Page 1 Main Menu Table of Contents Chassis and Paint Codes U.S. Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 2 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 3 Main Menu Table of Contents Warning/Caution Label Locations D: DRIVER'S INFLATOR CAUTION A: CABLE REEL CAUTION DANGER REFER TO SERVICE MANUAL FOR DETAILED INSTRUC- EXPLOSIVE/FLAMMABLE TIONS. CONTACT WITH ACID, WATER OR HEAVY METALS SUCH AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- FUL AND IRRITATING GASES OR EXPLOSIVE COM- B: STEERING WHEEL NOTICE POUNDS.
Page 4 Main Menu Table of Contents E: DRIVER INFORMATION: U.S. MODEL WARNING DEATH OR SERIOUS INJURY CAN OCCUR. • CHILDREN 12 AND UNDER CAN BE KILLED BY THE...
Page 5 Main Menu Table of Contents Warning/Caution Label Locations K: PASSENGER'S INFLATOR CAUTION M: TENSIONER ELR CAUTION DANGER WARNING EXPLOSIVE/FLAMMABLE EXPLOSIVE MATERIAL INSIDE CONTACT WITH ACID, WATER, OR HEAVY METALS SUCH YOU CAN BE SERIOUSLY HURT OR BURNED. AS COPPER, LEAD, OR MERCURY MAY PRODUCE HARM- •...
Page 6 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families Engine Family: Example: 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES. 49ST (49 States/Federal): THIS VEHICLE CONFORMS TO U.S.
Page 7 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6 *1: NIHON HATSUJO made, *2: CHUO HATSUJO made. M/T: Manual Transmission A/T: Automatic Transmission *3: Measured between the rocker arm and camshaft.
Page 8 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 9 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emission — Section 11 Clutch — Section 12 M/T: Manual Transmission A/T: Automatic Transmission...
Page 10 Main Menu Table of Contents Manual Transmission — Section 13...
Page 11 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 12 Main Menu Table of Contents Automatic Transmission — Section 14 * Clutch end plate diameter: 1st: 116 mm (4.57 in) 1st-hold, 2nd, 3rd and 4th: 120 mm (4.72 in)
Page 13 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 14 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 15 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 16 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 17 Main Menu Table of Contents Standards and Service Limits Steering — Section 17 Suspension — Section 18 Brakes —- Section 19 M/T: Manual Transmission A/T: Automatic Transmission...
Page 18 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23 *1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values.
Page 19 Main Menu Table of Contents Design Specifications...
Page 20 Main Menu Table of Contents Design Specification...
Page 21 Main Menu Table of Contents...
Page 22 Main Menu Table of Contents Body Specifications...
Page 23 *2: Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. *3: Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 24 Main Menu Table of Contents NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 25 Main Menu Table of Contents Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-5* 8-4* 10-2* 11-149* 6-9* 23-96* 6-14* ,10-11* 22-88* 23-109* 11-138* 11-129* 10-5* 13-3* 14-105*...
Page 26 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 27 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 4-7): 8-2, 10-2* 11-149* 6-10* 23-96* 6-14* 10-11* 22-88* 23-109* 11-138* 11-129* 10-5* 13-3* 14-105* -4, 19-6, 19-7,...
Page 28 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 29 Main Menu Table of Contents Engine Oil Inspection Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. Make certain that the oil level indicated on the dip- stick is between the upper and lower marks.
Page 30 Main Menu Table of Contents Engine Oil Replacement CAUTION: Remove the drain plug carefully while the engine is hot, the hot oil may cause scalding. Warm up the engine. Drain the engine oil. Reinstall the drain plug with a new washer, and refill with the recommended oil.
Page 31 Main Menu Table of Contents The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: Ambient Temperature An oil with a viscosity of 10W - 30 is preferred for improved fuel economy and year-round protection in the vehicle.
Page 32 When the 16P Data Link Connector (DLC) (located to the lower left of the glove compartment) is connected to the OBD II Scan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
Page 33 Main Menu Table of Contents Checking the Diagnostic Trouble Code (DTC) with the Service Check Connector and Special Tool When the TCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. When the Service Check Connector (2P) (located to the lower right of the glove compartment) is connected with the special tool as shown, the indicator light will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
Page 34 Main Menu Table of Contents Troubleshooting Procedures SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or service. 1. Remove the seat back panels (see section 20).
Page 35 • The TCM memory cannot be cleared by using the OBD II scan Tool or Honda PGM Tester; be sure to remove the CLOCK fuse to reset the TCM.
Page 36 Main Menu Table of Contents Symptom-to-Component Chart Electrical System 14-10 14-12 14-60 14-61 14-62 14-64 14-14 14-16 14-70 14-71 14-72 (DTC)*: The DTCs in the parentheses are the numbers the indicator light indicates when the service check connector is connected to the special tool (SCS service connector).
Page 37 Main Menu Table of Contents 14-73 14-74 14-18 14-77 14-79 14-19 14-20 (DTC)*: The DTCs in the parentheses are the numbers the indicator light indicates when the service check connector is connected to the special tool (SCS service connector). If the self-diagnostic indicator light does not blink, perform an inspection according to the table below.
Page 38 Main Menu Table of Contents Lock-up Control Solenoid Valve A/B Replacement Test Disconnect the 2P connector from the lock-up con- NOTE: Lock-up control solenoid valves A and B must be trol solenoid valve assembly. removed/replaced as an assembly. Remove the mounting bolts and lock-up control Measure the resistance between the No.
Page 39 Main Menu Table of Contents Shift Control Solenoid Valve A/B Test Replacement NOTE: Shift control solenoid valves A and B must be Disconnect the 2P connector from the shift control removed/replaced as an assembly. solenoid valve assembly. Remove the mounting bolts and shift control sole- Measure the resistance between the No.
Page 40 Main Menu Table of Contents Chassis and Paint Codes U.S. Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 41 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 42: California Regulations Applicable To
Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families Example: Engine Family: Evaporative Family: 50 STATE TIER 1: THIS VEHICLE CONFORMS TO U.S. ERA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES.
Page 43: Cylinder Head/Valve Train — Section
Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 44 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 45: Cooling — Section
Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emission — Section 11 Clutch — Section 12 M/T: Manual Transmission A/T: Automatic Transmission...
Page 46 Main Menu Table of Contents Manual Transmission — Section 13...
Page 47 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 48 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 49 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 50 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 51 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 52 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 53 Main Menu Table of Contents Standards and Service Limits Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 54 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23 *1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values.
Page 55 Main Menu Table of Contents Design Specifications...
Page 56 Main Menu Table of Contents Design Specification...
Page 57 Main Menu Table of Contents...
Page 58 Main Menu Table of Contents Body Specifications...
Page 59 Main Menu Table of Contents Rear Window Removal Remove the rear defogger sub-harness and ground CAUTION: Wear gloves to remove and install the rear window. cable/antenna lead from the upper molding. UPPER MOLDING To remove the rear window, first remove these items: •...
Page 60 Main Menu Table of Contents Apply protective tape along the edge of the body. Using an awl, make a hole through the adhesive from inside the vehicle. Push piano wire through the hole, and wrap each end around a piece of wood.
Page 61 Main Menu Table of Contents Rear Window Installation 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 rear window flange. NOTE: • Do not scrape down to the painted surface of the body;...
Page 62 Main Menu Table of Contents Rear Window Installation (cont'd) Set the rear window upright on the body, then cen- With a sponge, apply a light coat of body primer to ter it in the opening. Make alignment marks across the original adhesive remaining around the rear the rear window and body with a grease pencil at window opening flange.
Page 63 Main Menu Table of Contents Pack adhesive into the cartridge without air pockets 10. Use suction cups to hold the rear window over the to ensure continuous delivery. Put the cartridge in a opening, align it with the alignment marks made in caulking gun, and run a bead of adhesive around step 4, and set it down on the adhesive.
