear hub for wear. 7. Measure the clearance between each gear (A) and its synchro ring (B) all the way around. Hold the synchro ring against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the synchro ring and gear. Synchro Ring-to-Gear Clearance Standard: 0.70-1.49 mm 10.028-0.059 in.) Service Limit: 0.4 mm (0.016 in.) Triple Cone Synchro-to-Gear Clearance Standard: CD: Outer Synchro Ring (B) to Synchro Cone (C) 0.70-1.19 mm (0.028-0.047 in.) CD: Synchro Cone IC) to Gear (A) 0.50-1.04 mm (0.020-0.041 in.) CD: Outer Synchro Ring IB) to Gear IA) 0.95-1.68 mm 10.037-0.066 in.) Service Limit: CD: 0.3 mm 10.012 in.) CD: 0.3 mm 10.012 in.) CD: 0.6 mm 10.024 in.)
4. Inspect the cone surface (E) on each gear hub for wear and roughness. 5. Inspect the teeth on all gears (F) for uneven wear, scoring, galling, and cracks. 6. Coat the cone surface of each gear (E) with oil, and place its synchro ring on it. Rotate the synchro ring, making sure that it does not slip.
1
c
"
13-40
Mainshaft Bearing and Oil Seal Replacement

Special Tools Required Oil seal driver 07JAD-PL90100 Adjustable bearing puller, 20-40 mm 07736-AO 1OOOB Driver 077 49-0010000 Attachment, 42 x 47 mm 07746-0010300 Slide hammer, commercially available
1. Remove the differential assembly. 2. Remove the ball bearing (A) from the clutch housing (B) using the special tool and a commercially available 3/8" - 16 slide hammer (e).
4. Drive the new oil seal in from the transmission side
using the special tools.
07746-0010300
c
5. Drive the new ball bearing (A) in from the
transmission side using the special tool.
07JAD-PL90100
3. Remove the oil seal (A) from the clutch side. Be

careful when removing the seal so the clutch housing is not damaged .
A
13-41
Manual Transmission
Countershaft Bearing Replacement
Special Tools Required Adjustable bearing puller, 20~40 mm 07736-A010008 Oil seal driver 07JAD-APL90100 Slide hammer, commercially available
1. Remove the bearing set plate (A) from the clutch housing (8).
3. Position the oil guide plate C and new needle bearing (A) in the bore of the clutch housing (8).
A
4. Install the needle bearing using the special tool. 5. Install the bearing set plate (A) with bolts (8).
2. Remove the needle bearing (A) using the special tool and a commercially available 3/8" ~ 16 slide hammer (81. then remove the oil guide plate C.
13-42
Mainshaft Thrust Clearance Adjustment

Special Tools Required Mainshaft base 07GAJ-PG20130 Mainshaft holder 07GAJ-PG20110 1. Remove the 72 mm shim IAI and oil guide plate M from the transmission housing IBI. 5. Measure distance!JJ between the end of the clutch housing IAI and the bearing inner race IBI with a straight edge and depth gauge. Measure at three locations and average the readings.
0
~.
'-\, !(,
Shim Selection Formula: 2. Install the 3rd/4th synchro hub IAI, the distance collar IBI, the 5th synchro hub leI, distance collar IDI, and ball bearing lEI on the mainshaft IFI, then
install the assembled mainshaft in the transmission
6. Select the proper 72 mm shim from the chart. Follow the example below, and use the
measurements you made in steps 4 and 5:
housing IGI.
CD + !JJ CD + !JJ -
IBasic Formulal 10.8 + 0.11) = shim thickness Imaximuml 10.8 + 0.17) = shim thickness Iminimuml Add distance!JJ Istep 51 to distance CD Istep 41. 0.8 mm 10.031 in): Spring washer, a dimension in the installation. 0.11 mm 10.004 in): Minimum thrust clearance. 0.17 mm 10.007 in): Maximum thrust clearance.
IFor examplel 2.32 + 0.15 - 10.8 + 0.111 = 1.56 mm 10.061 in.) 2.32 + 0.15 - 10.8 + 0.171 = 1.50 mm 10.059 in.1 Take the middle value of the minimum value and the maximum value, and select the 1.53 mm 10.060 in.1 shim.
3. Install the washer IH) on the mainshaft. 4. Measure distance CD between the end of the
transmission housing and washer with a straight edge and vernier caliper. Measure at three locations and average the reading .
Iconl'd)
13-43
Manual Transmission
Mainshaft Thrust Clearance Adjustment (cont'd)
72mmShim Part Number A 23931-P21-000 B 23932-P21-000 e 23933-P21-000.D 23934-P21-000 E ' 23935-P21-000 F 23936-P21-000 G 23937 -P21-000 H 23938-P21-000 I 23939-P21-000 J 23940-P21-000 23941-P21-000 K L 23942-P21-000 23943-P21-000 N 23944-P21-000 a 23945-P21-000 P 23946-P21-000 Q 23947 -P21-000 R 23948-P21-000 23949-P21-000 S T 23950-P21-000 23951-P21-000 U V 23952-P21-000 W' 23953-P21-000 X 23954-P21-000 y 23955-P21-000 Z 23956-P21-000 AA 23957 -P21-000 AB 23958-P21-000 Ae 23959-P21-000 23960-P21-000 AD 23961-P21-000 AE AF 23962-P21-000 AG 23963-P21-000 AH 23964-P21-000 AI 23965-P21-000 AJ 23966-P21-000 23967 -P21-000 AK 23968-P21-000 AL AM 23969-P21-000 23970-P21-000 AN AO 23971-P21-000 Thickness 0.60 mm (0.0236 in.1 0.63 mm (0.0248 in.1 0.66 mm (0.0260 in.1 0.69 mm (0.0271 in.1 0.72 mm (0.0283 in.1 0.75 mm (0.0295 in.1 0.78 mm (0.0307 in.1 0.81 mm (0.0319 in,1 0.84 mm (0.0331 in.1 0.87 mm (0.0343 in,1 0.90 mm (0.0354 in.1 0.93 mm (0,0366 in.1 0.96 mm (0.0378 i.nl 0.99 mm (0.0390 in. I 1.02 mm (0.0402 in.1 1.05 mm (0.0413 in.1 1.08 mm (0.0425 in.1 1.11 mm (0.0437 in.1 1.14 mm (0.0449 in. I 1.17 mm (0.0461 in.1 1.20 mm (0.0472 in.1 1.23 mm (0.0484 in.1 1.26 mm (0.0496 in. I 1.29 mm (0.0508 in.1 1.32 mm (0.0520 in.1 1.35 mm (0.0531 in.1 1.38 mm (0.0543 in,1 1.41 mm (0.0555 in,1 1.44 mm (0.0567 in.1 1.47 mm (0.0579 in.1 1.50 mm (0.0591 in.1 1.53 mm (0.0602 in.1 1.56 mm (0,0614 in.1 1.59 mm (0.0626 in,1 1.62 mm (0,0638 in.1 1.65 mm (0.0650 in,1 1.68 mm (0.0661 in. I 1.71 mm (0.0673 in.1 1.74 mm (0.0685 in.1 1.77 mm (0.0697.Ln.L 1.80 mm (0.0709 in.1
7. Install the 72 mm shim (AI selected and oil guide plate M in the transmission housing (BI.
r#-.
8. Thoroughly clean the spring washer (AI and washer (BI before installing them on the clutch housing side ball bearing (el. Note the installation direction of the spring washer.
C~D/B
---------~---------- - - -------- -------------
~...
~-:--_-----I-----_--,:,
--- -+-------
~A
....
....
~>=r--:::
.. .
9. Install the mainshaft in the clutch housing.

10. Place the transmission housing over the mainshaft and onto the clutch housing,
11. Tighten the clutch and transmission housings with several 8 mm bolts,
NOTE: It is not necessary to use sealing agent between the housings. 12. Tap the mains haft with a plastic hammer.
13-44
13. Attach the special tool to the mainshaft as follows: Back-out the mainshaft holder bolt (A) and loosen the two hex bolts (BI. Fit the holder over the mainshaft so its lip is
towards the transmission.
16. Zero a dial gauge (Alan the end of the mainshaft.
Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
07GAJ-PG20110
~~b>
/07GAJ-PG20130
07GAJ-PG20130 17. Turn the mainshaft holder bolt (BI clockwise; stop
turning when the dial gauge (AI has reached its

maximum movement. The reading on the dial
gauge is the amount of mainshaft end play. NOTE: Do not turn the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge
14. Seatthe mainshaft fully by tapping its end with a plastic hammer.
stops moving, this may damage the transmission.
18. If the reading is within the standard, the clearance

15. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
is correct. If the reading is not within the standard,
recheck the shim thickness. Standard: 0.11-0.17 mm (0.004-0.007 in.)
13-45
Manual Transmission
Transmission Reassembly
NOTE: Priorto reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact
surfaces.
4. Install the reverse shift fork.

6x 1.0 mm
1. Install the magnet (A) and differential assembly (8).

B
~~::::1'f5~N~~~.
:':;:::==;J:'~~'- ,,~~
I).. . ..
~--~-'- j
~./f:.i"........ c --:->
"
f"
5. Install the reverse idler gear (A) and reverse gear shaft (8) by aligning the mark (C) with the reverse gear shaft hole (D).
'~
-'
"
------->, -
2. Install the 28 mm spring washer (A) and 28 mm washer (8) over the ball bearing (C). Note the installation direction of the spring washer (A).
3. Apply vinyl tape to the mainshaft splines (D) to protectthe seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install
them as an assembly.
13-46
6. Install the reverse lock cam.
8. Remove the dirt and oil from the tramsmission housing sealing surface. Apply liquid gasket (PIN 08718-0001) to the sealing surface. Be sure to seal
the entire circumference of the bolt holes to
prevent oil leakage. NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
a ..
"'
7. Select the proper size 72 mm shim (A) according to

the measurements made during the Mainshaft
Thrust Clearance Adjustment (see page 13-43). Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).
6- ---"0---
-----6-
-----0--
----0
_._.- Liquid gasket
(cont'd)
13-47
Manual Transmission
Transmission Reassembly (cont'd)
9. Install the 14 x 20 mm dowel pins (A).
D---~=
11. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release
the snap ring so it seats in the groove of the countershaft bearing.
34Nm
13.5 kglm, 25 fblltl ~~~~W~')
12. Check that the 52 mm snap ring is securely seated in the groove of the countershaft bearing. Dimension
CD as installed:
3.3-6.0 mm (0.13-0.24 in.)
13. Apply liquid gasket !PIN 08718-0001) to the threads of the 32 mm sealing cap (D), and install it on the
transmission housing.
14. Install the transmission hangers A, and B, and the 8 mm flange bolts finger-tight.
15. Tighten the 8 mm flange bolts in a crisscross

pattern in several steps.
8x 1.25mrn
27Nm 12.8 kgl.m, 20 fbllt)
-,-~,.J
10. Set the tapered cone ring (B) as shown. Place the
transmission housing overthe clutch housing,
being careful to line up the shafts.
13-48
16. Remove the dirt and oil from the shift lever cover
sealing surface. Apply liquid gasket (PIN 08718 0001) to the sealing surface. NOTE: If 5 minutes have passed after applying
liquid gasket, reapply it and assemble the housings.
19. Install the drain plug (A), filler plug (6), and 10 mm flange bolt (C) with new washers.
.. I
.
E!I
cl
Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.
V\
44Nm
14.5 kgfm, 33 Ibflt} A 39Nm 14.0 kgfm, 33 Ibflt}
,~
,0
~>~~~cc:-=
@
~
.-::
-'-"-Liquid gasket
~ 10x1.25mm
44 Nm 14.5 kgfm, 33Ibflt}
20. Install the detent bolts (A), spring, and steel balls
with new washers.
17. Install the 8 x 14 mm dowel pins (A), clutch line clip bracket (6), and change lever assembly (C).
~~d"/
\ /'~.~:~
39Nm 14.0 kgf.m, 29Ibflt}
22Nm 12.2 kgfm, 16Ibflt}
Q'"
~/29N.m
13.0 kgfm, 22Ibflt}
V!-~
21. Apply liquid gasket !PIN 087180001) to the threads of the backup light switch (6), and install it in the
transmission housing.
6x 1.0mm 12 Nm 11.2 kgfm, 9Ibflt}
18. Apply liquid gasket !PIN 087180001) to the threads of the interlock bolt (D), and install it on the
transmission housing .
(cont'd)
13-49
Manual Transmission
Transmission Reassembly (cont'd)
22. Install the vehicle speed sensor (VSS) (A) and O-ring (B).
13-50
Gearshift Mechanism Replacement
ax 1.25 mm
22 Nm (2.2 kglm, 16 Ibllt)
U-------(:)
..............-SHIFT LEVER KNOB 8 Nm (0.8 kglm, 5.8Ibllt)
~ ~f}
....
SHIFT LEVER HOUSING
~
CLAMP
!-~=-=~====~V~~7J~~
(PIN 08798-9002)
oj) Rotate the shift cable
toward the opening.
COTTER PINS Replace. (PIN 08798-9002)

@Removetheshiftcable from the shift lever bracket.
13-51
MIT Differential
~""'ALDRIVEN
GEAR
DIFFERENTIAL CARRIER /
Backlash Inspection, page 13-53 Replacement, page 13-53
13-52
Backlash Inspection
1. Place the differential assembly on V-blocks (A), and install both axles.
Final Driven Gear/Carrier Replacement

1. Remove the bolts (left-hand threads) in a crisscross pattern in several steps, then remove the final
driven gear (A) from the differential carrier (B).
2. Measure the backlash of both pinion gears (B) with a dial indicator (e). If the backlash is not within the
standard, replace the differential carrier.
Standard (New): 0.05-0.15 mm (0.002-0.006 in.)
2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Align the marks on the final driven gear and the carrier. Tighten the
bolts in a crisscross pattern in several steps .
13-53
MIT Differential
Carrier Bearings Replacement
Special Tool Required
Driver, 40 mm 1.0. 07746-0030100 1. Check the carrier bearings for wear and rough rotation. If they rotate smoothly and their rollers
show no signs of wear, the bearings are OK.
3. Install the new bearings (A) with the special tool and a press. Press each bearing on until it bottoms.
There should be no clearance between the bearings and the carrier.
NOTE: Turn the sealed (B) side of the bearing away from the differential to install it.
2. Remove the carrier bearing (A) with a commercially-available bearing puller (B).
07746-0030100
13-54
Oil Seal Replacement

Special Tools Required Driver 07749-0010000 Oil seal driver attachment 07NAD-P20Al00 1. Remove the differential assembly. 2. Remove the oil seal (A) from the transmission housing (B).
4. Install the new oil seal in the transmission housing
with the special tools .
07NAD-P20A 100
5. Install the new oil seal in the clutch housing with the special tools.
3. Remove the oil seal (A) from the clutch housing (B).
."
....,....
~~(.~{Jlil
"
:::~~
07NAD-P20A 100
13-55
MIT Differential
Differential Thrust Clearance Adjustment
Special Tool Required Driver, 40 mm 1.0. 07746-0030100
1. Install an 80 mm shim that's the same size as the
one you removed.
3. Install the transmission housing onto the clutch housing, then tighten the 8 mm flange bolts in a
crisscross pattern in several steps (see step 15 on
page 13-481.
o
"'tc'0--~~
I
axl.25mm 27 Nm 12.a kgf.m, 20 Ibfft)

4. Use the special tool to bottom the differential assembly in the clutch housing.
.... ~/:.~/
..
2. Install the differential assembly into the clutch

housing.
5. Measure the clearance between the 80 mm shim

and bearing outer race in the transmission housing.
Standard: 0-0.10 mm 10-0.004 in.)
13-56
6. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 5 is within the standard, go to step 9. 80mmShim Part Number Thickness 41441-PL3-BOOl 1.0 mm (0.0394 in.) A 41442-PL3-BOOl -1.1 mm (0.0433 in.) B -41443-PL3-BOOl 1.2 mm (0.0472 inJ._ -- . 41444-PL3-BOOl 1.3 mm (0.0512 in.) 0 41445-PL3-BOO 1 1.4 mm (0.0551 in.) E F 41446-PL3-BOO 1 1.5 mm 10.0591 in.) 41447-PL3-BOOl 1.6 mm (0.0630 in.) G 41448-PL3-BOOl H 1.7 mmj~0669 in.) 41449-PL3-BOOl I 1.8 mm 10.0709 in.) J 41450-PL3-BOOO 1.05 mm (0.0413 in.) K 41451-PL3-BOOO 1.15 mm 10.0453 in.) L 41452-PL3-BOOO 1.25 mm 10.0492 in.) M N I 41453-PL3-BOOO I 1.35_mm (0.0531 in.) 41454-PL3-BOOO I 1.45 mm (0.0571 in.) P Q 41455-PL3-BOOO 1.55 mm (0.0610 in.) 41456-PL3-BOOO 1.65 mm (0.0650 in.) R 41457 -PL3-BOOO 1.75 mm (0.0689 in.) S
--+-
-----.~~-
7. Remove the bolts and transmission housing. 8. Replace the thrust shim selected in step 6, then
recheck the clearance.

9. Reinstall the transmission .
13-57
Drivelinel Axle
Special Tools ................................................................. Driveshaft Inspection ................................................... Driveshafts Removal .................................................... Driveshafts Disassembly ............................................. Dynamic Damper Replacement .................................. Driveshafts Reassembly.............................................. Driveshafts Installation ................................................ Intermediate Shaft Removal ........................................ Intermediate Shaft Disassembly ................................. Intermediate Shaft Reassembly .................................. Intermediate Shaft Installation .................................... 16-2 16-3 16-3 16-5 16-8 16-9 16-17 16-19 16-20 16-22 16-24
Drivelinel Axle
Special Tools
Ref. No.
CD Cll
(J)
Tool Number 07GAD-PH70201 07MAC-SL00200 07NAF-SR30101 07XAC-001010A 077 46-00 10400 077 46-0030400 077 49-0010000 07947-SB00100
Description Oil Seal Driver Ball Joint Remover, 28 mm Half Shaft Base Threaded Adapter, 22 x 1.5 mm Attachment, 52 x 55 mm Driver, 35 mm I.D. Driver Oil Seal Driver
Otv
1 1 1 1 1 1 1 1
~. -
---~
c::>
eE'
16-2
Driveshaft Inspection
1. Check the inboard boot (A) and the outboard boot (8) on the driveshaft (C) for cracks, damage, leaking grease, and loose boot bands (D). If any damage is found, replace the boot and boot bands.
Driveshafts Removal
Special Tool Required Sail joint remover, 28 mm 07MAC-SL00200
1. Loosen the wheel nuts slightly. 2. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-8).
3. Remove the wheel nuts and front wheels.
.
o
2. Turn the drives haft by hand, and make sure the
splines (E) and joint are not excessively loose.
.
00
3. Make sure the driveshaft is not twisted or cracked; if it is, replace it.
. @
A
. " I,
/ ...1'........
'(~
f. .
.]
o o
'./':~.'. '
4. Lift upthe locking tab (A) on the spindle nut (8),

then
remove the nut.
5. If the left drives haft or the intermediate shaft is to

be removed, drain the transmission fluid. Reinstall
the drain plug using a new washer (see page 13-3). 6. Hold the stabilizer ball joint pin (A) with a hex wrench (S), and remove the flange nut (C). Separate the front stabilizer link (D) from the lower
arm .
(cont'd)
16-3
Drivelinel Axle
Driveshafts Removal (cont'd)
7. Remove the lock pin (A) from the lower arm ball joint castle nut (B), and remove the nut.
NOTE: To avoid damaging the ball joint, install a hex nut on to the threads of the ball joint. Be careful not to damage the ball joint boot when installing the remover.
10. Left driveshaft: Pry the inboard joint (A) from the differential case with a prybar. Right driveshaft: Drive the inboard joint (A) off of the intermediate shaft with a drift and hammer. Remove the driveshaft as an assembly. Do not pull on the
driveshaft (8), because the inboard joint may come
apart. Draw the drives haft straight out to avoid damaging the oil seal.
Left driveshat!:
A
07MACSl00200
8. Separate the ball joint from the lower arm (e) with the special tool (see step 3 on page 18-19). Be careful not to dislodge the lower ball joint from the knuckle. 9. Pull the knuckle outward, and remove the driveshaft outboard joint from the front wheel hub
using a plastic hammer.
Right driveshat!:
16-4
Driveshafts Disassembly
Special Tools Required Double Loop Type
Threaded adapter, 22 x 1.5 mm 07XAC-001010A Slide hammer, commercially available

Boot band pincers, commercially available
Inboard Joint Side:

1. Remove the set ring from the inboard joint.
E
Low Profile Type
2. Remove the boot bands. Be careful not to damage

the boot and dynamic damper.
If the boot band is a welded type IAI. cut the boot band IBI. If the boot band is a double loop type ICI, lift up the band bend IDI. and push it into the clip lEI. If the boot band is a low profile type IFI, pinch the boot band using a commercially available boot band pincers IGI. Welded Type
Icont'dl
16-5
Drivelinel Axle
Driveshafts Disassembly (cont'd)
3. Make a mark (A) on each roller (B) and inboard joint (e) to identify the locations of rollers and grooves
in the inboard joint. Then remove the inboard joint
8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
on the shop towel (D). Be careful not to drop the

rollers when separating them from the inboard joint.
9. Remove the inboard boot. Be careful not to damage the boot. 10. Remove the vinyl tape. 4. Make a mark (A) on the rollers (B) and spider (e) to identify the locations of rollers on the spider, then
remove the rollers.
5. Remove the eirelip (D). 6. Mark the spider (e) and driveshaft (E) to identify the position of the spider on the shaft. 7. Remove the spider (e).
16-6
Outboard Joint Side:

1. Remove the boot bands. Be careful not to damage the boot and dynamic damper. If the boot band is an ear clamp type (A), lift up the three tabs (B) with a screwdriver.
Ear Clamp Type
3. Wipe off the grease to expose the driveshaft and

the outboard joint inner race.
4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C) .
5. Carefully clamp the driveshaft in a vise.
2. Slide the outboard boot (A) to the inboard joint side . Be careful not to damage the boot.
6. Remove the outboard joint (A) using the special tool and a commercially available 5/8"x18 slide hammer (B).
7. Remove the driveshaft from the vise .
(cont'd)
16-7
Drivelinel Axle
Driveshafts Disassembly (cont'd)
8. Remove the stop ring from the driveshaft.
Dynamic Damper Replacement

1. Remove the inboard joint (see page 16-5).
2. Remove the dynamic damper bands. Be careful not to damage the dynamic damper (see page 16-5).
lithe boot band is a welded type, cutthe boot band. If the boot band is a double loop type, lift up the band bend, and push it into the clip. If the boot band is a low profile type, pinch the boot band using a commercially available boot
band pincers.
3. Wrap the splines on the driveshaft with vinyl tape

(A) to prevent damage to the dynamic damper.
9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
4. Remove the dynamic damper. Be careful not to damage the dynamic damper.
5. Adjust the position of the new dynamic damper to the figure below. 10. Remove the outboard boot. Be careful not to damage the boot.
11. Remove the vinyl tape.
left driveshaft (Directional): Right driveshaft (Directional):
296-300 mm 111.6-11.8 in.) 301-305 mm 111.9-12.0 in.)
6. Install the dynamic damper band (see step 9 on page 16-12). 7. Install the inboard joint (see page 16-11).
16-8
Driveshafts Reassembly
Exploded View
'02 model
I
~
SET RING Replace. /
INBOARO JOINT
'IdI~
I"~"~
........... ,
............
Right driveshaft ...................
Qf,j /
.......
CIRCLIP
IW~
~"'~'
ROLLER
I~OOT
Use the grease included in the
inboard boot set .
DYNAMIC DAMPER
-@~
'/"V
DOUBLE LOOP BAND Replace.
---~
DOUBLE LOOP BAND Replace
/ S T O P RING Replace.
~/DRIVESHAFT t
~
'
,i
N:rt ((J
---------EAR CLAMP BANDS
Replace.
/OUTBOARD JOINT
~
outboard boot set .
(cont'd)
16-9
Drivelinel Axle
Driveshafts Reassembly (cont'd)
Exploded View
'03 model
I
()
SET RING Replace. /
INBOARD JOINT
/ROLLER
0
I
DOUBLE LOOP BAND Replace. (Boot band replacement only.)
r'~>.
'.
1".
/
/
/ " , , '1if (})'~U'h ~r

I
/
~. (J
CIRCLIP
d~SPIDER
~
(/j
INBOARD BOOT
~~~
.:....
II":r
Right driveshaft
~ Use the grease included in the inboard boot set. /
~-
.~-'. . ,_@./>RePlace. -'~ c1~LOW

:','
CJ
,I
l:
UU
~..
Use the grease Included In the nboard boot set
PROFILE BAND
--
i.~l: .w.~
.
~
<;;--,
/"
/' - "'/,-"i/
.'
DYNAMIC DAMPER / ROW PROFILE BAND Replace.
DOUBLE LOOP BAND Replace. (Boot band replacement only.) DRIVESHAFT /STOPRING Replace.
~~/
I ",
.....
r:..y [
(j)).
------------~
EAR CLAMP BAND Replace.
WJ~
OUTBOARD BOOT (TPE)
l[Jiltflj, .' ..
~
/OUTBOARDJOINT
"v~ ~
',,'
",~--:'.'"
outboard boot set.
16-10
Boot band tool, KD-3191 or equivalent, commercially available Boot band pincers, Kent-Moore J-35910 or equivalent, commercially available
Boot band pincers,commercially available
3. Install the spider IA) onto the driveshaft by aligning the marks IB) on the spider and the end of the driveshaft.
B
NOTE: Refer to the Exploded View as needed during this procedure.
_________
Inboard Joint Side:

1. Wrap the splines with vinyl tape IA) to prevent damage to the inboard boot.
4. Fit the circlip IC) into the driveshaft groove. Always rotate the circiip in its groove to make sure it is fully seated.
5. Fit the rollers IA) onto the spider (8) with their high shoulders facing outward, and note these items:
Reinstall the rollers in their original positions on
2. Install the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot.
the spider by aligning the marks IC). Hold the driveshaft pointed up to prevent the rollers from falling off.
Icont'd)
16-11
Drivelinel Axle
6. Pack the inboard joint with the joint grease included in the new driveshaft set. Grease quantity Inboard joint: 130-140 9 (4.6-4.9 oz) 8. Make sure the ends of the boot are seated in the grooves in the driveshaft and joint, then install the boot bands. Forthe double loop type, go to step 12. (Replacement boot bands only) For the low profile type, go to step 9. 9. Install the new low profile band (A) onto the boot (8), then hook the tab (C) of the band.
B
~
inboard boot set.
~~
7. Fitthe inboard joint onto the driveshaft, and note

these items:
Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the rollers. Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off.
A
c
10. Close the hook portion of the band (A) with a commercially available boot band pincers (8), then hook the tabs of the band.
11. Install the boot band on the other end of the boot. and repeat steps 9 and 10.
16-12
12. Fit the boot ends onto the driveshaft and the inboard joint, then install the new double loop band (A) onto the boot.
15. Thread the free end of the band through the nose section of the commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).
A
13. Pull up the slack in the band by hand.
14. Mark a position (A) on the band 10-14 mm (0.40.6 in.) from the clip (8) .
16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip. 17. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip .
(cont'd)
16-13
Drivelinel Axle
18. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5-10 mm (0.2-0.4 in.1 tail protruding from the clip. 21. Install the new set ring.
19. Bend the band end (AI by tapping it down with a

hammer. NOTE:
Make sure the band and clip do not interfere with anything and the band does not move .
Remove any grease remaining on the surrounding surfaces
20. Repeat steps 12 through 19 for the band on the other end of the boot.
16-14
Outboard Joint Side:

1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.
4. Insert the driveshaft (A) into the outboard jOint (B) until the stop ring (e) is close to the joint.
. . .G,\
Push.
\"
"
Push.
2. Install the new ear clamp bands (B) and outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot.
5. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10
em (4 in.) onto a hard surface. Do not use a hammer as excessive force may damage the
3. Install the new stop ring into the drives haft groove
(A).
driveshaft. Be careful not to damage the threaded section (A) of the outboard jOint.
~-
10cm (4 in.1
~ ..
(conl'd)
16-15
DrivelinelAxle
6. Check the alignment of the paint mark (A) with the outboard joint end (8). 8. Adjust the length of the driveshafts to the figure below, then adjust the boots to halfway between
full compression and full extension. Make sure the
A
ends of the boots seat in the grooves of the driveshaft and joint.
left driveshaft: 497
r--- ----_._502 mm (19.6-19.8 in.)
~~--~
Rig~t
..
driveshaft: 475-480 mm 118.7-18.9 in.)

_-
7. Pack the outboard joint (A) with the joint grease included in the new joint boot set.
Grease quantity Outboard joint: 105-1159(3.7-4.10zl
9. Fit the boot (A) ends onto the driveshaft (8) and outboard joint (C).
~
Use the grease included in the outboard boot set.
16-16
Driveshafts Installation
10. Close the ear portion IA) of the band with a commercially available boot band pincers KentMoore J-35910 or equivalent (8).
1. Instali a new set ring onto the set ring groove of the driveshaft Ileft drives haft).
A 11. Check the clearance between the closed ear portion
2. Apply 0.5-1.0 g (0.02-0.04 oz) of specified grease to the whole splined surface IA) of the right driveshaft. After applying grease, remove the
grease from the splined grooves at intervals of 2~
of the bands. If the clearance is not within the standard, close the ear portion of the bands farther.
3 splines and from the set ring groove (8) so that air can bleed from the intermediate shaft.
3.0 mm 10. t2 in.! MAX
6.0 mm 10.24 in.! MAX
-----
12. Repeat steps 10 and 11 forthe band on the other end of the boot .
Iconl'd)
16-17
Drivelinel Axle
Driveshafts Installation (cont'd)
3. Clean the areas where the driveshaft contacts the differential thoroughly with solvent, and dry with compressed air. Insert the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) until the set ring (D) locks in the groove (E). 5. Wipe off the grease from the ball joint and lower arm tapered surfaces. Install the knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot. Wipe off the grease before tightening the nut at the ball joint. Torque the new castle nut (e) to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the nut by loosening it. NOTE: Make sure the ball joint boot is not damage
or cracks.
4. Install the outboard joint (A) into the front hub (B).
REA{I F/RONT 'OUTSIDE

D
m
-~I
/~
'c
12x1.25mm
59-69 Nm 16.0 - 7.0 kgfm, 43 51 Ibfltl
6. Install the new lock pin (D) into the ball joint pin hole from the inside to the outside of the vehicle. 7. Connect the front stabilizer link (A) to the lower arm. Hold the stabilizer link ball joint pin (B) with a hex wrench (C), and tighten the new flange nut (D).
c
A
10 x 1.25 mm 39Nm
-' ,: A r,@.
....
~~~
-'.~-----------~:;;-
14.0 kgfm, 29 Ibflt)
16-18
Intermediate Shaft Removal

8. Install a new spindle nut (A), then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (8) against the driveshaft. 1. Remove the right driveshaft (see page 16-3). 2. Remove the heat shield.
108 Nm 111.0 kglm. lOlb,.ltl
00
A
22x 1.5 mm
3. Remove the flange bolt (A) and two dowel bolts (8).
A , B
181 Nm 118.5 kglm, 1341blltl
9. Clean the mating surfaces of the brake disc and the front wheel, then install the front wheel with the
wheel nuts .
'1( ~
--------,
10. Turn the front wheel by hand, and make sure the
clearance between the driveshaft and circumference parts.
11. Refill the transmission with recommended transmission fluid (see page 13-3). 12. Check the front wheel alignment, and adjust it if necessary (see page 18-4).
-4'\ .
.~
Icont'd)
16-19
Drivelinel Axle
Intermediate Shaft Removal (cont'd)
4. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential to prevent damage to the differential oil seal (B).
Intermediate Shaft Disassembly

Special Tools Required Oil seal driver 07947-5B00100 Half shaft base 07NAF-5R30101 1. Remove the set ring (A), outer seal (B), and external snap ring (C).
2. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using a press. Be careful not to damage the metal rings (C) on the intermediate shaft during disassembly.
16-20
3. Remove the internal snap ring.
4. Press the intermediate shaft bearing (A) out of the bearing support (B) using the special tools and a press.
PRESS
'"
l47.SB00100
~07NAF.SR30101
16-21
DrivelinelAxle
Intermediate Shaft Reassembly
Exploded View
jj ~.~ '\~"'oo ,
391Vm 14.0 kgfm, 29Ibfft)
C)
FLANGE BOLT 10 x 1.25 mm
DOWEL BOLTS
'OX'.25mm 39Nm 14.0 kgfm, 29Ibfft)
INTERMEDIATE SHAFT
v'
INTERMEDIATE SHAFT BEARING Replace. EXTERNAL SNAP RING
/
BEARING SUPPORT
~o //=!~"
O(/JJ ()
\ SET RING Replace.
INTERNAL SNAP RING
Pack the interior of the outer seal.
16-22
Special Tools Required Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Attachment, 35 mm I.D. 077 46-0030400 Oil seal driver 07GAD-PH70201 NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean the disassembled parts with solvent, and dry
them with compressed air. Do not wash the rubber parts with solvent.
4. Press the intermediate shaft (AI into the shaft bearing (BI using the special tool and a press.
PRESS
2. Press the intermediate shaft bearing (AI into the bearing support (BI using the special tools and a press.
PRESS
077 460030400
5. Install, then seat the external snap ring (AI into the groove of the intermediate shaft (BI .
3. Install, then seat the internal snap ring into the groove olthe bearing support.
B A
(cont'dl
16-23
Drivelinel Axle
Intermediate Shaft Reassembly (cont'd)
6. Install the outer seal (A) into the bearing support (B)
using the special tool and a press.
PRESS
Intermediate Shaft Installation

1. Use solvent or brake cieaner to thoroughly clean the areas where the intermediate shaft (A) contacts the transmission (differential), and dry with
compressed air. Insert the intermediate shaft
...
assembly into the differential. Hold the intermediate shaft horizontal to prevent damage to the differential oil seal (B).
Pack the interior of the outer seal.
7. Install the set ring.
,
2. Install the flange bolt (A) and two dowel bolts (B).
----
a-. ,
t~
16-24
3. Install the heat shield, and tighten the three bolts.

\\ j'
8x 1.25mm 22Nm 12.2 kgfm, 16lbfftl
4. Install the right driveshaft (see page 16-17) .
16-25

Steering
Steering
Special Tools ................................................................. Component Location Index ......................................... Steering Wheel Rotational Play Check ....................... Power Assist Check ...................................................... Steering Linkage and Gearbox Inspection ................. Steering Wheel Removal ............................................. Steering Wheel Disassembly/Reassembly ................ Steering Wheel Installation ......................................... Steering Column Removal and Installation ............... Steering Column Inspection ........................................ Steering Lock Replacement ......................................... Rack Guide Adjustment ............................................... 17-2 17-3 17-4 17-4 17-5 17-6 17-7 17-8 17-9 17-11 17-12 17-13
Electrical Power Steering (EPS) ...................... 17-15
Steering
Special Tools
Tool Number 07MAA-SL00200
Descri tion Locknut Wrench, 43 mm
o
CD
17-2
DRIVER'S AIRBAG ASSEMBLY Removal/Installation, page 23-113
STEERING WHEEL
Removal. page 17-6 Disassembly/Reassembly, page 17-7 Installation, page 17-8
STEERING COLUMN
Steering Column Removal and Installation, page 17-9 Steering Column Inspection, page 17-11 Steering Lock Replacement, page 17-12
STEERING GEARBOX
Rack Guide Adjustment, page 17-13
17-3
Steering
Steering Wheel Rotational Play Check
1. Turn the front wheels to the straight ahead position.
2. Measure how far you can turn the steering wheel
Power Assist Check

1. Start the engine, and let it idle. 2. Attach a commercially available spring scale to the steering wheel. With the engine idling and the vehicle on a clean, dry floor, pull the scale as shown, and read it as soon as the tires begin to turn.
left and right without moving the front wheels. If the play is within the limit, the gearbox and linkage are OK. If the play exceeds the limit, adjust the rack guide (see page 17-131. If the play is still excessive after rack guide adjustment, inspect the steering linkage and gearbox (see page 17-51.
ROTATIONAL PLAY: 0-10 mm 10-0.39 in.1
....
L'r-----
3. If the scale reads no morethan 29 N (3.0 kgf, 6.6Ibfl, the power assist is OK. If it reads more, check these
items:
Front tire pressure
Steering linkage (see page 17-51 Rack guide adjustment (see page 17-131 EPS system (see page 17-181
17-4
Steering Linkage and Gearbox Inspection
BOOT Inspect for damage and deterioration.
TIE-ROD Check for looseness,

and bllndlnq.
12 mm BOLTS Inspect for looseness .
TIE-ROD LOCKNUTS Check for looseness. STEERING GEARBOX Inspect for loose mounting hardware. GEARBOX MOUNTING CUSHIONS Inspect for deterioration. BALL JOINT BOOT Inspect for damage and deterioration .
STEERING COLUMN
Inspect for loose column mounting hardware
STEERING JOINTS Check for loose joint bolts, and loose or binding joints.
TIE-ROD END BALL JOINT Inspect for looseness, binding, and damage.
,
17-5
Steering
Steering Wheel Removal
SRS components are located in this area. Review the SRS component locations Isee page 23-13), and precautions and procedures Isee page 23-14) in the SRS
section before performing repairs or service.
3. Install a commercially available steering wheel puller IA) on the steering wheeIIB). Free the steering wheel from the steering column shaft by turning the pressure bolt Ie) of the puller.
Note these items when removing the steering wheel: Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. If you thread the puller bolts ID) into the wheel hub more than 5 threads, the bolts will hit the cable reel and damage it. To preventthis, install a pair of jam nuts 5 threads up on each puller bolt.
1. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheellsee page 23-113).
2. Disconnect the cruise control set/resume switch
connector IA), and loosen the steering wheel nut IB).

A
B
~.
B
/'> ""f-,
4. Remove the steering wheel puller, then remove the

steering wheel nut and steering wheel from the steering column.
17-6
Steering Wheel Disassembly/Reassembly
CONNECTOR HOLDERS
ACCESS PANEL B
17-7
Steering
Steering Wheel Installation
1. Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reellAI. Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about two and a half turns. The arrow mark IBI on the cable reel label should point straight up.
A
B
/
-'~
3. Install the steering wheel nut IAi. and tighten it to the specified torgue.
A 39 Nm 14.0 kgl.m, 29 Iblltl
B
---
-----
4. Connectthe cruise control set/resume switch connector (8). Make sure the wire harness is routed
and fastened properly. 2. Position the two tabs IAI of the turn signal canceling sleeve IBI as shown. Install the steering
wheel onto the steering column shaft, making sure the steering wheel hub ICI engages the pins 101 of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column
5. Install the driver's airbag, and confirm that the system is operating properly Isee page 23-1131.
6. Check the horn, turn signal canceling and cruise control switches for proper operation.
shaft when installing the steering wheel. 7. Reconnect the battery and do the following: Do the engine control module IECMI idle learn procedure Isee page 11-1391.
Power window control unit resetting procedure
Isee page 22-1281.

Enter the anti-theft cord for the radio, then enter the custmer's radio station presets .
Set the clock.
17-8
Steering Column Removal and Installation

SRS components are located in this area. Review the SRS component locations (see page 23-131 and precautions and procedures (see page 23-141 in the SRS section before performing repairs or service.
Removal
1, Record the radio station presets, and disconnect the battery.
2. Remove the driver's airbag assembly (see page 23-1131 and the steering wheel (see page 17-61. 3. Remove the driver's dashboard lower cover (see page 20-591 and under cover (see page 20-601. 4. Remove the column covers (AI.
8x 1.25 mm
28 Nm 12.9 kgl.m, 21 Iblltl
8x 1.25 mm
16 Nm 11.6 kglm, 121b11t1

5. Disconnect the wire harness connectors from the combination switch assembly (B).
6. Remove the combination switch assembly from the steering column shaft by removing the screw (elan the top of
the combination switch. 7. Disconnect the connectors from the ignition switch, and release the wire harness clips from the steering column. 8. Disconnect the steering joint (0), and remove it from the column shaft. 9. Remove the steer:ing column (E) by removing the attaching nuts and bolts.
(cont'dl
17-9
Steering
Steering Column Removal and Installation (cont'd)
Installation
1. Install the steering column, and make sure the wires are not caught or pinched by any parts. 2. Insert the upper end of the steering joint onto the steering shaft (A) (line up the bolt hole (B) with the flat portion (C) on the shaft).
8x1.25mm 28Nm 12.9 kgfm, 21 IbMt) E
3. Slip the lower end of the steering joint onto the pinion shaft (D) (line up the bolt hole with the groove (E) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.
4. Pullan the steering jointto make sure that the steering joint is fully seated. Then install the upper joint bolt. and tighten it to the specified torque. Tighten the lower joint bolt to the specified torque. 5. Finish the installation, and note these items:
Make sure the wire harness is routed and
fastened properly.
Make sure the connectors are properly connected.
Reinstall the steering wheel (see page 17-8). Reconnect the battery.
- Do the power window control unit reset
procedure (see page 22-128). - Enter the anti-theft code for the radio, then
enter the custmer's radio station presets.
- Set the clock.

Verify horn, turn signal switch, and cruise control
switch operation. Check wheel alignment, if necessary (see page 18-4). Do the engine control module (ECM) idle learn procedure (see page 11-139).
17-10
Steering Column Inspection

Check the steering column ball bearing IA) and the steering joint bearings (8) for play and proper movement. If any
bearing is noisy or has excessive play, replace the steering column as an assembly .
Check the absorbing plates IC), absorbing plate guides ID), stop IE), and coating plates IF) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly.
c
A
/
E
B
17-11
Steering
Steering Lock Replacement
NOTE: Do not try to re-key a replacement steering lock. If necessary, re-key the other locks. 1. Remove the steering column (see page 17-91.
A
7. Tighten the shear bolts (AI until the hex heads (BI twist off.
2. Center punch each of the two shear bolts (AI, and drill their heads off with a 5 mm (3/16 in.1 drill bit. Be careful not to damage the switch body when removing the shear bolts.
EIO~I:J
B
. ", .
3. Remove the shear bolts from the switch body. 4. Install the switch body without the key inserted. 5. Loosely tighten the new shear bolts. 6. Insert the ignition key, and check for proper operation olthe steering wheel lock and thatthe ignition key turns freely.
17-12
Rack Guide Adjustment

Special Tool Required Locknut wrench, 43 mm 07MAA-SL00200 1. Set the wheels in the straight ahead position. 2. Remove the heat shield (A). 6. Tighten the rack guide screw (A) to 25 Nm 12.5 kgfm, 18Ibfft), then loosen it.
44Nm
3. Remove the transmission mount bracket (see step
14.5 kgfm, 33Ibfft)
32 on page 13-8). 4. Loosen the rack guide screw locknut (A) with the special tool, then remove the rack guide screw (8).
7. Retighten the rack guide screw to 6 Nm 10.6 kgfm, 4 Ibfft), then back it off to the specified angle. Specified Return Angle: 5 Max.
8. Hold the rack guide screw stationary with a wrench,
and tighten the locknut by hand until it's fully

seated.
9. Install the special tool on the locknut (8), and hold the rack guide screw IA) stationary with a wrench. Tighten the locknut an additional 30 with the
special tool.
B
10. Reinstall the transmission mount bracket and heat
shield. 5. Remove the old sealant from rack guide screw, and apply new sealant to the middle of the threads (A). Loosely install the rack guide screw on the steering
gearbox.
11. Check for unusual steering effort through the complete turning travel. 12. Check the steering wheel rotation play Isee page 17-4) and the power assist Isee page 17-4).
17-13
Electrical Power Steering (EPS)

Special Tools ................................................................. Component Location Index ......................................... General Troubleshooting Information ....................... DTC Troubleshooting Index ........................................ Symptom Troubleshooting Index ............................... System Description ...................................................... Circuit Diagram ............................................................. DTC Troubleshooting ................................................... EPS Indicator Circuit Troubleshooting ....................... Motor Removal/Installation ......................................... Steering Gearbox Removal ......................................... Steering Gearbox Overhaul ......................................... Steering Gearbox Installation ..................................... EPS Control Unit Removal/Installation ....................... Tie-rod Ball Joint Boot Replacement .......................... 17-16 17-17 17-18 17-22 17-23 17-24 17-26 17-28 17-47 17-49 17-51 17-55 17-63 17-67 17-67
EPS Components
Special Tools
Ref.No.
Q)
:n
Tool Number 07MAC-SLOO200 070AO-POA0100 07ZAA-S5A0100
Description Ball Joint Remover, 28 mm Attachment, 42 mm Locknut Wrench
Qty 1 1 1
Q)
':l)
17-16
,U"U\,O
ASSEMBLY
UNDERDASH FUSE/RELAY BOX
UNDERHOOD FUSE/RELAY BOX
---"
//
1/
'
DATA LINK CONNECTOR 116P) TORQUE SENSOR BATTERY EPS CONTROL UNIT EPS Control Unit Removal/Installation, page 17-67 MOTOR Removal/Installation, page 17-49 STEERING GEARBOX Steering Gearbox Removal, page 17-51 Steering Gearbox Overhaul, page 17-55 Steering Gearbox Installation, page 17-63
17-17
EPS Components
EPS Indicator
Under normal conditions, the EPS indicator comes on when the ignition switch is turned to the ON (II) position, then goes off after the engine is started. This indicates that the bulb and its circuit are operating correctly. If there is any trouble in the system after the engine is started, the EPS indicator will stay on, and the power assist is turned off. When EPS indicator light comes on, the control unit memorizes the DTC. In this case, the control unit will not activate the EPS system after the engine starts again, but it keeps the EPS indicator on.
When DTC 12, 16, 17, 18 or 67 is stored in the control unit, the EPS indicator will stay on until the DTC is erased. When a problem is detected and the EPS indicator comes on, there are cases when the indicator stays on until the ignition switch is turned OFF, and cases when the indicator goes off automatically when the system returns to normal. Even though the system is operating normally, the EPS indicator will come on under the following conditions: Condition 1: The vehicle was traveling at least 12.4 mph (20 km/h), then A rapid change in vehicle speed was detected, then The vehicle (or the vehicle speed sensor signal) stopped for at least 5 seconds The engine speed was still 1,640 rpm or higher for at least 5 The DTCs are memorized in the EEPROM (non-volatile memory) therefore the memorized DTCs cannot be erased by disconnecting the battery. Perform the specified procedures to clear DTCs.
Self-diagnosis
Self-diagnosis can be classified into two categories: Initial diagnosis: perforrned right after the engine starts and until the EPS indicator goes off. Regular diagnosis: performed right after the initial diagnosis until the ignition switch is turned OFF.
The EPS control unit performs the following functions when a problem is detected by self-diagnosis: 1. Turns on the EPS indicator. 2. Memorizes the DTC. 3. Stops power assist and manual steering operation begins. NOTE: When DTC 23 (a problem with the circuit for engine speed signal) is detected, the power assist will return to normal when the vehicle speed is 0.62 mph (1 km/h) or above. For DTCs 22, 23, 64, or 66 the EPS indicator goes off automatically when the system returns to normal. For all other codes, the EPS indicator goes off when the system is OK after the ignition switch is turned from OFF to ON (II).
seconds
Condition 2: After the vehicle (or the vehicle speed sensor signal) has stopped for at least 10 seconds, yet the engine speed was still 1,640 rpm or higherfor at least 20 seconds. Condition 3: When the engine speed is 280 rpm or less, and the vehicle is traveling at a speed of6.2 mph (10 km/h) or more for 3 seconds. To determine the actual cause of the problem, question the customer about the conditions during which the problem occured, taking the above conditions into consideration.
Restriction on Power Assist Operation

Repeated extreme steering force, such as turning the steering wheel continuously back-and-forth with the vehicle stopped, causes an increase of power consumption in the EPS motor. The increase of electric current causes the motor to heat up. Because this heat adversely affects the system, the control unit monitors the electric current of the motor. When the control unit detects heat build-up in the motor, it reduces the electric current to the motor gradually to protect the system, and it restricts the power assist operation. The EPS indicator does not come on during this function. When steering torque is not applied to the steering wheel, or when the ignition is turned off, and the motor cools, the control unit will restore the power assist gradually until it's fully restored (after approximately 15 minutes maximum).

If the CPU cannot be activated, or it fails, the EPS indicator comes on, but the DTC is not memorized. The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the most recent DTC is written over the prior DTC, therefore only one occurrence is memorized. The DTCs are indicated repeatedly until the ignition switch is turned OFF. If the DTC is not memorized, the EPS indicator blinks.
17-18
How to Troubleshoot EPS OTCs

The troubleshooting flowchart procedures assume that the cause of the problem is still present and the EPS indicator is still on. Following the flowchart when the
EPS indicator does not come on can result in incorrect
2. Turn the ignition ON (III, and follow the prompts on the PGM Tester to display the DTC(sl on the screen. After determining the DTC, refer to the DTC Troubleshooting Index. NOTE: See the Honda PGM Tester user's manual
for specific instructions.
diagnosis. The connector illustrations show the female terminal

connectors with a single outline and the male terminal connectors with a double outline. 1. Question the customer about the conditions when
Service Check Signal Circuit Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (AI to the 16P data link connector (DLCI (Bllocated under the dash on the driver's side of the vehicle.
the problem occured, and try to reproduce the

same conditions for troubleshooting. Find out when the EPS indicator came on, such as while turning, after turning, when the vehicle was at a certain speed, etc.
2. When the EPS indicator does not come on during

the test drive, but troubleshooting is done based on the OTe, check for loose connectors, poor terminal contact, etc in the affected circuit, before you start
troubleshooting.
3. After troubleshooting, clear the DTC and test-drive

the vehicle. Be sure the EPS indicator does not come on.
How to Retrieve EPS OTCs

Honda PGM Tester Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (AI to the 16P data link connector (DLCI (Bllocated under the dash on the driver's side of the vehicle. 2. Short the SCS circuit to body ground using the Honda PGM Tester. 3. Turn the ignition switch ON (II). 4. Record the DTC.
(cont'dl
17-19
EPS Components
5. The blinking frequency indicates the OTe. OTes are indicated by a series of long and short blinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the OTe. After determining the OTe, refer to the OTe Troubleshooting Index. The system will not indicate the OTe unless these
conditions are met:
How to Clear EPS OTCs

Honda PGM Tester Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P data link connector (OLe) (8) located under the dash on the driver's side of the vehicle.
Set the front wheels in the straight ahead driving

position.
A
The ignition switch is turned ON (II). The engine is stopped. The ses circuit is shorted to body ground before the ignition switch is turned ON (II).
Example of OTC 23
Long blinks
(two times)
Short blinks
(three times)
ON
OFF
l '----lhriUUUI I I U hnrl'--_->,
2. Turn the ignition switch ON (II), and clear the OTe(s) by following the screen prompts on the PGM Tester. NOTE: See the Honda PGM Tester user's manual
6. Turn the ignition switch OFF. 7. Oisconnect the Honda PGM Tester from the OLe.
17-20
Service Check Signal Circuit Method: NOTE: Use this procedure when the PGM Tester software does not match the year/model vehicle you
are working on.
7. Within 4 seconds after the EPS indicator goes off, return the steering wheel to the straight ahead
driving position again and release the steering
wheel. The EPS indicator blinks twice 4 seconds

after releasing the steering wheel, indicating that
the DTC was erased. 1. With the ignition switch OFF, connectthe Honda PGM Tester (AI to the 16P data link connector (DLCI (Bllocated under the dash on the driver's side of the vehicle. NOTE: If the EPS indicator does not blink twice, an error was made in the procedure and the DTC was not erased. Turn the ignition switch OFF, and repeat the operation from step 3. 8. Turn the ignition switch OFF afterthe EPS indicator blinks twice. 9. Disconnect the Honda PGM Tester from the DLC. 10. Perform the DTC code output operation, and be sure that the code has been erased .
2. With the vehicle on the ground, set the front wheels

in the straight ahead driving position.
3. Short the SCS circuit to body ground using the Honda PGM Tester. 4. Turn the ignition switch ON (III. The EPS indicator
comes on for about 6 seconds. Within 4 seconds of
turning the switch ON, while the EPS indicator is on, turn the steering wheel 45 degrees to the left from the straight ahead driving position, and hold the steering wheel in that position until the EPS indicator goes off. 5. Within 4 seconds after the EPS indicator goes off, return the steering wheel to the straight ahead
driving position and release the steering wheel.
The EPS indicator comes on again 4 seconds after

releasing the steering wheel.
6. Within 4 seconds after the EPS indicator comes on, turn the steering wheel 45 degrees to the left again
and hold it in that position.
The EPS indicator goes off after 4 seconds .
17-21
EPS Components
OTe Troubleshooting Index
DTe
OTC: 12 OTC: 16 OTC: 17 OTC: 18 OTC: 22
-,
Detection Item
Note
(see page 17-281 (see page 17-291 (see page 17-311 (see page 17-311 (see page 17-331
A problem with voltage for torque sensor T/SIG A problem with average of voltage for torque sensor VT3 and VT6 A problem with the voltage fortorque sensor 12 V power source Vee 1
A problem with the voltage for torque sensor 5 V power source Vee 2
A problem with the average for vehicle speed and engine speed
Excessive change of the vehicle speed sensor signal
-~-
(see page 17-331 (see page 17-331 (see page 17-351 (see page 17 -361
OTC: 23 OTC: 37 OTC: 41 OTC: 42 OTC: 43 OTC: 45 OTC: 47 OTC: 50 OTC: 51 OTC: 62 OTC:64
A problem with the engine speed signal circuit A problem with the circuit for input motor voltage in the EPS control unit A problem with the motor voltage A problem with the motor driven current (open circuit or short to groundl A problem with the motor driven current (short to power I
A problem with the motor driven current (open circuit or short to ground)
i
(see page 17-381
-(see page 17-411 (see page 17-381 (see page 17-421 (see page 17-431
A problem with the motor relay in the EPS control unit A problem with the CPU in the EPS control unit
A problem with EEPROM in the EPS control unit Fail-safe relay stuck ON A problem with low battery voltage
'-
-(see page 17-431 (see page 17-441 (see page 17-441
' -
-(see page 17-441

I
,
Fail-safe relay contact failure
OTC: 66 OTC: 67 OTC: 68 OTC: 69
A problem with the motor driven voltage A problem with the torque sensor IIF circuit A problem with the interlock circuit (torquel . A problem with the interlock circuit (currentl
(see page 17-451

I
!
i
(see page 17-451 (see page 17-451 (see page 17-461
17-22

Symptom
!
,
Diagnostic procedure
Also check for
EPS indicator does not
; EPS Indicator Circuit Troubleshooting (see page 17-471
come on
EPS indicator does not go off and no DTC is stored
EPS indicator does not stay
EPS Indicator Circuit Troubleshooting (see page 17-471
1.
Check the motor wires between the EPS control unit and the
motor for a short to ground. Repair as needed.
on, no DTC is stored, and

there is no power assist
2.
If the motor wires are OK, replace the steering gearbox (short in the motorl .
17-23
EPS Components
System Description
EPS Control Unit Inputs and Outputs at Connector A (2P)
EPS CONTROL UNIT CONNECTOR A 12P)
Terminal number
I
Wire color
Terminal sign
(Terminal name)
~
Description Terminals
Measurement
Conditions
lanition switch ON fill
Voltage
WHT/BLU BLK
BAT
Power source for the
1 Ground
Constant
Battery voltage
(Plus batter)
actuator motor
Ground for the actuator motor
PG
(Power around)
2-Ground
EPS Control Unit Inputs and Outputs at Connector B (2P)

EPS CONTROL UNIT CONNECTOR B 12P)
Terminal
number
I
Wire color
Terminal sign
(Terminal name)
Description
Measurement
Terminals
Drives the actuator motor
Conditions lanition switch ON (II)
Voltage
RED GRN
Ml (Motor 1) M2 (Motor 2)
l-Ground
2-Ground
I
Drives the actuator motor
17-24
EPS Control Unit Inputs and Outputs at Connector C (20P)

EPS CONTROL UNIT CONNECTOR C (20P)
V
Terminal
number 2 3 5 PNK OAN YELJAED YELJBLU BLU/WHT Wire color
II
2 3 10 5 6 7 8 11 1/ 13 / 15 1/ 17 / 19 20
Terminal sign (Terminal name)
Description
Measurement
Terminals
Conditions
(Ignition switch ON (lill
Voltage
6
7
8
10 11 13 15
BAN
I
YEL GAN/YEl BLU/OAN YELJBLK
17 19 20
LT GANI BlK BlU GAY
T/S GND Ground forthe torque (Torque sensor around) , sensor 3-Ground VCC1 Power source for torque (Voltaae common 1) sensor (12 VI VT6 Detects torque sensor 5 Ground (Voltage torque 6) si!=Jnal WLP Drives the EPS indicator 6 Ground (Warning lamp) light VSP Detects the vehicle speed 7 Ground (Vehicle speed pulse) input signal for the speed sensor or the ECM (4 pulsel Rev). Detects service check a-Ground SCS IService check sianal) connector sianal IG1 Power source for activating 10-Ground (Ignition 1) the system Drives the torque sensor l1-Ground VCC2 (Voltaae common 2) (5 VI Detects torque sensor 13-Ground VT3 (Voltaae toraue 3) sianal 15-Ground T/SIG Detects torque sensor (Torque sensor FIS signal sianal) PSW Provides power steering 17-Ground (Power steerina switch) switch sianal Detects the engine pulse , 19Ground NEP (Enaine Dulse) i DIAG-H 20-Ground Communications with (Diaanosis-Hl Honda PGM Tester
Start the en ine I "ition switch OFF Start the engine and turn the steering wheel EPS ON indicator OFF Raise the vehicle off the ground and spin the front wheel SCS not grounded I nition switch ON (II) lanition switch OFF Start the en ine lanition switch OFF Start the engine and turn the steerina wheel Start the engine
Batter~volta
OV About 5-0V OV
Batter'Lvoltage
Alternating voltage about OV-5V-OV-5V Battery voltage Batterv voltage OV About 5 V OV About 5-0V Momentarily 5 V
Start the engine and turn the steerina wheel Start the engine, and let it idle PGM Tester not connected
12 V
About 0-12 V 5V
17-25
EPS Components
Circuit Diagram
UNDER-HOOD
FUSE/RELAY BOX
No 18160AI
L...----f1"----_~_+WtfT/BlU
---------_,--------'WHT/BLU
UNDER-DASH
No.l0 ; ICANADA models: 50AI _ _ _ _ _ _ _ _ _ _I7.5AI.J. -_ _ m _ _