Page 64 Main Menu Table of Contents Emblems Installation Install the emblem. Push the speed nuts on all the way so there is no space between the emblem and the rear bumper. Attachment Points (Reference): type S EMBLEM SPEED NUT REAR BUMPER type S EMBLEM...
Page 65 Main Menu Table of Contents Battery Test • Battery fluid (electrolyte) contains sulfuric acid. It may cause severe burns if it gets on your skin or in your eyes. Wear protective clothing and a face shield. — If electrolyte gets on your skin or clothes, rinse it off with water immediately. —...
Page 66 Main Menu Table of Contents Charge on High Setting (40 amps) Charge until EYE shows charge is OK; plus an additional 30 minutes to assure full charge. NOTE: If the battery charge is very low, it may be necessary to bypass the charger's polarity protection circuitry.
Page 67 Main Menu Table of Contents Chassis and Paint Codes U.S. Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 68 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 69 Main Menu Table of Contents Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER AUTOMATIC TRANSMISSION MANUAL TRANSMISSION NUMBER NUMBER...
Page 70 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULA- TIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSEN- GER CARS.
Page 71 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6 *1: NIHON HATSUJO made, *2: CHUO HATSUJO made. M/T: Manual Transmission A/T: Automatic Transmission *3: Measured between the rocker arm and camshaft.
Page 72 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 73: Fuel And Emission — Section
Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emission — Section 11 Clutch — Section 12 M/T: Manual Transmission A/T: Automatic Transmission...
Page 74 Main Menu Table of Contents Manual Transmission — Section 13...
Page 75 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 76 Main Menu Table of Contents Automatic Transmission — Section 14 * Clutch end plate diameter: 1st: 116 mm (4.57 in) 1st-hold, 2nd, 3rd and 4th: 120 mm (4.72 in)
Page 77 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 78 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 79 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 80 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 81 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19 M/T: Manual Transmission A/T: Automatic Transmission...
Page 82 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23 *1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values.
Page 83 Main Menu Table of Contents Design Specifications...
Page 84 Main Menu Table of Contents Design Specification...
Page 85 Main Menu Table of Contents...
Page 86 Main Menu Table of Contents Body Specifications...
Page 87 *2: Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. *3: Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 88 Main Menu Table of Contents NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 89 Main Menu Table of Contents Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-2* 8-5* 8-4* 10-2* 11-149* 6-10* 23-96* 6-14* , 10-11* 22-88* 23-109* 11-138* 11-129* 10-5*...
Page 90 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 91 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 4-7): 8-2* 8-2* 10-2* 11-149* 6-10* 23-96* 6-14* 10-11* 22-88* 23-109* 11-138* 11-129* 10-5* 13-3* 14-105*...
Page 92 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 93 Main Menu Main Menu Table of Contents Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR VEHICLE SPEED SENSOR (VSS) THROTTLE POSITION (TP) SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR EVAPORATIVE EMISSION...
Page 94 Main Menu Main Menu Table of Contents Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. SERVICE CHECK CONNECTOR (2P) DATA LINK CONNECTOR (16P) INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM THROTTLE BODY (TB) ELECTRICAL AIR CLEANER (ACL) CURRENT...
Page 95 Main Menu Main Menu Table of Contents Table of Contents For Troubleshooting of DTC related components, see chart on page 11-52. ONBOARD REFUELING VAPOR RECOVERY (ORVR) VAPOR RECIRCULATION VALVE FUEL PUMP ONBOARD REFUELING FUEL FEED PIPE VAPOR RECOVERY (ORVR) VENT SHUT VALVE Testing, page 11-70 FUEL FILTER...
Page 96 Main Menu Table of Contents System Description Vacuum Connections For Troubleshooting of DTC related components, see chart on page 11-52. ONBOARD REFUELING VAPOR RECOVERY (ORVR) CONTROL VENT SHUT VALVE page 11-7 EVAP PURGE CONTROL SOLENOID To EVAP TWO-WAY VALVE VALVE AIR CONTROL VALVE To ONBOARD REFUELING...
Page 97 Main Menu Table of Contents Control Box: For Troubleshooting of DTC related components, see chart on page 11-52. AIR CONTROL SOLENOID VALVE EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INTAKE AIR BYPASS (IAB) CONTROL SOLENOID VALVE...
Page 98 Main Menu Table of Contents System Description Vacuum Connections Vacuum hose No. FRONT PRIMARY HEATED OXYGEN SENSOR (HO2S) FRONT THREE WAY CATALYTIC CONVERTER (TWC) (BANK 2, SENSOR 1) REAR THREE WAY CATALYTIC CONVERTER (TWC) REAR PRIMARY HEATED OXYGEN SENSOR (HO2S) POSITIVE CRANKCASE VENTILATION (PCV) VALVE (BANK 1, SENSOR 1) EXHAUST GAS RECIRCULATION (EGR) VALVE...
Page 99 Main Menu Table of Contents System Description Electrical Connections FUSES BRAKE LIGHTS HORN (20A) THL MOTOR (20A)** CLOCK (7.5A)* ACG (120A)** ACG(S) (20A)** IG COIL (30A)** No. 2 FUEL PUMP SRS2 (15A) In the under-hood fuse/relay box No. 5 BACK-UP LIGHTS In the engine compartment fuse/relay box ALTERNATOR In the under-dash fuse box...
Page 100 Main Menu Table of Contents System Description Electrical Connections...
Page 101 Main Menu Table of Contents TERMINAL LOCATIONS...
Page 102 Main Menu Table of Contents System Description Electrical Connections...
Page 103 Main Menu Table of Contents (To page 11-14)
Page 104 Main Menu Table of Contents System Description Electrical Connections (From page 11-13}...
Page 105 Main Menu Table of Contents (To page 11-16)
Page 106 Main Menu Table of Contents System Description Electrical Connections (From page 11-15)
Page 107 Main Menu Table of Contents...
Page 108 Main Menu Table of Contents System Description Electrical Connections...
Page 109 Main Menu Table of Contents...
Page 110 Main Menu Table of Contents System Description Electrical Connections...
Page 111 Main Menu Table of Contents...
Page 112 Main Menu Table of Contents System Description Electrical Connections...
Page 113 Main Menu Table of Contents...
Page 114 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Right Side)]...
Page 115 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL7BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 116 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Left Side)]...
Page 117 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 118 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 119 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 120 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 121 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 122 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 123 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 124 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd)
Page 125 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 126 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd)
Page 127 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 128 When the Malfunction Indicator Lamp (MIL) has been reported on, or there is a driveability problem, use the appropri- ate procedure below to diagnose and repair the problem. A. When the MIL has come on: MALFUNCTION 1. Connect the Honda PGM Tester or an OBD II INDICATOR scan tool to the 16P Data Link Connector (DLC) LAMP...
Page 129 The ECM is part of the immobilizer system. If you substitute a known-good ECM, the ECM will have a different immo- bilizer code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester.
Page 130 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures (cont'd) Symptom Chart Listed below are symptoms and probable causes for problems that do not cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL was reported on, go to page 11-38. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated.
Page 131 Main Menu Table of Contents Probable Cause List (For the DTC chart, see page 11-52.) Section 23 11-58 See DTC chart...
Page 132 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement ECM CONNECTOR A (26P) Wire side of female terminals ECM CONNECTOR A (26P) NOTE: Standard battery voltage is 12 V.
Page 133 Main Menu Table of Contents ECM CONNECTOR B (16P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR B (16P) *: M/T...
Page 134 Main Menu Table of Contents Troubleshooting - Engine Control Module Terminal Arrangement (cont'd) ECM CONNECTOR C (12P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR C (12P)
Page 135 Main Menu Table of Contents ECM CONNECTOR D (22P) Wire side of female terminals ECM CONNECTOR D (22P) NOTE: Standard battery voltage is 12 V.
Page 136 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR F (26P) *: M/T...
Page 137 Main Menu Table of Contents ECM CONNECTOR G (12P) Wire side of female terminals ECM CONNECTOR G (12P) NOTE: Standard battery voltage is 12 V.
Page 138 Main Menu Table of Contents Fuel Supply Fuel Line Check all hose clamps and retighten if necessary. Do not disconnect.
Page 139 Main Menu Table of Contents Emission Control System Evaporative Emission (EVAP) Controls Description The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system consists of the following components: A. Evaporative Emission (EVAP) Control Canister An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP control canister into the engine and burned.
Page 140 Main Menu Table of Contents Pulsed Secondary Air Injection System Description The air pump system is designed to advance the activation of the catalyst and to reduce the hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas. The system operates after the engine starts under the following conditions: •...
Page 141 Main Menu Table of Contents Mainshaft Assembly Index NOTE: The 3rd/4th and 5th/6th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th/6th synchro hubs, however, should be installed with a press before lubricating them. INNER SYNCHRO RING SYNCHRO CONE OUTER SYNCHRO RING...
Page 142 Main Menu Table of Contents Clearance Inspection Measure the clearance between the spacer collar Measure the clearance between the distance collar and 5th gear. and 6th gear. Standard: 0.06 - 0.19 mm Standard: 0.06 - 0.19 mm (0.002 - 0.007 in) (0.002 - 0.007 in) Service Limit: 0.3 mm (0.012 in) Service Limit: 0.3 mm (0.012 in)
Page 143 Main Menu Table of Contents Shift Lock Release Cover Installation —————————— Take the "SHIFT LOCK RELEASE" cover off the A/T Make sure the slot on the left end of the cover is exposed. If the slot is covered, remove the cover gear position indicator panel, and peel off the remaining adhesive.
Page 144 Main Menu Table of Contents Troubleshooting Precautions EPS Indicator Light Under normal conditions, the EPS indicator in the gauge assembly 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 circuits are operating correctly. If there is any trouble in the system, the EPS indicator turns on during driving, and the power steering assist is turned off.
Page 145 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Symptom-to-System Chart 17-25 • Initial diagnosis: Performed right after the engine starts until the EPS indicator goes off. • Regular diagnosis: Continuously performed (under some conditions) after the EPS indicator goes off until the engine stops. •...
Page 146 Main Menu Table of Contents Component Locations SERVICE CHECK RIGHT-REAR WHEEL SENSOR CONNECTOR (2P) UNDER-HOOD FUSE/RELAY BOX RIGHT-FRONT WHEEL SENSOR LEFT-REAR WHEEL SENSOR UNDER-DASH FUSE BOX ABS MODULATOR LEFT-FRONT CONTROL UNIT WHEEL SENSOR GAUGE ASSEMBLY UNDER-HOOD FUSE/RELAY BOX BRAKE LIGHTS/HORN ABS INDICATOR (20 A) FUSE (30 A) FUSE...
Page 147 Main Menu Table of Contents System Description Features/Construction 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.
Page 148 Main Menu Table of Contents ABS Control Unit Terminal Arrangement ABS CONTROL UNIT 25P CONNECTOR Terminal side of female terminals *1: WithTCS...
Page 149 Main Menu Table of Contents *1: WithTCS...
Page 150 Main Menu Table of Contents Troubleshooting Precautions ABS Indicator 1. If the system is OK, the ABS indicator comes on for two seconds (initial turn on) after turning the ignition switch ON (II), then the ABS indicator goes off. After that time, the ABS indicator comes on again after starting the engine, then the ABS indicator goes off two seconds after the ignition switch return to ON (II).
Page 151 ABS Function Test To simulate ABS operation and activate the solenoid valves and pump, use the Honda PGM Tester. Connect the PGM Tester to the 16P Data Link Connector (DLC). When the System Select menu is displayed, select the ABS...
Page 152 Diagnostic Trouble Code (DTC) Diagnostic Trouble Code (DTC) Indication NOTE: This operation can also be done with the Honda PGM Tester. 1. Connect the SCS service connector to the service check connector (2P) located under the glove box. 2. Turn the ignition switch ON (II) without the brake pedal depressed.
Page 153 Main Menu Table of Contents DTC Clearing NOTE: This operation can also be done with the Honda PGM Tester. 1. Connect the SCS service connector to the service check connector (2P) located under the glove box. 2. Depress the brake pedal.
Page 154 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Troubleshooting Index 19-13 19-15 19-18 19-19 19-20 19-21 19-22 19-23 19-24 19-25 19-26 19-27 19-28 19-28...
Page 155 Main Menu Table of Contents ABS Modulator-Control Unit Removal/Installation 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. • Take care not to damage or deform the brake lines during removal and installation.
Page 156 Main Menu Table of Contents ABS Indicator Relay Pulsers/Wheel Sensors Inspection Inspection Check for continuity between terminals Check the front and rear pulser for chipped or dam- There should be continuity. aged teeth. 2. Connect a 12 V battery across terminals Measure the air gap between the wheel sensor and There should be no continuity between terminals pulser all the way around while rotating the pulser.
Page 157 Main Menu Table of Contents Wheel Sensor Replacement NOTE: Be careful when installing the sensors to avoid twisting the wires. Front CORROSION RESISTANT BOLT 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) 8 x 1.25 mm 22 N-m (2.2 kgf-m,...
Page 158 Main Menu Table of Contents Interior Trim Replacement Coupe: Disassemble in numbered sequence. NOTE: • When removing the rear trim panels, take care not to damage the control units and relays. • Take care not to scratch the trim panels. Installation is the reverse of the removal procedure.
Page 159 Main Menu Table of Contents Seat Belt Child Seat Tether Anchor Removal/Installation An attachment point is provided for a seat mounted child restraint system that uses a top tether. The attachment point is located on the right rear trim panel behind the passenger's seat-back. The child seat tether anchor is installed on the right rear trim panel.
Page 160 Main Menu Table of Contents Relay and Control Unit Locations Front Compartment RADIATOR FAN HIGH RELAY RADIATOR FAN LOW RELAY UNDER-HOOD RELAY BOX A A/C COMPRESSOR WINDSHIELD WIPER HORN RELAY INTERMITTENT RELAY CLUTCH RELAY WINDSHIELD WIPER HIGH RELAY POWER AMPLIFIER RELAY CONDENSER FAN UNDER-HOOD RELAY...
Page 161 Main Menu Table of Contents Engine Compartment AIR PUMP RELAY Wire colors: YEL/BLK, BLK, WHT and BLK...
Page 162 Main Menu Table of Contents Gauge Assembly Gauge/Terminal Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or service. SPEEDOMETER: Indicates 60 mph [60km/h] at 1.026 [637] rpm of the vehicle speed sensor (VSS).
Page 163 Main Menu Table of Contents Gauge Assembly Coolant Temperature Gauge Test Coolant temperature gauge nee- dle does not move at all. ECM CONNECTOR A (26P) 1. Turn the ignition switch OFF. 2. Connect ECM connector ter- minal A18 to body ground with a jumper wire.
Page 164 Main Menu Table of Contents Coolant temperature gauge nee- dle goes past the Hot mark. 1. Turn the ignition switch OFF. 2. Disconnect ECM connector A (26P). 3. Turn the ignition switch ON (II), and watch the coolant temperature gauge. Substitute a known good ECM Does the coolant temperature and recheck.
Page 165 Main Menu Table of Contents Control Unit Input Test NOTE: The control unit only controls the driver's door POWER WINDOW window. POWER WINDOW CONTROL UNIT MASTER SWITCH Remove the driver's door panel and disconnect the 4P and 6P connectors from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact.
Page 166 Main Menu CAUTION: (if roof maintenance is required) Be careful not ot bend the edge of the roof opening. The roof is made of aluminum alloy. Take care not to dent or scratch the roof. If there is a minor dent or scratch on the roof, repair the roof with putty (refer to the body repair manual).