GAUGE ASSEMBLY
l~::-;=='O:'~~'~:"j-W~TN~:~K/VEL -~rO~'~~:tI:J--------m-------------EPS INOICATOR
FUSE/RELAY
,-----lTGRN/BlK
"'"
..:....K i , , ' J - - - - l TGRN/BlK
~~~---~"---------------------,.'"----------TORQUE SENSOR
, ,
,
jlNTEGRATEj ~
CIRCUIT
0"----_______- ________-0" ________________________

N/YEl - - - - - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ 'GRN/yEL _ _ _ _ _ _ _ _ _ _ _ _ __
G'
"
U/ORN - - - - - - - - - - - - - - - - - - - B l U / O R N - - - - - - - - - - - - -
i>-"
llRED - - - - - - - - - - - - - - - - - - Y E l / R E D - - - - - - - - - - - - -
iO
'-<i>-"l/SLK
- - - - - - - - - - - - - - - -_ _ _ _ VEl/BlK
m. ___________________". ______________
.J,.'
SPEED SENSOR 3P CONNECTOR
GAUGE ASSEMBLY 22P CONNECTOR IGreen Connector)
ECM 31P CONNECTOR lEI
8 9
2930 31
GAUGE ASSEMBL V 22P CONNECTOR (Blue Connector) TORQUE SENSOR
1 2 3 4 5
111213 16
6 8910 171819 21
SP CONNECTOR
145 111213141516
6
17
10
t:m:lli
17-26
EPS CONTROL UNIT
____________________________________ WHT/BLU
"
--------------------------------------""------~~.'~,~".---I
.,
."
MOTOR
__________________________________ VEL/8LU
____~W~"~)__.."
____________________________________ BLU/WHT
'"
___________________________________ LT GFlN/BlK
PSW 11
,w
0"'
GRN/YEl
'" "
Vcc1 3
EPS CONTROL UNIT
,..,
"" " "" '"
,U<
BLU/ORN
VEL/REO
.4IGi511
_____________________________________ yEL/BLK
T/SIG
"
______________________________________
, '"
_~'~I!'"G~'~O~)__,
.
~
'"
DIAGH
~
I."D
CONNECTOR A (2P)
DATA LINK CONNECTOR (16P)
F:': Connectorl
: Connector)
11
EPS CONTROL UNIT
2 3 13
5 6 7 8 10 15 17 1920
CONNECTOR B (2PI
([--: Connector)
MOTOR
CONNECTOR (2P)
17-27
EPS Components
DTe Troubleshooting
OTe 12: Torque Sensor T(SIG
1. Clearthe DTC. 2. Start the engine. 3. Wait at least 10 seconds.
EPS CONTROL UNIT CONNECTOR C 120P)
7. Turn the ignition switch ON (II). 8. Measure the voltage between EPS control unit connector C (20P) terminal No. 15 and body ground.
Does the EPS indicator come on?

YES-Go to step 4.
NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this
time . 4. Stop the engine, and verify the DTC.

Is DTC12 indicated? Is there battery voltage?

YES-Go to step 5. NO-Perform the appropriate troubleshooting for the code indicated . 5. Make sure the ignition switch is OFF, then disconnect EPS control unit connector C (20P) and
the torque sensor 6P connector.
YES-Repair short to power in the + circuit wire between the torque sensor and EPS control unit.. NO-Go to step 9. 9. Turn the ignition switch OFF. 10. Check for continuity between EPS control unit connector C (20P) terminal No. 15 and the torque sensor 6P connector terminal No.4.
6. Check for continuity between EPS control unit connector C (20P) terminal No. 15 and body ground.
EPS CONTROL UNIT CONNECTOR C 120PI
TORQUE SENSOR 6P CONNECTOR
=
YES-Go to step 11.
NO-Repair open in the wire between the torque
YES- Repair short to body ground in the wire

between the torque sensor and EPS control unit..
NO-Go to step 7.
sensor and the EPS control unit .
17-28
11. Substitute a known-good EPS control unit, and

connect the all disconnected connectors.
DTe 16: Torque Sensor VT3 and VT6

1. Clear the DTC. 2. Start the engine. 3. Wait at least 10 seconds. Does the EPS indicator come on?
12. Start the engine. Does the EPS indicator come on? YES-Go to step 13.
YES-Go to step 4. NO-Check for loose EPS control unit connectors. If necessary, replace the EPS control unit and retest . 13. Stop the engine, and verify the DTC. 4. Stop the engine, and verify the DTC. Is DTC12 indicated? Is DTC16 indicated?
YES-Check for loose torque sensor connectors. NO-Check for loose wires or poor connnections. If
the connections are good, the system is OK at this time .
If necessary, substitute a known-good steering gearbox and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
YES-Go to step 5. NO-Perform the appropriate troubleshooting for the code indicated . 5. Make sure the ignition switch is OFF, then disconnect EPS control unit connector C 120PI and
the torque sensor 6P connector.
6. Check for continuity between the appropriate EPS control unit connector C 120PI terminal and body ground Isee table).
Terminal name
I
i
Vccl Vcc2 VT3 VT6 TIS GND

TIS GND (PNIC)
EPS control unit connector C terminal No. 3 11 13
5 2
V 1 (ORN)
"
VT6 (YEL(RED)
I,
/12 31/5 6 78i/110
11
1
13
15
17
1920
(GRNI
YEll ~
Vcc2
: VT3 (BLU/ORN)
~@
@ G~
Wire Side oflemaletermirlals
YES- Repair short to body ground in the
appropriate sensor circuit between the torque sensor and EPS control unit..
NO-Go to step 7. Icont'd)
17-29
EPS Components
7. Turn the ignition switch ON (II). 8. Measure the voltage between the appropriate EPS control unit connector C (20P) terminal and body ground (see table). Terminal name Vccl Vcc2 VT3 VT6 T/S GND EPS control unit connector C terminal No. 3 11 13 5 2 9. Turn the ignition switch OFF. 10. Check for continuity between the appropriate EPS control unit connector C (20P) terminal and the
torque sensor terminal (see table),
Terminal name Vccl Vcc2 VT3 VT6 T/S GND
Torque Sensor terminal No.
EPS CONTROL UNIT CONNECTOR C 120P) TIS GND (PNK) ,.:V.::cc",t,,(.:::O.:cRc:..:N,,-)_ _ _ _ _- , VT6 (VELIRED)
2 3 1 6 5
EPS control unit connector C terminal No. 3 11 13 5 2
TOROUE SENSOR 6PCONNECTOR Vcc110RN)
I
Vcc2
(GRNI VEL)
i-+~VT~3~(B~L~U~I~O~RN~)~pj1j~ 3 .~'-'i'-J..:6T-J Q
Vcc1(ORN)
=
=
YES- Repair short to power in the + circuit wire between the EPS contra) unit and torque sensor . NO-Go to step 9.
TIS GND (PNK)
Q Q
EPS CONTROL UNIT CONNECTOR C (20P) VT6 (VELIRED)
Vcc2 (GRNIVEL) VT3(BLUIORN)

Wire s'lde of female terminals
Is there continuty?
YES-Go to step 11.
NO-Repair open in the appropriate torque sensor wire circuit between the EPS control unit and the torque sensor .
17-30
11. Substitute a known-good EPS control unit, and
OTC 17: Torque Sensor Vcc1 OTC 18: Torque Sensor Vcc2
reconnect the disconnected connectors.

12. Start the engine. 1. Clearthe DTC.

2. Start the engine. YES-Go to step 13. 3. Wait at least 10 seconds. NO-Check for loose or poor connections at the EPS control unit and the torque sensor connectors. If the connections are good, replace the EPS control unit and recheck . 13. Stop the engine, and verify the DTC.

YES-Go to step 4. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 4. Stop the engine, and verify the DTC.
Is oTC16 indicated?
YES-Replace the steering gearbox and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
Is oTCI? or oTCI8 indicated?

YES-Go to step 5.
NO- Do the troubleshooting for the DTC indicated .

5. Make sure the ignition switch is OFF, then disconnect EPS control unit connector C 120P) and the torque sensor 6P connector.
6. Check for continuity between EPS control unit connector C (20P) terminal No.3 and body ground.
EPS CONTROL UNIT CONNECTOR C (20PI
=
YES-Repair short to body ground in the wire between the torque sensor and EPS control unit. NO-Go to step 7. (cont'd)
17-31
EPS Components
7. Check for continuity between EPS control unit connector C (20P) terminal No.3 and the torque sensor 6P connector terminal No.2.
9. Check for continuity between EPS control unit connector C (20P) terminal No. 11 and the torque sensor 6P connector terminal No.3.
TOROUE SENSOR 6P CONNECTOR
TORQUE SENSOR 6P CONNECTOR Vcc2 (GRN/YELI
Is there continuity? YES-Go to step 8. NO-Repair open in the wire between the torque sensor and EPS control unit. 8. Check for continuity between EPS control unit connector C (20P) terminal No. 11 and body ground.
Is there continuity? YES-Go to step 10. NO-Repair open in the wire between the torque sensor and EPS control unit.. 10. Substitute a knowngood EPS control unit, and
connect all the disconnected connectors.
11. Start the engine. Does the EPS indicator come on? YES-Go to step 12. NO-Check for loose or poor connections at the
EPS control unit and the torque sensor connectors.
If the connections are good, replace the EPS control unit and recheck .
12. Stop the engine, and verify the DIC. Is DTC17 or DTC18 indicated?
Is there continuity? YES-Replace the steering gearbox and recheck . YES-Repair short to body ground in the wire
between the torque sensor and EPS control unit.
NO- Perform the appropriate troubleshooting for the code indicated .
NO-Go to step 9.
17-32
OTC 22: Vehicle Speed Sensor Signal OTC 23: Engine Speed Signal
3. Block the rear wheels and raise the vehicle, and make sure it is securely supported. 4. Turn the ignition switch ON (II).
NOTE: If the MIL indicator is ON, troubleshoot the PGM-FI system first. Even though the system is operating normally, the
EPS indicator will come on under the following conditions.
5. Block the right front wheel, and slowly rotate the left front wheel, and measure the voltage between EPS control unit connector C (20P) terminal No.7 and body ground.
EPS CONTROL UNIT CONNECTOR C (20PI VSP (BLU/WHTI
- Condition 1: The vehicle was traveling at least 12.4 mph (20 km/h), then A rapid change in vehicle speed was detected, then
The vehicle (or the vehicle speed sensor signal) stopped for at least 5 seconds, and
The engine speed was still 1,640 rpm or higher for

at least 5 seconds
- Condition 2: After the vehicle (or the vehicle speed sensor signal) has stopped for at least 10 seconds, yet the engine speed was still 1,640 rpm or higher for at least 20 seconds. - Condition 3: When the vehicle speed is 10 km/h (6.2 mph) or above and the engine is running at 280 rpm or below for 3 seconds. 1. Start the engine and check the tachometer.
=
Does the voltage pulse 0 V and 5 V?

YES-Go to step 6. NO-Repair open in the wire between the EPS control unit and the VSS. If the wire is OK,check for a loose or poor connections at the EPS control unit. If necessary, substitute a known-good EPS control unit, and recheck .
Is the tachometer working correctly?

YES-Go to step 2. NO-Go to step 9. 2. Test-drive the vehicle above 15 km/h (9.3 mph).
Is the speedometer working correctly?

YES-Go to step 3. NO-Perform the speedometer system troubleshooting (see page 22-65) .
(cont'dl
17-33
EPS Components
6. Turn the ignition switch OFF, and disconnect EPS control unit connector C (20PI. 7. Start the engine, and let it idle. 8. Measure the voltage between EPS control unit connector C (20PI terminal No.19 and body ground.
EPS CONTROL UNIT CONNECTOR C {20P}
11. Measure the voltage between EPS control unit connector C (20PI terminal No. 19 and body ground.
Is there about 6 Vat idle? (With the meter set for frequency, is there 33 Hz per 1,000 engine rpm?)
Is there about 6 Vat idle? (With the meter set for frequency, is there 33 Hz per 1,000 engine rpm?) YES-Check for loose EPS control unit connectors. If necessary, substitute a known-good EPS control unit and recheck . NO-Repair open in the wire between the EPS control unit and the ECM . 9. Turn the ignition switch OFF, and disconnect EPS control unit connector C (20PI. 10. Start the engine, and let it idle.
YES-Check for loose EPS control unit connectors. If necessary, substitute a known-good EPS control unit and recheck . NO-Go to step 12. 12. Turn the ignition switch OFF. 13. Disconnect the ECM connector E (31 PI connector.
17-34
14. Check for continuity between EPS control unit connector C (20P) terminal No. 19 and ECM connector E (31P) terminal No. 26.
DTC 37: EPS Control Unit Internal Circuit
(Input Circuit For Motor Voltage)

1. Clearthe DTC. 2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several
times, and wait 10 seconds or more.

YES-Go to step 4. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time .
Is there continuity? YES-Go to step 15. NO-Repair open in the wire between the EPS control unit and ECM . 15. Disconnect the gauge assembly 22P connector.
16. Check for continuity between EPS control unit
4. Stop the engine, and verify the DTC. Is DTe 37 indicated? YES-Check for loose EPS control unit connectors. If necessary, substitute a known-good EPS control
unit and recheck .
NO-Perform the appropriate troubleshooting for the code indicated .
connector C (20P) terminal No. 19 and body ground.

=
YES-Repair short to body ground in the wire between the EPS control unit, the test tachometer connector, the gauge assembly, and the ECM .
NO-Check for loose ECM control unit connectors. If necessary, substitute a known-good ECM control unit and recheck .
17-35
EPS Components
OTe 41: Voltage For Motor
1. Clear the DTC.
EPS CONTROL UNIT CONNECTOR B (2P)
7. Check for continuity between EPS control unit connector B 12P) terminal No.2 and body ground.
2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several

YES-Go to step 4.
=
NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time .
4. Stop the engine, and verify the DTC.
Is OTe 41 indicated?
YES-Go to step 5.
YES-Repair short to body ground in the GRN wire between the EPS control unit and the motor.. NO-Go to step 8.
NO-Perform the appropriate troubleshooting for the code indicated .

5. Make sure the ignition switch is OFF, then disconnect EPS control unit connector B (2P) and the motor 2P connector.
8. Check for continuity between EPS control unit connector B (2P) terminal No.1 and No.2.
EPS CONTROL UNIT CONNECTOR B (2PI
6. Check for continuity between EPS control unit connector B 12P) terminal No.1 and body ground.
M2(GRNI
=
YES-Repair short between the RED and GRN
wires in the motor circuit between the EPS control unit and the motor .
NO-Go to step 9.
YES- Repair short to body ground in the RED wire

between the EPS control unit and the motor.
NO-Go to step 7.
17-36
9. Turn the ignition switch ON (II), and measure the voltage between EPS control unit connector B (2P) terminal No.1 and body ground.
11. Turn the ignition switch is OFF.

12. Substitute a known-good EPS control unit, and connect all the disconnected connectors.
13. Start the engine, and turn the steering wheel from lock to lock several times. Does the EPS indicator come on? YES-Go to step 14. NO-Check for loose or poor connections at the EPS control unit and the motor connections. If the connections are good, replace the EPS control unit and recheck . 14. Stop the engine, and verify the DTC.

YES-Repair short to power in the + circuit wire between the EPS control unit and the motor..
fs DTe 41 indicated? YES-Replace the steering gearbox motor and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
NO-Go to step 10. 10. Measure the voltage between EPS control unit connector B (2P) terminal No.2 and body ground.
EPS CONTROL UNIT CONNECTOR B 12PI

YES-Repair short to power in the - circuit wire
between the EPS control unit and the motor.. NO-Gotostepll .
17-37
EPS Components
Ole 42, 45: Motor Driven Current
1. Clear the DTC. 2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several times, and wait 10 seconds or more.
7. Check for continuity between EPS control unit connector B (2P) terminal No.2 and body ground.

YES- Go to step 4.
Q
=
NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this
time .
4. Stop the engine, and verify the DTC.
YES-Repair short to body ground in the GRN wire between the EPS control unit and the motor. NO-Go to step 8.
Is DTC 42 or 45 indicated?
YES-Go to step 5. NO- Perform the appropriate troubleshooting for
the code indicated .

5. Make sure the ignition switch is OFF, then disconnect EPS control unit B connector (2P) and
8. Check for continuity between EPS control unit connector B (2P) terminal No.1 and No.2.
the motor 2P connector.

6. Check for continuity between EPS control unit connector B (2P) terminal No.1 and body ground.
EPS CONTROL UNIT CONNECTOR B 12P)
M2(GRN)
=
YES-Repair short between the RED and GRN wires in the motor circuit between the EPS control
unit and the motor .

YES-Repair short to body ground in the RED wire between the EPS control unit and the motor.. NO-Go to step 7. NO-Go to step 9.
17-38
9. Turn the ignition switch ON (II), and measure the voltage between EPS control unit connector B (2PI terminal No.1 and body ground.
11. Check for continuity between EPS control unit connector B (2PI terminal No.1 and the motor 2P
connector terminal No.2.
EPS CONTROL UNIT CONNECTOR B 12P) MOTOR CONNECTOR 12P)
M11RErm
n
@f-------'
F1IREO)
=

YES-Repair short to power in the + circuit wire between the EPS control unit and motor.
YES-Go to step 12. NO-Repair open in the RED wire between the EPS control unit and the motor.
NO-Go to step 10 . 10. Measure the voltage between EPS control unit connector B (2PI terminal No.2 and body ground.
=

YES-Repair shortto power in the
circuit wire
between the EPS control unit and the motor . NO-Go to step 11 .
(cont'dl
17-39
EPS Components
12. Check for continuity between EPS control unit connector B (2P) terminal No.2 and the motor 2P
connector terminal No.1.
15. Stop the engine, and verify the DTC. Is OTe 42 or 45 indicated? YES-Replace the steering gearbox motor and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
MOTOR CONNECTOR 12PI
M2IGRN)
Is there continuity? YES-Go to step 13. NO-Repair open in the GRN wire between the EPS control unit and the motor..
13. Check for loose wires or poor connections, if the connections are good, substitute a known-good EPS control unit, and connect all the disconnected
connectors. 14. Start the engine, and turn the steering wheel from
lock to lock several times.
Does the EPS indicator come on? YES-Go to step 15. NO-Check for loose EPS control unit connectors. If
necessary, replace the EPS control unit and
recheck .
17-40
DTC 43: Motor Driven Current is Excessively High

1, Clear the DTC, 2, Start the engine, 3, Turn the steering wheel from lock-to-Iock several
8, Measure the voltage between EPS control unit connector B (2P) terminal No, 2 and body ground,

YES-Go to step 4, NO-Check for loose wires or poor connections, If the connections are good, the system is OK at this time,. 4, Stop the engine, and verify the DTC,
YES-Repair short to power in the - circuit wire
=
YES-Go to step 5,
between the EPS contorl unit and the motor,. NO-Go to step 9, 9, Turn the ignition switch OFF, 10, Check for continuity between EPS control unit connector B (2P) terminals No, 1 and No, 2,
NO-Perform the appropriate troubleshooting for

the code indicated .
5, Make sure the ignition switch is OFF, then disconnect EPS control unit connector B (2P) and
the motor 2P connector.
6, Turn the ignition switch ON (II),

7. Measure the voltage between EPS control unit
connector B (2P) terminal No, 1 and body ground,

EPS CONTROL UNIT CONNECTOR B (2PI M2(GRN)
=
YES- Repair short between the GRN and RED

wires in the motor circuit between the EPS control unit and the motor.
NO-Go to step 11,
YES-Repair short to power in the + circuit wire between EPS control unit and motor.
NO-Go to step 8,
(conl'dl
17-41
EPS Components
11. Substitute a known-good EPS control unit, and connect all the disconnected connectors. 12. Start the engine, and turn the steering wheel from
lock to lock several times.
DTe 47: EPS Control Unit Internal Circuit (Power Relay)

1. Clear the DTC. 2. Start the engine.
Does the EPS indicator come on? Does the EPS indicator come on? YES-Go to step 13. YES-Go to step 3. NO-Check for loose or poor connections at the EPS control unit and the motor connections. If the connections are good, replace the EPS control unit and recheck . 13. Stop the engine, and verify the DTC.
Is DTC 43 indicated?
NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 3. Stop the engine, and verify the DTC.
YES-Replace the steering gearbox motor and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
YES-Check for loose EPS control unit connectors. If necessary, substitute a known-good EPS control unit and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
17-42
DTC 50: EPS Control Unit Internal Circuit (CPU or Microcomputer)

1. Clear the DlC. 2. Start the engine.
DTC 51: EPS Control Unit Internal Circuit (EEPROM)

1. Clear the DlC. 2. Start the engine.

YES-Go to step 3. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 3. Stop the engine, and verify the DlC.

YES-Go to step 3. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 3. Stop the engine, and verify the DlC.
YES-Check for loose or poor connections at the EPS control unit connections. If the connections are good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit. NO-Perform the appropriate troubleshooting for the code indicated .
YES-Check for loose or poor connections at the EPS control unit connections. If the connections are
good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit.. NO-Perform the appropriate troubleshooting for the code indicated .
17-43
EPS Components
DTC 62: EPS Control Unit Internal Circuit (Fail-safe Relay Stuck ON)
1. Clearthe DTC. 2. Start the engine. Does the EPS indicator come on? YES-Go to step 3. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this
time .
DTC 64: Battery Voltage is Excessively Low (Fail-safe Relay Contact Failure and Motor Voltage Fall Off)
1. Clear the DTC. 2. Start the engine. Does the EPS indicator come on? YES-Go to step 3. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this
time .
3. Stop the engine, and verify the DTC. Is DTC 62 indicated? YES-Check for loose or poor connections at the EPS control unit. If the connections are good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
3. Stop the engine, and verify the DTC. Is DTC 64 indicated? YES-Go to step 4. NO-Perform the appropriate troubleshooting for the code indicated. 4. Check the No. 18 (60A) fuse in the under-hood fuse/ relay box, and reinstall the fuse if it is OK. Is the fuse OK? YES-Go to step 5. NO-Replace the fuse and recheck . 5. Disconnect EPS control unit connector A (2P). 6. Measure the voltage between EPS control unit connector A (2P) terminal No.1 and body ground.
Wire Side of lernale terminal.
Is there battery voltage? YES-Check for loose or poor connections althe

EPS control unit connectors, and check for a poor ground at G151. If necessary, substitute a known-
good EPS control unit and recheck . NO-Repair open in the WHT/BLU wire between the No. 18 (60A) fuse and EPS control unit.
17-44
OTC 66, 68: EPS Control Unit Internal Circuit

1. Clearthe DTC. 2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several
OTC 67: Torque Sensor IIF Circuit

1. Clear the DTC. 2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several
Does the EPS indicator come on? YES-Go to step 4.

NO-Check for loose wires or poor connections. If
Does the EPS indicator come on? YES-Go to step 4. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 4. Stop the engine, and verify the DTC.
the connections are good, the system is OK at this time . 4. Stop the engine, and verify the DTC.
Is OTC 67 indicated? Is OTC 66 or 68 indicated? YES-Check for loose or poor connections at the EPS control unit. If the connections are good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit and recheck . NO-Perform the appropriate troubleshooting for the code indicated . YES-Check for loose or poor connections at the EPS control unit. If the connections are good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit and recheck . NO-Perform the appropriate troubleshooting for the code indicated .
17-45
EPS Components
OTC 69: EPS Control Unit Internal Circuit
1. Clear the DTC. 2. Start the engine. 3. Turn the steering wheel from lock-to-Iock several
Does the EPS indicator come on? YES-Go to step 4. NO-Check for loose wires or poor connections. If the connections are good, the system is OK at this time . 4. Stop the engi ne, and verify the DTC. Is DTC 69 indicated? YES-Check for loose or poor connections at the EPS control unit. If the connections are good, substitute a known-good EPS control unit. If the symptom/indication goes away, replace the original EPS control unit and recheck . NO- Perform the appropriate troubleshooting for the code indicated .
17-46
EPS Indicator Circuit Troubleshooting

I. Turn the ignition switch ON (III, start the engine, and watch the EPS indicator. Does the EPS indicator come on? 7. Turn the ignition switch ON (III. YES-If the EPS indicator comes on and goes off, it's OK. If the EPS indicator stays on or blinks, go to step 12. NO-Go to step 2. 2. Turn the ignition switch OFF, then ON (III again, and watch the brake system indicator. Does the brake system indicator come on? YES-Go to step 3. NO-Repair open in the indicator power source circuit. Blown No. 10 (7.5AI fuse. Open in the wire between the No. 10 (7.5AI fuse and gauge assembly. Open circuit inside the under-dash fuse/relay box. Faulty gauge assembly. 3. Turn the ignition switch OFF. 9. Turn the ignition switch OFF.
4. Connect a jumper wire between the gauge assembly 22P connector terminal No. 13 and body ground, then turn the ignition switch ON (III.
GAUGE ASSEMBLY 22P CONNECTOR IBlue connector)
5. Turn the ignition switch OFF. 6. Disconnect EPS control unit connector C (20PI.
8. Connect EPS control unit connector C (20PI terminal No.6 to body ground with a jumper wire.
WLP (YEL/BLU)
V 213V 516 7 8V 101

111/131/151/171/1920
JUMPER WIRE
Does the EPS indicator come on? YES-Go to step 9.

NO-Repair open in the wire between the gauge assembly and the EPS control unit.
10. Disconnect EPS control unit connector A (2PI. I I. Check for continuity between EPS control unit connector A terminal No.2 and body ground.
EPS CONTROL UNIT CONNECTOR A (2PI
WlP IYEl/BlU) JUMPER WIRE

Does the EPS indicator come on? YES-Go to step 5. NO-Inspect the EPS indicator bulb, if the bulb is OK, replace the bulb circuit board in the gauge assembly . YES-Check for loose or poor connections at the EPS control unit. If the connections are good, substitute a knowngood EPS control unit. If the symptom/indication goes away, replace the original EPS control unit and recheck .
NO-Repair open in the wire or a bad ground at GI51 . (cont'dl
17-47
EPS Components
EPS Indicator Circuit Troubleshooting (cont'd)
12. Turn the ignition switch OFF. 13. Disconnect EPS control unit connector C (20P).
16. Measure the voltage between EPS control unit connector A (2P) terminal No.1 and body ground.
14. Turn the ignition switch ON (II). Does the EPS indicator come on? YES-Repair short to ground in the YEL/BLU wire between the gauge assembly and the EPS control unit, or replace the bulb circuit board in the gauge assembly . NO-Goto step 15. 15. Measure the voltage between EPS control unit connector C (20P) terminal No. 10 and body ground.
EPS CONTROL UNIT CONNECTOR C 120PI
Is there battery voltage? YES-Go to step 17. NO-Check for a blown No. 18 (60A) fuse in the under-hood fuse/relay box or open/short in the WHT/BLU wire between the under-hood fuse/relay box and the EPS control unit..
VT3 IBLU/ORN}
17. 18. 19. 20.
Turn the ignition switch OFF. Reconnect EPS control unit connector A (2P). Turn the ignition switch ON (II). Measure the voltage between EPS control unit connector C (20P) terminal No.8 and body ground.

SCS IBRN)
YES-Go to step 16. NO-Repair open in the wire between EPS control unit connector C (20P) and the No.1 0 (7.5A) fuse .
11
2 3
13
=
Is there about 10 V?
YES-Check for loose or poor connections at the EPS control unit. If the connections are good,
substitute a known-good EPS control unit. If the

symptom/indication goes away, replace the
original EPS control unit and recheck . NO-Repair short to ground in the BRN wire between the data link connector and the EPS control unit..
17-48
Motor Removal/Installation
Removal
4. Remove the connector bracket (Alan the gearbox

housing, and disconnect the motor 2P connector
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons.
2. Disconnect the negative cable from the battery, and wait 3 minutes before beginning work. 3. Remove the air cleaner assembly (AI.
(BI.
5. Remove the motor (AI from the gearbox housing.
6. Remove the O-ring (BI and discard it.
(conrdl
17-49
EPS Components
Motor Removal/Installation (cont'd)
Installation
10. Install the motor on the gearbox by engaging the motor shaft and worm shaft (D). Note the motor
installation position (direction of motor wires).
7. Clean the mating surface of the motor (AI and gearbox.
,
/
8X1.25mm 20Nm (2.0 kgfm. 7 2 IbfftJ
11. Before tightening the bolts, turn the motor two or three times right and left about 45 degrees. Make sure the motor is evenly seated on the steering gearbox and that the O-ring is not pinched between the mating surfaces. 12. Install the removed parts in the reverse order of
removal, and note these items: Make sure the motor 2P connector is properly connected .
Make sure the motor and EPS wires are not caught or pinched by any parts. Reconnect the negative cable to the battery. Do the engine control module (ECM) idle learn procedure (see page 11-139). Enter the anti-theft code for the radio station presets. Reset the clock.
Do the power window control unit reset
procedure (see page 22-128). 13. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-Iock several times. Check that the EPS indicator does not come on.
8. Apply a thin coat of silicone grease !PIN 08733B070E) to the new O-ring (B), and carefully fit it on the motor. 9. Apply grease (Nippon Grease WR-S or equivalent steering gear grease) into the motor shaft (C).
17-50
Steering Gearbox Removal

Ball joint remover, 28 mm 07MAC-SL00200

1. Raise the front of vehicle, and make sure it is
8. Remove the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut.
securely supported.
2. Remove the front wheels. 3. Remove the driver's airbag (see page 23-113). 4. Remove the steering wheel (see page 17-6).
5. Remove the motor on the steering gearbox (see
page 17-49).
6. Remove the driver's dashboard lower cover (see page 20-59) and under cover (see page 20-60). 7. Remove the steering joint bolts (A), and disconnect the steering joint by moving the steering joint (B) toward the column.
07MACSL00200
9. Separate the tie-rod ball joint and damper steering arm using the special tool (see page 18-10). Repeat on the other side of the vehicle. 10. Grasp the right side tie-rod, and pull the rack all the
way to the passenger's side,
11. Remove the heat shield (A) mounting bolts from the body stiffener, and let the heat shield lay
,
against the exhaust.
I.
,,:J
'-....
"
,I;'
I,-Y
~-
,---
(cont'd)
17-51
EPS Components
Steering Gearbox Removal (cont'd)
12. Disconnect the EPS wire harness 6P connector (A), and remove the EPS wire harness (B) and mounting bracket (C). 14. Remove the engine wire harness clamps (A) from the three mounting brackets.
A
15. Remove the heater hose (B) from the bracket. 13. Remove the ground cable terminal (A) from the steering gearbox housing. 16. Open the heater valve cable clamp (A), and disconnect the heater valve cable (B). Remove the heater valve (C) from the bulkhead, and move it aside.
17-52
17. Remove the body stiffener (A).
19. Remove the steering stiffener B from the right side of the steering gearbox.
-----_r ---,,/
:~----\
---
18. Remove the steering stiffener A from the left side of the steering gearbox.
20. Lower the steering gearbox, and rotate it so the

pinion shaft points upward.
21. Remove the pinion shaft grommet (A) from the top of the torque sensor .
(cont'd)
17-53
EPS Components
Steering Gearbox Removal (cont'd)
22. Move the steering gearbox and tie-rod ends as an assembly to the wheelwell opening on the
passenger's side.
23. Carefully raise the driver's side (pinion sidel of the steering gearbox (AI and tie-rod (BI until clears the master cylinder and under-hood fuse relay box, then remove the steering gearbox. Be careful not to damage the hoses, lines and wire harnesses.
B
--------~
17-54
Steering G earbox Overhaul

Exploded View
MOTORCO~
'--.,a~J;;r\S2'L~ TORQUE SENSOR
RACK GUIDE
____________e
BOOT BAND
Replace.
DISC WASHER
, ____---SPRING .. @
i'_o
RACK GUIDE SCREW
.~
LOCKNUT
12 x 125 r7\Nk~.mmm 54Ibl.ft) ,
@"/iIlO~
BO~
STOP PLATE Replace.
Il
f
BRACKET
Replace.
@ J ' I>'."!) ~
(,,,, ,"?'>-
O-RINGS
Replace.
LOCK WASHER "IE-ROO 54 Nm 15.5 kglm, 40 Iblft) . . j:IE-ROD END
44Nm 145 kglm, 33 Iblft) .
@. /
~.
Iconl'd)
17-55
EPS Components
Steering Gearbox Overhaul (cont'd)
Locknut wrench 07ZAA-S5A0100

Pincers, Oetiker 1098 or equivalent, commercially
4. Remove the stop plate (AI, the 12 mm flange bolts (6)' the O-rings (CI, and the bracket (DI from the
steering gearbox.
available. NOTE: Refer to the Exploded View as needed during this procedure. Do not allow dust, dirt, or other foreign materials to
enter into the steering gearbox. Removal
1. Remove the steering gearbox (see page 17-511.

Disassembly
2. Unbend the lock washer (AI.
5. Loosen the locknut (AI, then remove the rack guide screw (61, spring (CI, disc washer (DI, and rack guide (EI from the steering gearbox.
3. Hold the bracket (AI with one wrench, and unscrew both tie-rod ends (61 with another wrench. Remove the lock washers.
17-56
6. Remove the two boot bands IAI from boot IBI. Compress the boot by hand, and apply vinyl tape ICI so the boot ends stay collapsed and pulled back.
8. Install the special toollAI on the lock screw IBI

securely, then loosen and remove the lock screw from the steering gearbox housing.
A 07ZAAS5A0100
7. Attach the yoke IAI of a universal puller to the steering gearbox mounts with bolts. Securely
clamp the yoke in a vise as shown. Do not clamp the steering gearbox housing in the vise.
9. Remove the special tool. 10. Pull on the rack housing IAI to remove it from the steering gearbox housing. Remove the boot IBI and slider guide ICI from the cylinder.
Icont'dl
17-57
EPS Components
11. Check the slider guide for damage and cracks.
Using vernier calipers to measure the thickness of
the slider guide. If the thickness is less than service limit, replace the slider guide.
15. Apply multipurpose grease to the indicated part (shaded part) ofthe outer surface of the rack housing. Do not apply to the dents and grooves.
\O.-_~_/_'_._; ,--==-------
((iD'i
\'>~/
25.3 mm 10.925 in.)
25.3 mrn 10.925 in.)
12. Remove and discard the stop ring (A) on the cylinder by expanding it with snap ring pliers. Remove and discard the lock screw (B).
13. Install the new lock screw on the rack housing. 14. Install the new stop ring in the groove (C) on the cylinder by expanding it with a snap ring pliers. Be
careful not to scratch or damage the housing
surface with the stop ring edges.
17-58
16. Set the new boot bands IAI on the band installation grooves of the boot IBI by aligning the tabs ICI with the holes 101 of the band. Do not close the ear of the boot band in this step.
19. Push the rack housing IAI into the steering gearbox housing IBI so the notch ICI is aligned with the pin 101 on the bottom of the gearbox housing inside.
17. Compress the boot by hand, and apply vinyl tape lEI to the bellows so the boot ends stay collapsed and pulled back.
Pass the boot over the rack housing so the smaller
20. Tighten the lock screw IAI by hand first, then install the special toollBI on the lock screw. Lightly tighten the lock screw. Do not tighten the lock
screw to the specified torque yet.
diameter end of the boot faces the steering gearbox housing. 18. Attach the yoke IAI of a universal puller to the gearbox housing mounts with bolts, then securely
clamp the yoke in a vise as shown. Do not clamp the steering gearbox housing in a vise.
21. Remove the special tool.
Icont'd)
17-59
EPS Components
22. Apply mUltipurpose grease to the sliding surface and circumference of the rack guide (A), and install it onto the gearbox housing. Wipe the grease off the threaded section of the housing. 25. Center the steering rack within its stroke, and align the slider guide (A) with the holes (8) in the boot (C). Fit the slider guide to the boot by pressing around the edges of the holes securely.
, \ \ ~([2~ . ~
I
Y~.'\-~__
//
~i.J"k';t.m,
(E).
t8lbl1t1
) 26. Before installing the bracket (D), clean the mating surface of the 12 mm flange bolts (E) and the bracket. Coat the new D-rings (F) with multipurpose grease, and install them on the 12 mm flange bolts. 27. Loosely install the bracket on the steering rack by tightening the 12 mm flange bolts to 25 Nm (2.5 kgfm, 18IbfIt). 28. Hold the gearbox housing using a yoke, then install the special tool on the lock screw (A). Retighten the
lock screw to the specified torque values.
07ZAA-S5A0100
23. Install the disc washer (8) with its convex side facing the rack guide. Install the spring (C). Apply sealant to the middle of the threads on the rack guide screw (D), then install and tighten it to 25 Nm (2.5 kgf.m, 18 Ibf.ft). Loosely install the locknut
24. Apply mulf'purpose grease to the sliding surface of the slider guide (A). Keep grease off of the rack-toslider guide mating surfaces and the boot-to-slider
guide mating surfaces.
Slide the steering rack all the way to lelt, and place the slider guide on the steering rack by aligning the bolt holes (B).
I;
,'.' ~'" .... /~

....
A 162 Nm f16.5 kgfm.119Ibfft)
29. Remove the special tool.
17-60
30. Retighten the 12 mm flange bolts IA) to the

specified torque value. A
74 Nm (7.5 kgfm, 54Ibfft) ____~-- B -::/-/-=--~~--"",__~~~==~ __
/
/
---/
34. Close the ear portion IA) of the bands IB) with
commercially available pincers, Oetlker 1098 or
equivalent IC).
j"",-""-,,,-0-" / .,J
-----{
--
<:------/.,
------/
/.
I
"
c
31. After tightening the 12 mm flange bolts, install a new stop plate IB) over one of the bolt heads. Be sure the tabs IC) of the stop plate are aligned with the flat surfaces of the bolt head.
1.8mm (0.07 in.)
32. Clean off any grease or contamination from the boot installation grooves on the housing.
33. Expand the boot IA) by removing the vinyl tape, and fit the boot ends IB) in the installation grooves on the cylinder housing.
35. Install the new lock washer IA) with its radiused side faCing IB) the tie-rod IC), and screw the tie-rod on the bracket (0). Repeat this step for the other side of the tie-rod. Hold the bracket with one wrench, and tighten the tie-rods to the specified torque with another wrench.
C 54 Nm (5.5 kgfm, 40 Ibfft)
Iconl'd)
17-61
EPS Components
36. Bend the lock washer against the flat spots on the bracket with a large pair of pliers.
37. Adjust the rack guide screw (see page 17-131.
17-62
Steering Gearbox Installation

1. Before installing the steering gearbox, slide the rack all the way to the passenger's side (right direction). 2. Pass the right side of the steering gearbox together with the tie-rods through the wheelwell opening on the passenger's side. Continue moving the steering gearbox toward the passenger's side until the driver's side tie-rod end and gearbox clears the master cylinder and under-hood fuse relay box. Lower the steering gearbox, and move it toward the driver's side until the steering gearbox is in position. 4. Insert the pinion shaft up through the bulkhead, then slip the right side of the steering gearbox housing (A) over the mounting stud (e) on the gearbox mounting bracket.
INOTICEI
Be careful not to damage the hoses, lines and wire harnesses.
5. Install the steering stiffener B, and lightly tighten

the steering gearbox mounting nuts.
3. Install the pinion shaft grommet (A) .
6. Install the steering stiffener A with the gearbox mounting bolts. Then tighten all the steering
gearbox mounting hardware to the specified torque.
(conl'd)
17-63
EPS Components
Steering Gearbox Installation (cont'd)
7. Install the body stiffener (A), and torque the mounting bolts to the specified torque.
9. Reinstall the heater hose (A) on the hose bracket.

B
10. Install the engine wire harness clamps (8) to the three harness brackets.
8. Install the heater valve (A) on the bulkhead, and

connect the heater valve cable end (B) to the heater valve arm (e). Readjust the heater valve cable (see page 21-46).
11. Under the steering gearbox, install the ground cable terminallA) on the steering gearbox housing.
9.8Nm 11.0 kgfm.
7.2Ibfftl
17-64
12. Install the EPS wire harness bracket (A) on the gearbox housing, and connect the 6P connector (B) properly.
14. Center the steering rack within its stroke. 15. Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod ends (A) to the damper steering arms. Install the ball joint nut (B) and tighten them.
A
"
---j
'/',
---~ ~ /-~--'
~---=-,,=-
-------~:... ----~:..-
13. Install the heat shield (A) .
10 x 1.25 mm 43Nm 14.4 kgl.m, 32Ibllt}
c
16. Install the new cotter pins (C), and bend them as
shown.
(conl'd)
17-65
EPS Components
Steering Gearbox Installation (cont'd)
17. Install the motor on the steering gearbox (see page 17-49). 18. Install the steering joint (A), and reconnectthe steering shaft (B) and pinion shaft (C). Make sure
the steering joint is connected as follows:
o
22. After installation, perform the following checks.

o
Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (0) with the flat portion (E) on the shaft). Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower jOint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt, and tighten it to the specified torque. Tighten the lower joint bolt to the specified torque.
Perform the front toe inspection. Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rods, if necessary.
8x1.25mm 28Nm 12.9 kgfm, 21lbfftl
19. Install the driver's dashboard lower cover (see page 20-59) and under cover (see page 20-60). 20. If the steering wheel was turned, center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two and half
turns) until the arrow mark on the label points
straight up. Reinstall the steering wheel (see page 17-8). 21. Install the front wheels.
17-66
EPS Control Unit Removal! Installation

1. Remove the passenger's under panel.
Tie-rod Ball Joint Boot Replacement

Attachment, 42 mm 070AD-POA0100 1. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin.
2. Turn up the floor carpet, remove the EPS control

unit.
2. Pack the lower area of the ball pin (A) with fresh
multipurpose grease.
..
3. Disconnect the EPS control unit connectors.
=--\./t==t-..
A
----,
-~.'
ri ~B
..... 0
4. Install the EPS control unit in the reverse order of

removal.
3. Pack the interior of the new boot (B) and lip (C) with
fresh multipurpose grease.

Note these items when installing new grease:
5. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-Iock several times. Check that the EPS indicator does not come on.
Keep grease off the boot installation section (D) and the tapered section (E) of the ball pin. Do not allow dust, dirt, or other foreign materials to enter the boot. 4. Install the new boot (A) using the special tool. The boot must not have a gap at the boot installation sections (B). After installing the boot, check the ball
pin tapered section for grease contamination, and wipe it if necessary.
07QA~
17-67
Suspension
Front and Rear Suspension
Special Tools ................................................................. Component Location Index ......................................... Wheel Alignment .......................................................... Wheel Bearing End Play Inspection ............................ Wheel Runout Inspection ............................................ Ball Joint Removal ....................................................... 18-2 18-3 18-4 18-8 18-9 18-10
Front Suspension
Knuckle/HubIWheel Bearing Replacement ................ Ball Joint Boot Replacement ....................................... Stabilizer Bar Replacement ......................................... Stabilizer Link Removal/Installation ........................... Lower Arm Removal/Installation ............................... Damper/Spring Replacement ......................................
18-11 18-16 18-17 18-18 18-19 18-20
Rear Suspension
Hub Bearing Unit Replacement ................................... Knuckle Replacement ................................................... Stabilizer Bar Replacement ......................................... Stabilizer Link Removal/Installation .......................... Upper Arm Removal/Installation ............................... Trailing Arm Removal/Installation ............................. Damper/Spring Replacement ...................................... 18-26 18-28 18-30 18-31 18-32 18-33 18-34
\1

Special Tools
Ref.No.
CD
CD
G)
Tool Number 07GAF-SE00100 07MAC-SL00200 077 46-0010500 07749-0010000 07965-SA50500 07965SD90100
Description Hub Dis/Assembly Tool Ball Joint Remover, 28 mm Attachment, 62 x 68 mm Driver Front Hub Dis/Assembly Tool Support Base
Qty
1 1 1 1 1 1
~
CD
CD
',-_/
r-~
'~
~-~
~
~)
G)
18-2

Front Suspension:
STABILIZER BAR Replacement, page 18-17 STABILIZER LINK Removal/Installation, page 18-18 / ' I(NlJ""'Lc.fHUIS/1NHccL BEARING Replacement, page 1 1 8all Joint Boot Replacement, page 18-16
LOWER ARM Removal/Installation, page 18-19
Rear Suspension:
STABILIZER BAR Replacement, page 18-30 UPPER ARM
Removal!1 nsta Itatian, page 18-32
DAMPER/SPRING Replacement, page 18-34
STABILIZER LINK
Remova 1/1 nstallation, page 18-31
HUB BEARING UNIT Replacement, page 18-26 KNUCKLE Replacement, page 18-28
TRAILING ARM Removal/Installation, page 18-33
18-3

Wheel Alignment
The suspension can be adjusted for front camber, front
Front Caster Inspection

Use commercially available computerized four wheel
alignment equipment to measure wheel alignment
toe, and rear toe. However, each of these adjustments

are interrelated to each other. For example, when you
adjust the toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust the camber or toe.
(caster, camber, toe, and turning angle). Follow the

equipment manufacturer's instructions.
Pre-Alignment Checks
For proper inspection and adjustment of the wheel
Check the caster angle. If the caster angle is not within the specification, check for bent or damaged
suspension components.
alignment, do these checks:

Front caster angle:
1. Release the parking brake to avoid an incorrect measurement.
140' 1
2. Make sure the suspension is not modified.
3. Check the tire size and tire pressure.

Tire size:
Front/rear: 195/60R15
Tire pressure:
Front:
Rear:
230 kPa (2.3 kgf/ern', 33 psi) 210 kPa (2.1 kgf/ern', 30 psi)
4. Check the runout of the wheels and tires. 5. Check the suspension ball joints. (Hold a wheel with your hands, and move it up and down and right and left to check for wobbling).
6. Bounce the vehicle up and down several times to stabilize the suspension.
18-4
Front Camber Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment Icaster, camber, toe, and turning anglel. Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, adjust the camber.
Front camber angle: -0'30'
Front Camber Adjustment

The front camber can be adjusted by exchanging one or
both of the damper pinch bolts with the smaller diameter adjusting boltlsl. The difference between the adjusting bolt diameter and the pinch bolt hole
diameter allows a small range of adjustment.
45'
Damper Pinch Bolt:
Adjusting Bolt:
PIN 90188-S5A000
1. Raise the front of the vehicle, and support it with safety stands in the proper location Isee page 1-81.
Remove the front wheels.
2. Loosen the damper pinch nuts and bolts IAI, and

adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play.
-+
116.0 kglm, 116 Iblltl
16x1.5mm 157 Nm
3. Tighten the bolts to the specified torque. 4. Reinstall the front wheels. Lower the front of the
vehicle to the ground, and bounce the vehicle several times to stabilize the suspension.
5. Check the camber angle. If it is within the specification, check the front toe. If it is not within the specification, go to step 6.
(cont'dl
18-5

Wheel Alignment (cont'd)
6. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8). Remove the front wheels.
Rear Camber Inspection

Use commercially-available computerized four wheel
7. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle.
NOTE: The camber angle can be adjusted up to 15' (center of tolerance) by replacing one damper pinch bolt with the adjusting bolt. The camber angle can be adjusted up to 30' by replacing both upper and lower damper pinch bolts with the adjusting bolts.
alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the
Check the camber angle. If the camber angle is not within the specification, check for bent or damaged
suspension components.
Rear camber angle:
-0"55'
45'
INOTICEI
.~\ 1--. \~~",-~~A .

157 Nm 116.0 kgfm, 1161bfftl
16x1.5mm
Do not loosen the special bolts on the trailing arm.
8. Tighten the bolts to the specified torque. 9. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle
several times to stabilize the suspension.
10. Check the camber angle. If it is within the

specification, check the front toe, and adjust it if necessary. If it is not within the specification,
readjust, and recheck. If the camber angle cannot be adjusted to the specification, check for bent or
damaged suspension components.
18-6
Front Toe Inspection! Adjustment

Use commercially-available computerized four wheel alignment equipment to measure wheel alignment
Rear Toe Inspection! Adjustment

Use commercially-available computerized four wheel
(caster, camber, toe, and turning angle). Follow the

alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the
1. Center the steering wheel spokes.

2. Check the toe. If it is not within the specification, go to step 3. Fronttoe-in: 0
1. Release the parking brake.
2. Check the toe. If it is not within the specification, go to step 3.

Rear toe-in (inspection): 1 3 mm 10.04 0.12 in.)
3 mm (0
0.12 in_)
3. Loosen the locknut (A) while holding the tie-rod end

(8).
A 14x 1.5 mm
3. Loosen the self-locking nut (A) while holding the adjusting bolt (8).
44Nm
INOTICEI
Do not loosen the special bolts (C) on the lower arm to adjust the alignment.
14.5 kgfm, 33 Ibfftl
4. Turn the tie-rod (C) until the toe is correct.
5. After adjusting, tighten the locknut while holding the tie-rod end. Make sure the toe setting does not change.
59Nm
A 12 x 1.25 mm
16.0 kgfm, 43lbfftl
4. Replace the self-locking nut with a new one, and lightly tighten. NOTE: Always use a new self-locking nut whenever it has been loosened. 5. Turn the adjusting bolt until the toe is correct.
Rear toe-in ladjustment): 2 2 1 mm (0.08 0.08 D.O( in.)
6. Tighten the self-locking nut to the specified torque while holding the adjusting bolt.
Icont'd)
18-7

Wheel Alignment (cont'd)
Turning Angle Inspection
Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the
Wheel Bearing End Play Inspection

1. Raise the vehicle, and support it with safety stands in the proper location (see page 1-81. Remove the wheels.
2. Install suitable flat washers (A) and wheel nuts, and
tighten the nuts to the specified torque to hold the brake disc securely against the hub. Front:
1. Turn the steering wheel fully to the right and left while applying the brake, and check the turning angles of both front wheels. If the turning angle is
not within the specification or the inward turning
angles differ between the right and left side, go to step 2. Turning angle: Inward: 3400' 2 Outward: 2800' (reference)
~~"!-t:-"L""''-----108 Nm 111.0 kgfm, 80lbfftl
Rear:
2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components.
3. Set up the dial gauge against the hub flange as

shown, and measure the bearing end play moving
the brake disc inward and outward. Bearing end play: Standard: Front/rear: 0-0.05 mm (0-0.002 in.) 4. If the bearing end play is more than the standard, replace the wheel bearing.
18-8
Wheel Runout Inspection

1. Raise the vehicle, and support it with safety stands in the proper location (see page 1-8).
4. Reset the dial gauge to the position shown, and
measure the radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0-0.7 mm (0-0.03 in.) Service limit: 1.5 mm (0.06 in.)
2. Check for a bent or deformed wheel.

3. Set up the dial gauge as shown, and measure the
axial runout by turning the wheel.
Front and rear wheel axial runout: Standard: Aluminum wheel: 0-0.7 mm (0-0.03 in.) Service limit: 2.0 mm (0.08 in.)
5. If the wheel runout is not within the specification, check the wheel bearing end play (see page 18-8), and make sure the mating surfaces on the brake disc and the inside of the wheel are clean. 6. If the bearing end play is within the specification
but the wheel runout is more than the service limit,
replace the wheel.
,
18-9

Ball Joint Removal
Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200
3. Loosen the pressure bolt (A), and install the special tool as shown. Insert the jaws carefully, making sure not to damage the ball joint boot. Adjust the jaw spacing by turning the adjusting bolt (B).
10mm HEX NUT
INOTICEI
Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it. 1. Install a hex nut (A) onto the threads of the ball joint (B). Make sure the nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint pin.
07MAC-SL00200
4. After adjusting the adjusting bolt, make sure the head (C) of the adjusting bolt is in the position shown to allow the jaw to pivot. 5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the steering arm or knuckle. If necessary, apply penetrating type lubricant to loosen the ball joint pin.
NOTE: Do not use pneumatic or electric tools on the pressure bolt.
t
B
2. Apply grease to the special tool on the areas shown (A). This will ease installation of the tool and prevent damage to the pressure bolt (B) threads.
6. Remove the tool, then remove the nut from the end of the ball joint pin, and pull the ball joint out of the steering arm or knuckle. Inspectthe ball joint boot, and replace it if damaged.
18-10
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement
Exploded View
5 mm SCREWS Replace. /
'0
FLAT SCREWS 6x 1.0 mm 9.8N.m 11.0 kglm, 7.2Iblft)
KNUCKLE Check for deformation and damage.
SPLASH GUARD ; / Check for corrosion, deformation, and damage. Replace if rusted. HUB Check for deformation, damage, and cracks.
/~
SPINDLE NUT 22x 1,5 mm 181 Nm 118.5 kglm. 134Iblft) Replace.
BRAKE DISC
Appya small amount of engine oil to the seating surface.
-,
Icont'd)
18-11
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement (cont'd)
5. Raise the stake (A), and remove the spindle nut (B).
Hub dis/assembly tool 07GAF-SE00100 Ball joint remover, 28 mm 07MAC-SL00200 Attachment 62 x 68 mm 07746-0010500 Driver 07749-0010000 Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8). 2. Remove the wheel cap, wheel nuts, and front wheel.
______ ---- ---
--/
I
108Nm 111.0 kgfm, 80Iblft)
6. Remove the brake disc retaining flat screws (A).
3. Remove the brake hose bracket mounting bolt (A).
A
--------
6x 1.0mm
'v" . ,-~ '-------." \\ ':ci--' J'! '.

. i
"VA
..
8 x 1.25 mm
22 N.m
9.8Nm 11.0 kglm. 7.2Iblftl
;/'
12.2 kglm, 261blftl
B 12 x 1.25 mm
108Nm 111.0 kglm, 801blftl
7. Screw two 8 x 1.25 mm bolts (8) into the disc to push it away from the hub. Turn each bolt two turns
at a time to prevent cocking the disc excessively,
4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the
caliper assembly from the undercarriage. Do not
twist the brake hose with force.
18-12
8. Remove the flange bolt (AI and wheel sensor (81

from the knuckle. Do not disconnect the wheel sensor connector.
10. Remove the lock pin (AI from the lower arm ball joint, and remove the castle nut (81. NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown.
, /~
".
. "/
6x 1.0 mm 9.8Nm
7.2Iblft) 11.. . 0 kglm,
A
07MACSL00200
4q,
9. Remove the flange nut (AI while holding the joint pin 181 with a hex wrench (CI, and disconnect the stabilizer link (DI from the lower arm (EI.
SJ----- B
12 x 1.25 mm 59-69Nm 16.0-7.0 kgl.m,
43 -51Iblft)
11. Disconnect the lower arm from the knuckle using
the special tool (see page 18101. 12. Loosen the damper pinch bolts (AI while holding the nuts (81, and remove the bolts and nuts.
----~------------ -----,/
D
E
A
10 x 1.25 mm 39 Nm 14.0 kgfm, 29lblft)
16xl.5mm
C
13. Remove the driveshaft outboard joint (CI from the knuckle (D) by tapping the driveshaft end (E) with a
plastic hammer while drawing the knuckle outward, then remove the knuckle.
NOTE: Do not pull the driveshaft end outward. The

driveshaft joint may come off.
Iconl'd)
18-13
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement (cont'd)
14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful notto deform the splash guard. Hold onto the hub to keep it from falling when pressed clear.
07GAF-SE00100
16. Remove the snap ring (A) and the splash guard (B) from the knuckle (C).
. .~.."" J .
Press
b~>
17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press.
Press
15. Press the wheel bearing inner race (A) off olthe hub (B) using the spetial tool, a commercially available bearing separator (C), and a press.
07GAF-SE00100 07749-0010000
~Pis
---B
18-14
18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal.
22. Press a new hub bearing unit (A) onto the hub (B)
using the special tools and a press.
METAL COLOR
23. Install the knuckle/hub/hub bearing unit in the
LL----"J~07965-SD90100
20. Install the snap ring (A) securely in the knuckle (B).
reverse order of removal, and note these items:
Be careful not to damage the ball joint boot when installing the knuckle . Tighten all mounting hardware to the specified
torque values. Torque the castle nut to the lower torque
specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Install a new look pin on the castle nut after
torquing. Use a new spindle nut on reassembly.
Before installing the spindle nut, apply a small

amount of engine oil to the seating surface of the
D 6 Nm 10.6 kgfm. 4lbfftl
21. Install the splash guard (C), and tighten the screws (D) to the specified torque.
nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. Before installing the wheel, clean the mating
surface of the brake disc and the inside ofthe
wheel. Check the front wheel alignment, and adjust it if necessary (see page 18-4) .
18-15
Front Suspension
Ball Joint Boot Replacement
Special Tools Required Front hub dis/assembly tool 07965-SA50500
1. Remove the boot. 2. Pack the interior and lip (A) of a new boot with fresh grease. Keep the grease off of the boot-to-knuckle mating surfaces (8).
A
4. Install the boot onto the ball joint pin, then squeeze it gently to force out any air. Do not let dirt or other foreign materials get into the boot. 5. Press the boot with the special tool until the bottom seats on the knuckle (A) evenly around.
Press
0796S-SASOSOO
--------- /
B
cil:::=~ : , ...:
6. After installing a boot, wipe any grease off the exposed portion of the ball jOint pin.
3. Wipe the grease off the tapered section of the pin (e), and pack fresh grease onto the base (D).
18-16
Stabilizer Bar Replacement

1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8).
4. Install the stabilizer bar in the reverse order of

removal, and note these items:
2. Remove the self-locking nuts (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer links (0) from the stabilizer bar (E) on the right and left.
Use new self-locking nuts on reassembly. Note the right and left direction of the stabilizer bar. Align the ends of the paint marks (A) on the stabilizer bar with each end of the bushings (B). Note the fore/aft direction of the bushing holders. Refer to Stabilizer Link Replacement to connect the stabilizer bar to the links (see page 18-18).
FORWARD
~--.--
/
B
A
39N.m (4.0 kgfm, 291bf.ltl
c
B
10 x 1.25 mm
3. Remove the flange bolts (A) and bushing holders (B), then remove the bushings IC) and the stabilizer bar (0).
A
10 x 1.25 mm 39Nm (4.0 kgfm. 29lbfftl
18-17
Front Suspension
Stabilizer Link Removal/Installation
I. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8). Remove the front wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (e) with a hex wrench (DI, and remove the stabilizer link (E).
E
4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly. 5. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight.
INOTICE I
Do not place the jack against the lower arm ball joint. 6. Tighten the self-locking nut (A) and flange nut (B) to the specified torque values while holding the respective joint pins (e) with a hex wrench (D).
A
10 x 1.25 mm
38Nm (3.9 kgfm. 28 Ibfltl
-:.-
'--
-- -
/ , "~-{
3. I nstall the stabilizer link (A) on the stabilizer bar (B) and lower arm (e) with the joint pins (D) set at the
center of their range of movement.
B 10 x 1.25 mm 39Nm 14.0 kgfm. 291bf1t1
c
7. After 5 minutes of driving, re-tighten the selflocking nut again to the specified torque.
18-18
Lower Arm Removal/Installation

1. Raise the front of the vehicle, and support it with safety stands in the proper location Isee page 1-8). Remove the front wheels.
2. Remove the flange nut IA) while holding the joint pin IB) with a hex wrench IC), and disconnect the stabilizer link ID) from the lower arm IE). 5. Remove the flange bolts IA), and remove the lower arm IB).
/~~T----1'--c---ID
6. Install the lower arm in the reverse order of removal, and note these items:
Be careful not to damage the ball joint boot when connecting the lower arm to the knuckle. Tighten all mounting hardware to the specified
10 x 1.25 mrn 39Nm (4.0 kgf.m, 29 Ibftt)
torque values.
3. Remove the lock pin IA) from the lower arm ball joint. and remove the castle nut IB).
NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be
in the range shown.
First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening it to the specified torques. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Install a new lock pin on the castle nut after torquing. Before installing the wheel. clean the mating
surface of the brake disc and the inside ofthe
wheel. Check the wheel alignment, and adjust it if necessary Isee page 18-4).
'ii~
c
07MAC-SL00200
--'-I-""-~
~2 x 1.25 mm 59-69Nm (6.0-7.0 kgf.m.

43-51Ibfft)
4. Disconnect the lower arm from the knuckle using
the special tool Isee page 18-10).
18-19
Front Suspension
Damper/Spring Replacement
Exploded View
SELF-LOCKING NUT
12 x 1.25 mm
44 Nm 14.5 kgfm, 33Ibfft)
DAMPER MOUNTING
BEARING~-=-"~-""
~;~_ ~UPPERSPRINGSEAT C~) )

\_
~
/ ""
Replace.
DAMPER MOUNTING BASE
....-------- Check for deformation.
m~/ ------ -------
Check for smooth operation.
~~
---_.
~
UPPER SPRING MOUNTING CUSHION
Check for deterioration and damage.
BUMP STOP
...-------- Check for weakness and damage.
DAMPER SPRING
Check for free length.
DAMPER UNIT Check for oil leaks,

gas leaks. and smooth operation.
18-20
5. Remove the damper pinch bolts (AI while holding the nuts (BI.
Removal
1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-81. Remove the front wheels. 2. Remove the cotter pin (AI from the tie-rod end ball joint, and remove the nut (BI.
---==-----
T
6. Remove the flange nuts (AI from the top of the damper.
07MACSl002000
3. Disconnectthe tie-rod end from the steering arm on the damper using the special tool (see page 18101.
4. Remove the bolts, and remove the wheel senSOr harness bracket (AI and brake hose bracket (BI from the damper. Do not disconnect the wheel sensor connector.
A
7. Lower the lower arm, and remove the damper assembly (BI .
(cont'dl
18-21
Front Suspension
Damper/Spring Replacement (cont'd)
Disassembly!lnspection
1. Compress the damper spring with a commercially
3. Reassemble all the parts, except for the upper spring seat and spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.
available strut spring compressor (A) according to

the manufacturer's instructions, then remove the
self-locking nut (8) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut.
B
2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.
5. Check for oil leaks, abnormal noises, and binding during these tests.
18-22
Reassembly
NOTE: Refer to the Exploded View as needed. 1. Install the upper spring mounting cushion (A) on the upper spring seat (8) by aligning the tab portion (C) on the cushion with the cutout (0) in the seat.
4. Install the upper spring seat and the spring on a commercially available strut spring compressor (A), and compress the spring lightly.
5. Insert the damper unit (8) up through the
compressed spring.
o
2. Install the spring (E) in the groove of the cushion
6. Align the bottom of the spring (C) and the stepped part (0) of the lower spring seat.
securely.
3. Install the damper mounting bearing and damper

mounting base on the upper spring seat.
7. Check that the cutout (A) in the side of the upper spring seat (8) is in position shown. If the cutout is out of position, remove all of the components from the spring compressor. Go to step 2, and reassemble the spring and upper spring seat accordingly.
Left side:
Front
(cont'd)
18-23
Front Suspension
Right side:
Installation
1. Lower the lower arm, and position the damper
assembly in the body. Turn the damper mounting base so the" 6L" or "6R" mark (AI faces toward the outside of the vehicle.
8. Hold the bottom of the damper with your hand, and

compress the spring. Do not compress the spring excessively.
9. Install the 12 mm nut (AI on the damper shaft (81. Hold the damper shaft with a hex wrench (el, and tighten the 12 mm nut to the specified torque. 2. Loosely install the flange nuts (AI onto the top of the damper.
A
12 x 1.25 rnm
44Nm 14.5 kgfm, 33Ibfft)
10. Remove the damper assembly from the strut spring

compressor.
18-24
3. Position the damper on the knuckle, and install the new damper pinch bolts (A) and nuts (B), and lightly tighten the nuts.
~~.t" ~;> .. ""0

~
~ ..'.~\\~:2'~
'i' . ~ {/;:.,,~ ..... ~,,-~\

A
8. Connect the tie-rod end to the steering arm, and tighten the nut (A) to the specified torque. Install the cotter pin (B) after tightening, and bend its end as shown.
:L _________ ,''/
i!
~.
16x 1.5 mm 157 Nm (16.0 k g f m . ' 116Ibftt)
A
10 x 1.25 mm
4. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight.
43Nm (4.4 kgfm, 32lbfttl B
iNOTICEi
Do not place the jack against the lower arm ball joint. 5. Tighten the flange nuts on the top of the damper to
the specified torque.
9. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels . 10. Check the wheel alignment, and adjust it if necessary (see page 18-4).
6. Tighten the damper pinch nuts to the specified torque. 7. Install the brake hose bracket (A) and the wheel sensor harness bracket (B) onto the damper, and tighten the bolt to the specified torque.
9.8Nm (1.0 kgfm. 7.2Ibftt) 22Nm (2.2 kgfm, 161bfttl
'v.i/~.:Y -,,~C~
'II
"f"y'
',. ,
18-25
Rear Suspension
Hub Bearing Unit Replacement
Exploded View
9,8 N,m (1,0 kgf,m, 71 (bf Itl
6xl.0mm
j
KNUCKLE Check for deformation. HUB BEARING UN(T Check for faulty movement and wear.
BRAKEDISC Check for wear and damage.
6x 1.0mm 9,8N,m (1,0 kgf,m, 7lbf,ltl

HUBCAP Replace. SPINDLE NUT 22)( 1.5 mm 181 N,m (18,5 kgf,m, 1341bf,ltl Replace. Appya small amount of engine oil to the seating surface.
18-26
1. Raise the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8).
2. Remove the wheel cap, wheel nuts, and rear wheel.
4. Release the parking brake lever.

5. Remove the brake hose mounting bolt IA).
B 10 x 1.25 mm
~reQ
"""iz,--r;,
A 8x1.25mm 22Nm
3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut Ie).
12.2 kgfm, 16 Ibfft)
6. Remove the caliper bracket mounting bolts IB), and hang the caliper Ie) to one side. To prevent damage to the caliper or brake hose, use a short piece of
wire to hang the caliper from the undercarriage.
7. Remove the brake disc retaining screws (A).
i" "/~
.
8)
(j
\ @/(j ~2
\
-~
---------
x 1.5 m: 181 Nm 118.5 kgfm, 1341bfftl
I
B
A 6x 1.0mm 9.8N.m
11.0 kgfm, 7.2Ibfft)
8. Screw two 8 x 1.25 mm bolts IB) into the disc Ie) to push it away from the hub. Turn each bolt two turns
at a time to prevent cocking the disc excessively. Remove the brake disc.
Iconl'd)
18-27
Rear Suspension
Hub Bearing Unit Replacement (cont'd)
9. Remove the hub bearing unit (A) from the spindle.
Knuckle Replacement
1.
Rai~e the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8).
Remove the rear wheels.
2. Remove the brake disc and hub bearing unit (see

step 1 on page 18-27).
3. Remove the flange bolts (A) and splash guard (B)

from the knuckle.
10. Install the hub bearing unit in the reverse order of

....'111>
""
Tighten all mounting hardware to the specified

torque values.
Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. Use a new spindle nut on reassembly. After tightening, use a drift to stake the spindle nut shoulder against the spindle. Use a new hub cap on reassembly. Before installing the wheel. clean the mating surface of the brake disc and the inside of the wheel.
4. Remove the wheel sensor (Ai. brake hose

mounting bracket (B), and parking cable mounting bracket (e) from the knuckle. Do not disconnect the
wheel sensor connector.
B
8x 1.25mm
22Nm 12.2 kgf.m, 161bf1t1
6x 1.0mm
9.8Nm (1.0 kgfm, 7.2 IbfItJ
18-28
5. Place the floor jack under the trailing arm (A), to support it.
9. Install the knuckle in the reverse order of removal. and note these items:
First install all the suspension components, and
INOTICE I
Do not place the jack against the plate section of the lower arm. Be careful not to
damage any suspension components.
lightly tighten the bolts and nuts, then place a

floor jack under the lower arm, and raise the
suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the
specified torque values.
Align the cam positions of the adjusting bolt (A) and adjusting cam (B) with the marked positions when tightening.
Use a new self-locking nut on reassembly.
Tighten all the mounting hardware to the

Use a new spindle nut on reassembly. Before installing the spindle nut, apply a small
amount of engine oil to the seating surface of the
nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc.
Use a new hub cap on reassembly.
6. Remove the flange bolt (BI, and disconnect the upper arm (CI from the knuckle.
7. Mark the cam positions of the adjusting bolt (AI and adjusting cam (B), the remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut.
Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the wheel alignment, and adjust it if necessary (see page 18-4).
D 12 x 1.25 mm 59 Nm (6.0 kgfm, 43 IbfttJ
12 x 1.25 mm
59 Nm 16.0 kgfm,
43 Iblltl
8. Remove the flange bolt (D), and remove the knuckle (EI.
18-29
Rear Suspension
Stabilizer Bar Replacement
Use new self-locking nuts on reassembly.
4. Ins!all the stabilizer bar in the reverse order of

2. Remove the self-locking nuts (A) while holding the joint pins (8) with a hex wrench (C), and disconnect the stabilizer links (D) from the stabilizer bar (E) on the right and left.
Make sure the right and left ends of the stabilizer

bar are installed on their respective sides ofthe
vehicle. Align the ends of the paint marks (A) on the stabilizer bar with the bushings (8). Refer to Stabilizer Link Replacement to connect the stabilizer barto the links (see page 18-31).
3. Remove the flange bolts (A) and bushing holders (8), then remove the bushings (C) and the stabilizer bar (D).
A 8x 1.25 mm
22Nm 12.2 kgf.m, 16lbfftl
-----------.~
....
18-30
Stabilizer Link Removal/Installation

4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly.
2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (e) with a hex wrench (0), and remove the stabilizer link (E).
5. Place a jack under the trailing arm at the knuckle side end, and raise the suspension to load it with the vehicle's weight.
6. Tighten the self-locking nut (A) and flange nut (B) to
the specified torque values while holding the respective joint pins (e) with a hex wrench (0).
--~
3. Install the stabilizer link (A) on the stabilizer bar (B) and trailing arm (e) with the joint pins (0) set at the
B
10 x 1.25 mm 39Nm 14.0 kg/m, 29Ib/ft)
center of each moving range.
7. After 5 minutes of driving, re-tighten the selflocking nut again to the specified torque.
18-31
Rear Suspension
Upper Arm Removal/Installation
1, Raise the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8),
Remove the rear wheels. 2. Place a floor jack under the trailing arm, and support the suspension.
5, Install the upper arm in the reverse order of

3, Remove the flange bolt (A) and wheel sensor harness bracket (B),
~---
First install all the suspension components and lightly tighten the bolts and nuts, then place a jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the specified torque values, Tighten all the mounting hardware to the
'- --.:::_ -;7--';=-=.o:f___ ,

--,---
. . . ~,
Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the wheel alignment, and adjust it if necessary (see page 18-4),
-.'
I
/
,"-
A 8x1.2Smm 22 N,m (2,2 kgf,m, 16lbf,ftl
4, Remove the flange bolts (A), and remove the upper arm (B),
l "
I
t)j
--'
/,~.,//
~
59 N,m (6,0 kgf,m, 43lbf,ftl B
A 12 x 1.25 mm
12 x 1.25 mm 59 N,m 16,0 kgf'm, 43lbf,ftl
18-32
Trailing Arm Removal/Installation

1, Raise the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8),
7, Remove the trailing arm rear mounting bolt (A),
INOTICEI
Do not loosen the special bolts (B) on the
trailing arm.
2, Remove the knuckle (see page 18-28),

3, Place the floor jack under the trailing arm (A) to
support it.
c
B 10 x 1.25 mm 38N,m 13,9 kgf,m, 281bf,1t1
12 x 1.25 mm
61 N,m 16,2 kgf,m,

451bf,1t1
8, Lower the jack, and remove the trailing arm,

9, Install the trailing arm in the reverse order of removal, and note these items:
4, Remove the flange nut (B), and disconnect the stabilizer link (C) from the trailing arm,
5, Remove the flange bolt (D), and disconnect the
damper (E) from the trailing arm,

6, Remove the trailing arm front mounting bolts (A),
First install all the suspension components and lightly tighten the bolts and nuts, then place a jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the specified torque values, Tighten all the mounting hardware to the
~__ A
~A
12 x 1.25 rnm
Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the wheel alignment, and adjust it if necessary (see page 18-4),
108 N,m 111,0 kgf,m, 80 Ibf,ltl
18-33
Rear Suspension
Damper/Spring Replacement
Exploded View
-------------- ..~==
________ RUBBER BUSHING Check for weakness.
, - - - - - - - - - - - - - - SElF-LOCKING NUT
~RePlaCe.
~g ~";~3~~gf.m, 22lbfftl
DAMPER MOUNTING COLLAR
\i;~~
:'=cc'
DAMPER MOUNTING BASE
RUBBER BUSHING Check for weakness.
SPRING MOUNTING CUSHION Check for deterioration and damage.
/<1
:
~~
~
BUMP STOP PLATE
BUMP STOP Check for weakness
and damage.
DAMPER SPRING Check for weakened compression and damage.
DAMPER UNIT Check for oil leaks, gas leaks, and smooth
operation.
18-34
Removal
1. Raise the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8). Remove the rear wheels.
5. Remove the damper assembly from the body.
2. Remove the flange bolt (A) from the bottom of the

damper.
3. Remove the rear bulkhead cover (see page 20-51). 4. Remove the flange nuts (A) from the top of the
damper in the trunk.
(cont'd)
18-35
Rear Suspension
Disassembly Iinspection
1. Compress the damper spring with a commercially
Reassembly
1. Install all the parts except the self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat IS), and align the damper mounting base as shown,
available strut compressor IA) according to the manufacturer's instructions, then remove the selflocking nut IS) while holding the damper shaft IC) with a hex wrench ID). Do not compress the spring more than necessary to remove the nut.
_________ c
LEFT
RIGHT
21 "3
r~~ _ "f~,OI21 3
2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.
2. Install the damper assembly on a commercially available strut spring compressor IC). 3. Compress the damper spring with the spring
compressor.
4. Install the new self-locking nut IA) on the damper shaft.
c
B
A
10 x 1.25
mm
29Nm
13.0 kgfm, 22 Ibfftl
5. Hold the damper shaft IS) with a hex wrench IC)' and tighten the self-locking nut to the specified
torque.
5. Check for oil leaks, abnormal noises, or binding

during these tests.
18-36
Installation
1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole dot on it is toward the front and inside olthe vehicle.
INSIDE FORWARD
3. Loosely install the flange bolt (A) on the bottom of the damper.
. f __ .
A~~
12x 1.25 mm
61 Nm (6.2 kg/m, 45 (b/ftl
4. Raise the suspension with a floor jack to load the vehicle weight, and tighten the nuts and bolt to the
2. Loosely install the flange nuts (A) onto the top of the damper.
5. Clean the mating surface of the brake disc and the inside of the wheel, then install the rear wheel. 6. Check the wheel alignment, and adjust it if necessary (see page 18-4) .
18-37
Brakes
Conventional Brake Components
Special Tools ................................................................. Component Location Index ......................................... Brake System Inspection and Tests ............................................................................. Brake Pedal and Brake Pedal Position Switch Adjustment .................................................................. Parking Brake Check and Adjustment .................................................................. Brake System Bleeding ................................................ Brake System Indicator Circuit Diagram ....................................................................... Parking Brake Switch Test ........................................... Brake Fluid Level Switch Test ...................................... Front Brake Pads Inspection and Replacement ............................................................... Front Brake Disc Inspection ......................................... Front Brake Caliper Overhaul ...................................... Master Cylinder Replacement ..................................... Master Cylinder Inspection .......................................... Brake Booster Pushrod Clearance Adjustment ................................ Brake Booster Test ....................................................... Brake Booster Replacement ........................................ Rear Brake Pads Inspection and Replacement ............................................................... Rear Brake Disc Inspection .......................................... Rear Brake Caliper Overhaul ....................................... Brake Hoses and Lines Inspection .............................. Brake Hose Replacement ............................................. Parking Brake Cable Replacement .............................. 19-2 19-3 19-4 19-6 19-7 19-8 19-9 19-10 19-10 19-11 19-13 19-14 19-15 19-16 19-16 19-18 19-19 19-20 19-22 19-23 19-24 19-25 19-26
it
l'
ABS (Anti-lock Brake System) Components ............................................... 19-29

Special Tools
Tool Number 07 JAG-SD40 100
Descri tion Pushrad Ad"ustment Gau e
Ot
CD
19-2
INDICATOR Brake System Indicator Circuit Diagram, page 19-9 Parking Brake Switch
Test, page 19-10

Brake Fluid Level Switch
Test, page 19-10

,PA,RKIING BRAKE CABLE rking Brake Cable Replacement, page 19-26
BRAKES Front Brake Pads, Inspection and Replacement, page 19-11 Front Brake Disc Inspection, page 19-13 Front Brake Caliper Overhaul, page 19-14 BRAKE BOOSTER Brake Booster Test, page 19-18 Brake Booster Replacement, page 19-19 BRAKE HOSES and LINES Brake Hoses and Lines Inspection, page 19-24 Brake Hoses Replacement, page 19-25 MASTER CYLINDER Master Cylinder Replacement, page 19-15 Master Cylinder Inspection, page 19-16 Brake Booster Push rod Clearance Adjustment, page 19-16 Brake System Bleeding, page 19-8
REAR DISC BRAKE Rear Brake Pads Inspection and Replacement page 19-20 Rear Brake Disc Inspection, page 19-22 Rear Brake Caliper Overhaul, page 19-23 PARKING BRAKE LEVER Parking Brake Check and Adjustment, page 19-7 BRAKE PEDAL Brake Pedal and Brake Pedal Position Switch Adjustment page 19-6
"
19-3

Brake System Inspection and Tests
C0rt:'p_onent nsoectlons:
Component Master Cylinder Procedure Look for damage or signs of fluid leakage at: Reservoir or reservoir grommets Line joints Also check for:
Between master cvlinder and booster
Brake Hoses
Caliper
Look for damage or signs of fluid leakage at: Line joints and banjo bolt connections Hoses and lines, also inspect for twisting or damage Look for damage or signs of fluid leakage at: Piston seal
Banjo bolt connections
Bulging, twisted or bent lines.
Seized or sticking caliper pins.
ABS Modulator
Bleeder screw Look for damage or signs of fluid leakage at: Line joints Modulator
Brake System Test

Brake pedal sinks/fades when braking
1. Start the engine, and let it warm up to operating temperature. 2. Attach a 2-inch piece of masking tape along the bottom of the steering wheel, and draw a horizontal reference
mark across it.
3. With the transmission in Neutral, press and hold the brake pedal lightly, then release the parking brake. 4. While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape. 5. Apply steady pressure to the brake pedal for 3 minutes. 6. Watch the tape measure . if it moves less than 10 mm, the master cylinder is OK . if it moves more than 10 mm replace the master cylinder.
19-4
Rapid brake pad wear, Vehicle vibration (after a long drivel, or High, hard brake pedal
5. Loosen the hydraulic lines at the master cylinder, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES-Go to step 6. NO-Replace the master cylinder..
1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more brake pedal applications during an extended test drive. 2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand.
6. Loosen the bleeder screws at each caliper, then
spin the wheels to check for brake drag. Is there brake drag at any of the wheels? Is there brake drag at any of the wheels? YES-Go to step 3. YES-Disassemble and repair the caliper on the wheel(sl with brake drag . NO-Inspect brake hose (si/line (sl. 3. Turn the engine off, pump the brake pedal to
deplete the vacuum in the brake booster, and then spin the wheels again to check for brake drag.
NO- Look for other causes of the pad wear, high

pedal, or vehicle vibration .
Is there brake drag at any of the wheels?
YES-Go to step 4. NO-Replace the brake booster .

4. Without removing the brake lines, unbolt and separate the master cylinder from the booster, then
spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES-Go to step 5. NO-Check the brake pedal position switch adjustment and pedal free play .
19-5

Brake Pedal and Brake Pedal Position Switch Adjustment
Pedal Height
1. Disconnect the brake pedal position switch
Pedal Free Play

4. With the engine off, inspect the play (A) on the pedal pad (8) by pushing the pedal by hand.
Free Play: 0.4' 3.0 mm (0.016-0.118 in.)
connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet and the insulator cutout (8). Measure the pedal height (C) from the middle of the left side of the pedal pad (0).
Standard Pedal Height (with carpet removed): 184 mm (7 4/16 in.)
5. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag.
D
3. Loosen the push rod locknut (A), and screw the push rod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed.
6. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (8) on the pedal arm). Then, turn the switch 45' clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.Q16-0.l1S in.) by locking the switch. Make sure the brake lights go off when the pedal is released.
7. Check the brake pedal free playas described below.
19-6
Parking Brake Check and Adjustment

Check
1. Pull the parking brake lever (AI with 196 N (20 kgf, 441bf) of force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks (BI. Lever locked clicks:
5. Remove the rear console (see page 20-571.
6. Pull the parking brake lever up one click.
7-8
.. ""
//
\PUII.dUPW;'h
196 N (20 kgf, 441bf)
2. Adjust the parking brake if the lever clicks are not within the specification.
7. Tighten the adjusting nut (AI until the parking brakes drag slightly when the rear wheels are turned.
A
Adjustment
1. Release the parking brake lever fully. 2. Loosen the parking brake adjusting nut, start the engine, and press the brake pedal several times to set the self-adjusting brake before adjusting the parking brake. 3. Block the front wheels, then raise the rear of the
vehicle, and support it with safety stands in the
proper location (see page 1-81. 4. Make sure the parking brake arm (AI on the rear brake caliper contacts the brake caliper pin (BI. NOTE: The parking brake arm will only contact the brake caliper pin when the parking brake adjusting
nut is loosened.
8. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are turned. Readjust if necessary. 9. Make sure the parking brakes are fully applied when the parking brake lever is pulled up fully.
10. Reinstall the rear console.
" ,-::.). r--I\.-
:;;;j '4~-!;,';~/'~
/
~~-O" __
-
J!'"
\.,
\-
o
B
19-7
,
Brake System Bleeding
NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it
off immediately with water. The reservoir on the master cylinder must be at the
5. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid.
BLEEDING SEQUENCE,
MAX (upperllevel mark at the start of the bleeding procedure and checked afler bleeding each brake caliper. Add fluid as required. Do not reuse the drained fluid. Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system.
Make sure no dirt or other foreign matter is allowed
@FrontRight
@RearRight
to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upperllevel line (AI.
A
CD Front left
-::DRear left
6. Refill the master cylinder reservoir to the MAX (upperl level line. FRONT BRAKE:
9 Nm 10.9 kglm, 7 Iblft)
2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a
container of new brake fluid.
3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the lefl-front, loosen the brake bleed
screw to allow air to escape from the system. Then
REAR BRAKE:
tighten the bleed screw securely.
19-8
Brake System Indicator Circuit Diagram
BATTERY

No.20140A)
CANADA (50
IGNITION
SWITCH
A,
WHT
IG1 HOT in ON (III and START (III)
--E7-
BlK/VEL
--fbi4-
VEL-
GAUGE ASSEMBLY
SYSTEM
BRAKE
INDICATOR
WHT/GRN
UNDER-OASH FU SE/RELA Y BOX
I MULTIPLEX 1 CONTROL. UNIT
I
,- GRN!ORN
IMMOBILIZER CONTROL UNIT-RECEIVER
---_ .. -
.-
r--'
GRN/RED
I I I I
L
GRN/DRN
GRN/R ED I 1 ILIGHTS CONTROL DAYTIME RUNNING

!UNIT
I
USAi_ .. _
GRNf ORN
$.
.-
_._1 -.S~NA[)~
BRAKE FLUID
LEVEL SWITCH
CLOSED: Float down

OPEN: Float up BLO
.J....G301
~
I
PARKING BRAKE
SWITCH
CLOSED: Lever up
OPEN: Lever down
19-9

Parking Brake Switch Test
1. Remove the rear console, and disconnect the connector (A) from the switch (8).
Brake Fluid Level Switch Test

Check for continuity between the terminals (A) with the float in the down position and the up position. Remove the brake fluid completely from the reservoir. With the float down, there should be continuity . Fill the reservoir with brake fluid to MAX (upper) level (8). With the float up, there should be no continuity.
UP
DOWN
r==:{
A
B
2. Check for continuity between the switch terminal and body ground: With the brake lever up, there should be
continuity .
With the brake lever down, there should be no

continuity.
19-10
Front Brake Pads Inspection and Replacement

Replacement
Frequent inhalation of brake pad dust, regardless of
material composition, could be hazardous to your
health. Avoid breathing dust particles .

Never use an air hose or brush to clean brake
1. Remove the bolt (A), and pivot the caliper (B) up out of the way. Check the hose and pin boots for damage and deterioration .
assemblies. Use an OSHA-approved vacuum

cleaner.
Inspection
1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8).
...~..
B
2. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the brake pad backing plate.
Brake pad thickness: Standard: 9.5-10.5 mm 10.37-0.41 in.) Service limit: 1.6 mm (0.06 in.)
/--
'\
2. Remove the pad shim (A) and pads (B) .

Inner pad:
Outer pad:
3. If the brake pad thickness is less than the service limit, replace all the pads as a set.
(cont'd)
19-11

Front Brake Pads Inspection and Replacement (cont'd)
3, Remove the pad retainers IAI, and check the caliper
pins for free movement.
,
'&)------B
ax 1.0mm 34Nm
10, Push in the piston IAI so the caliper will fit over the pad's, Check the brake fluid level. The brake fluid
may overflow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
3,5 kgf,m,
25 Ibf,ftl
4, Clean the caliper thoroughly; remove any rust. and check for grooves and cracks. 5, Check the brake disc for damage and cracks, 6, Apply Dow Corning Molykote M77 grease to the
retainers on their mating surfaces against the
caliper bracket. 7, Install the pad retainers, Wipe excess grease off the
retainers. Contaminated brake discs and pads
11, Pivot the caliper down into position, Being careful not to damage the pin boots, install the bolt IBI. and tighten it to the specified torque,
12. Press the brake pedal several times to make sure the brake works, then test-drive.
reduce stopping ability, Keep grease off the discs and pads,
8. Apply Molykote M77 grease to both sides of the pad shim IAI, the back of the pads IBI, and the other areas indicated by the arrows.
Wipe excess grease off the shim. Contaminated
NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake
pads have been replaced as a set. Several
applications of the brake pedal will restore the normal pedal stroke, 13, After installation, check for leaks at hose and line
joints or connections, and retighten if necessary.
brake discs and pads reduce stopping ability, Keep grease off the discs and pads,
"
-,
___
---y
_ '-T~" "
----- i '
-/
-,
'-,..:..-<
n,L_:"'/ '
9, Install the brake pads and pad shim correctly, Install the pads with the wear indicators ICI on the
inside. If you are reusing the pads, always reinstall the brake pads in their original pOSitions to prevent a momentary loss of braking efficiency.
19-12
Front Brake Disc Inspection

Runout
1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8). Remove the front wheels. 2. Remove the brake pads (seepage 19-11). 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust. 4. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub.
Thickness and Parallelism

1. Raise the front of the vehicle, and support it with safety stands in the proper location (see page 1-8). Remove the front wheels. 2. Remove the brake pads (see page 19-11). 3. Using a micrometer, measure disc thickness at eight points, approximately 45' apart and 10 mm (0.4 in.) in from the outer edge of the disc. Brake Disc Thickness: Standard: 20.9-21.8 mm (0.82-0.86 in.) Max. Refinishing Limit: 19.0 mm (0.75 in.) Brake Disc Parallelism: 0.015 mm (0.0006 in.)
max.
NOTE: This is the maximum allowable difference between the thickness measurements .
108Nm 111.0 kglm, 801blltl
5. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc. Brake Disc Runout: Service Limit: 0.10 mm (0.004 in.) 6. If the disc is beyond the service limit, refinish the brake disc. Max. Refinish Limit: 19.0 mm (0.75 in.) NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see page 18-11). A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.). 4. If the smallest measurement is less than the max. refinishing limit, replace the brake disc (see page 18-111. 5. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation .
19-13

Front Brake Caliper Overhaul
ACAUTION
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles .
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
To prevent dripping, cover disconnected hose joints with rags or shop towels.
Clean all parts in brake fluid and air dry; blowout all passages with compressed air. Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid. Always use Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fl uid as they may not be compatible.
Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Make sure no grease or oil gets on the brake discs or pads. Replace all rubber parts with new ones whenever disassembled.
After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
~: Honda caliper grease (PIN 08C30-B0234MI

BOOTS
PISTON BOOT Replace.
~
CALIPER PIN A
~If(o
BUSHING
W
PI~
OJ
B
PISTON BOOT Replace.
CALIPER
~/~'\
\
/If(o
f'
CALIPER BRACKET
WEAR INDICATOR Install inner pad with its wear indicator downward. OUTER PAD SHIM
12x1.25mm 108 Nm 111.0 kgf.m, 801bUt)
19-14
Master Cylinder Replacement

NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Remove the air cleaner assembly (A).
3. Remove the clutch reservoir (8) and engine wire
harness clip (C) from the master cylinder mounting base (D). 4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder mounting base. 6. Disconnect the brake lines (F) from the master cylinder (G). To prevent spills, cover the hose joints with rags or shop towels. 7. Remove the master cylinder mounting nuts (H) and
washers.
8. Remove the master cylinder from the brake booster. Se careful not to bend or damage the brake lines when removing the master cylinder.
2. Disconnect the brake fluid level Sensor connector (A).
9. Remove the rod seal (I) from the master cylinder. 10. Install the master cylinder in the reverse order of
Replace all the rubber parts with new ones

whenever the master cylinder is removed.
Check the push rod clearance before installing the

master cylinder, and adjust it if necessary (see
page 19-16). Use a new rod seal on reassembly.

Coat the inner bore lip and outer circumference
of the new rod seal (A) with the recommended

seal grease in the master cylinder set.
D F 15Nm (1.5 kgfm, 11lbfftl
15Nm (1.5 kgfm, 11Ibfft)
Install the rod seal onto the master cylinder with its grooved side (S) toward the master cylinder. Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary (see page 19-6).
MASTER CYLINDER SIDE
19-15

Master Cylinder Inspection
NOTE: Before reassembling, check that all parts are free of dust and other foreign particles. Do not try to disassemble the master cyl"lnder assembly. Replace the master cylinder assembly with a new part if necessa ry. Do not allow dirt or foreign matter to contaminate the brake fluid.
Brake Booster Push rod Clearance Adjustment

Special Tools Required Push rod adjustment gauge 07JAG-SD40100 NOTE: Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special toollAI on the master cylinder body IBI, push in the center shaft ICI until the top of it contacts the end of the secondary piston 101 by turning the adjusting nut lEI.
~ 0""'-------_ _ ,.,B) , _:--- _::.

RESERVOIR
_ _ RESERVOIR CAP Check for blockage of vent holes. RESERVOIR SEAL Check for damage
~.
~
C
,-
~,
and deterioration.
STRAINER Re~ove accumulated
sediment.
.,.,'~-
IE
07JAG-SD401000
RESERVOIR HOSES Inspect hoses for damage, leaks, and deterioration. MASTER CYLINDER Check for leaks, rust, and damage.
c
2. Without disturbing the center shaft's position, install the special toollAI backwards on the booster.
B 15 Nm 11.5 kgf.m, 11 Ibftt)
0-101 kPa
(0 760 mmHg, 30 in.Hgl
A 07JAG-SD40100
3. Install the master cylinder nuts IBI, and tighten them to the specified torque.
4. Connect the booster in-line with a vacuum gauge
ICI 0- 101 kPa 10'760 mmHg, 30 in.Hgl tothe

booster's engine vacuum supply, and maintain an
engine speed that will deliver 66 kPa 1500 mmHg, 20 in.Hgl vacuum.
19-16
S. With a feeler gauge (AI, measure the clearance between the gauge body and the adjusting nut (81 as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 in.l, the pushrod-topiston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is o mm, the pushrod-to-piston clearance is 0.4 mm (0.02 in.1 or more. Therefore it must be adjusted and rechecked. Clearance:
9. Check the pushrod length (AI as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (81, and turn the clevis (CI in or out to adjust.
A 116 mm 14.6 in.1
.'
0-0.4 mm (0-0.02 in.1
10x 1.0mm 1.5Nm 11.5 kgfm, lllbfftl
10. Install the master cylinder (see page 19- lSI .
6. If the clearance is incorrect, loosen the star locknut (AI, and turn the adjuster (81 in or out to adjust .
Adjust the clearance while the specified vacuum is applied to the booster. Hold the clevis (CI while adjusting.
A
0-0.4mm 10-0.02in.1
~I"
.
'j
I
I"i'""'~
' '"'r'
a
22Nm
07JAGSD40tOO 7. Tighten the star locknut securely .
\\
B
8. Remove the special tool (DI.
19-17

Brake Booster Test
Functional Test
1. With the engine stopped, press the brake pedal
several times to deplete the vacuum reservoir, then
A
--------<~-----
3. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster side.
press the pedal hard, and hold itfor 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, or calipers) is leaking. 2. Start the engine with the brake pedal pressed. If the pedal sinks slightly, the vacuum booster is working properly. If the pedal height does not vary, the booster or check valve is faulty. 3. With the engine running, press the brake pedal lightly. If the brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the NC compressor cycles on and off is normal. (The NC
compressor load changes the vacuum available to
__
I_r-~ '_~
~-
'\
~~{:~--4. Start the engine, and let it idle. There should be

vacuum available. If no vacuum is available, the
check valve is not working properly. Replace the

brake booster vacuum hose and check valve, and retest.
5. Reconnect the brake booster vacuum hose.
the booster.)
Leak Test
1. Press the brake pedal with the engine running, then stop the engine. If the pedal height does not vary
while pressed for 30 seconds, the vacuum booster
Start the engine, and then pinch the brake booster

vacuum hose between the check valve and the booster.
is OK. If the pedal rises, the booster is faulty. 2. With the engine stopped, press the brake pedal
several times using normal pressure. When the
6. Turn the ignition switch OFF, and wait 30 seconds. Press the brake pedal several times using normal
pressure,
pedal ',s first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, check the booster check valve.
When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, replace the brake booster. If the pedal position varies, replace the brake booster vacuum hose/check valve assembly.
19-18
Brake Booster Replacement

1. Remove the master cylinder Isee page 19-15). 2. Remove the master cylinder brake lines IA) from the brake line clip.
B
5, Remove the clip (A) and the jOint pin (B), and disconnect the yoke from the brake pedal.
..------P~
c
6x 1.0 mm 9.8Nm (1.0 kgfm, 7.2Ibfft)
C -------~, 8x 1.25 mm 13Nm (1.3 kgfm, 9Ibfft)
6. Remove the brake booster mounting nuts (C). 7. Remove the brake booster (A) from the engine compartment.
3. Remove the vacuum hose mounting bracket (B). 4. Disconnect the vacuum hose (C) from the brake booster.
iNOTICEi
Be careful not to damage the booster surfaces and threads of the booster stud bolts. Be careful not to bend or damage the brake lines.
8. Install the brake booster in the reverse order of

Adjust the push rod clearance before installing the brake booster (see page 19-16). Use a new clip whenever installing.
After installing the brake booster and master cylinder, fill the reservoir with new brake fluid,
bleed the brake system (see page 19-8). and adjust the brake pedal height and free play (see page 19-6).
19-19

Rear Brake Pads Inspection and Replacement
Replacement
Frequent inhalation of brake pad dust, regardless of
material composition, could be hazardous to your
1. Remove the bolt (A) and brake hose (B) from the
mounting bracket.
B
health.
Avoid breathing dust particles .

Never use an air hose or brush to clean brake
assemblies. Use an OSHA-approved vacuum

cleaner.
_
Inspection
1. Raise the rear of the vehicle, and support it with safety stands in the proper location (see page 1-8). Remove the rear wheels. 2. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the brake pad backing plate. Brake pad thickness: Standard: 8.5-9.5 mm (0.33-0.37 in.) Service limit: 1.6 mm (0.06 in.)
D
~~;~:;:i!J< / ",
2. Remove the caliper bolts (C), and remove the

caliper (D) from the caliper bracket.
3. Remove the pad shims (A) and pads (B).
";
>-,/
-,~--
--~-
3. If the brake pad thickness is less than the service limit, replace all the pads as a set.
19-20
4. Remove the pad retainers (A). and check the caliper

pins for free movement.
11. Rotate the caliper piston clockwise into the cylinder, then align the cutout (AI in the piston with the tab (BI on the inner pad by turning the piston back so the caliper can be installed on the pad. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly.
E
~-:::'--I-- 8 x 1.25 mm
5. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
6. Check the brake disc for damage and cracks. 7. Apply Dow Corning Molykote M77 grease to the
retainers on their mating surfaces against the
caliper bracket.
"--,
8. Install the pad retainers. Wipe excess grease off the

retainers. Contaminated brake discs and pads
reduce stopping ability. Keep grease off the discs and pads. 9. Apply Dow Corning Molykote M77 grease to both sides of the pad shims (AI, the back of the pads (BI, and the other areas indicated by the arrows. Wipe
excess grease off the shim. Contaminated brake
discs and pads reduce stopping ability. Keep grease off the discs and pads. 12. Install the brake caliper (C) and caliper bolts (DI, and tighten the bolts to the specified torque. 13. Install the brake hose (EI. 14. Press the brake pedal several times to make sure
the brake works, then test-drive.
NOTE: Engagement of the brake may require a greeter pedal stroke immediately after the brake
pads have been replaced as a set. Several
applications of the brake pedal will restore the

normal pedal stroke.
15. Check the parking brake adjustment (see page 19-7). 10. Install the brake pads and pad shims correctly.
Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
19-21

Rear Brake Disc Inspection
Runout
1. Raise the rear of the vehicle, and support it with safety stands in the proper location Isee page 1-81. Remove the rear wheels. 2. Remove the brake pads Isee page 19-201. 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust. 4. Install suitable flat washers IAI and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. 104 ',n)
10mm
Thickness and Parallelism

1. Raise the rear of the vehicle, and support with safety stands in the proper location Isee page 1-8). Remove the rear wheels. 2. Remove the brake pads Isee page 19-201. 3. Using a micrometer, measure disc thickness at eight points, approximately 45 0 apart and 10 mm 10.4 in.1 from the outer edge of the disc. Brake Disc Thickness: Standard: 9.9-10.1 mm 10.389-0.397 in.1 Max. Refinishing Limit: 9.0 mm 10.35 in.1 Brake Disc Parallelism: 0.016 mm (0.0006 in.1
r;u-,-.--/! /'\--. r-,,' '/
I, . . ,">i\;d
"v,V
'I
5;. 1}::
I
max.
NOTE: This is the maximum allowable difference between the thickness measurements.
108 Nm 111.0 kgfm, 80 Ibfft)
5. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm 10.4 in.1 from the outer edge of the disc. Brake Disc Runout: Service Limit: 0.10 mm (0.004 in.1 6. If the disc is beyond the service limit, refinish the brake disc. Max. Refinish Limit: 9.0 mm 10.35 in.1 NOTE: If the brake disc is beyond the service limit for refinishing, replace it Isee page 18-261 . A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.l. 4. If the smallest measurement is less than the max. refinishing limit, replace the brake disc Isee page 18-26). 5. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe.
19-22
Rear Brake Caliper Overhaul

~CAUTION
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles . Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping, cover disconnected hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blowout all passages with compressed air. Before reassembling, check that all parts are free of dust and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter contaminates the brake fluid. When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.
Do not mix different brands of brake fluid as they may not be compatible. Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Make sure no grease or oil gets on the brake discs or pads. Replace all rubber parts with new ones whenever disassembled. After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
~ : Honda caliper grease (PIN 08C30-B0234MI
=_
~BANJOBOLT 34 Nm (3.5 kgf.m, 25 Ibfftl

SEALING
~~
.-
. -'"_
"- ""
t?~~
:-'-
WASHERS
Replace. BRAKE HOSE
~ ........... CAM
~"
---BLEED SCREW /,",", ' 9 Nm (0.9 kgf.m, 7 Ibfftl '. ' ADJUSTING BOLT ,:',~ PIN SLEEVE
~;~
PISTON
BEARING A
LE~ /;'*'
/ /I
A
I~ I~
ARM
",Ibf.ftl, ,
/
~
CALIPER BODY
!(~ " ;:::::

\ "
O-RING CUP
SPRING
RETURN
10mmFLANGE 23N.m(2.3kgfm,
~aCIRCLIP @ ':1
\
COVER
PARKING NUT 27 Nm (2.8 kgf.m, 20Ibfft)
~~~
/~
BRAKE PADS
/JjJ rn~-;{)JJ![
~
~PAD/SP~:~PERBOLTS
,23 N./m
~~ ~
~.
~" ~t'N A
~;7Ibfftl ~~p1?,~:'::~N ~~Sp1?,~BOOT

'IlU;'
OUTER PAD SHIM
~1IlCrI
I~ ~ ~ <r~ ' ~RETAINER
~--
Replace.
~E~
10 mm FLANGE BOLTS 55 Nm (5.6 kgf.m, 41 Ibfft)
/~
--------
CALIPER BRACKET
19-23

Brake Hoses and Lines Inspection
1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder and ABS modulator unit for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced.
ABS MODULATOR UNIT-to-BRAKE LINE
15 Nm 11.5 kgl.m, l1lblftl
MASTER CYLINDER-to-BRAKE LINE
15 Nm 11.5 kglm.l1Iblftl
BRAKE HOSE-to-CALIPER IBANJO BOLTI
34 Nm 13.5 kgl.m, 251blftl

BLEED SCREW 9Nm LlNE-to-BRAKE HOSE
IpllOl'OF!TlClNIING CONTROL VALVE-toBRAKE LINE
15 Nm 11.5 kglm.lllblftl 15 Nm 11.5 kglm, lllblftl
10.9 kglm. 7 Iblftl
19-24
Brake Hose Replacement

NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water . To prevent dripping, cover disconnected line joints with rags or shop towels.
6. Install the brake hose bracket (A) on the damper with the flange bolt (B) first, then connect the brake hose (C) to the caliper with the banjo bolt (D) and new sealing washers (E).
A
Before reassembling, check that all parts are free of dust and other foreign particles. Replace parts with new ones whenever specified to doso. 1. Replace the brake hose (A) ifthe hose is twisted, cracked, or if it leaks.
B 8x 1.25mm 22Nm (2.2 kgfm, 161b1ft)
/)
, __"-=0-
~. "~-.'.'
/----
c o
34Nm 13.5 kgfm, 251b1ft)
--
7. Install the hose onto the hose bracket on the body with a new hose clip (A).
2. Disconnect the brake hose from the brake line (B) using a 10 mm flare nut wrench (C). 3. Remove the flange bolt (A), and remove the brake hose brackets from the damper.
8. Connect the brake line to the brake hose.
9. After installing the brake hose, bleed the brake system (see page 19-8). 10. Do the following checks: Check the brake hose and line joint for leaks, and
c
4. Remove and discard the hose clip (B). 5. Remove the banjo bolt (C), and remove the brake hose (D) from the caliper.
tighten if necessary . Check the brake hoses for interference and twisting.
19-25

Parking Brake Cable Replacement
Exploded View
PARKING BRAKE LEVER Check for smooth operation . /
---~~
(Sliding surface)
.. ~
/EQUALIZER
iil1ll1l!JJJlmI EJ Q - - -
~..
________ ADJUSTING NUT
if
~
PARKING BRAKE SWITCH
lilt
PARKING BRAKE CABLE Check for stiffness, binding, and damage.
'"
ax 1.25mm 22Nm 12.2 kgfm, 16Ibfft)
19-26
NOTE: The parking brake cables must not be bent or distorted. This will lead to stiff operation and
premature failure.
7. Install the new cable in the reverse order of

Refer to the Exploded View as needed during this

procedure.
Be careful not to bend or distort the cable. Make sure the parking brake cable clip is fully
seated on the cable housing.
1. Release the parking brake lever fully.

2. Remove the rear console (see page 20-57),
Do the parking brake cable adjustment Isee page 19-7).
3. Loosen the parking brake cable adjusting nut IA).

A
..'.::: ::::::'.c :::: . . . . . .;;' /

/
'y
4. Remove the parking brake cable clip IA) from the brake cable IB).
5. Disconnectthe parking brake cable from the lever
Ie).
6. Remove the parking brake cable mounting hardware, then remove the cable.
19-27

Brakes
Conventional Brake Components ................ 19-1 ABS (Anti-lock Brake System) Components
Component Location Index ......................................... General Troubleshooting Information ....................... DTC Troubleshooting Index ........................................ Symptom Troubleshooting Index ............................... System Description ...................................................... Circuit Diagram ............................................................. DTC Troubleshooting ................................................... ABS Indicator Circuit Troubleshooting ...................... Brake System Indicator Circuit Troubleshooting ....................................................... ABS Modulator-Control Unit Removal and Installation ................................................................. Wheel Sensor Inspection ............................................. Wheel Sensor Replacement ........................................ 19-30 19-31 19-34 19-35 19-36 19-42 19-45 19-52 19-55 19-57 19-59 19-59
ABS Components
RIGHT-REAR WHEEL SENSOR
Inspection, page '9-59

LEFT-REAR WHEEL SENSOR Inspection, page 19-59

DATA LINK CONNECTOR 116PI RIGHT-FRONT WHEEL SENSOR Inspection, page 19-59 Replacement, page' 9-59 ABS MODULATOR-CONTROL UNIT Removal and Installation, page 19-57
LEFT-FRONT WHEEL SENSOR Inspection, page 19-59 Replacement, page 19-59
19-30
~
~
ABS Indicator
lithe system is OK, the ABS indicator goes off 2 seconds after turning the ignition switch ON (II)
without starting the engine, and then comes on again

The memory can hold three DTes. However, when the same OTe is detected more than once, the more recent OTe is written over the earlier one.
Therefore, when the same problem is detected
and goes off 2 seconds later after starting the engine. This occurs because the ABS control unit is turned on by the IG2 power source. The ABS indicator comes on when the ABS control
unit detects a problem in the system. However, even
repeatedly, it is memorized as a single DTe. The DTes are in the order they occurred, beginning
with the most recent.
though the system is operating properly, the indicator

will
The DTes are memorized in the EEPROM (nonvolatile memory). Therefore, the memorized DTes
are not cleared when the battery is disconnected, the ignition switch is turned off, or the system returns to normal. Do the specified procedures to clear the
come on under these conditions:
Only the drive wheels rotate One drive wheel is stuck The vehicle goes into a spin The ABS continues to operate for a long time. The vehicle is subjected to an electrical signal
disturbance
DTes.
Selfdiagnosis
Self-diagnosis can be classified into two categories:
To determine the actual cause of the problem, question
the customer about the problem, taking the above

conditions into consideration.
- Initial diagnosis: Done right after the engine starts and until the ABS
indicator goes off
When a problem is detected and the ABS indicator

comes on, there are cases when the indicator stays on until the ignition switch is turned OFF, and cases
- Regular diagnosis: Done right after the initial diagnosis until the
ignition switch is turned OFF
when the indicator goes off automatically when the

system returns to normal.
- DTe 61: The ABS indicator goes off automatically

when the system returns to normal.
When a problem is detected by self-diagnosis, the system does the following: - Turns the ABS indicator on - Memorizes the DTe - Stops ABS control
- DTe 11, 13, 15, 17,31,32,33,34,35,36,37,38,54, or 81: The ABS indicator stays on until the ignition
switch is turned OFF whether or not the system returns to normal.
Kickback
The pump motor operates when the ABS is functioning,
and the fluid in the reservoir is forced out to the master
- DTe 12, 14, 16, 18,21,51,52, or 53: The ABS

indicator goes off when the vehicle is driven again
cylinder, causing kickback at the brake pedal.
and the system is OK after the ignition switch is turned from OFF to ON (II).
Pump Motor
The pump motor operates when the ABS is
functioning.
The ABS control unit checks the pump motor

operation when the vehicle is started the first time
after the ignition switch is turned ON (II). You may

hear the motor operate at this time, but it is normal.
(cont'd)
19-31
ABS Components
How to Troubleshoot ABS OTCs
The troubleshooting flowchart procedures assume that the cause of the problem is still present and the ABS indicator is still on. Following the flowchart when the
ABS indicator does not come on can result in incorrect
2. Turn the ignition switch ON (III, and follow the prompts on the PGM Tester to display the OTC(sl
on the screen. After determining the DTC, refer to
the OTC Troubleshooting Index. NOTE: See the Honda PGM Tester user's manual for specific instructions.
Service Check Signal (SCS) Circuit Method:
diagnosis. The connector illustrations show the female terminal connectors with a single outline and the male terminal
connectors with a double outline.
1. Question the customer about the conditions when the problem occured, and try to reproduce the same conditions for troubleshooting. Find out when the ABS indicator came on, such as during ABS control. after ABS control, when the vehicle
was at a certain speed, etc.
1. With the ignition switch OFF, connect the Honda PGM Tester (AI to the 16P data link connector (OLCI (B) under the driver's side of the dashboard.
2. When the ABS indicator does not come on during the test-drive, but troubleshooting is done based on the OTC, check for loose connectors, poor terminal contact, etc., before you start troubleshooting. 3. After troubleshooting, clear the OTC,disconnect the Honda PGM Tester, and test-drive the vehicle.
Make sure the ABS indicator does not come on.
How to Retrieve ABS OTCs

Honda PGM Tester Method:
2. Short the SCS circuit to body ground using the Honda PG M Tester. 3. Turn the ignition switch ON (II).
1. With the ignition switch OFF, connect the Honda PGM Tester (AI to the 16P data link connector (OLCI (BI under the driver's side of the dashboard.
19-32
4. The blinking Irequency indicates the DTe. DTCs are indicated by a series 01 long and short blinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the DTC. After determining the DTC, reler to the DTC Troubleshooting Index. NOTE: lithe DTC is not memorized, the ABS indicator will go off lor 3.6 seconds, and then come back on. II the ABS indicator stays on, troubleshoot for "ABS indicator does not go off" (see step 1 on page 19-53). The system will not indicate the DTC unless these
conditions are met:
How to Clear ABS DTCs

Honda PGM Tester Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P data link connector (DLC) (B) under the driver's side 01 the dashboard.
The brake pedal is not pressed. The ignition switch is turned ON (II). The SCS circuit is shorted to body ground belore the ignition switch is turned ON (II).
Example of DTe 15 Short blinks (five times)
II'
2. Turn the ignition switch ON (II), and clear the
I. ON
OFF
Long blink
'I
DTC(s) bylollowing the screen prompts on the PGM Tester . NOTE: See the Honda PGM Tester user's manual
Example of Ole 22
Short blinks
-------1 -
Long blinks (two times)
(two times)
Cycling the Ignition Switch Method: Clear the DTC by turning the ignition switch ON (II) then OFF at least 20 times.
lJUl
5. Turn the ignition switch OFF. 6. Disconnect the Honda PGM Tester lrom the DLC .
19-33
ABS Components
DTe Troubleshooting Index
Ole
OlC:11 OlC:12 OlC:13 OlC:14 OlC:15 OlC:16 OlC:17 OlC:18 OlC:21 OlC:31 OlC:32 OlC:33 OlC:34 OlC:35 OlC:36 OlC:37 OlC:38 OlC:51 OlC:52 OlC:53 OlC:54 OlC:61 OlC:81
Detection Item RiQht-front wheel sensor (open/short to body ground/short to power) Faulty right-front wheel sensor pulse signal Left-front wheel sensor (open/short to body ground/short to power) Faulty left-front wheel sensor pulse signal Right-rear wheel sensor (open/short to body ground/short to power) Faulty right-rear wheel sensor pulse signal Left-rear wheel sensor (open/short to body ground/short to power) Faulty left-rear wheel sensor pulse signal Continuous operation (chipped pulser) Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Motor locked Motor stuck off
Motor stuck on
Main relay stuck off IG2 voltage CPU (Central Processing Unit)
Note (see page 19-45) (see page 19-46) (see page 19-45) (see page 19-46) (see page 19-45) (see page 19-46) (see page 19-45) (see page 19-46) (see page 19-47) (see page 19-48) (see page 19-48) (see page 19-48) (see page 19-48) (see page 19-48) (see page 19-48) (see page 19-481 (see page 19-481 (see page 19-48) (see paoe 19-491 (see page 19-501 (see page 19-511 (see page 19-511 (see--",age 19-521
19-34
~
~
Symptom ABS indicator does not come on Diagnostic procedure Also check for
ABS indicator does not go off and no ABS DTC is stored

Brake system indicator does not come
on Brake system indicator does not go off and no ABS DTC is stored
ABS Indicator Circuit Troubleshooting (see page 19-521 ABS Indicator Circuit Troubleshooting (see step 1 on page 19-531 Brake System Indicator Circuit Troubleshooting (see-"age 19-551 Brake System Indicator Circuit Troubleshooting (see step 1 on paqe 19-551
19-35
ABS Components
System Description
ABS Control Unit Inputs and Outputs for 31P Connector
Terminal
number
Wire
color BLU/ YEL GRN/ YEL BLU
Terminal sign
Description
Terminals
RRS I I Detects right-rear wheel sensor signal Detects right-front
wheel sensor
Measurement Conditions IIgnition switch ON 11111
Voltage
1 2
1 2
,
RRSI+I FRS I I
Spin wheel at 1 turn/second Wheel
AC: 0.053 V or above

Oscilloscope
signal
GRN/ BLK BRN/ WHT BLU/ ORN GRY/ RED YEU RED LT BLU
FRSI+I
0.15 Vp-p or above FLS I-I FLS 1+1 RLS I-I RLSI+I DIAG-K Detects left-front wheel sensor signal Detects left-rear
wheel sensor signal
6 7
8 9
11
6-7
,
8-9
Communications with Honda PGM
--
tester
12 BRN DIAG-L DTC indication
----..
--
19-36
Terminal number
14 15
Wire
color
WHT/ BLK BLK/ ORN
SLK
Terminal sign
Description Terminals
Measurement
Conditions (Ignition switch ON llill Brake pedal Pressed Released
- -
Voltage Battery voltaQe Battery voltage Below 0.3 V Battery voltaae Battery voltaQe Below 0.3 V
STOP IG2
Detects brake switch siQnal
14-GND 15-GND
I
Power source for

activating the svstem Ground forthe pump motor
16
M-GND +B-MR +B-FSR
16-GND 17-GND 18-GND 19-GND
- -
17
18 19
WHT/ RED WHT/ GRN BLK
Power source for

the DumD motor Power source for the valve relav Ground for the modulator assemblv Drives ASS indicator
At all times At all times

----
GND
20 21
BLU/ RED BRN/ VEL
ABS EBD IElectronic brake distribution)
20-GND 21-GND
ABS
Drives brake system indicator
indicator Brake system indicator
ON OFF OFF ON for bulb check
About 11 V Below 1 V Below 0.3 V 8attery voltage
Iconrd)
19-37
ABS Components
System Description (cont'd)
Features
When the brake pedal is pressed during driving, the wheels can lock before the vehicle comes to a stop. In such an
event, the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is
reduced if the rear wheels are locked, creating an extremely unstable condition. The ASS precisely controls the slip rate aftha wheels to ensure maximum grip force from the tires, thereby ensuring the maneuverability and stability of
the vehicle. The ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed, then it controls the brake fluid pressure to reach the target slip rate. Grip Force of Tire and Road Surface
TARGET SLIP RATE
ROTATIONAL DIRECTION
COEFFICIENT OF FRICTION RADIAL DIRECTION OFTHE ROTATIONAL DIRECTION
SLIP RATE
19-38
ABS Control Unit

Main Control
The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel and transmits the control signal to the modulator unit solenoid valve when the slip rate is high.
The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying.
ABS CONTROL UNIT
r---------------------------~
I I I
I .:m~r-~~~~OR
WHEEL SPEED
VEHICLE SPEED
DETECT
REFERENCE SLIP RATE
REAR DETECT
I I I
ASS CONTROL
:::;l fL~~~~E
S~~'i'~OID
RIGHT.REAR SOLENOID
I I
I
LEFT-REAR WHEEL SENSOR
I I I WHEEL SENSOR
RIGtfTFRONT
W~~~~WPEED t-
~ SELECT LOW SPEEOWHEEL
r-:
RIGHT FRONT
I I
DRIVE SOLENOID
LEFT-REAR
SOLENOID
I I
--::
ASS CONTROL
I
I
I
I
DETECT WHEEL SPEED
~ Jt~~~~\E
DRIVE SOLENOID
~grlN"J'lgNT
I WHEEL SENSOR LEFTFRONT
LEFT-FRONT DETECT WHEEL SPEED
L___________________________ J
CONTROL
SOLENOID
~Jt~~~~~E I
ASS
DRIVE
I I I
lEFT-FRONT
SOLENOID
Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: Initial diagnosis Regular diagnosis
On-board Diagnosis Function
The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the Honda
PGM Tester. See the Honda PGM Tester user's manual for specific operating instructions.
(cont'd)
19-39
ABS Components
ABS Modulator
The ABS modulator consists of the inlet solenoid valves, outlet solenoid valves, reservoir, pump, pump motor, and the
damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has
three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent
four-channel type, one channel for each wheel.

ASS MODULA TOACONTROL UNIT
_0.
~~
/MODULATORUNIT
-,-~~~
\~0
c/.
....:......
~:)
\)
ij) ':
A8S CONTROL UNIT
MASTER CYLINDER
(5
Mel
r--'- ---- - ---- - ---- - - MODULATOR UNIT
Me2
- - - -,- - - - --- - ---,

DAMPING CHAMBER
I I I
PUM
DAMPING CHAMBER MOTOR
~
ACCUMULATO
====:::('~'PUMP
I
I
'7 "'lLjlJ.=l-'J
I
I
L _ _ _ _ _ _ _ _ _ _ _ _ _ ,_, _
,_,,_,,_. ____________________________
"
IN. INLET VALVE (NORMAllY OPENI OUT: OUTLET VALVE [NORMALLY CLOSEDI
Pressure intensifying mode:
Inlet valve open, outlet valve closed Master cylinder fluid is pumped out to the caliper. Inlet valve closed, outlet valve closed Caliper fluid is retained by the inlet valve and outlet valve. Inlet valve closed, outlet valve open Caliper fluid flows through the outlet valve to the reservoir. When starting the pressure reducing mode, the pump motor is ON. When stopping ASS operation, the pump motor is OFF. The caliper fluid is pumped out by the pump, through the damping chamber, to the master cylinder.
Pressure retaining mode:
Pressure reducing mode:
Motor operation mode:
19-40
Wheel Sensors
The wheel sensors are the magnetic contactless type. As the gear pulser teeth rotate past the wheel sensor's magnetic
coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ASS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed.
GEAR PULSER
O~
Wheel Speed and Modulator Control
SPEED
VEHICLE SPEeD
_t HIGH SPEED
.t lOW SPEED
REFERENCE VEHICLE
SPE~JL
WHEEL SPEED
TIME
PRESSURElLl0~.::====:::::::~_....::======:::::~~. _.......:::::::=
OUTLET VALVE 0::
INLET
VALVE OFF L_-L_________ ON
L--'.O...J...______-.JO....L__________..lO....L_
~~
In________________LLLL_______ I I0I
MOTOR ONt
OFF
~L-
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
When the wheel speed drops sharply below the vehicle speed, the inlet valve closes and if necessary, the outlet valve
opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, and the outlet valve closes, the inlet valve opens momentarily to increase the caliper fluid pressure .
,
19-41
ABS Components
Circuit Diagram
BATTERY
~,
UNDER-HOOD
FUSE/RELAV BOX
No. 1 (1511.)
BRAK E PEDAL POSITION SWITCH Clos ad: 8,.ke pedal pressed
' W, liGAN 'imL~

IGNITION SWITCH
WHTIBU(
WIfTIBLK UNDERDASH
FUSEIRELAYBOX
No_ 1918011.) N,,_201"'AJ
''-'
GAUGE ASSEMBLY
W,
'G1
~
T/BlK
ON 1111 ..... START [1"1
r..--~'~-:;;,",'">'----J,C!,~;)---'" --~.~,~, J.
YEUBlK
~YEL--,
m, .,mONI"]
~ otl.
...
No 11 (7 5A)
INDICATOR
BlU/RED
L...l>.-...........-<!jD---- '" ~
G!i'01
D I
BLK/DRN
BLK/DRN
No 8120A]
__________________________________________________________________ WIfT/GRN
...~
WHTIGRN
No. 10 (40AI
lr
T
WHTIRED
WHT/RED
WHEEL SENSOR LEFT.
""'~
RIGHT.
FRONT
LEFT
''''
- B
g~~~~~~~R (16P)
WHT/REO
RIGHTREAR
'7 l
Gl01
'"' '
'" ..Q...
"
~::::::::::::::::~==== ~':====-------------------------=-=:::~ ""------------~~ ~ ==========

BLU/ORN BRN/WHT GRN/BLK
)..
;...________________________________________ Btu/YEl
'"' '
YEL/RED
GRNIYEL
LTBLU
"" ~=====================================_____________________________________
- ----===========-:'''-LTBLU ____________
19-42
BS CABS MODULATOA-CONTAOL UNIT

ONTRO~
UNIT
MODULATOA UNIT
WHT/BlK BRAKE LIGHT
(j?
WHT/BLK
STOP
MULTIPLEX OONTJlOL UNIT
t-
BAN/YEL
'"
BLU/RED
,. '"
!!lKIORN
"
.,
BFSR
~I
FLO I
WHT/GRN
"
BMR
WHTIRED
"
!!lUIORN BRN/WHT
GRN/YEL BtU/YEl
====---'"
LTBLU
(cont'd)
~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 19-43
ABS Components
Circuit Diagram (cont'd)
UNDER-HOOD FUSE/RELAY BOX CONNECTORS CONNECTOR A (12P) CONNECTOR B (2P) BRAKE PEDAL POSITION SWITCH 4P CONNECTOR
lI[llif
UNDER-DASH FUSE/RELAY BOX CONNECTORS CONNECTOR I (5P) CONNECTOR K (17P) MULTIPLEX CONTROL UNIT 13P CONNECTOR
I1I2l
1 2 3 4 5 6 7 8 / 10 11 12113114 15 / 17
GAUGE ASSEMBLY CONNECTORS CONNECTOR A (22P)
1 2 3 / / 6 7 8 9110111 12 13
CONNECTOR B (22PI
145 111213141516
ABS CONTROL UNIT 31P CONNECTOR
10 22
1 2 3 4 5 6 1/ 8 9 10 11 12 13 / / 161XJ17 18 19 / 21 22
><
DATA LINK CONNECTOR 116P)
WHEEL SENSOR 2P CONNECTORS FRONT
~:ill:~
RIGHT-REAR LEFT-REAR
<ill:~
19-44
~
OTe Troubleshooting
OTe 11, 13, 15, 17: Wheel Sensor (Open/Short to Body Ground/Short to Power)
1. Disconnect the ASS control unit 31 P connector. 2. Start the engine. 3. Measure the voltage between the appropriate wheel sensor I + I circuitterminal of the ASS control unit 31 P connector and body ground Isee tablel. OTC 11 IRight-frontl 13 I Left-frontl 15lRillht-rearl 17lLeft-rearl Appropriate Terminal No.5: FRS 1+1 No.7: FLS 1+1 No.2: RRS 1+1 No.9 RLS 1+1 OTC 11 IRight-front) 13lLeft-frontl 15lRight-rearl 17lLeft-rearl Appropriate Terminal No.5: FRS 1+) No.7: FLS 1+1 No.2: RRS 1+1 No.9 RLS 1+1 5. Check for continuity between the appropriate wheel sensor I + I circuit terminal and body ground Isee tablel.
ABS CONTROL UNIT 31 P CONNECTOR FRS 1+ IIGNR/BLK) RRSI+I IGNR/YELI

1 2 16
FLS 1+) IBLU/ORN) RLSI+) IYEL/REDI
4 5 6 7 8 9 1112 1415 21 17 18 19 1"'2",0=."T'7r';n-'5.-'?I
ABS CONTROL UNIT 31P CONNECTOR FRS 1+ IIGNR/BLKI FLS I+IIBLU/ORNI RLSI+I IYEL/REDI
4 5 6 7 8 9 17 18 1112 1415
RRSI+I IGNR/YELI
1 2 16
19 p20",2",1""Y7r'On-'5.-'?I
Is there continuity? YES-Go to step 6. NO-Go to step 7.
Is there battery voltage? YES-Repair short to power in the I + I circuit wire between the ASS modulator-control unit and the
6. Disconnect the harness 2P connector from the appropriate wheel sensor, then check for continuity between the 1+1 and I-I terminals of the harness and body ground. Is there continuity? YES-Repair shortto body ground inthe 1+1 or I-I circuit wire between the ASS modulator-control unit and the wheel sensor.. NO-Replace the wheel sensor.
appropriate wheel sensor..