Page 167 Main Menu Table of Contents Chassis and Paint Codes Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 168 Main Menu Table of Contents Identification Number Locations...
Page 169 Main Menu Table of Contents Emission Group Identification Engine and Evaporative Families Example: 50ST (50 States): THIS VEHICLE CONFORMS TO U. S. ERA NLEV REGULA- TIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSEN- GER CARS.
Page 170 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6 *1: NIHON HATSUJO made, *2: CHUO HATSUJO made. M/T: Manual Transmission A/T: Automatic Transmission *3: Measured between the rocker arm and camshaft.
Page 171 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 172: Clutch — Section
Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11 Clutch — Section 12 M/T: Manual Transmission A/T: Automatic Transmission...
Page 173 Main Menu Table of Contents Manual Transmission — Section 13...
Page 174 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 175 Main Menu Table of Contents Automatic Transmission — Section 14 Clutch end plate diameter: 1st: 116 mm (4. 57 in) 1st-hold, 2nd, 3rd and 4th: 120 mm (4. 72 in)
Page 176 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 177 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 178 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 179 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 180: Steering — Section
Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19 M/T: Manual Transmission A/T: Automatic Transmission...
Page 181: Air Conditioning — Section
Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23 •1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values.
Page 182 Main Menu Table of Contents Design Specifications...
Page 183 Main Menu Table of Contents Design Specification...
Page 184 Main Menu Table of Contents...
Page 185 Main Menu Table of Contents Body Specifications...
Page 186 *2: Always use Honda ATF-Z1 (ATF). Using a non-Honda ATP can affect shift quality. *3: Always use genuine Honda DOTS Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 187 Main Menu Table of Contents NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 188 Main Menu Table of Contents Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-2* 8-5* 8-4* , 10-2* 11-149*' 6-10* 23-96* 6-14* , 10-11* 22-88*' 23-109*' 11-138*' 11-129*'...
Page 189 * According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 190 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY in Canada or under one or more of the Severe Driving Conditions (page 4-7): 8-2* 8-2* , 10-2* 11-149* 6-10* 23-96* 6-14* , 10-11* 22-88* 23-109* 11-138*...
Page 191 'According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 192 Main Menu Table of Contents Radiator Engine Coolant Refilling and Bleeding Open the hood, the rear window and the engine CAUTION: When pouring engine coolant, be sure to cover. shut the relay box lid and not let coolant spill on the electrical parts or the paint.
Page 193 9. Fill the expansion tank with Honda All Season plug. Antifreeze/Coolant Type 2. As coolant starts to run out in a steady stream without bubbles, tighten...
Page 194 Main Menu Table of Contents Radiator 10. After tightening all the bleeding bolts and plug, fill 1 3. Install the expansion tank cap, and turn it 60 degrees the expansion tank with coolant up to the MAX line. (where it engages the first lock tab of filler neck). 11.
Page 195 Main Menu Table of Contents Chassis and Paint Codes Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Paint Code...
Page 196 Main Menu Table of Contents Identification Number Locations...
Page 197 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families 50ST (50 States) and CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV and Canadian Tier 1 REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS AND CALI- FORNIA REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS.
Page 198 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 199 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 200 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11 Clutch — Section 12...
Page 201 Main Menu Table of Contents Manual Transmission — Section 13...
Page 202 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 203 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 204 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 205 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 206 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 207 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 208 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 209: Electrical — Section
Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23 *1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values.
Page 210 Main Menu Table of Contents Design Specifications...
Page 211 Main Menu Table of Contents Design Specification (cont'd)
Page 213 Main Menu Table of Contents Body Specifications...
Page 214 *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 ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality. *3: Always use Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 215 Main Menu Table of Contents NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 216 Main Menu Table of Contents Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-2* 8-4* ,10-2* 11-149* 6-10* 23-96* 6-14* ,10-11* 22-88* 23-109* 11-138* 11-129* 10-2* 13-3* 14-105*...
Page 217 Main Menu Table of Contents 17-57 18-14,18-15, 18-30,18-31 16-3 19-4,19-27 10-2, 13-3, 14-105 19-84 10-2 9-6,9-7 11-130 For 2002 Canada model: Follow the Severe Conditions Maintenance Schedule for 2002 Model on page and 4-7.
Page 218 Main Menu Table of Contents Component Locations Index...
Page 219 Main Menu Main Menu Table of Contents Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR VEHICLE SPEED SENSOR (VSS) THROTTLE POSITION (TP) SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR EVAPORATIVE EMISSION...
Page 220 Main Menu Main Menu Table of Contents Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. SERVICE CHECK CONNECTOR (2P) DATA LINK CONNECTOR (16P) INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM THROTTLE BODY (TB) ELECTRICAL AIR CLEANER (ACL) CURRENT...
Page 221 Main Menu Main Menu Table of Contents Table of Contents For Troubleshooting of DTC related components, see chart on page 11-52. ONBOARD REFUELING VAPOR RECOVERY (ORVR) VAPOR RECIRCULATION VALVE FUEL PUMP ONBOARD REFUELING FUEL FEED PIPE VAPOR RECOVERY (ORVR) VENT SHUT VALVE Testing, page 11-70 FUEL FILTER...
Page 222 Main Menu Table of Contents System Description Electrical Connections...
Page 223 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 224 Main Menu Table of Contents...
Page 225 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 226 Main Menu Table of Contents (To p a g e 11-8)
Page 227 Main Menu Table of Contents System Description Electrical Connections (cont'd) (From page 11-7)
Page 228 Main Menu Table of Contents (To page 11-10)
Page 229 Main Menu Table of Contents System Description Electrical Connections (cont'd) (From page 11-9)
Page 230 Main Menu Table of Contents...
Page 231 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 232 Main Menu Table of Contents...
Page 233 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 234 Main Menu Table of Contents (To page 11-16)
Page 235 Main Menu Table of Contents System Description Electrical Connections (cont'd) (From page 11-15)
Page 236 Main Menu Table of Contents...
Page 237 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Right Side)]...
Page 238 Main Menu Table of Contents...
Page 239 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Left Side)] (cont'd)
Page 240 Main Menu Table of Contents...
Page 241 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 242 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. • — Connector with male terminals (double outline): View from terminal side —...
Page 243 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 244 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side (cont'd)
Page 245 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 246 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side (cont'd)
Page 247 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd)
Page 248 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side...
Page 249 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd)
Page 250 Main Menu Table of Contents...
Page 251 Main Menu Table of Contents Wheel Alignment Height NSX/NSX-T four wheel alignment requires the use of equipment designed specifically for four wheel independent suspensions and capable of immediate feedback. NOTE: For proper inspection/adjustment of the wheel alignment, check and adjust the following before checking the alignment.
Page 252 Main Menu Table of Contents Front Bumper Replacement NOTE: • An assistant is helpful when removing and installing the front bumper. • Take care not to scratch the front bumper and body. 1. Remove the bumper mounting bolts on each side, and lower skirt mounting bolts. 2.
Page 253 Main Menu Table of Contents Front Bumper Disassembly...
Page 254 Main Menu Table of Contents Rear Bumper Disassembly...
Page 255 Main Menu Table of Contents Bumper Mesh Replacement NOTE: Take care not to scratch the bumper skirt. 4. Attach the bumper mesh together with new rivets. 1. Remove the bumper skirt, front bumper skirt (see page 20-3), rear bumper skirt (see page 20-4). 2.
Page 256 Main Menu Table of Contents Door lower Trim Replacement CAUTION: 6. Slide the door lower trim rearward, and remove it. • Put on gloves to protect you hands. The clips will stay in the door. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Page 257 Main Menu Table of Contents Remove the protective tape from the door, and 14. If the adhesive tape is replaced, fold the adhesive carefully scrape the adhesive tape from the door backing of the adhesive tape. Hold the trim up, and and door lower trim with a plastic putty knife.
Page 258 Main Menu Table of Contents Side Sill Panel Replacement NOTE: Take care not to twist the side sill panel. Take care not to scratch the body and related parts. 1. Remove the side sill panel. Pull the front and rear inner fender as necessary, and remove the expansion clips. On the bottom of the front fender, remove the adhesive tape of the side sill panel separator from the body with a utility knife.
Page 259 Main Menu Table of Contents 3. If the old side sill panel is to be reinstalled, check the adhesive tape of the separator for damage, and replace the adhe- sive tape. -1 Remove the separator from the panel. -2 Scrape the old adhesive tape, and clean the separator surface with a sponge dampened in alcohol. -3 Apply primer (3M N-200, or equivalent) to the separator where new adhesive tape will be applied.
Page 260 Main Menu Table of Contents Trunk Sub-spoiler Replacement NOTE: Take care not to scratch the trunk lid and related parts. 1. Apply protective tape to both inside face of the trunk lid spoiler. 2. Open the trunk lid. 3. Remove the trunk sub-spoiler. Remove the trunk striker.
Page 261 Main Menu Table of Contents Relay and Control Unit Locations Front Compartment...
Page 262 Main Menu Table of Contents...
Page 263 Main Menu Table of Contents Gauge Assembly Gauge/Terminal Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service.
Page 264 Main Menu Table of Contents Gauge Assembly Bulb Locations...
Page 265 Main Menu Table of Contents Lighting System Component Location Index DIMMER RELAY (USA) Test, page 23-45 HEADLIGHT HIGH BEAM RELAY Test, page 23-45 DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada ) Input Test, page 23-40 HEADLIGHT LOW BEAM RELAY Test, page 23-45 RIGHT HID INVERTER UNIT Replacement, page...
Page 266 Main Menu Table of Contents Lighting System Daytime Running Lights Control Unit Input Test (Canada) Remove the glove box lower panel and glove box. Disconnect the 14P connector from the daytime running lights control unit. Inspect the connector and socket terminals to be sure they are all making good contact.
Page 267 Main Menu Table of Contents...
Page 268 Main Menu Table of Contents Lighting System HID Bulb Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the combination light switch OFF. 3. Disconnect the battery negative cable, then disconnect the positive cable.
Page 269 Main Menu Table of Contents 6. Turn the socket 45° counterclockwise to remove it from the bulb. 7. Pull the retaining spring away from the bulb (B), then remove the bulb. 8. Install the new bulb in the reverse order of removal. 9.
Page 270 Main Menu Table of Contents Lighting System HID Lamp System Troubleshooting 7. Check for continuity between the No. 1 terminal of the inverter unit 2P connector and body ground. 1. Check the No. 49 (20 A) or No. 52 (20 A) fuse in the main under-hood fuse/relay box.
Page 271 Main Menu Table of Contents Headlight Low Beam Relay Test Headlight High Beam/Dimmer Relay (USA) Test 1. Remove the headlight high beam relay or the dimmer Remove the headlight low beam relay from the relay (USA) from the under-hood fuse/relay box. under-hood fuse/relay box.
Page 272 Main Menu Table of Contents Lighting System Dimmer Relay (Canada) Test Taillight Relay Test Remove the dimmer relay from the under-hood Remove the taillight relay from the under-hood relay box B. relay box B. Check continuity at the relay terminals. Check continuity at the relay terminals.
Page 273 Main Menu Table of Contents Headlights Headlight Replacement HID Inverter Unit Replacement 1. Combination light switch OFF. 2. Disconnect the battery negative cable, then disconnect the positive cable. 3. Remove the headlight. 1. Open the hood. 4. Remove the three mounting screws from the HID 2.
Page 274 Main Menu Table of Contents Headlights Adjustment Turn the low beams on. Determine if the headlights are aimed properly. Vertical adjustment: Measure the height of the headlights (A). The lights Before adjusting the headlights: should reflect 52 mm (2.1 in.) below the head-light •...
Page 275 Main Menu Table of Contents Front Turn Signal Light: Open the hood. Turn the bulb socket 45° counterclockwise, remove it from the headlight assembly, then replace the bulb. Front Parking Light: Open the hood. Turn the bulb socket 45° counterclockwise, remove it from the headlight assembly, then replace the bulb.
Page 276 Main Menu Table of Contents Horns Component Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice. Test, page 23-53 Test, page 23-53 SECURITY/LEFT (LOW) HORN Test, page...
Page 277 Main Menu Table of Contents Horns Horn Test Test the horn by connecting power to the A or B Disconnect the 2P connectors from the horns. terminals and ground to the other. The horn should sound. Remove the right and left horns. If the horn fails to sound, replace it.
Page 278 Main Menu Table of Contents Security/Low Horn Relay Test High Horn Relay Test Remove the high horn relay from under-hood relay Remove the security/low horn relay from under- box A. hood relay box B. Check continuity at the relay terminals. Check continuity at the relay terminals.
Page 279 Main Menu Table of Contents Security Alarm System Control Unit Input Test Remove the glove box, and disconnect the 22P connec- tor and 16P connector from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact. •...
Page 280 Main Menu Table of Contents Cavity Wire Test condition Test: Desired result Possible cause if result is not obtained...
Page 281 Main Menu Table of Contents Security Alarm System Control Unit Input Test (cont'd) Cavity Wire Test condition Test: Desired result Possible cause if result is not obtained...
Page 282: Table Of Contents
Main Menu Engine Engine Removal/Installation ......5–1 Cylinder Head/Valve Train ......6–1 Engine Block .
Page 283 Main Menu Table of Contents Component Location Index NOTE: • If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see section 23).
Page 284 Main Menu Table of Contents Manual Steering Gearbox Removal/Installation 6. Remove the cotter pin from the castel nut and NOTE: Before removing the steering gearbox, make sure the front wheels are straight ahead. remove the nut. Remove the steering joint cover. 7.
Page 285 Main Menu Table of Contents Manual Steering Gearbox Removal/Installation (Cont'd) 14. Install the gearbox in the reverse order of removal. 12. Remove the flange bolts and nuts from the gearbox and front crossbeam. CAUTION: Torque the castle nut of the tie-rod end to the lower torque specification, then tighten it on- ly far enough to align the slot with the pin hole.
Page 286 Main Menu Table of Contents Illustrated Index CAUTION: • Before disassembling the gearbox, wash it off with solvent and a brush. • Thoroughly clean all disassembled parts. • Replace parts with damaged sliding surfaces.
Page 287 Main Menu Table of Contents Manual Steering Overhaul 4. Before disassembly, install the special tool on the pin- 1. Carefully clamp the gearbox in a vise with soft jaws. ion shaft and check the preload. If the preload is out of the specification, adjust the Remove the boot band.
Page 288 Main Menu Table of Contents Move the rack toward the gearbox side (i.e. in the Remove the set screw locknut. direction of the arrow) as far as it goes, then pull the steering pinion out when the pinion gear clears the cutout in the rack.
Page 289 Main Menu Table of Contents Manual Steering Overhaul (Cont'd) • If the pinion bearing is noisy or has excessive 10. Remove the steering rack from the cylinder play, replace the bearing using the special tools housing. and a press. NOTE: The steering rack cannot be removed from NOTE: Hold the outer race with the tool securely.
Page 290 Main Menu Table of Contents • Press the new lower bearing into the gearbox 12. Install the steering pinion into the gearbox. housing until it seats using a press and special tool. NOTE: Do not engage the steering pinion with the steering rack this time.
Page 291 Main Menu Table of Contents Manual Steering Overhaul (Cont'd) 1 5. Wrap the splined area of the steering pinion with 18. Turn the pinion shaft right and left several times to vinyl tape and grease the surface of the tape. set it, then loosen the pinion set screw.
Page 292 Main Menu Table of Contents 20. Install the set screw locknut, then hold the pinion 22. The system is in neutral when the rack end projects set screw and tighten the set screw locknut. 60 mm (2.4 in) from the cylinder end. 23.