NO-Go to step 4. 4. Turn the ignition switch OFF.
Iconl'd)
19-45
ABS Components
7. Check the resistance between the appropriate wheel sensor 1+) and 1-) circuitterminals Isee table). DTC 11 IRight-lront) 13lLeft-frontl 15lRiQht-rearl 17 ILeft-rear) Appropriate Terminal 1-) Side 1+)Side NO.5: FRS 1+1 NO.4: FRS I-I ' No.7:FLSI-'-1 No.6: FLS I-I NO.2: RRS 1+1 No.1: RRS I-I No.9: RLS I-I No.8: RLS I-I
OTe 12. 14. 16. 18: Wheel Sensor Pulse Signal

NOTE: If the ASS indicator comes on lor the reasons described below, the indicator goes off when you testdrive the vehicle at 31 mph 150 km/hl. Only the drive wheel rotated The vehicle spun Electrical noise 1. Visually check for appropriate wheel sensor and pulser installation and condition Isee tablel. DTC 12 14 16 18 Appropriate Wheel Sensor Right-lront Left-front RiQht-rear Left-rear
1 2 16 17
4 5 6 7 8 9 18
1112
1415
19 1"2,"0=-21!J4--Y::.---":rJ4J.,i
Are they installed correctly and not damaged?

YES-Go to step 2.
NO-Reinstall or replace the appropriate wheel
sensor or pulser..
Is the resistance between 450- 2,000 Q ?
2. Disconnect the ASS control unit 31 P connector.
YES-Check for a loose ASS control unit 31 P connector. If necessary, substitute a knownMgood ASS modulator-control unit, and recheck . NO-Go to step 8.
3. Measure the resistance between the appropriate wheel sensor 1+) and I-I circuit terminals Isee tablel. DTC Appropriate Terminal (-)Side 1+)Side NO.5: FRS (+1 NO.4:FRSH No.6: FLS I-I No.7: FLS 1+1 No. 1: RRS H No.2: RRS 1+1 NO.8: RLS [-I No.9: RLSH
8. Disconnect the harness 2P connector from the appropriate wheel sensor, and check the resistance between the 1+) and I-I terminals of the wheel
sensor.
Is the resistance between 450-2,000 Q ?
12lRiaht-Irontl 14lLeft-frontl 16lRiQht-rearl 18lLeft-rearl
ASS CONTROL UNIT 31P CONNECTOR
YES-Repair open in the 1+ lor I-I circuit wire, or short between the 1+) circuit wire and the I-I circuit wire between the ASS modulator-control unit and the wheel sensor. NO-Replace the wheel sensor .
1415
Is there less than 450 Q ?

19-46
4. Check for continuity between the appropriate

wheel sensor (+) circuit terminal and other wheel sensor (+) circuit terminals (see table).
OTe 21: Continuous Operation (Chipped pulser)

1. Clear the OTC, then disconnect the Honda PGM
tester.
OTe Appropriate
12 14 16 18 Terminal No.5:
FRWI~)
Other Terminal No.7 No.5 No.5

i
No.2 No.2 No.7 No.7

,
No.9 No.9 No.9
2. Test-drive the vehicle at 19 mph (30 km/h) or more. Does the ABS indicator come on and is OTe 21 indicated? YES-Go to step 3.
No.7: FLWH No.2: RRWH
No.9: RLWH
No.5
i
No.2 NO-The system is OK althis time . 3. Check the pulser gear for a chipped tooth. Is the pulser OK? YES-Check for a loose ABS control unit 31 P connector. If necessary, substitute a known-good ABS modulator-control unit, and recheck . NO-Replace the driveshaft or hub unit (chipped pulser gear) .
Is there continuity? YES- Repair short in the wires between the appropriate wheel sensor and the other wheel
sensor harnesses .
NO-Clear the OTC, disconnect the Honda PGM Tester, and test-drive the vehicle. II the ABS indicator comes on and the same DTC is indicated, replace the ABS modulator-control unit.. 5. Disconnect the harness 2P connector from the
appropriate wheel sensor and check the resistance between the (+) side and the (-) side olthe wheel
sensor. Is there less than 450 Q ? YES-Replace the wheel sensor.

NO-Repair short to wire between the appropriate wheel sensor (+) and (-) circuits .
19-47
ABS Components
OTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid
1. Clearthe DTC, then disconnectthe Honda PGM Tester. 2. Test-drive the vehicle.
Does the ASS indicator come on and are 32, 33, 34, 35, 36, 37, 38 indicated?
OTC 51: Motor Locked

1. Check the No. 10 (40A) fuse in the under-hood fuse/ relay box.
Is the fuse OK?
orcs 31,
YES-Reinstall the fuse, and go to step 2. NO- Replace the fuse, and recheck .
YES-Replace the ASS modulator-control unit. 2. Disconnect the ASS control unit 31 P connector. NO- The system is OK atthis time . 3. Measure the voltage between the ASS control unit 31P connector terminal No. 17 and body ground.
1 2
1112
1415
16
YES-Go to step 4. NO-Repair open in the wire between the No. 10 (40A) fuse and the ASS control unit.
19-48
4. Check for continuity between the ABS control unit 31 P connector terminal No. 16 and body ground.
OTe 52: Motor Stuck OFF

1. Check the No. 10 (40A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES-Reinstall the fuse, and go to step 2. NO-Replace the fuse, and recheck . 2. Disconnect the ABS control unit 31 P connector. 3. Measure the voltage between the ABS control unit 31 P connector terminal No. 17 and body ground.
1245678911121415 2021
Is there continuity? YES-Go to step 5. NO-Repair open in the wire between the ABS control unit and body ground (G202).
1 2 16
1112
1415
5. Reconnect the ABS control unit 31 P connector. 6. Clearthe DTC, then disconnectthe Honda PGM
tester.
7. Test-drive the vehicle at 6 mph (10 km/h) or more. Is there battery voltage? Does the ABS indicator come on, and is OTe 51 indicated? YES-Replace the ABS modulator-control unit.. NO-The system is OK at this time . YES-Go to step 4. NO-Repair open in the wire between the No. 10 (40A) fuse and the ABS control unit.
Icont'dl
19-49
ABS Components
4. Check for continuity between the ABS control unit 31 P connector terminal No. 16 and body ground.
OTe 53: Motor Stuck ON

1. Clearthe DTC, then disconnect the Honda PGM
Tester.
1 [2 1/4 516 789/111121/1415 16 17 18 19 i2QL21J.(1/1/1/ /1. 1/ /1/1/1/

MGND IBLK)
2. Test-drive the vehicle.
Does the ABS indicator come on and is OTe 53 indicated?

YES, Go to step 3. NO-Intermittent failure, the system is OK at this time .
~~
3. Disconnect the ABS control unit 31 P connector.

4. Check for continuity between the ABS control unit 31P connector terminal No. 16 and body ground.
YES-Check for loose terminals in the ABS control unit 31P connector. If necessary, substitute a known-good ABS modulator-control unit, and recheck . NO-Repair open in the wire between the ABS control unit and body ground (G202) .
1245678911121415 2021
YES- Replace the ABS modulator-control unit.. NO-Repair open in the wire between the ABS control unit and body ground (G202) .
19-50
DlC 54: Main Relay Stuck OFF

1. Check the No.8 (20A) fuse in the under-hood fusel relay box, and reinstall the fuse if it is OK.
DlC 61: IG2 Voltage

NOTE: Check the No.1 1 (7.5A) fuse in the under-dash fuselrelay box before troubleshooting. 1. Clear the DTC, then disconnect the Honda PGM
tester.
Is the fuse OK?

YES~Go
to step 2. 2. Test-drive the vehicle. the fuse, and recheck .
NO~Replace
2. Disconnect the ASS control unit 31 P connector. 3. Measure the voltage between the ASS control unit connector terminal No. 18 and body ground.
Does the ABS indicator come on and is DTe 61 indicated?

YES~Go
to step 3. system is OK at this time .
NO~ The
3. Disconnect the ABS control unit 31 P connector.
1 2 16 17
4 5 6 7 8 9 18
1112
1415
19 1"2~0-".21'"T-1j,-l:~~-y
4. Turn the ignition switch ON (II). 5. Measure the voltage between the ASS control unit 31P connectorterminal No. 15 and body ground.
+B-FSR (WHT IGRNI
IG2 (BLK/ORNI
1245678911121415

YES~Replace
16
17
18
19 1=2",0=-21"'T-'Srl';,...>7c'Sc"?i
the ASS modulator-control unit..
NO~Repair open in the wire between the ASS control unit and the under-hood fuselrelay box .

YES~Replace
the ASS modulator-control unit..
NO~ Repair
open in the wire between the ASS
control unit and the under-hood fuse/relay box .
19-51
ABS Components
DTC 81: CPU (Central Processing Unit)
1. Clear the DTC, then disconnect the Honda PGM Tester. 2. Test-drive the vehicle.
ASS Indicator Circuit Troubleshooting

ABS indicator does not come on
1. Turn the ignition switch ON (II), and watch the ABS
indicator.
Does the ABS indicator come on and is DTC 81 indicated?

YES-Replace the ASS modulator-control unit .
Does the ABS indicator come on?

YES- The system is OK at this time . NO-Go to step 2.
NO- The system is OK at this time . 2. Pull up the parking brake lever.
Does the brake system indicator come on?

YES-Go to step 3.
NO- Repair open in the indicator power source
circuit. If necassary, substitute a known-good ASS modulator-control unit. and recheck . Blown No. 10 (7.5A) fuse. Open in the wire between the No. 10 (7.5A) fuse and the gauge assembly.
Open circuit inside the fuse box.
3. Turn the ignition switch OFF. 4. Disconnect the ASS control unit 31 P connector. 5. Turn the ignition switch ON (II).
Does the ABS indicator come on?

YES-Check for loose terminals in the ASS control unit 31 P connector. If necessary, substitute a known-good ABS modulator-control unit. and recheck . NO-Go to step 6. 6. Turn the ignition switch OFF. 7. Remove the gauge assembly (see page 22-64).
19-52
8. Disconnect the gauge assembly connector A (22P). 9. Check for continuity between gauge assembly connector A (22PI terminal No. 12 and body ground.
GAUGE ASSEMBLY CONNECTOR A 122PI
ABS indicator does not go off

1. Check the No.8 (20AI fuse in the under-hood fuse/ relay box, and reinstall the fuse if it is OK.
Is the fuse OK?
YES-Go to step 2.
4 5
17
ABS IBLU/REDI
10
22
111213141516
Q
=
NO-Replace the fuse, and recheck. If the fuse is blown, check for a short to body ground in this fuse circuit. If the circuit is OK, replace the ABS modulator-control unit. 2. Check the No. 11 (7.5AI fuse in the under-dash fuse/relay box, and reinstall the fuse if it is OK.
Is the fuse OK?
YES-Go to step 3. NO-Replace the fuse, and recheck. If the fuse is blown, check for a short to body ground in this fuse circuit. If the circuit is OK, replace the ABS modulator-control unit.. 3. Disconnect the ABS control unit 31P connector.
YES-Repair short to body ground in the wire between the gauge assembly and the ABS control unit. NO-Go to step 10. 10. Disconnect the gauge assembly connector B (22PI. 11. Check for continuity between gauge assembly connector B (22PI terminal No. 12 and body ground.
GAUGE ASSEMBLY CONNECTOR B 122P)
4. Measure the voltage between terminal No. 18 and body ground.

1 2
4
17
1112
1415
1 2 3 4 5
111213 16
GND IBlK)
6
171819
8 9 10
2122
16
+B-FSR IWHTIGRN)
Q
=
Is there battery voltage? Is there continuity?
YES-Go to step 5. YES-Check for loose terminals in the gauge assembly connectors. If the connectors are OK, replace the gauge assembly .
NO-Repair open in the wire between the gauge assembly and body ground (G501) .
NO-Repair open in the wire between the No.8 (20A) fuse and the ABS control unit..
(cont'd)
19-53
ABS Components
ASS Indicator Circuit Troubleshooting (cont'd)
5. Turn the ignition switch ON (II). 6. Measure the voltage between the ASS control unit 31P connectorterminal No. 15 and body ground.
10. Connectthe ABS control unit 31P connector terminal No. 20 and body ground with a jumper wire.
ABS CONTROL UNIT 3,P CONNECTOR
1 2 1/4 5167891/11121/1415 16 17 18[19 TiDr211/1/1/1/VT 1/1/1//

IG2 IBLK/ORNI
ABS IBLU/REDI JUMPER WIRE
1245678911121415 16 17 18 19 p20=21"'Y~;,->7r'7r-Y
=
Does the ABS indicator go off?
YES-Check for loose terminals in the ABS control unit 31 P connector. If necessary, substitute a known-good ABS modulator-control unit, and recheck . NO-Goto step 11. 11. Remove the gauge assembly, and leave the

YES-Go to step 7. NO-Repair open in the wire between the No. 11 17.5A) fuse and the ASS control unit.. 7. Turn the ignition switch OFF. 8. Check for continuity between the ABS control unit 31 P connectorterminal No. 19 and body ground.
connectors connected. Connect the gauge

assembly connector A (22P) terminal No. 12 and body ground with a jumper wire.
GAUGE ASSEMBLY CONNECTOR A 122P}
1 2
16 17
4
18
1112
1415
1 4 5 111213141516
JUMPER WIRE
6 17
10
22
ABS IBLU/RED}
=
=
YES-Go to step 9. NO-Repair open in the wire between the ABS control unit and body ground (G202) . 9. Turn the ignition switch ON (II).
Does the ABS indicator go off?

YES~Repair
open in the wire between the gauge assembly and the ABS control unit .
NO-Check for loose gauge assembly connectors. If the connectors are OK, replace the printed circuit board in the gauge assembly .
19-54
r5'I
Brake System Indicator Circuit Troubleshooting
Brake system indicator does not come on
1. Disconnect the multiplex control unit 13P connector and the ASS control unit 31 P connector. 2. Check for continuity between the ASS control unit 31Pconnectorterminal No. 21 and body ground.
Brake system indicator does not go off

1. Turn the ignition switch ON (II). 2. Release the parking brake.
Does the brake system indicator go off after several seconds?

YES- The system is OK at this time . NO-Go to step 3. 3. Check the brake fluid level.
12 16 17
456789 1112 1415 21 18 19 "2,,,0"."y'Sr";""><;rS--L,i

EBD IBRN/YELJ
Is the level OK?

YES-Go to step 4.
NO-Refill the brake fluid, and recheck . 4. Check the ASS indicator.
Is there continuity? Does the ABS indicator stay on?

YES-Repair short to body ground in the wire between the multiplex control unit and the ASS control unit.. NO-Go to multiplex control system troubleshooting (see page 22-1721 . YES-Read the ASS DTC (see step 1 on page 19-321. and do the applicable troubleshooting for the DTC. NO-Go to step 5. 5. Turn the ignition switch OFF. 6. Disconnect the ASS control unit 31 P connector. 7. Connect the ABS control unit 31 P connector terminal No. 21 and body ground with a jumper wire.
112 VI4 516 789/11121/1415 19 201211/1/ /1/1/1 16 17 18 I 1/1/1/1/1/

EBD IBRN/YELJ JUMPER WIRE
Iconl'dl
19-55
ABS Components
Brake System Indicator Circuit Troubleshooting (cont'd)
8. Turn the ignititon switch ON (III. 9. Check the brake system indicator.
Does the brake system indicator go off?

YES-Replace the ABS modulator-control unit.. NO-Go to step 10. 10. Turn the ignition switch OFF. 11. Connect the multiplex control unit 13P connector terminal No.1 and body ground with a jumper wire.
MULTIPLEX CONTROL UNIT 13P CONNECTOR
JUMPER WIRE
=
12. Turn the ignition switch ON (II). 13. Check the brake system indicator.
Does the brake system indicator go off?

YES-Repair open in the wire between the multiplex control unit and the ABS control unit. NO-Go to multiplex control system troubleshooting (see page 22-1721 .
19-56
.,..
~
ASS Modulator-Control Unit Removal and Installation
NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. Be careful not to damage or deform the brake lines during removal and installation. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.
Removal
1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31 P connector (B), then disconnect the connector.
BmmNUT 8.8 Nm (0.9 kgfm, 6.5 Ibfftl
~6mmBOLT
/
/ j
/9.8Nm (10 kg!.m, 7.2Ib!ftl
(conl'd)
19-57
ABS Components
ABS Modulator-Control Unit Removal and Installation (cont'd)
3. Disconnectthe six brake lines. 4. Remove the two 8 mm nuts.
5. Remove the ABS modulator-control unit (CI.
Installation
1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface olthe ABS control unit 31P connector.
3. Push in the lock of the ASS control unit 31 P connector until you hear it click into place, then connect the connector.
4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the PGM Tester, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the Honda PGM Tester. Test-drive the vehicle, and check that the ABS indicator and brake system
indicator do not come on.
19-58
nil
~
Wheel Sensor Inspection
1. Inspect the front and rear pulsers for chipped or damaged teeth.
2. Measure the air gap between the wheel sensor and the pulser all the way around while rotating the pulser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 in.), check for a bent suspension arm.
Wheel Sensor Replacement

NOTE: Install the sensors carefully to avoid twisting the
wires.
Front:
Standard: Front: Rear: Front:
0.4-1.0 mm (0.02-0.04 in.) 0.2-1.0 mm (0.01-0.04 in.)
O.4-1.0mm
10.02-0.04 in.)
Rear:
O.2--1.0mrn
6mmBOLT 9.8Nm 11.0 kgfm, 7.2Ibfft)
6 mm BOLT 9.8Nm 11.0 kgfm, 7.2Ibfft)
10.01-0.04 in.)
~J.=,~
WHEEL SENSOR
19-59
Body
Doors
Component Location Index ........................... Door Panel Removal/Installation .................. Door Outer Handle Replacement ................. Door Latch Replacement ............................... Door Glass and Regulator Replacement ............................................... Door Sash Trim Replacement ....................... Door Glass Outer Weatherstrip Replacement ............................................... Door Weatherstrip Replacement .................. Door Glass Adjustment ................................. Door Position Adjustment ............................. Door Striker Adjustment ................................ 20-2 20-4 20-6 20-7 20-9 20-10 20-10 20-11 20-11 20-12 20-13 20-14 20-15 20-15 20-16 20-17 20-19 20-25 20-29 20-35 20-36 20-37 20-37 20-38 20-39 20-40 20-41 20-42 20-44 20-46 20-48 20-49 20-50 20-51 20-52 20-53 20-54 20-55
Dashboard
Instrument Panel Removal/Installation Driver's Dashboard Lower Cover Removal/Installation .................................. Driver's Dashboard Under Cover Removal/Installation .................................. Driver's Pocket Removal/Installation ............ Shift Lever Trim Removal/Installation .......... Center Panel Removal/Installation ............... Passenger's Dashboard Lower Cover Removal/Installation .................................. * Glove Box Removal/Installation ................... Dashboard Side Vent Removal/Installation .................................. Beverage Holder Removal/Installation ........ Driver's Tray Removal/Installation ............... Passenger's Tray Removal/Installation ........ * Dashboard Removal/Installation .................. Steering Hanger Beam Replacement ........... 20-59 20-59 20-60 20-60 20-61 20-62 20-63 20-63 20-64 20-64 20-65 20-65 20-66 20-68
Mirrors
Component Location Index ......................... Power Mirror Replacement ........................... Mirror Holder Replacement ........................... Rearview Mirror Replacement ......................
Glass
Component Location Index ........................... Windshield Replacement .............................. Rear Window Replacement ........................... Quarter Glass Replacement ..........................
Seats
Component Location Index ........................... 20-70
* Front Seat Removal/Installation ................... 20-71

* Front Seat Disassembly/
Reassembly-Driver's ........... 20-73 20-74 20-80 20-81 20-81 20-82 20-84 20-85 20-86
Moonroof
Component Location Index ........................... Symptom Troubleshooting Index ................. Glass Height Adjustment ............................... Glass Replacement ........................................ Wind Deflector Replacement ........................ Drain Channel Replacement .......................... Sunshade Replacement ................................. Motor Replacement ....................................... Frame and Drain Tube Replacement ............ Drain Channel Slider and Cable Assembly Replacement ............................................... Limit Switch Adjustment ............................... Closing Force and Opening Drag Check ......
* Front Seat Disassembly/

Reassembly-Passenger's ................. Rear Seat RemovaUlnstallation ..................... Rear Seat-back Latch Replacement .............. Rear Seat-back Striker Replacement ............ Rear Seat-back Cover Replacement ............. Rear Seat Cushion Cover Replacement .......
* Front Seat Cover Replacement ..................... 20-75
Bumpers
Front Bumper Removal/Installation Rear Bumper Removal/Installation.
Hood
Adjustment ..................................................... 20-87 Hood Seal Replacement ................................ 20-88 Hood Insulator Replacement ......................... 20-89
Interior Trim
Component Location Index ........................... Trim Removal/Installation-Door Area .......... Trim Removal/Installation -Rear Side Area ........................................... Trim Removal/Installation -Cargo Floor Area ....................................... Trim Removal/Installation-Hatch Area ......... Headliner Removal/Installation ..................... * Carpet Replacement .......................................
Hatch
Adjustment ..................................................... 20-90 Hatch Support Strut Replacement ................ 20-91 Hatch Weatherstrip Replacement ................. 20-92
Fuel Fill Door

Adjustment ..................................................... 20-93
Exterior Trim
Front Grille Replacement .............................. . Cowl Covers Replacement ........................... . A-pillar Corner Trim Replacement ............... . Roof Molding Replacement ....................... . Rear License Trim Replacement .................. . Hatch Spoiler Replacement .......................... . Emblem Replacement ................................... . 20-94 20-95 20-96 20-97 20-98 20-99 20-100
Consoles
Consoles, Front and Rear Removal/Installation .................................. 20-57 Front Console Disassembly/Reassembly ..... 20-58
Fenderwell
Front Inner Fender Replacement .................. 20-102
Front Fender Fairing Replacement ............... 20-103 Fuel Pipe Protector Replacement .................. 20-104
Rear Air Outlet Replacement ......................... 20-104
Openers
Component Location Index ........................... 20-105 Hood Opener Cable Replacement ................ 20-106
* Fuel Fill Door Opener Cable

Replacement ............................................... 20-107 Hood Latch Replacement .............................. 20-108 Fuel Fill Door Opener Replacement .............. 20-109
Hatch Handle Replacement ........................... 20-110 Hatch Latch Replacement .............................. 20-110
Hatch Lock Cylinder Replacement ................ 20-111
Frame
Subframe Replacement ................................. 20-112 Frame Stiffener, Brace, and Gusset Replacement ............................................... 20-113 Frame Repair Chart ........................................ 20-114
Doors
DOOR
f
REFLECTOR TAPE DOOR SHOULDER PAD
OU:\TER
S
~__
T~ ~~~:c~~~~t:~~~e
'
20- 10
DOOR GLASS OUTER WEATHERSTRIP ~~__ Replacement, page 20-10

/
~"'-~ t.l if'1\i=iN>
~.~~ j;';J
PLASTIC\_'
~;0
~.
2~~ DOOR Adjustment, Position

page 20-12
'I
, 'I
~~
,,,-~, ,~
\
SPEAKER
'~HINGE
~ ~~
DOOR GLASS INNER WEATHERSTRIP
______ HINGE
DETENT ROD
"" c
INNER HANDLE DOOR WEATHERSTRIP Replacement, page 20-11 SWITCH PANEL POWER WINDOW SWITCH \ -
-~ --~
~~ ~ ,~--~::::~-~~-_.-~ _,---;;:;+;:,1-~-,"------ ;<

~
~~~ ~
';>--"y/
~
~
l!lR\
POWER DOOR LOCK SWITCH {Driver's}
---_S"-'--'-_.::-:::y
DOOR GRIP COVER
y~~
~
DOOR GRIP BASE \
ARMREST COVER
DOOR PANEL
Removal/Installation, page 20-4
20-2

IMMOBILIZER LABEL
==
.~
REGULATOR Replacement, page 209
FRONT LOWER CHANNEL
OUTER HANDLE PROTECTOR
LATCH Replacement, page 20-7
20-3
Doors
Door Panel Removal/Installation
Special Tools Required Trim pad remover, Snap-on A 177A or equivalent, 3. Remove the armrest cover (A). Take care not to
scratch the door panel.

-1 Pry out the front edge of the cover to release the hooks IB). -2 Pry out the bottom and rear edge of the cover to release the hooks Ie). -3 Pry out along the top to release the tabs ID).
A
commercially available. NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. 1. Remove the mirror mount COver Isee page 20-15). 2. Insert a hex wrench through the hole IA) in the door grip base IB). Push the door grip cover Ie) out to release the hook ID) and tab IE), and pullout the cover to release the tabs IF) and hook IG) by hand,
then remove the cover.
B
/ f
~.
>-
-----------
J..._--
4. Remove the screws lA, B), and release the tabs Ie), then remove the door grip base ID). Remove the
screw (A) securing the door panel from the armrest
portion.
Fastener Locations
A .... : Screw, 3
B .... : Screw, 5
20-4
5. Pull out the switch panel (A) to release the hook (8), then remove the panel from the door panel.
Disconnect the power window switch connector (C).
7. Disconnect the inner handle cable (A) from the inner handle 18i. and disconnect the power door lock switch connector (C) (driver's). Take care not to bend the cable.
----------===~==
---------
8. Detach the harness clip (A) from the door panel (8).
C
6. Release the clips that hold the door panel (A) with a commercially available trim pad remover (8), then remove the door panel by pulling it upward. Remove the door panel with as little bending as
possible to avoid creasing or breaking it.
Fastener Locations
95 mm (3.74 in.)
C>: Clip, 9
12mm (0.47 in.)
~ T-I,
:::::
1mm (0.04 in.) r-~
L-~
45 mm (1.77 in.)
9. Install the door panel in the reverse order of removal, and note these items:
Replace any damaged clips . Make sure the cable is connected securely, and the connector is plugged in properly. Check the window and power door lock
operations,
20-5
Doors
Door Outer Handle Replacement
NOTE: Put on gloves to protect your hands.
1. Remove these items:
4. Disconnect the cylinder rod IA). and release the retainer clip IB). then remove the lock cylinder Ie).
Door panel Isee page 20-4) Plastic cover, as necessary Isee page 20-2)
2. Raise the glass fully.

3. Remove the lock rod protector IA).
-1 Remove the screw. -2 Release the protector from the latch protector IB). -3 Pull the protector down to release the hook Ie) from the door.
Fastener location
~:
5. Disconnect the outer handle rod IA).

Fastener Locations
Screw, 1
~: Bolt, 2
6. Remove the maintenance cap IB). and remove the bolts securing the outer handle Ie) while holding the handle from outside. Release the hook (0), then remove the outer handle protector IE).
20-6
Door Latch Replacement

7. Pull out the outer handle (A), then remove it. NOTE: Put on gloves to protect your hands.
Door panel (see page 20-4) Plastic cover, as necessary (see page 20-2) 2. Raise the glass fully.
3. Remove the lock rod protector (see step 3 on page 20-6).
4. Pull the glass run channel (A) away as necessary,

and remove the bolt, then remove the center lower
channel (B) by pulling it downward. 8. Install the handle in the reverse order of removal,
and note these items: Make sure each rod is connected securely.
Fastener Location
~:
Make sure the door locks and opens properly. When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder installation, then tighten the handle bolts . Install the lock cylinder retaining clip on the handle, then install the lock cylinder. Be sure the clip is fully seated in the slot on the lock cylinder. When reinstalling the door panel, make sure the
plastic cover is installed properly, and is sealed around the covers perimeter.
.1
Bolt, 1
6xl.0mm SNm
(O.S kgfm, 6 Ibf!t)
(cont'd)
20-7
Doors
Door Latch Replacement (cont'd)
5. Disconnect the cylinder rod (see step 4 on page 206).
9. Install the latch in the reverse order of removal, and
note these items:

Make sure the actuator connectors are plugged in
6. Disconnect the outer handle rod (see step 5 on

page 20-6).
7. Disconnect the actuator connectors (A), and release the inner handle cable (B) from the door by detaching the cable clip (C).
properly, and that each rod and cable are

connected securely.
When reinstalling the door panel, make sure the plastic cover is installed properly, and is sealed
around the covers perimeter.
Make sure the door locks and opens properly.
8. Remove the screws, then remove the latch (A)
through the hole in the door. Take care not to bend the outer handle rod (8), cylinder rod (C), lock rod (D), and inner handle cable (E).
Fastener Locations
~: Screw, 3
c==j
C--t~-
6x 1.0 mm
20-8
Door Glass and Regulator Replacement

NOTE: Put on gloves to protect your hands. 1. Remove these items: Door panel (see page 20-41 Plastic cover, as necessary (see page 20-2) 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to drop the glass inside the door.
Fastener Locations
3. Disconnect and detach the connector (A) and harness clip (8) from the door.
Fastener Locations
c~: Bolt, 1 D~ : Bolt, 5
tiP
~D.g",r~
6xl.0mm BNm . D'. 10.B kgfm, 0 ~ . ~ "'. 6Ibf.ftl.I,
- .Lf
>\
~~ri.
0
~: Bait, 2
_/ ,
!
(-;I'.j
- A - .--_=cc~
--j/.
B
.'
-c
4. Remove the bolts (C), and loosen the bolts (D), then remove the regulator (E) through the hole in the door. 5. Apply multipurpose grease to all the sliding surfaces of the regulator (A) where shown.
6x1.0mm 9.B Nm (1.0 kgfm, 7.2Ibfftl
6. Install the glass and regulator in the reverse order

of removal, and note these items:
Roll the glass up and down to see if it moves freely without binding.
Make sure that there is no clearance between the
glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary (see page 20-111. Check for water leaks (see step 7 on page 20-12).
Test-drive and check for wind noise and rattles. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter.
20-9
Doors
Door Sash Trim Replacement
NOTE: Take care not to scratch the door. 1. Remove the door glass outer weatherstrip. NOTE: Put on gloves to protect your hands. Take care not to scratch the door.
1. Remove the power mirror (see page 20-151.
Door Glass Outer Weatherstrip Replacement
2. Pull back the door weatherstrip (AI at the rear

upper corner, and remove the screw.
Fastener Location
~: Screw, 1
2. Starting at the front, pry the door glass outer weatherstrip (AI up to detach the clips (BI, and
release the weatherstrip from the door sash trim
(CI, then remove the weatherstrip.

Fastener locations
B [>: Clip, 5
A
A
A
C
3. Lift up the door sash trim (BI to release the hooks (CI, then remove the trim.
C
3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips.
4. Install the trim in the reverse order of removal.
20-10
Door Weatherstrip Replacement

NOTE: Take care not to scratch the door.
Use a clip remover to remove the clips.
Door Glass Adjustment

NOTE: Check the weatherstrips and glass run channel for damage or deterioration, and replace them if
necessary .
1. At the A-pillar, remove the door stop mounting bolt

(A).
Wipe the run channel clean with a shop towel.

Lubricate the run channel with Shin-Etsu grease
PIN 08798-9013,
Fastener locations
A~: Bolt, 1
B C>: Clip, 1
CC>: Clip, 18
1. Place the vehicle on a firm, level surface.

Ooor panel (see page 20-4) Plastic cover (see page 20-2) 3, Carefully move the glass (A) until you can see the glass mounting bolts (B), then loosen them.
1--------
I
C
'c
\~,,~/~, ,f~~
\
~---c=;:--~-J;'~
\'...."';\' ./~--/-i:,
"
\
"
B 6x 1.0 mm 9.8 Nm 11.0 kgl.m, 7.2Iblftl
4. Push the glass against the channel (C), then tighten the glass mounting bolts. 2. Detach the clips (B, C), then remove the door weatherstrip (D).
3. Install the weatherstrip in the reverse order of removal and note these items:
5. Check that the glass moves smoothly.
Replace any damaged clips.

Make sure the weatherstrip is installed in the
holder (E) securely. Apply liquid thread lock to door stop mounting bolt before installation. Check for water leaks (see step 7 on page 20-12).
Test-drive and check for wind noise.
(cont'd)
20-11
Doors
Door Glass Adjustment (cont'd)
6. Raise the glass fully, and check for gaps. Check that the glass (A) contacts the glass run channel (8) evenly.
Door Position Adjustment

NOTE: Check for equal gaps between the front, rear, and bottom door edges and the body. Check that the door and body edges are parallel.
1. Place the vehicle on a firm, level surface when adjusting the door.
2. Adjust at the hinges (A):

Remove the front inner fender (see page 20-102) and front fender fairing (see page 20-103). Loosen the hinge mounting bolts (8) slightly, and move the door backward or forward, up or down as necessary to equalize the gaps. Place a shop towel (C) on the jack (D) to prevent damage to the door when adjusting the door.
7. Check for water leaks. Run water over the roof and
on the sealing area as shown, and note these items:
Use a 12 mm (1/2 in.) diameter hose (A). Adjust the rate of water flow as shown (8). Do not use a nozzle. Hold the hose about 300 mm (12 in.) away from the door (C).
12 mm (1/2 in.)
!I
!::~";;;J~'T
i i, .
0.5 m (18 in.1
B 8x1,25mm 29 Nm (3.0 kgfm, 22lbfttl
~--B
300 mm (12 in.1
_-=--=
/C----C
~--=--=:::-:-"-"-~-
---1--
-:=====::::::,-..<,,<>
8. Attach the plastic cover, and install the door panel (see page 20-4).
9. Test-drive and check for wind noise.
20-12
Door Striker Adjustment

3. Check that the door and body edges are parallel. If necessary, adjust the door cushions IAI to make the rear of the door flush with the body.
>---------
Make sure the door latches securely without slamming it. If necessary, adjust the striker IAI: The striker nuts are fixed, but the striker can be adjusted slightly up or
down, and in or out.
1. Loosen the screws 181, then insert a shop towellCI between the body and striker.
A
4. Apply body paint to the hinge mounting bolts and around the hinges. 5. Check for water leaks Isee step 7 on page 20-121.
6. Test-drive and check for wind noise.
8x 1.25 mm 18 Nm 11.8 kgfm, 13Ibfft)
2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer IDI. Do
not tap the striker too hard. 4. Loosen the screws, and remove the shop towel.
5. Lightly tighten the screws. 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the
screws and recheck.
20-13
Mirrors
POWERMIRRO RACTUATOR e22-118 Replacement, pa 9
~~
\ TWEETER
\ -~"-"
MIRROR MOUNT COVER
MIRROR HOLDER e 20-15

Replacement, pag
SPRING
REARVIEW ~IRp:~R20 16
Replacemen ,
20-14
Power Mirror Replacement

1. Lower the door glass fully.
2. Carefully pry out the mirror mount cover (A) by
hand in the sequence shown. Disconnect the tweeter connector (B), and release the wire harness
Mirror Holder Replacement
==
1. Carefully pull out the bottom edge of the mirror holder (A) by hand. Take care not to scratch the
mirror.
C
(C) from the hook (D).

Fastener Location
[>: Clip, 1
B
B
------....::
----------
3. Remove the door panel (see page 20-4).
2. Separate the mirror holder from the actuator (8) by slowly pulling them apart while detaching the clips (C). If equipped, disconnect the mirror defogger connectors(D) from the heater pad terminals. 3. If equipped, reconnect the mirror defogger
connectors.
4. Disconnect the connector (A), and detach the harness clip (8). While holding the mirror (C),
remove the nuts, then remove the mirror. Take care not to scratch the door.
Fastener Locations
4. Reattach the clips of the mirror holder to the

actuator, then position the mirror holder on the
actuator. Carefully push on the clip portions of the mirror holder until the mirror holder locks into place. 5. Check the operation of the actuator.
/
A
5. Install the mirror in the reverse order of removal, and note these items: Make sure the connector is plugged in properly .
Attach the harness clip .
20-15
Mirrors
Rearview Mirror Replacement
1. Turn the mirror base (A) 90 0 in either direction.
4. Fit the mirror base over the mount, and secure the mirror by turning the base 90,
~.t~~,.
I . . . .
................
~{<:. :: . .
2. Slide the rearview mirror (A) down toward the bottom of the windshield, then detach it from the spring (8) in the mount (C), and remove the
rearview mirror. Take care notta scratch the mirror
base.
3. If necessary, remove the spring from the mount.
20-16
Glass
PASSENGER' CAUTION LA~EtIRBAG
FASTENER 2 (Self-adhes'ive-t ype, glass side)
,p
l'J:3
JJ IJ
If
(f
---_~ /
,
~~
I,
FASTENER 2 IClip,type, body side) ' / WINDSHIELD MOLDING
~",y{SIDERUBBERDAM
"
;
'"
.' wY,.fj . , . , , _ _ 1
'"
11
tiP
,,J,y
7//""".,,.::
fY
./;:;;;:;;;>/
......
~,
WINDSHIELD
Replacement, page 20,19
/
"
""~__ ""
-=-"_c'--- ' \
-LOWER RUBBE ROAM R R\UBBER DAM 4 UPPE
X'/~
/;;_/
/--> \'-"-
"';'~~WIN
8'
DSHIELDSIDETRIM
f?~;i g~~2 "Jil,'

\J
CLIP CLIP, 4 Blue
aU
~~
~---~'.,~.,
'''"00
_ _ _ RETAINER 6
"""
~,
SPOILER FASTENER 2
'~"""~'
~"" CO
'CO
"",
OJ ; ; />--', " /
CO
/"~-'~
=:o:.m,\""
SIDE UPpDiEOCR;------FASTENER,2 (Self-adhesive-t hatch side) ype,
SIDE UPPER FASTENER 2 (Self-adhes'ive-t glass side) ype,
SEAL SIDE LOWER FASTENER 2 (Self-adhes'ive-t hatch side) ype, SlOE LOWER FASTENER 2 (Self-adhes'ive-t ype, glass side)
LOWER RUBBER DAM
(cont'd)
2\)-'\1
Glass
RUBBER DAM
QUARTER GLASS FRONT SEAL
UPPER CLIP (self-adhes;ve-lypel
\~. [J..
,'i
I'
... ..
/
'~~-........~ "'~,
ii
I' I'
"
I'
"
"
'
...
LOWER CLIP
(Setf-adhesive-type)
/'-J
~
......... /
---------------
........... )
\
LEV EMBLEM ('03 modell

QUARTER GLASS
REAR CLIP
(Self-ad hesive-type)
if
20-18
Windshield Replacement
NOTE: Put on gloves to protect your hands. Wear eye protection while cutting the glass adhesive
with piano wire.
3. Remove the cowl covers Isee page 20-951. 4. Remove the molding IAI from the upper edge of the windshield IBI. If necessary, cut the molding with a utility knife.
A
Use seat covers to avoid damaging the seats. 1. Remove these items: Rearview mirror Isee page 20-161 Windshield wiper arms Isee page 22-1451 2. Pull up the side trim IAI to release the clips IBI from the retainers lei, and pull the trim rearward to release it from the clip IDI then remove the trim from each side of the windshield.
5. If the old windshield is to be reinstalled, make alignment marks across the glass and body with a
grease pencil.
6. Pull down the front portion of the headliner Isee page 20-541. Take care not to bend the headliner excessively, or you may crease or break it. 7. Apply protective tape along the edge of the dashboard and body. Using an awl, make a hole through the rubber dam, adhesive, and dashboard
seal from inside the vehicle at the corner portion of
the windshield. Push a piece of piano wire through the hole, and wrap each end around a piece of wood .
Icont'dl
20-19
Glass
Windshield Replacement (cont'd)
8. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield (8) as possible to prevent damage to the body and dashboard. Carefully cut through the rubber dam and adhesive (C) around the entire windshield. 10. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire windshield opening
flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the rubber dam and fasteners from the body. 11. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil,
grease and water from getting on the clean surface.
--
----~--
c
Cutting portions:
A
12. If the old windshield is to be reinstalled, use a putty knife to scrape off all of the old adhesive, the fasteners and the rubber dam from the windshield. Clean the inside face and the edge of the windshield with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept
free of water, oil, and grease.
/
..... . . . r~\:
::i:/:'.........
'j---
/ ./
c
9. Carefully remove the windshield.
20-20
==
13. Glue the side rubber dams IAI and lower rubber dam IBI with adhesive tape INITIO 501 M, or equivalentl. Glue the fasteners lei with adhesive tape 13M 4215, or equivalentl to the inside face of the windshield IDI as shown: Be sure the rubber dams and fasteners line up with the alignment marks IE). Be careful not to touch the windshield where adhesive will be applied.
E
14. Glue the molding IA) with adhesive tape IB) 13M 4212, or equivalent) to the upper edge of the windshield Ie): Be sure the alignment mark ID) of the molding lines up with the alignment mark IE) of the windshield. Be careful not to touch the windshield where adhesive will be applied.
D
E B
12.5 mm
(0.49 in.1
B~' E
~---,
15. Install the fasteners IA), retainers IB, e), and clips ID) to the body.
12.5 mm
(0.49 in.1
Fastener Locations
A l> : Fastener, 2
B [> : Retainer, 2
c [>: Retainer, 6
D[>: Clip, 2
12.5 mm
(0.49 in.1
- --<-"'"
Iconl'd)
20-21
Glass
16. Set the windshield in the opening, and center it.
Make alignment marks (A) across the windshield and body with a grease pencil althe four points shown. Be careful not to touch the windshield where adhesive will be applied.
A
18. With a sponge, apply a light coat of glass primer around the edge of the windshield (A) between the dams (B) and molding (e) as shown, then lightly wipe it off with gauze or cheesecloth: Apply glass primer to the molding. Do not apply body primer to the windshield, and do not get body and glass primer sponges mixed up.
Never touch the primed surfaces with your hands.
!
------------
If you do, the adhesive may not bond to the windshield properly, causing a leak afterthe windshield is installed. Keep water, dust, and abrasive materials away from the primed surface.
: Apply glass primer here.
17. Remove the windshield.
c~
...
;
- r - - ---
Inside
'~A
--.---.--.:;:~---.-.---------
20-22
19. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes: Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges. Never touch the primed surfaces with your hands. Mask off the dashboard before painting the flange.
: Apply body primer here.
21. Pack adhesive into the cartridge without air pockets

to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive IAI around the edge of the windshield (BI between the dams (el and molding (DI as shown. Apply the adhesive within 30 minutes atter applying the glass primer. Make a slightly thicker bead at each corner.
12mm ~ ... 10.47 in.1 f 7mm 10.28in.1
A"
C /
""'II'lI'=-+-' Overlap in.1 1 mm10.04

'-.
o
20mm
'----B
2mm
Inside
10.79 in.1
- '--I
20mm
10.79 in.1
)\\
C
In5!~e
--=~::::::::::-,
20. Before filling a cartridge, cut a "V" in the end of the nozzle IAI as shown.
2mm
~d~1 ~
10.08 in.1
_' ....-- A
',\
Inside
10.08 in.1 ,-- -'

A
c~~~B
/
"~
12 mm (0.47 in.)
22. Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 16, and set it down on the adhesive. Lightly push on the windshield until its edges are fully
seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.
A'"
7 mm 10.27 in.)
(cont'dl
20-23
Glass
23. Scrape or wipe the excess adhesive off with a putty
knife or towel. To remove adhesive from a painted
surface or the windshield, wipe with a soft shop towel dampened with alcohol.
27. On both sides of the windshield, install the side trim (A) to the clip (8), then set the bottom edge of the side trim over the cowl cover (C). and align the clips (D) with the retainers (E), and push on the clip
portions of the trim until the trim is fully seated on
24. Let the adhesive dry for at least 1 hour, then spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant:
o
the windshield.
Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. Keep the windshield dry for the first hour after installation.
25. Reinstall the cowl covers (see page 20-95).

NOTE: The cowl cover clips may not set properly if the windshield adhesive is too wet.
26. Install the clips (A, 8) on both side trim (C). If the
clip (D) is damaged, replace the side trim and clips as an assembly.
A: Grey
C B
28. Reinstall all remaining removed parts. Install the
rearview mirror after the adhesive has dried
B: Blue
thoroughly. NOTE: Advise the customer not to do the following things for 2 to 3 days:
o
o
Slam the doors with all the windows rolled up. Twist the body excessively (such as when going
in and out of driveways at an angle or driving over rough, uneven roads),
20-24
Rear Window Replacement

Wear eye protection while cutting the glass adhesive with piano wire. Use seat covers to avoid damaging any surfaces.
6. With a helper on the outside, pull the piano wire (AI back and forth in a sawing motion. Hold the piano
wire as close to the rear window (8) as possible to
prevent damage to the hatch, and carefully cut through the adhesive (el around the entire rear
window.
Do not damage the rear window defogger grid lines

and terminals.

Hatch lower trim panel (see page 20-531 Hatch spoiler (see page 20-991
High mount brake light (see page 22-821 Rear window wiper motor (see page 22-1461
3. Disconnect the rear window defogger connectors
(AI.
B
----,
Cutting positions:
4. If the old rear window is to be reinstalled, make alignment marks across the glass and body with a grease pencil.
7. Carefully remove the rear window.
5. Apply protective tape along the inside and outside edges of the hatch. Using an awl, make a hole through the adhesive from inside the vehicle at the
corner portion of the rear window. Push the piano wire through the hole, and wrap each end around a piece of wood .
(cont'dl
20-25
Glass
Rear Window Replacement (cont'd)
8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire rear window
opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding Remove the fasteners from the tailgate. 9. Clean the hatch bonding surface with a sponge dampened in alcohol. After cleaning, keep oil,
grease and water from getting on the surface.
11. Glue the side upper fasteners IA) and side lower fasteners IB) with adhesive tape 13M 5312, or equivalent). Glue the upper rubber dams IC) with adhesive tape IN)TTO 501 M, or equivalent) and glue the lower rubber dam ID) with adhesive tape 13M 4216, or equivalent) to the inside face of the rear window IE) as shown. Before installing the lower rubber dam, apply primer 13M N-200, or equivalent) to the areas between the alignment marks IF), then glue the rubber dam on. If necessary, glue the spoiler fasteners IG) with adhesive tape 13M 5671, or equivalent) to the
outside face of the rear window:
10. If the old rear window is to be reinstalled, use a pUlly knife to scrape off all of the old adhesive, the
fasteners and the rubber dams from the rear
window. Clean the inside face and the edge of the

rear window with alcohol where new adhesive is to
Be sure the side upper fasteners, and upper rubber dams line up with alignment marks IH, II. Be sure both ends of the lower rubber dam line up with the edge of the glass.
Be sure the spoiler fasteners line up with
be applied. Make sure the bonding surface is kept free of water, oil and grease.
alignment marks IJ).

Be careful not to touch the rear window where
adhesive will be applied.
o.~~" (])~t \ 'c

H
: Apply primer here.
2mm 10.08in.1
41 mm 11.6 in.1
110mm
14.33in.1
20-26
==
12. Glue the side upper fasteners (A) and side lower fasteners (B) with adhesive tape (3M 5312, or equivalent) to the hatch as shown.
Fastener Locations
15. With a sponge, apply a light coat of glass primer along the edge of the rear window (AI. upper rubber dams (B), and lower rubber dam (e) as shown, then lightly wipe it off with gauze or cheesecloth: With the printed dots (D) on the rear window as a guide, apply the glass primer to both side
portions of the rear window.
A[>: Fastener, 2
B [>: Fastener. 2
Do not apply body primer to the rear window, and do not get hatch and glass primer sponges mixed up. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear
window is installed . Keep water, dust, and abrasive materials away
from the primed surface.

: Apply glass primer here.
13. Set the rear window in the opening, and center it. Align the clips (A) of the rear window with the holes in the opening flange. Make alignment marks (B)
across the rear window, hatch, and body with a
~,
-""'''''~
,,::de jlnside~
10.4310.1
9 mm
10.35 in.1
~
2mm
'"41 /
l
Il
A
11mm A (0.43 in.) \
grease pencil at the four points shown. Be careful

not to touch the rear window where adhesive will
be applied.
10.08 in.1
B~:::::.:::::
___
A
10.43 ~n.1
11 mm
In]ide ;-""""A
A
A
14. Remove the rear window .
(conl"dl
20-27
Glass
Rear Window Replacement (cont'd)
16. With a sponge, apply a light coat of body primer to
the original adhesive remaining around the rear
18. Pack adhesive into the cartridge without air pockets

to ensure continuous delivery. Putthe cartridge in a
window opening flange. Let the body primer dry for at least 10 minutes: Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges. Never touch the primed surfaces with your hands.
caulking gun, and run a bead of adhesive (AI around the edge of the rear window (BI as shown. With the glass primer (el you applied in step 15 as a guide, apply the adhesive to both side portions of
the rear window.
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker
bead at each corner.
20mm ---~'" (0.79 in.)
\~~~;"i:${:;:;;'; I.t:,( 20mm X, (o~n.) "Y~.

I' ,
Y.I2Q)
5mm (0.2 in.)
2mm (0.08 in.)
17. Before filling a cartridge, cut a "V" in the end ofthe nozzle (AI as shown.
12 mm (0.47 in.)
~,.
7 mm (0.27 in.)
20-28
Quarter Glass Replacement

19. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 13, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Do
not open or close the doors until the adhesive is dry.
==
NOTE: Put on gloves to protect your hands. Wear eye protection while cuning the glass adhesive
with piano wire.
Use seat covers to avoid damaging any surfaces. 1. Remove the C-pillar trim (see page 20-51). If necessary, remove the rear side trim panel (see page 20-51) and B-pillar upper trim (see page 2050). 2. Remove the front seal (A) from the front edge of the glass (B). If necessary, cut the seal with a utility knife.
20. Scrape or wipe the excess adhesive off with a puny

knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel
dampened with alcohol. 21. Letthe adhesive dry for at least 1 hour, then spray
water over the rear window and check for leaks.
Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at
least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 22. Reinstall all remaining removed parts.
J.'
NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
A
I',
, 'I
"~
ii,
",j "
I
:,','
, , ,
, I'
:~. :
,.
,J
.",
, ,
; ;' (\
,,"':~--i,
B
over rough, uneven roads).
I' " i' "I i,l
(cont'd)
20-29
Glass
Quarter Glass Replacement (cont'd)
3. Apply protective tape to along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piano wire through the hole, and
wrap each end around a piece of wood. Do not scrape down to the painted surface of the
6. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the
bonding surface around the entire quarter glass
opening flange:
4. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass.
body; damaged paint will interfere with proper bonding Remove the clips from the body. 7. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil,
grease and water from getting on the surface.
8. If the old quarter glass is to be reinstalled, use a putty knife to scrape off all of the old adhesive and the rubber dam from the glass. Clean the inside face and the edge of the glass with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and
grease.
, i
Cutting positions: A
A
5. Carefully remove the quarter glass.
20-30
==
9. Set the quarter glass (A) in the opening, and center
it. From inside the vehicle, make an alignment mark
IB) to the quarter glass where the rear clip will be installed with a grease pencil. Be careful not to touch the glass where adhesive will be applied.
11. Align the upper clip IA) and lower clip IB) with the edge of the quarter glass Ie), then attach them with adhesive tape INITIO 571, or equivalent) to the inside face of the quarter glass, and align the center of the rear clip ID) with the alignment mark (E) you made in step 9, and attach it with adhesive tape 13 M 4215, or equivalent) to the inside face of the quarter glass as shown. Be careful not to touch the glass where the adhesive tape will be applied.
B A
c
12.5mm
C ~ 10.9=9~i~n.:!..I_ _-::-:==:j'iii)
'----=~,
,-
17.5 mm 10.69 in.1
10. Remove the quarter glass.
ril\@1,:'
.
16.5 mm
(0.65in.1
Icont'dl
20-31
Glass
Quarter Glass Replacement (cont'dl
12. First glue the front seal (A) with adhesive tape (3M 4213, or equivalent), and glue the rubber dam (B) with adhesive tape (NITIO 501 M, or equivalent) to the inside face of the quarter glass (C) as shown. Before installing the front seal and rubber dam, apply primer (3M N-200, or equivalent) to the inside face of the glass, then glue the seal on: Be sure the front seal lines up with the bottom and front edges of the glass. Be careful not to touch the glass where adhesive will be applied.
13. With a sponge, apply a light coat of glass primer along the edge of the rubber dam (A) and front seal IB} as shown, then lightly wipe it off with gauze or cheesecloth: With the printed dots IC} on the quarter glass ID} as a guide, apply the glass primer to the upper and lower corner portions of the quarter glass. Do not apply body primer to the quarter glass, and do not get body and glass primer sponges
mixed up . Never touch the primed surfaces with your hands.
If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed.
Keep water, dust, and abrasive materials away
30mm 11.18 in.}
3mm 10.12 in.} / ' , _______ C

L711'
Inside
50mm 11.97 in. I ,

B
-~-'-I
from the primed surface.

-----~------B
r--
/~-:~~~"j1
13.94 in.}
100mm
A
C
Inside , \
G:J
~10~r..}
In.
/-~-+-
45mm
11.77 in.1
" t 10.14 c~ , I' e ,. -I
6 mm 10.24 in.} /3 .5 mm}

11 mm
10.43 in.}
Insid~
'1 mm
.i.
10.43 in.} .L.. ;
~
Inside --,
,
- '-
'D
..; /c::;J
....
\D
20-32
14, With a sponge, apply a light coat of body primer to

the original adhesive remaining around the quarter
16, Pack adhesive into the cartridge without air pockets

to ensure continuous delivery. Put the cartridge in a
glass opening flange, Let the body primer dry for at least 10 minutes: Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges, Never touch the primed surfaces with your hands,
caulking gun, and run a bead of adhesive (A) around the edge of the rubber dam (B) as shown, With the glass primer (e) you applied in step 13 on the quarter glass (D) as a guide, apply the adhesive to the upper and lower corner portions of the quarter glass, Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
10mm (0,39in,1
20mm 10,79 in,1
:~
7mm
(0,28 in,1
20mm (0,79 in,1
~------~
iiiiOii~~~ _l, ,
A
o
15, Before filling a cartridge, cut a "V" in the end ofthe nozzle (A) as shown,
A
~'
InSi~e '
''''
2mm
(0,08 in,1
~
/
InSid.~
0
B
10 mm (0.39 in.)
/
~.,..,
7 mm (0.27 in.)
(conl'd)
20-33
Glass
Quarter Glass Replacement (cont'd)
17. Use suction cups (AI to hold the quarter glass over the opening, align it with the clips (81 and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.
18. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted
surface or the quarter glass, use a soft shop towel
dampened with alcohol. 19. Let the adhesive dry for at least 1 hour, then spray water over the quarter glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 20. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up .
Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
20-34
Moonroof
GLASS Height Adjustment, page 20~37 Replacement, page 20-37 Closing Force and Opening Drag Check, page 20-48 / DRAIN CHANNEL Replacement, page 20-39
~--
'>-
,g
&>'''-:'>/
~--0? ___
/ WIND DEFLECTOR Replacement. page 20-38
SUNSHADE Replacement, page 20-40
SHIM
DRAIN CHANNEL SLIDER Replacement, page 20-44
?~
CABLE ASSEMBLY Replacement, page 20-44 MOTOR Replacement, page 20-41
S\.... v '\l
REAR DRAIN TUBE Replacement, page 20-42
\ \
"
MOONROOF CONTROL UNIT
~~
~~
REAR DRAIN VALVE
FRAME
20-35
Moonroof
Symptom Diagnostic procedure Also check for
Water leaks
1. 2.
3.
4.
Wind noise
Check for a clogged drain tube. Check for a gap between the glass weatherstrip and the roof panel. Check for a defective or an improperly installed glass
weatherstrip or drain channel.
Glass height
adjustment
Check for a gap between the drain seal and the roof panel.
Check for excessive clearance between the glass weatherstrip
1.
and the roof panel.

._"._-
Glass height adjustment
Deflector noise
1.
2.
Check for a improper clearance between deflector seal and roof panel.
Check for a insufficient deflector extension.
3. Check for a deformed deflector.

Motor noise
1. 2.
Check for a loose motor.

Check for a worn gear or bearing.
, Check closing force
3. Check for a deformed cable assembly.

Glass does not move, but motor turns
1. 2.
Check for a defective gear or inner cable.
3.
4.
Glass does not move and motor does not
Check for foreign matter stuck between the guide rail and the slider. Check for a loose inner cable. Make sure the cable assembly is attached properly. Check for a blown fuse. Check for a faulty moonroof switch. Check the limit switch. Check for a run down battery. Check for a defective motor. Check for a faulty relay.
1. 2.
turn (glass can be moved with

moonroof wrench)
3.
4. 5. 6.
20-36
Glass Height Adjustment

The roof panel (A) should be even with the glass weatherstrip (8), to within 2+0.5/-1 mm (0.08+0.02/ -0.04 in.) all the way around. If not, make the following adjustment:
Glass Replacement
1. Close the glass fully. 2. Slide the sunshade all the way back. 3. Remove the screws (A), then remove both bracket covers (8). Remove the nuts (C) and shims (D) from both glass brackets (E).
Fastener Locations
t
~.
A~:Screw,2
C.:Nut,4
_O=@
.~
A
,,'
1. Remove the bracket cover from each side. 2. Loosen the nuts (A), and install the shims (8) between the glass frame (C) and glass bracket (D) on each side. Shim thickness: Front and rear max. 2 mm (0.08 in.)
p=f \/
6 x 1.0 mm
9 Nm (0.9 kgfm, 7 Ibfftl
~-----~-- -,,-.---------------- --- --
~~4;.t \ .C
~.CA
.~-j~=~~~~J
---_=-__-=-c--- -- --D
4. Remove the glass (A) by lifting it up. Do not damage the roof panel.
..
Forward
A
6x 1.0 mm 9 Nm (0.9 kgfm, 7 Ibfftl
3. If necessary, repeat on the opposite side. 5. Install the glass in the reverse order of the removal, and adjust the glass height alignment. 6. Check for water leaks. Use free-flowing water from a hose without a nozzle. Do not use high-pressure
water .
20-37
Moonroof
Wind Deflector Replacement
,. Open the glass fully. 3. Install the deflector IA) in the reverse order of removal, and check that the deflector arm base IB) and deflector link pivot base IC) line up with the same alignment lines (D). If necessary, adjust them forward or backward so the edge of the deflector seal IE) touches the roof panel IF) evenly. Each
base must be moved the same amount for
2. Remove the screws lA, B), and release the hooks

IC), then remove the wind deflector ID).
Fastener Locations
A ~ : Screw, 2
B ~ : Screw, 2
A 5xO.8 mm
10.4 kgfm, 3lbfftl

16mm
(0.63 in.)
4Nm
adjustment. If the deflector seal and roof panel make a rubbing sound, move the deflector backward as necessary to position it properly.
43mm 11.7 in.)
"*----!
c
c
"'~---'=;~A
~,:,
20-38
Drain Channel Replacement

1. Remove the moonroof glass (see page 20-371. 2. With the moon roof wrench, move both glass brackets (AI to the position where the moonroof
normally pivots down, and remove the screws
4. Remove the drain channel (AI.
securing the drain channel (81.

Fastener locations
~:
-/
Screw, 2
,
----------;;;;,.
---->1'
~.
"';:~,
'-....../ "-.
'
.-
5. Install the channel in the reverse order of removal, and note these items:
Push the drain channel onto the hooks until a

faint click is heard .
3. Release the drain channel (AI from both hooks (81 of the drain channel slider by pulling the drain channel forward.
Check the glass height adjustment (see page 20371. 6. Check for water leaks. Let the water run freely from
a hose without a nozzle. Do not use a high-pressure
spray.
20-39
Moonroof
Sunshade Replacement
1. Remove the drain channel. 2. Slide the sunshade (A) until you can see both sunshade slider spacers (B).
Fastener locations
.... : Screw, 4
4. While lifting the front portion of the sunshade (A),

move the sunshade forward until you can see both sunshade rear hooks (8). Do not damage the sunshade and hooks.
Fastener Locations .... : Screw, 4
3. Remove the screws, then remove both spacers.
5. Remove the screws, then remove both hooks.
20-40
Motor Replacement
6. Remove the sunshade (A). 1. Remove the headliner (see page 20-541.
2. Put on gloves to protect your hands. Disconnect the connector (A), and remove the bolts, then remove
the motor (8).

Fastener Locations
.-:y"
~: Boll,2
@:=
~"
.. '
."~
7. Remove both front sunshade base sliders (A) and both rear sunshade base sliders (8).
.
. ... .--JSX1.0mm
9Nm
(0.9 kgfm,
7 Ibfft)
3. Install the motor in the reverse order of removal, and note these items:
Make sure the connector is plugged in properly.

Check the motor operation.
"-;,
-
- cc-.",--_"Cc::)J'
A
8. Install the sunshade in the reverse order of removal,
and check the glass height adjustment (see page 20-37). 9. Check for water leaks. Let the water run freely from
spray .
20-41
Moonroof
Frame and Drain Tube Replacement
1. Remove these items: Headliner (see page 20-54) Moonroof glass (see page 20-371
2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/close-tilt/close switch connector (B), moon roof control unit connector (e), auto-stop switch connector (D), and the drain tubes (E), and remove the
moonroof relays (F).

Fastener Locations
~: Bolt, 10
A
---,'
6x1.0mm
9.BNm (1.0 kgfm, 7.2Ibf.ftl
3. Remove the interior harness (G) by detaching the harness clips (H).
4. With an assistant holding the frame (IL remove the bolts, starting at the rear, and release the rear hooks (J) by moving the frame forward, then remove the frame. 5. With the help of an assistant, carefully remove the frame through the passenger's door opening. Take care not to scratch the interior trim and body, or tear the seat covers.
20-42
==
6. To remove a front drain valve (A) from the body, remove the kick panel, left or right (see page 20-50). Tie a string to the end of the drain tube, then pull the front drain tube (B) down out of the front pillar. 8. Install the frame and drain tube in the reverse order
Before installing the frame, clear the drain tubes

and drain valves using compressed air.
Check the frame seal. Clean the surface of the frame. When installing the frame, first attach the rear hooks into the body holes.
Make sure the connectors are plugged in
properly. When connecting the drain tube, slide it overthe frame nozzle at least 10 mm (0.39 in.). Install the tube clip (A) on the drain tube (B) as
shown.
7. To remove a rear drain valve (A) from the cargo compartment, remove the rear side trim panel (see
/"
"
Upward
page 20-51 ).Detach the clips (B), then remove the drain tube (C).
1
B B
9. Check for water leaks. Let the water run freely from
spray .
20-43
Moonroof
Drain Channel Slider and Cable Assembly Replacement
1. Remove the frame (see page 20-421.
2. Remove these parts from the frame:
5. Pivot the glass bracket (AI down by sliding the link litter (81 back, then slide both glass brackets back with the link lifter .
Sunshade (see page 20-401 Moonroof motor (see page 20-411
3. Put on gloves to protect your hands. Remove the

screws (A, 81, then remove the slide stops (CI and cable tube rear brackets (DI. Remove the bolts (E) from the cable tube side bracket (F) and the cable tube mounting screws (G) from both sides of the frame (HI.
Fastener Locations
Forward
A~: Screw, 2
B~: Screw, 2
E~:
Bolt, 2
~
F"": Screw, 2
C
6. Slide the cable assembly (AI and both glass brackets (81 back, then remove them from the frame (CI.
B
EP
No switch side:
6x 1.0 mm C
9.BNm 11.0 kgf.m, 7 2lbfttl

F
~E
~
>- -,'
4. Detach the onen switch connector clip (I) from the frame.
20-44
==
7. Remove the drain channel slider (A) from the glass bracket (8). 8. Install the slider and cable assembly in the reverse
order of removal, and note these items:
Damaged parts should be replaced. Apply multipurpose grease to the glass bracket (A) and guide rail portion of the frame (8) indicated by the arrows. Before reinstalling the motor, make sure both link lifters are parallel, and in the fully closed
position. Before reinstalling the motor, install the frame
A
i
..
and glass, then check the opening drag (see page 20-48).
.. IijjITijffi
B
20-45
Moonroof
Limit Switch Adjustment
1. Remove the headliner (see page
20-5~).
Fully closed position adjustment

2. With the moonroof wrench, close the glass (A) fully: Make sure both link lifters (B) are parallel, and in the position shown. Check the glass fit to the roof panel and the glass height (see page 20-37).
C 5 xO.8 mm 5 Nm 10.5 kglm, 4lblfti
3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D):
Move the switch plate (E) a little at a time, then secure it atthe position where you hear a faint click when the
switch cam (F) pushes the position switch (open/ciose). Check that the switch piate contacts the switch bracket (G).
20-46
==
Auto-stop position adjustment
5. With the moonroof wrench, operate the glass IA) to the auto-stop position.
::~
[ - ::-
it
.r5+--c
"
~./
!I :: -
I'"
!~
5xO.8mm
5 Nm 10.5 kgfm, 4 Ibfh)
6. With an open-end wrench, loosen the auto-stop switch mounting bolts IC). 7. Adjustthe auto-stop switch ID): Move the switch plate IE) a little at a time, then secure it at the position where you hear a faint click when the switch cam IF) pushes the switch lauto-stop). Check that the switch plate contacts the switch bracket IG). 8. Check the operation of the glass by operating the moonroof switch: From the tilt-up position to the fully closed position, from the fully open position to the auto-stop position, from the auto-stop position to the fully closed
position. 9. Check for water leaks. Let the water run fleely from a hose without a nozzle. Do not use a high-pressure spray .
20-47
Moonroof
Closing Force and Opening Drag Check
1. Remove the headliner (see page 20-541. 2. Closing force check: With a shop towel (Alan the leading edge of the glass (8), attach a spring scale (CI as shown. Have an assistant hold the switch to close the glass while you measure the force required to stop it. Read the force as soon as the glass stops moving,
then immediately release the switch and spring
,
4. Opening drag check: Protect the leading edge of the glass with a shop towel (AI. Measure the effort required to open the glass using a spring scale (81 as shown.
scale.
Closing Force: 200-290 N (20-30 kgf, 44-661bfl
5. If the load is over 40 N (4 kgf, 9 Ibfl, check: The side clearance and glass height adjustment (see page 20-371 . For broken or damaged sliding parts. If any sliding parts are damaged, replace them.
3. If the force in not within specification, remove the
moonroof motor (see page 20-411, then check: The gear portion and the inner cable for breakage and damage. If the gear portion is broken, replace the motor. If the inner cable is damaged, remove the frame (see page 20-421, and replace the cable assembly (see page 20-441. The moonroof motor (see page 22-1121. If the
motor fails to run or doesn't turn smoothly,
replace it (see page 20-411. The opening drag. Go to step 4.
20-48
Interior Trim
HATCH LOWER TRIM PANEL page 20-53 HATCH SIDE TRIM page 20-53 C-PILLAR TRIM
B-PILLAR UPPER TRIM page 20-50

~OOR OPENING TRIM
page 20-51
HATCH UPPER TRIM PANEL page 20-53
page 20-50
A-PILLAR TRIM page 20-50
\~~~~~~~~=:::=/:::::::s-::;,,(
HEADLINER Removal/Installation, page 20-54 KICK PANEL page 20-50 CARPET Replacement, page 20-55
DOOR SILL TRIM
page 20-50
CARGO AREA FLOOR page 20-52 REAR SIDE SHELF
page 20-51
REAR CENTER SHELF page 20-51 REAR SIDE TRIM PANEL page 20-51 CARGO FLOOR MAT page 20-52 REAR TRIM PANEL page 20-52
20-49
Interior Trim
Trim Removal/Installation - Door Area
NOTE:
Put on gloves to protect your hands.

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the door sill trim and B-pillar upper trim, remove the rear side trim panel
as necessary (see page 20-51).

2. Install the trim in the reverse order of removal, and note these items:
Replace any damaged clips. Apply liquid thread lock to the anchor bolts before reinstallation.
Before installing the anchor bolts, make sure there are no twists or kinks in the belts.
Fastener Locations
A [>: Clip, 2 (Black)
B [> : Clip, 3 (White)
[> : Clip, 7
FRONT SEAT BELT UPPER ANCHOR BOLT 7/16-20 UNF 32 Nm (3.3 kgfm, 24 Ibfft)
To body.
0.;
\
DOOR OPENING TRIM
/~~~NTSIDE
C.~
UPPER ANCHOR COVER
~j'-l':' B
~.~ _.~.~Jt._:.-~j~~c~" ., ._~" vr~~SCREW

J,-'';'"
KICK PANEL
(2:. _
VVc
DOOR Sill TRIM '0
__- -
lOWER ANCHOR CAP
FRONT SEAT BELT lOWER ANCHOR BOLT 7/16-20 UNF 32 Nm (3.3 kgfm, 24 Ibfft) REAR SIDE TRIM PANEL
20-50
Trim Removal/Installation - Rear Side Area

NOTE:
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels. 1. To remove the rear side trim panel, remove these items:
Rear seat cushion and rear seat-back (see page 20-801 Cargo floor mat and cargo area floor (see page 20-521 Rear trim panel (see page 20-521 2. Remove the trim as shown. On the right side, disconnect the cargo compartment light connector.
Replace any damaged clips. Make sure the cargo compartment light connector is plugged in properly.
If the threads on the rear side trim panel mounting self-tapping ET screws are worn out, use an oversized self-
tapping ET screw (PIN 90137-S1A-E0111 made specifically for this application . When installing the rear side shelf, slip the rear seat belt through the slit in the trim . Apply liquid thread lock to the anchor bolts before reinstallation. Before installing the anchor bolts, make sure there are no twists or kinks in the belt.
Fastener Locations
A[>:Clip,11
BC> Clip,2
c C>: Clip, 1
" ':~,
__~
LID
~,,!,EW A~-
~ ~., A~~
1
SHELF
T-_~~~:~L;::::LF
REAR SEAT BELT REAR SIDE TRIM PANEL REAR SEAT STRIKER C A P .
,
Ii,. .
BPILLAR
~~ '::- -
-Aif' A. - ' , . -SiD <1''''if' Aif'
SELF-TAPPING
SCREWS
5xO.8mm 4Nm (0.4 kgf.m. 3 Ibfft)
4l~1~~~~t ~oo~.,"m.
ANCHOR BOLT
~~'d~
REAR SPEAKER
CONNECTOR
----FRONT SEAT BElT
REAR BULKHEAD COVER
REAR SPEAKER COVER
7/1S-20UNF (33 kgf.m 24Ibf.ft) 32 Nm (3.3 kgf.m. 24 Ib'tt) . LOWER ANCHOR CAP
32N-m
7/16-20UNF
20-51
Interior Trim
Trim Removal/Installation - Cargo Floor Area
NOTE: Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend or scratch the trim and panels.
1. To remove the rear trim panel, remove the child seat tether anchor (see page 23-111.
2. Remove the trim as shown.

3. Install the trim in the reverse order of removal, and replace any damaged clips.
Fastener Locations
A~: Clip, 3
-
~;. .-
B~: Clip, 4
~-:.
----------------------
--~----------------
REAR SEATBACK COVER
CARGO AREA FLOOR B"
~~~~-/
HOO_K ___
HOOK
--III" ,. .,.,
--------------
r
To rear side
trim
panel.
To rear side trim panel. REAR TRIM PANEL
20-52
Trim Removal/Installation - Hatch Area

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Take care not to bend or scratch the trim and panels.

1. Remove the trim in the sequence shown.
Hatch upper trim panel Left hatch side trim Right hatch side trim
Hatch lower trim panel 2. Install the trim in the reverse order of removal, and replace any damaged clips.
Fastener Locations
A [> : Clip, 4
B [>: Clip, 2
e
C [>: Clip, 12
(White)
D [>: Clip, 1
E [>: Clip, 2
(Black)
ct
"i.
-~
",'2
t~Q)
.
~'~-
I
I
':11 HATCH LOWER TRIM

PANEL
HATCH LOWER TRIM PANEL
/l:..
HATCH SIDE TRIM
,.../.,. C.\
---f::,.-. \
f,--- -C
Cf::,.l).
",C /
\~ ~~!::,.
"
\........
'".
LEFTHATCHSIDETRIM
_______
::,q~C
\
__ ___________ .
~~BE=",~C
\~lj
r.
~ ...
',. y
'.:
,c
", , , -
~;~,--~~_~~~-:.==-~1~~~-~.\
CD
----------"
WRIGHT HATCH SIDE TRIM
HATCH UPPER TRIM PANEL
CD HATCH UPPER TRIM PANEL
HATCH SIDE TRIM
20-53
Interior Trim
Headliner Removal/Installation
NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend and scratch the headliner. Be careful not to damage the dashboard and other interior trim.
3. From both rear passenger's, remove the caps (A), and remove the screws, then remove the grab handles (8) .
Fastener Locations ....: Screw, 4
A-pillar trim, both sides (see page 20-50) B-pillar upper trim, both sides (see page 20-50) Hatch weatherstrip, as necessary (see page 2092) C-pillar trim, both sides (see page 20-51) Moonroof switch (see page 22- 112) Spotlights (see page 22-96) Ceiling light (see page 22-96) 2. Remove the sunvisor (A) and holder (B) from both sides. - 1 Remove the caps (C).
-2 Remove the screws. -3 Remove the sunvisor from the body and holder.
-4 Using a flat-tip screwdriver, push the hook (D), and turn the holder 90, then pull it out.
Fastener Locations
... : Screw, 4
-----
5x O.8mm 5Nm (0.5 kgfm, 4Ibfft)
20-54
Carpet Replacement
4. Remove the headliner. -1 Remove the socket plug (A). -2 Remove the remaining door opening trim (B)
from each roof portion.
==
SRS components are located in this area. Review the SRS component locations (see page 23-13) and the precautions and procedures (see page 23-14) in the SRS
section before performing repairs or service. NOTE:
-3 Detach the clips (C), and release the fasteners (D) by pulling the front portion of the headliner (E) down. -4 With the help of an assistant, release the clips (F) of the headliner from the moon roof frame (G), and release the headliner from the clips (H) by sliding the headliner forward, and lowering the headliner. -5 Remove the headliner through the passenger's opening.
Fastener Locations
C~: Clip, 3
Put on gloves to protect your hands . Take care not to damage, wrinkle, or twist the carpet. Be careful not to damage the dashboard or other
interior trim pieces. 1. Remove these items:
Front seats, both sides (see page 20-71) Driver's dashboard under cover (see page 20-60) Passenger's dashboard lower cover (see page
20-63)
F ~: Clip. 2
H ~: Clip. 2
.~~~
G
Rear seat cushion (see page 20-80) Kick panels, both sides (see page 20-50) Door sill trim, both sides (see page 20-50) Consoles, front and rear (see page 20-57) 2. Remove the nut (A), and using a hex wrench, release the clip (B), then remove the footrest (C).
t;
H
Fastener locations
Ae: Nut. 1
B~: Clip. 1
A A
6x 1.0 mm 9.8Nm
5. Install the headliner in the reverse order of removal, and note these items:
11.0 kgfm, 7.2Ibfftl
When reinstalling the headliner through the passenger's door opening, be careful not to fold or bend it. Also, be careful not to scratch the body. Check that both sides of the headliner are
securely attached to the trim. Replace any clips that remain in the roof during
~.
removal. Reinstall the clips back in the headliner before installation .
Icont'dl
20-55
Interior Trim
Carpet Replacement (cont'd)
3. Using a utility knife, cut the carpet (AI under the heater areas (B), and cut out the parking brake lever area (e) as shown, then pull back the carpet.
5. Install the carpet in the reverse order of removal, and note these items: Take care not to damage, wrinkle, ortwistthe carpet. Make sure the seat harnesses are routed
correctly. Slip the carpet under the rear side trim panel on each side properly. Replace the clip if it's damaged.
Reattach the cut areas under the heater around
'.,
\ \ Ie:::;,
'
"'-I
\~
the parking brake lever with a wire tie . When installing new carpet, cut the carpet (A) under the heater areas (B), and around the parking brake lever (e). After installing the new carpet. slip the carpet from the driver's and
passenger's side through the space between the heater unit and body, and reattach the cut area (e) around the parking brake lever with wire ties.
I' I ,
_"':
I~
1~B I .
II~c
4. Remove the clip (A), and release the fasteners (B). Pull the carpet out from both rear side trim panels (D), then remove the carpet (e).
Fastener Location
AI>: Clip, 1
20-56
Consoles
Console, Front and Rear Removal/Installation
NOTE: Take care not to scratch the front seat, dashboard, and related parts. 1. Remove the rear console IAI. -1 Slide the front seat forward fully on each side. -2 Remove the screws (8) from the rear portion of
the rear console.
2. Remove the front console IA). -1 Pullout the dashboard center lower cover (8) to detach the clips IC).
-2 Disconnect the accessory power socket connector (0).
-3 Slide the front seat rearward fully on each side. -4 Pull the front portion of the rear console up to detach the clips IC) and hooks ID), then release the rear console from the front console IE). -5 Starting althe rear, pull the rear console up,
then remove it.
Fastener Locations
-3 Remove the console box mat IE). -4 Remove the bolts IF), screws IG), and clips IH). -5 Gently pullout the front console to release the hooks II) and pins IJ).
Fastener Locations
CC>:Clip,3 F~:Bolt,2 G~:Screw, 2 HC>:Clip,2
0=>
o
@p CI-p~
B ~:Screw, 2
C C>: Clip, 2
'.~. :. 2tl
.
,
,
~'<
,.B
:~
6x1.0mm
9.8Nm
11.0 kgfm, 7.2Ibf1t1

3. Install the console in the reverse order of removal, and note these items:

Make sure the accessory power socket connector
is plugged in properly.
Push the clips into place securely .
20-57
Consoles
Front Console Disassembly/Reassembly
NOTE: Take care not to scratch the console and related parts.
Fastener Locations
~:Screw,8
I)
,I,
,;-<
CONSOLE BOX
20-58
Dashboard
Instrument Panel Removal/ Installation
NOTE:
When prying with a flat-tip screwdriver, wrap it with
Driver's Dashboard Lower Cover Removal/Installation

NOTE: Take care not to scratch the dashboard and related parts . 1. Remove the driver's dashboard lower cover (A). -1 Turn the lock knob (8) 90'. -2 Gently pull out the left side to release the hooks (C). -3 Pullout the panel to release the hooks (D).
protective tape, and apply protective tape around the related parts, to prevent damage. Take care not to scratch the dashboard and related parts. 1. Tilt the steering column down.
2. Remove the steering column upper cover (see page 179).
3. Remove the instrument panel (A). -1 Gently pullout along the bottom to release the clips (8) and hooks (C). -2 Gently pullout the upper portion to release the clips (D) and hooks (E).
Fastener locations Bt>:Clip,2 Ot>:Clip,2
~
2. Install the cover in the reverse order of removal,
and push the hook portions into place securely.
/':.y>----~-
4. Install the panel in the reverse order of removal,
and push the clip and hook portions into place

securely .
20-59
Dashboard
Driver's Dashboard Under Cover Removal/Installation
NOTE: Take care not to scratch the dashboard and related parts.
1. Remove the driver's dashboard under cover (A).
Driver's Pocket Removal/ Installation

NOTE:
Put on gloves to protect your hands . Take care not to scratch the dashboard and related
parts.
-1 Turn the lock knob 18190. -2 Gently pull down the rear edge to release the clip ICI. -3 Pull the cover away to release it from the clip IDI.
Fastener Locations
1. Remove the driver's pocket IAI.

-1 Remove the driver's dashboard under cover.
-2 Remove the screws IBI. -3 From behind the dashboard, push the pocket back by hand to release the clips ICI. -4 Release the hook IDI.
Fastener Locations
B~:Screw,2
cl>: Clip, 2
11
t. c
2. Install the
cover in the reverse order of removal,
and push the clip portion into place securely.
2. Install the pocket in the reverse order of removal, and push the clip portions into place securely.
20-60
Shift Lever Trim Removal/Installation

NOTE:
Take care not to scratch the dashboard and related parts . Put on gloves to protect your hands. 1. Remove the glove box (see page 20-63). 2. Remove the shift knob.
4. Pull out the shift lever trim (A) by hand to release the remaining clips (B, C) and hooks (DI. and
disconnect the hazard warning switch connector (E), then remove the trim.
Fastener Locations
B[>:Clip,1
W ---=-----V :r
C[>: Clip, 1 0[>: Hook, 3
E
B~_)__~~~ _____ ..~~.
3. Using a ratchet wrench and an 11 inch extension
(A) wrapped with a shop towel (B), carefully insert

the extension through the glove box opening, and
push the shift lever trim (C) from under the trim to release the clips (D) and hooks (E) of the left side.
Fastener Locations
5. Install the trim in the reverse order of removal, and note these items. Make sure the hazard warning switch connector
0[>Clip.2
E [>Hook, 2
is plugged in properly. Push the clip and hook portions into place securely,
-_------
"-----=--_-_---.J
20-61
Dashboard
Dashboard Center Panel Removal/Installation
When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the
4. Pull out the center panel (A) to release the clips (8) and hooks (e), and remove the harness holder (D)
from the bracket (E). Disconnect the audio unit
connector (F), antenna lead (G), heater switch

connector (H) and heater control unit connectors (I).
Fastener Locations
related parts, to prevent damage. Take care not to scratch the dashboard and related parts.
Be>: Clip, 8
the write down the frequencies for the preset
buttons.
~: ,'"
Driver's dashboard lower cover (see page 20-59) Passenger's dashboard lower cover (see page
20-63).
Glove box (see page 20-63). Shift lever trim (see page 20-61).
3. From the glove box and driver's dashboard lower cover openings, loosen the bolts (A) securing the center panel (8).
Fastener Locations
A~: Bolt, 2
5xO.8mm 5Nm
5. Install the panel in the reverse order of removal, and note these items: Make sure each connector is plugged in properly, and antenna lead is connected properly.
10.5 kgfm, 4Ibfft)
Push the clip portions into place securely. Reconnect the negative cable to the battery. Do the EeM/peM idle learn procedure (see page
11-139). Enter the anti-theft code for the radio, then enter the customer's radio station presets .
Reset the clock.
20-62
Passenger's Dashboard Lower Cover Removal/Installation

1. Remove the passenger's dashboard lower cover
(A).
Glove Box Removal/Installation

SRS components are located in this area. Review the
SRS component locations (see page 2313) and the precautions and procedures (see page 2314) in the SRS
-1 Gently pull down the rear edge to release the

clips (8). -2 Pull the cover away to release the pins (e) from the holders (D).
Fastener Locations
1. Remove the passenger's dashboard lower cover.

2. While holding the glove box (A), remove the glove box stop (8) on each side.
Fastener Locations
B~: Clip, 3
~Bolt,2
~
- =-=-=-::::--=::_---
!J. . '. B
"
B
."1.
B
~A
.... _ _-- 5 x 0.8 mm _
5Nm (0.5 kgfm, 4 Ibfftl
2. Install the under cover in the reverse order of removal, and push the clip portions into place securely.
3. Remove the bolts, then remove the glove box. 4. Install the glove box in the reverse order of removal.
20-63
Dashboard
Dashboard Side Vent Removall Installation
NOTE:
Beverage Holder Removall Installation

NOTE: Take care not to scratch the dashboard .
Take care not to scratch the dashboard. Put on gloves to protect your hands.
1. Remove the dashboard (see page 20-661.
Put on gloves to protect your hands .

1. Remove the dashboard (see page 20-661.
2. Remove the screws, then remove the beverage
2. Remove the steering hanger beam from the dashboard (see page 20-681.
3. Remove the screws, then remove the air duct (AI from the dashboard (81.
Fastener Locations
holder (AI.
Fastener Locations
"':Screw,2
"':Screw,7
4. Remove the screws, then remove the side vent (A).

Fastener Locations
3. Install the beverage holder in the reverse order of

removal.
"":Screw,4
0:~
5. Install the side vent in the reverse order of removal.
20-64
Driver's Tray Removal/Installation

NOTE: Take care not to scratch the dashboard . Put on gloves to protect your hands.
Passenger's Tray Removal/ Installation

NOTE: Take care not to scratch the dashboard. Put on gloves to protect your hands.
1. Remove the dashboard (see page 20-661. 2. Remove the beverage holder (see page 20-641.
1. Remove the dashboard (see page 20-661. 2. Remove the steering hanger beam from the dashboard (see page 20-681. 3. Remove the air duct (see step 3 on page 20-641 .
4. Remove the screws, then remove the passenger's
3. Remove the screws, then remove the driver's tray

(AI.
Fastener Locations .... :Screw, 3
tray (AI.
Fastener Locations
~:Screw, 8
4. Install the tray in the reverse order of removal.
5. Install the tray in the reverse order of removal.
20-65
Dashboard
Dashboard Removal/Installation
SRS components are located in this area. Review the SRS component locations (see page 23-131 and the precautions and procedures (see page 23-141 in the SRS section before performing repairs or service. NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts to prevent damage.
4. From the center panel opening, remove the screws, then remove the center bracket IAI.
Fastener Locations .....:Screw,2
Have an assistant help you when removing and

installing the dashboard. Take care not to scratch the dashboard, body, and other related parts. Put on gloves to protect your hands. 1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the preset buttons.

2. Disconnect the negative cable from the battery, and
wait at least three minutes before beginning work.

3, Remove these items:
5. Remove the shift lever Isee page 13-511. 6. From outside of the passenger's door, gently pull out along the edge of the dashboard side cover IAI to release the hooks 181, then release the upper hook ICI, to remove the cover.
Driver's dashboard lower cover (see page 20-591 Driver's dashboard under cover (see page 20-60) Passenger's dashboard lower cover (see page 20-631 Glove box (see page 20-631 Consoles, front and rear (see page 20-571 Shift levertrim (see page 20-611 Center panel (see page 20-621 Kick panels, both sides Isee page 20-501 A-pillar trim, both sides Isee page 20-501 Steering column Isee page 17-91
20-66
Driver's side: 7. From under the dash, disconnect the interior wire harness connector (A), driver's door wire harness
Middle portion:
8. Disconnect the floor wire harness connectors (A) and combination subharness connector (8).
connectors (BI, side turn signal light connector (C), roof antenna connector (D), antenna lead (E), clutch switch connectors (F), and brake switch connector (G), and disconnect the floor wire harness connectors (H) and engine compartment wire harness connectors ()) from the under-dash fuse! relay box (J).
---~-;/
Passenger's side:
9. From under the dash, disconnect the dashboard

wire harness connectors (Al, EPS subharness connectors (8), engine compartment wire harness
connectors (C), AlC subharness connectors (DI,

passenger's door wire harness connectors (El, and
side turn signal light connector (F).
F
,
A
B
10. Detach all of the harness and connector clips.
(cont'd)
20-67
Dashboard
Dashboard Removal/Installation (cont'd)
11. From outside the driver's door, remove the caps (A), then remove the bolts (B, C, 01, and lift up on the dashboard (EI to release it from the guide pins (F, GI on the body.
Fastener Locations
Steering Hanger Beam Replacement

NOTE: Put on gloves to protect your hands. 1. Remove the dashboard (see page 20-661. 2. Remove these items from the dashboard:
B~:Bolt,3
C~:Bolt,2
D~:Bolt,2
Instrument panel (see page 20-591 Driver's pocket (see page 20-601 Gauge assembly (see page 22-641 Passenger's airbag (see page 23-1141
F
3. Remove the screws, then remove the glove box
striker IAI.
Fastener Locations
"':Screw,4
0::::c>
8x 1.25 mm 22Nm 12.2 kgfm, 16lbfftl
12. Carefully remove the dashboard through the front

door opening.
13. Install the dashboard in the reverse order of

Make sure the dashboard fits onto the guide pins

correctly.
-------
Apply liquid thread lock to the dashboard mounting bolts of the middle portion before
reinstallation. Before tightening the bolts, make sure each wire harness and control cables are not pinched.

properly, and the antenna lead is connected
properly. Reconnect the negative cable to the battery. Enter the anti-theft code for the radio, then enter
Reset the clock. Do the ECM/PCM idle learn procedure (see page 11-1391.
20-68
4. Remove the bolts (A) and screws (8) securing the dashboard (e) and steering hanger beam (D), and
disconnect the power mirror switch connector (E) and cruise control main switch connector (F).
5. Install the beam in the reverse order of removal, and note these items:
Separate the dashboard and steering hanger beam.