Page 293 Main Menu Table of Contents 29. Install the new boot bands on the boot and bend both sets of locking tabs. 30. Lightly tap on the doubled portions to reduce their height. NOTE: After assembling, slide the rack right and left to be certain that the boots are not deformed or twisted.
Page 294 Main Menu Table of Contents Manual Steering Ball Joint Boot Replacement Insert the special tool into the threads in the ball pin 1 . Remove the circlip and the boot; and align the end of the tool with the groove in the boot.
Page 295 Main Menu Table of Contents Chassis and Paint Codes Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Paint Code...
Page 296 Main Menu Table of Contents Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER MANUAL TRANSMISSION AUTOMATIC TRANSMISSION NUMBER NUMBER...
Page 297 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families Example: Engine Family: 50ST (50 States) and CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV and Canadian Tier 1 REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW LEV PASSENGER CARS AND CALI- FORNIA REGULATIONS APPLICABLE TO 2003 MODEL YEAR NEW LEV PASSENGER CARS.
Page 298 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 299 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 300 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11 Clutch — Section 12...
Page 301 Main Menu Table of Contents Manual Transmission — Section 13...
Page 302 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 303 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 304 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 305 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 306 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 307 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 308 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 309 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23...
Page 310 Main Menu Table of Contents Design Specifications...
Page 311 Main Menu Table of Contents Design Specification (cont'd)
Page 312 Main Menu Table of Contents...
Page 313 Main Menu Table of Contents Body Specifications...
Page 314 Main Menu Table of Contents Opener/Latch Trunk Lid Opener Actuator Replacement Canadian Models NOTE: Put on gloves to protect your hands. 1. Remove the left trunk side trim panel. 2. Remove the trunk lid opener actuator. —1 Disconnect the trunk lid opener actuator connec- tor.
Page 315 Main Menu Table of Contents Chassis and Paint Codes...
Page 316 Main Menu Table of Contents Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER MANUAL TRANSMISSION AUTOMATIC TRANSMISSION NUMBER NUMBER...
Page 317 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Example:...
Page 318 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 319 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 320 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11 Clutch — Section 12...
Page 321 Main Menu Table of Contents Manual Transmission — Section 13...
Page 322 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 323 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 324 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 325 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 326 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14 Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 327 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14 Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 328 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 329 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23...
Page 330 Main Menu Table of Contents Design Specifications...
Page 331 Main Menu Table of Contents Design Specification...
Page 332 Main Menu Table of Contents...
Page 333 Main Menu Table of Contents Body Specifications...
Page 334 Main Menu Table of Contents Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the illustrated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
Page 335 Main Menu Table of Contents NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 336 Main Menu Table of Contents Maintenance Schedule Listed by Distance/Time for Normal Conditions This two-page Maintenance Schedule outlines the minimum 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.
Page 337 NOTE: According 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.
Page 338 NOTE: According 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.
Page 339 Main Menu Table of Contents PCV Collar Replacement Remove the positive Crankcase ventilation (PCV) Remove the PCV collar locknut, then remove the PCV collar. valve (see page 11-52). Remove any old liquid gasket from the cylinder Remove the rear cylinder head cover, refer to the head cover mating surfaces, bolts, and bolt holes.
Page 340 Main Menu Table of Contents Tighten the new PCV collar locknut to 39.2 N-m 11. Install the breather cover (A), then tighten the bolts (4.0 kgf-m, 29 Ibf-ft), then stake the PCV collar lock- (B) to 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft). nut tab (A) into the PCV collar groove (B) using a punch.
Page 341 Main Menu Table of Contents Component Locations Index EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR VEHICLE SPEED SENSOR (VSS) ENGINE COOLANT TEMPERATURE (ECT) SENSOR THROTTLE POSITION (TP) SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR EVAPORATIVE EMISSION CRANKSHAFT POSITION/ (EVAP) PURGE CONTROL CAMSHAFT POSITION (CKP/CMP) SOLENOID VALVE (CRANKSHAFT POSITION/...
Page 342 Main Menu Table of Contents Component Locations Index (cont'd) CLUTCH SWITCH (M/T only) ACCELERATOR POSITION (AP) Troubleshooting, page 11-125 SENSOR in the 1997 NSX Service Manual Troubleshooting, page 11-114 in the 1997 NSX Service Manual THROTTLE CABLE Inspection/Adjustment, page 11-150 in the 1997 NSX Service Manual Installation, page 11-150...
Page 343 Main Menu Table of Contents DATA LINK CONNECTOR (16P) Self-diagnostic Procedures, page 11-38 in the 1997 NSX Service Manual...
Page 344 Main Menu Table of Contents Component Locations Index (cont'd) THROTTLE BODY (TB) Inspection, page 11-151 in the 1997 NSX Service Manual Disassembly, page 11-152 in the 1997 NSX Service Manual AIR CLEANER (ACL) Disassembly, page 11-149 in the 1997 NSX Service Manual INTAKE AIR DUCT INTAKE AIR BYPASS (IAB) VALVE INTAKE AIR BYPASS (IAB) CONTROL...
Page 345 Main Menu Table of Contents FUEL PUMP RELAY Troubleshooting, page 11-139 in the 1997 NSX Service Manual ONBOARD REFUELING VAPOR RECOVERY (ORVR) VAPOR RECIRCULATION VALVE FUEL PUMP ONBOARD REFUELING FUEL FEED PIPE VAPOR RECOVERY (ORVR) VENT SHUT VALVE Testing, page 11-70 in the 2000 NSX Service Manual Supplement...
Page 346 Troubleshooting Troubleshooting Procedures ECM Replacement 1. Turn the ignition switch OFF. 2. Jump the SCS line with the HDS (Honda Diagnostic System). 3. Remove the bulkhead (1) then (2). 4. Disconnect the connectors from the ECM mounting bracket. Disconnect the ECM connectors (A) from the ECM.
Page 347 Main Menu Table of Contents Fuel Supply System Fuel Injectors (cont'd) Replacement Do not smoke during this work. Keep open flames away from your work area. 1. Relieve the fuel pressure Refer to the 1997 NSX Service Manual, P/N 61SL006 (see page 11-132). 2.
Page 348 Main Menu Table of Contents 13. Install the injectors and fuel pipe assembly in the manifold. 14. Align the center line on the connector with the mark on the fuel pipe. 15. Install and tighten the retainer nuts. 16. Coat new O-rings with clean engine oil and put them on the fuel hose. 17.
Page 349 Main Menu Table of Contents Symptom-to-Component Chart Electrical System 14-5 in this supplement 14-7 in this supplement H-60 (61SL006) 14-9 in this supplement 14-10 in this supplement 14-11 in this supplement 14-13 in this supplement 14-14 (61SL007) 14-16 (61SL007) 14-15 in this supplement...
Page 350 Main Menu Table of Contents 14-16 in this supplement 14-71 (61SL006) 14-72 (61SL006) 14-73 (61SL006) 14-17 in this supplement 14-19 in this supplement 14-21 in this supplement 14-77 (61SL006) 14-79 (61SL006) 14-4 (61SL009) 14-22 in this supplement 14-20 (61SL007)
Page 351 Main Menu Table of Contents Symptom-to-Component Chart Electrical System (cont'd) If the self-diagnostic D indicator does not blink, perform an inspection according to the table below. 14-84 (61SL006) 14-86 (61SL006) 14-87 (61SL006) 14-88 (61SL006) 14-91 (61SL006) NOTE: • If a customer describes the symptom for code P1790 (3) or P1795 (20), yet the D indicator is not blinking, it will be nec- essary to recreate the symptom by test-driving, then recheck the DTC.