Fastener Locations
Make sure the dashboard wire harness (G) is not pinched.

properly.
A~: Bolt, 4
B ~: Screw, 9
5xO.8mm
5 Nm (0.5 kgfm, 4 IbMt)
20-69
Seats
~='b--~
/,,-------------
REAR SEAT Removal/Installation, page 20-80 Seat-back Latch Replacement, page 20-81 Seat-back Striker Replacement page 20-81 Seat-back Cover Replacement, page 20-82 Seat Cushion Cover Replacement, page 20-84
()
"<
----- - --
--
FRONT SEAT Removal/Installation, page 20-71 Disassembly/Reassembly-Driver's, page 20-73 Disassembly/Reassembly-Passenger's, page 20-74
Seat Cover Replacement, page 20-75
20-70
Front Seat Removal/Installation

For some models: SRS components are located in this
area. Review the SRS component locations (see page
==
4. Remove the bolts securing the front seat.
Fastener Locations
~: 8011,4
23-13) and the precautions and procedures (see page 23-14) in the SRS section before performing repairs or service.
NOTE When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care notto scratch the body or tear the seat covers. Put on gloves to protect your hands.
then write down the frequencies for the preset
--2j
buttons. 2. Disconnect the negative cable from the battery, and

wait at least 3 minutes before beginning work.
3. Remove the seat track end covers (A) from the back of both seat tracks.
Outer:
L
~ ;!
.J.____ ..,-
/ --. _______ 10 x 1.25 mm
34 Nm
(3.5 kgf.m, 25lbfftl
Inner:
~".~ .t__.'.--'-..... .......... .......

'
~ ~
.'~'
.,;s
--
-(
(cont'd)
20-71
Seats
Front Seat Removal/Installation (cont'd)
5. Lift up the front seat, then detach the harness clip
(A), and disconnect the seat belt switch connector
(8) and seat belt buckle tensioner connector IC)' If

equipped with a side airbag, disconnect the side airbag connector (D), and on the passenger's seat,
disconnect the OPDS unit connector lEi. The

passenger's seat is shown, the driver's seat is similar except it has no OPDS unit connector.
E
B
6. With the help of an assistant, carefully remove the front seat through the front door opening.
7. Install the seat in the reverse order of removal, and note these items:
Make sure each connector is plugged in properly . Apply liquid thread lock to the seat mounting
bolts before reinstallation. Reconnect the negative cable to the battery. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
Reset the clock. Do the ECM/PCM idle learn procedure Isee page 11-139).
20-72
Front Seat Disassembly/Reassembly - Driver's

For some models: SRS components are located in this area. Review the SRS component locations (see page 23-131 and the precautions and procedures (see page 23-14) in the SRS section before performing repairs or service.
NOTE:
Take care not to tear the seams or damage the seat covers. Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat cushion cover, stretch the material evenly over the pad.
Release the seat cushion cover from the cushion frame spring.
SEAT-BACK
~
HOOK (Five places)
"
CENTER COVER _;;{", HANGER SPRING (With side airbag)
10x1.25mm
~ --~!.I
. c
-~:
'.'
/ 4 7 Nm 14.8 kgfm,
35lbfftJ
~
"tc-
CLIP
. . ""'cD
_______________ SIDE AIRBAG
HARNESS
: 9
(- ~
CLIP
~'Q
CLIP .' -. ~.-
SEAT CUSHION FRAME/SEAT TRACKS
~
....
'Ir~ t-,i.
HOOK
).'@-__ ._
~
RECLINE COVER
. \ c3
HOOK \ RECLINE KNOB
SLIDE LEVER
20-73
Seats
Front Seat Disassembly/Reassembly - Passenger's
For some models: SRS components are located in this area. Reviewthe SRS component locations (see page 23-13)
and the precautions and procedures (see page 23-14) before doing repairs or service.
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. o Apply multipurpose grease to the moving portion of the seat track . To prevent wrinkles in the seat cushion cover, stretch the material evenly over the pad.
o
Make sure the rear seat access cable is connected properly on each side. Replace any damaged clips, and replace the wire ties with new ones.
SIDE AIRBAG HARNESS
Release the seat cushion cover from the cushion frame spring.
HOOKS HOOKS HOOKS

(Five places)
10 x 1.25 mm
47 Nm 14.8 kgfm, 35Ibfft)

OPDS HARNESS
CLIPS WIRE TIE
".""A/.
SCREW ----------.....
~~
t., ~ CENTER COVER
SEAT CUSHION FRAME/SEAT TRACKS
<:3;.!!)~.-/ &>.___CLIP .~' ,

~
HOOK
-~~ ~
REAR SEAT ACCESS CABLE
ACCESS KNOB HOOK
RECLINE KNOB
RECLINE COVER
SLIDE LEVER
20-74
Front Seat Cover Replacement

For some models: SRS components are located in this area. Review the SRS component locations (see page 23-131 and the precautions and procedures (see page 23-141 in the SRS section before performing repairs or service.
3. Fold the seat-back forward.
4. Release the hooks (AI, and unzip the seat-back cover (BI.
NOTE: Take care not to tear the seams or damage the seat covers. On the passenger's seat with side airbag, do not touch the OPOS sensor in the seat-back pad, and keep it away from oil. Oil can corrode the sensor causing it to fail. Put on gloves to protect your hands.
B~I
+
A
+
A
Seatback Cover
1. Remove the front seat (see page 20-71 I.
2. With side airbag: From under the seat cushion, detach the side airbag connector clip (AI, and on
the passenger's seat, detach the OPOS unit connector clip (BI. Release the hook springs (el from the seat cushion frame spring (01, then pull the guide cover (EI back, and remove the wire ties
(F). The passenger's seat is shown, the driver's seat is symmetrical except it has no OPDS unit connector.
B
o
F
Iconl'dl
20-75
Seats
Front Seat Cover Replacement (cont'd)
5. Release the hooks IA) and hook springs IB), then loosen the seat-back cover Ie). Pull the side airbag harness ID) and the OPDS harness IE) Ipassengr's seat) out through the guide cover IF) and holes IG). Take care not to bend the cable. 6. With side airbag: Remove the side airbag Isee page 23-115), and release the hooks IA) from the airbag module holder IB).
A
A
A~P
I I
7. Pull back the seat back cover IA) all the way around, and release the clips IB).
B
,---"
,'T'--~-+" , ,
20-76
8. Using a fiat-tip screwdriver wrapped with protective tape, insert it into the hook portions (seven places) of the headrest rear trim (A) from the headrest front trim side. Pry up the hooks (8) to release the tabs (e) of the headrest front trim (0) while pulling the headrest front trim forward, and remove the trim.
9. Unzip the headrest portion of the seat-back cover (A), then remove the zipper (8), and remove the
cover.
10. Install the cover in the reverse order of removal, and note these items:
Fit all the hooks of the headrest front trim into the
holes in the headrest rear trim, then push on the headrest trim until the hooks snap into place . To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the clips, hooks,
and hook springs. Make sure the side airbag harness, OPOS harness (passenger's seatL and rear seat access cable (passenger's seat) are routed properly. If necessary, reinitialize the OPOS control unit (see page 23-124).
(conl'd)
20-77
Seats
Front Seat Cover Replacement (cont'd)
Seat Cushion Cover
1. Remove the front seat (see page 20-71).
2. Remove these items from the front seat:
Outside:
Recline cover, driver's seat (see page 20-73) passenger's seat (see page 20-74) Front seat belt buckle (see step 4 on page 23-6) 3. From under the seat cushion, detach the side airbag connector clip, and on the passenger's seat, detach the OPDS unit connector clip. Release the hook springs from the seat cushion frame spring, then pull the guide cover back, and remove the wire ties. 4. Release the hooks (A). 5. Release the seat-back cover (A) from the cushion frame spring (B), and release the hooks (e) from under the seat cushion.
Inside:
<:. ----- --
;" -~-~
-I~
- ,.-,...
~; -~-
_.:
,
----
'.
.f:::5..
---'\
= = ~A '-'-'----'
A
20-78
6. Remove the seat cushion cover (A) with the seat

cushion pad from the seat cushion frame.

and note these items: To prevent wrinkles when installing a seat cushion cover, make sure the material is
A~~ .. .
...
---
stretched evenly over the pad before securing the clips and hooks. Make sure the side airbag harness and OP~S harness (passenger's seat) are routed properly.
Replace any clips you removed with new ones
(A). Install them with commercially available upholstery ring pliers (B).
7. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove the seat cushion cover (B).
//-~7 . A
,j,
~-I--.J.
..
B
:..._+-__ -+
--I
+
I
__-,I
L___ _ _ _ _
20-79
Seats
Rear Seat Removal/Installation
NOTE: Take care not to scratch the body or tear the seat covers.
1. Remove the rear seat as shown. To remove the seat-back, remove the front portion of the cargo floor mat (see
page 20-52).
2. Install the seat in the reverse order of removal, and note these items:
Before installing the center anchor bolts on the seat-back with the center shoulder belt, make sure there are no twists or kinks in the belt. Make sure the seat-backs lock securely.
Fastener Locations
A ~: Bolt, 2
B ~ : Bolt,
C ~ : Bolt,
DC>: Clip, 2
@pJ
~ ~Wt@ -...
8x1.25mm 22 Nm 12.2 kglm, .6Ibllt)
(1:
CENTER PIVOT BOLT 8 x '.25 mm 22 N.m 12.2 kglm, '6Ibllt) RIGHT SEAT-BACK
~
HINGE COVER
~~,~,,~ .c>s~ --ct-~~~-_,~

<'''' .
'-,::
~~
SEAT-BACK CENTER HINGE BUSHING LEFT SEAT-BACK HOOK
BUSHING CLIP
CENTER ANCHOR BOLT 7/.6-20 UNF 32Nm 13.3 kglm, 24 Iblltl CLIP
SEAT BELT BUCKLE
SEAT CUSHION
6x 1.0mm
SLITS HOOK
9.8Nm 1'.0 kglm, 7.2Ibllt)
20-80
Rear Seat-back Latch Replacement

1. Remove the seat-back (see page 20-801. 2. Remove the seat-back cover (see page 20-821. 3. Remove the seat-back pad (AI from the seat-back frame (81. On right seat-back with center shoulder belt, pass the center belt (CI through the hole in the seat-back pad.
Rear Seat-back Striker Replacement

NOTE: Take care not to scratch the interior trim. 1. Remove the rear side trim panel (see page 20-511.
2. Remove the bolts, then remove the seat-back
==
A
striker (AI.
Fastener Locations
~: 801t, 2
CJ=
ax 1.25 mm 22 Nm 12.2 kgfm, 16lbfftl

3. Install the striker in the reverse order of removal, and move the striker (A) up or down until it is
4. Remove the bolts, then remove the seat-back latch (AI from the seat-back frame (8). and release the pivot pin (CI of the latch lever (DI from the seatback frame.
Fastener Locations
~: 801t.2
centered in the seat-back latch (81.
./[J
5. Install the latch in the reverse order of removal, and make sure the seat-back locks and unlocks properly.
f)---+
.- ............ .
.................
20-81
Seats
Rear Seat-back Cover Replacement
NOTE: Take care not to tear the seams or damage the seat
covers .
5. On right seat-back: Using a Torx T30 bit, remove the bolts, then remove the belt holder trim (A), and remove the trim from the center belt (8).
Fastener locations
~: Bolt, 2
1. Remove the seat-back (see page 20-80).

2. Remove the headrest. 3. Pull up the latch cover (A) to release the clips, then
remove it.
Fastener Locations
'I
/
6x 1.0 mm s.8N.m 11.0 kgfm, 7.2IblftJ
,-;~I, '\i/
I
-r~,
/'
1>: Clip, 4
6. ReJease the hook (AI. and unzip the seat-back cover (8). The right seat-back is shown, the left seat-back
is similar.
B~
4. Pull up the outside edge of the latch lever cover (A)
to release the clips, and release the cover from the
...
pivot pins (8) of the latch lever (e) while pulling the latch lever.
Fastener Locations
I
B
1>: Clip, 2
20-82
==
7. Pull back the edge of the seat-back cover (A), and release the clips (B). 9. Remove the seatback cover (A) from the seat-back pad (B). On right seat-back with center shoulder belt, pass the center belt (C) through the hole in the seat-back cover.
8. Pull back the edge of the seat-back cover, and pull out the seat-back frame (A) from the seat-back pad (B), then pullout the headrest guide (C) while pinching the end of the guides, and remove them.
and note these items:
B~
To prevent wrinkles when installing a seat-back
cover, make sure the material is stretched evenly over the pad before securing the hooks and clips. On right seat-back: When installing the seat-back frame to the pad, slip the center belt through the
hole in the seat-back cover and pad. Replace any clips you removed with new ones.
Install them with commercially available upholstery ring pliers .
20-83
Seats
Rear Seat Cushion Cover Replacement
1. Remove the rear seat cushion (see page 20-80). 2. Release all the clips (A) from under the seat cushion, and fold back the seat cushion cover (8).
4. Install the cover in the reverse order of removal, and note these items: To prevent wrinkles, make sure the material is stretched evenly over the pad before securing
the clips . Replace any clips (A) you removed with new ones. Install them with commercially available upholstery ring pliers (8).
A
~
A
3. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove
the seat cushion cover.
<,_+_ ---t--\ _ , _ _ --+ (-
-t----__+_
t-->-----t-,
-t- -
--.----
20-84
Bumpers
Front Bumper Removal/Installation
NOTE: Have an assistant help you when removing and installing the front bumper.
Take care not to scratch the front bumper and body. Put on gloves to protect your hands. 1. Remove the front bumper as shown.
2. Install the bumper in the reverse order of removal, and note these items:
Make sure both front side marker light connectors are plugged in properly.
Make sure the front bumper engages the hooks of the side spacers and upper beams on both sides securely_

Fastener locations
A ~: Screw, 2 B ~: Screw, 2
C~:Bolt,4
D
t> :Clip, 7
t>: Clip, 2
ABSORBER RIGHT FRONT SIDE MARKER LIGHT CONNECTOR HOOKS
HOOKS
-:...:.:..""::....::::....::;~..:j ..----------SIDE SPACER
.~
~
UPPER BEAM lEFT FRONT SIDE MARKER LIGHT CONNECTOR
BUMPER
PLATE AIR SPOilER PLATE
..
FRONT INNER FENDER FRONT BUMPER
B
,
/:,
E
FRONT AIR SPOilER SPOilER
6x 1.0mm 9.8 Nm (1.0 kgfm, 7.2Ibfftl
20-85
Bumpers
Rear Bumper Removal/Installation
NOTE:
Have an assistant help you when removing and installing the rear bumper. Take care not to scratch the rear bumper and body. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.

1. Remove the rear bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items:
Make sure both rear side marker light connectors are plugged in properly.
Make sure the rear bumper engages the hooks of the side spacers, side brackets, and upper brackets on both
sides securely. Make sure the upper spacers of the rear bumper engage the clips on the body securely. Replace any damaged clips.
Fastener locations
A~ : Bolt, 2
B ~ : Screw, 2
C ~ : Screw, 2
C 1>: Clip, 2
&'1-,:
.~, ~I
HOOKS
HOOKS
UPPER BRACKET
~ :/9.8N.m
REAR SIDE MARKER LIGHT CONNECTOR
RIGHT
6x 1.0 mm
~
~
_ "
72Ibfft)
11.0 kg!m,
SIDE SPACER
~
=
ABSORBER
~'---
~o
----- -LEFT REAR SIDE MARKER LIGHT CONNECTOR
,~ -1
o
CAP
~O
\
CAP
UPPER SPACER
D
REAR BUMPER
20-86
Hood
Adjustment
1. Slightly loosen each hood hinge bolt.
2. Adjust the hood IAI alignment in this sequence .
==
Adjust the hood right and left, as well as forward and rearward, by using the elongated holes on the hood hinge IBI . Turn the hood edge cushions lei, as necessary, to make the hood fit flush with the body atthe front and side edges.
6x 1.0mm 9.8Nm
6x 1.0 mm 9.8Nm
3. Adjust the hood latch IDI to obtain the proper height at the forward edge, and move the hood latch right or left until the striker lEI is centered in the hood latch.
4. Tighten each bolt securely .
(conrdl
20-87
Hood
Adjustment (cont'd)
5. Check that the hood opens properly and locks securely. 6. Apply body paint to the hinge mounting bolts and around the hinges. 7. Apply multipurpose grease to each location of the hood latch and hood hinge as indicated by the
arrows.
Hood Seal Replacement

1. Using a clip remover, detach the clips, then remove
the hood seal (AI. Take care not to scratch the hood.
Fastener Locations
1>: Clip, 20
A
/
,-------
2. Install the seal in the reverse order of removal, and
note these items:

Push the clips into place securely.
20-88
Hood Insulator Replacement

1. Disconnect the windshield washer tubes IAI.
Fastener Locations
[> : Clip. 10
2. Using a clip remover, detach the clips. Release the hooks 18), then remove the hood insulator Ie). Take care not to scratch the hood.
3. Install the insulator in the reverse order of removal, and note these items:
Replace any damaged clips. Push the clips into place securely.
20-89
Hatch
Adjustment
1. Remove the support strut from each side (see page 20-91). 2. Remove the C-pillar trim from each side (see page 20-51), and pull down the rear portion of the headliner (see page 20-54). Take care not to bend the headliner excessively. 3. Remove the rear trim panel (see page 20-52). 4. Slightly loosen each bolt and nut. 5. Adjust the hatch (A) alignment in the following sequence. Adjust the hatch hinges (8) right and left, as well as forward and rearward, using the elongated holes. Turn the hatch edge cushions (C), in or out as necessary, to make the hatch (D), fit flush with the body at the side edges. Adjust the fit between the hatch and hatch opening by moving the striker (D).
A
8 x 1.25 mm 22Nm 12.2 kgfm, 16 Ibf.ftl
----- _____________
ax 1.25mm 18 Nm 11.8 kgfm, 13lbfftl
20-90
Hatch Support Strut Replacement

6. Tighten each bolt and nut securely. 7. Check that the hatch opens properly and locks securely. 8. Reinstall the support struts securely. 9. Reinstall all remaining removed parts. 10. Apply multipurpose grease to the pivot portion of the hatch hinges (A) as indicated by the arrows.
==
1. With the help of an assistant, use a flat-tip screwdriver (A) to pry the support strut clips (B) from each end of the support strut (C) althe hatch and body, then release the support strut from the pivot bolts (D). Do not remove the clips from the support strut.
c
A
------~
8 x 1.25 mm 22 Nm 12.2 kgf.m, 16Ibf.!t}
2. Set the clips (A) to the original position, then reattach the support strut (B) on the pivot bolts (C) by pushing on the support strut.
---_--,\ CD ,~
~B
20-91
Hatch
Hatch Weatherstrip Replacement
1. Remove the hatch weatherstrip (AI by pulling out
on it.
Forw~
2. Locate the painted alignment mark (BI on the hatch weatherstrip. Align the painted mark with the alignment tab in the the center of the hatch opening, and install the hatch weatherstrip all the way around in the direction shown. Make sure there are no wrinkles in the weatherstrip. 3. Check for water leaks.
20-92
Fuel Fill Door

Adjustment
,. Remove the nut IAI, and remove the fuel fill door open spring IBI.
==
7. Apply multipurpose grease to each location indicated by the arrows.
6x 1.0 mm
9.8 11.0
7.2Ibllt)
8. Apply body paint to the hinge mounting bolts and

xO.8 mm
around the hinges.
1.8Nm 10.18 kgl.m, 1.3 Ibllt)
2. Slightly loosen the hinge mounting bolts IAI. 3. Adjust the fuel fill door IBI in or out until it's flush with the body, and up or down as necessary to
equalize the gaps.
4. Tighten the hinge mounting bolts. 5. Reinstall the fuel fill door spring. 6. Check that the fuel fill door opens properly and locks securely, and check that the rear of the door is flush with the body.
20-93
Exterior Trim
Front Grille Replacement
1. Remove the front bumper (see page 20-85). 2. Remove the front grille (A). Take care nollo scratch the front bumper (8).
-1 Remove the screws (e).
-2 Remove the clips (D). -3 Release the bottom hooks (E) of the grille.
-4 Pullout the bottom of the grille to release the upper hooks (F). -5 Pullout the grille to release the slits (G) from the ribs (H), then remove the grille.
Fastener Locations
C ~:Scr.w,4
0 i>:Clip,4
~
"='
..
H A
3. Install the grille in the reverse order of removal, and replace any damaged clips.
4. Reinstall the front bumper.
20-94
Cowl Covers Replacement

1. Remove the windshield wiper arms (see page 22-145). 2. Remove the windshield side trim from both sides (see step 2 on page 20-191.
==
3. Pull the hood rear seal (A) away from the cowl covers, then remOve it, and using a clip remover, detach the clips (8) from the cowl covers. Take care not to scratch the cowl covers.
Fastener Locations
B l> : Clip, 3
C l> : Clip, 8
D~
4. Detach the clips (C) by carefully pulling the passenger's cowl cover (D) upward, to release the hooks (E), and pull
out the cover forward to release the hooks (F), then remove the cover. Take care not to scratch the body.
5. Detach the clips (C) by carefully pulling the driver's cowl cover (G) upward, and pull out the cover forward to release the hooks (H), then remove the cover. Take care not to scratch the body.
6. Install the covers in the reverse order of removal, and note these items:

Push the clip portions into place securely .
Reinstall both windshield side trim properly (see step 26 on page 20-24) .
20-95
Exterior Trim
A-Pillar Corner Trim Replacement
1. Open the door.
2. Wrap a flat-tip screwdriver with protective tape,
5. Replace any damaged clips, 6. Hold the trim up, and fit the upper clip and lower clips into the holes in the body, then push on the trim until the clips snap into place.
and apply protective tape around the body to prevent damage. Carefully insert a flat-tip screwdriver next to the upper clip, and detach the clip by prying on the A-pillar corner trim (AI. Take care not to scratch the body and related parts.
Fastener location
1>: Clip, 1
r:JuL ..
~-
3. Close the door half-way. 4. Pull the A-piller corner trim (AI out to detach the
lower clips, then remove the trim.
Fastener Locations
1>: Clip, 2
20-96
Roof Molding Replacement

1. Apply protective tape to the body IAI. Using a flat-tip screwdriver wrapped with protective tape 181, pry up on the roof molding ICI. Take care not to scratch the body.
==
4. Pull up and release the rear bracket IAI from the pin 181, then remove the roof molding ICI.
B
5. Install the molding in the reverse order of removal, and note these items:
Take care not to damage the windshield molding. Make sure the roof molding is installed securely.
2. Pull up and slide the roof molding to release the front bracket IDI from the pin lEI. 3. Pull up the front portion of roof molding .
~-~-.~ --~~~
20-97
Exterior Trim
Rear License Trim Replacement
NOTE: Put on gloves to protect your hands. 1. Remove the hatch lower trim panel (see page 20 53).
2. On inside the hatch, remove the bolts securing the
3. From inside the hatch, release the clips lA, 8) while holding the rear license trim (e), then remove the
trim. Take care not to scratch the hatch.
Fastener Locations
A 1>: Clip, 2
B 1>: Clip, 2
rear license trim (A) and hatch lock cylinder (8).

Fastener Locations
~: Bolt, 2
~
.
...
I
=-=-=
..
' ~
.
.I',
i
A
6x1.0mm 9.8 Nm 11.0 kgfm, 7.2Ibfft)
Replace any damaged clips. Push the clip portions into place securely.
20-98
Hatch Spoiler Replacement

NOTE: Put on gloves to protect your hands. 1. Remove the hatch upper trim Isee page 20-531. 2. Remove the high mount brake light Isee page 22821. 3. From inside the hatch, remove the bolts (AI and nuts IBI.
Fastener locations
A~:
4. From inside the hatch, release the clips, while pulling the hatch spoiler IAI away, and release the
fasteners (B), then
remove the spoiler. Take care
notto scratch the body.

Fastener Locations
t>: Clip. 2
Bolt, 2
B.: Nut, 2
~ "
.~
.....t... .,
---
--
, -,
';~~/' ':
6x 1.0 mm 9.8Nm
5. Install the spoiler in the reverse order of removal, and note these items:
11.0 kglm. 7.2Ibl1t1
Replace any damaged clips. Replace any damaged fasteners. Before

installing the fastener to the spoiler, clean the spoiler bonding surface with a sponge
dampened in alcohol. Glue the fastener with adhesive tape 13M 5671, or equivalentl to the
spoiler. Push the clip and fastener portions into place securely.
20-99
Exterior Trim
Emblem Replacement
NOTE: When removing the emblem, take care not to scratch the body. 1. To remove the front "H" emblem and front type emblem, remove the front bumper (see page 20-85).
2. Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
3. Apply the emblem, where shown . When installing the side i-VTEC emblem on the body, align the application tape with the edge of the wheel arch,
then press the emblem into place, and remove the application tape.
'03 model: When installing the LEV emblem on the quarter glass, align the application tape with the edge of the
black ceramic and alignment mark on the quarter glass, then press the emblem into place, and remove the
application tape.
- - ----------
FRONT TYPE EMBLEM
__
'-=-c:""-~-
FRONT "H" EMBLEM
FRONT "H" EMBLEM BASE
FRONT "H" EMBLEM
FRONT Si EMBLEM PLATE
FRONT Si EMBLEM
PUSH NUT
FRONT SiR
PUSH NUTS
EMBLEM
6!!5~ ,~,~,,~ ~--'

PUSH NUTS FRONT GRILLE
-~~~ ..~~/
-~ ~~
---
---'"::-'--
PINS FRONT GRILLE
20-100

~
LEV EMBLEM (Left side only)
==
,~'~"""M~M
..
, --- ---------
-":
REAR VERSION EMBLEM
l'03~""'1
SIDE i-VTEC EMBLEM
REAR "H" EMBLEM

Unit: rnm (in.) Adhesive tape:
3M 4213E, or equivalent Thickness: 0.8 mm (0.03 in.) REAR "H" EMBLEM APPLlCA\TAPE
E~e black ceramic.
-- -~-L--ADHESIVE T"A'=-PE"---_ _'-P,INS HATCH LINE ADHESIVE TAPE
~'
REAR LICENSE TRIM REAR Si EMBLEM
."~~
. ""21<" MARK ~",,', ALIGNMENT

/
',Align.
~
LEV EMBLEM Onto inside face of the guarter glass. REA, R, ,SiR EMBLEM (Canada)
--,
d---,--'~
CIVIC EMBLEM LeltSide: 1!,4 14.4~ "!
I
~~~~-l~~~109~
49
t-Z--?
SIDE i-VTEC EMBLEM 118 4 BODY LINE
=t,
/
34 11.31
'~
'f
Edge of the
hatch.
~ _AD~ESIVE
...
,,/ 49
11.931
i
~-_-ccc i
TAPE\___
Edge of the
hatch.
ADHESIVE TAPE
Edge of the hatch.

Right Side: / 6312.51
SIDE i-VTEC EMBLEM
[i:C;X~-c~;;~,-=~,~~~"
"").
/142 15.591
~jI~~~+~~i=J/~Edge .. I'
--------------1 .6YI
,'----~--0___-
althe
wheel arch.
+_ ". 121 I t 14.761

Edge of the wheel arch. APPLICATION TAPE
'-
\
APPLICATION TAPE
' '" 142

15.591
BODY LINE
4. After installing the front "H" enblem and front type emblem, reinstall the front bumper .
20-101
Fenderwell
Front Inner Fender Replacement
NOTE: Take care not to scratch the body. 1. Remove the front inner fender IAI. -IOn the back of the wheel arch, remove the screws IBI. -2 From under the front bumper (el, remove the screw IBI securing the front bumper, splash shield IDI, and front inner fender, and remove the clip (EI securing the front air spoiler, front bumper, and front inner fender. -3 From the wheel arch, remove the clips (F, GI securing the front inner fender (and splash shield I on the body. -4 Release the hook (HI of the splash shield, then remove the front inner fender.
Fastener Locations
B ~: Screw, 4
E~ : Clip, 1
F ~: Clip, 1
G~:Clip,8
2. Install the inner fender in the reverse order of removal, and note these items:
20-102
Front Fender Fairing Replacement

1. Remove the front inner fender as necessary (see page 20-1021.
3. From the wheel arch, remove the clip (AI, and release the clip (BI, then remove the front fender fairing (el.
Fastener locations
A [> : Clip. 1 B [> : Clip. 1
2. Open the front door. From outside the door,

remove the upper clip (A), and from inside the door,
remove the lower clip (AI securing the front fender fairing (BI and front fender (el.
Fastener Locations
A[>: Clip, 2
J,x
-@
_------
- It I
<l
A
- . - . fl
..
:
,:'
",
4. Install the fender fairing in the reverse order of

o
~C
Replace any damaged clips. Route the side turn signal light harness (AI through the slit (BI of the front fender fairing (el. Before installing the clips of the door upper and lower portions, install the front fender fairing (AI to the front fender (BI properly as shown.
Push the clips into place securely.
C
..
~
A
.~
fI
\ B
20-103
FenderweU
Fuel Pipe Protector Replacement
1. Remove the clips, then remove the fuel pipe
Rear Air Outlet Replacement

1. Remove the rear bumper (see page 20861.
protector (AI. Take care not to scratch the body.

Fastener Locations
2. Detach the hooks (AI, then remove the rear air

outlets (81. Take care not to scratch the body.
[> : Clip, 4
~I
A
3. Install the air outlets by pushing on the hook

2. Install the protector in the reverse order of removal, and note these items:
portions until the hooks snap into place.
20-104
Openers
==
HATCH LOCK CYLINDER
Replacement, page 20-11 1

HATCH HANDLE
Replacement, page20-110
HATCH LATCH

FUEL FILL DOOR LATCH
page 20-107
HOOD LATCH
()
--------
',-
FUEL FILL DOOR OPENER CABLE

FUEL FILL DOOR OPENER
Replacement, page 20-109 Replacement, page 20-108

HOOD OPENER CABLE Replacement, page 20- 106 HOOD RELEASE HANDLE page 20-106
20-105
Openers
Hood Opener Cable Replacement
NOTE: Put on gloves to protect your hands . Take care not to scratch the body and related parts.
Front bumper (see page 20-851 Front inner fender, left side (see page 20-1021 Kick panel, left side (see page 20-501 2. Disconnect the hood opener cable (AI from the hood latch (Bllsee page 20-108), and remove the bolts lei, then remove the hood release handle IDI from the body.
Fastener locations
C ~: Bolt, 2 E 6x 1.0 mm 9.8Nm 11.0 kgfm. 7.2Ibfft)
I> :Clip,3
3. Using a clip remover, detach the clips lEI, and remove the grommet IFI from the body, then remove the hood opener cable from the vehicle. Take care not to bend the cable. 4. Install the cable in the reverse order of removal, and replace any damaged clips.
20-106
Fuel Fill Door Opener Cable Replacement

SRS components are located in this area. Review the SRS component locations (see page 23-13) and the precautions and procedures (see page 23-14) in the SRS section before performing repairs or service.
NOTE: Put on gloves to protect your hands . Take care not to scratch the body and related parts.
1. Remove these items from the left side of the vehicle: Door sill trim (see page 20-50) Rear side trim panel (see page 20-51) 2. Pull the carpet back as necessary (see page 20-55). 3. Disconnect the fuel fill door opener cable (A) from the opener (B) (see step 3 on page 20-109).
Fastener Locations
c [> : Cushion tape, 1
o t> : Clip. 1
t>: Clip. 2
~
I._~'
~
F--...c:....
E ________ A
(:.c,,:' .
"--..;-
~" ~"~'__.;;<C> o : "-~ -0-~-_/ ",

.
.c,-::,;":~
/' .
/
/---
4. KC model: Remove the left middle floor cross-member gusset Isee page 20-113). 5. Remove the cushion tape IC), and release the cable from the clips ID, E). 6. Remove the fuel fill door latch IF) from the body by turning it 90. 7. Remove the fuel fill door opener cable from the vehicle. Take care not to bend the cable.
8. Install the opener cable in the reverse order of removal, replace the cushion tape, and replace the clip if it is damaged.
20-107
Openers
Hood Latch Replacement
NOTE: Put on gloves to protect your hands. Take care not to scratch the body.
1. Remove the bolts, then remove the hood latch (A) from the body.
Fastener locations
~:
3. Instali the hood latch in the reverse order of

Apply multipurpose grease to each location of the hood latch indicated by the arrows.
Make sure the hood opener cable is connected
801t, 3
properly. Make sure the cable actuates the latch before you close the hood. Adjust the hood latch alignment (see step 3 on page 20-87). Make sure the hood opens properly and locks
securely.
6x 1.0 mm 9.8 Nm 11.0 kgfm, 7.2Ibfft)
2. Disconnect the hood opener cable (B) from the hood latch. Take care not to bend the cable.
20-108
Fuel Fill Door Opener Replacement

1. Using a flat-tip screwdriver wrapped with protective tape, detach the hooks (AI by prying the front side cap (81, then remove it from the left door sill trim (el, and loosen the bolt (01 securing the fuel fill door opener. 4. Disconnect the fuel fill door opener cable (AI, then remove the opener (81. Take care not to bend the cable.
5. Install the opener in the reverse order of removal, and note these items:
2. Remove the left door sill trim (see page 20-501. 3. Remove the opener (AI from the bolt (81.
Make sure the opener cable is connected properly . Make sure the fuel fill door opens properly and locks securely .
20-109
Openers
Hatch Handle Replacement
Hatch Latch Replacement

NOTE: Put on gloves to protect your hands. 1. Remove the hatch lower trim panel (see page 20531. 2. Disconnect the hatch opener cable (AI, cylinder rod (BI, hatch actuator connector (el, and hatch latch switch connector (D), and detach the hatch actuator
connector and hatch latch switch connector from
Hatch lower trim panel (see page 20-531 Rear license trim panel (see page 20-981 2. Remove the rear window wiper motor (see page 22-1461.
the hatch.
3. Disconnect the hatch opener cable (AI from the hatch handle (BI, and remove the nuts.
Fastener Locations
Fastener Locations
~:
Bolt, 3
.:Nut,2
B
6xl.0mm 9.BNm ('.0 klllm, 7.2 IbMt\
()P
4. Pull outthe hatch handle (AI, then remove it.
<1..._____6 x 1.0 mm
..
9.8 Nm 11.0 kgfm, 7.2Ibfftl
3. Remove the bolts, then pull the hatch latch (E) out, then remove it.
4. Install the latch in the reverse order of removal, and note these items: Make sure each connector is plugged in properly,
and the rod and cable are connected properly. Make sure the cable actuates the latch before you close the hatch.
Make sure the hatch opens properly and locks securely. 5. Install the handle in the reverse order of removal, and note these items: Make sure the hatch opener cable is connected securely .
Make sure the hatch opens properly.
20-110
Hatch Lock Cylinder Replacement

4. Install the lock cylinder in the reverse order of

Hatch lower trim panel (see page 20-53). Rear license trim (see page 20-98). 2. Disconnect the cylinder rod (A).
Make sure the rod is connected properly. Make sure the hatch opens properly and locks
securely.
3. From outside the hatch, remove the bolt securing the lock cylinder (A). From inside the hatch, pull the lock cylinder out by releasing the hook (B).
Fastener Location
~: Bolt, 1
6x1.0mm 9.8Nm
11.0 kgf.m, 7.2Ibf.ftl
20-111
Frame
Subframe Replacement
Subframe Torque
NOTE: After loosening the subframe mounting bolts, be sure to replace them with new ones.
FRONT SUSPENSION SUBFRAME
Reference holes alignment:
SUBFRAME
REFERENCE HOLE {Body Side I
INSTALLATION REFERENCE HOLE (Subframe side)
INSTALLATION REFERENCE HOLE
SCREWDRIVER or TAPERED PUNCH
To body .
.I
'"\
FRONT SUSPENSION To body . INSTALLATION REFERENCE HOLE
.I
SPECIAL BOLTS 14x1.5mm 103 Nm
{lO.5 kgfm. 76 Ibfftl

Replace.
20-112
Frame Stiffener, Brace, and Gusset Replacement

Frame Stiffener, Brace, and Gusset Torque
==
NOTE: When installing the middle floor cross-member brace or gussets, torque the mounting hardware in the following sequence to avoid damage to the quarter panel.
,
,,--
MIDDLE FLOOR CROSS-MEMBER BRACE/GUSSET SIDE FRAME STIFFENER
'1--.j,.;~v.... " ,
To body.
/ SIDE FRAME STIFFENER
,~~ ~1
L "
8x 1.25mm 29 Nm 13.0 kgfm, 221bf1t1
To body.
U.S. model: 10 x 1.25 mm Canada model:
38 Nm
(l:
MIDDLE FLOOR CROSSMEMBER GUSSET
13.9~a A!~~g~~~~~~~~R /' I BRACE

MIDDLE FLOOR CROSS-MEMBER BRACE BRACKET'
,I
CJ)
.cc~ c:{;~
. .
"I
; / ~~<JJe:.~
. .
{ -t~d-~-"
~10X1.25mm G
38 Nm 13.9 kgfm, 281bf1t1
. . . . ./';,.. 1:
/'r!P,'
5--
~
V'
r~
1
\ )c~
20-113
.. c
"""S10X1.25mm
"~ .....
38Nm 13.9 kgf.m, 28 Ibfltl
Frame
Frame Repair Chart
Top view
Unit: mm (in.) 0: Inner diameter
a b1
b2 b3 01
For subframe ",15 (0.59) For engine mount 013 (0.51)
e
f 9
h
For engine mount 013 (0.51)

For engine mount 013 (0.51) For manual transmission mount .013 (0.51)
For damper mount .011.5 (0.45) For damper center 078 (3.07) For damper mount 011.5 (O.45) For damper mount ,,",5 (0.45) For subframe .015 (0.59)
02 03
For manual transmission mount 013 (0.51)

For manual transmission mount ",13 (0.51)
Locating hole 025 (0.98) Locating hole 050 (1.97)
.1
LINE
UNE
20-114
k I
locating hole 825 (0.98) for trailing arm 013 (0.51)

Locating hole 825 (0.98) Locating hole 020 (O.79) Trailing arm center Rear damper center For upper arm 013 (0.51)
s
t1, t2
For trailing arm 013 (D.51) For upper arm bracket center 015 (0.59)
m n
0
Locating hole 013 (0.51' for upper arm 013 (D.S1'
p
q
x,
x2
v w
for rear lower arm center locating hole 050 (1.97) Locating hole 020 (0.79) Locating hole 025 (0.98)
3040 1119.691
I I
~
I
I
;=11
j
I
I
~
/~
'/ i/'\ r
=--
(conl'dl
20-115
Frame
Frame Repair Chart (cont'd)
Side view
Unit: mm (in.)
a
b1 b2 b3 01 02 03
0: Inner diameter
For subframe 015 10.59) For engine mount 013 10.511 For engine mount 013 (0.51) For engine mount ,,13 (0.51) For manual transmission mount 013 (0.51) For manual transmission mount 013 (0.51)
e
f 9 h
For damper mount 011.5 (0.45) For damper center .878 (3.07)
For damper mount "1'.5 (0.45)

For damper mount .011.5 (0.45) For subframe 015 10.59) Locating hole 025 (0.98)
For manual transmission mount ,,13 10.51)
Locating hole" (1.97)
3 - .".5 iO.451
""'" d
A
,,1
,.
SEcnONAA
BASE
UN"
MUX1.5
VERTICAL LINE
20-116
Frame
Frame Repair Chart (cont'd)
Side view
Unit: mm (in.)
a
b1 b2 b3 01 02 03
0: Inner diameter
For subframe 015 10.59) For engine mount 013 10.511 For engine mount 013 (0.51) For engine mount ,,13 (0.51) For manual transmission mount 013 (0.51) For manual transmission mount 013 (0.51)
e
f 9 h
For damper mount 011.5 (0.45) For damper center .878 (3.07)
For damper mount "1'.5 (0.45)

For damper mount .011.5 (0.45) For subframe 015 10.59) Locating hole 025 (0.98)
For manual transmission mount ,,13 10.51)
Locating hole" (1.97)
3 - .".5 iO.451
""'" d
A
,,1
,.
SEcnONAA
BASE
UN"
MUX1.5
VERTICAL LINE
20-116
k I m
n
0
Locating hole 025 (0.98)
For trailing arm 813 (0.51) Locating hole 825 (0.98)

Locating hole 020 (0.79) Trailing arm center Rear damper center For upper arm 013 (0.51)
s
t1, t2 u
v
For trailing arm 013 (0.51) For upper arm bracket center 015 (0.59) Locating hole 013 (0.51) For upper arm 013 (0.51)
For rear lower arm center

Locating hole 050 (1.97)
p q
w xl x2
Locating hole 020 (0.79) locating hole 025 (0.98)
10.451
I
,nPOiNT s
.105 1413) POINT P
SECTION BB
_M~X_125
_.!'~_NT P
--,
POINT.
M12Xl2'S
POINT n
POINT
~2
.
~
POINT 0
20-117
HVAC (Heating, Ventilation, and Air Conditioning)

Heating and Air Conditioning
Special Tools ................................ 21-2 Component Location Index ........ 21-3 AlC Service Tips and Precautions ............................... 21-6 AlC Refrigerant Oil Replacement ............................ 21-6 General Troubleshooting Information ............................... 21-8 DTC Troubleshooting Index ....... 21-9 Symptom Troubleshooting Index ......................................... 21-10 System Description ..................... 21-11 Circuit Diagram ............................ 21-14 DTC Troubleshooting .................. 21-16 Recirculation Control Motor Circuit Troubleshooting .......... 21-25 Heater Control Power and Ground Circuits Troubleshooting ........ 21-27 Condenser Fan Circuit Troubleshooting ...................... 21-28 Radiator and Condenser Fans Common Circuit Troubleshooting ...................... 21-29 Compressor Clutch Circuit Troubleshooting ...................... 21-30 AlC Pressure Switch Circuit Troubleshooting ...................... 21-32 Air Mix Control Motor Test and Replacement ............. 21-34 Mode Control Motor Test and Replacement ............. 21-35 Recirculation Control Motor Test and Replacement ............. 21-36 Evaporator Temperature Sensor Replacement and Test ............. 21-37 Power Transistor Test ................. 21-38 Heater Control Panel and Push Switch Assembly Removal and Installation ........ 21-38 Dust and Pollen Filter Replacement ............................ Blower Unit Removal and Installation ................................ Blower Unit Components Replacement ............................ Evaporator Core Replacement ............................ *Heater Unit/Core Replacement ............................ Heater Valve Cable Adjustment ............................... Compressor Replacement .......... Compressor Clutch Check .......... Compressor Clutch Overhaul ..... Compressor Thermal Protector Replacement ............................ Compressor Relief Valve Replacement ............................ Condenser Replacement ............ Refrigerant Recovery .................. System Evacuation ...................... System Charging ......................... Refrigerant Leak Test .................. AlC System Tests ........................ 21-39 21-39 21-41 21-42 21-43 21-46 21-47 21-48 21-49 21-51 21-51 21-52 21-53 21-54 21-55 21-56 21-57
HVAC (Heating, Ventilation, and Air Conditioning)

Special Tools
f-=~,-+::=:-:-~=~T=oo 1N=u=m=ber _ _ _--+.o;--;-----c-~c---=D=escription ... 07SAZ-001000A Back robe Set
Q)
I
21-2

Component location Index
SERVICE VALVE (LOW-PRESSURE SlOE I SERVICE VALVE (HIGH-PRESSURE SIDEI
RECEIVER/DRYER
CONDENSER Clutch Check, page 21-48 Replacement, page 21-52 Clutch Overhaul, page 21-49 Thermal Protector Check, page 21-48 Thermal Protector Replacement, page 21-51 Relief Valve Replacement, page 21-51
COMPRESSOR Replacement, page 21-47
1cont'd)
21-3

RAOIATOR FAN RELAY Test, page 22-51 COMPRESSOR CLUTCH RELAY Test, page 22-51 BLOWER MOTOR RELAY ~.......,,I-_--,L-Test, page 2251
CONOENSER FAN RELAY Test, page 2251
, , A/C
SWITCH
, 'I
1'
RADIATOR FAN CONDENSER FAN
21-4

HEATER UNIT/CORE Replacement, page 21-43 BLOWER UNIT Removal and Installation, page 21-39 BLOWER UNIT COMPONENTS Replacement, page 21-41 ,HF4T"RVALVE CABLE Adjustment, page 21-46
~~~
DUST AND POLLEN FILTER Replacement, page 21-39 RECIRCULATION CONTROL MOTOR Test, page 21-36 Replacement, page 21-36 CONTROL MOTOR Test, page 21-35

POWER TRANSISTOR Test, page 21-38
AIR MIX CONTROL MOTOR Test, page 21-34 Replacement, page 21-34 EVAPORATOR TEMPERATURE SENSOR Replacement, page 21-37 Test, page 21-37 PUSH SWITCH ASSEMBLY Removal and Installation, page 21-38
HEATER CONTROL PANEL Removal and Installation, page 21-38
21-5

A/C Service Tips and Precautions A/C Refrigerant Oil Replacement
Recommended PAG oil: KEIHIN SP-10: PIN 38897-P13-A01AH: 120 mQ (4 IIozl PIN 38899-P13-A01: 40 mQ (1 1/311ozl
Add the recommended refrigerant oil in the amount
AWARNING
Compressed air mixed with R-134a forms a combustible vapor. The vapor can burn or explode causing serious injury. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
listed il you replace any 01 the lollowing parts.

To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
ACAUTION
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment . Do not breathe refrigerant or vapor.
Immediately after using the oil, reinstall the cap on

the container, and seal it to avoid moisture absorption.
Do not spill the relrigerant oil on the vehicle; it may damage the paint. II it gets on the paint, wash it off
immediately.
The air conditioning system uses HFC-134a IR-134al relrigerant and polyalkyleneglycol (PAGI relrigerant oil, which are not compatible with CFC-12 IR-121 relrigerant
and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result. Use only service equipment that is U.L.-listed and is
Condenser .......... Evaporator ........... Line or hose ......... Receiver/Dryer .... Leakage repair ....
25 mQ (5/6 IIoz, 0.9 Impozl 45 mQ 11 1/3 IIoz, 1.4Impozl 10 mQ (1/3 IIoz, 0.4Impozl 10 mQ 11/3 IIoz, 0.4Impozl 25 mQ 15/6 IIoz, 0.9Impozl
Compressor ......... For compressor replacement, subtract the volume of oil drained from the removed compressor from
certilied to meet the requirements 01 SAE J2210 to

remove R-134a from the air conditioning system. If accidental system discharge occurs, ventilate the work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.
130 mQ 14 1/3 IIoz, 4.6 Impozl, and

drain the calculated volume of oil from the new compressor: 130 mQ
141/3 IIoz, 4.6Impozl - Volume 01

removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the removed compressor, don't
Additional health and salety inlormation may be

obtained from the refrigerant and lubricant manufacturers. Always disconnect the negative cable from the battery whenever replacing air conditioning parts. Keep moisture and dirt out of the system. When disconnecting any lines, plug or cap the fittings immediately; don't remove the caps or plugs until just before you reconnect each line. Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring. When tightening or loosening a fitting, use a second wrench to support the matching fitting . When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don't release refrigerant into the atmosphere.
REMOVED COMPRESSOR
drain more than 50 mQ 112/3 IIoz, 1.8Impozl lrom the new

compressor.
NEW COMPRESSOR
: D
D
_
SAME LEVEL
-u
n::} D
DRAINING} VOLUME :A
A: 130 mQ. (41/3 floz, 4.6Impozl
21-6

HEATER UNIT
RE(~E"JER
LINE B
~RE(~EI\'ER
LINE A
fd{1J.--~-
RECEIVER/DRYER
/A~~-- 'COI~DE,NSER LINE
CONDENSER
COMPRESSOR BRACKET
~.~~
"11)
COMPRESSOR
'I~
Discharge hose to the compressor (6 x 1.0 mm): 9.8 Nm (1,0 kgfm, 7.2Ibfft)
(1:: Discharge hose to the condenser (6 x 1.0 mm): 9.8 Nm (1.0 kgfm, 7.2Ibfft) J:; Condenser line to the condenser (6 x 1.0 mm): 9.8 Nm (1.0 kgfm, 7.2Ibfft)
:~) Condenser line to the receiver/dryer (6 x 1.0 mm) : 9.8 Nm (1.0 kgfm, 7.2 Ibfft) rJ:', Receiver line A to the receiver/dryer (6 x 1.0 mm) : 9.8 Nm (1.0 kgfm, 7.2 Ibfft) .:]:: Receiver line A to the receiver line B: 13 Nm (1.3 kgfm, 9.4Ibfft) (7) Receiver line B and the suction line to the evaporator (6 x 1.0 mm): 9.8 Nm (1.0 kgfm, 7.2Ibfft) I'!} Suction line to the suction hose: 31 Nm (3.2 kgfm, 23Ibfft) ,:]) Suction hose to the compressor (6 x 1.0 mm) : 9.8 Nm (1.0 kgfm, 7.2 Ibfft) QW Compressor to the compressor bracket (8 x 1.25 mm) : 22 Nm (2.2 kgfm, 16Ibfft) ':II> Compressor bracket to the engine block (10 x 1.25 mm): 44 Nm (4.5 kgfm, 33 Ibfft)
21-7

How to Retrieve a Ole
The heater control panel has a self-diagnosis function. To run the self-diagnosis function, do the following: 1. Turn the fan switch OFF. 2. Press and hold the recirculation control switch and the rear window defogger switch down. 3. Turn the ignition switch ON (II).
4. Release both switches. The recirculation indicator and the rear window defogger indicator come on. The
recirculation indicator goes off 3 seconds later and the NC indicator comes on, then the self-diagnosis will begin. About 10 seconds later, the self-diagnosis will finish and the NC indicator goes off . If any trouble is found, the recirculation indicator blinks the diagnostic trouble code (DTC) to indicate a faulty
circuit or component.
If the system is OK, the recirculation indicator stays off.
@
FANSWITCH
'" ~ ~e ~~~
/ RECIRCULATION CONTROL SWITCH
AIC INDICATOR
RECIRCULATION INDICATOR REAR WINDOW ?GER INDICATOR
REAR WINDOW DEFOGGER SWITCH
Example of OTC indication Pattern (OTC 7)
~~5ec
DTC7 _ _A _ __
(
Recirculation indicator comes on Recirculation ------- - ,
indicator goes off
:..
3 sec
~:.-, 0.3 sec
'..
1.5
sec:
.'
Resetting the Self-diagnosis Function

Turn the ignition switch OFF to cancel the self-diagnosis function. After completing repair work, run the self-diagnosis function again to make sure that there are no other malfunctions.
21-8
OTe Troubleshooting Index

Dle (Recirculation Indication Blinks)
-~
Detection Item An open in the air mix control motor circuit A short in the air mix control motor circuit
Page
7 8 9 10 11 12 13 14 15
A problem in the air mix control linkage, door, or motor

An open or short in the mode control motor circuit
A problem in the mode control linkage, doors, or motor A problem in the blower motor circuit A problem in the EEPROM in the heater control panel; the control panel must be replaced
An open in the evaporator temperature sensor circuit A short in the evaporator temperature sensor circuit
(see page 21-161 (see page 21-161 (see page 21-171 (see page 21-181 (see page 21-191 (see page 21-201 I (see page 21-381 (see page 21-231 (see page 21-241
In case of multiple problems, the recirculation indicator will indicate only the OTC with the least number of blinks. In case of an intermittent failure, the heater control panel will store the OTC until the ignition is turned off.
21-9

Symptom
Recirculation control doors do not change between Fresh and Recirculate
Diagnostic procedure
Recirculation Control Motor Circuit Troubleshooting (see page
Also check for

Cleanliness and tightness of all
connectors
Both heater and NC do not work
21-25) , Heater Control Power and Ground Circuits Troubleshooting (see page 21-27)
Condenser fan does not run at all Ibut radiator fan runs with the NC on) Both fans do not run with the NC on
Blown fuse No. 14110A) in the under-dash fuse/relay box Poor ground at G501 Cleanliness and tightness of all connectors Condenser Fan Circuit Poor ground at G301 Troubleshooting Isee page 21-28) Cleanliness and tightness of all connectors __ I , Blown fuse No.1 120A) and No.4 Radiator and Condenser Fans Common Circuit Troubleshooting I (20A) in the under-hood fuse/relay ! Isee page 21-29) box Poor ground at G301 Cleanliness and tightness of all
connectors
Compressor clutch does not engage Iboth fans run with NC on) NC system does not come on (both fans and compressor)
I
: Cleanliness and tightness of all Troubleshooting Isee page 21-30) .c-.connectors NC Pressure Switch Circuit i Blown fuse No.1 120A) and No.4 (20A) in the under-hood fuse/relay Troubleshooting Isee page 21-32) I box Poor ground at G301 Cleanliness and tightness of all
Compressor Clutch Circuit
connectors
21-10
System Description
Heater Control Panel Inputs and Outputs
HEATER CONTROL PANEL CONNECTORS
CONNECTOR A (14P)
CONNECTOR B (22Pj
CONNECTOR A I Cavity 1 2 3 4 5 6 7 , 8 9 10 11 12 13 14 CONNECTOR B ( Cavity 1 2 -, 3 4 5 j 6 7 8 9 10 11 12 13 14 15 I 16 17 18 19 20 21 22
"0" Ircult laQram on C" Wire color GRY LTGRN PNK/BLU BLU GRN/YEL GRN/WHT BLU/YEL BLU/RED GRN YEL/RED YEL/BLU YEL/BLK BLK BLK/YEL
IrcUlt laQram on C"" 0" Wire color
----
Signal AIR MIX POTENTIAL +5V ----! SENSOR COMMON GROUND ,AIR MIX HOT NC PRESSURE SWITCH RECIRCULATE FRESH -, POWER TRANSISTOR BLOWER FEEDBACK 'AIR MIXCOOL I MODE DEF MODE VENT REAR WINDOW DEFOGGER RELAY GROUND IG2 (Power!
----
---
_._"-
- - -,
OUTPUT INPUT OUTPUT INPUT INPUT INPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT INPUT
---
1- ,.
Signal
,"
,--
BLK/RED LTGRN LT GRN/BLK PNK/BLK BRN

------
REAR WINDOW DEFOGGER SWITCH LED
INPUT-~
NC SWITCH LED
- ,
RECIRCULATION CONTROL SWITCH LED AIR MIX POTENTIAL EVAPORATOR TEMPERATURE SENSOR - .
- --. ,
INPUT INPUT OUTPUT OUTPUT

- _..
.~,
- ----
RED RED/BLK
---
GAUGE ASSEMBLY TAILLIGHTS RELAY
,-
OUTPUT INPUT
-----
--------
---
BLU LT GRN/RED YEL/RED YEL/GRN WHT/BLU RED/BLU RED/YEL BRN/WHT RED/WHT
REAR WINDOW DEFOGGER SWITCH NCSWITCH RECIRCULATION CONTROL SWITCH MODE4 MODE3 MODE2 MODE 1 ----' IGN (Power! (Not used!
INPUT INPUT_ INPUT OUTPU1-OUTPUT OUTPUT OUTPUT OUTPUT
(conl'dl
21-11

The air conditioning system removes heat from the passenger compartment by circulating refrigerant through the system as shown below.
BLOWER FAN
~\~I
EXPANSION VALVE (Meters the required amount of refrigerant into the evaporator)
EVAPORATOR (Absorption of heat)
EVAPORATOR TEMPERATURE SENSOR THERMAL PROTECTOR (opens the compressor clutch circuit when the compressor temperature becomes too high)
AIC PRESSURE SWITCH When the refrigerant is below or above 3,140 kPa (32 kgf/cm l , 455 psi). the Ale pressure switch opens the circuit to the Ale switch and stops the air conditioning to protect the compressor .
196 kPa 12.0 kgf/em', 28 psil
t
OA'. . . ~.
.
/
RELIEF VALVE (Relieves pressure at the compressor when the pressure is too high)
t
RECEIVERIORYER (Traps debris, and removes moisture)
AIC COMPRESSOR (Suction and compression)
CONDENSER (Radiation of heat)
HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID
Wi.
LOW PRESSURE VAPOR
This vehicle uses HFC-134a IR-134a) refrigerant which does not contain chlorofluorocarbons. Pay attention to the following service items: Do not mix refrigerants CFC-12 (R-12) and HFC-134a (R-134a). They are not compatible. Use only the recommended polyalkyleneglycol (PAG) refrigerant oillKEIHIN SP-l0) designed for the R-134a compressor. Intermixing the recommended WAG) refrigerant oil with any other refrigerant oil will result in compressor failure. All Ale system parts (compressor, discharge line, suction line, evaporator, condenser, receiver/dryer, expansion valve, O-rings for joints) have to be designed for refrigerant R-134a. Do not exchange with R-12 parts. Use a halogen gas leak detector designed for refrigerant R-134a. R-12 and R-134a refrigerant servicing equipment are not interchangeable. Use only a recovery/recycling/charging station that is U.L.-listed and is certified to meet the requirements of SAE J2210 to service R-134a air conditioning system . Always recover the refrigerant R-134a with an approved recovery/recycling/charging station before disconnecting any AlC fitting.
21-12

Circuit Diagram
IGNITlONSWITCIi IG2 HOT in ON 1111 UNDER-DASH FUSE/RELAY BOX No.141"" BLK/RED -1+--<""V:~-+-1------------ BLK/YEL
BATIERY
UNDER HOOD FUSE/RELAY BOX r='-'====-=:"""" NO.19181)A) No.20 (40A)
H---<T'J:>-1""",,eJ'..D--i-WHT No.12)40A)
No" (lOA)
-r 1G'
13
RADIATOR
,
FAN RELAY
...........
f~
BLU BLK
13
CONDENSER FAN
RELAY
,
~j
1
COMPRESSOR
I'
CLUTCH RELAY
G q
1'
'j
BLOWER MOTOR
RELAY
GRNfWHT
BLU!YEL
RED
BLU/RED 1
'lJ(
'.fY THERMAL PROTECTOR
--t-()C~ll
H
I"" T l
-1
ACC m ..
SEFMJ
[3J iP~~SSOR
~
x llt;:6I
~E1C
G:CMESSU~
SWITCH
E2y--VEL
f-{
.1.
'LJ
(F9r-SLU/WHT
~BLU-
GRN/WHT
,
M
1
,
RADIATOR FAN
MOTOR
,
RADIATOR FAN
SWITCH 1 (ClOSed: Above I 199'F 191"C) ;
M
1
CONDENSER FAN MOTOR
I I I
G301
: In the under- dash fuse/relay box
G3D1
G301
21-14
----- 'lJ(IYEl--+----------------------------,
BLU/WHT
H+-@-
'lJ(/VEL
BLU BLK
POWER TRANSISTOR
...-----{i)-- BLU/RED
BLU/WHT
PUSH SWITCH ASSEMBLY
L----------~+.J,VV\
BRN/WHT
o-...-{'i)-- BLU/VEl
[][I
BLK/RED
A/C
LTGRN
2
LTGRN/BLI{
-'-'-o-JV
[][I
BlU
,' ? I
,
'v
EVAPORATOR TEMPERATURE SENSOR
"::-
7_BRN~LTGRN
A/C
LTGRN/RED
:ll
16
~
UGHT
10
YELIRED
t :~=~~~=-:PNK/BLK_~-----, ~
'V SV GAY
S5V
S-COM
AMD-P AIR MIX
GRN
--.: M -COOL
M -HOT
CONmOL MOTOR
PNK/BLU
DRIVING CIRCUIT
11 YEL/BLU M-VENT
LTGRN
L--''1''r-- VEL/REO
RED REDIBLK
M -OEF
MODEl
TAILUGHTS 2:ED/BLK RELAY
12
LIGHT
~~~BlY
RED
11
- - - - - - - - - - - B l U --W---~
-y-
,v
>
( 20
".19
18 '17
RED/YEl
MOOEl
M002
REDIBLU
WHT/BLU YEL/GRN LTGRN
MODE comROl MOTOR

S-COM 10
MODE3
MODE3
MODE4
REAR WINOOW DFOGGER

RELAY
C>-
YEL/BLK
~:
13
HEATER CONTROL PANEL
GRN/WHT GRN/YEL
BLK
..,
REC
CONTlIOL
RECIRCULATION MOTOR
IG2
BLK/YEL
,U<
--~=======:...--,1 0
:::J
'CONNECTOR A114P1 CONNECTOR B(22P) G50'
GS02
21-15

OTC Troubleshooting
DTC 7: An Open in the Air Mix Control Motor Circuit
1. Test the air mix control motor (see page 21-341. Is the air mix control motor OK? YES-Go to step 2. NO-Replace the air mix control motor.
2. Disconnect the air mix control motor 5P connector.
DTC 8: A Short in the Air Mix Control Motor Circuit

1. Testthe air mix control motor (see page 21-341. Is the air mix control motor OK? YES-Go to step 2. NO-Replace the air mix contorol motor..
2. Disconnect the air mix control motor 5P connector.
3. Disconnect heater control panel connectors A (14PI and B (22PI. 4. Check for continuity between the following terminals of heater control panel connectors A (14PI and B (22PI and the air mix control motor 5P
connector,
3. Disconnect heater control panel connectors A (14PI and B (22PI. 4. Check for continuity between body ground and heater control panel connector A (14PI terminals No.1, 2, 3, and 9 individually, and between body ground and heater control panel connector B (22PI terminal No.6.
14P: No.1 No.2 NO.3 No.9 22P: No.6
5P: No.5 No.4 No.2 No.1 5P: No.3

HEATER
A114P1
HEATER CONTROL PANEL CONNECTOR A (14PI

LTGRN GRY ",-'-,-c:,P.NK/BLU r-T-::T'-'
123
7 8 9 10 11
456
12 13 14
GRN
AIR MIX CONTROL
5P CONNECTOR Wire side of female terminals
HEATER CONTROL PANEL CONNECTOR B (22PI
3
I terminals
"IZ
14
5
15 16
YES-Check for loose wires or poor connections at
heater control panel connectors A (14PI and B (22PI

and at the air mix control motor 5P connector. If the connections are good, substitute a known-good air
mix control motor, and recheck. If the symptom/

indication goes away, replace the original air mix control motor. If the symptom/indication continues, substitute a known-good heater control panel, and
Is there continuity? YES-Repair any short to body ground in the

wire(s) between the heater control panel and the air mix control motor.
recheck. If the symptom/indication goes away, replace the original heater control panel.. NO-Repair any open in the wire(sl between the
heater control panel and the air mix control
NO-Go to step 5.
motor..
21-16
5. Turn the ignition switch ON (II), and check the same terminals for voltage.
HEATER CONTROL PANEL CONNECTOR A 114PI
Ole 9: A Problem in the Air Mix Control Linkage, Door, or Motor

1. Test the air mix control motor (see page 21-341. Is the air mix control motor OK? YES-Substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel..
NO-Replace the air mix control motor, or repair the linkage and door.
HEATER CONTROL PANEL CONNECTOR B t22PI PNK/BLK

3
11 12
4
14
5
15 16
19
20
21
22
Is there any voltage? YES-Repair any short to power in the wiretsl

between the heater control panel and the air mix
control motor. This short may also damage the

heater control panel. Repair the short to power before replacing the heater control panel.. NO-Substitute a known-good air mix control motor, and recheck. If the symptom/indication goes away, replace the original air mix control motor. If the symptom/indication continues, substitute a known-good heater control panel. and recheck. If the symptom/indication goes away, replace the original heater control panel..
21-17

DTC Troubleshooting.(cont'd)
Ole 10: An Open or Short in the Mode Control Motor Circuit
1. Test the mode control motor Isee page 21-351. 5. Turn the ignition switch ON 1111. and check the same terminals for voltage.
Is the mode cotrol motor OK?

YES-Go to step 2. NO-Replace the mode control motor . 2. Disconnect the mode control motor 10P connector. 3. Disconnect heater control panel connectors A (14P) and B 122PI. 4. Check for continuity between body ground and heater control panel connector A (14P) terminals No.2, 10, and 11 individually, and between body ground and heater control panel connector B 122PI terminals No. 17, 18, 19, and 20 individually.
HEATER CONTROL PANEL CONNECTOR A 114PI LTGRN
1 2 3
4 5 6
=
HEATER CONTROL PANEL CONNECTOR B 122PI
Is there any voltage?

YES-- Repair any short to power in the wirelsl between the heater control panel and the mode control motor. This short may also damage the heater control panel. Repair the short to power before replacing the heater control panel.. NO-Go to step 6.
HEATER CONTROL PANEL CONNECTOR B (22P)
YES-Repair any shortto body ground in the wire(s) between the heater control panel and the
mode control motor..

NO-Go to step 5.
21-18
6. Turn the ignition switch OFF, and check for continuity between the following terminals of heater control panel connectors A (14P) and B (22P) and the mode control motor 1OP connector. 14P: 10P: No.2 No.10 No.10 No.1 No.2 No.11 22P: No.17 No. 18 No.19 No. 20 10P: NO.8 No.6,9 No.5 No.4,7
DTC 11: A Problem in the Mode Control Linkage, Doors, or Motor

1. Testthe mode control motor (see page 21-35). Is the mode control motor OK? YES-Substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel.. NO-Replace the mode control motor, or repair the linkage and doors .
HEATER CONTROL PANEL CONNECTOR A (14P) Wire side offemale terminals LTGRN
1 2 3
Q Q
WHT/BLU YEL/GRN MODE CONTROL MOTOR lOP CONNECTOR Wire side of female terminals
HEATER CONTROL PANEL CONNECTOR B (22P) Wire side of female terminals
YES-Check for loose wires or poor connections at
heater control panel connectors A (14P) and B (22P),

and at the mode control motor 1OP connector. If the connections are good, substitute a knowngood
mode control motor, and recheck. If the symptom/

indication goes away, replace the original mode control motor. If the symptom/indication continues, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel.. NO-Repair any open in the wire(s) between the heater control panel and the mode control motor.
21-19

OTe 12: A Problem in the Blower Motor Circuit
1. Check the No. 12 (40A) fuse in the under-hood fuse/relay box, and the No. 14 (lOA) fuse in the under-dash fuse/relay box. Are the fuses OK?
3 4
7. Check for continuity between the No.3 terminal of

the power transistor 4P connector and body ground.
POWER TRANSISTOR 4P CONNECTOR
YES - Go to step 2.
NO-Replace the fuse(s), and recheck . 2. Connect the No.2 terminal of the blower motor 2P connector to body ground with a jumper wire.
BLOWER MOTOR 2P CONNECTOR
=
Is there continuity? YES-Go to step 8.
2
JUMPER BLU/BLK WIRE
NO-Check for an open in the wire between the power transistor and body ground. If the wire is OK, check for poor ground at G502 . 8. Connect the No.1 and No.3 terminals of the power
transistor 4P connector with a jumper wire.
=
POWER TRANSISTOR 4P CONNECTOR

BLU/BLK
Does the blower motor run? YES-Go to step 4. NO-Go to step 17. 4. Turn the ignition switch OFF.
JUMPER WIRE
BLK
5. Disconnect the jumper wire. 6. Disconnect the power transistor 4P connector.
9. Turn the ignition switch ON (II). Does the blower motor run at high speed? YES-Go to step 10.
NO-Repair open in the wire between the power transistor and the blower motor..

11. Disconnect the jumper wire.
21-20
12. Disconnect heater control panel connector A (14P). 13. Check for continuity between the NO.7 and No.8 terminals of heater control panel connector A (14P) and body ground individually.
HEATER CONTROL PANEL CONNECTOR A {14PI
15. Reconnect heater control panel connector A (14P). 16. Test the power transistor (see page 21-38). Is the power transistor OK? YES-Check for loose wires or poor connections at heater control panel connector A (14P) and at the power transistor 4P connector. If the connections are good, substitute a knowngood heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel.. NO-Replace the powertransistor. 17. Disconnectthe jumper wire.
18. Disconnect the blower motor 2P connector. Is there continuity? YES-Repair any short to body ground in the wire(s) between the heater control panel and the power transistor . NO-Go to step 14. 14. Check for continuity between the following terminals of heater control panel connector A (14P) and power transistor 4P connector. 14P: 4P: No.4 No.7 No.8 No.2
HEATER CONTROL PANEL CONNECTOR A (14PI Wire side of female terminals
19. Measure the voltage between the No.1 terminal of the blower motor 2P connector and body ground.
BLOWER MOTOR 2P CONNECTOR
BLU/WHT
=
Is there battery voltage? YES-Replace the blower motor.. NO-Go to step 20. 20. Turn the ignition switch OFF.
4
BLU/VEL
L -_ _ _~
21. Remove the blower motor relay from the underhood fuse/relay box, and test it (see page 22-51).
POWER TRANSISTOR 4P CONNECTOR Wire side of female terminals
Is the relay OK? YES-Go to step 22. NO- Replace the blower motor relay .
YES-Go to step 15. NO-Repair any open in the wire(s) between the heater control panel and the power transistor.
(conl'd)
21-21

22. Measure the voltage between the No.3 terminal of the blower motor relay 4P socket and body ground. 25. Turn the ignition switch OFF. 26. Check for continuity between the No.1 terminal of the blower motor relay 4P socket and body ground.
BLOWER MOTOR RELAY 4P SOCKET BLOWER MOTOR RELAY 4P SOCKET
Is there battery voltage? YES-Go to step 23. NO-Replace the under-hood fuse/relay box . 23. Turn the ignition switch ON (II). 24. Measure the voltage between the No.2 terminal of the blower motor relay 4P socket and body ground. NO-Check for an open in the wire between the blower motor relay and body ground. If the wire is OK, check for poor ground at G301 . Is there continuity? YES-Repair open in the BLU/WHT wire between the blower motor relay and the blower motor..
BLOWER MOTOR RELAY 4P SOCKET
Is there battery voltage? YES-Go to step 25. NO-Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the blower motor relay .
21-22
OTe 14: An Open in the Evaporator Temperature Sensor Circuit

1. Remove the evaporator temperature sensor (see page 21-37). 2. Measure the resistance between the No.1 and No.2 terminals of the evaporator temperature sensor. * Dip the sensor in ice water, and measure resistance. Then pour hot water on the sensor, and check for change in resistance.
4. Check for continuity between the No.7 terminal of heater control panel connector B (22P) and the No.1 terminal of the evaporator temperature sensor 2P connector.
HEATER CONTROL PANEL CONNECTOR B 122PI Wire side of female terminals
BRN
EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals
YES-Go to step 5. NO-Repair open in the wire between the heater control panel and the evaporator temperature sensor .
40,--------------,
30
RESISTANCE
kQ
20
l
!
5. Disconnect heater control panel connector A (14P).
10r---------~~~
32
50 10
68
20
TEMPERATURE
Is the resistance within the specifications shown on the graph?

YES-Go to step 3.
NO-Replace the evaporator temperature

sensor . 3. Disconnect heater control panel connector B (22P).
Iconl'd)
21-23

6. Check for continuity between the No.2 terminal of heater control panel connector A (14P) and the No.2 terminal of the evaporator temperature sensor 2P connector.
HEATER CONTROL PANEL CONNECTOR A 114PI Wire side offemale terminals LT GRN , - - - - - - - - - - ,
OTe 15: A Short in the Evaporator Temperature Sensor Circuit

1. Remove the evaporator temperature sensor (see page 21-37). 2. Test the evaporator temperature sensor (see page 21-37). Is the resistance within the specifications shown on the graph? YES-Go to step 3. NO-Replace the evaporator temperature sensor.
EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side offemale terminals
3. Disconnect heater control panel connector B (22P). 4. Check for continuity between the No.7 terminal of heater control panel connector B (22P) and body ground.
HEATER CONTROL PANEL CONNECTOR B (22P)
Is there continuity? YES-Check for loose wires or poor connections at heater control panel connector A (14P) and B (22P) and at the evaporator temperature sensor 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. II the symptom/indication goes away, replace the original heater control panel.. NO-Repair open in the wire between the heater control panel and the evaporator temperature sensor .
Is there continuity? YES-Repair short to body ground in the wire between the heater control panel and the evaporator temperature sensor.. NO-Substitute a known-good heater control pane), and recheck. lithe symptom/indication goes away, replace the original heater control panel .
21-24
Recirculation Control Motor Circuit Troubleshooting

1. Check the No. 14 (10A) fuse in the under-dash fuse! relay box. 8. Check for continuity between the No.5 and No.6 terminals of heater control panel connector A (14P) and body ground individually.
HEATER CONTROL PANEL CONNECTOR A It4PI ,.....,..L.,-..,GRN/WHT
6
14
Is the fuse OK?

YES-Go to step 2. NO-Replace the fuse, and recheck . 2. Disconnect the recirculation control motor 5P
connector.
3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.5 terminal of the recirculation control motor 5P connector and body ground.
RECIRCULATION CONTROL MOTOR 5P CONNECTOR
=
YES-Repair any short to body ground in the wire(s) between the heater control panel and the recirculation control motor.. NO-Go to step 9. 9. Turn the ignition switch ON III), and check the same wires for voltage.
=

YES-Go to step 5. NO- Repair open in the wire between the No. 14 fuse in the under-dash fuse!relay box and the recirculation control motor . 5. Turn the ignition switch OFF.
6. Testthe recirculation control motor (see page 2136).
=
Is there any voltage?

YES- Repair any short to power in the wirels) between the heater control panel and the recirculation control motor. This short may also damage the heater control panel. Repair the short to power before replacing the heater control panel.. NO-Go to step 10.
Is the recirculation control motor OK?

YES-Go to step 7.
NO- Replace the recirculation control motor, or repair the linkage and doors . 7. Disconnect heater control panel connector A (14P).
(cont'dl
21-25

Recirculation Control Motor Circuit Troubleshooting (cont'd)
10. Turn the ignition switch OFF. 11. Check for continuity between the following terminals of heater control panel connector A (14P)
and the recirculation control motor 5P connector.
14P: NO.5 No.6
5P: No.1 No.2
HEATER CONTROL PANEL CONNECTOR A (14P)

.Q
GRN/YEL
RECIRCULATION CONTROL MOTOR 5P CONNECTOR

YES-Check for loose wires or poor connections at heater control panel connector A (14P) and at the
recirculation control motor 5P connector. If the connections are good, substitute a known-good
heater control panel, and recheck. If the symptom/

indication goes away, replace the original heater
control panel.. NO-Repair any open in the wire(s) between the

heater control panel and the recirculation control motor.
21-26
Heater Control Power and Ground Circuits Troubleshooting

1. Check the No.14 (lOA) fuse in the under-dash fuse/relay box. 6. Check for continuity between the No. 13 terminal of heater control panel connector A (14P) and body
ground.
Is the fuse OK?

YES-Go to step 2. NO-Replace the fuse, and recheck . 2. Disconnect heater control panel connector A (14P). 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No. 14 terminal of heater control panel connector A (14P) and body ground.
HEATER CONTROL PANEL CONNECTOR A (14PI HEATER CONTROL PANEL CONNECTOR A 114PI
=
YES-Check for loose wires or poor connections at heater control panel connector A (14P). If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel..
NO-Check for an open in the wire between the heater control panel and body ground. If the wire is OK, check for poor ground at G501 .

YES-Go to step 5. NO-Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the heater control panel.. 5. Turn the ignition switch OFF.
21-27

Condenser Fan Circuit Troubleshooting
NOTE: If neither the condenser fan nor the radiator fan work, go to Radiator and Condenser Fans Common Circuit Troubleshooting (see page 21-29). 1. Check the No.1 (20A) fuse in the under-hood fuse/relay box, and the No. 14 (lOA) fuse in the under-dash fuse/relay box. Are the fuses OK? 4. Connectthe No.1 and No.2 terminals of the condenser fan relay 4P socket with a jumper wire.
CONDENSER FAN RELA V 4P SOCKET
BLU /VEL
I
1
JUMPER WIRE
~
YES~Go
to step 2. the fuse(s), and recheck .

4
NO~Replace
I3
2. Remove the condenser fan relay from the under-hood fuse/relay box, and test it (see page 22-51). Does the condenser fan run? Is the relay OK?
YES~Go
YES~Go
to step 5.
to step 3.
NO~Go
to step 8.
NO~Replace
the condenser fan relay .

5. Disconnect the jumper wire.
3. Measure the voltage between the No.2 terminal of the condenser fan relay 4P socket and body ground.
CONDENSER FAN RELAV 4P SOCKET
6. Turn the ignition switch ON (II). 7. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.
CONDENSER FAN RELA V 4P SOCKET
2 4 3 4
2
=
YES~Go
=
to step 4. the under-hood fuse/relay box .

YES~Replace
NO~Replace
the under-hood fuse/relay box .
NO~Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the
condenser fan relay . 8. Disconnect the jumper wire.
21-28
Radiator and Condenser Fans Common Circuit Troubleshooting

9. Disconnect the condenser fan 2P connector. 10. Check for continuity between the No.1 terminal of the condenser fan relay 4P socket and the No.2 terminal ofthe condenser fan 2P connector.
CONDENSER FAN RELAY 4P SOCKET
NOTE: If both fans and the AlC compressor clutch do not work when the AlC switch is on, go to AlC Pressure Switch Circuit Troubleshooting (see page 21-32). 1. Check the No.1 (20A) and No.4 (20A) fuses in the under-hood fuse/relay box, and the No. 14 (10A) fuse in the under-dash fuse/relay box.
r--,
2
BLU/YEL
Are the fuses OK?

3
YES-Go to step 2. NO-Replace the fuse(s), and recheck . 2. Remove the condenser fan relay from the under-hood fuse/relay box. 3. Turn the ignition switch ON (II).
CONDENSER FAN 2P CONNECTOR
YES-Go to step 11. NO- Repair open in the wire between the condenser fan relay and the condenser fan . 11. Check for continuity between the No.1 terminal of the condenser fan 2P connector and body ground.
CONOENSER FAN 2P CONNECTOR
4. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.
CONDENSER FAN RELAY 4P SOCKET
3
BlK/YEL
BlK
=
YES-Go to step 5. NO-Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the radiator fan relay, and the condenser fan relay . 5. Turn the ignition switch OFF.
6. Reinstall the condenser fan relay.
Q
=
YES-Replace the condenser fan motor..
NO-Check for an open in the wire between the condenser fan and body ground. If the wire is OK, check for poor ground at G301 .
7. Make sure the AlC switch is OFF. 8. Turn the ignition switch ON (II).
(cont'd)
21-29

Radiator and Condenser Fans Common Circuit Troubleshooting (cont'd)
9. Using a Backprobe Set, measure the voltage between the No.6 terminal of ECM connector B (24P) and body ground with the ECM connectors connected.
IGRN
Compressor Clutch Circuit Troubleshooting

1. Check the No.1 (20A) fuse in the under-hood fuse/relay box, and the No. 14 (lOA) fuse in the under-dash fuse/relay box. Are the fuses OK? YES-Go to step 2. NO-Replace the fuse(s), and recheck .
1 8 17
14 15 1 9 10 1/ / 13 / 18 1/ V 21 /
2 3
6 15 23
/ 1/
'L
=
2. Check the engine coolant temperature, the throttle position sensor, and the idle speed (use the Honda PGM Tester PGM-FI data list if possiblel. Is the coolant temperature above nomal, the throttle position sensor reading too high, or the idle speed too low?
YES- Troubleshoot and repair the cause of the

high engine coolant temperature, high throttle Is there battery voltage? YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM .
NO-Repair open in the wire between the radiator fan relay, the condenser fan relay and the ECM .
position sensor reading, or low idle speed .
NO-Go to step 3. 3. Remove the compressor clutch relay from the under-hood fuse/relay box, and test it (see page 2251). Is the relay OK? YES-Go to step 4. NO-Replace the compressor clutch relay . 4. Measure the voltage between the No.2 terminal of the compressor clutch relay 4P socket and body ground.
COMPRESSOR CLUTCH RELAY 4P SOCKET
Is there battery voltage? YES-Go to step 5. NO-Replace the under-hood fuse/relay box .
21-30
5. Connect the No.1 and No.2 terminals of the compressor clutch relay 4P socket with a jumper wire.
9. Turn the ignition switch OFF. 10. Reinstall the compressor clutch relay. 11. Make sure the AlC switch is OFF. 12. Turn the ignition switch ON (II).
BLU IRED
I
1
2
JUMPER WIRE
13. Using the Backprobe Set, measure the voltage between the No. 18 terminal of ECM connector E (31 P) and body ground with the ECM connectors
connected.
Does the compressor clutch click? YES-Go to step 6. NO-Go to step 14. 6. Disconnect the jumper wire. 7. Turn the ignition switch ON (II).
22
31
Is there battery voltage? 8. Measure the voltage between the NO.3 terminal of the compressor clutch relay 4P socket and body ground.
YES-Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see page 11-6). If the symptom/indication goes away with a known-good ECM, replace the original ECM . NO-Repair open in the wire between the compressor clutch relay and the ECM . 14. Disconnectthe jumper wire.
2
4
BLK/YEL
15. Disconnect the compressor clutch 1P connector.
'::I.
=
Is there battery voltage? YES-Go to step 9.
NO-Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the compressor clutch relay .
(conl'd)
21-31

Compressor Clutch Circuit Troubleshooting (cont'd)
16. Check for continuity between the No.1 terminal of the compressor clutch relay 4P socket and the No.1
terminal of the compressor clutch 1P connector.
COMPRESSOR CLUTCH RELAY 4P SOCKET BLUIRED
AIC Pressure Switch Circuit

Troubleshooting
1. Turn the ignition switch ON 1111. 2. Turn the blower switch on, and check for blower
motor operation.
Does the blower motor run on alf speeds? YES-Go to step 3.
2
4 3
.Q
NO- Troubleshoot the blower motor circuit Isee page 21-201. 3. Turn the ignition switch OFF.
BLU/RED COMPRESSOR CLUTCH lP CONNECTOR Terminal side of male terminals
4. Disconnect heater control panel connector A 114PI. 5. Turn the ignition switch ON 1111. 6. Measure the voltage between the No.4 terminal of heater control panel connector A 114PI and body ground.
YES-Check the compressor clutch clearance, the thermal protector, and the compressor clutch field coillsee page 21-48).. NO-Repair open in the wire between the
compressor clutch relay and the compressor
clutch .
=

YES-Go to step 7. NO-Go to step 9. 7. Start the engine.
21-32
8. Connect the No.4 terminal of heater control connector A 114PI to body ground with a jumper wire.
11. Check for continuity between the No.2 terminal of the Ale pressure switch 2P connector and the No.9 terminal of under-dash fuse relay box connector F 112P).
Ale PRESSURE SWITCH 2P CONNECTOR
JUMPER WIRE
=
UNDER-DASH FUSE/RELAY BOX CONNECTOR F (12P) Wire side of female terminals
Does the AlC system come on?

YES- Replace the heater control panel.. NO-Refer to the multiplex control system Isee page 22-168) . 9. Using the 8ackprobe Set, connect the No.9 terminal of under-dash fuse/relay box connector F 112PI to body ground with a jumper wire.
UNDER-DASH FUSE/RELAY BOX CONNECTOR F (12PI
YES-Go to step 12.
NO-Repair open in the wire between the under-dash fuse/relay box and the NC pressure switch .
12. Check for continuity between the No.1 and No.2 terminals ofthe Ale pressure switch.
Ale PRESSURE SWITCH
BLU/WHT JUMPER WIRE
=
Is there continuity? Does the AlC system come on?

YES-Go to step 10. NO- Refer to the multiplex control system Isee page 22-1681 . NOTE: Check for multiplex codes in mode 1. Follow the troubleshooting for any codes found. If no codes are found, subsititute a known-good multiplex control unit and a ECM one at a time. 10. Disconnect the Ale pressure switch 2P connector and under-dash fuse/relay box connector F 112PI. YES-Repair open in the wire between the heater control panel and the NC pressure switch . NO-Go to step 13. 13. Check for proper NC system pressure.
Is the pressure within specifications?

YES-Replace the NC pressure switch . NO- Repair the NC pressure problem .
21-33

Air Mix Control Motor Test
1. Disconnect the 5P connector from the air mix control motor.
Air Mix Control Motor Replacement

1. Remove the under-dash fuse/relay box (see page 22-491. 2. Disconnect the 5P connector (AI from the air mix control motor (81. Remove the self-tapping screws
and the air mix control motor from the heater unit.
2. Connect battery powertothe No.1 terminal of the

air mix control motor, and ground the No.2 terminal; the air mix control motor should run, and
stop at Max Cool. If it doesn't reverse the connections; the air mix control motor should run, and stop at Max Hot. If the air mix control motor
does not run, remove it, then check the air mix control linkage and door for smooth movement.
Remove the rod (CI from the arm (DI of the air mix
control motor.
D
If the linkage and door move smoothly, replace

the air mix control motor.
If the linkage or door stick or bind, repair them as needed.

If the air mix control motor runs smoothly, go to
step 3.
AIR MIX CONTROL MOTOR
,-----J
1
L
2
3. Install the motor in the reverse order of removal. After installation, make sure the motor runs
smoothly.
3. Measure the resistance between the No.4 and No.5 terminals. It should be between 2.1 k to 3.9 kQ.
4. Reconnect the air mix control motor 5P connector,
then turn the ignition switch ON (III. 5. Using the 8ackprobe Set, measure the voltage between the No.3 and No.4 terminals. Max Cool - about 1 V Max Hot - about 4 V
6. If either the resistance or VOltage readings are not as specified, replace the air mix cotrol motor.
21-34
Mode Control Motor Test

1. Disconnectthe 10P connector from the mode
control motor.
Mode Control Motor Replacement

1. Remove the ECM (see page 11-41. 2. Remove the relay mount bracket bolt, and move the relays out of the way. 3. Disconnectthe 10P connector (AI from the mode control motor (81. Remove the self-tapping screws and the mode control motor from the heater unit.
2. Connect battery power to the No.1 terminal of the mode control motor, and ground the No.2
terminal; the mode control motor should run
smoothly and stop at Defrost. If it doesn't, reverse

the connections; the mode control motor should
run smoothly and stop at Vent. When the mode

control motor stops funning, disconnect battery power immediately.
---------
--,
___________ B
-T",~Y
MODE CONTROL MOTOR
.JIll
--------
....--A
4. Install the motor in the reverse order of removal.
Make sure the pin on the linkage is properly engaged with the motor. After installation, make 3. If the mode control motor does not run in step 2, remove it, then check the mode control linkage and doors for smooth movement. If the linkage and doors move smoothly, replace the mode control motor. If the linkage or doors stick or bind, repair them as needed.
Ifthe mode control motor runs smoothly, go to sure the motor runs smoothly.
step 4. 4. Use a digital multimeter with an output of 1 mA or less at the 20 k Q range. With the mode control motor running as in step 2, check for continuity between the No.4, 5, 6, 7, 8, and 9 terminals and the No. 10 terminal individually. There should be
continuity for a moment at each terminal as the motor moves past each mode position. 5. If there is no continuity for a moment at each terminal, replace the mode control motor.
21-35

Recirculation Control Motor Test
1. Disconnect the 5P connector from the recirculation control motor. 1. Remove the ECM (see page 11-4).
Recirculation Control Motor Replacement
iNOTICEi
Incorrectly applying power and ground to the recirculation control motor will damge it. Follow the instructions carefully. 2. Connect battery power to the NO.5 terminal of the recirculation control motor, and ground the No.1 and No.2 terminals; the recirculation control motor should run smoothly. To avoid damaging the recirculation control motor, do not reverse power and ground. Disconnect the No.1 or No.2 terminals from ground; the recirculation control motor should stop at Fresh or Recirculate. Don't cycle the recirculation control matorfor a long time.
RECIRCULATION CONTROL MOTOR
__ -;:;:-'---1
2. Remove the relay mount bracket bolt, and move

the relays out of the way. 3. Disconnect the 5P connector (A) from the recirculation control motor (8). Remove the selftapping screws and the recirculation control motor from the blower unit.
A_ _ _
~
\;-J~--o;;-:--~
",-_.~_c."\-'> .
s-
'\ , .. Cj1c-
~
-
1 2
4. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.
3. If the recirculation control motor does not run in step 2, remove it, then check the recirculation control linkage and doors for smooth movement . If the linkage and doors move smoothly, replace the recirculation control motor . If the linkage or doors stick or bind, repair them as needed.
21-36
Evaporator Temperature Sensor Replacement

1. Remove the driver's dashboard lower cover (see
Evaporator Temperature Sensor Test

1. Dip the sensor in ice water, and measure the resistance between its terminals.
page 20-591 and the under cover (see page 20-601. 2. Remove the under-dash fuse/relay box (see page 22-491. 3. Disconnect the 2P connector (AI from the
evaporator temperature sensor (8), then remove
the connector clip (CI. Remove the self-tapping screw, and carefully pull out the evaporator
temperature.
2. Then pour hot water on the sensor, and check for a

change in resistance. B 3. Compare the resistance readings with the specifications shown in the graph; the resistance
should be within the specifications.

40
RESISTANCE
30
kQ
20
10
I~
32
N
,
---..
50 10
TEMPERATURE
21-37

Power Transistor Test
1. Disconnect the 4P connector from the power
transistor.
Heater Control Panel and Push Switch Assembly Removal and Installation
1. Remove the center panel (see page 20-62). 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel IB) from the center panel IC). Remove the self-tapping screws and the push switch assembly (D) from the center panel.
2. Measure the resistance between the No.1 and No.2 terminals of the power transistor. It should be about1.4-1.5kQ. If the resistance is within the specifications, go to step 3.
If the resistance is not within the specifications, replace the power transistor.
POWER TRANSISTOR
2
3 4
"--_--{Q)--_---.J
3. Carefully release the lock tab on the No.4 terminal (BLU/yEU (A) in the 4P connector, then remove the terminal and insulate it from body ground. 3. Install the control panel and push switch assembly
in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly.
4. Run the self-diagnosis function to confirm that
there are no problems in the system (see page 218).
JUMPER WIRE
(To 12 V power source on vehicle)
4. Reconnect the 4P connector to the power transistor.
5. Supply 12 volts to the No.4 cavity with a jumper

wire.
6. Turn the ignition switch ON (II), and check that the

blower motor runs. Ifthe blower motor does not run, replace the power transistor. If the blower motor runs, the power transistor is
OK.
21-38
Dust and Pollen Filter Replacement

The dust and pollen filters should be replaced every 30,000 miles (48,000 kml or 24 months whichever
comes first. Replace the filters more often if the air flow
Blower Unit Removal and Installation

For some models: SRS components are located in this area. Review the SRS component locations (see page 23-131 and precautions and procedures (see page 23-141 in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset
buttons.
is less than usual. 1. Open the glove box. Remove both glove box stops, then let the glove box hang down (see page 20-631.
2. Remove the filter lid (AI from the blower unit, then pull out the first dust and pollen filter (81. Slide the second filter to the left, and pull it out.
2. Disconnect the battery negative cable, and wait 3

minutes before beginning work.
3. Remove the right kick panel (see page 20-501, passenger's dashboard lower cover, and the glove box (see page 20-631.
4. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown. Remove and discard the plastic cross brace.
3. Remove the filter (AI from the housing (81, and replace the filter.
Cut heare.
4. Install the filters in the reverse order of removal.
(cont'dl
21-39

Blower Unit Removal and Installation (cont'd)
5. Remove the steering hanger beam bracket cover from the right side of the glove box opening, then remove the bolts and the glove box frame. 10. Disconnect the connector (A) from the recirculation
control motor, then remove the wire harness clip
(8). Remove the mounting bolts, the mounting nuts and the blower unit (C).
B~~:~~~
6. Remove the ECM (see page 11-4). 7. Remove the EPS control unit (see page 17-67). 8. Disconnect and remove the PGM-FI main relays and bracket assembly, then remove the ECM bracket. 9. Disconnect the connectors (A) from the blower
motor and the power transistor, then remove the
,
A-..............
4,
6x 1.0mm
6x1.0mm
7.2Iblft)
9.8 Nm 11.0 kglm,
7.2Iblft)
9.8 Nm 11.0 kglm,
11. Install the unit in the reverse order of removal. Make sure that there is no air leakage.
12. Reconnect the negative battery terminal.
wire harness clips (8) and the connectors (C). Remove the self-tapping screws and the bracket (D).
A
13. Do the engine control module (ECM) idle learn procedure (see page 11-139). 14. Enter the anti-theft code for the radio, then enter
-----,
21-40
Blower Unit Components Replacement

Note these items when overhauling the blower unit: The recirculation control motor (A), the power transistor (8), the blower motor (e)' and the dust and pollen filters (D) can be replaced without removing the blower unit. Before reassembly, make sure that the recirculation control linkage and doors move smoothly. After reassembly, make sure the recirculation control motor runs smoothly (see page 21-36),
21-41

Evaporator Core Replacement
1. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-53).
2. Remove the bolt, then disconnect the suction line
5. Carefully pullout the evaporator core without bending the pipes.

-=::::'::::'// / /-~--------------~~
-----------"
-----J ','
~ ~' :,1
/
(A) and the receiver line (8) from the evaporator

core.
----~----
\1 -'" i
A~:=.,,/_.i
'-------
.~" .....~(:
",_/'11
,
.~.
"
6x 1.0mm
6. Install the core in the reverse order of removal, and note these items.
9.8 Nm (1.0 kglm, 7.2Iblft)
3. Remove the blower unit (see page 21-39). 4. Remove the self-tapping screws and the expansion
valve cover.
II you're installing a new evaporator core, add refrigerant oil (KEIHIN SP-10) (see page 21-6). Replace the G-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
--00
,.-
for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately. Charge the system (see page 21-551.
"-
21-42
Heater Unit/Core Replacement

SRS components are located in this area. Review the SRS component locations (see page 23-13), and precautions and procedures (see page 23-14) in the SRS
6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C)
from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery.
3. Disconnect the suction and receiver lines from the
the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.
evaporator core (see page 21-42). 4. From under the hood, open the cable clamp (AI, then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown.
/:;~~<'"
~J
.-.
7. Remove the bolt and the heater valve, then remove the mounting nut from the heater unit. Take care
not to damage or bend the fuel lines and the brake

lines, etc.
,r-\I ,i,:
-"
',,;'\."----------------
'"'. - -'"~ ~-=,<"

5. When the engine is cool, drain the engine coolant
from the radiator (see page 10-6).
8 x 1.25 mm 12 Nm 11.2 kgfm, 8.7Ibfft)
(cont'd)
21-43

Heater Unit/Core Replacement (cont'd)
8. Remove the dashboard (see page 20-66). 9. Disconnect the connectors (A) from the blower motor, the recirculation control motor, the mode
control motor, and the power transistor, then
11. Remove the mounting bolts, the mounting nuts,

and the heater unit.
/
t
/16X1.0mm 9.8 Nm (1.0 kgfm. 7.2Ibfftl
remove the wire harness clips (8) and the connector (C). Remove the self-tapping screws and the bracket (D).
~~~
..... ~.
6x .Omm
9.8Nm (1.0 kgfm. 7.2Ibfftl
10. Disconnect the connectors (A) from the evaporator temperature sensor and the air mix control motor,
then remove the wire harness clips (8) and the connector (C). Remove the self-tapping screw and the cover (D). Disconnect the heater valve cable (E).
12. Remove the self-tapping screws and the expansion valve cover (A). Carefully pull out the evaporator core (8) so you don't bend the inlet and outlet pipes. Remove the grommet (C), then remove the selftapping screws and the flange cover (D). Remove the self-tapping screws and the pipe cover (E), then carefully pullout the heater core (F) so you don't bend the inlet and outlet pipes.
21-44
13. Install the heater core and the evaporator core in

the reverse order of removal.
14. Install the heater unit in the reverse order of

Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Refill the cooling system with engine coolant (see page 10-61 . Adjust the heater valve cable (see page 21-461. Make sure that there is no coolant leakage.
Make sure that there is no air leakage.
Refer to evaporator core replacement (see step 6 on page 21-421. Do the engine control module (ECMI idle learn procedure (see page 11-1391. Enter the anti-theft code for the radio, then enter
21-45

Heater Valve Cable Adjustment
,. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (8) from the heater valve arm (C). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (8) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A).
~"
----A
-------------
c
--------
2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (8) from the air mix control linkage (C).
~.. ~
...'
"
"'- <'{
3. Set the temperature control dial on Max Cool with the ignition switch ON (II). 4. Attach the heater valve cable (8) to the air mix control linkage (C) as shown above, then snap the heater valve cable housing into the cable clamp (A).
21-46
til
Compressor Replacement
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning
work for a few minutes, then shut the engine off.
8. Remove the mounting bolts and the compressor.
then write down the frequencies for the radio's
preset buttons. 3. Disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery!recycling! charging station (see page 21-531. 5. Remove the alternator (see page 4-291.
8x1.25mm
--or
6. Remove the AlC condenser fan assembly (see page 10-101. 7. Disconnectthe compressor clutch connector (AI,
remove the bolts, then disconnect the suction line
22 Nm (2.2 kglm, 16 Iblltl

9. Install the compressor in the reverse order of removal, and note these items: Before installing the new compressor, check for metal or other contamination in the line. Replace any contaminated parts. If you're installing a new compressor, you must calculate the amount of refrigerant oil to be
(81 and the discharge line (CI from the compressor. Plug or cap the lines immediately after
disconnecting them to avoid moisture and dust contamination.
removed from it (see page 21-61.

Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before

installing them. Be sure to use the correct O-rings
for HFC-134a (R-134al to avoid leakage . Use refrigerant oil (KEIHIN SP-l01 for HFC-134a KEIHIN spiral type compressor only .
To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
Immediately after using the oil, reinstall the cap

on the container, and seal it to avoid moisture absorption.
Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil
contacts the paint, wash it off immediately.
Charge the system (see page 21-551. Do the engine control module (ECMI idle learn procedure (see page 11-1391.
Enter the anti-theft code for the radio, then enter the customer's radio station presets.
21-47

Compressor Clutch Check
1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set (see page 21-491. 2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see page 21-491. 4. Release the field coil connector from the holder, then disconnect it. Check the thermal protector for continuity. If there is no continuity, replace the thermal protector (see page 21-511. NOTE: The thermal protector will have no continuity above 252 to 270F (122 to 132C). When the temperature drops below 241 to 219F (116 to 104CI, the thermal protector will have continuity.
!1.1
3. Measure the clearance between the rotor pulley (AI and the armature plate (81 all the way around. If the
clearance is not within specified limits, remove the
5. Check resistance of the field coil. If resistance is not

within specifications, replace the field coil
armature plate (see page 21-491 and add or remove

shims as needed to increase or decrease clearance.
(see page 21-491. Field Coil Resistance: 3.05-3.35 ohms at 68F (20CI
Clearance:
0.50.15 mm (0.0200.006 in.1
NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.
,----- \
\..
n-
21-48
Compressor Clutch Overhaul

Ne clutch holder, Robinair 10204, Kent-Moore J37872,

or Honda Tool and Equipment KMT-J33939, commercially available 1. Remove the center nut (A) while holding the armature plate with a commercially available Ne clutch holder (8).
17.6Nm 11.8 kgf.m, 13lbfftl
3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the rotor pulley (B). Be careful not to damage the rotor pulley
or the compressor.
2. Remove the armature plate (A) and shim(s) (8), taking care not to lose the shim(s). If the clutch
needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and recheck its
4. Remove the bolt and holder (A), then disconnect the field coil connector (B). Loosen the clamp screw (e) to free the field coil wire. Remove the snap ring (D) with snap ring pliers, then remove the field coil (E). Be careful not to damage the field coil or the
compressor.
o
E
clearance (see page 21-48). NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.
~~~
O--~---B
(cont'dl
21-49

Compressor Clutch Overhaul (cont'd)
5. Reassemble the clutch in the reverse order of disassembly, and note these items: Install the field coil with the wire side facing down, and align the boss on the field coil with the
hole in the compressor.
Clean the rotor pulley and compressor sliding surfaces with contact cleaner or other
non-petroleum solvent. Install new snap rings, note the installation
direction, and make sure they are fully seated in

the groove.
Make sure that the rotor pulley turns smoothly after it's reassembled. Route and clamp the wires properly or they can be damaged by the rotor pulley.
21-50
Compressor Thermal Protector Replacement

1. Remove the bolt, the ground terminal (A), and the holder (8). Disconnect the field coil connector (C), then remove the thermal protector (D).
Compressor Relief Valve Replacement

1. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-53).
2. Remove the relief valve (A) and the O-ring (8). Plug the opening to keep foreign matter from entering the system and the compressor oil from running out.
7.4Nm
10.75 kgfm, 5lbfftl

D--+-~
-~. ~,,: ..~ .........

,
.':
:'1::"_ '.-
.c-~.-
I / ..... - . ~,
'
2. Replace the thermal protector (A) with a new one, and apply silicone sealant (8) to the bottom of the thermal protector.
3. Clean the mating surfaces.
4. Install a new O-ring on the relief valve, and apply a thin coat of refrigerant oil to the O-ring.
5. Remove the plug, and install and tighten the relief valve.
6. Charge the system (see page 21-55).
21-51

Condenser Replacement
1. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-531.
2. Remove the front bumper (see page 20-851. 3. Remove the bolts, then disconnect the discharge line (AI and the condenser line (BI from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust
contamination.
6x 1.0mm 9.8 Nm 11.0 kgfm. 7.2 Ibfftl
4. Remove the mounting bolts, then remove the condenser by lifting it up. Be careful not to damage
the radiator or the condenser fins when removing the condenser.
",' J;-
f;~~j
- >--
........
~,<~-,,' 6x 1.0mm 9.8 Nm 11.0 kgfm. 7.2Ibfftl
~~
5. Install the condenser in the reverse order of removal, and note these items.
If you're installing a new condenser, add refrigerant oil (KEIHIN SP-1 01 (see page 21-61.
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings for HFC-134a (R-134al to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture
absorption.
B-
Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately. Be careful not to damage the radiator or the condenser fins when installing the condenser. Charge the system (see page 21-551.
21-52
Refrigerant Recovery
ACAUTION
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.
1. Connect a R-134a refrigerant recovery/recycling/ charging station IA) to the high-pressure service port IB) and the low-pressure service port IC), as
shown, following the equipment manufacturer's instructions.
Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a IR-134a) from the air conditioning system. If accidental system discharge occurs, ventilate the
work area before resuming service.
Additional health and safety information may be

obtained from the refrigerant and lubricant manufacturers. (
/
"
2. Measure the amount of refrigerant oil removed from the Ale system after the recovery process is completed. Be sure to put the same amount of new
refrigerant oil back into the AlC system before charging.
21-53

System Evacuation
ACAUTION
2. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (S) and the low-pressure service port (C), as
shown, following the equipment manufacturer's instructions. Evacuate the system.
Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning
system.
If accidental system discharge occurs, ventilate the

,(,
I I
I
I
/

obtained from the refrigerant and lubricant manufacturers.
/
/'
1. When an AlC system has been opened to the

atmosphere, such as during installation or repair, it
/
\
must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be
evacuated for several hours.)
"
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (see step 3 on page 2156).
21-54
System Charging
~!W!\lji[.]~_
I
2. Evacuate the system (see page 21-54). 3. Add the same amount of new refrigerant oil to the
system that was removed during recovery. Use
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.
only KEIHIN SP- 10 refrigerant oil. 4. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged.
Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity:
Do not breathe refrigerant or vapor.
Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC- 134a (R- 134al from the air conditioning
system.
If accidental system discharge occurs, ventilate the


obtained from the refrigerant and lubricant manufacturers.
500 to 550 g 0.50 to 0.55 kg 1.10to 1.21 ib. 17.6to 19.4 oz

5. Check for refrigerant leaks (see page 21-56).
1. Connect a R-134a refrigerant recovery!recycling! charging station (AI to the high-pressure service port (81 and the low-pressure service port (C)' as
shown, following the equipment manufacturer's
6. Check for system performance (see page 21-58).
instructions.
/
/
(
\
"
21-55

Refrigerant Leak Test.
Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM commercially available 1. Connect a R-134a refrigerant recovery/recycling/ charging station IAI to the high-pressure service port 181 and the low-pressure service port ICI, as shown, following the equipment manufacturer's instructions.
Compressed air mixed with R-134a forms a combustible vapor. The vapor can burn or explode causing serious injury. Never use compressed air to pressure test R134a service equipment or vehicle air conditioning system.
/
/
"
Use only service equipment that is U.L.-listed and is certiified to meet the requirements of SAE J2210 to remove HFC-134a IR-134al from the air conditioning system. If accidental system discharge occurs, ventilate the work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
~\
2. Open the high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers.
Select the appropriate units of measure for your refrigerant charging station.
Refrigerant capacity:
500 to 550 g 0.5010 0.55 kg 1.10101.21Ibs 17.610 19.40z 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g 10.5 ozl per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system.
5. After checking and repairing leaks, evacuate the system.
21-56
Ale System Tests

Pressure Test
Test results Discharge (high} pressure abnormally high
Related s.'Lrnptoms After stopping compressor, pressure drops quickly, and then continues to fal!.graduallv. Reduced or no air flow through condenser
Probable cause Air in system
Line to condenser is excessively hot. Discharge pressure abnormally low High and low pressures are balanced soon after stopping compressor. Low side is higher than normal. Outlet of expansion valve is not frosted, low-pressure gauge indicates vacuum. Expansion valve is not frosted, and low-pressure line is not cold. Lowpressure gauge indicates vacuum. Discharge temperature is low, and the air flow from vents is restricted. Expansion valve is frosted. Receiver/dryer outlet is cool, and inlet is warm (should be warm during operation). Low-pressure hose and check joint are cooler than the temperature around evaporator. Suction pressure is lowered when condenser is cooled bv water. High and low-pressure are equalized as soon as the compressor is stopped, and both gauges fluctuate while running. Reduced air flow through condenser.
1
Clogged condenser or radiator fins Condenser or radiator fan not workinQ properly Restricted flow of refrigerant in
Remedy Recover, evacuate (see page 21-54), and recharge with specified amount (see pooe 21 551. Clean Check fan voltage and rpm.
Check fan direction.

Replace restricted lines. Replace the compressor.
system
Faulty compressor discharge valve Faultv compressor seal Faulty expansion valve Moisture in system
,
Suction (low) pressure abnormally low
Frozen expansion valve (Moisture in system) Faulty expansion valve Frozen evaporator Cloooed exoansion valve Clogged receiver/dryer
Replace the expansion valve. Recover, evacuate for at least 30 minutes, and recharge with specified amount. Recover, evacuate for at least i 30 minutes, and recharge with specified amount. i Reolace the expansion valve. I Run the fan with compressor off, then check evaporator temperature sensor. Clean or reolace. Replace receiver/dryer.
Suction pressure abnormally high

I
Expansion valve open too long
Repair or replace.
Excessive refrigerant in system Faulty gasket Faulty high-pressure valve Foreign particle stuck in high oressure valve Clogged condenser or radiator fins Condenser or radiator fan not working properl Clogged or kinked low-pressure . hose parts Clogged high-pressure line
Recover, evacuate, and recharge with soecified amount. Replace the compressor.
Suction and discharge pressures abnormallv high Suction and Low-pressure hose and metal end discharge pressure . areas are cooler than evaporator. abnormally low Temperature around expansion valve is too low compared with that around receiver/dryer. Refrigerant leaks Compressor clutch is dirty. Compressor bolt(s} are dirty. Compressor gasket is wet with oil.
Clean Check voltage and fan rpm. Check fan direction. Repair or replace . Repair or replace.
Compressor shaft seal leaking Leaking around bolt(s) Gasket leaking
Replace the compressor. Tighten bolt(s) or replace compressor. Replace the compressor.
(cont'd)
21-57

Ale System Tests (cont'd)
Performance Test
3. Open the glove box. Remove both glove box stops, then let the glove box hang down Isee page 20-631. 4. Insert a thermometer IAI in the center vent, and
place another thermometer (B) near the blower unit.
AWARNING
Compressed air mixed with R-134a forms a
combustible vapor.
The vapor can burn or explode causing serious injury. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
ACAUTION
5. Test conditions:
The performance test will help determine if the air

conditioner system is operating within specifications.
Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a IR-134al from the air conditioning system. If accidental system discharge occurs, ventilate the
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.
Avoid direct sunlight. Open the hood. Open the front doors. Set the temperature control dial on Max Cool, the
mode control dial on Vent, and the recirculation control switch on Recirculate. Turn the NC switch on and the fan switch on Max.
Run the engine at 750 rpm.

No driver or passengers in vehicle.
6. After running the air conditioning for 10 minutes

under the above test conditions, read the delivery temperature from the thermometer in the center vent, the intake temperature near the blower unit,
Additional health and safety information may be obtained from the refrigerant and lubricant
manufacturers. 1. Connect a R-134a refrigerant recover/recycling/ charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions. 2. Determine the relative humidity and air temperature.
and the high and low system pressure from the AlC gauges.
21-58
7. To complete the charts: Mark the delivery temperature along the vertical line. Mark the intake temperature (ambient air temperature) along the bottom line. Draw a line straight up from the air temperature to the humidity. Mark a point 10 % above and 10 % below the humidity level. From each point, draw a horizontal line across the delivery temperature. The delivery temperature should fall between the two lines.
Complete the low-side pressure test and high-side pressure test in the same way. Any measurements outside the line may indicate the need for further inspection.
kPa (kgfjCm') [psi 2500 (25) [360j kPa (kg'jcm')
[psi
600 (6) [85'
80%
2000 (20) [280J
500 (5) 71J
'F
('C)
1500 (15) :210J
400 (4) [57J
86 (30)
1000 (10) :140J
300 (3) ,43J
77
(25)
500 (5) [71) DELIVERY PRESSURE
200 (2)
68 (20)
[28J
100 (1 ) [14J INTAKE PRESSURE
59 (15)
50 (10)
41
(5)
DELIVERY TEMPERATURE
I
68 (20)
I
86 (30)
I
104
(40)
77
(25)
95 (35)
of
('C)
INTAKE TEMPERATURE
21-59
Body Electrical
Body Electrical
Special Tools ............................................... 22-2 General Troubleshooting Information ...... 22~3
Entry Lights Control System

Component Location Index ....................... Circuit Diagram ........................................... Ignition Key Switch Test ............................ Ignition Key light Test ............................... Control Unit Input Test ............................... 22-89 22-90 22-91 22-91 22-92
Relay and Control Unit Locations ..... 22-7 Connectors and Harnesses ............... 22-13
Interior Lights Fuse/Relay Boxes ............................... 22-44 Power Distribution ............................. 22-46 Ground Distribution ........................... 22-48 Under-dash Fuse/Relay Box .............. 22-49 Battery ................................................. 22-50 Relays ................................................... 22-51 *Ignition Switch ................................... 22-53 *Gauges
Component Location Index ....................... Self-diagnostic Procedure .......................... Circuit Diagram ........................... " .............. Gauge Bulb Replacement .......................... Gauge Assembly Replacement ................. Coolant Temperature Gauge Troubleshooting ......................... Vehicle Speed Signal Circuit Troubleshooting ...................................... VSS Replacement ...................................... 22-54 22-56 22-58 22-63 22-64 22-64 22-65 22-67 Component Location Index ....................... Circuit Diagram ........................................... Ceiling Light/Spotlights Test/Replacement ................................... Rear Ceiling lightTest/Replacement ........ Cargo Area Light Test/Replacement ......... Hatch Latch Switch Test ............................. 22-94 22-95 22-96 22-96 22-97 22-97
*Audio System
Component Location Index ....................... Circuit Diagram .......................................... Audio Unit Removal/Installation ............... Audio Unit Connector Replacement ......... Speaker Replacement ................................ Roof Antenna Replacement ....................... 22-98 22-99 22-100 22-101 22-102 22-103
Rear Window Defogger

Component Location Index ....................... Circuit Diagram ........................................... Function Test ............................................... Defogger Wire Repair ................................. Noise Condenser Capacity Test ................ 22-104 22-105 22-106 22-106 22-107
Moonroof
Component Location Index ....................... Circuit Diagram ........................................... Moonroof Control Unit Input Test ............. Switch Test/Replacement .......................... MotorTest ................................................... Limit Switch Test ........................................ Auto-stop Switch Test ................................ 22-108 22-109 22-110 22-112 22-112 22-113 22-113
Exterior Lights
Component Location Index ....................... Circuit Diagram ........................................... Daytime Running Lights Control Unit InputTest (Canada) ........................ Headlight Adjustment ................................ Headlight Replacement .............................. Combination Light Switch Test/Replacement ................................... Bulb Replacement ...................................... Taillight Replacement ................................ High Mount Brake Light Replacement ...... License Plate Light Replacement .............. Side Marker Light Replacement ................ Brake Pedal Position Switch Test ............. Side Turn Signal Light Replacement ........ 22-68 22-71 22-76 22-78 22-79 22-80 22-81 22-82 22-82 22-83 22-83 22-84 22-84
Power Mirrors
Component Location Index ....................... Circuit Diagram ........................................... Function Test ............................................... Power Mirror Switch Test .......................... Power Mirror Actuator Test ....................... Power Mirror Actuator Replacement ........ 22-114 22-115 22-116 22-117 22-117 22-118
* Horns
Component Location Index ....................... Circuit Diagram ........................................... Horn Test/Replacement ............................. Horn Switch Test ........................................ 22-120 22-121 22-122 22-122
Turn Signal/Hazard Flasher System

Component Location Index ....................... Circuit Diagram ........................................... Turn Signal/Hazard Relay Input Test ........ Hazard Warning Switch Test ..................... 22-85 22-86 22-87 22-88
Power Windows
Component Location Index ....................... 22-124 Circuit Diagram ........................................... 22-125
Multiplex Control System

Component Location Index ....................... 22-168 Circuit Diagram ........................................... 22-169 System Description .................................... 22-171
Master Switch Input Test ........................... 22-126 Master Switch Test ..................................... 22-128
Driver's Window Motor Test ..................... 22-129
Troubleshooting ......................................... 22-172 Multiplex Control Unit Input Test .............. 22-175
Passenger's Window Switch InputTest ... 22-130 Passenger's Window Switch Test ............. 22-132
Passenger's Window Motor Test .............. 22-132 Master Switch Replacement ...................... 22-133 Passenger's Window Switch
Replacement ............................................ 22-133
Wipers/Washers
Component Location Index ....................... 22-134 Circuit Diagram ........................................... 22-136 Rear Window Wiper Intermittent
Control Unit Input Test ........................... 22-138

Wiper/Washer Switch
Test/Replacement ................................... Control Unit Input Test ............................... Wiper Motor Test ........................................ Washer Motor Test .....................................
Washer Fluid Level Switch Test!
22-140 22-141 22-143 22-144
Replacement (Canada) ........................... 22-144 Windshield Wiper Motor Replacement .... 22-145
Rear Window Wiper Motor
Replacement ............................................ 22-146

Washer Reservoir Replacement ................ 22-146 Washer Tubes Replacement ...................... 22-147
Accessory Power Socket

Circuit Diagram ........................................... 22-149 Accessory Power Socket
Test/Replacement ................................... 22-149
Keyless/Power Door Lock System

Component Location Index ....................... 22-150 Circuit Diagram ........................................... 22-151 Keyless Receiver Unit Input Test ............... 22-153
Control Unit Input Test ............................... 22-155

Door Lock Actuator Test ........ ,." .. ,"'" ... "." 22-158
Hatch Lock Actuator Test ........................... 22-159 Door Lock Knob Switch Test ...................... 22-160 Door Lock Switch Test ................................ 22-160
Transmitter Test "."."" ............................... 22-161 Transmitter Programming ......................... 22-161
Immobilizer System
Component Location Index ....................... 22-162 System Description .................................... 22-163 Circuit Diagram ........................................... 22-164
Troubleshooting ......................................... 22-165

Immobilizer Control Unit -Receiver Replacement ........................... 22-167
r--:'II
Body Electrical
Special Tools
Ref. No.
CD
@
CD
Tool Number 07WAZ-0010l0A 07LAJ-PT3020A 07TAZ -001 020A
Description MPCS Service Connector Test Harness Back Probe Adapter
Qty 1 1 1
CD
I
22-2
r--:'I t.='..I
Tips and Precautions
Before Troubleshooting Some connectors have a clip on their side used to
attach them to a mount bracket on the body or on another component. This clip has a pull type lock,
Some mounted connectors cannot be disconnected unless you first release the lock and remove the
1, Check applicable fuses in the appropriate fuse/relay box, 2, Check the battery for damage, state of charge, and clean and tight connections,
connector from its mount bracket (AI,
INOTICEI
Do not quick-charge a battery unless the battery
ground cable has been disconnected, otherwise
you will damage the alternator diodes, Do not attempt to crank the engine with the battery ground cable loosely connected or you
will severely damage the wiring. Handling Connectors Make sure the connectors are clean and have no loose wire terminals. Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors).
All connectors have push-down release type locks (AI,
Never try to disconnect connectors by pulling on their wires; pullan the connector halves instead. Always reinstall plastic covers.
Before connecting connectors, make sure the terminals (A) are in place and not bent.
(conl'dl
22-3
Body Electrical
Check for loose retainer (AI and rubber seals (BI. Handling Wires and Harnesses
Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
A
Remove clips carefully; don't damage their locks (A).

B
The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the
grease is contaminated, replace it.
Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the Clip.
Insert the connector all the way and make sure it is securely locked.
Position wires so that the open end of the cover faces
After installing harness clips, make sure the harness doesn't interfere with any moving parts. Keep wire harnesses away from exhaust pipes and
other hot parts, from sharp edges of brackets and

holes, and from exposed screws and bolts.
down.
Seat grommets in their grooves properly (AI. Do not leave grommets distorted (BI.
y
22-4
i.!=..I
Testing and Repairs
Do not use wires or harnesses with broken insulation.
r--:'I
Use back probe adaptor 07TAZ-001020A.
Replace them or repair them by wrapping the break with electrical tape.
After installing parts, make sure that no wires are
pinched underthem. When using electrical test equipment, foliowthe manufacturer's instructions and those described in this manual. If possible, insert the probe of the tester from the wire side (except waterproof connector).
Refer to the instructions in the Honda Terminal Kit for

identification and replacement of connector terminals .
icont'dl
22-5
Body Electrical
Five-step Troubleshooting
1. Verify The Complaint Turn on all the components in the problem circuit
to verify the customer complaint. Note the
Wire Color Codes

The following abbreviations are used to identify wire
symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of

the circuit operation, identify one or more possible
colors in the circuit schematics: WHT.................................... YEL...................................... BLK...................................... BLU ..................................... GRN..................................... RED ..................................... ORN..................................... PNK..................................... BRN..................................... GRY..................................... PUR ..................................... LT BLU ................................ LT GRN ...............................
White Yellow Black Blue Green Red Orange Pink Brown Gray Purple Light Blue Light Green
causes of the problem. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause offailure first. Try to
make tests at points that are easily accessible.
The wire insulation has one color or one color with another color stripe. The second color is the stripe.
4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all
modes to make sure you've fixed the entire
problem. If the problem was a blown fuse, be sure

to test all of the circuits on the fuse. Make sure no
new problems turn up and the original problem does not recur.
22-6
Relay and Control Unit Locations

., Engine Compartment
r--:'I a.=:.J
A/C COMPRESSOR CLUTCH RELAY
REAR WINDOW DEFOGGER RELAY BLOWER MOTOR RELAY
DO' ~D
RADIATOR FAN RELAY HORN RELAY CONDENSER FAN RELAY ELD UNIT UNDER-HOOD FUSE/RELAY BOX
HEADLIGHT RELAY 1
HEADLIGHT RELAY 2
22-7

Dashboard
DAYTIME RUNNING LIGHTS RELAY ICanada) Wire colors: RED, RED!YEL, [ RED/BLK and RED/BLU LOW BEAM CUT RELAY ICanada) Wire colors: RED/WHT, RED/BLK, [ RED/YEL and RED/BLU
KEYLESS RECEIVER UNIT CRUISE CONTROL UNIT
--------
--
-:::-~-
/--~-,
'----;::.::- ,----
GJ-j
//
-"
DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)
TAILLIGHT RELAY
1['----,_-_
1'-'--
STARTER CUT RELAY
MULTIPLEX CONTROL UNIT
22-8
r:-:'I I..!::..J
IMMOBILIZER CONTROL UNITRECEIVER AUDIO UNIT
~~,-"~- - , , '
<.--~---
__
c-~
/
----,
/
(conl'd)
22-9

Dashboard (cont'd)
"
:f
~ ~
. "... . 0
ECM EPS CONTROL UNIT
SRS UNIT
AIR/FUEL RATIO SENSOR RELAY [Wire colors: WHT, WHT/RED,
LORN and BLKJORN
PGM-FI MAIN RELAY 1 Wire colors: VEL/BLK, [ WHT/BLK, WHT/BLK and RED/yEL PGM-FI MAN RELAY 2 fWire colors: YEUBLK,
LYEL/GRN, YEL/BLK and GRN/YEL
1 1
22-10
t=:.I
Rear and Roof
MOONROOF CONTROL UNIT
MOON ROOF OPEN RELAY Wire colors: GRNIYEL, GRN, [ RED/YEL. BLK and YEL/GRN MOONROOF CLOSE RELAY Wire colors: GRN/BLK, GRN, [ GRN/WHT. BLK and YEL/GRN
1 1
,-
--
--, @
,"
/'
.:,-- -- t-----.'
'-----I--~
" '->--
REAR WINDOW WIPER INTERMITTENT CONTROL UNIT
22-11

Door and Seat
Driver's Door:
" i
, I
I, I
,
i ,~ .
~~-- ------~----
~--
POWER WINDOW MASTER SWITCH (Has built-in control unit)
Passenger's Seat:
/~-
c-!r
OPDS UNIT
22-12
Connectors and Harnesses

., Connector Index
r:-:'I
Identification numbers have been assigned to in-line connectors. The number is preceded by the letter "e" for connectors, "G" for ground terminals or "T" for non-ground terminals. Harness
!
location Engine Compartment

C102 and C103 T1 and T2 T101 and T102
Dashboard
Others (Floor. Door, Trunk and Roof)
Notes
(see page 22-15l
Starter subharness
(+1
Battery ground cable Engine ground cable
T3 Gl and ( -I T4 G2
C101 through C104
(see page 22-14)

(see page 22-14)
!
Engine wire harness Engine compartment wire harness (riqht branch) Engine compartment wire harness (left branch) Engine compartment wire harness (dashboard)
{see page 22 ,6} (see page 22 18) ; (see page 22 18)
Gl0l G201 and G202 G301
! !
C151 C401
C451 and C452 C501 through C503
(see page 22-18)
C551 C851 G402

EP$ subharness Dashboard wire harness A (left branch) Left side turn signal light sub harness Dashboard wire harness A (right branch) C151 and C152 (see page 22 24) (see page 22-26)
G151
C504 through C510 G501 and G503
C506
C501 through C503 C511 through C515 C852 and C853
,
!
I
,
(see page 22-26) ; (see page 22-26)
Right side turn signal light sub harness Dashboard wire harness B
G502 C513
C401 through C403
{see page 22-26} {see page 22-30}
ECM wire harness
C510 G401 Cl0l C152

C451 through C453
(see page 22-32)
C511 G451
Floor wire harness {front side} C402 and C403
,,
G551
(see page 22-34)
C453
C508 and C509
C512
C551 and C552 Floor wire harness (rear side) Roof wire harness Hatch wire harness Driver's door wire harness Passen er's door wire harness OPDS wire harness AlC wire harness C553 and C554 G552 and G553 C507 C553 and C554 C504 and C505 C514 and C515
I
! {see page 22-34}

(see (see (see (see (see (see paQe 22-38) page 22-39) page 22-40) a e22-41) a e 22-42) Da e 22-43)
C552
C851 throuah C853
.. .,
22-13

Connector to Harness Index
Battery Ground Cable
Connector or Terminal
T3
Gl
Ref 3
1
Cavities
Location
Left side of enQine compartment Left side of engine compartment Battery
Connects to Body ground via battery Qround cable Battery neQative terminal
Notes
I I
Engine Ground Cable

T4
G2
Ref 5 4
Cavities
location
Riaht side of enqine
Right side of engine compartment
Connects to Body ground via engine
Notes
around cable
ENGINE GROUND CABLE
BATTERY GROUND CABLE
()
22-14
r--:'I
Starter Subharness
Connector or Terminal Alternator Knock sensor Starter solenoid
! ,
Ref
10
8 5
7
Cavities 4
location
Right side of engine compartment Front of engine Middle of engine compartment Front of engine compartment : Front of engine compartment
Connects to
Notes
C102 C103 T1 T2 T101 T102 1+1
1 1 6 1
i Engine wire harness (see

page 22-16) Engine wire harness (see
6 2
4
poo.22-16) 1
9
Left side of engine compartment Middle or enaine compartment Under-hood fuse/relay box Alternator Batterv
Under-hood fuse/relay box

Starter motor
Batter, positive terminal
10
STARTER SUB HARNESS
,
8 7
22-15

Connector to Harness Index (cont'd)
Engine Wire Harness
Connector or Terminal Back-up light switch Camshaft position (eMP) sensor CKP sensor
ECM connector A
ECM connector B
Engine coolant temperature (ECT)
Ref 14 9 26 2 1 11
28 16 18 4 5 6 7 25 24 20 19 12 15
Cavnies
2 3 3 31 24 2 1 2 3 3 3 3 3 2 2 2 2 2 3 3
Location Transmission housing Left side of engine Right side of engine Under glove box Under glove box Left side of engine
Connects to
Notes
I
I
, ,
sensor
Engine oil pressure switch EVAP canister purge valve Idle air control (lAC) valve Ignition coil No.1 Ignition coil No.2 Ignition coil No.3 Ignition coil No.4 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Intake air temperature (IAT) sensor MAP sensor TDC sensor Throttle position (TP) sensor Vehicle speed sensor (VSS) VTC oil control solenoid valve VTEC oil pressure switch VTEC solenoid valve C101
C102 C103
Right side of engine Left side of intake manifold Left side of intake manifold Middle of engine compartment Middle of engine compartment Middle of engine compartment
Middle of engine compartment

Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Intake air duct Left side of intake manifold Left side of engine Left side of intake manifold Transmission housing Right side of engine Right side of engine Right side of engine Under right side of dash Front of engine compartment Front of engine compartment Left side of enaine Cylinder head cover
8 17 10 27 29 30 3
22 21 13 23
3
3 2 2 2 20 6 1 24
C104 G101
ECM wire harness {see page '22-321 Starter subharness (see page 22-151 Starter subharness (see page 22-151 Junction connector Engine ground via engine wire harness
22-16
r:-:'I a.=:.J
ENGINE WIRE HARNESS
9
10 11
12
30
29
13
14
28
15
27
26 25
17
16
18
21 23
20
19
22-17

Engine Compartment Wire Harness (Right branch)
Connector or Terminal ABS modulator-control unit Rear washer motor Right front ASS wheel sensor Right front airbag sensor Right front parking light Right front side marker light Right front turn signal light
Ref 13
8
12
4
1 10 11 2 3
Right headlight
Right horn Washer fluid level switch Windshield washer motor G201
G202
7 9
6
Cavities 26 2 2 2 2 2 2 3 1 2 2
location
Right side of engine compartment Behind right side of front bumper Right side of engine compartment Behind right side of front bumper
Connects to
Notes
Behind right headlight

Behind right side of front bumper
Behind right headlight

Behind Behind Behind Behind Behind right headlight front bumper right side of front bumper right side of front bumper right side of front bumper
Canada
Body ground via engine compartment wire harness Body ground via engine comoartment wire harness
Behind right side of front bumper
22-18
r--:'I
ENGINE COM PARTMENT WIRE HARNESS
13
12
11
2
3 9
4
8
7
(conl'd)
22-19

Engine Compartment Wire Harness (Left branch)
Ale compressor dutch
Ale pressure switch

Air fuel (NFl ratio sensor Brake fluid level switch Condenser fan motor Cruise control actuator ELD unit Fog light connector Left front ASS wheel sensor Left front airbag sensor Left front parking light Left front side marker light Left frontturn signal light Left headlight Left horn Radiator fan motor Radiator fan switch Secondary heated oxygen (SH02S) sensor Test tachometer connector Windshield wiper motor Under-hood fuse/relay box connector A (see page 22-44) Under-hood fuse/relay box connector B (see page 22-44) Under-hood fuse/relay box connector C (see page 22-44) Under-hood fuse/relay box connector 0 (see page 22-44) Under-hood fuse/relay box connector E (se~'nane 22-44)
Ref 24 22 2
25 1 9 15 12 19 17 16 13 20 21 23 26 3 14 11 7 8 10 5 6
I
Cavities
Location
1 2 4 2 2 4 3 1 2 2 2 2 2 3 1 2 2 4 2 5 2 5
iFront of engine compartment

Left side of engine compartment Left side of engine compartment Left side of engine compartment Front of engine compartment Under right side of cowl cover Under-hood fuse/relay box Left side of engine compartment , Left side of engine compartment : Behind left side of front bumper Behind left headlight Behind left side of front bumper Behind left headlight Behind left headlight Behind front bumper Left side of engine compartment Front of engine compartment Left side of engine compartment Left side of engine compartment Under left side of cowl cover Under-hood fuse/relay box Under-hood fuse/relay box Under-hood fuse/relay box
1
i i
._Connects to
-t
I
!
NOte -'---
Option
,.
7
!
12
I
,
Under-hood fuse/relay box , Under-hood fuse/relay box Behind left side of front bumper
I
Body ground via engine com'oartment wire harness
G301
18
22-20
r:-:'I L=:..I
2 3
5
4
26
25
12
24
ENGINE COM PARTMENT WIRE HARNESS

23
22
21
14
13
20 19
_ _- ' 16
15
18
(cont'd)
22-21

Engine Compartment Wire Harness (Dashboard)(cont'dl
Fog light connector Under-dash fuse/relay box connector F (see page 22-45) Under-dash fuse/relay box connector G (see page 22-45) Under-dash fuse/relay box connector H (see page 22-45) Under-dash fuse/relay box connector I (see page 22-45) Under-dash fuse/relay box connector J (see page 22-45) Ref
Cavities
Location
Under middle of dash Under left side of dash Under left side of dash
Connects to
15 1 5 4 2 3 12
7
1 12 10 3 5 8 2 4 13 4 10 4 8 5 10 1
I
Notes Option
Under left side of dash Under left side of dash Under left side of dash Under right side of dash
EPS subharness (see page 22-
C151 C401 C451 C452 C501 C502 C502 C503 C551 C851 G402
241 Under right side of dash

Under right side of dash
Dashboard wire harness B
(see page 22-30)

8
ECM wire harness (see page
22-321
9
10 6 6 13 16 14 11
Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under middle of dash Under right side of dash
ECM wire harness (see page
22-321
Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) Floor wire harness (see page
USA
Canada
22-341
NC wire harness (see page

22-431
Body ground via engine compartment wire harness
22-22
r:-:'I t=!.I
3
2
ENGINE COMPARTMENT WIRE HARNESS
16
10
12 11
22-23

EPS Subharness
EPS EPS EPS EPS control unit connector A control unit connector B control unit connector C
Ref
Cavities
2 2 20 2 6 2
location
Under right side of dash Under right side of dash Under right side of dash Middle of engine compartment Middle of engine compartment Under right side of dash
Co"nectsto
Notes
2 1 3
7
motor EPS torque sensor C151

C152 G151
8 6
4
5
Engine compartment wire harness (see page 22-18) ECM wire harness (see page
22-321 Body ground via EPS sub harness
22-24
r-:'I t=:.I
/.
EPS SUB HARNESS
22-25

Dashboard Wire Harness A (Left branchl
Accessory power socket Audio antenna Brake pedal position switch Clutch interlock switch Clutch pedal poistion switch Cruise control un'lt Cruise main switch Daytime running lights control unit Daytime running lights relay Gauge assembly connector A Gauge assembly connector B Hazard warning switch Heater control panel connector A Heater control panel connector B HVAC push switch assembly Keyless receiver unit Low beam cut relay Optional security connector Power mirror switch Under-dash fuse/relay box connector K (see page 22-45) Under-dash fuse/relay box connector L (see page 22-45) Under-dash fuse/relay box connector M (see page 22-45) Under-dash fuse/relay box connector N (see page 22-45) Under-dash fuse/relay box connector 0 (see page 22-45) Under-dash fuse/relay box connector Y (see page 22-45)
Ref
22 2 26 31 30 29 6 28 4 9 8 20 17 18 19 10 5 3 27 13 14 12 15 16 11 32 33 34 1 23 24 25 7 21
Cavities 2 2 4 2 2 14 5 14 4 22 22 10 22 14 10 5 5 16
13
Location
Under middle of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Behind gauge assembly Behind gauge assembly Behind hazard warnning switch Behind heater control panel Behind heater control panel Behind HVAC switch assembly Under middle of dash Under left side of dash Under left side of dash Under left side of dash In the under-dash fuse/relay box In the under-dash fuse/relay box
Connects to
Notes
Canada Canada
17 10 12 6 12 13 20 13 2 8 4 6 12
In the under-dash fuse/relay box In the under-dash fuse/relay box In the under-dash fuse/relay box In the under-dash fuse/relay box Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under middle of dash Under middle of dash Under middle of dash Under gauge assembly Under left side of dash Driver's door wire harness (see page 22-40) Driver's door wire harness (see page 22-401 Left side turn signal light subharness Roof wire harness {see page
C504 C505 C506 C507 C508 C509 C510 G501 G503
22-381
Floor wire harness (see page
22-341
22-341
Dashboard wire harness B
(see Daoe 22-301

Body ground via dashboard wire harness A Body ground via dashboard wire harness A
Left Side Turn Signal Light Sub harness

Left side turn signal light
i
location
Behind left side turn signal light Under left side of dash
Connects to
Dashboard wire harness A
C506
22-26
r:-:'I t=:.I
13
14
DASHBOARD WIRE
HARNESS A
17
18
3
19
2
34
m:
~~EN1~~N SIGNAL LIGHT

33
32
30
21
(conl'd)
22-27

Dashboard Wire Harness A (Right branch)
Connector or Terminal Audio unit connector A C501 C502 C502 C503 C511 C512 C513 C514 C515 C852 C853 G502
i
Ref
1
6
5 5 4
Cavities 20 10
4 8 5 13 8 2 13
Location Behind audio unit Under right side of dash
Connects to
Engine compartment wire harness (see page 22-18) Engine compartment wire harness (see page 22-18) Engine compartment wire harness (see page 22-18) Engine compartment wire harness (see page 22-18) ECM wire harness (see page 22-321 Floor wire harness (see page 22-341 Right side turn signal light subharness Passenger's door wire harness (see page 22-41) Passenger's door wire harness (see page 22-41) AlC wire harness {see page 22-431 AlC wire harness {see page 22-431 Body ground via dashboard wire harness A
Notes
USA
Canada
Under right side of dash Under right side of dash

Under middle of dash Under middle of dash
13
12 8

Under right side of dash Under right side of dash Under middle of dash Under middle of dash Under right side of dash
9
10 2 3 11
6
21 1
Right Side Turn Signal light Sub harness

Connector or Terminal Right side turn signal light C513 Location Behind right side turn signal light Under ri ht side of dash Connects to
22-28
~ ~
DASHBOARD WIRE HARNESS A
2
3
4
5 6
~~:~ARNESS
8 13 12 10
RIGHT ~~~AL LIGHT
22-29

Dashboard Wire Harness B
Connector or Terminal Cable reel Combination light switch Driver's airbag inflator Ignition key switch
Ignition switch
Immobilizer control unit-receiver
Passenger's airbag inflator SRS unit connector A
Wiper/washer switch
Under-dash fuse/relay box
connector A (see page 22-45) Under-dash fuse/relay box connector B (see page 22-45) Under-dash fuse/relay box connector C (see page 22-45) Under-dash fuse/relay box connector S (see page 22-45) Under-dash fuse/relay box connector X (see page 22-45)
Ref 2 1 17 16 19 18 9 13 3 5
Cavities
Location
In steering column GOVer In steering column cover In steering column cover In steering column cover In steering column cover In steering column cover
Connects to
Notes
5 16 4 6 7 7 4 18 14 5 6 14 2 8 4 10 4 12

In steering column cover Under left side of dash
Under left side of dash
6 4 7 8 10 12 11 14 15
Under left side of dash Under left side of dash Under left side of dash Under right side of dash Under middle of dash Under middle of dash Under middle side of dash Under gauge assembly Engine compartment wire harness (see page 22-18) Floor wire harness (see page
C401 C402 C403 G510 G401
22-341
22-341
(see paoe 22-261

Body ground via dashboard wire harness B
22-30
5
4
c~c
,_
___
r-
-=.cS
- - r
rl
----c:-,-r~'lL-L.J---
==:;~~~~~:
J
Jl
'-' U-.J
DASHBOARDWIR=E~~r-----------------~
2
HARNESS B
1
T~.
10
19
18
17
16
11
15
22-31

ECM Wire Harness
Air fuel (A/F) ratio sensor relay Data link connector
Ref 5 15
Cavities
4 16 31 4 4 12 13 6 20
I
Location
Behind glove box Under middle of dash Behind glove box Behind glove box Behind glove box In the under-dash fuse/relay box In the under-dash fuse/relay box In the under-dash fuse/relay box Under right side of dash Under right side of dash
Connects to
Notes
ECM connector E
PGM-FI main relay 1 PGM-FI main relay 2 Under-dash fuse/relay box connector D (see page 22-45) Under-dash fuse/relay box connector E (see page 22-45J Under-dash fuse/relay box connector R (see page 22-45) C101
C152 C451 C452 C453 C511 G451
8
7
6 1 2 3 4 11
8
13 4
9
10 14 12 13
Under right side of dash Under middle of dash Under middle of dash Under gauge assembly
6
13
Engine wire harness (see page 22-16) EPS sub harness (see page 22-241 Engine compartment wire harness (see page 22- 18) Engine compartment wire harness (see page 22- 18) Floor wire harness (see page 22-341 Dashboard wire harness A Isee paOe 22-261 Body ground via ECM wire harness
22-32
r--:'I L=.I
~~ ~~r :-,:, ~ =~- '

_W..J'-'LL.J..JL. _ _
n,,;,n--,--
__ WUWW _ _ L"
'~~-
~
-<
,
~----
~- - - -
'
\,
10
ECM WIRE HARNESS
11
15
22-33

Floor Wire Harness (Front side I
Ref
11 10 13 12 19 9 5 3 7 4 20 21
Driver's seat belt switch Driver's side airbag inflator Driver's side impact sensor Left side seat belt buckle tensioner Memory erase signal (MES) connector Parking brake switch Passenger's seat beft switch Passenger's side airbag inflator
Passenger's side impact sensor

Right side seat belt buckle tensioner SRS unit connector B SRS unit connector C Under-dash fuse/relay box connector P (see page 22-45) Under-dash fuse/relay box connector Q (see page 22-45)
C402 C403 C453 C508 C509 C512 C551 C552 G551
17
18
Cavities 3 2 2 4 2 1 3 2 2 4 18 8 18
8 10 4 6 4 6 8 10 4
Location
Under driver's seat Under driver's seat Left side of floor Under driver's seat Under-dash fuse/relay box Middle of ftoor Under passenger's seat Under passenger's seat Right side of floor Under passenger's seat Under middle of dash Under middle of dash Under-dash fuse/relay box
Connects to
Notes
Under-dash fuse/relay box Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under passenger's seat Dashboard wire harness B (see page 22-30) Dashboard wire harness B (see page 22-30) ECM wire harness (see page
22-321
22
23 15 2 14 1 16 6 8
Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) Engine compartment wire harness (see page 22-18) OPDS unit harness {see page
22-421
Body ground via floor wire harness
22-34
r--:'I t=:..I
8
6 7
5
9
10 11
12
13
23
22
21
.. "G>/< .
..
15 16
FLOOR WIRE HARNESS
14
20
18
19
(cont'dl
22-35

Floor Wire Harness (Rear side)(cont'dl
Connector or Terminal Cargo area light
Driver's door switch EVAP emission bypass solenoid valve EVAP emission control canister vent shut valve Fuel pump/sending unit Fuel tank pressure sensor Left back~up light Left rear ABS wheel sensor Left rear side marker light Left rear speaker
Ref
Cavities
2 1 2 2 5 3 2 2 2 2 2 2 3 2 2 1 20 2 3 2 2 2 2 2 12 12
Location
Right side of cargo area left 8-pillar Fuel tank Fuel tank
CQnnects to
Not.e~
16 6 2 24 9 3 25 1 26 4 28 5 27 13 18 10 17 22 20 21 15 19 12 11 7 8
Left rear turn signal light

Left side seat belt tensioner Left taillight/brake light Noise condenser (rear window defogger) Noise condenser (rear window wiper) Passenger's door switch Rear window wiper intermittent control unit Right back-up light Right taillight/brake light Right rear turn signal light Right rear ABS wheel sensor Right rear side marker light Right rear speaker Right side seat belt tensioner
Fuel tank Fuel tank Left taillight Left rear of floor Behind left side of rear bumper left quarter panel Left taillight Left B-pillar Left taillight Right quarter panel
Right quarter panel Right B-pillar Right quarter panel Right taillight Righttaillight Right taillight Right side of cargo area Behind right side of rear bumper Right quarter panel Right B-pillar Right quarter panel Right quarter panel Behind right rear seat back
C553 C554 G552 G553
Hatch wire harness (see page
22-391
Hatch wire harness (see page
22-391
14 23
i Right side of cargo area
Body ground via floor wire harness , Body ground via floor wire , harness
22-36
r:-:'I t=:.I
FLOOR WIRE HARNESS
26
10
25
12 24
11
18
14
"
____
~c
?_4 _~->-~
' ------.
23
22-37

Roof Wire Harness
Connector or Terminal Maonroef close relay Maenroof control unit Moonroef motor Moonroof open relay Moonroof position sensor 1 Moonroef posiflon sensor 2 Maenroof switch Rear ceiling light Spotlight/ceiling light Ref 6 9 4
Cavities 5 5
2
Location
Middle of roof Middle of roof Middle of roof Middle of roof Middle of roof Middle of roof Front of roof Middle of roof Front of roof Under left side of dash
Connects to
Notes
7 8 5 1 3
2
5
2 4
C507
10
5 3 4 8
Dashboard wire harness A ilsee pooe 22~26)
3 2
6
7
ROOF WIRE HARNESS
22-38
r:-:'I
~
Hatch Wire Harness

Hatch latch switch

Hatch lock actuator High mount brake light License plate light connector A License plate light connector B Rear window defogger connector A (+1
Ref 7 5
8
4 9 3 10
Cavities 2 2 2 2 2 1
Location Middle of hatch Middle of hatch Behind high mount brake light Middle of hatch Middle of hatch Right C-pillar
Connects to
Not..
Rear window defogger connector B

(-I
1 4 12 2
Left C-pillar Middle of hatch Right quarter panel Right quarter panel
Rear window wiper motor C553 C554
6
2
Floor wire harness (see page 22-341 Floor wire harness (see page 22-341
HATCH WIRE HARNESS
10
8
2
3
4
22-39

Driver's Door Wire Harness
Connector or Terminal Driver's door lock actuator Driver's door lock knob switch Driver's door lock switch Driver's door speaker
Ref
9
10 1 7 2 3 4
Driver's power window motor Left power mirror actuator

Left tweeter Power window master switch C504
C505
8
5 6
Cavities 2 3 3 2 4 6 2 14 20
13
location
Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Under left side of dash Under left side of dash
Connects to
Notes
Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see paoe 22-261
3
2
. I I I . I
----------5
10
6
9 8
DRIVER'S DOOR WIRE HARNESS 7
22-40
r:-:, I..!!:..I
Passenger's Door Wire Harness
Passenger's door lock actuator Passenger's door speaker Passenger's power window motor Passenger's power window switch Right power mirror actuator
Ref 6 8
5
Caviti,!s
Location
Connects to
Notes
2 2 2
5
Passenger's door
Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Under right side of dash Under right side of dash
7
4 3
Right tweeter
C514
6 2
13
2
1
(see page 22-26)

C515
Isee page 22-261
PASSENGER'S
~OOR
WIRE HARNESS
,i
6 8
7
22-41

OPDS Unit Harness
OPOS unit C552
Rei
2
Cavities 8
4
Location
In front passenger's seat Under front passenger's seat
Connects to
Floor wire harness (see page 22-341
Notes
FLOOR WIRE HARNESS
OPDS UNIT HARNESS
22-42
r:-:'I t=:.I
Ale Wire Harness
Connector or Terminal Air mix control motor Blower motor Evaporator temperature sensor Mode control motor Power transistor Recirculation control motor
Ref
Cavities
Location
Under Under Under Under Under Under Under middle of dash right side of dash middle of dash right side of dash right side of dash right side of dash middle of dash
Connects to
Notes
9 2 8 3
4
5 2 2 10
4
1
7
i
C851 C852 C853
5 1 21 1
6 5
Engine compartment wire harness (see page 22-18) Dashboard wire harness A (see page 22-26) Dashboard wire harness A
Isee page 22-261
Ale WIRE HARNESS
"
22-43
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index
Under-hood Fuse/Relay Box Socket A AlC compressor clutch relay B Blower motor relay C Condenser fan relay D E ELD unit Headlight relay 1 Headlight relay 2 Horn relay Radiator fan relay Rear window defogger relay T1 (Batterv) T1 0 I (Alternator)
2
3
Connects to Engine compartment wire harness (see page 22- 18) Engine compartment wire harness (see page 22- 18) Engine compartment wire harness (see page 22-18) Engine compartment wire harness (see page 22- 18) Engine compartment wire harness (see page 22- 18) Engine compartment wire harness (see page 22- 18)
Ref 14 2 13 4 15
9
12 1I 16 5 6 10 1 3 8 7
4
Terminal 2 4 5 4 12 4 14 7 3 4 4 4 4 4
Starter sub harness (see page 22-15) Starter subharness (see page 22-15)
5
II
12
DO
D
10
OODD[]uuu
bl[][][]OODnnn.
CJ[] [] [ ]
.~u~i.i~i
,
. 7i
8 7
DO
[] [] [] nn
~-][]D ; I
i
.
-'
6
16
15
14
(View of front side)
(View of back side!
22-44
Under-dash Fuse/Relay Box Socket

A B C D E F
G
H
I
J
K L
a
Q
M N
P Power window relay
R
S Starter cut relay T Taillight relay Turn signal/hazard relay U V W (Memory erase signal (MES) connector)
Ref 2 3 1 4 5 19 9 8 20 21 23 24 22 27 26 7 12 6 10 25 14 18 13 11 15 16 17
28 29
Terminal Connects to 5 Dashboard wire harness B (see page 22-30) 6 Dashboard wire harness B (see page 22-30) 14 Dashboard wire harness B (see page 22-30) 12 ECM wire harness (see page 22-32) ECM wire harness (see page 22-32) 13 12 Engine compartment wire harness (see page 22-18) 10 Engine compartment wire harness (see page 22-18) 3 Engine compartment wire harness (see page 22-18) 5 Engine compartment wire harness (see page 22-18) 8 Engine compartment wire harness (see page 22-18) 17 Dashboard wire harness A (see page 22-26) 10 Dashboard wire harness A (see page 22-26) 12 Dashboard wire harness A (see page 22-26) Dashboard wire harness A (see page 22-26) 6 12 Dashboard wire harness A (see page 22-26) 18 Floor wire harness (see page 22-34) 4 Floor wire harness (see page 22-34) 8 ECM wire harness (see page 22-32) 6 2 Dashboard wire harness B (see page 22-30) 4 3 Multiplex control unit service check connector 4 3 I 1 I Optional connector 4 Optional connector 2 Floor wire harness (see page 22-34)
8 13
3
X
y
(Plugs directly into the multiplex control unit) (Pluas directlv into the multiolex control unit)
22
23~~l
DOLl
2.
26
CJ
Do
27
14
13
12
29
28
(View of front side)
(View of back side)
22-45
Power Distribution
Fuse to Components Index
Under-hood Fuse/Relay Box Fuse Number Amps Wire Color Component{s) or Circuit{s) Protected Condenser fan motor
1 2 3 4 5 6 7
20A 15A 7.5A 20A lOA 15A 15A
BLU/yEL BLU/RED WHT/GRN WHT/BLU BLU/BLK WHT/BLK WHT/BLK WHT/GRN BLU/RED WHT/GRN WHT/RED
AlC compressor clutch Dash lights, Front parking lights, Front side marker lights, License plate light, Rear side marker lights, Taillights Cargo area light, Ceiling lights, Ignition Kev light, Spotlights
Radiator fan motor
_.
Turn signal/hazard relav, Turn signal lights CKP sensor, ECM, lAC valve, Immobilizer control unit-receiver, Injectors, PGM-FI main relay 1 and 2, TDC sensor Brake lights, Brake signals (to ABS modulator-control unit, Cruise control unit, ECM) ----Horns
8 9
20A lOA
ABS modulator-control unit Audio unit, Data link connector {DLCI, Gauge assembly, Immobilizer
control unit-receiver, Immobilizer indicator light, Keyless receiver unit,
10 11 12 13 14 15 16 17 18 19 20
40A 30A 40A 40A 40A 15A 20A 15A 60A 80A 40A' 50A'
WHT/RED BLK/YEL BLU/WHT WHT/BLK WHT/RED RED/YEL WHT RED WHT/BLU WHT
Multiplex control unit ABS modulator-control unit Noise condenser, Rear window defogger
Blower motor
No.7 fuse (in the under-dash fuse/relay box), Power window relay No.2 and No.3 fuses lin the under-dash fuse/relay box I Daytime running lights control unit {Canadal, Daytime running lights relay {Canada I, High beam indicator light, Left headlight Multiplex control unit Daytime running lights control unit {Canadal, Right headlight EPS control unit Batterv, Power distribution Ignition switch {BATI
* 1: USA
* 2: Canada
e: Spare fuse
22-46
r:-:'I t=:.I
Under-dash Fuse/Relay Box Fuse Number 1 2 3 4 Amps 15A 20A lOA lOA Wire Color BLKJWHT WHT/RED RED/BLU BLKJORN Component(s) or Circuit(s) Protected Ignition coils Air/fuel ratio sensor, ECM Daytime running lights control unit (Canada) Air/fuel ratio sensor relay, Alternator, CMP sensor, Cruise control main switch, Cruise control unit, ELD unit, Evaporative emission (EVAP) bypass solenoid valve, Evaporative emission (EVAP) canister purge valve, Evaporative emission (EVAP) canister vent shut valve, Secondary H02S, Vehicle speed sensor Not used Moonroof control unit, Moonroof open and close relay, Power window relay Moonroof motor Audio unit OPDS unit, Rear window wiper motor, Rear window washer motor, Rear window wiper intermittent control unit Back-up lights, Cruise indicator light, EPS control unit, Gauge assembly, Keyless receiver unit, Multiplex control unit, Security control unit connector (optional) ABS modulator-control unit Daytime running lights control unit (Canada) SRS unit NC compressor clutch relay, Blower motor relay, Condenser fan relay, Heater control panel, Power mirror actuator, Power mirror defogger (Canada), Radiator fan relay, Rear window defogger relay, Recirculation control motor Not used Not used ECM, Fuel pump SRS unit Accessory power socket Turn signal/hazard relay, Turn signal lights Multiplex control unit, Windshield washer motor, Windshield wiper motor Not used Passenger's window motor Driver's window motor Not used _. Not used
5 6 7 8 9 10
- -
- -
7.5A 20A 7.5A lOA 7.5A
YEljGRN GRN YEljRED GRN YEL
11 12 13 14
7.5A 7.5A lOA lOA
BLKJORN YEljRED PNK BLKJYEL
15 16 17 18 19 20 21 22 23 24 25
- - -
-----
15A 15A 7.5A 30A

- -
YEL/BLK BLKJYEL YEljGRN YEljBLK GRN/BLK

--
20A 20A
---
GRN/BLK GRN/WHT
--
., Not used
22-47
Ground Distribution
Ground to Components Index
Ground Component or circuit grounded Battery, Transmission housinq
Gl G2 Gl0l
G151 G201
G202 G301
I
i
Engine ECM (PG is BLK; LG is BRN/YEL) BLK: lAC valve, Ignition coils, Vehicle speed sensor, VTEC solenoid valve BRN/YEL: Camshaft position (CMP) sensor, CKP sensor, TDC sensor, VTEC oil pressure switch EPS control unit ELD unit, Multiplex control inspection connector, Multiplex control unit, Power window relay, Rear window washer motor, Right front parking light, Right front side marker light, Right front turn signal light, Turn signal/hazard relay, Washer fluid level sensor (Canada), Windshield washer motor, Windshield wiper motor ABS modulator-control unit
Blower motor relay, Brake fluid level switch, Condensor fan motor, Cruise control actuator, Left front
G401 G402 G451 G501
parking light, Left front side marker light, Left front turn signal light, Radiator fan motor, Radiator fan switch Combination light switch, Ignition key switch, Wiper/washer switch Left and riqht airbaQ sensors, SRS unit Data link connector (DLC) Clutch interlock switchm Clutch pedal position switch (for cruise cantrall. Cruise control main switch,
Cruise control unit, Daytime running lights control unit (Canada), Driver's door lock knob switch, Driver's door lock switch, Driver's power window motor, Heater control panel, Left power mirror
defogger (Canada), left side turn signal light, Moonroof control unit, Monroof open and close relays,
Moonroof position sensor 1, Moonroof seitch, Power mirror switch, Power transistor, Power window
master switch, Spotlights G502 G503 G551 G552 G553

Accessory power socket, Gauge assembly, Keyless receiver unit, Multiplex control unit, Right power
mirror defoqger (Canada)

Audio unit
--~-
Driver's seat belt switch, Fuel gauge sending unit, Fuel pump, Memory erase signallMES) connector, OPDS unit, Riqht seat belt switch High mount brake light, License plate lights, Rear window defogger, Rear window defogger noise condenser, Rear window wiper motor, Hatch latch switch i Back-up lights, Brake lights, Rear side marker lights, Rear turn signal lights, Rear window wiper noise
I
condenser, Rear window wiper intermittent control unit, TailliQhts
22-48
Under-dash Fuse/Relay Box

., Removal and Installation
SRS components are located in this area. Review the SRS component locations (see page 23-13) and precautions and procedures (see page 23-14) in the SRS
r:-:'I I.!!:.I
5. Remove the mounting bolt, and slide the underdash fuse/relay box (A) down from the bracket (8).
6. Disconnect the back side from connectors from the
Removal
then write down the frequencies for the radio's preset buttons.
back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type (see page 23-11).
Installation
2. Disconnect the battery negative cable, then
disconnect the positive cable, and wait at least three minutes.
1. Install the under-dash fuse/relay box in the reverse

order of removal and connect all connectors to the
under-dash fuse/relay box. 3. Remove the driver's dashboard lower cover (see page 20-59). 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter
5. Confirm that all systems work properly. 6. Do the engine control module (ECM) idle learn procedure (see page 11-139) .
22-49
Battery
Battery Test
AWARNING
A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby. Follow all procedures carefully and keep sparks and open flames away from the battery. Use either a JCI or Bear ARBST tester, and follow the manufacturer's procedures. If you don't have one of these computerized testers, follow this conventional
test procedure:
1. Be sure the temperature of the electrolyte is between 70"F (21"C) and 100"F (38"C). 2. Inspect the battery case for cracks or leaks. If the case is damaged, replace the battery . If the case looks OK, go to step 3. 3. Check the indicator EYE. If the EYE indicates the battery is charged, go to step 4. If the EYE indicates a low charge, go to step 7. 4. Apply a 300 amp load for 15 seconds to remove the surface charge. 5. Wait 15 seconds, then apply a test load of 280 amps for 15 seconds. 6. Record battery voltage. If voltage is above 9.6 volts, the battery is OK . If voltage is below 9.6 volts, go to step 7. 7. Charge the battery on High (40 amps) until the EYE shows the battery is charged, plus an additional 30 minutes. If the battery charge is very low, it may be necessary to bypass the charger's polarity
protection circuitry.
If the EYE indicates the battery is charged within 3 hours, the battery is OK . If the EYE indicates the battery is not charged
within 3 hours, replace the battery .
22-50
Relays
Power Relay Test
Use this chart to identify the type of relay, then do the test listed for it. NOTE: Turn signal/hazard relay input test (see page 2287).
r:-:'I a=:.J
type 1:
Relav
AlC compressor clutch relay Air/fuel ratio sensor relay Condenser fan relay HeadliQht relay 1 Headlight relay 2 Horn relay Power window relay Radiator fan relay Reverse relay Starter cut relay Taillight relay Daytime running lights relay (Canada) PGM-FI main relay 1 PGM-FI main relay 2 Blower motor relay Rear window defogger relay Moonroof close relay Moonroof open relay .. _--c--c-Low beam cut rela.v (Canada)
Test Normally-open type A
type 2:
Normally-open type B
Five terminal
3
type
PGM-FI main relay 1 PGM-FI main relay 2 type 1:
Normally-open type A:
Check for continuity between the terminals . There should be continuity between the No.1 and
No.2 terminals when power and ground are
connected to the No.3 and No.4 terminals . There should be no continuity between the No.1 and
No.2 terminals when power is disconnected.
3
type 2:
BJ
1 4
(conl'd)
22-51
Relays
Power Relay Test (cont'd)
Normally-open type B:
Check for continuity between the terminals. There should be continuity between the No.1 and No.3 terminals when power and ground are
Five-terminal type
Check for continuity between the terminals .
There should be continuity between the No.1 and

No.2 terminals when power and ground are connected to the No.3 and No.5 terminals.
connected to the No.2 and NO.4 terminals. - There should be no continuity between the No.1 and
There should be continuity between the No.1 and

[-',]
Rear window defogger relay type 1:
Blower motor relay type 1:
~ ~,
3
.-@
2
type 2:
~-
type 2:
~,
3
.@-.'---.
-~-
3
4
22-52
Ignition Switch
Test
SRS components are located in this area. Review the SRS component locations (see page 23-13) and precautions and procedures (see page 23-14) in the SRS
1. Remove the driver's dashboard lower cover (see page 20-59). 2. Disconnect the 5P connector from the under-dash fuse/relay box.
BLK/YEL
3. Check for continuity between the terminals in each switch position according to the table.
1\
Terminal
Position
WHT/ RED WHT (ACC) IBAT)

----,.
BLK/ YEL IIG1)
BLK/l BLK/ RED WHT (lG2) ,1ST)
a ILOCK)
IIACC) iliON) III ISTART)
,--_..
4. If the continuity checks do not agree with the table, replace the steering lock assembly (see page 17-121.
22-53
Gauges
PARKING BRAKE SWITCH page 19~ 10 FUEL GAUGE SENDING UNIT page 11~156
----:---I.~.:----
ENGINE OIL PRESSURE SWITCH page 8-4
GAUGE ASSEMBLY Self-diagnostic Procedure, page 22-56 Gauge Bulb Replacement, page 22-63 Replacement. page 22-64 Coolant Temperature Gauge Troubleshooting, page 22-64
VEHICLE SPEED SENSOR IVSS) Troubleshooting, page 22-65 Replacement, page 22-67
BRAKE FLUID LEVEL SWITCH page 19-10
22-54
B1
.................. 810
.. 822
CONNECTOR A (blue) CONNECTORB
(green)
SPEEDOMETER \ehicle Speed Signal Circuit roubleshooting, page 22-65 TACHOMETER COOLANT TEMPERATURE GAUGE Troubleshooting page 22-64 '
---------
ODO/TRIP METER
FUEL GAUGE Test, page 11-156
22-55
Gauges
Self-diagnostic Procedure
The gauge assembly has a self-diagnosis function. o The Beeper Drive Circuit Check
The Indicator Drive Circuit Check
o o o
The LCD Segments Check The Gauges Drive Circuit Check (Speedometer, Tachometer, Fuel gauge, Coolant temperature gaugel The Communication Line Check (the coolant temperature signal line between the gauge and ECM)
NOTE: Indicators are also controlled via the communication line.
Entering the self-diagnosis function:

Before doing the self-diagnosis function, check the NO.9 (lOA) fuse in the under-hood fuse/relay box and No. 10 (7.5A) fuse in the under-dash fuse/relay box. 1. 2. 3. 4. 5. Push and hold the trip/reset button. Turn the lighting switch ON. Turn the ignition switch ON (II). Within 5 sec., turn the lighting switch OFF, then ON and OFF again. Within 5 sec., release the trip/reset button, then push and release the button four times repeatedly.
NOTE: o While in the self-diagnosis mode, the dash lights brightness controller operates normally. o While in the self-diagnosis mode, the trip/reset button is used to start the beeper drive circuit check and the gauge drive cicuit check. If the vehicle speed exceeds 1.2 mph (2 km/h) or the ignition switch is turned OFF, the self-diagnosis mode ends.
Ignition
ONII~
OFF
Switch
lighting
Switch
Trip/Reset
u
::F~r-----------------~~
5 sec.
________________________________
Switch
.... ------.,
5 sec.
: -----. Move to self-diagnosis mode .
The Beeper Drive Circuit Check:

When entering the self-diagnosis mode, the beeper sounds five times.
The Indicator Drive Circuit Check:

When entering the self-diagnosis mode, the following indicators blink.
Seat belt indicator, Door/hatch indicator, Brake system, Lowfuel indicator, Maintenance required indicator (USA),
Washer fluid level indicator (Canada), Oil pressure light.
22-56
r--:'I t=:J
The LCD Segment Check:
When entering the self-diagnosis mode, the odo/trip segment blinks five times.
The Gauge Drive Circuit Check:

When entering the self-diagnosis mode, the speedometer, the tachometer, the fuel gauge, and the coolant temperature gauge needles sweep from the minimum position to maximum position, then return to the minimum position. NOTE: After the beeper stops sounding and the needles return to the minimum position, pushing the trip/reset button starts the beeper drive circuit check (one beep) and the gauge drive circuit check again. The check cannot be started until the needles return to the minimum position.
Self-diagnosis
mode
Trip/Reset
ON OFF ON OFF ON OFF ON OFF
-----.J
switch Gauge needles

Beeper
n
U
rLJl
LJ
The needles sweep from the minimum position to the maximum position, then return to the minimum position.
--------5 sec
..
The Communication Line Check:

In the self-diagnosis mode, after the ado/trip LCD segments check, the self-diagnosis starts the communication line check. If all segments comes on, the communication line is OK. If the word "Error" is indicated, there is a malfunction in the communication line between the gauge assembly, the multiplex control unit, and the ECM.
Normal:
Faulty:
::: ::: ::: ::: :::.:::

Ending the self-diagnosis function:
Turn the ignition switch OFF.
-",
I.-. .-. I III

I
NOTE: If the vehicle speed exceeds 1.2 mph (2 km/hl, the self-diagnosis function ends.
22-57
Gauges
Circuit Diagram
IGNITION SWITCH
No,ZIl(40AI : USA
BATTERY
No.20 I50AI : Canilda

BLK/VEL -
NO.19 (SOA)
NolO'
WHT
-&C
~1
No.9111lAj
IG1 IfOT in ON 1111 andSTART{OI)
-u
WHT/RED
ECMIPCM
y
BlU
B4
No.lll
(7.5A)
! 2 'r
No.4
(10A)
'OX
h
GAUGE ASSEMBLY
Yl
'lK/f"
VEHICLE
';
OOOtTRll'LCD DISPLAY DRIVE CIRCUIT
TEST TACHOMETER CONNECTOR
SPUD SENSOR
81
B2
(VSSI
SP~ER T~m F~G' ('~

DRIVE CIRCUIT
COOLANT TEMPERATURE GAUGE
~)
I
IMMOBILIZER CONTROL UNIT .'To page\

\22-62 .I
+
POWER CIRCUIT
II g~XGIT I
I----i
TXD 'XD
I CIRCUIT DRIVE
IDR., I
CIRCUIT
I
B5
No,4110AI FUSE
BLU/WHT
'Intheundef-dash
818
813
'J
UNrr
CRUISE CONTROL
~WHT/G'N
VEL/BlK
WHTIGRN
....,.,----,
W~N
'CM
~==t~_JUNrr
~_~
FUEL
FUEL
GAUGE
UNIT
~t~~~G
1
Gl01
T
G5S1
22-58
r:-:'I t=!..I
GAUGE ASSEMBLY
ODO/TRIPLeD BACKLIGHT STABILIZING POWER CIRCUIT
~i~~ ~~HT' (~ ~::;ATOR @ ~ ,~.m. ~~_" ~<ATOR (~ ~~~NG @

<so
REMINDER
LCD BACKlIGHT
\7'
SYSTEM 01
DOOR (LEDI
HATCH HT (LED(
LIGHT (LEDI
LOW'UEL: INDICATOR UGHT (LEDI
" r
""\A)\TonlXl
..,.
REOUIRED INDICATOR LIGHT (LED(
MA~TENANCE
...l.
DRIVE CIRCUIT
~I
8U(
TRIP/RESET SWITCH
I
DRIVE CIRCUIT
l
I
\ BEEPER
-,(T'""") \ ~), \pllge

81' 812
BLK
.5O'
(cont'd)
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 22-59
Gauges
No,211SAI FUSE ,tin the under-hood\

'fuse/relay box "
DASH
LIGHTS
RED/BlK
YY
RED
I
I
I I
I (:~:~ous J~C I \1 ClC.B~=i==i========f===========t====i======t=====~-----.j~____~--------i
,page
,c
81'
PN'
WASHER
RUID LEVEl SWITCH
I
{Canadal
22-60
~ ~
$RSUNIT
I
GAUGE ASSEMBLY
, K
'14
:';
~~
\
LOW ENGINE OIL PRESSURE INDICATOR

LIGHT
ILEDI
I7'\ P'
EPS INDICATOR LIGHT

{LED)
I f'1 I~~<ATOR I I \) IlEDI I I I

UGHT
IT
--,
SIDE AIRBAG CUTOFF INDICATOR (LED)
ABS INDICATOR LIGHT (LED)
J ~~CATORl I LCIRCUIT : r
SRS INDICATOR CIRCUIT
1-
======f;~======~;;======~I==~~=====I==:!==:!____+-____________-1___~G~ ~:~TOR =
" A13
I I
I I
i I I i " ":,.."r,
'15
'12
'TU
(Canada)
B~
~
OPOS UNIT
ABS MODULATOR UNIT
.JL
(cont'dl
22-61
I
Gauges
TURN SIGNAL/HAZARD RELAY
GRN
I I
0
GRN El
No.15 (15AI FUSE
G;'
GAUGE ASSEMBLY
G;l
GRN/RED
810
GRN VEL A12
RIGHTTURN SIGNAL
(In the under hoodl "fu$e/relaVbo~ )
LEFT TURN SIGNAL INDICATOR LIGHTS
REDlYEL A1
No,9 (lOA) FUSE
INDICATOR
UGHTS
\
(~
( LEFT TURN S~NAl INDICATOR
UGHT 11.4W)
(~o~sfage ,)
(D
:l~[URN
INDICATOR UGHT (14WI
(D
HIGHBEAM INDICATOR
I1.4W)
UGHT
(D
IMMOBIUZER
INDICATOR LIGHT
(UWI
\ previous
(From
'page
'I
,""--0).---------.1_____-1 '~
AI1
'19
~~N
COMBINATION
LIGHT SWITCH
IMMOBIUZER
CONTROL UNIT - RECEIVER
22-62
r:-:'I t=:.I
Gauge Bulb Replacement
RIGHT TURN SIGNAL INDICATOR LIGHT 11.4 WI CRUISE INDICATOR LIGHT 11.4 WI LEFT TURN SIGNAL INDICATOR LIGHT 11.4 WI HIGH BEAM INDICATOR LIGHT 11.4 WI GAUGE LIGHT 11.4 WI
GAUGE LIGHT 11.4 WI
IMMOBILIZER INDICATOR LIGHT 11.4 WI
22-63
Gauges
Gauge Assembly Replacement
1. Remove the instrument panellsee page 20-591,
then remove the upper column cover (see page 17-
Coolant Temperature Gauge Troubleshooting

Before testing, check the No.9 11 OAI fuse in the underhood fuse/relay box and the No. 10 17.5AI fuse in the under-dash fuse/relay box. 1. Start the engine, and check the malfunction indicator lamp IMILI.
91. 2. Place a clean shop towellAI under the gauge

assembly to prevent scratching the steering
column or dash panel. 3. Remove the screws from the gauge assembly IBI.
Does the MIL come on?

-<--
YES~ Troubleshoot
"
the cause of the ECM DTC Isee page 11-57), and recheck. NO~Go to step 2.
2. Check for a multiplex control unit DTC Isee page 22-1681.
Is a DTC indicated?
YES~ Troubleshooting
the cause of the multiplex control unit DTC Isee page 22-1681, and recheck. NO~Go to step 3.
4. Disconnect the connectors (e), and remove the gauge assembly. 5. Install the gauge assembly in the reverse order of
removal.
3. 00 the communication line check with the selfdiagnosis procedure Isee page 22-561.
Is the word "Error" indicated on the ado/trip display?

YES The gauge cannot receive the signal from the multiplex control un',t and the ECM. Check for an open in the WHT/GRN wire Igauge connector terminal B131. If no open is found, go to step 5. NO~Go to step 4. 4. Do the gauge drive circuit check with the selfdiagnosis procedure Isee page 22-561.
'-'
Does the temperature gauge needle sweep from

the minimum position to the maximum, then return to the minimum position?
YES~Go
NO~Replace
to step 5. the gauge assembly .
5. Substitute a known-good ECM and recheck.
Did the symptom/indication go away?

YES~Replace
NO~Substitute
the ECM. a known-good gauge assembly. If
the symptom/indication goes away, replace the gauge assembly .
"-
til
22-64
r:-:'I --=:.J
Vehicle Speed Signal Circuit Troubleshooting
Special Tools Required: Test Harness 07LAJ-PT3020A
Before testing, inspect the No.4 (1 OAI and No.1 0 (7.5AI fuses in the under-dash fuse/relay box.
1. Disconnect the 3P connector from the vehicle
5. Connect the WHT test harness clip (BI to the positive probe of a voltmeter, and connect the RED test harness clip (CI to the negative probe.
07LAJ-PT3020A
speed sensor (VSSI (AI.

07LAJ-PTJ020A
~
eV.
~
eO.
YES-Go to step 7. 2. Connect the test harness only to the engine wire
harness.
NO-Repair open in the BLK/YEL wire between the VSS and the under-dash fuse/relay box . 7. Disconnect the WHT test harness clip (B). 8. Connect the GRN test harness clip (D) to the
3. Connect the RED test harness clip (BI to the positive probe of an ohmmeter. Cover the white (C) and green (01 test harness leads with protective tape (EI. 4. Check for continuity between the RED test harness clip and body ground.
positive probe of a voltmeter.

07LAJ-PT3020A
YES-Go to step 5. NO-Repair open in the BLK wire between the VSS and G101 .
~
eV.
Is there 5 V or more?
YES--Go to step 9. NO-Repair short or open in the BLU/WHT or WHT/

GRN wire between the VSS and the cruise control
unit, or the ECM .
(conl'd)
22-65
Gauges
Vehicle Speed Signal Circuit Troubleshooting (cont'd)
9. Turn the ignition switch OFF. 10. Connect the other test harness connector IA) to the VSS (8). 14. Disconnect the 22P connector "8" from the gauge assembly.
GAUGE ASSEMBLY CONNECTOR B 122PI
Bl B2 B3 B4
811 B12 B13
B6 B17 B18 B19
B8 B9 BIO B22
=
15. Connect the positive probe of a voltmeter to the 8LU/WHT wire and the negative probe to ground.
11. Raise the front of the vehicle, and make sure it is securely supported. 12. Putthe vehicle in neutral with the ignition switch ONIIII. 13. Slowly rotate one wheel with the other wheel blocked.
16. Slowly rotate one wheel with the other wheel blocked.
Does voltage pulse from 0 to about 5 V or more?

YES-Replace the speedometer assembly . NO-Repair open in the 8LU/WHTwire between the VSS and the speedometer .
Does voltage pulse from 0 to about 5 V or more?

YES-Gotostep 14. NO-Replace the VSS .
22-66
VSS Replacement
1. Remove the intake resonator. 2. Disconnect the 3P connector from the vehicle
speed sensor (VSS) (A).
3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal.
22-67
Exterior Lights
UNDER-HOOD FUSE/RELAY BOX HEADLIGHT RELAY 1 Test, page 22-51
c -HEADLIGHT RELAY 2
Test, page 22-51
BRAKE PEDAL POSITION SWITCH
Test, page 22-84 Adjustment, page 19-6
SIDE TURN SIGNAL LIGHT Replacement, page 22-84
FRONT TURN SIGNAL LIGHT Bulb Replacement, page 22-81 HEADLIGHTS Replacement, page 22-79 PARKING LIGHT Bulb Replacement, page 22-81 FRONT SIDE MARKER LIGHT Bulb Replacement, page 22-83
Adjustment, page 22-78

Bulb Replacement, page 22-81
22-68
r:-:'I t=:.I
...~
HIGH MOUNT BRAKE LIGHT Replacement, page 22-82
tEA .. \::?,
_/
LICENSE PLATE LIGHTS Replacement, page 22-83
BACK-UP LIGHT Replacement, page 22-82 TAILLIGHTS and BRAKE LIGHTS Replacement, page 22-82 REAR TURN SIGNAL LIGHT Replacement, page 22-82
REAR SIDE MARKER LIGHT Replacement, page 22-83
(conl'd)
22-69
Exterior Lights
DAYTIME RUNNING LIGHTS RELAY ICanadal

Wire colors: RED, REDIYEL, [ RED/BLK and RED/BLU Test, page 22-51
LOW BEAM CUT RELAY ICanadal

Wire colors: RED/WHT, RED/BLK, [ RED/YEL and RED/BLU
Test, page 22-51
------------ .--
DRL INDICATOR LIGHT ICanadal HIGH BEAM INDICATOR LIGHT COMBINATION LIGHT SWITCH
Test/Replacement, page 22-80 Bulb Replacement, page 22-63
DAYTIME RUNNING LIGHTS CONTROL UNIT ICanadal

Input Test, page 22-76
UNDER-DASH FUSE! RELAY BOX TAILLIGHT RELAY Test, page 22-51
22-70
I..:=.J
Circuit Diagram - USA
UNDER - HOOD FUSE/RELAY BOX BATTERY
r--:'I
No.19 (80A)
No.211SAI
HEADLIGHT RELAY 2
r
No.15
(15A)
r ?: .. =
~
T
fO
------ p
;',
~
HEADLIGHT RELAY 1
No.17
115AI
BLU1ED
WHT/G RN
BLu/lED
UNDER - DASH FUSE/RELAY BOX
HEADLIGHT
LEFT
RED/VEL
RED/VEL RIGHT HEADLIGHT
AD
I~
LOW
I55Wj
TAILLIGHT RELAY
)SSWI
LOW
HIGIi
)SOW)
~)
HIGH BEAM INOICATOR UGHT (UWI
H~H
{SOWI
~f"
MULTIPlEX CONTROL UNIT
RED/WliT
REO/BLU
RED/BLU
RED/BLU
RED/WHT
BlU/RED
BlU
13
REDlYEL
lOW 12
H~
......
~ ....~
DASH UGHTS
DIMMER
(NI OFF
COMBINA TlON LIGHT SWITCH
RED/VEL
REONEL
RED/YEL
RED/VEL
RED/YEL
PARKING
lEFT
UGHT
15Wj
FRONT SIDE
LEFT
MARKER lIGHT
(5WI
RIGHT PARKING UGHT 15WI
RIGHT
FRONT
lEFT
.DE MARKER UGHT

15W)
TAILLIGHT 15W)
REAR SIDE
LEFT
{5Wl
MARKER lIGHT
BU(
RIGHT REAR SIDe MARKER LIGHT

(SWI
RIGHT TAILLIGHT {5WI
UCENSE PlATE lIGHTS

15Wx2j
BLK
BLK
BLK
1 1 I 1 1
G'" G10l G30' G26' G26'
BLK
BLK
BLK
BLK
I
G553
BLK
1
G552
"
.;
22-71
Exterior Lights
Circuit Diagram - Canada
BATTERY
NO.19180A)
+~~~~--------~-----------------------------------
No.20 150A)
,~ I40A)
No.1.
WHT No.l0 {7,5A) FUSE 'In the under--dash\ \ fuse/relay box !
WHT .ED
'ED}El
y
Yl
BAT
~
IGNFOON
102 SWITCH
REO'VEl
~ HlGHBEAM c INDICATOR
LIGHT IUWl
162 HOT in ON (II)
BLK/RED
RED/BLU
RED/VEL
RED! LU
REDIBLU
E
ILEDI
NO.12
~UGHT
~ ~~ICATOR
17.SAI
No.3 {lOA)
UNDER-DASH FUSf/RELAV BOX
f9
VEL/RED 12
RED/BLU RED/BLU
-------p '~
DAVTlME
RUNNING LIGHTS RELAY

RED/BLI<
WHTBLU
RfD/YEL 10
REDIBLK
"
LIGHTS CONTROL UNIT
DAYTIME RUNNING
~\
BLK GRN BLK
l
BLU/RED
8
-
13
BRAKE SYSTEM LIGHT
IMMOBILIZER CONTROL
UNIT - RECEIVER
GRN BlI(
BlK
ED GRNIY'
GRN~O'N
GRNIORN
BRAKE
GRN RED
FLUID
PARKING
BRAKE
LEVEL SWITCH iClosed:
SWITCH
I'Closed: \
'IF1oatdown "
ILever up I
Sf
G301
1
G'" G5<)'
22-72
,
No.2 (15A)
r:-:'I
t=:..I
[
1 2
NO.15 " (15A)
KC>
~.
HEADLIGHT RELAY 2
f~
62No.17
{1SAI
~,
~.
HEADLIGHT
RELAY 1
RED/IYEl
LEFT
HEADLIGHT
RiD
RIGHT
BLU/RED
WHT GAN
HEADUGHT
1160W'
RED)'LU
lH~H
1- (SSW) 1
RED/fHT
" LOW
I,LOW
TI55Wl
~'H~H
RED/',LX
BLU,IRED
(SOW]
UNDER DASH FUSE/RELAY BOX
REO+HT
= "
~j
TAILlIGHT
RELAY
~,~~:-----
CUT RELAY
77
MULTlPLEX CONTROL UNIT BtU
REO/BlK
RED/YEL
REDNEL
----------+--------- - - - - - GRNiBLX -+----.

LOW
H~H
RE~
DASH LIGHTS
BLU/RED
13
DIMMER
{=JI n
";a'
---------:,
OFF
('1)1)
12
COMBINATION LIGHT SWITCH
RED/YEl
RED/YEL
p
RED/VEL
b
RED/VEl
p
LEFT PARKING
LIGHT
p
RIGHT PARKING LIGHT
{5WI
LEFT FRONT
15Wl
SIDE MARKER LIGHT

{5WI
RIGHT FRONT
SIDE
MARKER UGHT 15Wj
l-llll~
TAILLIGHT [5Wl REAR SIDE MARKER
LIGHT {5WI
REAR SIDE MARKER

LIGHT {SWI
TAILUGHT (5W)
PLATI LIGHTS
(5Wx2)
'tl(
'tl(
BLK
'tl(
BLK
BLK
1
G501
1
G301
BLK
'tl(
BLK
1
G201
BLK
1
6553
G301
G201
1
G552
'LX
22-73
Exterior Lights
Circuit Diagram - Brake Lights
I~
SAMRY
f7\
No.711SA)
\!::;I--+--<UV:>-+--WHT/GRN -
.......
'--------.1
W;N
BRAKE PEDAL POSITION SWITCH Closed: Pedal pressed HORN SYSTEM
WHT/GRN
WHTBLK
WHTBLK
,eM
ABSMODULATOR--CONTROLUNIT CRUISE CONTROL UNIT MULTIPLEX CONTROL UNIT
WHT BLK
WHT BLK
WHT BlK
, Lm
BRAKE
H.H
MOUNT
p
3 RIGHT
UGHT
2 IZ1WI
BRAKE LIGHT 15Wx5)
~~~E
2 121WI
'LX
BLK
'LX
1 I 1
G." G."
6553
'22-74
r--:'I t=:..I
Circuit Diagram - Back-up Lights
No.2<I (40A] : USA No.20 (SOA) . Canada
UNDER- HOOD FUSE-IREtA YBOX
B~ WHT +
==
IGNITION SWITCH BAT
101
1G1 HOTinON (II) and START (III)
NO.l0 (7.5A]
BOX
{
1
BACK-UP UGHTSWITCH
(On the transmission \1 ,lIousing I

(Closed: In position" R"
T T
GRN
GRN
UFT
P ~~~
2 (21WI
UP
' :'-UP C) [.1fT

2 [21W)
BLX
BlX
.l.
22-75
Exterior Lights
Daytime Running Lights Control Unit Input Test - Canada
The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. It should go off when you turn on the headlight switch and release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard lower cover (see page 20-60). 2. Disconnect the 14P connector (A) from the daytime running lights control unit (8).
B~
RED/BlU RED/BLU
BlK BLU/RED RED/VEL VEL/RED
3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
If the terminals look OK, go to step 4.
22-76
r--:'I
4. Make these input tests at the connector.