Page 352 Main Menu Table of Contents Power Door Locks Component Location Index TRANSMITTER Test, page 23-21 Programming, page 23-21 IGNITION KEY SWITCH KEYLESS DOOR LOCK CONTROL UNIT Input Test page 23-16 KEYLESS BUZZER Test/Replacement, page 23-20 PASSENGER'S DOOR SWITCH DRIVER'S DOOR LOCK SWITCH PASSENGER'S DOOR LOCK PASSENGER'S DOOR LOCK ACTUATOR ASSEMBLY...
Page 353 Main Menu Table of Contents Power Door Locks Control Unit Input Test Remove the glove box, then disconnect the 20P connector from the control unit. 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. •...
Page 354 Main Menu Table of Contents Reconnect the connector to the control unit, and make these input test 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.
Page 355 Main Menu Table of Contents Power Door Locks Control Unit Input Test (cont'd)
Page 356 Main Menu Table of Contents...
Page 357 Main Menu Table of Contents Power Door Locks Keyless Buzzer Test/Replacement 1. Open the hood. 2. Disconnect the 2P connector (A) from the keyless buzzer (B). 3. Test the buzzer by connecting battery power to the No. 2 terminal and grounding the No. 1 terminal. You should hear a slight chirp.
Page 358 Main Menu Table of Contents Transmitter Programming Transmitter Test Storing transmitter codes: NOTE: The codes of up to three transmitters can be stored into • If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the the keyless receiver unit memory.
Page 359 Main Menu Table of Contents Security Alarm System Control Unit Input Test Remove the glove box, and disconnect the 22P connec- tor and 16P connector from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact. •...
Page 360 Main Menu Table of Contents (cont'd)
Page 361 Main Menu Table of Contents Security Alarm System Control Unit Input Test (cont'd)
Page 362 Main Menu Table of Contents Stereo Sound System CD Changer Removal NOTE: When you check a right taillight, perform bulb Open the trunk lid. check of a right taillight according to the following pro- Push the lock lever. cedures. Push the lock lever. Remove the mounting bolt.
Page 363 000001 SR8M 8000001 Manufacturer, Make and Transmission Type Type of Vehicle SR8M: 6-speed Manual Transmission JH4: HONDA MOTOR CO., LTD. MR9A: 4-speed Automatic Transmission ACURA, passenger vehicle Serial Number Line, Body, and Engine Type SR8M: 8000001~ NA1: NSX-T/C30A1 MR9A: 9500001~...
Page 364 Main Menu Table of Contents Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER MANUAL TRANSMISSION AUTOMATIC TRANSMISSION NUMBER NUMBER...
Page 365 Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families Example: Engine Family: 03.2 Model Year 5: 2005 Manufacturer HNX: Honda Type V: Light Duty Vehicle/Passenger Car Displacement Sequence Characters Evaporative Family: 0152 Model Year 5: 2005 Manufacturer...
Page 366 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6 MEASUREMENT STANDARD (NEW) SERVICE LIMIT Compression Check the engine with the Minimum 980 (10.0, 142) starter cranking Maximum variation 200 (2.0, 28) kPa (kgf/cm , psi) Cylinder head Warpage —...
Page 367 Main Menu Table of Contents Design Specifications ITEM METRIC ENGLISH NOTES DIMENSIONS Overall length 4,425 mm 174.2 in Overall width 1,810 mm 71.3 in Overall height 1,170 mm 46.1 in Wheelbase 2,530 mm 99.6 in Track F/R 1,510/1,540 mm 59.4/60.6 in Ground clearance 130 mm 5.1 in...
Page 368 Main Menu Table of Contents Design Specification (cont’d) ITEM METRIC ENGLISH NOTES AIR CONDITIONING Cooling capacity 4,000 Kcal/h 15,872 BTU/h Conditions: Compressor RPM 1,800 rpm Outside air temperature 27 °C 81 °F Outside air humidity 50 % Condenser air temperature 35 °C 95 °F Condenser air velocity...
Page 369 Main Menu Table of Contents ITEM METRIC ENGLISH NOTES WHEEL Camber Front – 0 °20 ’ ALIGNMENT Rear – 1 °30 ’ Caster 8 ° Front Out 3.5 mm Out 0.14 in Rear In 4.0 mm In 3/16 in BRAKE SYSTEM Type, front and rear Power assisted self-adjusting ventilated disc...
Page 370 *2: Always use Honda ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality. *3: Always use Honda Heavy Duty DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 371 Main Menu Table of Contents NOTE: • Lubricate all hinges, latches, and locks once a year. • In corrosive areas, more frequent lubrication is necessary. &...
Page 372 72,000 km 3 years Do items in A and B. – – 3 years Replace brake fluid (see page 19-11)* Use Honda Heavy Duty DOT3 Brake Fluid 52,500 miles 84,000 km – Do item in A. 60,000 miles 96,000 km 4 years Do items in A, B, C, and D.
Page 373 Main Menu Table of Contents Do the items in parts A, B, C, D, E, F, and G as required for the mileage/time interval listed. Part Maintenance Items Replace engine oil (see page 8-2)* , every 7,500 miles (12,000 km) or 1 year. Engine oil capacity: without oil filter: 4.3 L (4.5 US qt).
Page 374 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years. Capacity: 12.0 L (3.2 US gal); use Honda All Season Antifreeze/Coolant Type 2. NOTE: According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void the customer’s emissions warranties.
Page 375: Engine
1997-2005 NSX Main Menu General Info Suspension Specifications *Brakes (Including ABS) Maintenance *Body Engine *Heating, Ventilation and Air Conditioning Cooling *Body Electrical Fuel and Emissions *Engine Electrical *Transaxle *SRS Steering As sections w/ * include SRS components, special precautions are required when servicing.
Page 376 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 377 Main Menu Table of Contents Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page...
Page 378 Main Menu Table of Contents Warning/Caution Label Locations (cont'd)
Page 379 Main Menu Table of Contents...
Page 380 Main Menu Table of Contents Warning/Caution Label Locations (cont'd)
Page 381 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families...
Page 382 Main Menu Table of Contents Lift and Support Points Lift and Safety Stands CAUTION: • If ground clearance is inadequate to clear the shop lift, either; — Install rubber spacers on the coil springs to raise the vehicle. Use the floor jack procedures to raise the vehicle (page 1-11).
Page 383 Main Menu Table of Contents Floor Jack CAUTION: Place a rubber pad between the lift platform and the center support point to avoid damaging the vehicle. The lift platform must contact the support point only; it must not come in contact with any other part of the vehicle. Set the parking brake, and block the wheels that are not being lifted.
Page 384 Main Menu Table of Contents Towing If the vehicle needs to be towed, call a professional tow- ing service. Never tow the vehicle behind another vehi- cle with just a rope or chain. It is very dangerous. There are three widely used methods of towing a vehicle. Flat-bed Equipment —...
Page 385 Main Menu Table of Contents Service Precautions Handling of Special Nuts and Bolts Handling of Tires Because many sections on this vehicle are constructed • The tires on NSX & NSX-T should not be rotated. The with aluminum alloys, use only the special "Dacro" type front wheels are 16"...
Page 386 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 387 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 388 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emission — Section 11 Clutch — Section 12...
Page 389 Main Menu Table of Contents Manual Transmission — Section 13...
Page 390 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 391 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 392 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 393 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 394 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 395 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 396 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 397 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23...
Page 398 Main Menu Table of Contents Design Specifications...
Page 399 Main Menu Table of Contents Design Specifications (cont'd)
Page 400 Main Menu Table of Contents...
Page 401 Main Menu Table of Contents Body Specifications...
Page 402 Main Menu Table of Contents Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the illustrated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
Page 403 Main Menu Table of Contents...
Page 404 Main Menu Table of Contents Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-4, 10-2 11-149 6-10 23-96 6-14, 10-11 22-88 23-109 11-138 11-129 10-5 13-3 14-105 19-4, 19-6, 19-7,...