If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty. Replace it. Cavit,,Wire Test condition f-"='-"+~==~+-c"==== --+~__Test: Desired result 2 RED/BLU Underall conditions
.....
Check for voltage to ground: There should be battery voltage.'
I' Blown No. 14 (40A) fuse in the

i
Possible cause if result is not obtained under-hood fuse/relay box Blown No.3 (lOA) fuse in the under-dash fuse/relay box
,
12 YEL/RED
Ignition switch
,
Check for voltage to ground: There should be battery voltage.
An open in the wire
ON (II) 4 BLK
Under all Check for continuity to ground: There should be continuity. conditions 7 BLK Under all Check for continuity to ground: I conditions ~~~-I-~c~~~-;-'o"''''!'''''-'''___--t_T~h"e"r"e~s~h"o",u Id be conti nu ity. 10 RED/YEL i Combination Check for voltage to ground: light switch ON There should be battery voltage.
Blown No. 12 (7.5A) fuse in the under-dash fuse/relay box An open in the wire Poor ground (G501)
An ODen in the wire
Poor ground (G501)

An open in the wire
(iilD)
1 RED/BLU
Combination
Connect a jumper wire between
light switch ON ,No.3 and No.1 terminals. (iilD), and : Both headlights (HIGH) and J dimmer switch ,high beam indicator light 1--___'____--+-'i"'n"H-"I"G"H'--_ _ _-I--'s"h"o"u"l"d-"c"'"o"'m~e"_"'o'.'n'_._ _~---+_'~AC"'n.'o=D'en in the wi re 11 RED/BLK Combination Connect a jumper wire between Blown bulb light switch ON No.5 and No. 11 terminals. I Faulty combination light switch (iD), and Right headlight (HIGH) should Poor ground (G501l
Blown No. 15 (15A) fuse in the under-hood fuse/relay box Faulty headlight relay 2 Faulty combination light switch An open in the wire Blown bulb Faulty low beam cut relay Faulty combination light switch Poor ground (G501)
~~~~~ switch
3 5 GRN/BLK
Combination
come on..
_~~_ _ _ _~--L_'~A~n___c0-p-e-n-i-nccth~w-ir~cc_~-c-cc-1
Faulty combination light switch
I'
Check for continuity to ground:
light switch ON (iD), and
'There should be continuity.

I
I
Poor ground (G501) An open in the wire
i
6 8
,
dimmer switch
GRN/ORN
in HIGH Parking brake lever pulled BLU/RED , Combination light switch OFF
Ignition switch
I
Check for continuity to ground: There should be continuity"__ Check for voltage to ground: There should be battery voltage. Attach to ground: The DRL indicator light should
come on.
Faulty parking brake switch An open ',n the wire Faulty headlight relays Short to ground
An open in the wire
9
i
WHT/BLU
ON (II)
1---.13 GRN/RED
Blown No. 10 (7.5A) fuse in the under-dash fuse/relay box

Faulty DRL indicator
Ignition switch
ON (II)
Attach to ground: The brake system light should come on.
_~___~_____---jl_'-oA n. "open int~e. w=ir",-e-c-~_ _---j ..

I
Faulty brake system indicator An open in the wire
22-77
Exterior Lights
Headlight Adjustment
~CAUTION
Headlights become very hot during use; do not touch them or any attaching hardware immediately alter they have been turned off.
Before adjusting the headlights:
2. Park the vehicle 7.5 m (25 Itl away from a wall or a screen (AI.
A
/7.5mI25ftl
Park the vehicle on a level surface.

Make sure the tire pressures are correct. The driver or someone who weighs the same should sit in the driver's seat.
1. Clean the outer lens so that you can see the center of the headlights (A).
3. Open the hood.
22-78
r--:'I I..!::..I
Headlight Replacement
4. Turn the low beams on.
1. Remove the front bumper Isee page 20-85).

2. Disconnect the connectors IA) from the headlight IB).
5. Determine if the headlights are aimed properly.

Vertical adjustment: Measure the height of the headlights IAI. The lights should reflect 52 mm 12.1 in.) below headlight height IB).
6. If necessary, adjust the headlights to local requirements by turning the vertical adjuster.
3. Remove the five mounting bolts, then remove the
corner upper beam Ie) and headlight assembly.

5. After replacement, adjust the headlights to local

requirements.
22-79
Exterior Lights
Combination Light Switch Test/Replacement
1. Remove the driver's dashboard lower cover Isee page 20-60). 2. Remove the steering column covers Isee page 17-9), 3. Disconnect the 16P connector IAI from the combination light switch 18).
--.-:=-
2V Ls;==;U 4V
/ /
10 11 112 13 14 15 16
...-.' y ~
---,-.
-." ".-.-.'. ~.'.'
-' :
"-_C...
. i/
4. Remove the two screws, then slide out the combination light switch.
5. Inspect the connector terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. ~ If the continuity is not as specified, replace the switch. Light switch: Terminal
4
Position
OFF
'lJE
12
13
Headlight switch
-D
OFF
Passing switch
LOW HIGH
ON
Turn signal switch:
Terminal Position
LEFT NEUTRAL RIGHT
10
11
22-80
r:-:'I
J
Bulb Replacement
Headlight:
1. Disconnect the 3P connector IA) from the headlight. 1. Remove the inner fender Isee page 20-102).
Headlight (high/low): 60/55 W
Front Turn Signal Light: Parking Light:
2. Disconnectthe connectors IA) from the lights.

Front turn signal light: Parking light:
21W
5W
2. Remove the rubber cover IB). 3. Pull the retaining spring Ie) away from the bulb ID), then remove the bulb.
4. Install a new bulb in the reverse order of removal. Make sure the notches in the bulb align with the tabs in the headlight.
3. Turn the bulb sockets IB) 45 0 counterclockwise to remove them from the headlight housing. 4. Install the new bulbls) in the reverse order of removal.
22-81
Exterior Lights
Taillight Replacement
1. Remove the rear bumper (see page 20-86). 2. Open the tailgate, and disconnect the connectors (A) from the taillight (8).
Brake/Taillight: 21/5W Turn Signal Light: 21W Back-up Light: 21W
High Mount Brake Light Replacement

1. Open the hatch. 2. Remove the plastic trim. 3. Disconnect the 2P connectors (A) from the high mount brake light (8).
High Mount Brake Light: 5W x5
--~-
4. Carefully remove the high mount brake light. 3. Remove the mounting nuts and bolts, then remove the taillight. 4. Turn the bulb socket 45 0 counterclockwise to remove the bulb socket. 5. When installing the taillight, check the gasket; if it is distorted or stays compressed, replace it. 6. After installing the taillight, run water over the taillight to make sure it does not leak. 5. Install the light in the reverse order of removal.
22-82
t.=:..I
License Plate Light Replacement
1. Remove the hatch lower trim panel (see page 2053).
r--:'I
Side Marker Light Replacement

1. Carefully pry the light (A) out of the rear bumper, and disconnect the 2P connector (8) from the light.
Be careful not to damage the rear bumper.
2. Pull the license plate light assembly out, and disconnect the 2P connector (A) from the light.
License Plate Light: 5 W x 2
Side Marker Light:
5W
3. Separate the lens (81 and housing (C), then remove the bulb. 4. Install the light in the reverse order of removal.
2. Remove the bulb socket (A) by turning it 45 0 counterclockwise, then replace the bulb.
22-83
Exterior Lights
Brake Pedal Position Switch Test
1. Disconnect the 4P connector IA) from the brake pedal position switch IB).
Side Turn Signal Light Replacement

NOTE: Be careful not to damage the fender. 1. Push the retaining spring IA), and remove the side turn signal light IB). Side Turn Signal Light: 5W
2. Check for continuity between the No.1 and No.2

terminals.
2. Disconnect the 2P connector IC) from the light. There should be continuity when the brake pedal
is pressed.
There should be no continuity when the brake pedal is released. 3. Check for continuity between the No.3 and No.4
terminals (with cruise control).
There should be no continuity when the brake pedal is pressed. There should be continuity when the brake pedal
is released. 4. If necessary, adjust or replace the switch, or adjust
the pedal height Isee page 19-6).
22-84
Turn Signal/Hazard Flasher
r:-:'I t=!.I
oJ
COMBINATION LIGHT/TURN SIGNAL SWITCH
Test, page 22-80

TURN SIGNAL INDICATOR LIGHTS (In the gauge assembly) Bulb Replacement, page 22-63
--- ,---=-::>
___ I
HAZARD WARNING SWITCH
,I'
Test. page 22-88

-~
TURN SIGNAL/HAZARD RELAY
22-85

Circuit Diagram
NO.20 I411AJ USA No.20 150A) . Canada
BAmRY
+}---h-".D---"~-1f--WHT
No,19180AI
NolO
--Q-IGNITION SWITCH
BAT
BLK/YEL
~A~I-1_ _- '
YEll LK
IGI
'----00""''"''"-1--------
No.5 {10A1
IG1 HOT in ON 1111 and START IIUI
WHT/BlJ( - - - - - - , No.2jlSAI FUSE

,'In the under - hood)
',fuse/relay box
, - - - - GANIRED - - - - - - - - ,
'
GRN VEL
TURN SIGNAL SWITCH
11
RED/BLK
10
lEFT
RIGHT
10
HAZARD WARNING SWITCH
__ 0/_R~HT
'i'
pLIGHT
IO.84W)
BLK/RED
GRN WHT
'------+---- BlK/RED
TURN SIGNAl! HAZARD RELAY
GRN/RED
GRN VEL
DASH LIGHTS BRlGtfTNESS CONTROLLER (I" Ihe gauge \1 ,assembly ;
LEFT TURN SIGNAL LIGHTS
RIGHT TURN SIGNAL LIGHTS
SIDE
15WI
~
BlJ(
INDICATOR LIGHT
(1.4WI
INDICATOR bLIGHT
I1.4WI
ref:\RE" '-lJ 121WI
BlJ(
BlK
BlK
BlK
BlK
BlK
BlK
BLK
BLK
-'L
1
G501
G201 G502
--'-'G553
--'-'G201
G553
G501
G301
'22-86
r--:'I t.=:..I
Turn Signal/Hazard Relay Input Test
1. Remove the turn signal/hazard relay IAI from the under-dash fuse/relay box IBI.
2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact.
Ifthe terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. If the terminals look OK, go to step 3.
3. Make these input tests at the fuse/relay box .
If any test indicates a problem, find and correct the cause, then recheck the system . If all the input tests prove OK, the turn signal/hazard relay must be faulty. Replace it.
Cavity I Test condition , Under all conditions 1 3 Ignition switch ON III)

Hazard warning switch
Test: Desired result Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be battery voltage.
OFF
Possible cause if result is not obtained Poor ground IG201) An open in the wire Blown No. 19 17.5A) fuse in the under-dash fuse/relay box Faulty hazard warning switch Blown No. 5110AI fuse in the under-hood fuse/relay box
An open in the wire

ION Ignition switch OFF
I . I
Faulty hazard warning switch
Ignition switch ON III) in Right or Left position Ignition switch OFF

, and turn signal switch
ON
I
Connect No.2 terminal to No.3 terminal: Right or left turn signal lights should come on. Connect No.2 terminal to No.3 terminal: Hazard warning lights should come on.
An open in the wire Poor ground IG201, G301, G501, G502, G553) Faulty turn signal switch An open in the wire Poor ground IG201, G301, G501, G502, G553)
I i
Faulty hazard warning switch An open in the wire
22-87

Hazard Warning Switch Test
1. Remove the center panellsee page 20-62).
2. Disconnect the 1OP connector IA) from the hazard warning switch (8).
3. Push out the hazard warning switch from behind
the center paneIIC). 4. Check for continuity between the terminals in each
switch position according to the table.
5. If the continuity is not as specified, replace the bulb ID) orthe hazard warning switch.
Terminal Position
\ 5
(>
10
OFF ON
0--0 0--0
(>
.n. -0
22-88
r:-:'I
Entry Light Control System
a..=:.J
CEILING LIGHTISPOTLIGHTS Test. page 22-96 Replacement, page 22-96 REAR CEILING LIGHT Test, page 22-96 Replacement, page 22-96 FRONT PASSENGER'S DOOR SWITCH
-------
IGNITION KEY LIGHT Test, page 22-91 IGNITION KEY SWITCH Test, page 22-91 DRIVER'S DOOR SWITCH HATCH LATCH SWITCH
Test, page 22-97

CARGO AREA LIGHT
Test, page 22-97

22-89

Circuit Diagram
No.20 (40AI UNDER- HOOD FUSE/RELAY BOX BAmRY USA
No.20 (50AI :Canada
No,19 (80AI
No.317.5A)
WHT/BLU
I
No.20
WHT
BAT
"~1
( TRANSMITTER )
IGNITION
SWITCH
IG1 HOTinON 1111 and START 1111)
~
CEILING
LIGHT
WHT BlU
BLKIYEL
'/
KEYLESS
(
I
No.10
(7,SA)
~ IGNITKlN KEY
UGHT
5 (1.4Wj
RECEIVER
UNrr
2
UNDER-DASH FUSE/RtlAV
BOX
BLUt AN
IFll$e/relaybox socket)
GRN AfD
WHT BlK
K2
UNOER-DASH FUSE/RELAY BOX
07
X8
MULnPl..X CONTROL UNIT

,
-r
VB
03
Q4
-r
X5
-r
'18
REO
DOQR LOCK
KNOB
VEL/RED
Cl
~D
REO
r
HATCH
CARGO AREA LIGHT
KEY
GAN
LTGRN/RED
RED/WHT
UNLOCK 0,
DRIVER'S
LOCK
L---+,---'
DOOR LOCK KNOB SWITCIi
DRIVER'S
DOOR
SWITCH
PASSfNGER'S
DOOR
IGNITlON
(Closed: I \Dooropen )
SWITCH
I'Closed \D1:Ior open
2 (Closed:
SWITCH
KEY
LATCH SWITCH
iClosed:
\,
IKey inserted "
IHatch open ;'
1
G501
I
G401
I
G552
22-90
t=:.I
Ignition Key Switch Test
NOTE: For more key-in beeper information, refer to the circuit diagram (see page 22-90) and input test (see page 22-92). When the ignition key is in the ignition switch the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the multiplex control unit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers (see page 17-9). 2. Disconnect the 6P connector.
Ignition Key Light Test

1. Remove the steering column upper and lower covers (see page 17-9).
2. Disconnect the 6P connector.
111 121
ill I' 16 I
3. The LED should come on when power is connected to the No.6 terminal and ground is connected to No.5 terminal. 4. If the LED does not come on, replace the ignition
switch.
111 121
ill I' 16 11

terminals .
There should be continuity with the key in the

ignition switch .
There should be no continuity with the key

removed from the ignition switch.
4. If the continuity is not as specfied, replace the ignition switch,
22-91

Control Unit Input Test
1. Before testing, troubleshoot the multiplex control system (see page 22-172). 2. Remove the dashboard lower cover.
3. Disconnect the under-dash fuse/relay box connectors.
NOTE: All connectors are wire side of female terminals.

UNDER-DASH FUSE/RELAY BOX CONNECTOR K I17P) /BLU/ORN
[~ 1]<I/IJI131~]]]
UNDER-DASH FUSE/RELAY BOX CONNECTOR 0 112P)
[31: 1516171819\101121112]
GRN/RED UNDER-DASH FUSE/RELAY BOX CONNECTOR P 118P)
UNDER-DASH FUSE/RELAY BOX CONNECTOR Q 18P)
UNDER-DASH FUSE/RELAY BOX CONNECTOR X 18P)
UNDER-DASH FUSE/RElAY BOX CONNECTOR Y 113P)
[~I ~ I: IJI101?R[d
4. Inspect the connector and socket terminals to be sure they are all making good contact .
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system .
"
YEL/RED
22-92
r:-:'I I..!:!.I
5. With the connectors still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, go to step 6.
Cavity K2
! BLU/ORN
1
Wire
Test condition
i
Test: Desired result

Check for continuity between the K2 terminal and the keyless receiver unit 5P connector No.2 terminal: There should be continuitY'.: Attach to ground: Ceiling light(s) should come on.
I
Possible cause if result is not obtained An open in the wire

I
07
GRN/RED
Ceiling light switch in middle position.
X8
I WHT/BLK
Under all cond;';ons
Attach to ground: Ignition key light should come on.
Blown No.3 (7.5A) fuse in the under hood fuse/relay box Blown bulb Faulty ceiling light An open in the wire o Blown No.3 (7.5A) fuse in the under hood fuse/relay box o Faulty ignition key light (LED) o An open in the wire
6. Reconnect the connectors to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Cavity Wire Test condition Hatch open Test: Desired result Check for voltage to ground: There should be 1 V or less. ; Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. . Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Possible cause if result is not obtained POOr ground (G552) Faulty hatch latch switch o An open in the wire o Faulty hatch latch switch o Short to ground o Faulty driver's door switch o An open in the wire Faulty driver's door switch o Short to around o Faulty passenger's door switch o An ODen in the wire Faulty passenger's door switch Short to around Poor ground (G401) Faulty ignition key switch o An aDen in the wire o Faulty ignition key switch o Short to ground Poor ground (G501) Faulty driver's door lock knob switch An open in the wire o Faulty driver's door lock knob switch o Short to qround
o o
P18
RED
Hatch closed Driver's door open Driver's door closed
Q3
GRN
O'
LT GRN/ RED RED/WHT
X5
Y8
YEURED
Passenger's door ODen Passenger's door closed Ignition key inserted into the ignition switch Ignition key removed Check for voltage to ground: from the ignition There should be 5 V or more. switch . Check for voltage to ground: Driver's door lock knob switch locked There should be 1 V or less. Driver's door lock knob switch unlocked Check for voltage to ground: There should be 5 V or more.
22-93
Interior Lights
CEILING LIGHT ISPOTLIGHTS Test, page 22-96 Replacement, page 22-96 REAR CEILING LIGHT
Test, page 22-96

CARGO AREA LIGHT Test, page 22-97 Replacement, page 22-97
22-94
Circuit Diagram
BArnRY
8r-__
IUNDER
HOODFUSE/RELAVBOX
l.~NO~) .-
.....-
WHT/BLU
WI!T BW
WHT BLU
WHT BlU
CEILING LIGHT fSPOTLlGHTS
b
91
3
SPOTLIGHTS 15Wx21
(D
(
ON
LIGHT (5WI
CEILING
(~
ON
18W)
MAR
CARGO
II
o0
:", OFF
' ", OFF
"UNO
LIGHT
yO
1
( ~ 15W)
2
AREA LIGHT
-!Bl'
GRN M' GRN M'
MULTIPLEX CONTROL UN"
MULTIPlEX CONTROL
Y
RE'
UN"
d
Bl'
,~ HATCH LATCH
SWITCH
r;'''''oPen ') atch
G'"
1
G552
22-95
Interior Lights
Ceiling light/Spotlights Test/ Replacement
1. Turn the ceiling lighVspotlights switches OFF. 2. Carefully pry off the lens (A) with a small screwdriver,
Rear Ceiling light Test/ Replacement

1. Turn the light switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver.
Ceiling Light: Spotlight:
5W 5Wx2
Ceiling Light: 8 W
5x1.0mm
!J!iJt- -------------- ----
3. Remove the two screws and the housing (8).

4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table.
Terminal
,
3. Remove the two mounting screws. 4. Disconnect the 3P connector (8) from the housing
(C).
Position
CEILING LIGHT ( Spotlights'; I,OFF OFF
\
MIDDLE ON R
~
3
i
1\
Position
Terminal
OFF
SPOTLIGHTS (Ceiling light\. IOFF ! ' L
ION .. OFF ON OFF
-f--
MIDDLE ON
nj"" -n In "'" -0
,
~
6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling lighVspotlights.
6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the rear ceiling light.
22-96
~ ~
Cargo Area Light Test/Replacement
1. Open the hatch. 2. Carefully pry out the cargo area light (A).
Cargo Area Light: 5 W
Hatch Latch Switch Test

1. Open the hatch. 2. Remove the hatch lower trim panel (see page 2053). 3. Disconnect the 2P connector (A) from the hatch latch (8).
B
3. Disconnect the 2P connector (8) from the light. 4. Check for continuity between the No.1 (+) and No.2 (-) terminals. There should be continuity. If there is no continuity, check the bulb. If the bulb is OK, replace the cargo area light. 4. Check for continuity between the No.1 and No.2
terminals.
There should be continuity with the hatch open. There should be no continuity with the hatch closed. 5. If the continuity is not as specified, replace the hatch latch.
22-97
Audio System
AUDIO UNIT Removal/Installation, page 22-100 Connector Terminals, page 22-101 LEFT DOOR TWEETER
RIGHT DOOR TWEETER Replacement, page 22-102 FRONT PASSENGER'S DOOR SPEAKER Replacement. page 22-102 ROOF ANTENNA Replacement, page 22-103
ANTENNA SUB LEAD
DRIVER'S DOOR SPEAKER Replacement, page 22-102
--~\
.. .
~/
./
LEFT REAR SPEAKER Replacement, page 22-102 RIGHT REAR SPEAKER Replacement, page 22-102 ANTENNA LEAD
22-98
t=!..I
Circuit Diagram
No.20 14OA) . USA
UNDER-HOOD FUSE/RHA YBOX

BAmRY
IGNITION SWITCH
WHT/RED -
No 20 150A) . Canada
~ ,--+_N-c'r19,I80J.A)-I~p--dN,'''J,_+-_ ___+c8AT rc.\..._ __ r WHT ~ -""1

ACe
No.9Il0A) L.....c0.v:.--+-...,
Ace HOT in ACe III and ON 1111
No.8 I7.5A)
Nol (15AI FUSE pnthe under-hoodl ',fuse/relay box I
ANTENNA AMPLIFIER
RED BLK
I
BLK
ANTENNA LEAD
WHT RED
VEL/GRN
ANTENNA SUBLEAD
! I
VEL/RED
A9
AlO
A1
: i
A2
AUDIO UNIT
'~:
~
~)
~-
'~.
L--Q-"'----Q~A-19----~rA-'--(1~A-,'-------~~A17
GRN Bu( LT GRN GRN VEL GRY/REO
8
A6 A16 A5 A15
BRIGHTNESS
DASH UGHTS
I
CONTROLLER
(In the gauge

'assembly
T"r:
DRIVER'S
GRN VEl GRTED
t~~
RIGHT TWEETER
BLU/WHT BlU BLK
I
LEFT REAR SPEAKER
J~I':
RIGHT REAR
SPEAKER
lEFT TWEETER
DOOR SPEAKER
PASSENGER'S DOOR SPEAKER
"<l3
22-99
,
Audio System
Audio Unit Removal/Installation
NOTE: Put on gloves to protect your hands. Take care not to scratch the dashboard and related parts. 1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
5. Remove the heater control panellsee page 21-381.

6. Remove the four mounting bolts and the audio unit
from the radio brackets.
preset buttons. 2. Remove the driver's dashboard lower cover Isee page 20-591. 3. Remove the two mounting bolts, then pullout the center panellAI.
(]
';
/
I
c
7. Install the audio unit in the reverse order of removal, and note these items: Make sure the audio unit and
Ale connectors are
plugged in properly, and the antenna lead is connected properly . Enter the anti-theft code for the radio, then enter
4. Disconnect the audio connector (8) and antenna the customer's radio station presets.
lead ICI, heater control panel connectors IDI and HAVC push switch assembly lEI. then remove the
center panel.
22-100
Audio Unit Connector Replacement

Cavitv
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Wire YEljGRN YEljRED
-
Connects to
Roof antenna ACC (Power) Not used Not used Riaht rear soeaker (+) Left rear soeaker (+) Front oassenaer's door speaker (+ )/Riaht tweeter (+) Driver's door speaker (+ I/Left tweeter (+) Liqhts-on siqnal Constant Dower Not used Not used Not used
' Not used
--
I
,
I
-------t-
PNK BLU/WHT GRN/YEL GRN/BLK RED/BLK WHT/RED

-------------
BLU/YEL BLU/BLK GRY/RED LTGRN RED BLK
Riaht -rear soeaker (-) Left rear sneaker (-) Front passenaer's daar speaker (-)/Riqht tweeter (-) Driver's door soeaker (-I/Left tweetr (-) Dash liahts briahtness cantroller Ground (G503)
AUDIO UNIT 20P CONNECTOR
..
..
................. ILVI. ....... ---"_I .....

cJLII
~.
r
--
'--
,,~
.r(c'\
1 11
2 12
3 13
6 16
9 19
10 20
14 15
17 18
22-101
Audio System
Speaker Replacement
Door Speaker:
1. Remove the door panel (see page 20-4). 2. Pull the top of the speaker (A) straight out, just enough to release the upper clip. If you pull the speaker out too far, you will damage the lower clips (C). Then lift the speaker straight up to release the
lower clips.
Rear:
1. Remove the speaker cover (A).
2. Remove the three screws, then disconnect the 2P
connector (8) from the speaker (C).
3. Disconnect the 2P connector (8), and remove the

speaker.
Tweeter:
Carefully pry the tweeter (A) out of the mirror mount cover, then disconnect the 2P connector (8) from the
tweeter.
22-102
r:-:'I I..!=.I
J
Roof Antenna Replacement
1. Remove the rear part 01 headliner (see page 20-541. 2. Disconnect the antenna lead connector (A) and 1P connector (8) lrom the rool antenna (e).
3. Remove the mounting nut and the antenna.
22-103

*:Rear window defogger switch is built into the heater control panel.
REAR WINDOW DEFOGGER RELAY
Test, page 22-51
REAR WINDOW DEFOGGER SWITCH'
----=-::-:-:-
_.0j}
---"
NOISE CONDENSER Capacity Test, page 22-107
REAR WINDOW DEFOGGER Function Test, page 22-106 Defogger Wire Repair, page 22-106
22-104
Circuit Diagram
UNDER HOD oFUSE/RELAY BOX No.20 (40AI USA NO.20 (50AI : Canada
IGNITION SWITCH
ATTERV
~
No.19180AI
~
No.20
l,"
,130M
WHT
--@-' 1G2
1G2 HOT in ON {III
BLK/RED
UNDER - DASH
No.14
(1OAI
:~~'RELAY
I
Bl.K!YEL
BlK/VEL
f:
7
b b
~,
REAR WINDOW DEFOGGER RELAY
BlK VEL
VEl
BlK
BLK VEL
812
Re~ window defogger s.witch and defog er timer circuit built ~nto
81.
~
REAR WINDOW DEFOGGER SWITCIi

(LED)
heater control panel
INDICATOR
81J
BlK/YEL
BlK VEL
('
REAR
I 1 1
~
=-'
WINDOW
.J
NOISE
DEFOGGER
CONDENSER
BlK
BlK
r
G501
G552
G552
22-105

Function Test
NOTE: Be careful not to scratch or damage the defogger
wires with the tester probe .
Defogger Wire Repair

NOTE: To make an effective repair, the broken section
must be no longer than one inch.
Before testing, check the No. 11 130AI fuse in the under-hood fuse/relay box and No. 14110AI fuse in the under-dash fuse/relay box. 1. Check for voltage between the vertical dividers and body ground with the ignition switch and defogger switch ON. There should be voltage as shown. If there is no voltage, check for: - faulty defogger relay. - an open in the BLK, BLK/YEL, or YEL/BLK wire. - faulty heater control panel. If there is battery voltage, go to step 2.
1. Lightly rub the area around the broken section IAI with fine steel wool, then clean it with alcohol.
A
c
B
A
2. Carefully mask above and below the broken portion of the defogger wire IBI with transparent tape ICI.
3. Mix the silver conductive paint thoroughly. Using a small brush, apply a heavy coat of paint extending about 1/8 inch on both sides of the break. Allow 30
minutes to dry.
6V
2. Check for continuity between the negative terminal
IBI and body ground. If there is no continuity, check for:

an open in the BLK wire.
Poor body ground at the window antenna coil mounting bolt. 3. Touch the voltmeter positive probe to the halfway point of each defogger wire, and the negative
probe to the negative terminal.
There should be about 6 V with the ignition switch and the defogger switch ON. If the voltage is as specified, the defogger wire is OK. If the voltage is not as specified, repair the defogger wire.
- If it is more than 6 V, there is a break in the negative half of the wire.
4. Check for continuity in the repaired wire.
5. Applya second coat of paint in the same way. Let it dry 3 hours before removing the tape.
- If it is less than 6 V, there is a break in the

positive half of the wire.
22-106
Noise Condenser Capacity Test

1. Remove the right rear side trim panel (see page 2066). 2. Disconnect the 2P connector (A) from the noise
condenser.
Noise condenser capacity: 0.47 0.09 microfarads

,
3. Use a commercially available condenser tester.
Connect the condenser tester probes, and the

measure condenser capacity.
4. If it is not within the specification, replace the noise condenser.
22-107
Moonroof
MOONROOF SWITCH
Test,page22-112
Replacement page 22-112
MOON ROOF MOTOR Test. page 22-112 Replacement. page 20-41 MOON ROOF LIMIT SWITCH Test, page 22-113
MOONROOF CONTROL UNIT Input Test, page 22-110
r::::-:,-- ----MOONROOF AUTO-STOP SWITCH
----'
'
Test, page 22-113
MOONROOF OPEN RELAY Wire colors: GRNIYEL, GRN, [ RED/YEL, BLK and YElJGRN Test, page 22-51 MOONROOF CLOSE RELAY Wire colors: GRN/BLK, GRN, [ GRN/WHT, BLK and YEL/GRN
1 1
Test, page 22-51
22-108
l.!:..I
J
Circuit Diagram
No.20 I40AI : USA

BAmRV
IGNITION SWITCH
No.21lISOA) : Canada
No.19 (BOA)
No.21l"
. 2
No.13
I40AI
IGl HOTinON IIIJ and START 11111
A B C D
Closed from the auto-stop position to the closed position Closed in the tilt or closed position Closed in any open (not tiltl pOSition Closed in the tilt position
WHT BLK
BLK/VEl
No,7 1lOA)
No.6
(7,5Al
BOX
UNDER DASH fUSE/RELAY
GRN
VEL! RN
,-t-------------t---1f--- YEl/GRN
q C'+-
RELAY
MOONROOF OPEN
MOONROOF
CLOSE
RELAY
MOONROOF CONTROL "NIT
MOONROOF MOTOR REO/YEt

2
,
GRN/WHT
GRN WHT RED/YEl
REOh'
C\ .,',0
,
TILT SWITCH
OPENI
B
CLOSE SWITCH
9
BlK
RED/YEl
"i'i
" S
MOONRDOF MIT WITCH
LT RN
2
A
LTGRk:l.K
GRN ORN
.0
STOP
AUTO -
r-
~r
,:ICLOSE
,
MOONROOF SWITCH
SWITCH
'IOPEN
rl
ylTllT
y
1
GSO,
I
GSO, GSO,
22-109
Moonroof
Moonroof Control Unit Input Test
1. Remove the headliner (see page 20-541. 2. Disconnect the 5P connector (AI from the control unit (81.
3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
22-110
=
4. Reconnect the moon roof control unit SP connector, and make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, go to step 5.
Cavity
5
1
Wire
Test condition
Possible cause if result is not obtained

Poor ground (G501) An open in the wire Blown NO.6 (7 .SA) fuse in the underdash fuse/relay box An open in the wire Poor ground (GS01) o Faulty moon roof auto-stop switch o An open in the wire
BLK YEL/GRN
! Check for continuity to ground:

There should be continuity. Check for voltage to ground: There should be battery voltage.
Ignition switch ON (II)
LTGRN
Ignition switch ON (II) Moonroof closed
Check for voltage to ground: There should be 1 V or less.
Moonroof open Check for voltage to ground: There should be battery voltage.
---
Short to ground Faulty moonroof auto-stop switch
S. Disconnect the moonroof control unit SP connector, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit must be faulty. Replace it.
Cavity
Wire
Test condition Ignition switch ON (II)
Test: Desired result Connect a jumper wire between No. 3 and No. S terminals. Moonroof motor should run (opened).

o o
RED/YEL
,
i
o o o o
Poor ground (GS01) Blown No.6 (7.5A) fuse in the underdash fuse/relay box Blown NO.7 (20A) fuse in the underdash fuse/relay box Faulty moonroof open relay Faulty moonroof close relay Faulty moon roof motor An open in the wire Poor ground (GS01) Blown No.6 (7.5A) fuse in the underdash fuse/relay box Blown No.7 (20A) fuse in the underdash fuse/relay box Faulty moon roof open relay Faulty moon roof close relay Faulty moonroof motor An open in the wire
GRNIWHT
Connect a jumper wire between No. 2 and No. S terminals. Moonroof motor should run (closed).
o o
o o
o o
22-111
Moonroof
Switch Test/Replacement
1. Carefully pry the moon roof switch (A) out of the headliner.
Motor Test
1. Remove the headliner (see page 20-54).
2. Disconnect the 2P connector from the moon roof motor.
2. Disconnect the 5P connector (8) from the moon roof

switch.
3. Check the motor by connecting power and ground according to the table.
1\
Terminal
Position
'\
1\
Terminal
OPEN
1 2
0
0
Position
CLOSE TILT
5
CLOSE
Oi ~
~
4. Ifthe motor does not run, replace it.
OPEN
-0
NOTE: See closing force check (see page 20-48) for motor clutch test.
4. If the continuity is not as specified, replace the

moonroof switch.
22-112
Limit Switch Test

1. Remove the headliner (see page 20-541.
2. Disconnect the 4P connector from the moonroof lim it switch.
Auto-stop Switch Test

1. Remove the headliner (see page 20-541.
2. Disconnect the 2P connector from the moon roof
auto-stop switch.
3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench.
3. Check for continuity between the terminals in each

1\
Terminal
Position
NOTE: Turn the motor by hand with the wrench. The auto-stop position is about 145 mm (5.75 in.1 from fully closed.
TILT OPEN CLOSE
0- -0 0
0
--0
--0
\
Position
Terminal
-0
1\
Between AUTO-STOP and CLOSE

Between OPEN and AUTO-STOP
-0

moonroof limit switch.
4. If the continuity is not as specified, repair or replace the auto-stop switch.
22-113
Power Mirrors
POWER MIRRORS
Function Test, page 22-116 Replacement, page 20-15 Actuator Test, page 22-117 Actuator Replacement, page 22-118
..
"'"
POWER MIRROR and MIRROR DEFOGGER SWITCH Test, page 22- 117
22-114
r:-:'I
Circuit Diagram
., No.20 14IlA) :USA NolO ISOA) :Canada '2: Canada
Be.
y __
t-I_N-(~_+
J
__ ~,~YEl --P~I...,'---,I
IGNmON SWITCH
1G2 HOT in ON 1111 BLKLYEl
(fuse/relay box
No.2 (15AI FUSE
"~-RED/BLK
')7
9
BLKIYEL
BLK/YEL
POWER MIRROR SWITCH
2 UP lEFT
11
....
RIGHT
UGHT (D (1.4WI
~
'
DEFOGGER SWITCH"
DASH LIGHTS BRIGHTNESS
INDICATOR UGHT" ----.....LILEDI

0
--0:
LEFT
';>
c.
------_ .....
RED
DOWN
~
...
.~
'<J
------------------RIGHT
LEFT
12
BLU/WHT
RIGHT
13
10
11
CONTROllER
aLK
(~~t~ge)
ORN
GRN/WHT
RED/JEl
BlU
aLK
5
ORN
1
aiN
RIGHT MIRROR
5
lEFT MIRROR
DOW: e
UP
e M Me
ruGHT
DEFOGGER"'
2
BlK
DO~ CB M
UP
0 Me
RIGHT
DEFOGGER"
H GRT '
BLU/WHT
RED GRNr' WH'
aLK
G",
"
G502
G501
22-115
Power Mirrors
Function Test
1. Remove the driver's pocket (see page 20-60). 2. Reach through the pocket opening, and push out the power mirror switch (A).
Left mirror
7. Connectthe No.2 terminal to the No. 10 terminal, and the No. S (or No. 12) terminal to the No.6 terminal with jumper wires. The left mirror should tilt down (or swing left) with the ignition switch ON (II). If the mirror does nottilt down (or does not swing left), check for an open in the GRN/WHT (or BLU/ WHT) wire between the left mirror and the 13P connector. If the wire is OK, check the left mirror
actuator. If the mirror neithertilts down nor swings left,
repair the BLU/BLK wire.

BLK/YEL BLK/YEL
B
If the mirror works properly, check the mirror switch.
~
BLK
"-.......,(( ~'+Z7t':+f=r+:4+':-15 ~ re si de of
6 8 9 10 11 12 13
GRN/WHT
Right mirror
~ale terminals
WHT/RED
ORN RED/BLK 3. Disconnect the 13P connector (B) from the switch. 4. Choose the appropriate test based on the symptom: Both mirrors don't work, go to step 5. Left mirror doesn't work, go to step 7, Right mirror doesn't work, go to step 8. Defogger doesn't work (Canada), go to step 9.
Both mirrors
8. Connect the No.2 terminal to the No. 11 terminal, and the No.5 (or No. 13) terminal to the No.6 terminal with jumper wires. The right mirror should tilt down (or swing left) with the ignition switch ON (II). If the mirror does not tilt down (or does not swing left), check for an open in the GRN/WHT (or WHT/ RED) wire between the right mirror and the 13P connector. If the wire is OK, check the right mirror actuator. If the mirror neither tilts down nor swings left, repair the RED/VEL wire. If the mirror works properly, check the mirror switch. Defogger (Canada)
S. Check for voltage between the No.2 terminal and body ground with the ignition switch ON (II). There should be battery voltage. If there is no battery voltage, check for: - blown No. 14 (10A) fuse in the under-dash fuse/relay box. - an open in the BLK/VEL wire. If there is battery voltage, go to step 6. 6. Check for continuity between the No.6 terminal and body ground. There should be continuity.
If there is no continuity, check for: - an open in the BlK wire.
9. Connect the No.1 and No.8 terminals with a jumper wire, and check for voltage between the No.2 terminal of the mirror connector and body ground. There should be battery voltage and both
mirrors should warm up with the ignition switch ON (II). If there is no voltage or neither warms up, check
for:
- an open in the BLK/VEL or ORN wire. - blown No. 14 (10A) fuse in the under-dash fuse/relay box. If only one fails to warm up, check: - its defogger. - poor ground (GS01, GS02). If both warm uP. check the defogger switch.
- poor ground (GS01). If there is continuity, check both mirrors individually as described in the next column.
22-116
r--:'I t.=.I
Power Mirror Switch Test
1. Remove the driver's pocket (see page 20-60).
Power Mirror Actuator Test

1. Remove the door panel (see page 20-4).
2. Reach through the pocket opening, and push out the power mirror switch (A).
2. Disconnect the 6P connector (A) from the power mirror actuator (8).
--'-~~' .-----::_--:- ,(co
B.
~~...~-.r:_-. < .' j~;\ '. y

........... ....
~ " ~:Q\a
""',
"
,...
..
\"""""",\",( \'. 'o, \
---------1
2
8
9 10 11 12 13
3. Disconnecllhe 13P connector (8) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. Mirror Switch:
Terminal Position
[ZEEEJ
3. Check actuator operation by connecting power and ground according to the table.
2
0-
5 I 6
10
11
12
13
1\
Terminal
Position
UP DOWN Lf---LEFT
f-o
0-
0-
f-<>
TILT UP TILT DOWN SWING LEFT

,
"
e e
<>
f-<>
._-
SWING RIGHT
<> <>
<>
RIGHT UP
I
4. If the mirror fails to work properly, replace the

0-
f-o .
o-I--v
i
I
,
mirror actuator.
Defogger Test (Canada): 5. Check for continuity between the No.1 and No.2 terminals of the 6P connector. There should be
continuity. Ifthere is no continuity, check for an open circuit.
DOWN RI LEFT RIGHT

!
o-hJ
!
1 __
i
Defogger Switch (Canada):
1\
Terminal Position
8
'}
ON OFF
5. If the continuity is not as specified, replace the power mirror switch.
22-117
Power Mirrors
Power Mirror Actuator Replacement
1. Remove the power mirror (see page 20-15).
2. Carefully remove the mirror holder from the mirror
8. Remove the three Torx screws, and separate the actuator (A) from the mirror housing (B).
housing. Gently pull it out by hand (see page 20-151.

3. Disconnect the connector.
4. Remove the cover, then remove the two Torx

screws from the mirror connector. 5. Record the terminal locations and wire colors. 6. Cut the wire harness with the wire cutter.
9. Route the wire harness (A) of the new actuator
through the hole in the bracket (B) .
.________8
7. Remove the three screws, and separate the mirror housing from the mirror base.
22-118
10. Insert the terminals into the connector in the original arrangement as shown below.
LEFT MIRROR CONNECTOR
RIGHT MIRROR CONNECTOR
BLK*
Clmffi Clmffi, 1+'

GRV VEL LT GRN BRN
BLK*
BLK*
BLK*
1\
PNK
ORN
*:Canada
11. Reassemble in the reverse order of disassembly. Be careful not to break the mirror holder when reinstalling it to the actuator. 12. Reinstall the mirror assembly on the door.
13. Operate the power mirror to ensure smooth operation.
22-119
Horns
, ,
L~
,-,'
-c
y ,'y"!
~~
J _
i~',
~,'-)
,~
~~ ~,'~;',
-1_
'I, 12" 1
',~ ""'I ,J-L-~
HORN RELAY
Test, page 22-51
HORN SWITCH Test, page 22-122
HORNS
CABLE REEL Replacement, page 23-119
22-120
Circuit Diagram
BAmRV
-'-
UNDER-HOOD fUSE/RELAV BOX
2 t,
0
No.7
{15AI
GRN
~)
~j
HORN
RELAV
BRAKE UG HTS
0 RN
h
CABLE
REEL
8LU/RED
HORN
IiORN
CRUISE CONTROL SET/RESUME!

CANCEL SWITCH
HORN SWITCH
22-121
Horns
Horn Test/Replacement
1. Remove the front bumper (see page 20-851. 2. Disconnect the 1P connector (8). and remove the horn (AI.
Horn Switch Test

1. Remove the steering column covers (see page 17-
91.
2. Disconnect the dashboard wire harness 8 5P connector (AI from the cable reel (81.
3. Testthe horn by connecting battery powerto the terminal (AI and ground to the bracket (81. The horn should sound.
B
3. Using a jumper wire connect the dashboard wire

f
harness 8 5P connector (AI No.2 terminal to body ground . If the horns sound, go to step 4. If the horns do not sound, check these items: - Horn relay - No.7 (15A) fuse in the under-hood fuse/relay box - Horns (see page 22-1221.
- An open in the wire
4. If it fails to sound, replace it.
22-122
t=!..I
4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B).
A
7. Using a jumper wire, connent the steering wheel to body ground. 8. Close the contacts between the horn plate and the contact plate. If the horns sound, replace the steering column. If the horns do not sound, replace the horn and contact plate.
5. Using a jumper wire, connectthe horn switch positive 1P connector (B) to ground.
If the horns sound, go to step 6. If the horns do not sound, replace the cable reel. 6. Reconnect the horn switch positive 1P conector (B).
22-123
Power Windows
POWER WINDOW RELAY
Test, page 22-51
_ ' - - - . J L J l __ '-.JL'
",-r,n--'--'"rn"'nr-n-,LL,U..JUL--'U_'~
UL
Uc..-.JL2_ULJ_
FRONT PASSENGER'S WINDOW MOTOR Test, page 22-132
DRIVER'S WINDOW MOTOR Test, page 22-129
POWER WINDOW MASTER SWITCH Input Test, page 22-126
Test, page 22-128

'-::~,- -------
FRONT PASSENGER'S WINDOW SWITCH Input Test, page 22-130

~~
22-124
Circuit Diagram
No.20I40A) :USA NO.20150A) :Camlda
UNDER HOllO FUSE/RELAY BOX

~
BAmRY
No.19180AI )-+-.:.;.~_;:'.
NNoo,,20
,~
BAT WHT IG, IG1 HOT in ON UI) and START (III) WHT/BLK BLK/VEL
NO.61~,5~
~40A)
:::l
(
!
...............
~ WINDOW
RELAY
POWER
No.Z3
\' 120Al
1
!;
2
No,12 I20AI
LGRN WHT GRN BlK
MASTER SWITCH
"
~P J
VMPl
,I,,
PASSENGER'S
~
DRIVER'S
.
:>
rf
l~HT
-\ 1~~~~lllr
OOWN
UP
~OFf
""'\, ,ON
POWER WINDOW CONTROL UNIT
ILED)
DNG)
upG
MAIN SWITCH
10
---'
14
,
RED VEL REO
BlK
2
(
13
3
BLU RED
,
BlU WHT GRN BLK
BLK
~
3
BLK
r,
T
5 }'
LJ
DRIVER'S WINDOW MOTOR
\U~6DN
Off
Off
PASSENGER'S WINDOW SWITCH
..I
-
G50'
I
-
[tl
M
PASSENGER'S WINDOW MOTOR
G501
G501
G201
__~_______________________________________ 22,2-125
Power Windows
Master Switch Input Test
NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the window master switch (A) (see page 22-133). 2. Disconnect the 14P connector (8) from the master switch.
~:-;:::;:-"!,,
___A
BLK
RED/VEL
BLK
GRN/WHT
ORN
3. Inspect the connector and socket terminals to be sure they are all making good contact. If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
22-126
r--:'I
J
4. With the connector still disconnected, make these input tests at the connector.
If all the input tests prove OK, go to step 5.
Cavity
Wire
Test condition
10 14 11 2
BLK
Check for continuity to . ground: i There should be continuity. Check for voltage to , ground: There should be battery voltage.
:
Poor ground (G5011

An open in the wire
GRN/WHT GRN/BLK
Ignition switch ON (III
Poor ground (G2011

An open in the wire
Blown No.6 (7.5AI fuse in the under-dash fuse/relay box Blown No. 22, 23 (20AI fuse in the under-dash fuse/ relay box
Faulty power window relay
7 4
RED/YEL RED/BLK
Connect the No. 11 and No.7 terminals, and the No.4 and No. 14 terminals,
and turn the ignition switch i ON (III.
Check for driver's window motor operation:
Faulty driver's window
motor
An open in the wire
It should run (the driver's

i
I
3 1
window moves down),

.
BLU/RED ' Connect the No.2 and No.1 terminals, and the No.3 BLU/WHT and No. 10 terminals, and
turn the ignition switch ON
Check for passenger's

window motor operation:
Faulty passenger's window motor switch
(III.
It should run (the passenger's window moves downl.
Faulty passenger's window An open in the wire
5. Reconnect the 14P connector to the switch, and perform the following input tests. If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty. Replace the power window master switch.
Cavity
Wire
Test condition
Possible cause if result is not
obtained Check for voltage between the No. 13 and No. 14

terminals:
13
I I
ORN
Connect the No. 11 and NO.7 terminals, and the No.4 and No. 14 terminals,
and turn the ignition switch
About 6 V should be
indicated with the driver's window motor running.
Faulty driver's window motor An open in the wire
ON (III.
I
22-127
Power Windows
Master Switch Test
1. Remove the power window master switch (see
3. Check for continuity between the terminals in each

page 22-1331. 2. Disconnectthe 14P connector from the switch (A).
Driver's Window Switch:
The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures on page 22-126. If the tests are normal, the driver's switch must be faulty. Passenger's Window Switch:
+
I
1
""3 4 5 6
Terminal
1
Main Switch " "
10
Position
ON OFF
2
\
UP
OFF ON OFF ON OOWN OFF
101"
12
13 14
0 0 0
0- -0 -0
0- -0
,-,
0- -0 0- r-O 0- -0 0- f--o
4. If the switch is faulty, replace the switch.
22-128
Driver's Window Motor Test

Motor Test:
,. Remove the door panel (see page 20-4).
Pulser Test:
1. Reconnect the 4P connector to the driver's window
motor, and reconnect the 20P connector to the 2. Disconnect the 4P connector (A) from the driver's
window motor.
power window master switch.
2. Connect the test leads of a voltmeter to the No.3 and No.4 terminals of the driver's window motor 4P connector.
3. Run the motor using the master switch. The voltmeter should read about 6 v. 4. If the voltage is not as specified, check for an open in the wires. If the wires are OK, replace the driver's
window motor.
3. Test the motor in each direction by connecting battery power and ground according to the table.
When the motor stops running, disconnect one
lead immediately.
\ Terminal
Direction
UP
DOWN
e
cl
cl
4. If the motor does not run or fails to run smoothly, replace it.
22-129
Power Windows
Passenger's Window Switch Input Test
1. Remove the switch panel (see page 20-41. 2. Disconnect the 5P connector (A) from the switch (B).
RED/BLU
BLU/RED BLU/WHT
B
GRN/BLK
3. Input the connector and socket terminals to be sure they are all making good contact.
Ifthe terminals are bent, loose or corroded, repair them as necessary, and recheck the system.

4. Reconnect the connector, and using a back probe, make these input tests at the connector. If any test indicates a
problem, find and correct the cause, then recheck the system. Cavity 3
Wire
Test condition
GRN/BLK
Test: Desired result Check for voltage to ground: There should be battery voltage.
Possible cause if result is not obtained Blown No. 6(7 .5A) fuse in the under-dash fuse/relay box Blown No. 22 (20A) fuse in the under-dash fuse/relay box
Faulty power window relay An open in the wire

Faulty master window switch An open in the wire
Poor Qround (G201) 2 BLD/WHT Ignition switch ON I Check for voltage to (II) ground: Althe master There should be battery window switch, voltage. press and hold down the
passenQer's swit~h
I
BLU/RED
I At the master I wi ndow switch,
Check for voltage to

ground:
Faulty master window switch An open in the wire
There should be battery voltage.
pull up and hold

the passenger's switch
22-130
,
5. Disconnect the 5P connector, and make these input tests. Cavity 1 5 Wire RED RED/BLU Test condition Connectthe No.2 terminal to the No. 1 terminal, and the No.4 terminal to the No.5 terminal, and turn the ignition switch ON (II), and press the down button on the power window
master switch for
I
r--:'I
Test: Desired result Check for passenger's

window motor operation: If
Possible cause ~ result is not obtained Faulty master's window switch
should run (the passenger's

window moves down).
An open in the wire
Faulty passenger's window

motor.
There should be battery Voltage.
the passenger's window. 6. If all the tests prove OK, the switch must be faulty. Replace it.
22-131
Power Windows
Passenger's Window Switch Test
1. Remove the switch panel (see page 20-41. 2. Remove the power window switch (AI from the door panel. 3. Disconnect the 5P connector (81 from the
passenger's power window switch.
Passenger's Window Motor Test

1. Remove the passenger's door panel (see page 2041. 2. Disconnect the 2P connector (AI from the
passenger's power window motor.
3. Test the motor in each direction by connecting
battery power and ground according to the table.

When the motor stops running, disconnect one
lead immediately.
1\
Terminal
I'... Terminal
Position ""
Direction
UP
DOWN
UP
OFF DOWN
V- IV
0
D
{)
0- c-()
()
0- -0 0- -0
4. If the motor does not run or fails to run smoothly, replace it.

switch.
22-132
t.=:..I
Master Switch Replacement
1. Remove the door grip (see page 20-41. 2. Remove the power window master switch (AI from
the door panel.
r--:'I
Passenger's Window Switch Replacement

1. Remove the door grip (see page 20-41. 2. Remove the power window switch (AI from the door panel.
3. Disconnect the 14P connector (81 from the switch.

4. Remove the three screws and the switch from the switch panel.
3. Disconnect the 5P connector (81 from the switch.

4. Remove the two screws and the switch from the switch panel.
22-133
Wipers/Washers
WINDSHIELD WIPER ARMS and LINKAGE
WIPER/WASHER SWITCH
Test, page 22-140

Replacement,page 22-140
'. - .0:.)v.. . ../

" /1
WINDSHIELD WIPER MOTOR
"----
Test, page 22-143

: 1--
__
-I..--r--'
J.~.
INTERMITTENT WIPER CIRCUIT (In the multiplex control unit)
22-134
,
WASHER TUBES Replacement, page 22-147 WASHER RESERVOIR Replacement, page 22-146
r--:'I a..=:.J
WASHER FLUID LEVEL SWITCH ICanada)
Test, page 22- 144

REAR WINDOW WASHER MOTOR Test, page 22-144 Replacement, page 22-146
WINDSHIELD WASHER MOTOR
Test, page 22-144

NOISE CONDENSER
Capacity Test, page 22-107
REAR WINDOW WIPER INTERMITTENT CONTROL UNIT Input Test, page 22-138
REAR WINDOW WIPER MOTOR Test page 22-143
REAR WINDOW WIPER ARM

-----
22-135
Wipers/Washers
Circuit Diagram - Windshield
No.20 i40A) . USA
UNDER HOOD FUSE/RELAY BOX
B~+ERYY
~~-+:--WHT~
IGI HOT i" ON Hli and START 11111
Noo,.1199118800AJj N
No.20
IGNITION SWITCH
No.20 150A] : Canada
BlK/VEl
I N.20130A1 I 1F"~I"I.,b",,",k"l -r-::r--vo--r-l-I::::::'::::!..:::::"::::::::'"
,---------r---GRN BlK
GRNIBLK - - - - - - - - - - '
14
WINDSHIELD WIPER/WASHER SWITCH
INT
6
v,;,,~,~' 'j~90
LO 13 12
uu ''Cuu)u uu/>--oryc'lM'ST!lM~T
voe
HI
GR N BlK
WHT BLU
5 BLUIRED BlU/BlK
11
"
B1
MULTIPLEX
Xl
CONlllOL
WHT/BLU
WINDSHiElD WIPER MOTOR
iHasbuilt iii intermittent " " wiper relav "

I'
UN"
BLU VEl
.
5
HI
LO
r
BLutwHT
\circu~
~ ~
r"-"-"
GAUGE ASSEMBLY
[Canadal
-fJ
I I
I
:
~3
G7
V6
I
I I
J4
PN'
WASHE RFLUID LEVEL 5WITCH (Closed
9 ?
I
WINDSHIELD WASHER
MOTOR
2 \Floatd own'
BL'
BlJ(
Bl'
BlJ(
BlJ(
Bl'
1
G201
.. _
.. J
G201
1 1
'G201 G401
1 1
G~l G5~
22-136
r:-:'I
J
Circuit Diagram - Rear Window
Nolill40AI : USA No.20 iSOAI : Canada
a..=:.J

NO.19 (80A) No20'
IGNmoN SWITCH
BLK!YEl
No.9
('OAI
BOX
UNDER- DASH fUSE/RELAY
GRN
GRN
LTJRN
7
GN
,
WIPER/WASHER SWITCH
REAR WINDOW WIPER MOTOR
REAR WINDOW
Ti
--
~,>
--~
~L:
,
WHT REO
OFF
8
W;
ON
1
,
LTGRN
BLK
LTGRN/BLk
LT GRN/BLK LTGRNIREO
LTGRN
J~
REAR WINDOW WIPER INTERMmENT CONTROL UNIT
i
)
LTGRr"LX
9
10
f 1
,
M
1
LTGRN
WINDOW WASHER REAR MOTOR
1 I
G553
'LX
NOO,
CONDENSER
1 1
G553
G'"
22-137
j
Wipers/Washers
Rear Window Wiper Intermittent Control Unit Input Test
1. Remove the right rear side trim panel (see page 20-51). 2. Disconnect the 20P connector (A) from the rear windowwiper intermittent control unit (81.
LT GRN/RED
WHTIRED
LT GRN
G\
1]%t7Utg~] ~~
I
I-
,BLK
LT GRN/BLK
3. Inspect the connector and socket terminals to be sure they are all making good contact . If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . If the terminals look OK, go to step 4.
22-138
r:-:'I a.=:J
J
4. With the connector still disconnected, make these input tests at the connectors.
If all the input tests prove OK, the control unit must be faulty. Replace it.
Cavity
Wire GRN
Test condition
Ignition switch ON , III) Under all
conditions
I Check for voltage to ground:

i
10
BLK
WHT/RED
Ignition switch ON (II) and rear

window washer
There should be battery voltage. Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be battery voltage. Attach to ground: The rear window wiper motor should run. Attach to ground:
The rear window wiper motor
Possible cause if result is not obtained o Blown No.9 110A) fuse in the under-dash fuse/relay box o An open in the wire o Poor ground IG553)
An open in the wire
Blown No.9 110A) fuse in the under-dash fuse/relay box Faulty rear window wiper/
LT GRN/
RED
switch ON Ignition switch ON (II) and rear

window wiper
washer switch An open in the wire
LTGRN
switch ON Ignition switch ON

(II)
Blown No. 9110A) fuse in the under-dash fuse/relay box

Faulty rear window wiper motor
should run. 20
LT GRN/
BLK
An open in the wire Blown NO.9 110A) fuse in the under-dash fuse/relay box
Faulty rear window wiper motor
An open in the wire
22-139
Wipers/Washers
Wiper/Washer Switch Test/Replacement
1. Remove the driver's dashboard lower cover (see page 20-60). 2. Remove the steering column covers (see page 17-9). 3. Disconnect the 14P connector (A) from the wiper/washer switch (8)
1
7
2
B
3~ 4
10111
12 13 14
4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch.
\.
Position
Terminal
\.
14
13
12
~
11
~
OFF
INT
~
~
LO
HI
Mist switch ON Washer switch ON
0
~
0 D
~
{)
22-140
r--:'I
t.=:.I

1. Before testing, troubleshootthe multiplex control system (see page 22-172).
2. Remove the dashboard lower cover.
3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals.
UNDERDASH FUSE/RELAY BOX CONNECTOR B 16PI WHT/BLU UNDERDASH FUSE/RELAY BOX CONNECTOR G II OP) UNDER-DASH FUSE/RELAY BOX CONNECTOR J IBP)
[Bffi ,
BLU/RED
BLK UNDER-DASH FUSE/RELAY BOX CONNECTOR Y 113P)
rnml~I:1
UNDER-DASH FUSE/RELAY BOX CONNECTOR X IBP)
,
If the terminals are OK, go to step 5.
[: 11121 ~:
\BLK
10
I/>[Bj
4. Inspect the connector and socket terminals to be sure they are all making good contact. If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system .
(cont'd)
22-141
Wipers/Washers
Control Unit Input Test (cont'd)
5. Reconnect the connectors, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system . If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly.
Cavity J4 Wire BLK Test condition , Under all I conditions i Under all
conditions
Y6 B1
BLK WHT/BLU
Ignition switch ON (II) and washer switch ON Ignition switch ON (II) and wiper switch OFF (wiper motor stopped) Ignition switch ON (II) and wipers in
! park position
Test: Desired result Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be battery voltage.
"_.
I Possible cause if result is not obtained

Poor ground (G501) An open in the wire Poor ground (G502)
B6
BLU/RED
Check for voltage to ground: There should be battery

voltage.
__
G7
BLU/WHT
Check for voltage to ground: There should be battery voltage. Check for voltage to ground: There should be battery
voltage.
X7
BLU/BLK
Ignition switch ON (II) and wiper switch in INT
- An open in the wire Blown No. 20 (20A) fuse in the under-dash fuse/relay box Faulty wiper/washer switch An open in th_e wire Blown No. 20 (20A) fuse in the I under-dash fuse/relay box Faulty wiper/washer switch Faulty windshield wiper motor An open in the wire Blown No. 20 (20A) fuse in the I under-dash fuse/relay box Faulty windshield wiper motor An open in the wire Blown No. 20 (20A) fuse in the under-dash fuse/relay box Faulty wiper/washer switch
An open in the wire
22-142
r:-:'I
Wiper Motor Test
Windshield:
1. Open the hood, and carefully remove the cap nuts and the wiper arms. Make sure they do not touch the hood. 2. Remove the hood seal and cowl cover.
B
I.!!.I
Rear Window:
1. Open the hatch, and remove the hatch trim panel (see page 20-53). 2. Disconnect the 4P connector (A) from the motor (8).
3. Disconnect the 5P connector (A) from the motor (8).
3. Test the motor by connecting battery power and ground according to the table. If the motor does not run or fails to run smoothly, replace it.
4. Test the motor by connecting battery power and ground according to the table. If the motor does not
run or fails to run smoothly, replace it.
1\
Battery
Terminal
\
Connected
(j")
\
Position
Terminal
LOW SPEED
8 8
i
HIGH SPEED
-=-(j") (j")
4. Test the wiper motor park switch by connecting an analog voltmeter between the No.4 (+) terminal and ground, and run the motor. The voltmeter
5. Test the wiper motor park switch by connecting an analog voltmeter between the No.5 (+) terminal
should indicate 12 V and 4 V or less alternately. If it

does not, replace the motor.
and ground, and run the motor at low or high speed. The voltmeter should indicate 12 V and 4 V or less alternately. If it does not, replace the motor.
,
22-143
Wipers/Washers
Washer Motor Test
1. Partially remove the right inner fender (see page 20-102). 2. Disconnect the 2P connectors (A) from the washer motors (8). 1. Partially remove the right inner fender (see page 20-102). 2. Disconnect the 2P connector (A) from the washer level switch.
Washer Fluid Level Switch Testl Replacement - Canada
3. Test the washer motor by connecting battery power and ground according to the table. 3. Remove the washer fluid level switch from the
\
Battery
Terminal
1 G)
reservoir.
Connected
NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (8) position according to the table.
4. If the motor does not run, replace it.
\
Position
Terminal
FLOAT UP FLOAT DOWN
_.

switch.
22-144
r--:'I
J
Windshield Wiper Motor Replacement
1. Open the hood. Remove the nuts IA) and the windshield wiper arms (8).
5, Scribe a line IA) across the link and windshield wiper linkage to show the original adjustment. Separate the windshield wiper linkage (8) from the wiper motor IC).
Nm 12.5 kgfm, 18lbfftl
2. Remove the hood seal and cowl cover. 3, Disconnect the 5P connector IA) from the wiper motor (8). 6. Install in the reverse order of removal, and note these items. Apply multipurpose grease to the moving parts.
Before reinstalling the wiper arms, turn the wiper
~=BD
E
switch ON, then OFF to return the wiper shafts to

the park position.
If necessary, replace any damaged clips, Check the wiper motor operation.
4. Remove the bolts IC), move windshield wiper linkage assembly (0) toward the passenger's side of the vehicle until it slides off of the pin IE), then
remove the assembly.
22-145
Wipers/Washers
Rear Window Wiper Motor Replacement
1. Open the hatch, and remove the hatch trim panel Isee page 20-53). 2. Remove the mounting nut IA), the wiper arm (8) and the special nut IC).
Washer Reservoir Replacement

1. Partially remove the right inner fender. 2. Disconnect the 2P connectors IA) from the washer motors (8) and level switch ICanada).
IZi
--c
A "') /9.8 Nm 11.0 kgfm, / 7.2Iblltl
8 Nm 10.8 kglm. 6.0Ibllt}
3. Disconnect the tubes IC) from the washer motors. 4. Remove the three bolts IA) and the washer reservoir (8).
3. Disconnect the 4P connector IA), remove the three mounting bolts (8), then remove the rear window wiper motor IC).
B
B~--~~--~~~
'd~>--~_+':; :.8 N.m

11.0 kglm. 7.2Ibllt}
__.(
9.8Nm 11.0 kglm, 7.2Ibllt}
4. Install in the reverse order of removal, and note these items.
Apply mUltipurpose grease to the moving parts.

Before reinstalling the wiper arm, turn the wiper
switch ON, then turn OFF to return the wiper shaft to the park positon. If necessary, replace any damaged clips.
Check the wiper motor operation.
22-146
a..=:J
Washer Tubes Replacement
1. Remove the right inner fender (see page 20- 102).
2. Remove the washer nozzles and clips, then remove the tubes.
R1,/',,)
(conrd)
22-147
Wipers/Washers
Washer Tubes Replacement (cont'd)
3. Install in the reverse order of removal. Take care not to pinch the washer tubes. Check the washer operation.
22-148
Accessory Power Socket

Circuit Diagram
BAmRY
~ ~
Accessory Power Socket Testl Replacement
No.20 [4OA1 . USA No.20 [50A[ : Canada
1. Carefully pry the accessory power socket (A) out

from the center lower cover.
2. Disconnect the 2P connector IB) from the socket.

No.19 [!KIAI
UNDER HOOD FUSE/RELAY
BOX
No.20
~NlnoN
'WITCII
ACC HOT in ACC (I) .nd ON IMI
3. Inspect the connector terminals to be sure they are

WHT RED
all making good contact. If the terminals are bent, loose or corroded,
repair them as necessary, and recheck the
NaJ8 [15AI
FUSE/RELAY
UNDER-DASH
BOX
system. If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals.
VEWGRN
There should be battery voltage. If there is no battery voltage, check for: - poor ground IG502).
I'<lWER ,oem ACCESSORY
- an open in the wire.
- blown No. 18 (15A) fuse in the under-dash fuse/relay box.
1
G5112
22-149

~;Y'"~'~'
"'=~.~.~.''-..rpANICBunON .. D
~TRANSMlnER
DRIVER'S DOOR LOCK SWITCH Test, page 22-161 Programming, page 22-161
Test, page 22-160

KEYLESS RECEIVER UNIT

IGNITION KEY SWITCH Test, page 22-91 PASSENGER'S DOOR LOCK ACTUATOR
Test, page 22-158
MUTIPLEX CONTROL UNIT Input Test, page 22-155
/8 ~/ ~
DRIVER'S DOOR SWITCH

'-,---
HATCH LATCH SWITCH
Test, page 22-97

HATCH LOOK ACTUATOR Test, page 22-159 PASSENGER'S DOOR SWITCH
DRIVER'S DOOR LOCK ACTUATOR/KNOB SWTICH
Actuator Test, page 22-158

Knob Switch Test, page 22-160
22-150
Circuit Diagram
No,ZO 140A) : USA NoZO(50A I :Canitda
(Fuse/relay box socket)
UNOER- HOOD FUSE/RELAY BOX
UNDER-DASH fUSE/RELAY BOX

BAT WHT
No,10(7.5A)
BATTERY
No.19180AJ
No.20
BlK/YEL
10'
""
lv
No.7 115AI
~10AI
WHT/RED
No 16 (20A)
tGl HOT"In 0N(III and START 11111

WHTlRED -
VL
HDRN
(Tonextpagei
, TRANSMiTTER)
--
--'~{ -
KEYLESS RECEIVER UNIT
WHT
WHT RED
BLU ORN
l'
0502
l
"\
J7
J'
K2
,
KEY
,
r
-~
~. ~
Y7 VB
11.
=a
---j6
M9
1. T
M7
" =
__ ~7
---r
1. 1.
P17
M6
~-
,-
LOCK KNOB
DOOR
'"
VEL
PASSENGER'S DOOR LOCK ACTUATOR
P16
J.
0
UN-
VEL/RED
VEL
YEl/BLK
VEL/BLK
VEL/BlK
VEL
[[p
WHT BLK
,
LOCK
LOCK
,
BLK
DRIVER'S DOOR lOCK KNOB SWITCH
r$
l1-Or'
DOOR LOCK
ACTUATOR
DRiVER-'
HATCH LOCK
ACTUATOR
Lj--J
'tot'
1
GSO,
r
GSOl
(conl'd)
22-151

Circuit Diagram (cant'd)
No.7 (15A! FUSE

~rom
revious page j
I
I
~-
~l
HORN RELAY
HEADUGIfT RELAY
TAUIGIfT RELAY
BLU/RED
IFuse/relay box socilet)

J6
F7
~
\
Y10 Y12
, ,-
~
X5
03
Q4
CARGO
AREA
L~HT
".
e11
8lU
WHT RN
LREO~O
GRN LTGRN ~ED REO r'HT
WHTIBLU
l
RED
COMBINATION
LIGHTSWrrCH
7
\
UN-
LOCK
LOCK
DRIVER'S
DOOfI
DRIVER'S
OOOR
SWITCH
~Iosed:
LOCK
SWITCH
lOooropen /
PASSENGER'S OQOR SWITCH ~Iosed : \ \lJGOropen /
~'
KEY
IGNITION
~ ,
HATCH LAT,,"
SWITCH 2 IClosed: ) '\Key inserted
SWITCH 2 ~IoSed:
ateh open;'
.LK
.LK
.LK
1
GSOl
-'L
1 1
G552
22-152
I.!!:..J
Keyless Receiver Unit Input Test
1. Remove the driver's dashboard lower cover (see page 20-591. 2. Remove the audio unit (see page 22-1001.
r:-:'I
3. Disconnect the 5P connector (AI from the keyless receiver unit (BI.
WHT/RED
If the terminals are bent loose or corroded, repair them as necessary, and recheck the system .
If the terminals are OK, go to step 5.
(conl'dl
22-153

Keyless Receiver Unit Input Test (cont'd)
5. With the connector still disconnected, make the input test at the connector . If test indicates a problem, find and correct the cause, then recheck the system . If the input test proves OK, go to step 6. Cavity 2 Wire BLu/ORN Test condition Under all conditions I Possible cause if result is not obtained Test: Desired result Check for continuity between ! An open in the wire the No.2 terminal and the No.2 terminal of the under-dash fuse/relay box connector K (17P). There should be continuitv. i
6. Reconnect the 5P connector, and make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, replace the keyless receiver unit. Cavity 1
Wire
BLK VEL
Test condition Under all

conditions Ignition switch
ON (II) 5 WHT/RED Under all conditions
Test: Desired result Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be battery voltaae. Check for voltage to ground: There should be battery voltaae.
Possible cause if result is not obtained Poor ground (G502) An ooen in the wire Blown No. 10 (7.5A) fuse in the under-dash fuse/relay box An open in the wire Blown NO.9 (lOA) fuse in the under-hood fuse/relay box An open in the wire
22-154
r:-:'I I..!:..I
1. Before testing, troubleshoot the multiplex control system (see page 22-172).
2. Remove the dashboard lower cover.

3. Disconnect the under-dash fuse/relay box connectors.
NOTE: All connectors are wire side of female terminals.

UNDER-DASH FUSE/RELAY BOX CONNECTOR C 114P) UNDER-DASH FUSE/RELAY BOX CONNECTOR F (12P) UNDER-DASH FUSE/RELAY BOX CONNECTOR J (BP)
1 6
2
7
8 19
= /10
11 12
BLU
BLU/RED
!
2
7
BLK
ORN
WHT
UNDER-DASH FUSE/RELAY BOX CONNECTOR K (17P)
UNDER-DASH FUSE/RELAY BOX CONNECTOR M (12P)
UNDER-DASH FUSE/RELAY BOX CONNECTOR P (1BP)
U ORN /
[:1/1<1/1bTI21>1>1]
UNDER-DASH FUSE/RELAY BOX CONNECTOR 0 (BP)
3
8 9 10 11 12
/ / /
1
1/ 12 1/114 15
16 17 18
YEL/BLK
I \
YEL/BLK
YEL
YEL
YEL
YEL/BLK
/ t
RED
UNDER-DASH FUSE/RELAY BOX CONNECTOR X (BP)
UNDER-DASH FUSE/RELAY BOX CONNECTOR Y (13P)
GRN
I \
VlZvDDlA 71
LTGRN/RED
2
8] 6 7
3
8
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system .
"
RED/WHT
WHT/BLK
YEL/RED
WHT/GRN
WHT/BLU
{f the terminals look OK, go to step 5.
(cont'd)
22-155

Control Unit Input Test (cont'd)
5. Reconnect all connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system . If all the input tests prove OK, go to step 6.
CaYi~ C11
Wire
Test condition
BLU
Attach to ground:
Parking, side marker, license plate lights, and taillights should come on.
Possible cause if result is not obtained Blown No.2 (15A) fuse in the underhood fuse/relay box Faulty taillight relay Faulty under-dash fuse/relay box An oDen in the wire
F7
BLU/RED
J2 J4 J6
WHT/RED BLK ORN
! !
I
J7 P18 WHT RED
03
GRN
Q4
1
I
LTGRN /RED
X5
i REDIWHT
Y7
WHT/BLK
Y8
YELJRED
Y10
WHT/GRN
Y12
WHT/BLU
Blown No. 15 or 17 (15A) fuse in the under-hood fuse/relay box o Faulty headlight relay 1 or 2 1 o An oDen in the wire I Under all conditions Check for voltage to ground: o Blown No.9 (15A) fuse in the underThere should be battery voltage. hood fuse/relay box I o An aDen in the wire Check for voltage to ground: o Poor ground (G501) Under all conditions o An aDen in the wire There should be 1 V or less. Under all conditions Attach to ground: Blown NO.7 (15A) fuse in the underThe horns should sound. hood fuse/relay box Faulty horn relay I o Faulty horns o An aDen in the wire Under all conditions Check for voltage to ground: o Blown No. 16 (20A) fuse in the underThere should be battery voltage. hood fuse/relay box o An aDen in the wire Hatch open o Poor ground (G552) : Check for voltage to ground: ! There should be 1 V or less. o Faulty hatch latch switch o An aDen in the wire Hatch closed o Faulty hatch latch switch Check for voltage to ground: There should be 5 V or more. o Short to around Driver's door open Check for voltage to ground: o Faulty driver's door switch o An aDen in the wire There should be 1 V or less. Driver's door closed Check for voltage to ground: o Faulty driver's door switch There should be 5 V or more. o Short to around Passenger's door open Check for voltage to ground: o Faulty passenger's door switch There should be 1 V or less. o An aDen in the wire Passenger's door closed Check for voltage to ground: o Faulty passenger's door switch o Short to around There should be 5 V or more. Ignition key inserted into Check for voltage to ground: o Poor ground (G401) the ignition switch There should be 1 V or less. o Faulty ignition key switch o An open in the wire Ignition key removed from Check for voltage to ground: Faulty ignition key switch the innition switch There should be 5 V or m9re. __ Short to nround Driver's door lock knob Check for voltage to ground: Poor ground (G501) switch unlocked There should be 1 V or less. Faulty driver's door lock knob switch - - - ~_IlQQlLnjn~h~_w~r~L _______ . __ ._________ Driver's door lock knob Check for voltage to ground: Faulty driver's door lock knob switch switch locked There should be 5 V or more. Short to Qround Driver's door lock knob Check for voltage to ground: Poor ground (G501) switch locked There should be 1 V or less. Faulty driver's door lock knob switch o An onen in the wire Driver's door lock knob Check-for voltage to ground: Faulty driver's door lock knob switch switch unlocked Short to around There should be 5 V or more. Driver's door lock switch Check for voltage to ground: Poor ground (G501) unlocked Faulty driver's door lock switch There should be 1 V or less. o An aDen in the wire Driver's door lock switch in Check for voltage to ground: : Faulty driver's door lock switch neutral There should be 5 V or more. ~hort to ground Driver's door lock switch Check for voltage to ground: . Poor ground (G501) locked There should be 1 V or less. , Faulty driver's door lock switch , An open in the wire hDriver's door lock switchiri Check for voltage to ground: Faulty driver's door lock switch neutral There should be 5 V or more. o Short to nround
Attach to ground:
Headlights should come on.
+-:
22-156
r:-:'I --=:.J
, J
6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connectors. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly.
Cavity K2
Wire
BLU/ORN
Test condition Under all conditions
M7 MS
YELJBLK YEL YELJBlK YEL YEL YELJBlK
M6 MS
P16 P17
Connect J7 terminal to M7 [MS] terminal, and M9 [M7] terminal to J4 terminal. Connect J7 terminal to M6 [MS] terminal, and M8 [M6] terminal to J4 terminal. Connect J7 terminal to P17 [P16] terminal, and P16 [P17] terminal to J4 terminal.
Test: Desired result Check for continuity between the K2 terminal and the keyless receiver unit 5P connector disconnected: There should be continuity. Check actuator operation: The driver's door lock actuator should lock [unlock]
Check actuator operation: The passenger's door lock actuator should lock [unlock] Check actuator operation: The hatch lock actuator should lock [unlock]
Possible cause if result is not obtained An open in the wire
Faulty driver's door lock actuator An open in the wire
Faulty passenger's door lock actuator An open in the wire
Faulty hatch lock actuator An open in the wire
22-157

Door Lock Actuator Test
Driver's door:
1. Remove the driver's door panel (see page 20-4).
2. Disconnect the 2P connector from the actuator.
Passenger's door:
1. Remove the passenger's door panel (see page 204). 2. Disconnect the 2P connector from the actuator.
3. Check actuator operation by connecting power and
ground according to the table. To prevent damage to the actuator, apply battery voltage only
momentarily.
3. Check actuator operation by connecting power and
ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily,
1\
Terminal
Position
Terminal Position
c------UNLOCK
LOCK
8 8
8
(B
LOCK UNLOCK
(B
. ._-
----
(B
4. If the actuator does not operate as specified, replace it.
4. If the actuator does not operate as specified, replace it.
22-158
r--:'I t=:..I
Hatch Lock Actuator Test
,. Open the hatch. 2. Remove the hatch lower trim panel (see page 2053). 3. Disconnect the 2P connector from the hatch lock
actuator.
4. Check actuator operation by connecting power and ground according to the table. To prevent damage
to the actuator, apply battery voltage only

momentarily.
"'" Terminal Position "-
LOCK UNLOCK
e
EEl
EEl
22-159

Door Lock Knob Switch Test
2. Disconnect the 3P connector from the actuator.
Door Lock Switch Test

2. Remove the two mounting screws and the door
\J
Tr
NO
II
t'
lock switch.
i~
I'
I'
e 1
- ___ I
~-=---=-----'------_\
2
terminals.
3. Check for continuity between the terminals. There should be continuity between the No.1 and No.2 terminals when the door lock switch is in the LOCKED position. There should be continuity between the No.2 and No.3 terminals when the door lock switch is in the UNLOCKED position. 4. If the continuity is not as specified, replace the door
There should be continuity when the door lock knob switch is in the LOCKED position. There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No.2 and No.3
terminals.
There should be continuity when the door lock knob switch is in the UNLOCKED position.
There should be no continuity when the door lock
lock switch.
knob switch is in the LOCKED position. 5. If the continuity is not as specified, replace the door lock actuator.
22-160
r--:'I t=:..I
Transmitter Test
NOTE: If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty. Replace the transmitter. If any door is open, you cannot lock the door with the
transmitter.
Transmitter Programming
Storing transmitter codes: The codes of up to three transmitters can be stored in the keyless receiver unit memory. (If a fourth code is
If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. The doors do not lock or unlock with the transmitter if
the ignition key is inserted in the ignition switch. 1. Press the lock or unlock button five or six times to reset the transmitter.
stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the hatch are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec., push the transmitter lock or
unlock button with the transmitter aimed at the
receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec., turn the ignition switch OFF.
If the locks work, the transmitter is OK. If the locks don't work, go to step 2. 2. Open the transmitter and check for water damage. If you find any water damage, replace the
transmitter.
4. Within 1 to 4 sec., turn the ignition switch ON III). 5. Within 1 to 4 sec., push the transmitter lock or
unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the
driver's side of the dash. 6. Within 1 to 4 sec., turn the ignition switch OFF.
If there is no water damage, go to step 3. 3. Replace the transmitter battery (A) with a new one, and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button
five or six times.
7. Within 4 sec., turn the ignition switch ON (II). 8. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the mupltiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec., turn the ignition switch OFF. 10. Within 4 sec., turn the ignition switch ON (II). 11. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hearthe sound of the door lock
actuators. Within 1 to 4 sec., push the transmitter
If the doors lock and unlock, the transmitter is OK. If the doors don't lock and unlock, go to step 4.
lock or unlock button again. 13. Within 10 sec., aim the transmitters (up to two 4. Reprogram the transmitter, then try to lock and unlock the doors. If the doors lock and unlock, the transmitter is OK. If the doors don't lock and unlock, replace the
transmitter. additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons.
Confirm that you can hear the sound of the door

lock actuators after each transmitter code is stored.
14. Turn the ignition switch OFF, and pullout the key.
15. Confirm proper operation ofthe transmitter.
22-161
Immobilizer System
IMMOBILIZER INDICATOR LIGHT

Bulb Replacement, page 22-63
ECM
Replacement, page 11-4 Substitute known-good for testing, page 11-5
~--~~-
"
'--0
--- -- i
,
~~.-
, j" r-l ___

, I
'
IMMOBILIZER CONTROL UNIT-RECEIVER

~TRANSPONDER
/"
(Built into the ignition key)
~~/~O
IGNITION KEY
22-162
r:-:'I a=:.J
System Description
The vehicle is equipped with an immobilizer system that will disable the vehicle unless the proper ignition key is used.
This system consists of a transponder located in the ignition key, an immobilizer control unit-receiver, an indicator
light, and the ECM.

When the key is inserted in the ignition switch and turned to the ON (II) position, the immobilizer control unit-receiver
sends power to the transponder in the ignition key. The transponder then sends a coded signal back to the immobilizer control unit-receiver which then sends a coded signal to the ECM.
IMMOBILIZER CONTROL UNITRECEIVER
\
c===+----+
ECM FUEL SUPPLY SYSTEM
IGNITION KEY (Has built-in transponder)
KEY CYLINDER
If the proper key has been used, the immobilizer indicator light will come on for about 2 seconds, then go off. If the wrong key has been used or the code was not received or recognized by the unit, the indicator light will come on for about 2 seconds, then it will blink until the ignition switch is turned OFF. If the ignition switch is turned OFF, the indicator will blink for about 5 seconds to signal that the unit has reset correctly, then the indicator will go off.
If the customer has lost his key, and cannot start the engine, contact Honda Customer Relations.
IMMOBILIZER INDICATOR LIGHT BLINKING PATIERN:
IGNITION SWITCH
ON OFF
PROPER KEY INSERTED INDICATOR LIGHT ON
5 sec
OFF
WRONGKEV INSERTED
INDICATOR LIGHT
ON OFF
- ~
I",
22-163
Immobilizer System
Circuit Diagram
UNDfR-ItOOD FUSE/RELAY BOX BArrERY
NolO (40AI . USA
No.2il (50AI : Canada
+ l-+-'V>--1"""""'.n-+----------- WHT/RED
NolO
NO.19 (BOA)
No.9110AI
----t"----,
BAT
n.1G1
IGNITION SWITCH
No.6
I1SAI
IGI HOT in ON (II) and START III)
WHT RED
W~h
WHT BLK WHT BLK
BLK/YEl
GAUGE ASSEMBLY
IMMOBILIZER
PGM A MAIN RELAY' No.17 IISAI
UNDER DASH FUSE/RELAY
b
l~~ATOR
BOX
IUW)
YEl/BLK
YEL/BlI(
YEL/BLK
t----+YEll LK
YELIBLK
WHT RED
BLU DRN
KEY
PGM-FI MAIN RELAY 2
YEL/GRN
GRN YEl
RED/YEL
YEl/BlK
h
YEl/BLK
A2
IMMOBILIZER CONTROL UNIT - RECEIVER
YEL/BLK
BRN YEL
RED/BlU
El IMOflR
E7 MAIN RlY
~1
E9
AJ
E3
E27
IGPI
1GP2
lG2 A23
lG'
IMOCe
DATA LINK PARKING BRAKE SWITCH BRAKE
'CM
lGl
CONNECTOR
{DLC]
All
LEVEL SWITCH
FLUID
fun
""
PUMP
I
G551
P
BTL
G101
22-164
r:-:'I t=:.I
Troubleshooting
Before troubleshooting the immobilizer system, troubleshoot any ECM Diagnostic Trouble Codes (DTCs) (see page 11-3), and make sure the ECM has no
malfunction.
5. Disconnect the 7P connector (A) from the

immobilizer control unit-receiver (8).
Note these items before troubleshooting: Due to the action of the immobilizer system, the engine takes slightly more time to start than on a
vehicle without an immobilizer system .
)r"\.~",,,=--A
When the system is normal, and the proper key is

inserted, the indicator light comes on for 2 seconds,
then it wi II go off. If the indicator starts to blink after 2 seconds, or if the

engine does not start, remove any other immobilizer
keys or large key fobs on the key ring, then repeat the
starting procedure.
If the engine still does not start, continue with this

procedure.
5. Check for voltage between the immobilizer control

unit-receiver 7P connector No.7 terminal and body
ground. 1. Turn the ignition switch ON (II) with proper key.

2. Check to see if the immobilizer indicator light

comes on.
YES-Go to step 7. NO-Check for these problems: Blown No.9 (lOA) fuse in the under-hood fuse/ relay box . An open in the WHT/RED wire . 7. Check for voltage between the immobilizer control unit-receiver 7P connector NO.6 terminal and body ground with the ignition switch ON (II).
Does the indicator light blink?
YES-Disconnect the 7P connector from the

immobilizer control unit-receiver, then go to step 9.
NO-Check for these problems, then go to step 3. Blown No.9 (lOA) fuse in the under-hood fuse/relay box . An open in the wire between the gauge assembly
and the immobilizer control unit-receiver.
A faulty immobilizer indicator light..

An open in the wire between the gauge assembly
YES- Go to step 8. NO-Check for these problems:
and the under-hood fuse/relay box .

page 20-59).
4. Remove the steering column lower cover (see page
17-9) .
Blown No. 5(15A) fuse in the under-hood fuse/relay box . Faulty PGM-FI main relay 1. An open in the YEUBLK wire .
(cont'd)
22-165
Immobilizer System
Troubleshooting (cont'd)
8. Check for voltage between the immobilizer control unit-receiver 7P connector No.6 terminal and No.1 terminal. Is there battery voltage? YES-Go to step 12. NO-Check for these problems: Open on the BRN/YEL wire . Faulty ECM . 9. Remove the driver's dashboard lower cover (see page 20-59).
10. Remove the steering column lower cover (see page
12. Check for continuity between the immobilizer

control unit-receiver 7P connector No.2 terminal
and ECM terminal E27.

YES-Go to step 13. NO-Repairthe open in the RED/BLU wire .

13. Reconnect the 7P connector to the immobilizer control unit-receiver.
14. Check for voltage between the immobilizer control unit-receiver 7P connector No.4 terminal and body ground with the parking brake lever pulled, then
released.
17-9).
Is there 1 V or less, then 5 V or more? 11. Disconnect the 7P connector (A) from the
immobilizer control unit-receiver (B).
YES-Replace the immobilizer control unit-receiver.

After replacing the immobilizer control unitreceiver, rewrite the unit with a Honda PGM
Tester. NO-Check for these problems: Faulty parking brake switch or a poor body ground of the parking brake switch . Repair short or open in the GRN/ORN wire .
22-166
r:-:'I
Immobilizer Control Unit-Receiver Replacement
page 20-59).
2. Remove the steering column covers (see page 179).
3. Disconnect the 7P connector (A) from the

immobilizer control unit-receiver (8).
4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (e). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with a Honda
PGM Tester, then check the immobilizer system .
22-167

REAR CEILING LIGHT Test, page 22-96

~ ... ~
CEILING LIGHT ISPOTLIGHTS
Test, page 22-96
IGNITION KEY LIGHT
Test, page 22-91
----
' .". D
~'"
/--\
"':'.<--./
/'
/,/
ECM
MULTIPLEX CONTROL UNIT (Built into the under-dash fuse/relay box) Troubleshooting, page 22-172 Input Test, page 22-175
22-168
Circuit Diagram
No.20 (40A) : USA
IGNITION SWITCH

BUCtyEL
NolO (SOA) :Canada
BAmRY
No,19(80AI
NG.20
t,
No.317.SAJ
r~
WHT
No.9110A)
--~,
I
I
No,10 (7.SA)
1131 HOT in ON (III
and START (1111
IGNITION KEYUGHT
ITo nut pagel
qJ
'"
<1.
VEl W1IT RED
(Fuse/relay box socket)
J2
i--
r
J4
-f03
"
X5
<1,
a.
\
CARGO
'18
AREA UGHT
BlK
iff
MULTIPLEX CONTROL INSPECTION CONNECTOR
WHT
GRN
A2
GAN
LTGR IRED
Y
RLj
RED/WliT
GAUGE ASSEMBLY
(
1c
DRIVER'S DOOR SWITCH
{Closed: 'I
I
RED
,
PASSENGER'S DOOR SWITCH (Closed: ) IDooropen
IGNITlON
\Dooropen
(CIond,
SWITCH
KEY
Keyinslrted )
'
{
2
BlK
HATCH
LATCH
SWITCH
(=';,.. )
"
G201
1 1 .
.,
G552
BlK
(conrd)
22-169

No.3 (7.5AJ FUSE
1'ln the under -l'Iood

Ifuse/relay box
y
eo
~
1< '-
IGNITION
UGHT ILEDI
CEILING LIGHT
KEY
IMMOBILIZER CONTROL UNIT RECEIVER
'OS
MODULATOR CONTROL UNIT
TAILLIGHT
RELAY
~
5
WHT
,U<
UNDER - DASH FUSE/RELA YBOX
GRN RED
I I I
GRN ORN BAN
lfusa/relay box socketl
I
Y6
07
C8
Xi
Y1
i-+\-
~
\
,
06 05 F8
\
DAYTIME RUNNING lIGHTS CONTROL UNIT ICanadal
F1
DB
ell
y
o
0
'~
BlU RED
SRSUNIT
GRNj"'D
GRNr O
"T' "
RED
. - . -IUSAI j
GRN/RED
'-"-"~
GRN ORN
,U<
COMBINATlON
LIGHT SWITCH
BlU
(Canadal
DRIVER'S SEAT8ELT SWITCH 1 iClosed: \ \Unbuckle )
1 (CI.... , \
Aoatdown I
BRAKE FLUID LEVEL SWIT""
r'-~
1 1
G551
G301
BlK
,U<
1 I
GANIORN
I ~~WS :
7 .
I
:
I . I . .
BRAKE SWITCH
PARKING
"Closed: "
\Leveruj) "
DAVTIME RUNNING
CONTROL
L .. _ .. _
.. .J
"
G50'
22-170
System Descriptions
The Multiplex Control System has four internal functions: Multiplexing (send multiple signals over shared
wires)
Multiplex Communication
To reduce the number of wire harnesses, digital signals are sent via shared multiplex communication lines rather than sending normal electrical signals through individual wires.
Wake up/sleep (runs at full power only on demand to reduce battery draw) Fail-safe (fixes or ignores faulty signals) Self-diagnosis (Mode 1 for the system, Mode 2 for input lines)
The system controls the function of these circuits:
The input signals from each switch are converted to digital signals at the central processing unit (CPU). The digital signals are sent from the transmitting unit
to the receiving unit as serial signals. The transmitted signal is converted to a switch signal at the receiving unit, and it operates the related component or monitors a switch.
Entry light controllignition key light and ceiling light)

Wiper/washer intermittent wipe and park functions
Keyless/power door lock

Meter assembly, temperature gauge, and indicator
lights HVAC (compressor and fan control)

Key-in reminder
There are exclusive communication lines between the ECM, the gauge assembly, and the under-dash fuse/relay box.
Wake-up and Sleep

The multiplex control system has "wake-up" and
"sleep" functions to decrease parasitic draw on the
Headlight reminder Seatbelt reminder
battery when the ignition switch is OFF. In the sleep mode, the multiplex control unit stops functioning (communication and CPU control) when it
is not necessary for the system to operate. As soon as any operation is requested (for example, a door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function.
When the ignition switch is turned OFF, and the

driver's or front passenger's door is opened, then
closed, there is about a 10 second delay before the control unit goes from the wake-up mode to the sleep mode.
If any door is open, the sleep mode will not function.
If a key is in the ignition switch, the sleep mode will

not function. When in sleep mode, the draw is reduced from
70-80 rnA to less than 10 rnA.
Fail-safe
To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode,
the output signal is fixed when any part of the system

malfunctions (for example a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally .
22-171

Troubleshooting
Mode 1 Tset 1. Remove the driver's dashboard lower cover (see
7. Check for continuity between terminal 4 of the under-dash fuse/relay box connector J and body ground. Is there continuity?
page 20-59). 2. Check the NO.9 (lOA) fuse in the under-hood fuse/ relay box and the No. 10 (7.5A) fuse in the underdash fuse/relay box. Are the fuses OK? YES-Go to step 2. NO-Find and repair the cause of the blown fuse . 3. Turn the ignition switch ON (11I.lfthe driver's seat be It is unbuckled the seat belt reminder will
chime 6 times.
YES-Replace the under-dash fuse/relay box . NO-Repair the open in the wire.lf the wire is ok, repair G301 . 8. If ther are any DTCs present, the spotlight and ceiling light will blink to indicate the DTC(s). If more than one DTC is present, the DTCs will be displayed in ascending order, If there are no DTCs the spotlight and ceiling light will not blink again after the mode 1 indication. Are there any OTes?
4. Set the ceiling light to the center position and close all the doors. 5. Connect the special tool to the multiplex inspection
connector.
YES-Go to step 9. NO-Go to the Mode 2 test. 9. Troubleshoot the DTC(s) in the order indicated using the following charts.
If a faulty control unit is suspected, substitute it
6. After about 5 seconds the spotlight and ceiling light should come on for 2 seconds, go out, then blink on for 0.2 second to show the system is now in mode 1. Did the spotlight and ceiling light indicate mode
with a known food part and recheck for DTCs, If the DTC(s) is still present, go to the next step listed fa r the DTC. If the DTC(s) is no longer present replace the
original part.
I?
22-172
r--:'I L=:..I
Individual OlCs Multiplex Probable Cause
OlC
1 The multiplex control unit cannot
receive signals from the gauge
assembly. 1. Faulty power or ground to the gauge assembly 2. Faulty gauge assembly 3. Faulty under-dash fuse/relay box 2
The multiplex control unit cannot
receive signals from the ECM 1. Faulty power or ground to the ECM -2. Faulty ECM 3. Faulty under-dash fuse/relay i box Internal failure of the multiplex
control unit
1.
Faulty under-dash fuse/relay box
The gauge assembly cannot receive
J
6
signals from the multiplex control unit and the ECM 1. Faulty power or ground to the gauge assembly 2. Faulty gauge assembly
The ECM cannot receive signals from multiplex control unit and the
M uI' I 0 TCs tlplex Multiplex Probable Cause OTC 1,2 and 3 Short to ground on one of the communication wires. & ECM DTC 1. I Short to ground on the YEL wire between the PCM terminal E24 P0600 Simultane and the under-dash fuse/relay ously box terminal E10 2. . Short to ground on the WHT/ GRN wire between the Gauge assembly terminal A2 and under-dash fuse/relay box terminal K10 1 and 6 ~en in the communication wire Simultane 1. Open in WHT/GRN wire between the under-dash fuse/ ously relay box terminal Kl0 and the Gauge assembly terminal A2 Open in the communication wire 2 and 5 Simultane 1. Open in the YEL wire between the under-dash fuse/relay box ously terminal E10 and ECM terminal E24
gauge assembly 1. Faulty power or ground to the ECM 2. Faulty ECM. Before replacing a Faulty ECM/PCM make sure it has the latest software revision. Update if
necessary before swapping or replacing.
,
(cont'd)
22-173

Troubleshooting (cont'd)
Made 2 Tes!
4. If all inputs were confirmed, or multiple circuits failed at the same time in mode 2, go to the multiplex sleep mode test. If a single switch fails in mode 2, troubleshoot its circuit.
1. From Mode 1, disconnect the special tool from the multiplex inspection connector for 5 to 10 seconds, and then reconnect it. 2. The spotlight and ceiling light should come on for 2 seconds, go out, then blink twice, 0.2 seconds each time. The system is now in mode 2. 3. Operate the switches listed below: If the circuit is ok, the spotlight and ceiling light will blink once. If the circuit is faulty, the lights will not blink. Tip: Operate the switches most closely related to the problem you are diagnosing is a quick way of testing the circuits integrity.
switch
Windshield washer switch Windshield wiper switch Driver's door switch passenger's door switch
Hatch latch switch
lights blinks when: washer switch pulled Switch in the I NT pas. As door is opened As door is opened
As hatch is Opened As parking brake applied Driver's door lock Pushed to lock and unlock switch Driver's lock knob Knob in unlock or lock position switch AlC switch ON and AlC switch blower switch ON . switched to the .PARK Headlight switch position Brake pedal position Brake pedal pressed switch Parking brake switch
22-174
r:-:'I
Multiplex Control Unit Input Test
1. Remove the driver's dashboard lower cover Isee page 20-59). 2. Disconnect the under-dash fuse/relay box connectors C, E, F, J, K, 0, P, Q, X and Y.
NOTE: All connectors are wire side of female terminals. CONNECTOR C Il4PI CONNECTOR E (13P) CONNECTOR F (12P) GRN/RED (USA) GRN/ORN (Canada) CONNECTOR J (8P) WHT/RED
I..!::..I
1
7
2 8
3 9
/\11
F=I
4 12
5 13
GRN/ORN
! \
V V
VEL CONNECTOR 0 (12P)
I
1 6
2
7
F=I 8\ 9 10 11 12
BLU
GRN/RED
BLK
I (5J6D m tffiJ 1
6
7
CONNECTOR K (17PI
CONNECTOR P (18P)
[3
I: 1516 fYill9110 11~ 112]

GRN/RED
/ V/
5 11/ 3 1/ 12 1/114 15
16 17 18
WHT/GRN
RED
CONNECTOR Q (8P) LTGRN/RED GRN/ORN
CONNECTOR X (8P) WHT/BLK
CONNECTOR V (13PI BRN/VEL
GRN
~'7'~"j
BLU/RED
L/
BLU/RED
~1/~ITsl717 I 8 J
RED/WHT
BLK
/ [:I~I:~m 1
(conl'd)
22-175

Multiplex Control Unit Input Test (cont'd)
3. Inspect the connector and socket terminals to be sure they are all making good contact. If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . Ifthe terminals look OK, go to step 4.
Cavity J4
Y6 Y1
Wire
BLK BLK BRN/YEL
Test condition
Under all conditions Under all conditions

Check for voltage to ground: There should be 1Vor Jess. Check for voltage to ground: There should be 1 V or less.
J2
WHT/RED
: Parking brake lever ' Check for voltage to ground: There should be battery voltage down, turn the igntion switch ON (II) while the Brake system indicator is on for the buld check. Check for voltage to ground: There should be 1 V or less when the Brake system. I Blown No.9 (lOA) fuse in the under-hood Under all conditions Check for voltage to ground: There should De battery voltage. fuse/relay box o An ODen in the wire
Possible cause if result is not obtained Poor ground (G201) An open in the wire Poor ground {G501} An open in the wire An open in the wire Short to ground Faulty ABS modulator-control unit
4. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the underdash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly.
Cavity
Q3
Wire GRN
Test condition Driver's door open Driver's door closed
04
LT GRN/RED
08 C8 F1 F8
GRN/ORN GRN/ORN GRN/RED (USA) GRN/ORN (Canada) GRN/RED BLU/RED
Passenger's door open I Passenger's door . dosed Parking brake lever uo Parking brake lever down
Test: Desired result Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. , Check for voltage to ground: There should be 5 V or more . Check for voltage to ground: There should be 1 V or less. Che~k for voltage to ground: There should be 5 V or more.
o o
o o o o o o o o
Possible cause if result is not obtained Faulty driver's door switch An open in the wire Faulty driver's door switch Short to ground Faulty passenger's door switch An open in the wire Faulty passenger's door switch Short to around Faulty parking brake switch An ooen in the wire Faulty parking brake switch Short to ground
05 06 P18
I
BLU/RED
I \
Ignition switch ON (II), driver's seat belt is unbuckled. Ignition switch ON (II), driver's seat belt is buckled.
Check for voltage to ground: There should be 1 V or less.
o o o
I
I
Check for voltage to ground: There should be 6 V or more. Check for voltage to ground: There should be 1 V or less.
-
Faulty driver's seat belt switch Poor ground (G551) An open in the wire Faulty driver's seat belt switch Short to ground Faulty hatch latch switch Poor ground (G552) An o"pen in the wire Faulty hatch latch switch Short to Qround Faulty ignition key switch Poor ground (G401) An o'p_en jn the wire __ Faulty ignition key switch Short to ground
I
,
RED
CChopen
Hatch closed
X5
RED/WHT
I Ignition key in the
ignition switch
Check for voltage to ground: There should be 5 V or more I Check for voltage to ground: There should be 1 V or less.
o o
~nftion key out of the

ignition switch
cfleck for voltage to ground: There should be 5 V or more.
22-176
r--:'I I.!:!.I
Cayi~
Wire
X8
WHT/BLK
! Under all conditions

I
Test condition
Test: Desired result Attach to ground: The ignition key

light should come on.

07
GRN/RED
I
Ceiling light switch in the middle position, all doors closed
Attach to ground: The ceiling light, spotlights should come on.
e11
BLU
Attach to ground: Dash lights should
come on.
F8 GRN/RED
Brake fluid reservoir float in down position (brake fluid removed) Brake fluid reservoir float in up position (brake fluid at full level) Under all conditions
Check for voltage to ground:
i There should be less than
1 V.
Blown NO.3 (7.5A) fuse in the under-hood fuse/relay box Blown LED An QQen in the wire Blown No.3 (7.5A) fuse in the under-hood fuse/relay box Faulty ceiling light An 9j}en in the wire Blown NO.2 (1SA) fuse in the under-hood fuse/relay box Faulty taillight relay An open in the wire Faulty brake fluid level switch An open in the wire
Check for voltage to ground: There should be 5 V or more.
Faulty brake fluid level switch Short to ground
E10
VEL
K10
WHT/GRN
' Under all conditions
Check for voltage to ground: There should be battery voltage in the sleep mode and 3-7 volts when awake. Check for voltage to ground: There should be battery voltage in the sleep mode and 3-7 volts when awake.
An open or short in the wire

,
An open or short in the wire
22-177
Restraints
Restraints
Special Tools ................................................................. 23-2
Seat Belts
Component Location Index ......................................... Front Seat Belt Replacement ....................................... Rear Seat Belt Replacement ........................................ Inspection ...................................................................... Child Seat Tether Anchor Removal/Installation ........ 23-3 23-4 23-6 23-8 23-9
SRS (Supplemental Restraint System)

Component Location Index ......................................... 23-13 Precautions and Procedures ....................................... 23-14 General Troubleshooting Information ....................... 23-23 DTC Troubleshooting Index ........................................ 23-28 Symptom Troubleshooting Index ............................... 23-30 System Description ...................................................... 23-31 Circuit Diagram ............................................................. 23-34 DTC Troubleshooting ................................................... 23-36 SRS Indicator Circuit Troubleshooting ....................... 23-105 Component Replacement/Inspection After Deployment ..................................................................23-112 Driver's Airbag Replacement ...................................... 23-113 Front Passenger's Airbag Replacement ..................... 23-114 Side Airbag Replacement ............................................ 23-115 Airbag Disposal ............................................................ 23-116 Cable Reel Replacement .............................................. 23-119 SRS Unit Replacement ................................................. 23-122 Side Impact Sensor Replacement ............................... 23-123 OPDS Unit Replacement .............................................. 23-124 Front Impact Sensor Replacement .............................. 23-125
Restraints
Special Tools
Tool Number Descri~tion 07HAZ-SGOO500 Deployment Tool 07PAZ-0010100 SCS Service Connector 07SAZ-TB4011A SRS Inflator Simulator (4) 07TAZ-SZ5011A SRS Simulator Lead C (~)*2 ! 07TAZ-001020A Backprobe Adapter, 17 mm . 07XAZ-S1A0200 SRS Simulator Lead E i (j) , SRS Simulator Lead F 07XAZ-SZ30100 @ SRS Simulator Lead H i 07YAZ-S3AA100 *1: Included In SRS Tool Set 07MAZ-SM5000B *2: Use with the stacking patch cords from TIN 07SAZ-001 OOOA, Backprobe Set. Ref.No.
CD*' C?)
- -
--- Qty 1 1 1 1 2 1 1 1
~,
23-2
Seat Belts
REAR CENTER BELT and REAR SEAT BELT BUCKLES step 1 on page 23-8
Inspection, page 23-9
SHOULDER ANCHOR ADJUSTER

step 8 on page 23-4
FRONT SEAT BELT

Replacement, page 23-4 Inspection, page 23-9
--------
CHILD SEAT TETHER ANCHORS

Removal!1 nstallation, page 23-11
REAR SEAT BELT

Replacement, page 23-7 Inspection, page 23-9
FRONT SEAT BELT BUCKLES

step 1 on page 23-6
23-3
Seat Belts
Front Seat Belt Replacement
SRS components are located in this area. Review the SRS component locations (see page 23-13) and the precautions and procedures (see page 23-14) in the SRS
6. Remove the upper anchor cover (AI. and remove the upper anchor bolt (B).
B
7/16-20 UNF 32 Nm 13.3 kgfm, 24lbfftl
NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation.
Front Seat Belt

buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Slide the front seat forward fully. 4. Remove the lower anchor cap (A), and remove the lower anchor bolt (BI.
B B
7. Disconnect the seat belt tensioner connector (A). Remove the retractor mounting self-tapping ET
screw (BI. and the retractor bolt (C), then remove the front seat belt (D) and retractor (E).
6x1.0mm 3.4 Nm 10.35 kg!m, 2.5Ibfftl
D~
A~
~--
-)
-I
'
\\)1:", c.______rSJP '

5. Remove the rear side trim panel (see page 20-51 I.
@."
8. If necessary, remove the front seat belt protector

(F).
23-4
9. Remove the B-pillar upper trim (see page 20-501 10. Remove the shoulder anchor adjuster(AI.
Upper anchor bolt construction:
UPPER ANCHOR
COLLAR
\
BUSHING
~ij
TOOTHED LOCK WASHER
/
/
Lower anchor bolt construction:

8x1.25mm
BUSHING WASHER WAVE WASHER LAR COt COr R
22 Nm 12.2 kgfm, '6Ibfftl
11. Install the seat belt in the reverse order of removal,

If the threads on the retractor mounting selftapping ET screw are worn out, use an oversized self-tapping ET screw (PIN 90133-SZ4-00301 made specifically for this application.
Check that the retractor locking mechanism
~)!~,i(~1
LOWER ANCHOR BOLT
--j'
\
~I:
functions (see page 23-91. Assemble the washers, collars, and bushing on the upper and lower anchor bolts as shown. If the seat belt tensioner has been deployed
replace the front seat belt protector with a new one.
o
-J .'
Ii
J)
.. ~.
SPRING WASHER
LOWER ANCHOR
TOOTHED LOCK WASHER
Apply liquid thread lock to the anchor bolts

before reinstallation.
Before installing the anchor bolts, make sure there are no twists or kinks in the front seat belt.
Make sure the seat belt tensioner connector is
plugged in properly. Reconnect the negative cable to the battery. Enter the anti-theft code for the radio, then enter
Reset the clock. Do the ECM/PCM idle learn procedure (see page 11-1391.
(conl'dl
23-5
Seat Belts
Front Seat Belt Replacement (cont'd)
Seat Belt Buckle
7. Install the buckle in the reverse order of removal,

buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the front seat (see page 20-71). 4. Detach the seat belt switch connector clip (A), seat belt buckle tensioner connector clip (8), and harness clip (e).
Assemble the washers on the center anchor bolt as shown. Apply liquid thread lock to the center anchor bolt before reinstallation. If the seat belt tensioner has been deployed, replace the front seat belt protector with a new one. Apply liquid thread lock to the seat mounting bolts before reinstallation Reconnect the negative cable to the battery. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Reset the clock. Do the EeM/peM idle learn procedure (see page 11-139).
SPRING WASHER
CENTER ANCHOR BOLT
TO~
5. Remove the center anchor bolt (A), and remove the seat belt buckle (8).
@~@-~
\ COLLAR
;\
CENTER ANCHOR
LOCK WASHER
7/16-20 UNF
32 Nm (3.3 kgfm. 24Ibfft)
6. Pull the seat belt switch/tensioner harness (e) out through the hole on the seat track.
23-6
Rear Seat Belt Replacement

NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage
them during removal and installation.
5. Install the seat belt in the reverse order of removal,

If the threads on the retractor mounting self-
Rear Seat Belt

1. Remove the rear seat cushion (see page 20-801. 2. Remove the lower anchor bolt (AI.
A 7/16-20 UNF 32 Nm 13.3 kgf.m, 24lbfltl
tapping ET screw are worn out, use an oversized
self-tapping ET screw !PIN 90133-5Z4-00301 made specifically for this application. Apply liquid thread lock to the anchor bolt before rei n5tallation, Check that the retractor locking mechanism functions (see page 23-91. Before installing the anchor bolt, make sure there
are no twists or kinks in the rear seat belt.
~
~----Forward
~..~
~~ .
'--'
3. Remove the rear side trim panel (see page 20-511.

4. Remove the retractor mounting self-tapping ET
screw (AI, and the retractor bolt (BI. then remove the rear seat belt (CI and retractor (DI.
B
7/16-20 UNF 32 Nm 13.3 kgf.m, 24lbfltl
/
A
6x 1.0mm
3.4 Nm 10.35 kgf.m, 2.5 Ibfltl
(conl'dl
23-7
Seat Belts
Rear Seat Belt Replacement (cont'd)
Center Belt and Seat Belt Buckles
1. Remove the seat cushion (see page 20-80). 2. Remove the center anchor bolts (AI. and remove the seat belt buckles (B) and center belt (e).
A
7/16-20 UNF
32 Nm 13.3 kgfm,
7. Remove the seat belt guide (A) from the pin (B), and release the center belt (e) from the seat belt guide.
24lbf.ft)
8. Remove the retractor mounting bolt (A), and the retractor bolt (B), then remove the center belt (e) and retractor (D) from the seat-back frame (E).
B 7/16-20 UNF 32 Nm 13.3 kgfm, 24Ibf!t}
3. Remove the right seat-back (see page 20-80). 4. Remove the seat-back cover (see page 20-82). 5. Remove the seat-back pad from the seat-back frame (see step 3 on page 20-81). 6. Remove the screw, and release the hooks (A), then
remove the retractor cover (B).
Fastener Location
.. : Screw, 1
23-8
Inspection
9. Install the seat belt and buckles in the reverse order
Check that the retractor locking mechanism functions (see step 1 on page 23-10). Assemble the washers on the center anchor bolt as shown (except center shoulder belt). Apply liquid thread lock to the anchor bolts before reinstallation. Before installing the center anchor bolt, make
sure there are no twists or kinks in the center belt.
Center anchor bolt construction:
/CENTER ANCHOR ,/ BOLT
For front seat belt retractors with seat belt tensioners, review the SRS component locations (see page 23-13) and the precautions and procedures (see page 23-14) in the SRS section before performing repairs or service.
Retractor, Front and Rear

1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 from the mounted position. The seat belt should lock when the retractor is leaned over 40. Do not attempt to disassemble the retractor.
Front:
W~" ~
/
~/
~I~~TOOTHED
~
LOCK WASHER
2.50
40
II _
I'
40
40 ------- 40
CENTER ANCHOR
Forward
..
40
Inside
Rear:
40 .----r-- ..
"~5'~n 15>'"
Forward
..
Inside
3. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of
the seat belt for any reason.
(conl'd)
23-9
Seat Belts
Inspection (cont'd)
Retractor, Rear Center
1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 from the mounted position.
In-vehicle
1. Check that the seat belt is not twisted or caught on anything. 2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts and check that the washers and other parts are not damaged or improperly installed. 3. Check the seat belts for damage or discoloration. Clean with a shop towel if necessary. Use only
soap and water to clean.
NOTE: Dirt build-up in the loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol.
Inside
..
..
Forward
4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact. 5. For rear center shoulder belt, check that the seat belt locks when pulled out over 400 mm (15.7 in.) with the seat-back folded down. 6. Make sure that the seat belt will retract automatically when released. 7. For each passenger's seat belt, check the seat belt
retractor locking mechanism ALR (automatic locking retractor). This function is for securing child seats.
3. Lean the retractor over 40, and make sure that the seat belt does not lock when pulled out over 900 mm (35.4 in.). Do not attempt to disassemble the
retractor.
4. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason.
-1 Pull the seat belt all the way outto engage the ALR. The seat belt should retract with a ratcheting sound, but not extend. This is
normal.
-2 To disengage the ALR, release the seat belt and allow itto fully retract, then pull the seat belt out part-way. The seat belt should retract and
extend normally.
8. Replace the seat belt with a new assembly if there

is any abnormality. Do not disassemble any part of the seat belt for any reason.
23-10
Child Seat Tether Anchor Removal/Installation

Middle
,. Remove the child seat tether anchor cover IA) in the rear trim panel (8).
Side
1. Remove the rear bulkhead covers from both sides
Isee page 20-511. 2. Remove the anchor bolt IA). then remove the child seat tether anchor (8) from behind the seat-back on each side of the cargo compartment. Do not remove the toothed washer IC) from the tether
anchor.
(J 'kJ------------
I~
........
------=-~---=~
"--.-
B~
C 8x 1,25 mm
22 Nm 12.2 kgfm. 161bf1t1
2. Remove the anchor bolt IC). then remove the child seat tether anchor ID). Do not remove the toothed washer IE) from the tether anchor.
3. Install the anchor in the reverse order of removal.
~~~
.~.
~~
8 x 1.25 mm 22 Nm 12.2 kgfm. 161bf1t1
3. Install the anchors in the
reverse
order of removal.
.J
23-11
SRS
LEFT FRONT IMPACT SENSOR RIGHT FRONT IMPACT SENSOR
SRS INDICATOR Troubleshooting, page 23-105 SIDE AIR BAG CUTOFF INOICATOR
DRIVER'S AIRBAG Replacement. page 23-113 Disposal, page 23-116
FRONT PASSENGER'S AIRBAG Replacement, page 23-114 Disposal, page 23-116
OPOS SENSORI SEAT BACK Replacement, page 20-75 FRONT PASSENGER'S SIDE AIRBAG
,
CABLE REEL Replacement, page 23-119 MEMORY ERASE SIGNAL IMES) CONNECTOR 12P)
Replacement,
page 23-115 Disposal. page 23-116
FRONT PASSENGER'S SlOE IMPACT SENSOR
Replacement,
page 23-123
FRONT PASSENGER'S SEAT BELT BUCKLE TENSIONER DRIVER'S SEAT BELT BUCKLE TENSIONER ORIVER'S SlOE AIRBAG Replacement, page 23-115 Disposal, page 23-116
23-13
SRS
Precautions and Procedures
General Precautions
Please read the following precautions carefully before
performing airbag system service. Observe the instructions described in this manual, arthe airbags
Steering-related Precautions
Cable Reel Alignment
Misalignment of the cable reel could cause an open in
could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks,
or deformation.
the wiring, making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed (see step 6 on page 23-121). Installation of the steering wheel Installation of the cable reel Installation of the steering column Other steering-related adjustment or installation
Do not disassemble the cable reel. Do not apply grease to the cable reel. If the cable reel shows any signs of damage or
contamination, replace it with a new one. For example, it does not rotate smoothly.
Before removing any SRS parts (including the

disconnection of connectors), always disconnect the
SRS connector. Use only a digital multi meter to check the system. If it
is not a Honda multimeter, make sure its output is 10
mA (O.OlAI or less when switched to the lowest value

in the ohmmeter range. A tester with a higher output
could cause accidental deployment and possible

injury .
Do not put objects on the front passenger's airbag .

The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations
before disconnecting the battery cable.

Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine
control module (ECMI idle learn procedure (see page 11-1391.
23-14
,
Airbag Handling and Storage
Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of an airbag during service, observe the following precautions. Store the removed airbag with the pad surface up. Never put anything on the airbag. Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200F/
93C).
Never perform electrical inspections to the airbags, such as measuring resistance. Do not position yourself in front of the airbag during removal, inspection, or replacement.
To prevent damage to the airbag, keep it free from any oil, grease, detergent, or water.
Refer to the scrapping procedures for disposal of a damaged airbag.
(conl'd)
23-15
..I
SRS
Precautions and Procedures (cont'd)
SRS Unit, Front Impact Sensors, and Side Impact Sensors
Be careful not to bump or impact the SRS unit, front impact sensors, or side impact sensors whenever the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit, front impact sensors, and side impact sensor. The airbags could accidentally deploy and cause damage or injury. Do not disassemble the SRS unit, front impact sensors, or side impact sensors. Turn the ignition switch OFF, disconnect the battery
negative cable, and wait at least 3 minutes before
beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. Be sure the SRS unit, front impact sensors, and side impact sensors are installed securely, with the mounting bolts torqued to 9.8 Nm (1.0 kgfm, 7.2Ibfft) Do not spill water or oil on the SRS unit, front impact sensors, or the side impact sensors, and keep them away from dust. Store the SRS unit, front impact sensors and side impact sensors in a cool (less than 104F/40C) and dry (less than 80 % relative humidity, no moisture)
area .
After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front
impact sensors, and other related components (see
page 23-112). After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side and the SRS unit. After a collision in which the airbags or the side airbags did not deploy,
inspect for any damage or any deformation on the SRS unit, front impact sensors, and the side impact
sensors. If there is any damage, replace the SRS unit and/or the sensors.
23-16
l
Wiring Precautions
Some of the SRS wiring can be identified by a special
yellow outer covering, and the SRS connectors can be
Precautions for Electrical Inspections

When using electrical test equipment, insert the
probe of the tester into the wire side of the connector.

Do not insert the probe of the tester into the terminal
identified by their yellow color. Observe the instructions described in this section. Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace
the harness.
side of the connector, and do not tamper with the connector .
c o
==c~
. __ /
Use a U-shaped probe. Do not insert the probe forcibly.
Be sure to install the harness wires so they do not get pinched or interfere with other parts.
c-.--------~t:=)~_____
Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Make sure all SRS ground locations are clean, and
grounds are securely fastened for optimum metal-tometal contact. Poor grounding can cause intermittent
problems that are difficult to diagnose.
, J
(cont'd)
23-17
SRS
Spring-loaded Lock Connector
Some SRS system connectors have a spring-loaded lock.
Front Airbag Connectors: Disconnecting Side Airbag Connector: Disconnecting
To release the lock, pull the spring-loaded sleeve (A) and the slider (8) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pullan the sleeve and not on the connector half.
B
To release the lock, pull the spring-loaded sleeve (A) toward the stop (8) while holding the opposite half of the connector. Then pull the connector halves apart. Be
sure to pull on the sleeve and not on the connector.
A
Connecting
Connecting Hold both connector halves, and press them firmly
together until the projection (C) of the sleeve-side

connector clicks.
1. To reconnect, hold the pawl-side connector, and

press on the back ofthe sleeve-side connector in the direction shown. As the two connector halves
are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve.
2. When the connector halves are completely

connected, the pawl is released, and the springloaded sleeve locks the connector.
23-18
,
Backprobing Spring-loaded Lock Connectors
When checking voltage or resistance on this type of
connector the first time, you must remove the retainer to insert the tester probe from the wire side.
Seats with Side Airbags

Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back
cover, cushion, etc.) of seats with and without airbags
are different, make sure you install only the correct NOTE: It is not necessary to reinstall the removed retainer; the terminals will stay locked in the connector housing.
replacement parts.
SIDE AIRBAG LABEL
A To remove the retainer (Al, insert a flattip screwdriver
When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat.
Do not repair a torn or frayed seat-back cover.
(BI between the connector body and the retainer, then carefully pry out the retainer. Take care not to break the
connector.
Replace the seat-back cover.

After a collision in which the side airbag was
deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced.
B Never put aftermarket accessories on the seat (covers,
pads, seat heaters, lights, etc.).
,
(cont'd)
23-19
SRS
Disconnecting System Connectors
Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the front impact sensors, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting
connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors
or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures . Before disconnecting SRS unit connector A (1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). Before disconnecting SRS unit connector B (8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). Before d'isconnecting the floor wire harness 4P connector (5), disconnect both seat belt tens'loner 2P connectors (6,7).
DRIVER'S
SEAl BElT
WIRE HARNESS
BUCKLE nNSIONER
FRONT
PASSENGER'S
SEAT BELT
BUCKLE
FRONT PASSENGER'S SIDE IMPACT
SENSOR
23-20
,
,. Disconnect the battery negative cable, and wait at
least 3 minutes.
Side Airbag 4. Disconnect both side airbag 2P connectors (A) from
Driver's Airbag
the floor wire harness.
2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (B) from the cable reel.
Front Passenger's Airbag
3. Disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B.
(cont'd)
23-21
SRS
Seat Belt Tensioner
5. Disconnect both seat belt tensioner 2P connectors (AI from the floor wire harness.
,
SRS Unit
7. Disconnect SRS unit connector A, SRS unit connector B, and/or SRS unit connector C from the SRS unit.
,I,
,I
',I
","""
Seat Belt Buckle Tensioner

6. Disconnect both seat belt buckle tensioner 4P connectors (AI.
23-22

DTC (Diagnostic Trouble Codes)
The self-diagnostic function of the SRS system allows it
to locate the causes of system problems and then store this information in memory. For easier troubleshooting, this data can be retrieved via a data link circuit.
o
Reading the DTC

When the SRS indicator is on, read the DTC using either of the following methods: PGM Tester "SRS" Menu Method: Connect the Honda PGM Tester (A) to the 16P data link connector (DLC)(B), and follow the Tester's prompts in the "SRS" menu. If the Tester indicates no DTC, no communication, DTC 3-6 to 3-10, DTC 4-6 to 4-10, DTC 9-1, or DTC 9-2, double-check by using the "SCS" menu method.
When you turn the ignition switch ON (II), the SRS indicator will come on. If it goes off after 6 seconds, the system is normal. If there is an abnormality, the system locates and
defines the problem, stores this information in memory, and turns the SRS indicator on. The data will remain in the memory even when the ignition switch is turned off or if the battery is disconnected.
When you connectthe Honda PGM Tester to the 16P data link connector (DLC) to short the SCS terminal, and turn the ignition switch ON (II), the SRS indicator will indicate the diagnostic trouble code (DTC) by the number of blinks. When you connect the Honda PGM Tester to the 16P data link Connector (DLC), you can retrieve the DTC in the Honda Systems "SRS" menu. After reading and recording the DTC, proceed with the troubleshooting procedure for this code.
Precautions
Use only a digital multimeterto check the system. If it's not a Honda multi meter, make sure its output is 10 mA (O.OlA) or less when switched to the smallest
value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause accidental airbag deployment and possible injury . Whenever the ignition switch is ON (II), or has been turned OFF for less than 3 minutes, be careful not to
bump the SRS unit; the airbags could accidentally

deploy and cause damage or injuries. Before you remove the SRS harness, disconnect the driver's airbag connector, the front passenger's airbag connector, both side airbag connectors, both seat belt buckle tensioner connectors, and both seat belt tensioner connectors. Make sure the battery is sufficiently charged. If the battery is dead or low, measuring values won't be correct. Do not touch a tester probe to the terminals in the SRS unit or harness connectors, and do not connect the terminals with a jumper wire. Use only the
backprobe set and the Honda PGM Tester. Backprobe

spring-loaded lock type connectors correctly.
(cont'd)
23-23
SRS
PGM Tester "SCS" Menu Method (retrieving the flash codes): The SRS indicator (A) indicates the OTC by the number of blinks when the Honda PGM Tester (S) is connected to the OLC (data link connector) (16P) (t). 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (S) to the OLC (C), and follow the Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). Reading the main code:
Incaseof1~10
Count the number of blinks.

Example:
1.251.2$ 1.25 1.25 1.25
ON
OFF
1-1-1-1-1-1
+
Maincode=
=3
In case of 11~15 Four fast blinks count as 10. Add any further blinks together as shown.
Example:
ON
OFF
A -11111111-1-f---f---1
1.25 1.25 1.25 1.25
10
0.15
Main code=
3. Make sure the SCS line is grounded, then turn the ignition switch ON (II). The SRS indicator comes on for about 6 seconds, and then goes off. Then it will blink to indicate the OTC (see the table below). 4. Read the OTC. 5. Turn the ignition switch OFF, and wait for 10
seconds.
In case of 20 or more Two sets of four fast blinks count as 20. Add any further blinks together as shown.
Example:
ON
A -11111111-11111111-1-1
1.25 1.25 1.25
10
0.15
0.15
6. Disconnect the Honda PGM Tester from the OLC. 7. Do the troubleshooting procedure for the OTC. Patterns of OTC Indications:
The DTC consists of a main code and subcode.
OFF
Main code=
10
= 21
Reading the subcode:

Count the number of blinks.
Example:
s: Second
65 35 25 35
0.350.350.35 0.3 5 0.3 5 0.3 5 0.3 5
:~F
IlJ::::::U:::Lr
1-11-11-1
First emitting Main code Subcode
1-1-1
I-I I-I
ON
OFF Sub code=
1-1-1-1-1-1-1-1
+
+
=4
If the main code is '3', and the subcode is '4', record a DTC 3-4.
23-24
l
Including the most recent problem, up to three different DTCs can be indicated (see example 1 below). In case of a continuous failure, the DTC will be indicated repeatedly (see example 1 below). In case of an intermittent failure, the SRS indicator will indicate the DTCs one time, then it will stay on (see example 2 below).
If both a continuous and an intermittent failure occur, both DTCs will be indicated as continuous failures .
When the system is normal (no DTCs), the SRS indicator will stay on (see example 3). If the SRS indicator comes on continuously without a DTC, there may be a problem with the system. If the SRS indicator does not come on as indicated above, always check for an open or a short to ground in the SCS circuit before troubleshooting the system. Example of DTC Indications:
1. Continuous failure, SRS Indicator blinks like this:
'.25 '.25
25
0.35
0.35
.....
0.35
s: Second
ON
OFF
Bulb check
period
Main code (2) Subcode (1)
DTC2-'
Most recent problem
DTC '-3 Second-most recent

problem
DTC ,-,
Third-most recent problem
2. Intermittent failure, SRS Indicator blinks like this:
Indications are repeated in case of continuous failure.
ON
OFF
Bulb check
-=_----'='----'===--'===~~
-
case of intermittent failure.
Indicator stays on in
period
DTC5-'
3. Normal (no failure), SRS Indicator blinks like this:
ON
OFF
Bulb check period No OTe, system is normal, the indicator stays on.
J
(cont'd)
23-25
SRS
Erasing the DTe Memory
Troubleshooting Intermittent Failures

If there was a malfunction, but it doesn't recur, it will be
stored in the memory as an intermittent failure, and the
SCS service connector 07PAZ-0010l00 To erase the OTC(s) from the SRS unit, use a Honda PGM Tester (see the Honda PGM Tester SRS Vehicle System Supplement) or the following procedure. 1. Make sure the ignition switch is OFF. 2. Connect the SCS service connector (A) to the MES 2P connector (B). 00 not use a jumper wire.
SRS indicator will come on. After checking the OTC, troubleshoot as follows: 1. Read the OTC (see "Reading the OTC"). 2. Erase the OTC memory (see "Erasing the OTC Memory"). 3. With the shift lever in neutral, start the engine, and let it idle. 4. The SRS indicator will come on for about 6 seconds and then go off.
5. Shake the wire harness and the connectors, take a
test drive (quick acceleration, quick braking, cornering), turn the steering wheel fully left and right, and hold itthere for 5 to 10 seconds. If the problem recurs, the SRS indicator will come on. 6. If you can't duplicate the intermittent failure, the system is OK at this time.
A 07PAZ-0010l00
3. Turn the ignition switch ON (II). 4. The SRS indicator will come on for about 6 seconds, and then go off. Remove the SCS service connector from the MES connector within 4 seconds after the
indicator goes off.
5. The SRS indicator will come on again. Reconnect

the SCS service connector to the MES connector within 4 seconds after the indicator comes on.
6. When the SRS indicator goes off, remove the SCS

service connector from the MES connector within 4
seconds. 7. The SRS indicator will blink two times indicating

that the memory has been erased.
8. Turn the ignition switch OFF, and wait for 10 seconds. 9. Turn the ignition switch ON (II) again. The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.
23-26
Initializing the OPDS (Occupant Position Detection System) Unit

SCS service connector 07PAZ-001 01 00 When a seat-back cover, seat-back cushion, andlor OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: Make sure the front passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the seat. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (A) to the DLC (16P) (8), and lollowthe Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (C) to the MES 2P connector (D). Do not use a jumper wire.
C 07PAZ-0010100
4. Turn the ignition switch ON (II). 5. The SRS indicator comes on lor about 6 seconds and goes off. Remove the SCS service connector lrom the MES
connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds
after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector lrom the MES connector within 4 seconds. 8. Watch the SRS indicator . lithe indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. If the indicator stays on without lirst blinking, the OPDS is not initialized. Read the DTC. If DTC 15-1 is indicated, repeat the initialization procedure. II another DTC is indicated, go to the appropriate page in the DTC Troubleshooting Index. 9. Turn the ignition switch off, and disconnect the PGM Tester.
4 sec or less
Blinking
SRS indicator
~
ON
OFF
MES
connector terminals
CONNECTED - - - -
DISCONNECTED
23-27
SRS
OTC Troubleshooting Index
DTe 1-1 1-2 1-3 Detection Item Open in driver's airbag inflator Increased resistance in driver's airbaq inflator
Short to another wire or decreased resistance in driver's airbag
Notes (see page 23-361 (see paQe 23-361 (see page 23-371
1-4 1-5 2-1 2-2 2-3 2-4 2-5 3-1 3-2 3-3 3-4 3-5 21-1 21-3 21-4 21-5 4-1 4-2 4-3 4-4 4-5 22-1 22-3 22-4 22-5 5-1 5-2 5-4 5-8 6-3
6-4_~
inflator Short to power in driver's airbaq inflator Short to ground in driver's airbag inflator Open in front passenger's airbag inflator Increased resistance in front passenger's airbag inflator
Short to another wire or decreased resistance in front passenger's
I (see paQe 23-391 ' (see page 23-401 (see page 23-421 (see page 23-421 (see page 23-431 (see (see (see (see (see (see (see (see (see paQe page page page page paQe page page page 23-451 23-461 23-481 ?3-481 23-491 23-511 23-521 23-541 23-551
airbag inflator Shortto power in front passenger's airbaq inflator Short to ground in front passenQer's airbag inflator Open in driver's seat belt tensioner
Increased resistance in driver's seat belt tensioner Short to another wire or decreased resistance in driver's seat belt tensioner Short to power in driver's seat belt tensioner Short to ground in driver's seat belt tensioner Open or increased resistance in driver's seat belt buckle tensioner Short to another wire or decreased resistance in driver's seat belt
buckle tensioner
Short to power in driver's seat belt buckle tensioner
Short to ground in driver's seat belt buckle tensioner Open in front passenger's seat belt tensioner
Increased resistance in front ~asse~.9.~r'~_s_eat belttensioner Short to another wire or decreased resistance in front passenger's seat belt tensioner
(see page 23-561 (see page 23-571 , (see paQe 23-581 (s~age 23-581 (see page 23-601 (see page 23-61) (see page 23-631 (see page 23-641 (see page 23-651 (see page 23-661 (see paQe 23-681 (see page 23-691
Short to power in front passenQer's seat belt tensioner Short to ground in front passenger's seat belt tensioner
Open or increased resistance in front passenger's seat belt buckle tensioner Short to another wire or decreased resistance in front passenger's
seat belt buckle tensioner Short to power in front passenger's seat belt buckle tensioner Short to Qround in front jlassenoer's seat belt buckle tensioner Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-6, check battery/system voltage. If the voltage is low, repair the charging system before troubleshooting the SRS.
6-7 6-8 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6
23-28
,
DTC Detection Item Notes
9-1
Internal failure of the SRS unit. If intermittent, ',t could mean internal
failure of the unit or a faulty indicator circuit. Refer to
(see page 23-69)
9-2
9-3 9-4 9-6 9-7 10-1 10-2 10-3 10-4 10-5 10-6 10-7 11-1 11-3 11-4 11-5 12-1 12-3 12-4 12-5 13-1 13-2 13-3 13-4 14-1 14-2 14-3 14-4 15-1 15-2 15-3
Troubleshooting Intermittent Failures (see page 23-26). NOTE: Before troubleshooting DTC 9-1 or 9-2, check battery/system voltage. If the voltage is low, repair the charging system before troubleshooting the SRS. Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-26). NOTE: Before troubleshooting DTC 9-1 or 9-2, check battery/system voltage. If the voltage is low, repair the charging system or replace the battery before troubleshooting the SRS. Faulty driver's seat belt buckle switch Faulty front passenger's seat belt buckle switch Faulty left front impact sensor Faulty right front impact sensor Seat belt and seat belt buckle tensioners (and airbag(s)) deployed Driver's side airball deployed Seat belt and seat belt buckle tensioners (and airbag(s)) and driver's side airbag deployed Front passenger's side airbag deployed Seat belt and seat belt buckle tensioners (and airbag(s)) and front passenger's side airbag deployed , Driver's and front passenger's side airbags deployed Seat belt and seat belt buckle tensioners (and airbag(s)) and driver's and front passenqer's side airbaqs deployed
Open or increased resistance in driver's side airbag inflator Short to another wire or decreased resistance in driver's side airbag . inflator
(see~e23-71)
(seepage 23-74) (see page 23-77) (see page 23-79) (see page 23-69)
. .-
(see page 23-81 ) (see page 23-82) (see page 23-83) (see page 23-85) (see page 23-86) (see page 23-87) (see page 23-88) (see page 23-90) (see page 23-70)
Short to power in driver's side airbag inflator Short to ground in driver's side airbag inflator
Open or increased resistance in front passenger's side airbag inflator Short to another wire or decreased resistance in front passenger's
side airbag inflator Short to power in front passenger's side airbag inflator Short to ground in front passenger's side airbag inflator Internal failure of the driver's side impact sensor
No signal from the driver's side impact sensor Faulty pO'{ller supply to the driver's side imp.Bct sensor Internal failure ofthe front passenger's side impact sensor No siqnal from the front passenQer's side impact sensor
I (see page 23-92)

(see page 23-70) (see page (see page (see page . (see page (see page 23-94) 23-95) 23-96) 23-99) 23-104)
(see page 23-91)

---
Faulty power supply to the front passenger's side impact sensor Faulty OPDS unit or OPDS not initialized
Faul~ side airbaq cutoff indicator circuit
I Faulty OPDS sensor
J
23-29
SRS
Symptom SRS indicator doesn't come on Diagnostic procedure Also check for SRS Indicator Troubleshooting (see page 23-105) SRS Indicator Troubleshooting (see . Inability to retrieve OTCs with the step 1 on page 23-107) PGM Tester. Retrieve the flash codes using the SCS menu method (see page 23-24) . Make sure nothing is on the front OTC 15-2 troubleshooting passenger's seat . If the side airbag cutoff indicator I stays on after the ignition switch is turned ON (II), initialize the OPOS unit (see page 23-27). - If the side airbag cutoff indicator operates normally, the system is OK. - If the side airbag cutoff
indicator stays on, replace the
SRS indicator stays on when in "SCS" menu method
Side airbag cutoff indicator stays on after bulb check (If the indicator stays on, it does not set a OTC). Side airbag cutoff indicator is flashing
OPDS sensor (see section 20). The sensor is part of the seatback pad.
23-30
System Description
SRS Components
Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (8), the driver's airbag (e), the front passenger's airbag (D), seat belt tensioners (I), seat belt buckle tensioners (JI, and front impact sensors (K). Since the driver's and front passenger's airbags use the same sensors, both normally inflate at the same time. However, it is possible for only one airbag to inflate. This can occur when the severity of a collision is at the margin, or threshold, that determines whether or not the airbags will deploy. In such cases, the seat belt will provide sufficient protection, and the supplemental protection offered by the airbag would be mininal. Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an occupant position detection system (OPDS). This system consists of sensors (G) and an OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the passenger's side airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the side airbag cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the side airbag cutoff indicator will go off after a few seconds, alerting the driver that the passenger's side airbag will deploy in a side impact.
8 C
~E
(conl'd)
23-31
SRS
SRS Operation
The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Belt Tensioners and Seat Belt Buckle Tensioners (1) A front impact sensor must activate and send electric signals to the microprocessor. (2) The microprocessor must compute the signals and send them to the tensioners. (3) The charges must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) (1) A front impact sensor must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). (3) The inflators that received signals must ignite and deploy the airbags. Side Airbagls) (1) A side impact sensor must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger's head is in the deployment path of the side airbag. (3) The inflator that received the signal must ignite and deploy the side airbag.
,_
..
.. _ .. _
'.lNT
'~T
..
..
_ .. _ .. _ .. _
.. -
.. ~o"
_ .. _ .. IWltiIsideairtllgsl
DR~'S
PASSENGER'S SIDE A1RBAG

INFLATOR
P.l.SSENGER'S
SIDE AIRtIAG
INRATDR
..."
ARST
ORMR'S
""''''
..." ""'''
SECOND INI'LATOR
""" """
PASSNGER'S
SECOND
INRATOR
."
FUSE/RELAV
UNDER-DASHl
M~O~OCESSOR ,lid DIAGNOSTIC CIRCUIT
TRIGGERt:mCUIT
OLe
w:s
scs
IDC
LHTSIOE SU1BElT
RlGffTSlot
r>RlVER'S
TENSIOmR
,UOF("
SEAT BEll BUCKLE

TENSIONER
TENSiONER
SEAT BELl
PASSENGER'S !)EATBRT TENSIONER
FRONT
23-32
,
Self-diagnosis System
A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the SRS is operating normally. If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the SRS. The SRS must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC) (see page 23-231.
23-33
SRS
Circuit Diagram
BATTERY
CRIVER'S
A~BAG
ORIVER'S
FIfIST INFLATOR
AIRMO SECOND INFLATOR
,
1G1HOTinONIIII .nd START 11111
101
,
~~
11
,
FRONT PASSENGtR'S AIRBAG FIRST INfLATOR
fRONT
PASSENGER'S
AIRBAG SECOND INFLATOR
DRIVl:R'S SEAT BELl
TENSIONER
FRONT PASSENGER'S SEAT BELT TENSKlNER
I) i
I
il
I
CABLE REEL
&~ ,---r'
RECIYEl RED! lK
21>1010 _, 115A!
T
"
"
:1
SRSUNIT
,:[1' ,:]
"'
.
'
'I 'I 'I

P K
v LON
DASHBOARD WIREflARNESSA
HARNESS
W"'
flOOR
",~~ \",',' ~ ~ t:..:J

LIGHT
~~iJJ~~ r " - -
"
'"'
INDICATOIl CIRCUIT
~~f~;:_G_ PNKIBl]-1 : :
-I'-'-
C509
iJ
:
1
f_----~,+'C'"--,.,
~mO'C-'~--f_----~I-------~
'"'
INDICATOR
'"
DASHBOARD WIRE HARNl:SS A
GAUGE ASSEMBLY
em
~'~I~d~d
PNKIBLU
GRN
BLK
"'" HARNESS
~"
."
RED/l!LU
BLU/RED
I
G"'
-""-I
1.._
'-----
L:::::::::::::f-----1
'"
UNBUCKltO
I:' '"
FRONT
BUCKLED
PASSENGERS SEAT8ELT BUCKLE SWITCH
23-34
,
0:::
[[
'OZMod.1
OlMO<101
'''' COMPARTMENT
~"' HARM:SS
""
,j'
.. "
..-
J :rl~ ~ .
, ,
,
DRIVER'S SEAT BELT BUCKLE TENSIONER
PASSENGER'S SEAT BELT BUCKLE THiSlONER
.,,'
OIIIVER'S SDEAlRBAG I"'LATOII
.,""
--,
DRIVER'S
rwithsidelirb'gJ
PASSENGER'S SlDEAIRBAG INFLATOII
,~ ,
,
SRSUNfT
, , ,~ ,~
'"i""""""""-"'00 W ..
HARNESS
SENSOR
SIDE "'PACT
-~
"
,'
"
, " " L_ ------ --- --- ------- --

"
_____ ,It ,1
"""" , , , "
PASSENGER'S
SDEIMPACT SENSOR
,
,1
1
2
LTGRN
'I 'I
, ,
;
aLUI EO
"
'"
;
flOOR
HARNESS
W ..
~ ~1l\1"
SfGNAlIMESI CONNECTOR 12PI
~;LTPLEX ",mm
.
HARNESS
ECUSUB
"
"'"
, 'I
"
,
BLUI ED
~ ~
DATA LIM!. CONNECTOR \16P1
'I
I '"
FUSE/RELAY
rNDER-OAS14
,
o
REDI U
.I
awr
::m~
"
UNBUCKLED
OIIIVER'$ SEAT BELT BUCKLE SWITCH
""
, J
6551
23-35
SRS
OTe Troubleshooting
OTC 11: Open in Driver's Airbag Inflator OTC 12: Increased Resistance in Driver's
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC .
Airbag Inflator
SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.
Is OTC 1-1 or OTC 1-2 indicated?

YES~Go
to step 9.
NO-Open or increased resistance in the driver's
airbag inflator; replace the driver's airbag (see page 23-113) .
Does the SRS indicator stay on?

YES~Go
9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect the front passenger's airbag 4P connector from dashboard wire harness B (see step
to step 3. failure, system is OK at this time.
NO~lntermittent
Go to Troubleshooting Intermittent Failures (see
3 on page 23-21).
11. Disconnect both seat belt tensioners 2P connectors
page 23-26). 3. Turn the ignition switch OFF. Disconnect the

battery negative cable, and wait for 3 minutes.
from the floor wire harness (see step 5 on page 2322). 12. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). Do not disconnect the special tool from the cable reel.
4. Disconnect the driver's airbag 4P connector (A) from the cable reel.
L/
07XAZ-SZ30100
~?(
-~
~_/
07SAZ-TB4011A
tw
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to the cable
reel.
23-36
,
13. Check resistance between the No.7 and the No. 16 terminals and between the No.6 and the No. 15 terminals of SRS unit connector A (18P). There should be 2.0-3.0 Q. SRS UNIT CONNECTOR A (18PJ
Ole 1-3: Short to Another Wire or Decreased Resistance in Driver's Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the
SRS indicator comes on for about 6 seconds and
then goes off. Does the SRS indicator stay on? YES-Go to step 3.
Is the resistance as specified? YES-Faulty SRS unit or poor contact at SRS unit connector A (18P) and the SRS unit, check the
connection between the connector and the SRS
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the
unit. If the connection is OK, replace the SRS unit (see page 23-122J .
NO-Open or increased resistance in dashboard
4. Disconnect the driver's airbag 4P connector (A) from the cable reel.
wire harness B orthe cable reel; replace the cable reel. If the problem still present, replace dashboard
wire harness B.
A
I
07SAZ-TB4011A
~ 07XAZ-SZ30100
reel.
7(::0/
-~~
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to the cable
6. Reconnect the battery negative cable. 7. Erase the DTC memory.
(cont'd)
23-37
SRS
8. Read the DTC. Is DTC 1-3 indicated? YES-Go to step 9. NO-Short in the driver's airbag; replace the driver's airbag (see page 23-113) .
SRS UNIT CONNECTOR A (18P) GRN/WHT ,------'----, GRN/RED
14. Check resistance between the No.7 and the No. 16 terminals and between the No.6 and the No. 15 terminals of SRS unit connector A (18P). There should be an open circuit. or at least 1 M Q.
9. Turn the ignition switch OFF. Disconnect the

10. Disconnect the front passenger's airbag 4P connector from dashboard wire harness B (see step 3 on page 23-21).
11. Disconnect both seat belt tensioner 2P connectors
GRN/YEL
GRN/BLK
from the floor wire harness (see step 5 on page 2322). Is the resistance as specified? 12. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 13. Disconnect the special tool from the cable reel. NO-Go to step 15. 15. Disconnect the cable reel from dashboard wire harness B. Check resistance between the No.7 and the No. 16 terminals and between the NO.6 and the No. 15 terminals of SRS unit connector A (18P). There should be an open circuit, or at least 1 M Q. Is the resistance as specified? YES-Replace the cable reel.. NO-Replace dashboard wire harness B.. YES-Faulty SRS unit; replace the SRS unit (see page 23-122) .
23-38
DTe 1-4: Short to Power in Driver's Airbag Inflator

SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (III, and check that the
8. Read the DTC.
Is OTe 1-4 indicated?

YES-Go to step 9 . NO-Short to power in the driver's airbag; replace the driver's airbag (see page 23-1131 . 9. Turn the ignition switch OFF. Disconnect the
battery negative cable, and wait for 3 minutes. 10. Disconnect the front passenger's airbag 4P connector from dashboard wire harness B (see step
then goes off.

YES-Go to step 3.
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see
3 on page 23-211.
11. Disconnect both seat belt tensioner 2P connectors from the floor wire harness (see step 5 on page 23-
221. 12. Disconnect SRS unit connector A (18PI from the SRS unit (see step 7 on page 23-221. 13. Disconnect the special tool from the cable reel.
page 23-261.
3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 4P connector (A) from the cable ree1.
14. Reconnect the battery negative cable.
---4-~.
....
.{ ?
07XAZ-SZ30100
~-" =W
07SAZ-TB4011A
5. Connect the SRS inflator simulator (2
connectors) and the simulator lead F to the cable reeL
7. Erase the DTC memory.
,
(conl'dl
23-39
SRS
15. Turn the ignition switch ON (III. 16. Check for voltage between the NO.7 terminal of SRS unit connector A (18PI and body ground, the No. 16 terminal and body ground, the No.6 terminal and body ground, and the No. 15 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR A Il8P)
Ole '-5: Short to Ground in Driver's Airbag

Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 4P connector (AI from the cable reel.
Is the voltage as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-1221 . NO-Go to step 17.
- ---
",
17. Turn the ignition switch OFF. 18. Disconnect the cable reel from dashboard wire harness B. 19. Turn the ignition switch ON (III. 20. Check for voltage between the No.7 terminal of SRS unit connector A (18PI and body ground, the No. 16 terminal and body ground, the No.6 terminal and body ground, and the No. 15 terminal and body ground. There should be 0.5 V or less. Is the voltage as specified? YES-Replace the cable reel.. 6. Reconnect the battery negative cable.
NO~Replace
'000"."-
I
07SAZTB40llA
07XAZSZ30100
?(::/
"~~
5. Connect the SRS inflator simulator (2 Q connectorsl and the simulator lead F to the cable
reel.
dashboard wire harness B.
23-40
l
8. Read the DTC. Is OTe 1-5 indicated?
YES~Go
to step 9.
14. Check resistance between the No.7 terminal of SRS unit connector A (18PI and body ground, the No. 16 terminal and body ground, the No.6 terminal and body ground, and the No. 15 terminal and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR A (1aPI GRN/WHT GRN/RED
NO~Short
to ground in the driver's airbag inflator; replace the driver's airbag (see page 23-1131 .

10. Disconnectthe front passenger's airbag 4P

connector from dashboard wire harness B (see step
2 on page 23-21). 11. Disconnect both seat belttensioner 2P connectors from the floor wire harness (see step 5 on page 23221. 12. Disconnect SRS unit connector A (18PI from the SRS unit (see step 7 on page 23-221. 13. Disconnect the special tool from the cable reel.
Is the resistance as specified?

YES~Faulty
SRS unit; replace the SRS unit (see page 23-1221 . 15.
NO~Gotostep
15. Disconnect the cable reel from dashboard wire
harness B. 16. Check resistance between the No.7 terminal of SRS unit connector A (18PI and body ground, the No. 16 terminal and body ground, the No.6 terminal and body ground, and the No. 15 terminal and body ground. There should be an open circuit, or at least 1 M Q. Is the resistance as specified?
YES~Replace
the cable reel..
NO~Replace
,
23-41
SRS
DlC 2-1: Open in Front Passenger's Airbag Inflator DlC 2-2: Increased Resistance in Front Passenger's Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-261. 9. Turn the ignition switch OFF. Disconnect the 2. Turn the ignition switch ON (III, and check that the
battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 4P connector from
8. Read the DTC.

Is DTC 2-1 or DTC 2-2 indicated?
YES-Go to step 9. NO-Open or increased resistance in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-1141 .
then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
the cable reel (see step 2 on page 23-211.

11. Disconnect both seat belt tensioner 2P connectors from the floor wire harness (see step 5 on page 23-
221. 12. Disconnect SRS unit connector A (18PI from the SRS unit (see step 7 on page 23-221. Do not
disconnect the special tool from dashboard wire harness B.
07SAZ-TB4011A
~~ i._:~I_
07XAZ-SZ30100
5. Connect the SRS inflator simulator (2 Q

connectors) and the simulator lead F to dashboard wire harness B.
23-42
13. Check resistance between the No.4 and No. 13 terminals and between the No.5 and No. 14 terminals of SRS unit connector A (18P). There should be 2.0-3.0 Q. SRS UNIT CONNECTOR A Il8PI
OTe 2-3: Short to Another Wire or Decreased Resistance in Front Passenger's Airbag Inflator
Special Tools Required - SRS inflator simulator 07SAZ-TB4011A - SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the
battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B.

YES-Faulty SRS unit or poor contact at SRS unit connector A (18P). Check the connection; if the connection is OK, replace the SRS unit (see page 23-122) .
NO-Open or increased resistance in dashboard wire harness B; replace dashboard wire harness B.
07SAZ-TB40llA
~~ G::
.
.~ ~
07XAZSZ30100
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to dashboard
wire harness B.
J
(conl'd)
23-43
SRS
8. Read the DTC. 12. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 13. Disconnect the special tool from dashboard wire YES-Go to step 9. NO-Short in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23114). 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect the driver's airbag 4P connector from harness B.
Is DTe 2-3 indicated?
14. Check resistance between the No.4 and No. 13 terminals and between the NO.5 and No. 14 terminals of SRS unit connector A (18P). There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR A 118P)
the cable reel (see step 2 on page 23-211.

BLU/RED BLU/YEL
from the floor wire harness (see step 5 on page 2322).
BLU/BLK
YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short in dashboard wire harness 8; replace
23-44
DTC 24: Short to Power in Front Passenger's Airbag Inflator

SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on?
YES~Go
8. Read the DTC. Is DTe 2-4 indicated?

YES~Go
to step 9 .
NO~Short
to power in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-114) .
9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 4P connector from the cable reel (see step 2 on page 23-21). 11. Disconnect both seat belt tensioner 2P connectors from the floor wire harness (see step 5 on page 2322).
to step 3.
failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the
NO~lntermittent
07SAZ-TB4011A
~-~ 0:: ~
-~
07XAZ-SZ30100

connectors) and the simulator lead F to dashboard wire harness B.
J
(cont'd)
23-45
SRS
12. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 13. Disconnect the special tool from dashboard wire harness B. 14. Reconnectthe battery negative cable. 1. Erase the DTC memory (see page 23-26). 15. Turn the ignition switch ON (II). 16. Check for voltage between the No.4 terminal of SRS unit connector A (18P) and body ground, the No. 13 terminal and body ground, the No.5 terminal and body ground, and the No. 14 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR A IlaPI
DTC 2-5: Short to Ground in Front Passenger's Airbag Inflator

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100
2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B.
=
Is the voltage as specified?

YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short to power in dashboard wire harness B; replace dashboard wire harness B.
07SAZ-TB40l1A
-.-~
~,~~ G:: ~
07XAZ-SZ30100
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to dashboard wire harness B.
23-46

7. Erase the DTC memory. 8. Read the DTC.
12. Disconnect SRS unit connector A 118P) from the SRS unit Isee step 7 on page 23-22). 13. Disconnectthe special tool from dashboard wire harness B. 14. Check resistance between the No.4 terminal of SRS unit connector A 118P) and body ground, the No. 13 terminal and body ground, the No.5 terminal and body ground, and the No. 14 terminal and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR A (tBPI

YES-Go to step 9. NO-Short to ground in the front passenger's airbag inflator; replace the front passenger's airbag Isee page 23-114) .
10. Disconnect the driver's airbag 4P connector from the cable reellsee step 2 on page 23-21).
11. Disconnect both seat belt tensioner 2P connectors from the floor wire harness Isee step 5 on page 2322).
.Q
.Q

YES-Faulty SRS unit; replace the SRS unit Isee page 23-122) . NO-Short to ground in dashboard wire harness B; replace dashboard wire harness B.
23-47
SRS
OTC 3-1: Open in Driver's Seat Belt Tensioner OTC 3-2: Increased Resistance in Driver's
Seat Belt Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory Isee page 23-261.
NO-Open or increased resistance in the driver's
8. Read the DTC.

Is OTe 3-1 or OTe 3-2 indicated? YES-Go to step 9.
2. Turn the ignition switch ON 1111, and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-261. 3. Turn the ignition switch OFF. Disconnect the
seat belt tensioner; replace the driver's seat belt Isee page 23-41 . 9. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes.
10. Disconnect the floor wire harness 4P connector
C403 IAI from dashboard wire harness B.
4. Disconnect the driver's seat belt tensioner 2P connector (A) from the floor wire harness.
~
"
"
0(
..J
07XAZ-SZ30100 A
::0
"~~
"'~-".
11. Connect the SRS inflator simulator 12 Q

connectors) and simulator lead F to dashboard wire harness B.
07SAZ-TB4011A
,/
07TAZ-SZ5011A
12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC. Is OTe 3-1 or OTe 3-2 indicated? YES-Go to step 15.
NO-Open or increased resistance in the floor wire harness; replace the floor wire harness .
'" '~i
FEJ
'I
~'""'-----
iC.=C'
_),1
5. Connect the SRS inflator simulator 12 Q connectorl

and simulator lead C to the floor wire harness.

\.. ,.I
23-48
16. Disconnect the driver's airbag connector (see step 2 on page 23-211. front passenger's airbag connector (see step 3 on page 23-211. and front
passenger's seat belt tensioner connector (see step
DTe 3-3: Short to Another Wire or Decreased Resistance in Driver's Seat Belt Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ301 00 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.
5 on page 23-22). 17. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). Do not disconnect the special tool from dashboard wire harness B. 18. Check resistance between the No.8 terminal and the No. 17 terminal of SRS unit connector A (18P). There should be 2.0-3.0 Q. SRS UNIT CONNECTOR A (laPI RED/WHT

page 23-26).
3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's seat belt tensioner 2P connector (A) from the floor wire harness.
l
RED/BLU
YES-Faulty SRS unit or poor contact at SRS unit connector A (18P) and the SRS unit. Check the
connection; jf the connection is OK, replace the
SRS unit (see page 23-122) .

NO-Open or increased resistance in dashboard wire harness 8; replace dashboard wire harness 07SAZ-TB40llA
B.
07TAZ-SZ50"A
~G
5. Connect the SRS inflator simulator (2 Q connector) and simulator lead C to the floor wire harness.
J
(cont'd)
23-49
SRS
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Is OTC 3-3 indicated? YES-Go to step 9.
18. Disconnect the special tool from dashboard wire
16. Disconnect the driver's airbag connector (see step
2 on page 23-21), front passenger's airbag connector Isee step 3 on page 23-21), and front
5 on page 23-22). 17. Disconnect SRS unit connector A 118P) from the SRS unit Isee step 7 on page 23-22).
NO-Short in the driver's seat belt tensioner; replace the driver's seat belt (see page 23-41.. 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect floor wire harness 4P connector C403 (AI from dashboard wire harness B.
A
harness B.
19. Check resistance between the No.8 terminal and
the No. 17 terminal of SRS unit connector A 118P). There should be an open circuit. or at least 1 M Q.
SRS UNIT CONNECTOR A (ISP) RED/WHT
RED/BLU 07SAZ-TB401IA

07XAZ-SZ30100
11. Connect the SRS inflator simulator 12 Q

connectors) and simulator lead F to dashboard wire harness 8.
YES-Faulty SRS unit; replace the SRS unit Isee page 23-122) .
NO--Short in dashboard wire harness B; replace dashboard wire harness B.
12. Reconnect the battery negative cable. 13. Erasethe DTC memory. 14. Read the DTC. Is OTC 3-3 indicated? YES-Go to step 15. NO-Short in the floor wire harness; replace the
floor wire harness . 15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
23-50
,J
ole 3-4: Short to Power in Driver's Seat Belt lensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. 6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Is DTC 3-4 indicated? YES-Go to step 9. NO-Short to power in the driver's seat belt tensioner; replace the driver's seat belt (see page 23-4) .

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
~
10. Disconnect floor wire harness 4P connector C403 (A) from dashboard wire harness B.
It
4. Disconnect the driver's seat belt tensioner 2P connector (A) from the floor wire harness.
07XAZ-SZ30100 A
~-t:J
.
-/
07SAZ-TB4011A
-,>
07SAZ-TB4011A
07TAZ-SZ5011A
A ~w
11. Connect the SRS inflator simulator (2 Q connectors) and simlator lead F to dashboard wire harness B. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC. Is DTC 3-4 indicated? YES--Go to step 15.
NO-Short to power in the floor wire harness; replace the floor wire harness . 15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
5. Connect the SRS inflator simulator (2 " connector) and simulator lead C to the floor wire harness.
(conl'd)
23-51
SRS
16. Disconnect the driver's airbag connector (see step 2 on page 23-21), front passenger's airbag connector (see step 3 on page 23-21), and front passenger's seat belt tensioner connector (see step 5 on page 23-22). 17. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 18. Disconnect the special tool from dashboard wire harness B. 19. Reconnect the battery negative cable. 20. Turn the ignition switch ON (II). 21. Check for voltage between the No.8 terminal of SRS unit connector A (18P) and body ground, and the No. 17 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR A
\.
OTe 3-5: Short to Ground in Driver's Seat Belt Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3.
Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's seat belt tensioner 2P connector (A) from the floor wire harness.
"
{18PI
..-
=
A
Is the voltage as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Shortto power in dashboard wire harness B; replace dashboard wire harness B.
07TAZ-SZ5011A
5. Connect the SRS inflator simulator (2 Q connector)

23-52
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Is OTC 3-5 indicated? YES-Go to step 9. NO-Short to ground in the driver's seat belt
tensioner; replace the driver's seat belt
16. Disconnect the driver's airbag connector (see step 2 on page 23-21), front passenger's airbag connector (see step 3 on page 23-211, and front
5 on page 23-22). 17. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-221. 18. Disconnect the special tool from dashboard wire harness B. 19. Check resistance between the No.8 terminal of SRS unit connector A (18P) and body ground, and the No. 17 terminal and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR A 11BPI
(see page 23-41 . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect floor wire harness 4P connector C403
(AI from dashboard wire harness B.
07XAZ-SZ30100
c(-c/
-r;~c
07SAZ-TB4011A Wire side of female terminals
Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short to ground in dashboard wire harness B; replace dashboard wire harness B.

connectors) and simulator lead F to dashboard wire
harness B. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC. Is OTC 3-5 indicated? YES-Go to step 15.
NO-Short to ground in the floor wire harness; replace the floor wire harness .
15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes .
23-53
A
_______________ 07XAZ-SZ30100 GRN/BLK
::eJ
.....----- 07SAZ-TB4011A
5. Connect theSRS intlator simulator (2 Q. connectors) and simulator lead F to the floor wire harness.
YES-Faulty SRS unit or poor contact at SRS unit connector B (18P) and the SRS unit. Check the connection; if the connection is OK, replace the SRS unit (see page 23-122) .
23-54
OTe 21-3: Short to Another Wire or Decreased Resistance in Driver's Seat Belt Buckle Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off.
8. Read the DTC.

YES-Go to step 9. NO-Short in the driver's seat belt buckle tensioner; replace the driver's seat belt buckle . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect both side airbag 2P connectors (see step 4 on page 23-21 I and the front passenger's seat belt buckle tensioner 4P connector (see step 6 on page 23-221. 11. Disconnect SRS unit connector B (18PI from the SRS unit (see step 7 on page 23-221. 12. Disconnect the special tool from the floor wire harness. 13. Check resistance between the No.1 and No. 10 terminals of SRS unit connector B (18PI. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B (18P) GRN/VEl

YES-Go to step 3.
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261.
3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's seat belt buckle tensioner 4P connector (A) from the floor wire harness.
~'~?9-~A
______________ 07XAZ-SZ301 00
GRN/BlK
::0--------
07SAZ-TB4011A

5. Connect the SRS inflator simulator (2 " connectors) and simulator lead F to the floor wire harness. 6. Reconnect the battery negative cable. 7. Erase the DTC memory. YES-Faulty SRS unit; replace the SRS unit (see page 23-1221 . NO-Short in the floor wire harness; replace the floor wire harness .
J
23-55
SRS
DTC 214: Short to Power in Driver's Seat Belt Buckle Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB401 1A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the
8. Read the DIC.

VES~Go
to step 9 .
NO~Short to power in the driver's seat belt buckle tensioner; replace the driver's seat belt buckle .
9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect both side airbag 2P connectors (see
then goes off.

VES~Go
to step 3. failure, system is OK at this time.
step 4 on page 23-21) and the front passenger's seat belt buckle tensioner 4P connector (see step 6 on page 23-22).
NO~lntermittent
page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's seat belt buckle tensioner 4P connector (A) from the floor wire harness.
~~;z.....-A
_________ 07XAZ-SZ301 00 ....---- 07SAZ-TB4011A
::f)
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to the floor
wire harness.
6. Reconnect the battery negative cable. 7. Erase the DIC memory.
23-56
J
11. Disconnect SRS unit connector B (lBP) from the SRS unit (see step 7 on page 23-22). 12. Disconnect the special tool from the floor wire harness. 13. Reconnect the battery negative cable. 1. Erase the DTC memory (see page 23-26). 14. Turn the ignition switch ON (II). 15. Check for voltage between the No.1 terminal of SRS unit connector B (lBP) and body ground, and the No. 10 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR B (tBPI
OTe 21-5: Short to Ground in Driver's Seat Belt Buckle Tensioner

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100
2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's seat belt buckle tensioner 4P connector (A) from the floor wire harness.
Is the VOltage as specified?

YES-Faulty SRS unit; replace the SRS unit (see page 23-1221 . NO-Short to power in the floor wire harness; replace the floor wire harness .
A _______________ 07XAZ-SZ301 00
-~ .= -\J
07SAZ-TB4011A
5. Connect the SRS inflator simulator (2 Q connectors) and simulator lead F to the floor wire harness. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.
J
(cont'd)
23-57
SRS
8. Read the DTC. Is DTe 21-5 indicated? YES-Go to step 9. NO-Short to ground in the driver's seat belt buckle tensioner; replace the driver's seat belt buckle . Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory Isee page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK atthis time. 12. Disconnect the special tool from the floor wire harness. 13. Check resistance between the No.1 terminal of SRS unit connector B 11ap) and body ground, and the No. 10 terminal and body ground. There should be an open circuit, or at least 1 M Q. SRS UNIT CONNECTOR B Il8PI
DTC 4-1: Open in Front Passenger's Seat Belt Tensioner DTC 4-2: Increased Resistance in Front Passenger's Seat Belt Tensioner

battery negative cable, and wait for 3 minutes. 10. Disconnect both side airbag 2P connectors Isee step 4 on page 23-21) and the front passenger's seat belt buckle tensioner 4P connector Isee step 6 on page 23-22). 11. Disconnect SRS unit connector B 118P) from the SRS unit Isee step 7 on page 23-22) .
page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
4. Disconnect the front passenger's seat belt tensioner 2P connector (A) from the floor wire
harness.
,
07SAZ-TB40llA
~t3,.-~cc., I
"
!Ii ..",
Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit Isee page 23-122) .
NO-Short to ground in the floor wire harness;
replace the floor wire harness .
.:==~~
07TAZ-SZ50llA
5. Connect the SRS inflator simulator 12 Q connector)

23-58
6. Reconnect the battery negative cable. 7. Erase the DTC memory. S. Read the DTC. Is OTe 4-1 or OTe 4-2 indicated? YES-Go to step 9.
NO-Open or increased resistance in the front
15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 16. Disconnect the driver's airbag connector Isee step 2 on page 23-21), front passenger's airbag connector Isee step 3 on page 23-21), and driver's seat belt tensioner connector Isee step 5 on page 23-22). 17. Disconnect SRS unit connector A IISP) from the SRS unit Isee step 7 on page 23-22). Do not disconnect the special tool from dashboard wire harness B. IS. Check resistance between the NO.9 terminal and the No. IS terminal of SRS unit connector A IISP). There should be 2.0-3.0 Q.
SRS UNIT CONNECTOR A IISP} RED/VEL
passenger's seat belt tensioner; replace the front passenger's seat belt Isee page 23-4) . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect the floor wire harness 4P connector
C4031A) from dashboard wire harness B.
07XAZSZ30100
~c(-r~l/ -@
07SAZTB4011A
RED/BLK
I 1. Connect the SRS inflator simulator 12 harness B. 12. Reconnect the battery negative cable.
,2
YES- Faulty SRS unit or poor contact at SRS unit connector A IISP) and the SRS unit. Check the connection; if the connection is OK, replace the SRS unit Isee page 23-122) .
NO-Open or increased resistance in dashboard
13. Erase the DTC memory. 14. Read the DTC. Is OTe 4-1 or OTe 4-2 indicated? YES-Go to step 15.
wire harness B; replace dashboard wire harness
B.
23-59
SRS
OTe 4-3: Short to Another Wire or Decreased Resistance in Front Passenger's Seat Belt Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off. 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the floor wire harness 4P connector C403 (AI from dashboard wire harness B. 8. Read the DTC.
Is OTC 4-3 indicated?

YES-Go to step 9. NO-Short in the front passenger's seat belt tensioner; replace the front passenger's seat belt (see page 23-41 .

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's seat belt tensioner 2P connector (A) from the floor wire harness.
"
11. Connect the SRS inflator simulator (2 Q connectorsl and simulator lead F to dashboard wire harness B. 12. Reconnect the battery negative cable.
13. Erase the DTC memory. 14. Read the DTC.
Is OTC 4-3 indicated?

07TAZSZ5011A
YES- Go to step 15. NO-Short in the floor wire harness; replace the floor wire harness . 15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
5. Connect the SRS inflator simulator (2 Q connectorl and simulator lead C to the floor wire harness. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.
23-60
16. Disconnectthe driver's airbag connector (see step 2 on page 23-21), front passenger's airbag connector (see step 3 on page 23-21), and driver's
seat belt tensioner connector (see step 5 on page
Dle 4-4: Short to Power in Front Passenger's Seat Belt Tensioner

Special Tools Required SRS inflator simulator 07SAZ-TB401 lA SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26).
23-22). 17. Disconnect SRS unit connector A (lap) from the SRS unit (see step 7 on page 23-22).
la. Disconnect the special tool from dashboard wire harness B.

19. Check resistance between the No.9 terminal and the No. la terminal of SRS unit connector A (lap). There should be an open circuit, or at least I M Q.
SRS UNIT CONNECTOR A IISP) RED/YEL
2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3.
Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes .
Il
RED/BLK
4. Disconnectthe front passenger's seat belt tensioner 2P connector (A) from the floor wire harness.
YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short in dashboard wire harness B; replace dashboard wire harness B.

(conl'd)
23-61
SRS
6. Reconnect the battery negative cable. 7. Erase the DTC memory. S. Read the DTC.
/s DTC 4-4 indicated?
-...
15. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 16. Disconnect the driver's airbag connector (see step 2 on page 23-21), front passenger's airbag connector (see step 3 on page 23-211. and driver's seat belt tensioner connector (see step 5 on page 23-221. 17. Disconnect SRS unit connector A (1SP) from the SRS unit (see step 7 on page 23-22). IS. Disconnect the special tool from dashboard wire harness B. 19. Reconnect the battery negative cable. 20. Turn the ignition switch ON (II). 21. Check for voltage between the No.9 terminal of SRS unit connector A (1SP) and body ground, and the No. 18 terminal and body ground. There should be 0.5 V or less.
..J
YES-Go to step 9. NO-Short to power in the front passenger's seat

belt tensioner; replace the front passenger's seat
belt (see page 23-4) .


10. Disconnect floor wire harness 4P connector
C403 (A) from dashboard wire harness B.
~
07XAZSZ30100
c(
__
--~
J~'
//
SRS UNIT CONNECTOR A (1SPI
-...
......
07SAZ-TB40llA
I 1. Connect the SRS inflator simulator (2 Q

harness B. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC. NO-Shortto power in dashboard wire harness B;
replace dashboard wire harness 8 .
/s the voltage as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-122) .
YES-Goto step 15.

NO-Short to power in the floor wire harness;
23-62
OTe 4-5: Short to Ground in Front Passenger's Seat Belt Tensioner

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead C 07TAZ-SZ5011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, and checkthatthe SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
8. Read the DTC.

Is DTC 4-5 indicated?
YES-Go to step 9. NO-Short to ground in the front passenger's seat belttensioner; replace the front passenger's seat belt (see page 23-41 . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect the floor wire harness 4P connector C403 (AI from dashboard wire harness B.
4. Disconnect the front passenger's seat belt tensioner 2P connector (A) from the floor wire
harness.
11. Connect the SRS inflator simulator (2 Q connectorsl and simulator lead F to dashboard wire harness B. 12. Reconnect the battery negative cable.
A

07SAZ-TB4011A
~t3.-=.,/ ,L._:'
'I'
14. Read the DTC.

07TAZ-SZSOllA
YES-Gotostep 15. 5. Connect the SRS inflator simulator (2 Q connectorl

and simulator lead C to the floor wire harness. 6. Reconnect the battery negative cable.
(conrdl
23-63
SRS
16. Disconnect the driver's airbag connector Isee step 2 on page 23-21 I, front passenger's airbag connector Isee step 3 on page 23-21), and driver's
seat belt tensioner connector (see step 5 on page
~
Ole 22-1: Open or Increased Resistance in Front Passenger's Seat Belt Buckle lensioner
Special Tools Required - SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory Isee page 23-261. 2. Turn the ignition switch ON 1111, and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-261. 3. Turn the ignition switch OFF. Disconnect the
.J
23-221. 17. Disconnect SRS unit connector A 118PI from the SRS unit Isee step 7 on page 23-221. 18. Disconnect the special tool from dashboard wire
harness B.
19. Check resistance between the No.9 terminal of SRS unit connector A 118PI and body ground, and the No. 18 terminal and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR A (tSPI
4. Disconnect the front passenger's seat belt buckle tensioner 4P connector (A) from the floor wire
harness.
..J
Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit Isee page 23-1221 . NO-Short to ground in dashboard wire harness B;
replace dashboard wire harness B.
5. Connect the SRS inflator simulator 12 Q connectorsl and the simulator lead F to the floor
wire harness.
23-64
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC.
DTe 22-3: Short to Another Wire or Decreased Resistance in Front Passenger's Seat Belt Buckle Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 9. NO-Open or increased resistance in the front passenger's seat belt buckle tensioner; replace the front passenger's seat belt buckle . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect both side airbag 2P connectors (see step 4 on page 23-21) and the driver's seat belt buckle tensioner 4P connector (see step 6 on page 23-22). 11. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). Do not disconnectthe special tool from the floor wire harness. 12. Check resistance between the No.2 and No. 11 terminals of SRS unit connector B (18P). There should be 2.0-3.0 Q.
SRS UNIT CONNECTOR B Il8PI

YES-Go to step 3.
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26).
3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's seat belt buckle tensioner 4P connector (A) from the floor wire harness.

YES-Faulty SRS unit or poor contact at SRS unit connector B (18P) and the SRS unit. Check the connection; if the connection is OK, replace the SRS unit (see page 23-122) . NO---Open or increased resistance in the floor wire harness; replace the floor wire harness .
5. Connect the SRS inflator simulator (2 Q connectors) and the simulator lead F to the floor wire harness. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.
(conl'd)
23-65
SRS
8. Read the DTC.
OTe 22-4: Short to Power in Front Passenger's Seat Belt Buckle Tensioner
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead F 07XAZ-SZ30100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (III. and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 9. NO-Short in the front passenger's seat belt buckle tensioner; replace the front passenger's seat belt buckle . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect both side airbag 2P connectors (see step 4 on page 23-211 and the driver's seat belt buckle tensioner 4P connector (see step 6 on page 23-22). 11. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). 12. Disconnect the special tool from the floor wire harness. 13. Check resistance between the No.2 and No. 11 terminals of SRS unit connector B (18P). There should be an open circuit, or at least 1 Mil.
SRS UNIT CONNECTOR B (lSP) GRN/RED

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's seat belt buckle tensioner 4P connector (A) from the floor wire harness.
o
A
07XAZ-SZ30100 "
GRN
,,~.;:;;;;-~

YES-Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short in the floor wire harness; replace the floor wire harness .
5. Connect the SRS inflator simulator (2 &1 connectors) and simulator lead F to the floor wire harness.
23-66

10. Disconnect both side airbag 2P connectors (see step 4 on page 2321) and the driver's seat belt buckle tensioner 4P connector (see step 6 on page 2322). 11. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 2322). 12. Disconnect the special tool from the floor wire harness. 13. Reconnect the battery negative cable. 14. Turn the ignition switch ON (II).
8. Read the DTC.

YES-Go to step 9. NO-Short to power in the front passenger's seat belt buckle tensioner; replace the front passenger's seat belt buckle .

battery negative cable, and wait for 3 minutes. 15. Check for voltage between the No.2 terminal of SRS unit connector B (18P) and body ground, and the No. 11 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR B (18P)

YES-Faulty SRS unit; replace the SRS unit (see page 23122) . NO-Short to power in the floor wire harness;
23-67
SRS
DTC 22-5: Short to Ground in Front
S, Read the DTC, Is DTC 22-5 indicated? Special Tools Required SRS inflator simulator 07SAZ-TB401 lA SRS simulator lead F 07XAZ-SZ30100 1, Erase the DTC memory (see page 23-261, 2, Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off, Does the SRS indicator stay on?
YES~Go YES~Go
Passenger's Seat Belt Buckle Tensioner

to step 9,
NO~Short to ground in the front passenger's seat belt buckle tensioner; replace the front passenger's seat belt buckle,.
9, Turn the ignition switch OFF, Disconnect the banery negative cable, and wait for 3 minutes,
to step 3,
la, Disconnect both side airbag 2P connectors (see step 4 on page 23-21 I and the driver's seat belt buckle tensioner 4P connector (see step 6 on page 23-221,
11, Disconnect SRS unit connector B (1SPI from the SRS unit (see step 7 on page 23-221, 12, Disconnect the special tool from the floor wire harness. 13, Check resistance between the No, 2 terminal of SRS unit connector B (1SPI and body ground, and the No, 11 terminal and body ground, There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B ItSPI
NO~lnterminent failure, system is OK atthis time, Go to Troubleshooting Interminent Failures (see page 23-261,
3, Turn the ignition switch OFF, Disconnectthe banery negative cable, and wait for 3 minutes, 4, Disconnect the front passenger's seat belt buckle
tensioner 4P connector (A) from the floor wire harness.
5, Connect the SRS inflator simulator (2 Q

connectors) and simulator lead F to the floor wire
Is the resistance
YES~Faulty
as specified?
harness.
6, Reconnect the banery negative cable, 7, Erase the DTC memory,
SRS unit; replace the SRS unit (see page 23-1221,.
23-68
J
OTC 5-1, 5-2, 5-4, 5-8, 6-3, 6-4, 6-7, 6-8, 7-1, 7-2,7-3,8-1,8-2,8-3,8-4,8-5,8-6,9-1,9-2:
Internal Failure of the SRS Unit
NOTE: Before troubleshooting any of these DTCs, check the battery/system voltage. If the voltage is low, repair the charging system or replace the battery before troubleshooting the SRS.lfthe battery/system voltage is now OK, ask the customer if the battery ever went dead.
1. Erase the DTC memory (see page 23-26).
OTC 10-1, 10-2, 10-3, 10-4, 10-5, 10-6, 10-7:

Airbags, Side Airbags, and/or Seat Belt and Seat Belt Buckle Tensioners Deployed
The SRS unit must be replaced after any airbags and/or tensioners have deployed (see page 23-122) .
2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Replace the SRS unit (see page 23-122) . NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26).
23-69
SRS
OTC 13-1, 13-2: Internal Failure of the Driver's Side Impact Sensor
1. Erase the DTC memory Isee page 23-26).
OTC 14-1, 14-2: Internal Failure of the Front Passenger's Side Impact Sensor
1. Erase the DTC memory Isee page 23-26).
2. Turn the ignition switch ON III), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Replace the driver's side impact sensor Isee page 23-123) . NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-26).
2. Turn the ignition switch ON III), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Replace the front passenger's side impact sensor Isee page 23-123) . NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-26).
23-70
J
DTC 9-3: Faulty Driver's Seat Belt Buckle Switch
1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), then buckle and unbuckle the driver's seat belt several times. 3. Read the DTC. 6. Buckle the driver's seat belt. Check resistance between the No.1 and No.3 terminals of the driver's seat belt buckle switch 3P connector. There should be 0-1 [2. Check resistance between the No.1 and No.2 terminals of the same connector. There should be an open circuit, or at least 1 M [2.
DRIVER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR

YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 4. Turn the ignition switch OFF. 5. Disconnect the driver's seat belt buckle switch 3P connector (A) from the floor wire harness.
a
A
Are the resistance readings as specified?
YES-Go to step 7.
NO- Replace the driver's seat belt buckle assembly, then clear the DTC .
(conl'd)
23-71
SRS
7. Unbuckle the driver's seat belt. Check resistance between the No.1 and No.2 terminals of the driver's seat belt buckle switch 3P connector. There should be 0-1 Q. Check resistance between the No.1 and No.3 terminals of the same connector. There should be
an open circuit, or at least 1 M Q.
DRIVER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR
8. Check resistance between the No.1 terminal of the

floor wire harness 3P connector and body ground.
There should be 0 -1 Q.
FLOOR WIRE HARNESS 3P CONNECTOR
=
ijl~"'~"
123
YES-Go to step g.
NO-Open in the floor wire harness or poor ground
connection at G551. If G551 is OK, replace the floor

wire harness .

9. Disconnect the negative cable from the battery.
YES-Go to step 8. NO-Replace the driver's seat belt buckle assembly, then clear the DTC . 10. Disconnect SRS unit connector C (8P) from the SRS unit (see step 7 on page 23~22).
23-72
J
11. Check resistance between the No.2 terminal of the floor wire harness 3P connector and body ground. There should be an open circuit, or at least 1 M Q.
FLOOR WIRE HARNESS 3P CONNECTOR FLOOR WIRE HARNESS 3P CONNECTOR SRS UNIT CONNECTOR C IBPI
13. Check resistance between the No.8 terminal of SRS unit connector C (8P) and the No.3 terminal of the floor wire harness 3P connector. There should beO-1 Q.
234
LTGRN
'---------(Q)------:-::-::-::'
LTGRN
Is the resistance as specified? YES-Go to step 12.

NO-Short to ground in the floor wire harness or multiplex control unit. Replace the faulty harness or part.
Is the resistance as specified? YES-Go to step 14. NO-Open in the floor wire harness; replace the floor wire harness .
14. Check resistance between the No.4 terminal of SRS unit connector C (8P) and the No.2 terminal of the floor wire harness 3P connector. There should beO-1 Q.
FLOOR WIRE HARNESS 3P CONNECTOR SRS UNIT CONNECTOR C IBP)
12. Check resistance between the No.3 terminal of the floor wire harness 3P connector and body ground. There should be an open circuit, or at least 1 M Q.
BLU/RED
123
678
=
Is the resistance as specified? Is the resistance as specified? YES- Replace the SRS unit (see page 23-122) . YES-Go to step 13. NO-Short to ground in the floor wire harness; replace the floor wire harness . NO-Open in the floor wire harness or multiplex control unit, or poor connection at the floor wire harness, the under-dash fuselrelay box, and the multiplex control unit. Check the connection at the floor wire harness, the under-dash fuse/relay box, and the multiplex control unit. If the connection is OK, replace the faulty harness or part .
23-73
SRS
OTe 9-4: Faulty Front Passenger's Seat Belt Buckle Switch
1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, then buckle and unbuckle the front passenger's seat belt several times. 3. Read the DTC. Is DTC 9-4 indicated? YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 4. Turn the ignition switch OFF. 5. Disconnect the front passenger's seat belt buckle switch 3P connector (A) from the floor wire harness.
6. Buckle the front passenger's seat belt. Check resistance between the No.1 and No.3 terminals of the front passenger's seat belt buckle switch 3P connector. There should be 0-1 [2. Check resistance between the No.1 and No.2 terminals of the same connector. There should be an open circuit, or at least 1 M Q.
FRONT PASSENGER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR
ilrwi)"'"W
1 2 3
Is the resistance as specified? YES-Go to step 7. NO-Replace the front passenger's seat belt buckle assembly, then clear the DTC .
23-74
7. Unbuckle the front passenger's seat belt. Check resistance between the No.1 and No.2 terminals of the front passenger's seat belt buckle switch 3P connector. There should be 0-1 ". Check resistance between the No.1 and NO.3 terminals of the same connector. There should be an open circuit, or at least 1 M Q.
FRONT PASSENGER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR
S. Check resistance between the No.1 terminal of the

There should be 0-1 Q.

=
"~~TI"'~O
1 2 3
YES-Go to step 9. NO-Open in the floor wire harness or poor ground connection at G551. If G551 is OK, replace the floor
wire harness .
9. Disconnect the negative cable from the battery. YES-Go to step S. NO-Replace the front passenger's seat belt buckle assembly, then clear the DTC . 10. Disconnect SRS unit connector C (SP) from the SRS unit (see step 7 on page 23-22).
(conl'd)
23-75
SRS
11. Check resistance between the No.2 terminal of the floor wire harness 3P connector and body ground. There should be an open circuit, or at least 1 M 12.
FLOOR WIRE HARNESS 3P CONNECTOR FLOOR WIRE HARNESS 3P CONNECTOR SRS UNIT CONNECTOR C 18P)
13. Check resistance between the No.7 terminal of SRS unit connector C (8PI and the No.3 terminal of
the floor wire harness 3P connector.
'--------(Q}------"
Is the resistance as specified? YES-Go to step 12. NO-Short to ground in the floor wire harness; replace the floor wire harness . 12. Check resistance between the No.3 terminal of the
YES-Go to step 14.

NO-Open in the floor wire harness; replace the floor wire harness .
There should be an open circuit, or at least 1 M 12.

14. Check resistance between the No.3 terminal of SRS unit connector C (8PI and the No.2 terminal of
the floor wire harness 3P connector.

FLOOR WIRE HARNESS 3P CONNECTOR SRS UNIT CONNECTOR C (8PI
,-----(Ql---~
VEL
=

YES-Go to step 13.

NO-Short to ground in the floor wire harness; replace the floor wire harness . Is the resistance as specified?
YES-Replace the SRS unit (see page 23-1221 .

23-76
OTC 96: Faulty Left Front Impact Sensor

Special Tools Required SRS inflator simulator 07SAZTB4011A SRS simulator lead H 07YAZS3AA100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.
8. Disconnect the engine compartment wire harness 2P connector (A) from the left front impact sensor.
----------- --- --- .--- -- - --- -- -- .-- - --~---------

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Check the connections between SRS unit connector A (18P) and the SRS unit, between the engine compartment wire harness 2P connector and the left front impact sensor (see page 23-13), and at connector C401.
J
SRS UNIT CONNECTOR A (18PI
9. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 10. Check resistance between the No. 10 and No. 11 terminals of SRS unit connector A (18P). There should be an open circuit, or at least 1 M Q.
Are the connections OK?

YES-Go to step 4. NO-Repair the poor connections and retest. If DTC 9-6 is still present, go to step 4.

5. Disconnect the driver's airbag 4P connector from the cable reel (see step 2 on page 23-21).

6. Disconnect the front passenger's airbag 4P connector from dashboard wire harness B (see step 3 on page 23-21). 7. Disconnect both seat belt tensioner 2P connectors from the floor wire harness (see step 5 on page 2322). YES-Goto step 11. NO-Short in the engine compartment wire harness or dashboard wire harness B; replace the faulty harness . 11. Reconnectthe battery negative cable. 12. Turn the ignition switch ON (II).
(cont'd)
23-77
SRS
13. Check voltage between the No. 10 terminal of SRS unit connector A (lap) and body ground. There should be 1 V or less.
SRS UNIT CONNECTOR A (18P)
16. Check resistance between the No. 10 and No.1 1 terminals of SRS unit connector A (lap). There should be 1 Q or less.
=
Is the voltage as specified? YES-Go to step 14. NO-Short to power in the engine compartment
wire harness or dashboard wire harness 8; replace
/s the resistance as specified?

YES-Faulty left front impact sensor or SRS unit; replace the left front impact sensor (see page 23-125). If the problem is still present, replace the SRS unit (see page 23- 122) . NO-Poor connection at C401, faulty engine
the faulty harness . 14. Turn the ignition switch OFF. 15. Connectthe SRS inflator simulator (jumper connector) and simulator lead H to the engine compartment wire harness 2P connector (A).
compartment wire harness, or faulty dashboard
wire harness B. Inspect C401. If it is OK, replace the faulty harness .
A~ /07YAZ-S3AA100
/07SAZ.TB4011A
~
Gi
-tJ
23-78
OTe 9-7: Faulty Right Front Impact Sensor

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead H 07YAZ-S3AA100 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (II), and check that the
8. Disconnect the engine compartment wire harness
2P connector (AI from the right front impact sensor.

-------------~--
then goes off. Does the SRS indicator stay on? YES-Go to step 3.
A

page 23-261. 3. Turn the ignition switch OFF. Check the connections between SRS unit connector A (18PI and the SRS unit, between the engine
compartment wire harness 2P connector and the
9. Disconnect SRS unit connector A (18PI from the SRS unit (see step 7 on page 23-221. 10. Check resistance between the No.1 and No. 12 terminals of SRS unit connector A (18PI. There should be an open circuit, or at least 1 M Q.
SRS
right front impact sensor (see page 23-131, and at connector C401. Are the connections OK? YES-Go to step 4. NO-Repair the poor connections and retest. If DTC 9-7 is still present, go to step 4. 4. Turn the ignition switch OFF. Disconnect the
UNIT CONNECTOR A (18PI
GRN
5. Disconnect the driver's airbag 4P connector from
the cable reel (see step 2 on page 23-211. Is the resistance as specified?
6. Disconnect the front passenger's airbag 4P connector from the dashboard wire harness (see
YES-Go to step 11. NO-Short in the engine compartment wire
step 3 on page 23-211.

7. Disconnect both seat belt tensioner 2P connectors harness or dashboard wire harness 8; replace the
from the floor wire harness (see step 5 on page 23221.
faulty harness . 11. Reconnect the battery negative cable. 12. Turn the ignition switch ON 1111.
(cont'dl
23-79
SRS
13. Check voltage between the No.1 terminal of SRS unit connector A (18P) and body ground. There should be 1 V or less.
SRS UNIT CONNECTOR A Il8P}
16. Check resistance between the No.1 and No. 12 terminals of SRS unit connector A (18P). There should be 1 Q or less.
SRS UNIT CONNECTOR A Il8P} GRN
=

YES-Go to step 14. NO-Short to power in the engine compartment
wire harness or dashboard wire harness 8; replace

YES-Faulty right front impact sensor or SRS unit; replace the right front sensor (see page 23-125). If the problem is still present, replace the SRS unit (see page 23-122) .
the faulty harness .
NO- Poor connection at C401, faulty engine

14. Turn the ignition switch OFF. 15. Connect the SRS inflator simulator (jumper connector) and simulator lead H to the engine compartment wire harness 2P connector (A).
compartment wire harness, or faulty dashboard
.,J
wire harness B.lnspect C401.lf it is OK, replace the faulty harness .
-A
07SAZ-TB40llA
tJ.l~
23-80
OTe 11-1: Open or Increased Resistance in
Driver's Side Airbag Inflator

SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory Isee page 23-261.
8. Read the DTC .

YES-Go to step 9. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off.
NO-Open or increased resistance in the driver's side airbag inflator; replace the driver's side
airbag Isee page 23-1151..

YES-Go to step 3.
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261.
10. Disconnect the front passenger's side airbag 2P
connector Isee step 4 on page 23-21) and both seat belt buckle tensioner 4P connectors Isee step 6 on page 23-221.
4. Disconnect the floor wire harness 2P connector IAI

from the driver's side airbag.
5. Connect the SRS inflator simulator 12 Q connectorl

and simulator lead E to the floor wire harness.
Icont'dl
23-81
SRS
11. Disconnect SRS unit connector B (18PI from the SRS unit (see step 7 on page 23-221. Do not disconnect the special tool from the floor wire harness 2P connector. 12. Check resistance between the No.6 and No. 17 terminals of SRS unit connector B (18PI. There should be 2.0-3.0 Q.
SRS UNIT CONNECTOR B (18PI
OTe "-3: Short to Another Wire or Decreased Resistance in Driver's Side Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off.
WHT/BLU

YES-Go to step 3.
WHT/BLK

page 23-261. 3. Turn the ignition switch OFF. Disconnect the

YES-Faulty SRS unit or poor contact at SRS unit connector B (18PI and the SRS unit. Check the connection; if the connection is OK, replace the SRS unit (see page 23-1221 .
NO-Open or increased resistance in the floor wire
4. Disconnect the floor wire harness 2P connector (A) from the driver's side airbag.
harness; replace the floor wire harness .
07XAZ-S1A0200
~~A -u
/07SAZ-TB40llA
5. Connect the SRS inflator simulator (2 Q connectorl

23-82
8. Read the DTC.
OTe 11-4: Short to Power in Driver's Side Airbag Inflator

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory Isee page 23-261. 2. Turn the ignition switch ON 1111, and check thatthe SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 9. NO-Short to another wire in the driver's side airbag inflator; replace the driver's side airbag Isee page 23-1151 . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnectthe front passenger's side airbag 2P connector Isee step 4 on page 23-211 and both seat belt buckle tensioner 4P connectors Isee step 6 on page 23-221. 11. Disconnectthe special tool from the floor wire harness 2P connector. 12. Disconnect SRS unit connector B 118PI from the SRS unit Isee step 7 on page 23-221. 13. Check resistance between the No.6 and No. 17 terminals of SRS unit connector B 118PI. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B (18PI WHT/BLU

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
4. Disconnect the floor wire harness 2P connector (A) from the driver's side airbag.
WHT/BLK
07XAZ-S1A0200
~~A -w
/07SAZ-TB4011A
5. Connect the SRS inflator simulator 12 Q connectorl and simulator lead E to the floor wire harness.
YES-Faulty SRS unit; replace the SRS unit Isee page 23-1221 . NO-Short to another wire in the floor wire harness; replace the floor wire harness .
Icont'dl
23-83
SRS
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 12. Turn the ignition switch ON (II). 8. Read the DTC. 13. Check for voltage between the No.6 terminal of SRS unit connector B (18P) and body ground, and between the No. 17 terminal and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR B (ISP)
11. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22).

YES~Go
to step 9.
NO~Short to power in the driver's side airbag inflator; replace the driver's side airbag (see page 23-1151 .
9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the front passenger's side airbag 2P connector (see step 4 on page 23-21) and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22).

YES~ Faulty
SRS unit; replace the SRS unit (see page 23-122) . to power in the floor wire harness;
NO~Short
23-84
Ole 115: Short to Ground in Driver's Side Airbag Inflator

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.
B. Read the DTC. Is OTe 11-5 indicated? YES-Go to step 9 . NO-Short to ground in the driver's side airbag inflator; replace the driver's side airbag (see page 23-115) . 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the front passenger's side airbag 2P connector (see step 4 on page 23-21) and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22). 11. Disconnect SRS unit connector B (lBP) from the SRS unit (see step 7 on page 23-22). 12. Check resistance between the No.17 and No.15 terminals of SRS unit connector B (lBP), and between the No. 17 and No. 16 terminals. Then check resistance between the No. 17 terminal and body ground. There should be an open circuit, or at least 1 M Q.

YES-Go to step 3. NO-Intermittent failure, system is OK althis time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the floor wire harness 2P connector (A) from the driver's side airbag.
07XAZ-S1A0200
~~~ -u
.~
/07SAZ-TB4011A
GRY/RED
=
5. Connect the SRS inflator simulator (2 Q connector) and simulator lead E to the floor wire harness.

YES- Faulty SRS unit; replace the SRS unit (see page 23-122) . NO-Short to ground in the floor wire harness; replace the floor wire harness .

23-85
SRS
DTe 12-1: Open or Increased Resistance in Front Passenger's Side Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the OTC memory (see page 23-261. YES-Go to step 9. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off.
NO-Open or increased resistance in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-1151 .
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the OTC .

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-261. 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the floor wire harness 2P connector (AI
from the front passenger's side airbag.
10. Disconnect the driver's side airbag 2P connector
(see step 4 on page 23-211 and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-221.
07S~
AP,
i-JI-
07XAZ-S1A0200
5. Connect the SRS inflator simulator (2 Q connectorl and simulator lead E to the floor wire harness.
23-86
11. Disconnect SRS unit connector B (18PI from the SRS unit (see step 7 on page 23-221. Do not disconnect the special tool from the floor wire harness 2P connector. 12. Check resistance between the No.7 and No. 18 terminals ofSRS unit connector B (18PI. There should be 2.0-3.0 [2. SRS UNIT CONNECTOR B 118P) WHT/RED
OTe 12-3: Short to Another Wire or Decreased Resistance in Front Passenger's Side Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory Isee page 23-261. 2. Turn the ignition switch ON 1111, and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES WHT/GRN
Go to step 3.
NO - Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-26).
4. Disconnect the floor wire harness 2P connector (A) from the front passenger's side airbag.

YES-Faulty SRS unit or poor contact at SRS unit connector B 118P) and the SRS unit. Check the connection; If the connection is OK, replace the SRS unit Isee page 23-122) .
07S~'~
nP"
u-
07XAZ-SIA0200
5. Connect the SRS inflator simulator 12 Q connectorl and simulator lead E to the floor wire harness.
(conl'dl
23-87
SRS
6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory (see page 23-26). YES-'-:Go to step 9 2. Turn the ignition switch ON (II), and check that the
NO-Short to another wire in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-115) .
Ole 12-4: Short to Power in Front Passenger's

Side Airbag Inflator
then goes off.

battery negative cable, and wait for 3 minutes. YES-Go to step 3. NO-Intermittent failure, system is OK at this time.
10. Disconnect the driver's side airbag 2P connector (see step 4 on page 23-211 and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22).
11. Disconnectthe special tool from the floor wire harness 2P connector. 12. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). 13. Check resistance between the No.7 and No. 18 terminals of SRS unit connector B (18P). There
should be an open circuit, or Cit least 1 M Q.
SRS UNIT CONNECTOR B (1SP} WHT/RED
page 23-26). 3. Turn the ignition switch OFF. Disconnect the

4. Disconnect the floor wire harness 2P connector (A) from the front passenger's side airbag.
07S~
Ah~ W-y
07XAZS1A0200
Q
WHT/GRN
5. Connect the SRS inflator simulator (2

connector)

YES-Faulty SRS unit; replace the SRS unit (see page 23-122) .
NO-Short to another wire in the floor wire
harness; replace the floor wire harness .
23-88
11. Disconnect SRS unit connector B 118P) from the SRS unit Isee step 7 on page 23-22). 12. Turn the ignition switch ON (II).
8. Read the DTC.

YES-Go to step 9. NO-Short to power in the front passenger's side airbag inflator; replace the front passenger's side airbag Isee page 23-1151.. 9. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
10. Disconnect the driver's side airbag 2P connector
13. Check for voltage between the No.7 terminal of SRS unit connector B 118P) and body ground, and between the No. 18 terminal and body ground.
There should be 0.5 V or less.
Isee step 4 on page 23-21) and both seat belt buckle tensioner 4P connectors Isee step 6 on page 23-22).
~,

YES-Faulty SRS unit; replace the SRS unit Isee page 23-1221..
NO-Short to power in the floor wire harness; replace the floor wire harness .
23-89
SRS
OTe 12-5: Short to Ground in Front Passenger's Side Airbag Inflator
Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead E 07XAZ-S1A0200 1. Erase the DTC memory (see page 23-26). YES-Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. NO-Short to ground in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-115) . 6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC .

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the floor wire harness 2P connector (A) from the front passenger's side airbag.
10. Disconnectthe driver's side airbag 2P connector
(see step 4 on page 23-21) and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22). 11. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). 12. Check resistance between the No. 15 and No. 18 terminals of SRS unit connector B (18P) and between the No. 16 and No. 18 terminals. Then
check resistance between the No. 18 terminal and body ground. There should be an open circuit, or at
least 1 M Q.
SRS UNIT CONNECTOR B (tSPI
07S~ ~.')O
-~ 0-
18
WHT/GRN
07XAZ-StA0200
GRY/RED
Q
=

YES-Faulty SRS unit; replace the SRS unit (see page 23-122) .
23-90
OTe 133: No Signal from the Driver's Side Impact Sensor

Special Tools Required SRS inflator simulator 07SAZ-TB4011A SRS simulator lead H 07YAZ-S3AA100 1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Check the connection between the floor wire
harness 2P connector and the driver's side impact sensor.
5. Disconnectthe driver's side airbag and front passenger's side airbag 2P connectors (see step 4 on page 23-21). Also disconnect both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22) . 6. Disconnect the floor wire harness 2P connector (A)
from the driver's side impact sensor.
0;:.:...-------I====,-, I
07SAZ-TB4011A
7. Connect the SRS inflator simulator (2 Q connector) and simulator lead H to the floor wire harness.
Is the connection OK? YES-Go to step 5. NO-Replace the driver's side impact sensor and/
or the floor harness, as needed .
(conl'd)
23-91
SRS
8. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). 9. Check resistance between the No.8 and No. 15 terminals of SRS unit connector B (18P). There should be 0-1.0 Q.
SRS UNIT CONNECTOR B (18PI BRN/VEL
J
OTe 13-4: Faulty Power Supply to the Driver's Side Impact Sensor
1. Erase the DTC memory (see page 23-26). 2. Turn the ignition switch ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26).
LT GRN/RED
3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (see step 4 on page 23-21). Also disconnect both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22).
Is the resistance as specified? YES-Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-123). If the problem is still present, replace the SRS unit (see page 23-122) . NO-Open in the floor wire harness; replace the floor wire harness .
23-92
5. Disconnect the floor wire harness 2P connector (A)

from the driver's side impact sensor.
8. Check resistance between the No.8 and No. 15 terminals of SRS unit connector B (18P). There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B IISPI BRN/VEL
LTGRN/RED Wire side of female terminals
6. Disconnect SRS unit connector B (18P) from the SRS unit (see step 7 on page 23-22). 7. Check resistance between the NO.8 terminal of SRS unit connector B (18P) and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B IISP) BRN/YEL
Is the resistance as specified? YES-Faulty driver's side impact sensor or SRS

unit; replace the driver'S side impact sensor (see
page 23-125). If the problem is still present, replace the SRS unit (see page 23-122) . NO-Short in the floor wire harness; replace the
floor wire harness .
Is the resistance as specified? YES-Go to step 8. NO-Short to ground in the floor wire harness;
replace the floor wire harness.
23-93
SRS
OTC 14-3: No Signal from the Front Passenger's Side Impact Sensor
Special Tools Required SRS inflator simulator 07SAZ-TB401 1A SRS simulator lead H 07YAZ-S3AA100 1. Erase the DTC memory Isee page 23-261. 2. Turn the ignition switch ON III), and check that the SRS indicator comes on for about 6 seconds and then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures Isee page 23-26). 3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Check the connection between the floor wire harness 2P connector and the front passenger's
side impact sensor.
(s
J
5. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (see step 4 on page 23-211. Also disconnect both seat belt buckle tensioner 4P connectors Isee step 6 on page 23-22) . 6. Disconnect the floor wire harness 2P connector IA) from the front passenger's side impact sensor.
7. Connect the SRS inflator simulator 12 Q connector) and the simulator lead H to the floor wire harness.
the connection OK?
YES-Go to step 5.
NO- Poor contact between the floor wire harness 2P connector and the front passenger's side impact sensor; replace the front passenger's side impact sensor and/or the floor harness, as needed.
23-94
S. Disconnect SRS unit connector B (1SPI from the SRS unit (see step 7 on page 23-221. 9. Check resistance between the No.9 and No. 16 terminals of SRS unit connector B (1SPI. There should be 0-1.0 Q. SRS UNIT CONNECTOR B (ISPI PNK/BLU
OTC 144: Faulty Power Supply to the Front Passenger's Side Impact Sensor
1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (III, and check that the SRS indicator comes on for about 6 seconds and then goes off.

YES-Go to step 3. NO-Interminent failure, system is OK at this time. Go to Troubleshooting Interminent Failures (see page 23-261.
GRY/REO

YES-Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23- 1251. If the problem is still present, replace the SRS unit (see page 23- 1221.
4. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (see step 4 on page 23-21 I. Also disconnect both seat belt buckle tensioner 4P connectors (see step 6 on page 23-221. 5. Disconnect the floor wire harness 2P connector (A) from the front passenger's side impact sensor.
6. Disconnect SRS unit connector B (1SPI from the SRS unit (see step 7 on page 23-221.
(conl'dl
23-95
SRS
7. Check resistance between the No.9 terminal of SRS unit connector B (1SP) and body ground. There should be an open circuit, or at least 1 M [2.
SRS UNIT CONNECTOR B 118PI
OTe 151: Faulty OPDS Unit

NOTE: An incorrect OPDS unit can cause DTC 15-1. A new (uninitialized) OPDS unit installed with a faulty OPDS sensor can cause DTC 15-1. )f you install a new OPDS unit and a new SRS unit at the same time, initialize the OPDS manually (see page 23-27), do not use the Honda PGM Tester. 1. Make sure nothing is on the front passenger's seat.
PNK/BLU
=
2. Initialize the OPDS unit (see page 23-27). 3. Erase the DTC memory (see page 23-26). 4. Read the DTC.

YES-Go to step 5. YES-Go to step S. NO-Short to ground in the floor wire harness; replace the floor wire harness . S. Check resistance between the No.9 and No. 16 terminals of SRS unit connector B (1SP). There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR B 118PI PNK/BLU
NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-26). 5. Check the No. 9110A) fuse in the under-dash fuse/ relay box.
Is the fuse OK?
YES-Go to step 6. NO-Go to step 9. 6. Disconnect OPDS unit harness SP connector IA) from the OPDS unit IA) (see page 23-124).
GRY/RED Wire side of female terminals
YES-Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-125). If the problem is still present, replace the SRS unit (see page 23-122) .
NO-Short in the floor wire harness; replace the floor wire harness .
23-96
8. Check for voltage between the NO.4 terminal of OPDS unit harness 8P connector and body ground. There should be battery voltage.
OPOS UNIT HARNESS 8P CONNECTOR
13. Disconnect OPDS unit harness 8P connector IAI from the OPDS unit.
14. Turn the ignition switch ON 1111 for 30 seconds, then turn it off. 15. Check the No. 9110AI fuse.
Is there battery voltage? Is the fuse OK?
YES-Go to step 16. NO-Open in the floor wire harness or OPDS unit harness; replace the faulty harness . 9. Replace the No. 9110AI fuse in the under-dash fuse/relay box. 10. Turn the ignition switch ON III) for 30 seconds, then turn it off.
11. Check the No. 9 110A) fuse. Is the fuse OK?
YES-Short to ground in the OPDS unit; replace the OPDS unit Isee page 23-1241 . NO-Short to ground in the No. 9110A) fuse circuit Ifloor harness, or OPDS harness); replace the
affected harness .
16. Turn the ignition switch OFF. 17. Check resistance between the No.8 terminal of OPDS unit harness 8P connector and body ground. There should be 0-1.0 Q.
Go to Troubleshooting Intermittent Failures Isee page 23-26). NO-Go to step 12. 12. Replace the No.9 110AI fuse.
YES-Go to step 18.

NO-Open in the floor wire harness or OPDS unit
harness, or poor ground IG5511. If G551 is OK,

replace the faulty harness .
Icont'dl
23-97
SRS
1S. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 19. Disconnect both side airbag connectors (see step 4 on page 23-21 I and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-221. 20. Disconnect SRS unit connector B (1SPI from the SRS unit (see step 7 on page 23-221. 21. Check resistance between the NO.3 terminal of SRS unit connector B (1SPI and body ground. There should be an open circuit, or at least 1 MQ .
SRS UNIT CONNECTOR B Il8P) GRN/ORN
J
22. Check resistance between the No.3 terminal of SRS unit connector B (1SPI and the No.7 terminal of OPDS unit harness SP connector. There should beo-l.0Q.
SRS UNIT CONNECTOR B Il8P) GRN/ORN
YES- Go to step 23.
=
NO- Open in the floor wire harness or in the OPDS unit harness; replace the faulty harness.
YES- Go to step 22.

NO- Short to ground in the floor wire harness or OPDS unit harness; replace the faulty harness.
23-98
25. Check for voltage between the No.3 terminal of SRS unit connector B 11BPI and body ground. There should be 0.5 V or less.
SRS UNIT CONNECTOR B It8PI
OTe 152: Faulty Side Airbag Cutoff Indicator Circuit

1. Make sure nothing is on the front passenger's seat.
2. Erase the DTC memory Isee page 23-261. 3. Turn the ignition switch ON (III, and check thatthe SRS indicator comes on for about 6 seconds and then goes off.
=
YES- Turn the ignition switch OFF, and go to step

4.
/s the vOltage as specified? YES-Go to step 26.

NO-Short to power in the floor wire harness or in the OPDS unit harness; replace the faulty harness .
NO-Intermittent failure, system is OK atthis time. Go to Troubleshooting Intermittent Failures Isee page 23-261. NOTE: This DTC may have been caused by turning the ignition switch ON (III with the gauge assembly disconnected. 4. Turn the ignition switch ON (III, and check that the side airbag cutoff indicator comes on.
26. Replace the OPDS unit Isee page 23-1241, then initialize the system Isee page 23-271. 27. Erase the DTC memory, then check for DTC 15-1.
Does the side airbag cutoff indicator come on?

YES-Go to step 5. NO-Go to step 6. 5. Make sure the side airbag cutoff indicator goes off after 5 seconds.
YES-Replace the SRS unit Isee page 23-1221 . NO- The system is OK .
Does the side airbag cutoff indicator go off after 5
seconds?
YES-Faulty OPDS unit or SRS unit; replace the OPDS unit Isee page 23-1241. lithe problem is still present, replace the SRS unit Isee page 23-1221 . NO-Go to step 32. 6. Turn the ignition switch OFF.
Icont'dl
23-99
SRS
7. Check the No. 10 (7.5A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
J
11. Turn the ignition switch OFF. 12. Disconnect the dashboard wire harness 17P connector K from the under-dash fuse/relay box.
YES-Go to step S. NO-Replace the fuse, then turn the ignition switch ON (II). If the fuse blows again, check for a short in the No. 10 (7.5A) fuse circuit (ECM wire harness, floor harness, or OPDS harness) . S. Disconnect the OPDS unit harness SP connector (A) from the OPDS unit (see page 23-124).
Q
13. Turn the ignition switch ON (II). 14. Check for voltage between the NO.3 terminal of the OPDS unit harness SP connector and body ground. There should be 0.5 V or less.
OPOS UNIT HARNESS BP CONNECTOR

GRN,-----,
10. Check for voltage between the No.3 terminal of the OPDS unit harness SP connector and body ground. There should be battery voltage.
7 8
YES-Faulty OPDS unit; replace the OPDS unit (see page 23-124) . NO-Go to step 15.
23-100
15. Turn the ignition switch OFF. 16. Remove the gauge assembly (see page 22-64).
Then disconnect gauge assembly connector A from

(A) from the dashboard wire harness.
the gauge assembly.
----_.........
21. Turn the ignition switch ON (II). 17. Turn the ignition switch ON (II). 18. Check for voltage between the No.3 terminal of the OPDS unit harness 8P connector and body ground. There should be 0.5 V or less.
OPDS UNIT HARNESS 8P CONNECTOR
22. Check for voltage between the No.3 terminal of the OPDS unit harness 8P connector and body ground. There should be 0.5 V or less.
OPDS UNIT HARNESS 8P CONNECTOR
GRN,----, GRN,-----,
=
Is the voltage as specified? Is the vOltage as specified?

YES-Short to power in dashboard wire harness A; replace dashboard wire harness
YES-Short to power in the gauge assembly; replace the gauge assembly . NO-Go to step 19.
A..
NO-Short to power in the floor wire harness or in
the OPDS unit harness; if the OPDS unit harness is

OK, replace the floor wire harness .
(cont'd)
23-101
SRS
23. Turn the ignition switch OFF. 24. Remove the gauge assembly Isee page 22-641. With the connectors stili connected to the gauge assembly, backprobe the No. 15 terminal of gauge assembly connector A 122PI. 25. Turn the ignition switch ON (II). 26. Check for voltage between the No. 15 terminal of gauge assembly connector A 122PI and body ground. There should be battery voltage.
GAUGE ASSEMBLY CONNECTOR A (22P)
29. Turn the ignition switch ON III). 30. '02 model: Check for voltage between the No.4
terminal of dashboard wire harness A 6P connector
C509 and body ground. There should be battery voltage. '03 model: Check for voltage between the No.5
terminal of dashboard wire harness A 8P connector
C509 and body ground. There should be battery voltage. '02 Model:
DASHBOARD WIRE HARNESS A 6P CONNECTOR
11
12 13 14
22
=
=
'03 Model:
DASHBOARD WIRE HARNESS A 8P CONNECTOR

YES~Go NO~Go
to step 27.
to step 31.

IAI from dashboard wire harness.
=

YES-Poor contact at the dashboard wire harness A 6P or 8P connector and floor wire harness, an open in the floor wire harness, or an open in the
OPDS unit harness. Check the connection; if the

connection is OK, replace the faulty harness .
NO-Poor contact at gauge assembly connector A

(22P) or an open in dashboard wire harness A.
Check gauge assembly connector A (22PI; if the

connections are OK, replace dashboard wire harness A..
23-102
31. Check for voltage between the No.2 terminal of gauge assembly connector B (22PI and body ground. There should be battery voltage.
GAUGE ASSEMBLY CONNECTOR B (22P) YEL
32. Turn the ignition switch OFF. 33. Disconnect the OPDS unit harness 8P connector (AI from the OPDS unit (see page 23-1241.
2
11
9 10
21 22
12 13

YES-Faulty side airbag cutoff indicator circuit; replace the gauge assembly . NO-Open in dashboard wire harness A; replace
dashboard wire harness A..
Does the side airbag cutoff indicator come on?

YES-Go to step 35. NO-Faulty OPDS unit; replace the OPDS unit. 35. Turn the ignition switch OFF. 36. Remove the gauge assembly (see page 22-641. Then disconnect gauge assembly connector A from the gauge assembly.
A
(conl'dl
23-103
SRS
37. Check resistance between the No. 15 terminal of gauge assembly connector A (22P) and body ground. There should be an open circuit, or at least 1 MQ.
J
Ole 15-3: Faulty OPDS Sensor
1. Erase the DTC memory (see page 23-261. 2. Turn the ignition switch ON (II), and check that the
then goes off.

11 12 13 14
YES-Go to step 3.
NO-Intermittent failure, system is OK atthis time. Go to Troubleshooting Intermittent Failures (see page 23-26).
NOTE: Aftermarket devices (fluorescent lights,

laptop computers, etc.) used near the front passenger's seat-back can interfere with the seat-

YES-Short to ground in the side airbag cutoff indicator circuit; replace the gauge assembly. NO-Short to ground in the dashboard wire
harness A, floor wire harness, or OPDS unit
back sensors and cause a false DTC 15-3. If one of these devices was used, erase the DTC, operate the device near the seat-back, and recheck for DTCs. If DTC 15-3 is reset, erase it, and do not use the device near the seat-back. 3. Check the connection at the OPDS sensor harness connector and the OPDS unit connector.
Are the connections OK?
harness; replace the faulty harness .
YES-Go to step 4. NO-Reconnect the OPDS sensor harness connector, and clear the DTC . 4. Replace the OPDS sensor/seat-back foam (see page 20-74), and initialize the OPDS (see page 23-271. 5. Erase the DTC memory, then check for DTC 15-3.
YES- Replace the OPDS unit Isee page 23-1241 .

NO- The system is OK.
23-104
SRS Indicator Circuit Troubleshooting

The SRS Indicator Doesn't Come On
1. Turn the ignition switch ON (III, and see if the other
indicators come on (brake system, etc).
4. Check for voltage between the No. 14 terminal of gauge assembly connector A (22PI and body ground within the first 6 seconds after turning the ignition switch ON (III. There should be 8.5 V or less.
GAUGE ASSEMBLY CONNECTOR A (22PI
Do the other indicators come on?

YES-Go to step 2. NO-Go to step 8. 2. Turn the ignition switch OFF, then remove the gauge assembly (see page 22-641. Disconnect gauge assembly connector A and B from the gauge assembly.
11
12 13
17
22
=
A

YES-Faulty SRS indicator circuit in the gauge assembly; replace the gauge assembly . NO-Go to step 5. 5. Turn the ignition switch OFF.
3. Check resistance between the No. 12 terminal of gauge assembly connector B (22PI and body ground. There should be 0-1.0 Q.
GAUGE ASSEMBLY CONNECTOR B (22PI
2
11
6
17 18 19
9 21
10 22
12 13
=
YES-Go to step 4. NO-Open in the BLK wire of dashboard wire harness A or faulty body ground terminal (G5011. If the body ground terminal is OK, replace dashboard
wire harness A..
(cont'dl
23-105
SRS
SRS Indicator Circuit Troubleshooting (cont'dl
6. Disconnect SRS unit connector C (8PI from the SRS unit (see step 7 on page 23-221. 7. Disconnect gauge assembly connector A (22PI.
Connect a voltmeter between the No. 14 terminal of
9. Connect a voltmeter between the No.2 terminal of gauge assembly connector B (22PI and body ground. Turn the ignition switch ON (III, and measure the voltage. There should be battery voltage.
GAUGE ASSEMBLY CONNECTOR B 122PI YEL
gauge assembly connector A (22PI and body ground. Turn the ignition switch ON (II), and measure voltage. There should be 0.5 V or less.
234 11 12 13
6
17 18 19
10
21 22
11
12 13
22

YES-Faulty SRS indicator circuit in the gauge

YES-Faulty SRS unit; replace the SRS unit Isee page 23-1221 . NO-Short to power in the PNK wire of dashboard wire harness A or in the floor wire harness; replace the faulty harness . 8. Turn the ignition switch OFF. Check the No. 10 (7 .5AI fuse in the under-dash fuse/relay box.
assembly or poor contact at gauge assembly
connector B (22PI and the gauge assembly; if the connection is OK, replace the gauge assembly . NO-Open in the under-dash fuse/relay box No. 10 (7.5AI fuse circuit, or open in the YEL wire of dashboard wire harness A. If the under-dash fuse/ relay box is OK, replace the faulty harness . 10. Replace the No. 10 (7.5AI fuse, then check to see if
the indicators comes on.
Is the fuse blown?

Do the indicators come on?
YES- The system is OK at this time .

NO-Repair the short to ground in the under-dash fuse/relay box No. 10 (7.5AI fuse circuit .
23-106
The SRS Indicator Stays On When In Menu Method
"ses"
6. Replace the No. 13 (lOA) fuse. 7. Turn the ignition switch OFF. Disconnect the
NOTE: If you cannot retrieve DTCs with the PGM Tester using the SRS menu method, retrieve the flash codes with the Tester in SCS mode (see page 23-24). A new SRS unit must sense the entire system is OK before completing its initial self-test. The most
common cause of an incomplete self-test is the
battery negative cable, and wait for 3 minutes. 8. Disconnect the driver's airbag 4P connector (see
step 2 on page 23-21). 9. Disconnect the front passenger's airbag 4P connector (see step 3 on page 23-21).
failure to replace all deployed parts after a collision,

in particular, seat belt tensioners and seat belt buckle tensioners.
(see step 5 on page 23-22). 11. Disconnect SRS unit connector A (18P) from the SRS unit (see step 7 on page 23-22). 12. Reconnect the battery negative cable. 13. Turn the ignition switch ON (III. and wait for 30 seconds. Then turn the ignition switch OFF. 14. Check the No. 13 (lOA) fuse.
An incomplete self-test prevents the PGM Tester from retrieving DTCs, although flash codes are available in the Tester's SCS mode. 1. Erase the DTC memory using the MES connector (see page 23-26).
Does the SRS indicator go off while you are erasing the OTC memory?
YES-Go to step 42.
Is the fuse OK?

NO-Go to step 2. 2. Check the No. 13 (lOA) fuse in the under-dash fuseJrelay box. YES-Short to ground in the SRS unit; replace the SRS unit (see page 23-122) . NO-Go to step 15.
Is the fuse OK?

15. Replace the No. 13 (lOA) fuse. YES--Gotostep 19. NO-Go to step 3. 3. Replace the No.13 (lOA) fuse. 4. Turn the ignition switch ON (II), and wait for 30 seconds. Then turn the ignition switch OFF. 5. Check the No. 13 (lOA) fuse.
Is the fuse OK?
YES- The system is OK atthis time .

NO-Go to step 6.
(conl'd)
23-107
SRS
SRS Indicator Circuit Troubleshooting (cont'd)
16. Disconnect dashboard wire harness B connector S from the under-dash fuse/relay box. 24. Reconnect the battery negative cable. 25. Connect a voltmeter between the NO.3 terminal of SRS unit connector A (18PI and body ground. Turn the ignition switch ON (III, and measure the voltage. There should be battery voltage.
SRS UNIT CONNECTOR A ItBP)
17. Turn the ignition switch ON (III, and wait for 30

seconds. Then turn the ignition switch OFF.
18. Check the No. 13 (10AI fuse. Is there battery voltage? Is the fuse OK? YES-Go to step 29. YES-Short to ground in dashboard wire harness B; replace dashboard wire harness B. NO-Short to ground in the under-dash fuse/relay box; replace the under-dash fuse/relay box . 19. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.
20. Disconnect the driver's airbag 4P connector (see
NO-Go to step 26. 26. Turn the ignition switch OFF.

27. Disconnect dashboard wire harness B connector S
from the under-dash fuse/relay box.
step 2 on page 23-211. 21. Disconnect the front passenger's airbag 4P connector (see step 3 on page 23-211.
(see step 5 on page 23-221. 23. Disconnect SRS unit connector A (18PI from the SRS unit (see step 7 on page 23-221.
23-108
28. Check resistance between the NO.3 terminal of SRS unit connector A (18PI and the No.2 terminal of dashboard wire harness B connector S. There should be 0-1.0 Q.
DASHBOARD WIRE HARNESS B CONNECTOR S
31. Connect the NO.3 terminal of SRS unit connector A (18P) and the No.5 terminal of SRS unit connector C (8P) with a jumper wire.
SRS UNIT CONNECTOR C (8P)
Wire side of female terminals SRS UNIT CONNECTOR A (18PI
PNK JUMPER WIRE PNK

Wire side afternale terminals Wire side of female terminals
32. Turn the ignition switch ON (II). Is the resistance as specified? 33. Check the SRS indicator. YES-Open in the under-dash fuse/relay box or poor contact at dashboard wire harness B connectors; check the connection. If the connection is OK, replace the under-dash fuse/relay box . NO-Open in dashboard wire harness B; replace dashboard wire harness B. 29. Turn the ignition switch OFF. 30. Disconnect SRS unit connector C (8P) from the SRS unit (see step 7 on page 23-22). Did the SRS indicator go off? YES-Faulty SRS unit; replace the SRS unit (see page 23-122) .
NO - Go to step 34.
34. Turn the ignition switch OFF. 35. Disconnect the jumper wire between the NO.3 terminal of SRS unit connector A (18P) and the No.5 terminal of SRS unit connector C (8P). 36. Check the No. 13 (lOA) fuse in the under-dash fuse/relay box. Is the fuse OK? YES-Go to step 40. NO-Go to step 37. 37. Replace the No. 13 (lOA) fuse.
(cont'd)
23-109
SRS
SRS Indicator Circuit Troubleshooting (cont'd)
3B. Remove the gauge assembly (see page 22-64), then disconnect gauge assembly connector A from the gauge assembly.
A
40. Remove the gauge assembly (see page 22-64), then disconnect gauge assembly connector A from the gauge assembly.
A
4'
39. Check resistance between the No.5 terminal of SRS unit connector C (BP) and body ground. There should be an open circuit, or at least 1 M Q.
SRS UNIT CONNECTOR C 18PI
41. Check resistance between the No. 14 terminal of gauge assembly connector A (22P) and the No.5 terminal of SRS unit connector C (SP). There should be 1 Q or less.
SRS UNIT CONNECTOR C 18PI
PNK
'---------{Q)---,

GAUGE ASSEMBLY CONNECTOR A 122P}
Is the resistance as specified? Is the resistance as specified? YES-Faulty SRS indicator circuit in the gauge assembly; replace the gauge assembly .
NO-Short to ground in the floor wire harness or in
dashboard wire harness A; replace the faulty
YES-Faulty SRS indicator circuit in the gauge

assembly or poor contact at gauge assembly
connector A (22P); check the connection. If the

connection is OK, replace the gauge assembly .
harness .
NO-Open in the floor wire harness or in dashboard wire harness A; replace the faulty harness .
23-110
,
42. Turn the ignition switch OFF. 43. If necessary, remove the SCS service connector from the MES connector. 44. Turn the ignition switch ON (III. 47. Check resistance between the No.6 terminal of SRS unit connector C (BPI and body ground. There should be 0-1.0 Q. SRS UNIT CONNECTOR C IBPI
Does the SRS indicator come on for about 6 seconds and then go off?
YES- The system is OK a!this time . NO-Go to step 45. 45. Disconnect SRS unit connector C (BPI from the SRS unit (see step 7 on page 23-221. 46. Connect the Honda PGM Tester (AI to the Data Link Connector (BI, and follow the Tester's prompts in the "SCS" menu (see the Tester's operating manual!.

YES-Faulty SRS unit or poor contact at SRS unit connector C (BPI; check the connection. If the connection is OK, replace the SRS unit (see page 23-1221 . NO-Open in the SCS line between the No.6 terminal of SRS unit connector C (BPI and the No.9 terminal (BRN wirel of the data link connector (DLC)' or open between the No.4 terminal of the DLC and body ground. Repair the open wire(sl .
23-111
SRS
Component Replacement/Inspection After Deployment
NOTE: Before doing any SRS repairs, use the PGM Tester SRS menu method to check for DTCs; refer to the DTC Troubleshooting Index for the less obvious deployed parts Iseat belt tensioners, front sensors, side
airbag sensors, etc.)
After a collision where the seat belt tensioners deployed, replace these items: Seat belt tensioners Seat belt buckle tensioners SRS unit Front impact senSOrs After a collision where the front airbagls) deployed,
replace these items:
SRS unit Deployed airbagls)

Seat belt tensioners
Seat belt buckle tensioners

Front impact sensors
After a collision where the side airbag(s) deployed,

replace these items:
SRS unit Deployed side airbagls) Side impact sensor(s) for the side(s) that deployed
During the repair process, inspectthese areas:
Inspect all the SRS wire harnesses. Replace, don't

repair, any damaged harnesses.
Inspect the cable reel for heat damage. If there is any damage, replace the cable reel. Afterthe vehicle is completely repaired, turn the ignition switch ON III). If the SRS indicator comes on for about 6 seconds and then goes off, the SRS airbag system is OK. If the indicator does not function properly, use the PGM Tester SRS Menu Method to read the DTC Isee page 23-23). If this doesn't retrieve any codes, use the Tester's SCS menu method (see page 23-24). If you still cannot retrieve a code, go to SRS Indicator Circuit Troubleshooting.
23-112
Driver's Airbag Replacement

Removal
1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (8) from the cable reel.
Installation
1. Connect the horn switch connector (1 P) to the driver's airbag. 2. Place the new driver's airbag (A) in the steering wheel, and secure it with new Torx bolts (8), and install the maintenance cover (C).
B 9.8 Nm (1.0 kglm, 7.2Iblft)
3. Remove the maintenance cover (A), then remove the two Torx bolts (8) using a Torx T30 bit.
B
--~-------------
3. Connect the cable reel to the driver's airbag 4P connector (A), then install the access panel (8) on the steering wheel.
o
4. Disconnect the horn switch connector (1 P) (D).
/,
---
/'
4. Connect the battery negative cable. 5. Remove the driver's airbag (C).
5. After installing the airbag, confirm proper system operation:
Turn the ignition switch ON (II); the SRS indicator

should come on for about 6 seconds and then go
off.
Make sure the horn works.
23-113
SRS
Front Passenger's Airbag Replacement
Removal
1. Disconnect the battery negative cable, and wait at
least 3 minutes before beginning work,
J
Installation
1. Place the new front passenger's airbag (AI into the dashboard. Tighten the front passenger's airbag mounting nuts (B(.
A
2. Remove the glove box stops, and lower the glove box. 3. Disconnect the front passenger's airbag 4P connector (AI from dashboard wire harness B.
B 9.S Nm (1.0 kgfm, 7.2Ibfftl
2. Connect the front passenger's airbag 4P connector
(AI to dashboard wire harness B.
4. Remove the three mounting nuts (AI from the bracket. Cover the lid and dashboard with a cloth, and pry carefully with a screwdriver to lift the front passenger's airbag (BI out of the dashboard. NOTE: The airbag lid has pawls on its side which attach it to the dashboard.
/~:
3. Raise the glove box, and reinstall the stops.

4. Reconnect the battery negative cable. 5. After installing the airbag, confirm proper system
operation: Turn the ignition switch ON (III; the SRS

indicator should come on for about 6 seconds and
then go off.
23-114
Side Airbag Replacement

NOTE: Review the seat replacement procedure in the Body section before performing repairs or service.
Installation
NOTE: If the side airbag lid is secured by a tape, remove the tape. Do not open the lid of the side airbag cover. Use new mounting nuts tightened to the specified
torque.
Removal
least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector (A).
Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment.
Be sure to install the harness wires so that they are
not pinched or interfering with other parts. 1. Place the new side airbag on the seat-back frame (A). Tighten the side airbag mounting nuts (B).
3. Remove the seat assembly (see page 20-71) and seat-back cover (see page 20-75). 4. Remove the mounting nut (A) and the side airbag (B).
~B
6.3Nm to.6 kgfm,
4.3Ibfftl
2. Install the seat-back cover (see page 20-75). 3. Install the seat assembly (see page 20-71), then
connect the side airbag harness 2P connector.
4. Move the front seat and the seat-back through their

full ranges of movement, making sure the harness wires are not pinched or interfering with other parts.
5. Reconnect the battery negative cable. 6. After installing the side airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
23-115
SRS
Airbag Disposal
Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt
tensioners, or seat belt buckle tensioners (including
J
Driver's Airbag:
4. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector
from the cable reel (see step 2 on page 23-21). Front Passenger's Airbag: 5. Lower the glove box, then disconnect the front
passenger's airbag 4P connector from dashboard
those in a whole vehicle to be scrapped). the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service
Manager must give approval and/or special instruction
before deploying the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners. Only after the
airbags, side airbags, seat belt tensioners, or seat belt
wire harness B (see step 3 on page 23-211. Side Airbag: 6. Disconnect the side airbag 2P connectors from the floor wire harness (see step 4 on page 23-21).
Seat belt tensioner:
buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners appear intact (not deployed),
treat them with extreme caution. Follow this procedure.
Deploying Airbags in the Vehicle

If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners should be deployed while still in the
vehicle. The airbags, side airbags, seat belttensioners,
7. Disconnect the seat belt tensioner 2P connectors from the floor wire harness (see step 5 on page 2322). Pull the seat belt out all the way, and cut it off.
Seat belt buckle tensioner: 8. Disconnect the seat belt buckle tensioner 4P
connectors from the floor wire harness (see step 6
and seat belt buckle tensioners should not be

considered as salvageable parts and should never be installed in another vehicle.
on page 23-22).
1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, or seat belt
tensioner is securely mounted.
3. Confirm that the special tool is functioning properly by following the check procedure on the tool label.
23-116
9. Cut off each connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and the front passenger's airbag each have four wires, two yellow and two red. Twist each pair of unlike colored wires together, and connect an alligator clip to each pair.
10. Connect a 12 volt battery to the tool. If the green light on the tool comes on, the igniter
circuit is defective and cannot deploy the
component. Go to Disposal of Damaged
Components. If the red light on the tool comes on, the component is ready to be deployed. 11. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). If the components deploy and the green light on the tool comes on, continue with this procedure. If a component doesn't deploy, yet the green light comes on, its igniter is defective. Go to
Disposal of Damaged components.
A
A
During deployment, the airbags can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbags.
A
A
12. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal
it securely.
A
/
- -- -----
07HAZ-SG00500
(conl'd)
23-117
SRS
Airbag Disposal (cont'd)
Deploying Components Out of the Vehicle
If an intact airbag or tensioner has been removed from
Deployment Tool Check

,. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips.
a scrapped vehicle, or has been found defective or

damaged during transit, storage, or service, it should be
deployed as follows:
1. Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool label.
2. Position the airbag face up, outdoors, on flat
ground, at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 9 through 11 of the in-vehicle
deployment procedure.
Disposal of Damaged Components

1. If installed in a vehicle, follow the removal procedure for the driver's airbag (see page 23-' 13), front passenger's airbag (see page 23-1'41. side airbag (see page 23-'15), seat belt tensioner (see page 23-4), and seat belt buckle tensioner.
2. In all cases, make a short circuit by cutting,
stripping, and twisting together the two inflator

wires.
NOTE: The driver's and passenger's airbag each

have four wires: twist each pair of like-colored wires together 3. Package the component in the same packaging that the new replacement part came in.
4. Mark the outside of the box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED", "DAMAGED SEAT BELTTENSIONER NOT DEPLOYED" or "DAMAGED SEAT BELT BUCKLE TENSIONER NOT DEPLOYED" so it does
not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal.
23-118
Cable Reel Replacement

Removal
1. Make sure the front wheels are aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 6. Remove the dashboard lower cover (AI.
3. Remove the driver's airbag (see page 23-1131.

4. Disconnect the connector (Al from the cruise control set/resume switch, then remove the
steering wheel bolt (BI.

B
7. Remove the column cover screws (A), then remove
the column covers (B, CI .
5. Align the front wheels straight ahead, then remove the steering wheel with a steering wheel puller (see step 3 on page 17-61.
Do not tap on the steering wheel or steering column shaft when removing the steering wheel.
~c
(cont'dl
23-119
SRS
Cable Reel Replacement (cont'd)
8. Disconnect the dashboard wire harness 4P connector IAI from the cable reel, then disconnect the dashboard wire harness 5P connector IBI from the cable reel.
J
Installation
1. Before installing the steering wheel, align the front wheels straight ahead. 2. If not already done, disconnect the battery negative cable, and wait at least 3 minutes. 3. Set the cancel sleeve IAI so the projections IBI are aligned vertically.
t
B
9. Release the tab IBI, then pull off the cable reellAI.
4. Carefully install the cable reellAI on the steering column shaft. Then connect the 5P connector IBI and the 4P connector ICI.
B
23-120
5. Install the steering column covers.

6. If necessary, center the cable reel. (New replacement cable reels come centered.) Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise (about 2 1/2 turns) until the arrow mark on the cable reel label points straight up.
8. Install the driver's airbag (see page 23-113).

10. After installing the cable reel, confirm proper
system operation:
Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off . After the SRS indicator has turned off, turn the steering wheel fully left and right to confirm the SRS indicator does not come on. Make sure the horn works.
Make sure the cruise control works.
:""gn the projections on the cable reel with the
holes on the steering wheel, and install the steering ..."eel with a new steering wheel bolt (A).
38Nm 13.9 kgf.m, 28lbfftl
23-121
SRS
SRS Unit Replacement
Removal
least 3 minutes before beginning work.
Installation
1. Install the new SRS unit (A) with Torx bolts (8), then connect the connectors (e) to the SRS unit; push
them into position until they clicks.
2. Disconnect the driver's and front passenger's airbag connectors (see page 23-21). 3. Disconnectthe side airbag connectors (see page 23-21).
4. Disconnect both seat belt tensioner connectors (see
NOTE: When tightening the Torx bolts to the specified torque, be careful to turn them in so that their heads rest squarely on the brackets.
B
9.S Nm (1.0 kgfm, 7.2Ibffll
page 23-22) and both seat belt buckle tensioner connectors (see page 23-22).
5. Remove the dashboard center lower cover (see

step 2 on page 20-57). 6. Pull down the console carpet on the passenger's side, then remove the Torx bolt (A) from the SRS unit.
A
c
2. Reinstall the dashboard center lower cover (see step 2 on page 20-57).
3. Reconnect the driver's and front passenger's airbag
connectors (see page 23-21). 4. Reconnect the side airbag connectors (see page 2321).
5. Reconnect both seat belt tensioner connectors (see
page 23-22) and both seat belt buckle tensioner connectors (see page 23-22). 7. Pull down the console carpet on the driver's side,
then disconnectthe connectors. Remove the Torx
6. Reconnect the battery negative cable. 7. Initialize the OPDS unit (see page 23-27). 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS
indicator should come on for about 6 seconds and
bolts (A), then pull out the SRS unit.
then go off.
23-122
Side Impact Sensor Replacement

Removal
least 3 minutes before beginning work.
Installation
1. Install the new side impact sensor with a new Torx
bolt (AI. then connect the floor wire harness 2P connector (B) to the side impact sensor (e).
2. Disconnect the appropriate side airbag 2P connector (see step 4 on page 23-21). 3. Remove the seat assembly (see page 20-71). 4. Remove the front door sill trim and the B-pillar lower trim panel (see page 20-50).
5. Disconnect the floor wire harness 2P connector from the side impact sensor.
6. Remove the Torx bolt (A) using a Torx T30 bit, then
remove the side impact sensor (8).
~c
2. Reconnect the negative battery cable.
3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch
ON (II); the SRS indicator should come on for about

6 seconds and then go off.
4. Install all removed parts.
23-123
SRS
OPDS Unit Replacement
NOTE: Review the seat replacement procedures in the
body section before performing repairs or service.
Installation
1. Place the new OPDS unit (AI on the seat-back frame. Tighten the two screws (BI, and connect the OPDS
unit harness 8P and sensor connectors (C) to the
Removal
1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the passenger's side airbag harness 2P connector (see step 4 on page 23-211.
3. Remove the front passenger's seat assembly (see
OPDS unit. Reinstall the cover (DI.
page 20-711 and seat-back cover (see page 20-751. 4. Remove the cover (AI, then disconnect the OPDS unit harness 8P and sensor connectors (BI from the OPDS unit.
c
2. Install the seat-back cover (see page 20-751. 3. Install the seat assembly (see page 20-711, then
connect the side airbag harness 2P connector.
4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make
sure there is nothing on the front passenger's seat.
B
6. Initialize the OPDS unit (see page 23-271. 5. Remove the two screws (el and the OPDS unit (DI. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (III; the SRS indicator should come on for about 6
seconds and then go off.
23-124
Front Impact Sensor Replacement

Removal
1. Disconnectthe battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnectthe driver's airbag 4P connector (see step 2 on page 23-211. the front passenger's airbag 4P connector (see step 3 on page 23-21), both seat belt tensioner 2P connectors (see step 5 on page 23-22), and both seat belt buckle 4P connectors (see step 6 on page 23-22). 3. Remove the front inner fender (see page 20-102).
4. Disconnect the engine compartment wire harness
Installation
1. Install the new front impact sensor with new Torx
bolts (AI, then connect the engine compartment wire harness 2P connector (8) to the front impact sensor
(C).
2P connector (A), and remove the two Torx bolts (B) using a Torx T30 bit, then remove the front impact sensor (C).
~ '---'''''1 -p;;",'-:J
I
2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm
proper system operation: Turn the ignition switch
ON (II); the SRS indicator should come on for about 6 seconds and then go off.
23-125
Service Manual Index
NOTE: Refer to the following list to look up DTCs, symptoms, fuses, connectors, wire harnesses, specifications, maintenance schedules, and general service information: DTC Troubleshooting Indexes .... 19-34 ABSfTCS Components EPS Components. .. ..................... 17-22 Fuel and Emissions ... .............. 11-7
AIC Pressure Switch Circuit

Troubleshooting ... ....................... 21-32
B
Back-up Light Switch
Test
....................... 13-3
AIC Signal Circuit

Troubleshooting ............................... 11-133
AIF (Air Fuel Ratio) Sensor

Replacement .... ............ 11-113
Back-up Lights
Circuit Diagram ................................... 22-75
A-pillar Corner Trim

Replacement .. ..20-96
HeatingNentilation ................................ 21-9

SRS .......................... ................. 23-28
Ball Joint Boots

Replacement ........................................ 18-16
ABS Indicator Circuit Symptom Troubleshooting Indexes

ABS{TCS Components .. 19-35 Cruise Control System ....... ..4-38 EPS Components ................................. 17-23 Fan Controls ........................................ 10-12 '1-10 Fuel and Emissions ........................ Heating/Ventilation 21-10 Moonroof/Sunroof ............................. 20-36 SRS ... . .......................................... 23-30
Troubleshooting
................ 19-52
Ball Joints
Removal ............................................... 18-10
ABS Modulator-control Unit

Removal/Installation ........ .
............ 19-57
Battery
Test .......... .
.... 22-50
ABS/TCS Components
Component Location Index ..... 19-30 Description ........................................... 19-36 Circuit Diagram .. ......................... 19-42
Beverage Holder
Removal/Installation ............................ 20-64
Blower Motor FuselRelay Indexes

Power Distribution .............................. 22-46 ...... 22-45 Under-dash Fuse/Relay Box. Under-hood Fuse/Relay Box ........ 22-44
Accessory Power Socket, Front

Test/Replacement .. ..... 22-149
Replacement ....................................... 21-41
Blower Power Transistor Accessory Power Sockets

Circuit Diagram.
. ........ 22-149
Test ...................................................... 21-38
Connector and Wire Harness Indexes

Component Connectors (to harness) ......................................... 22-14 Grounds (to components) ............ 22-48 In-line Connectors (to harness) .......... 22-13
Blower Unit Air Cleaner

Replacement ........... 11-162 Removal/Installation ............................ 21-39
Brake Booster Air Cleaner Element

Replacement ...................................... 11-162 Adjustment ......................................... 19-16 Test ................... .................. 19-18 Replacement .... .................... 19-19
Specifications section .................. Section 2 Air Mix Control Motor Maintenance section .................... Section 3 General Information section ........ Section 1 Airbag, Driver's
Replacement Test .......................... 21-34 .................. 21-34
Brake Calipers
Overhaul ....... .
. ....................... 19-14,23
Brake Discs
........ 23-113 . ..... 23-116
A
Ale
Component Location Index ...... 21-3 Description ......................................... 21-11 Circuit Diagram .................................... 21-14 Test ................... ................. 21-57
Replacement ..... . Repair ........... .
Inspection ...
........ 19-13,22
Brake Fluid level Switch Airbag, Front Passenger's

Replacement
........ 23-114
Test ....
. ....................................... 19-10
Brake Lights Alternator

Replacement ................................... 4-29 Overhaul.. ....... 4-30 Circuit Diagram .................................... 22-74
Brake Lines and Hoses

Inspection ............................................ 19-24 Replacement ................. . 19-25
Alternator FR Signal Circuit

AIC Compressor
Replacement ......................................... 21-47 Troubleshooting ................................ 11-134
Brake Master Cylinder Antenna

Replacement ..... 22-103 Replacement ............. ................. 19-15 Inspection ............................................ 19-16
AIC Compressor Clutch

Inspection .................................... 21-48 Overhaul .............................................. 21-49
Audio Unit
Removal/Installation ....................... 22-100
Brake Pads
Inspection/Replacement ............... 19-11,20
AIC Compressor Clutch Circuit

Troubleshooting. ........................... 21-30
Audio Unit Connector

Replacement ....... .
....................... 22-101
Brake Pedal
Adjustment ............................. .
. .... 19-6
AIC Compressor Relief Valve

Replacement ................................... 21-51
AudiolEntertainment
Component Location Index ................. 22-98 Circuit Diagram .................... ..22-99
Brake Pedal Position Switch

Test ........................................................ 22-84
A/C Compressor Thermal Protector

Replacement ........................................ 21-51
Brake Pedal Position Switch Signal Circuit

Troubleshooting ................................ 11-137
A/C Condenser
Replacement .................. . ....... 21-52
A/C Condenser Fan Circuit

Troubleshooting .................................. 21-28 (cant'd)

(cont'd)
Brake System Indicator Circuit Circuit Diagram Conventional Brake Components ..... 19-9 Troubleshooting ABSfTCS Components ....... 19-55
Bulb, Gauge Replacement ...... .
Combination Light Switch Test/Replacement ................................ 22-80 Connecting Rod Bearings Replacement ..................... . Cylinder Head Assembly Component Location Index Inspection Removal Installation
............. 7-8
......... 6-3 ...... 6-6 ............ 6-23 ............... 6-39
............. 22-63
Connecting Rod Bolts Inspection .......................................... 7-24 Connecting Rods Inspection ........................................ 7-5 Connectors (See first page of this Index) Conventional Brake Components Component Location Index .................. 19-3 Troubleshooting ..................................... 19-4 Repair .................................................... 19-8 Coolant Inspection Replacement
Cylinder Head Cover Removal ................................................ 6-22 Installation ....... 6-41 Cylinder Head, Bare Inspection ................................. .
Bulb, Headlight Replacement ......................................... 22-81

Bumper, Front Removal/I nstallation Bumper, Rear
. .... 6-25
.............. 20-85
D
Dampers, Front Replacement ........................................ 18-20 Dampers, Rear Replacement ........................................ 18-34 Dash Vents Removal/Installation ............................ 20-64 Dashboard Removal/Installation Dashboard Center Panel Removal/Installation ....
Removal/Installation
............... 20-86
c
Cable Reel Replacement
................ 10-6 ................................. 10-6
...... 23-119
Coolant Temperature Gauge Troubleshooting .................................. 22-64 Cooling System Component Location Index ................... 10-2 Countershaft Bearings Replacement ..................................... 13-42 Cowl Cover Replacement
Camshaft Inspection ............................................. 6-29
................ 20-66 . ... 20-62
Cargo Area light

Test/Replacement
.......... 22-97
Carpet Replacement ......................................... 20-55
........................... 20-95
Dashboard Lower Cover Removal/Installation ..................... 20-59,63 Dashboard Under Cover Removal/Installation ...
Ceiling light Test/Replacement ............................... 22-96

Charging System Component Location Index ................... 4-20 ................. 4-21 Circuit Diagram ... Troubleshooting. ....................... 4-22 Child Seat Tether Anchor Removal/Installation ............................ 23-11 CKP (Crankshaft Position) Sensor Replacement ....... 11-116 Clutch Component Location Index ...... 12-3 Replacement ............................ 12-9 Clutch Interlock Switch Test ............................................................ 4-6 Clutch Master Cylinder Replacement .......................................... 12-5 Clutch Pedal Adjustment ............... .
Crankshaft Removal ................................................ 7-12 Inspection .............................................. 7-14 Installation ............................................ 7-24 Crankshaft Main Bearings Replacement ......................... .
..... 20-60
Differential Carrier Bearings, M/T Replacement ............ .............. 13-54 Differential Oil Seals, MIT Replacement ...................... 13-55 Differential Pinion Gears, MIT Inspection .... DLC Circuit Troubleshooting
. .... 7-6
Crankshaft Oil Seal, Transmission End Instanation .. .......................... 7-28 Crankshaft Pulley Removal/Installation .............................. 6-11 Cruise Control Actuator Test. .4-43 Replacement ........................................ 4-44 Cruise Control Actuator Cable Adjustment ......... .................... 4-45 Cruise Control Main Switch Test/Replacement ............................. 4-42 Cruise Control Set/Resume/Cancel Switch Test/Replacement .................................. 4-42 Cruise Control System Component Location Index ................... 4-36 Circuit Diagram .................................... 4-37 Cruise Control Unit Input Test ............................................... 4-40
........ 13-53
...................... 11-109
Door Glass Replacement ...................................... 20-9 Adjustment ........................................... 20-11 Door Glass Weatherstrips Replacement ......................................... 20-10 Door Latches Replacement ........................................... 20-7 Door Lock Actuators Test ..................................................... 22-158 Door Lock Knob Switches Test ...................................................... 22-160 Door Lock Swnches Test ............... .
... 12-4
Clutch Pedal Position Switch Test ......................................................... 4-45 Clutch Slave Cylinder Replacement ........................................... 12-7 CMP (Camshaft Position) Sensor Replacement. ................. ..... 11-128 CMP (TDC) Sensors Replacement.
.............. 22-160
Door Outer Handles Replacement .......................................... 20-6
....................... 11-114
Door Panels Removal/Installation.
................... 20 .. 4
EPS Control Unit Removal/I nstallation EPS Indicator Circuit Troubleshooting ....
.......... 17 ..67
Front Speakers Replacement ....
..................... 22 .. 102
Door Sash Trim Replacement ....................................... 20-10 Door Strikers Adjustment .......... .. Door Weatherstrips Replacement
.......... 17-47
Front Suspension Component Location Index ................... 18-3 Fuel and Emissions Description.
................ 20 .. 13
EPS Motor Removal/Installation ............................ 17-49 EVAP Canister Replacement ............... .. EVAP Control System Component Location Index EVAP Two-Way Valve Test ................................ ..
.. ........................ 11-12
....................... 20 .. 11
. ....... 11 .. 189
Fuel Fill Door Adjustment .......................................... 20-93 Fuel Fill Door Opener Replacement Fuel Fill Door Opener Cable Replacement ................... .. Fuel Filter Replacement ..
Drive Bett Inspection ........................ ................... 4-26 Replacement .......................................... 4-26 Drive Belt Auto-tensioner Inspection Replacement Driver's Pocket Removal/Installation. Driver's Tray Removal/Installation ...
........ 11-170
.. 20.. 109
. ...... 11 .. 186
.. 20 .. 107
... 4.. 27
........ 4-28
Evaporator Core Replacement .....
.......... 21-42
.......................... 1,..,52
..... 20 ..60
Evaporator Temperature Sensor Replacement ....... .. ....... 21-37 Test ...................................................... 21-37 Evaporator-Heater Unit Replacement. Exhaust Manifold Removal/I nstallation Exhaust Pipe Replacement ...................... ..
Fuel Gauge Sending Unit Test. .. ............................................. 11-156
................ 20 ..65 .......... 21 .. 43
Fuel Injection System (PGM-FII Component Location Index. Fuel Injectors

Replacement ....
.... 11-49 .. 11 .. 111
DRl (Daytime Running lightsl Control Unit Input Test ................. 22-76 DTCs (See first page of this Index) Dust and Pollen Filter Replacement ............ .
.... 9 .. 7
Fuel lines and Hoses

.............. 9 ..8
Inspection Removal. Installation.
Fuel Pipe Protector Replacement.
.. 11-146 ..11-149
..11 .. 150
................. 21 .. 39
Dynamic Damper. Driveshafts Replacement ...
F
. .. 16..8
Fan Controls Component Location Index. Circuit Diagram Fender Fairing. Front Replacement ..
.. 20.. 104
Fuel Pressure Regulator Replacement .............................. 11-152
.. ........ 10- 11
E
ECT Sensor Replacement.
......... 10 .. 13
Fuel Pulsation Damper Replacement Fuel Pump Replacement
.. 11-154
........ 20.. 103
.. ............................ 11-114
Final Driven Gear, MIT Replacement Frame Repair Chart. Frame Stiffener Replacement .......................... Front Console Removal/Installation. Disassembly/Reassembly. Front Doors Component Location Index .. Adjustment. Front Driveshaft Assembly Inspection ................... .. Removal Disassembly Resassembly . Installation. Front Impact Sensors Replacement ................... ..
..11 .. 153
Electrical Power Steering (EPS) Signal Circuit . Troubleshooting ............... 11-135 Emblems Replacement Engine Assembly Removal. Installation
.......... 13-53
Fuel Pump Circuit Troubleshooting ................................ 11-141 Fuel Supply System Component Location Index Adjustment ............................. .. Test ... Fuel Tank Replacement .. Fuel Tank Vapor Control Valve Test Replacement Fuses {See first page of this Index}
........ 20-114
............... 20.. 100

..................... 5.. 2 ................ 5.. 9
.. 11 .. 140 .. 11 .. 144
.. 11-145
.... 20-113
.......... 20 .. 57 . ........ 20 .. 58
.. 11 .. 155
Engine Block Assembly Component Location Index. Engine Block, Bare Inspection ..... Repair.
. ......... 7.. 3
.. 11-187
............ 20 .. 2 .......... 20 . 12 .......... 16 ..3

............. 16-3 .......... 16-5
.. 11 .. 189
. ........ 7 .. 15 ......... 7-17
Entry light Control System Component Location Index ................. 22-89 Circuit Diagram ................................... 22-90 EPS Components Component Location Index ................ 17-17 Description. .. ............... 17-24 Circuit Diagram ................... ... 17-26
.16..9
.......... 16-17
........ 23 .. 125
(cont'd)

(cant'd)
G
Gauge Assembly Replacement ...... .
Heater Valve Cable Adjustment ......................................... 21-46 High Mount Brake Light Replacement Immobilizer System Component Location Index ... 22-162 .... 22-163 Description ................ .. Circuit Diagram .......................... . .... 22-164 .... 22-165 Troubleshooting Inner Fender. Front ........................ 20,102 Replacement . Inside Rearview Mirror Replacement ..................................... 20-16 Instrument Panel Removal/Installation .
........... 22-82
. ... 22-64
Hood Adjustment ... Hood Insulator Replacement Hood Latch Replacement
Gauges
Component Location Index ................ 22-54 How-to Information .......... ..... 22-56 Circuit Diagram .............. ................... 22-58
........................... ...... 20-87
.......................... 20-89
General Information
(See section 1)
..................... 20-108
..... 20-59
Glove Box
Grille
Replacement ..
..... 20-63 ................... 20-94
Hood Opener Cable Component Location Index ....... 20-105 Replacement ..................................... 20-106 Hood Seal Replacement
Intake Air Bypass Control Thermal Valve Test. .. .. 11-161 Intake Air System Component Location Index .............. 11-159
... 20-88
Intake Manifold Removal/Installation ................... ..
H
Hatch
Adjustment
Horn Test/Replacement ............................. 22-122 Horn Switch Test
. .... 9-2
......... 22-122
..................................... 20-90
Horns Component Location Index ........... 22-120 .. 22-121 Circuit Diagram ... H02S. Secondary Replacement ............................ Hubs Replacement ................ .
Intermediate Shaft Assembly Removal ...... 16-19 .16-20 Disassembly............ Resassembly . ............... ........... ...16-22 Installation ........................................... 16-24
Hatch Handle Replacement .................................... 20-110
Hatch Latch Replacement ........ . Hatch Latch Switch

Test ................................... Hatch Lock Actuator
K
.. .... 11-1'3 Keyless Entry Transmitter Repair ....... . Test .................. .
. ............... 20-110 ............... 22-97
. .... 18,26
.... 22-161
.... 22-161
Test..
.................................. 22-159
Hatch lock Cylinder Replacement ....................................... 20-111
Keyless Entry/Security Alarm System Component Location Index .... 22-150 .. .. 22-151 Circuit Diagram. IAT (Intake Air Temperature) Sensor Replacement ....................................... 11- 115 Keyless Receiver Unit Input Test .................................. 22-153 Knock Sensor Replacement . Knuckles Replacement Front Suspension Rear Suspension
Hatch Spoiler
Replacement ............. .
................... 20-99
Idle Control System Component Location Index Inspection ...................... . Ignition CoiUs) Removal/Installation. Ignition Key Light Test ......... . Ignition Key Switch Test. Ignition Switch Test .............. .. ....... 11-129
Hatch Support Struts Replacement .... .. ............... :....... 20-91 Hatch Weatherstrip Replacement ................... .. ................. 20-92 Hazard Warning Switch Test ...................................................... 22-88 Headlight Adjustment ........................................ 22-78
.... 11-115
..... 11-138 ............... 4-18

.. ..... 22-91
...... 18-11
...... 18-28
L
............. 22-91 . ............................. 22,53 . ... 4-15
.... 4-16 License Plate Light Replacement .. License Trim Replacement .. Lights, Exterior Component Location Index Lights, Interior Component Location Index. Circuit Diagram. ........ 22-83
Re\'l\a.cement ......................................... '2..1-19

Headlights Circuit Diagram .... Headliner Removal/Installation. Heater Control Panel Removal/Installation.
............... 22-71,72
.. ................... 20-54 Ignition System Component Location Index. Circuit Diagram ...................... .. Inspection ............................. ..
....... 20-98 ....... 22-68 22-94

.. ....... 22-95
.4,17
.. ................... 21-38
Immobilizer Control Unit-Receiver Replacement ............. 22-167
Heater Control Power and Ground Circuits Troubleshooting ................................. 21-27
Low Fuel Indicator Test ........................................ 11-158
Moonroof Drain Channel Slider Replacement ................... 20-44 Moonroof Frame Replacement
Oil Pressure Switch Test .... ........................................... 8-4 Replacement ......................................... 8-16 Oil Pump, Engine Overhaul .................. .
Lower Arms
Removal/Installation ............................ 18-19
Lubrication System Component Location Index . 8-3 Test ........................................................... 8-4
............... _._._ .... _._ 20-42
.8-8
Moonroof Glass Adjustment ........................................ 20-37 Replacement .... ................... 20-37 Moonroof Limit Switch Adjustment Test ...................... . Moonroof Motor Replacement. Test ................ .
Oil. Engine Replacement ............................................ 8-5
OPOS Unit
._ ...... _._._._ 20-46 . ._ .... 22-113 ................... _ 20-41 .. 22-112
Replacement ...................... .
Outside Mirror Holders Replacement ..... .
M
MIT Assembly
Removal ....... . Installation .. Disassembly ...... . Resassembly .
..... 23-124 ._ ..... 20-15
............ _ _ ....... _._ 13-4 ... ............... _._._._._ .... _._ 13-8 .. _ 13-14 ..... . ............... __ ._ ... 13-46
Moonroof Sunshade Replacement ............................... 20-40 Moonroof Switch Test/Replacement .............................. 22-112 Moonroof Wind Deflector .. _._._ .... _._._ .... 20-38 Replacement Moonroof/Sunroof Component Location Index ... 20-35, 22-108 Test ..................................... ........... 20-48 Circuit Diagram ................................. 22-109
Outside Power Mirror Actuators Test .............................. 22-117 Replacement ................................. '" 22-118 Outside Power Mirror Switch Test ................ ............. 22-117 Outside Power Mirrors Replacement .. Component Location Index Circuit Diagram Test ...................... .
MIT Change Lever Inspection ................... . Disassembly/Reassembly
...... 13-19 ........ 13-20
MIT Countershaft Assembly Inspection ..... ......................... 13-31,33 Disassembly ............................. 13-32 Resassembly ................. .......... 13-34 MIT Differential Component Location Index ................ 13-52 Adjustment ....... 13-56 MIT Mainshaft Assembly Inspection ... 13-23,26 Disassembly......... .................... 13-25 Resassembly ... ........................... 13-28 Adjustment .............................. 13-43 MIT Reverse Shift Fork Inspection .......... .
. ........ 20-15 .. 22-114 ___ .. 22-115 _. _._. 22-116
p
Parking Brake I nspection/Adjustment
MTF
Inspection/Replacement.
.... 13-3 .............. 19-7
Multiplex Control System Component location Index .22-168 Circuit Diagram. . .................... 22-169 Description ........................................ 22-171 Troubleshooting .............................. 22-172 Multiplex Control Unit, Under-dash Input Test Entry light Control System ............. 22-92 Keyless Entry/Security Alarm System. ............... 22-155 Multiplex Control System ............. 22-175 Wiper/Washer ..... ............... 22-141
Parking Brake Cable Replacement. ............................. 19-26 Parking Brake Switch Test.
. ... _._._._. 13-19
_ ........... _19-10
MIT Shift Lever Replacement ....................................... 13-51 Mainshaft Bearings Replacement .... ,.. Maintenance (See section 3)
Passenger's Tray Removal/Installation ............................ 20-65 PCVValve Replacement. Test ..................... . Piston Rings Replacement. Pistons Replacement Installation
. ...................... 13-41
_ 11-169 .... . ... 11-169
N
........ 11-46
Noise Reduction Condenser Test .................... ................ 22-107
. ................................. 7-21 ...... _7-18 .......... _ ........ _ _._._ ..... _7-23 ..
MIL
How-to Information.
MIL Circuit Troubleshooting.
. .. _ _._ ... _._._ ..... _11-97 ....
Mirrors Component Location Index Mode Control Motor Replacement. Test ...... .
........... 20-14 .21-35 ..21-35
o
Oil Filter Replacement. Oil Filter Feed Pipe Replacement.
Power Relay Test. . ......................................... 22-51 Power Window Motor, Driver's Test. ................................... 22-129
.... 8-6 ......... 8-7 .............. 7-11 ...... 7-27
Power Window Motors, Passenger's Test. ......... 22-132 Power Window Switch, Master Input Test . ............... 22-126 Test ..................................................... 22-128 Replacement ...................................... 22-133
Moonroof Auto Stop Switches Test ..... .................................... 22-113 Moonroof Control Unit Input Test . ......................... 22-110 Moonroof Drain Channel Replacement. ................................... 20-39
Oil Pan Removal Installation.
(cont'd)

(cont'd)
Power Window Switch, Passenger's Input Test ........ .... 22-130
J
Rocker Arm Assembly
Removal............................ .. ....... 6-26 Disassembly/Reassembly ....... 6-27 Installation ........................................... 6-38
Specifications (See section 2)

SRS Component Location Index .. 23-13 .. 23-31 Description Circuit Diagram .................................... 23-34 Inspection/Replacement ... .23-112
Test .................................................... 22-132 Replacement ....................................... 22-133

Power Windows Component Location Index .............. 22-124
Rocker Arms
Test ........................................... 6-7 .. .................. 6-28 Inspection ..........
Circuit Diagram..
.22-125
Roof Moldings
a
Ouarter Window Glass Replacement ........................................ 20-29
Replacement ........................................ 20-97
SRS Indicator Circuit Troubleshooting .............................. 23105 SRS Unit

Replacement.
5
Seat Belts
Component location Index ................... 23-3
.......... 23122
Stabilizer Bar
Replacement Front Suspension ............................. 18-17 Rear Suspension ............................. 18-30
R
Radiator Test Replacement ... Common Circuit
Troubleshooting .......... 21-29
Seat Belts, Front

Replacement Inspection
Stabilizer links
............................ 234 ............................ 239
Removal/Installation Front Suspension ............................. 18-18 Rear Suspension ............................. 18-31
................................. 103 .............................. 1010
Seat Belts, Rear

Replacement ........................................... 23-7
Starter
Test ............................................................ 4-8 Replacement ........................................... 4-9 Overhaul ................................................. 4-10
Radiator and Condenser Fans
Seat Cover, Front

Replacement ......................................... 20-75
Radiator Cap Test .............................................. 10-3
Seat Cushion Cover, Rear

Replacement ... .. ........................ 20-84
Starter Solenoid
Test ........................................................... 4-7
Radiator Fan Assembly Test .......................................................... 10-4 Radiator Fan Circuit

Troubleshooting ................................... 10-14
Seat, Driver's
Removal/Installation ............................ 20-71 Disassembly/Reassembly ................... 20-73
Starting System
Component Location Index ........... .4-3 Circuit Diagram ........................................ 4-4 Troubleshooting ....................................... 4-5
Seat, Front Passenger's

Disassembly/Reassembly ................... 20-74
Steering
Component Location Index ................... 17-3 Inspection ............................................... 17-4
Radiator Fan Switch

Replacement ......................................... 10-17 Test ........................................................ 10-17
Seat, Rear
...... 2080
Steering Column Radiator Fan Switch Circuit

Troubleshooting ..................... . .. ... 10-16
Seat-back Cover, Rear

Replacement ........................................ 20-82
Removal/Installation .............................. 17-9 Inspection ........... .17-11
Rear Air Outlet

Replacement ....................................... 20-104
Seat-back Latch, Rear

Replacement ..................... .. .. .... 20-81
Steering Gearbox
Removal ................................................ 17-51 Overhaul.. .. .......... 17-55 Installation .............................. 17-63

Component Location Index ........... 22-104 Circuit Diagram .................................. 22-105 Test. .................. 22-106
Seat-back Striker, Rear

Replacement ........................................ 20-81
Steering Hanger Beam Seats

Component Location Index ................ 20-70 Replacement .......
............ 2068
Rear Window Defogger Wires

Repair .................... .. ..... 22-106
Steering linkage Shift Forks

Inspection ............................................ 13-21 Disassembly/Reassembly .................. 13-22 Inspection ............................................... 17-5
Rear Window Glass

Replacement ....................................... 20-25
Steering Lock
Replacement.
.......................... 1712
Shift Lever Trim Recirculation Control Motor

Replacement ......................................... 21-36 .21-36 Test ................................ Removal/Installation ........................... 20-61
Steering Rack Guide

Adjustment ........................................... 17-13
Side Airbag, Driver's

Replacement ......................... 23-115
Steering Wheel
Inspection ............................................. Removal ................................................. Disassembly/Reassembly ..... Installation ......... 17-4 17-6 17-7 17-8
Recirculation Control Motor Circuit

Troubleshooting ................................. 21-25
Side Impact Sensors

Replacement ...................................... 23-123
Refrigerant
Replacement Test ............... . ..... 21-53,54,55
Side Marker light

Replacement ......................................... 22-83
.......................... 2156
Subframes
Replacement ....................................... 20-112
Refrigerant Oil
Replacement ........................................ 21-6
Spark Plugs
Inspection ............................................... 4-19
Suspension
Adjustment ........................................... 18-4
Synchro Ring, Triple-cone Inspection
v
Valve Guides Inspection .......................... .. Replacement .................. . Valve Seats Repair .......................... ..
Windows Component Location Index Windshield Glass Replacement ..
....... 20-17 ..20-19
.............. 13-39
Synchro Sleeve
Inspection/Reassembly . ............... 13-39
........... 6-32 ........... 6-33 ........... 6-35
Wiper Intermittent Control Unit, Rear Window ......... 22-138 Input Test Wiper Motor, Rear Window Replacement ..................................... 22-146
T
Taillight Replacement ................. .
............... 22-82 10-4 ..10-8
Valves Adjustment ....................... .. Removal Inspection Installation Vehicle Speed Signal Circuit Troubleshooting.
............. 6-9 ........... 6-31 ........... 6-32 ........... 6-37 ......... 22-65 ......... 22-67 ............. 6-8
........ 6-24
Wiper Motor. Windshield Test. .. ............................................ 22-143 Replacement ..................................... 22-145 Wiper/Washer Component Location Index .............. 22-134 Circuit Diagram .......................... 22-136,137 Wiper/Washer Switch Test/Replacement .............................. 22-140 Wire Harnesses (See first page of this Index) Wiring System How-to Information .............................. 22-3 Relay and Control Unit Locations ............................... 227,8,11.12
Thermostat Test ... Replacement .......................... .

Throttle Body
VSS
Replacement
VTC Actuator Inspection Replacement .................. ..
Test ...
11-160 ............. 11-165 Removal/Installation .. Disassembly/Reassembly. ............. , 1-166 ....... 11-163 ......... 11-164 ........... 17-67
..... 6-12 . .... 6-15
Throttle Cable Adjustment. Removal/Installation ........ . Tie-rod Ball Joint Boots
VTC Oil Control Solenoid Valve Removal ............................................. 11-127 VTCSystem Component Location Index VTEC Solenoid Valve Removal/Inspection
Replacement
Timing/Cam Chain Removal
Installation.
....... 11-117
..... 11-128
Timing/Cam Chain Auto-tensioner Removal/Installation ... ............ 6-19 Timing/Cam Chain Case Oil Seal Installation .................. 6-21 Trailing Arms Removal/Installation ....... .
W
Washer Fluid level Switch Test/Replacement. Washer Fluid Reservoir Replacement Washer Motor, Windshield Test ....................... . Washer Tube, Windshield Replacement ........................ .
.. ..... 22-144
........... 18-33
....... 22-146
Trim Component Location Index ................. 2049 Removal/Installation .......... 20-50, 51, 52, 53 Troubleshooting (See first page of this Index) Turn Signal Light Replacement ......... Turn Signal/Hazard Relay Input Test . ........................
...... 22-144 ...... 22-147
................ 22-84
Water Outlet Installation ........................................... 10-9 Water Passage Installation. Water Pump Inspection .. Replacement Wheel Bearings Inspection Wheel Speed Sensors Inspection .......................... . Replacement. Wheels and Tires Inspection
.. .............. 22-87
.. ......... 10-9
Turn Signal/Hazard Warning Lights Component Location Index. ....... 22-85 Circuit Diagram. ...2286
........... 10-5
........... 10-5
... 18-8
u
Under-dash Fuse/Relay Box Removal/Installation. .. .............. 22-49 Upper Arms Removal/Installation.
......... 19-59 .. ....... 1959

........... 18-9
.. .............. 18-32

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INTRODUCTION

Specifications Maintenance Engine Electrical Engine Cooling Fuel and Emissions

Instructions - how to service this vehicle correctly and safely.

Under-hood Emission Control Label .................... ................. 1-7

Lift and Support Points ........................ 1-8

NRH3: 5-speed Manual b. Serial Number

Chassis and Paint Codes - 2003 Model

a. Transmission Type NRH3: 5-speed Manual b. Serial Number

Vehicle Identification Number IVIN)

Vehicle Identification Number (VIN)

Engine Number Transmission Number

Warning/Caution Label Locations

SRSWARNING INFORMATION FRONT PASSENGER MOOULE OANGER MONITOR NOTICE

SlOE MOOULE DANGER SIDE AIRBAG CAUTION

RADIATOR CAP CAUTION

AIR CONDITIONING INFORMATION

Under-hood Emission Control Label

Engine and Evaporative Families:

vehicle, first support the front of the vehicle with tali

2. Raise the hoist a few inches, and rock the vehicle

vehicle that is supported only by a jack.

on the back of a truck. This is the best way of

designed to support the vehicle's weight.

Standards and Service Limits

.Ev_________ ----1-3-4-2 NGK: IZFR6Kll DEN SO: SKJ20DR-Mll

Firing order Spark plug

'1.0-1.1 mm (0.039-0.043 in.)

I 1.3 mm (0.051 in,)

Ignition timing Alternator

temperature Coif (rotorl resistance

14.4 mm (D.S7 in.)

, '4.0 mm (0,55 in.!

I 1.5 mm 10.06 in.1

2.9-3.5 N (0,30-0.36 kgf, O.7-0.Blbs)

1.1 kW 0.50-0.80 mm (0.020-0.031 in.) 0.02 mm (0.001 in.) max.

Commutator run cut Commutator O.D.

0.05 mm 10.002 in.1

,Iy Ename Assem bl

200 kPa 12.0 kgf/em', 28 psi I

0.05 mm (a.D02 in.)

0.4 mm (0.02 in.)

0.030-0.069 mm (O.OOl-0.003 in.) ' 0.060-0.099 mm (0.002- 0.004 in.)

0.15 mm W,006 in.) 0.'5 mm (0.006 in.)

Cam lobe height

Intake, primary Intake, secondary

Installed height Rocker arms Arm-to-shaft clearance

Intake Exhaust Intake Exhaust

Standards and Service Limits

I 0.07 mm (0.003 in.) max.

186.070 mm (3.3886 in.)

186.000-86.010 mm (3.3858- 3.3862 in,)

Bore taper Rebaring limit

0.05 mm (O.OO~_~ 0.25 mm (0.01 in.)

Skirt 0.0. at 11 mm (0.4 in.) from

0.020-0.040 mm (O.Og08-0.0016 in.) 1.220-1.230 mm (0.0481-0.0484 in.) 1.220-1.230 mm {Q.0481-Q.0484 in.}

2.005 -2.025 mm (0.0789

~r:nm (D.OSl in.) o.6~-.~-io~0.0~) I 0.13 ~m (0.005 j~'.)

Second (REKEN) , Second (FEDERAL MOGULI Top Second

Ring end gap

-+--.___..__ .~:-_2_1._96_5mm 1O.8646_0_._86_48",i",n:'j.1..:2,-,1:.::.95_3_m_m_IO,8_64_3_in_.1

0.15-0.30 mm (0.006 -0.012 in.) , 54.984-55.008 mm (2.1648-2.1657 in.)1

"Ro::.d::i."m"a",in."I,, o:.::u:.:rn"ac.l"ta"p:.::e."r_ _ _ _--l_______+0-'-.0:..:0:.::5-'m"m l.::.O:.::.O.::.00:::2=in .) max. ccc

-+--._.. .~:-_2_1._96_5mm 1O.8646_0_._86_48",i",n:'j.1..:2,-,1:.::.95_3_m_m_IO,8_64_3_in_.1