Page 405 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 406: Follow The Severe Conditions Maintenance Schedule If The Vehicle Is Driven Mainly Under One Or More Of The Severe Driving Conditions
Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 4-7): 8-4, 10-2 11-149 6-10 23-96 6-14, 10-11 22-88 23-109 11-138 11-129 10-5 13-3 14-105 19-4, 19-6, 19-7,...
Page 407 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 408 Main Menu Table of Contents Special Tools...
Page 409: Engine Removal/Installation
Main Menu Table of Contents Engine Removal/Installation Removal Remove the strut brace (NSX-T (open top)). • Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct posi- tions on the engine (see section •...
Page 410 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) Disconnect the fan motor connector, then remove Disconnect the spark plug voltage detection module the engine room fan assembly (A/T). connectors, ground cable and engine wire harness clamps. Remove the rear trim panels behind the passenger's seat, then disconnect four connectors from the Disconnect the fuel pump resistor connector.
Page 411 Main Menu Table of Contents 10. Relieve fuel pressure (see section 11). 14. Remove the expansion tank cap. Do not smoke while working on the 15. Raise the hoist to full height. fuel system. Keep open flame away from work 16.
Page 412 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 21. Disconnect the engine wire harness connectors. 24. Disconnect the two connectors from the emission control box, then remove the control box. 22. Remove the battery cable from the main fuse box. •...
Page 413 Main Menu Table of Contents 26. Loosen the idler pulley center nut and adjusting nut, 28. Raise the hoist to full height. then remove the air conditioning (A/C) compressor 29. Remove the slave cylinder (M/T see section 12). belt. • Do not disconnect the clutch hose. 30.
Page 414 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 33. Remove the left and right parking brake cables (see 36. Remove the A/C compressor (see section 22), then section 19). suspend it from the body. 34. Remove the rear beam rod assembly and parking NOTE: brake cable clamps.
Page 415 Main Menu Table of Contents 40. Remove the right wheel sensor wire clamps and 43. Remove the muffler (M/T). stabilizer link. 44. Position the special tool under the car. Lower the car just above the fixture. With the help of an assistant, 41.
Page 416 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 47. Remove the two bolts from the side engine mount 49. Remove the twelve subframe-to-body mounting near the alternator. Pivot the mounting bracket into bolts. the housing of the body. 50. Raise the car a few inches. 51.
Page 417 Main Menu Table of Contents NOTE: Perform steps 53 thru 56 only if the engine assembly is to be removed from the subframe. 53. Remove the adjusting bolt and flange bolt, then separate the lower control arm from the subframe (see section 18).
Page 418 Main Menu Table of Contents Engine Removal/Installation Installation Additional Torque Value Specifications: NOTE: For manifold replacement, refer to section...
Page 419 Main Menu Table of Contents Engine Installation: Install the subframe, then tighten the subframe-to- Install the engine in the reverse order of removal. Reinstall body mounting bolts (see section 20). the mount bolts/nuts in the following sequence. Failure to NOTE: Align the bolt holes of the beam brackets follow these procedures may cause excessive noise and vibration, and reduce bushing life.
Page 420 Main Menu Table of Contents Engine Removal/Installation Installation (cont'd) Install the side engine mount, then tighten the bolts Tighten the rear mount mounting bolt. in the numbered sequence as shown • Check that the spring clip on the end of each driveshaft clicks into place.
Page 421 Main Menu Table of Contents Special Tools 07HAH - PJ7010B Valve Guide Reamer, 5.5 mm 6-43 07JAA - 001020A Socket, 19 mm 6-12 07JAB - 001020A Holder Handle 6-12 Tappet Adjuster 07MAA - PR70110 6-10 07MAA - PR70120 Tappet Locknut Wrench 6-10 07MAF - PR9010A Valve Spring Compressor Attachment...
Page 422 Main Menu Table of Contents VTEC VTEC Solenoid Valve Inspection Disconnect the 2P connector from the VTEC sole- If the filter is not clogged, push the VTEC solenoid noid valve. valve with your finger and check its movement. • If VTEC solenoid valve is normal, check the engine 2.
Page 423 Main Menu Table of Contents Rocker Arms — Manual Inspection Remove the ignition coil covers (see page 6-15). Remove the ignition coils (see page 6-15). Remove the cylinder head covers. NOTE: Refer to pages 6-49, 6-50 when installing the cylinder head cover. Set the No.
Page 424 Main Menu Table of Contents Rocker Arms — Inspection Using Special Tools CAUTION: • Before using the special tool, make sure that the air pressure gauge on the air compressor indicates over 250 kPa (2.5 kgf/cm , 36 psi). • Inspect the valve clearance before rocker arm inspec- tion.
Page 425 Main Menu Table of Contents VTEC Rocker Arms — Inspection Using Special Tools (cont'd) Remove the 10 mm sealing bolt and washer from Make sure that the primary and secondary rocker the inspection hole and connect the tools. arms are mechanically connected by pistons and that the mid rocker arms do not move when pushed manually.
Page 426 Main Menu Table of Contents Valve Clearance Adjustment NOTE: Rotate the crankshaft to set No. 1 piston at TDC. • Valves should be adjusted cold, when the cylinder • TDC mark (white paint) on the crankshaft pulley head temperature is less than 100°F (38°C). should align with pointer on the timing lower •...
Page 427 Main Menu Table of Contents Valve Clearance Adjustment (cont'd) Tighten the locknut and check the clearance again. Manually inspect the rocker arms for independent operation (see pages 6-7, 6-8). Repeat adjustment if necessary. Adjust valves on No. 1 cylinder. • Adjusting screws are on primary and secondary FEELER rocker arms.
Page 428 Main Menu Table of Contents 7. Rotate the crankshaft 120° clockwise (camshaft pulley 10. Rotate the crankshaft 120° clockwise (camshaft pulley turns 60°). Check that the front intake camshaft pulley turns 60°). Check that the front intake camshaft pulley is positioned as shown. is positioned as shown.
Page 429 Main Menu Table of Contents Crankshaft Pulley and Pulley Bolt Replacement When installing and tightening the pulley, follow the procedure below. Clean, remove any oil and lubricate points shown below. Clean Remove any oil Lubricate CRANKSHAFT PULLEY TIMING BELT CRANKSHAFT DRIVE PULLEY WASHER PULLEY BOLT...
Page 430 Table of Contents Main Menu Timing Belt Illustrated Index NOTE: • Refer to page 6-18 for positioning crankshaft and pulley before installing the belt. • If it is to be reused, mark the direction of rotation on the belt before removing it. •...
Page 431 Main Menu Table of Contents Timing Belt Inspection Tension Adjustment Remove the ignition coil covers and harness clamps. CAUTION: Disconnect the connectors, then remove the ignition • Always adjust timing belt tension with the engine cold. coils. • Do not rotate the crankshaft when the adjusting bolt Remove the cylinder head covers.
Page 432 Table of Contents Main Menu Removal NOTE: Remove the ignition coil covers, the injector cover • Before removing the belt, turn the crankshaft pulley and the wire harness covers. so the No. 1 piston is at top dead center (TDC) (see page 6-19).
Page 433 Main Menu Table of Contents Timing Belt Removal (cont'd) 7. Remove the breather hose and the air cleaner hous- 12. Remove the transmission mount (see page 5-10). ing (see page 6-26). 13. Install a brace under the engine, then tilt the engine 8.
Page 434 Main Menu Table of Contents 15. Loosen the idler pulley center nut and adjusting nut, 18. Loosen the adjusting bolt 180° turn. Push the ten- then remove the air conditioning (A/C) compressor sioner to remove tension from the timing belt, then belt.
Page 435 Main Menu Table of Contents Timing Belt Installation Install the timing belt in the reverse order of removal; Set the rear camshaft pulleys so that the No. 1 pis- ton is at TDC. Align the TDC mark on the rear intake Only key points are described here.
Page 436: See Section
Main Menu Table of Contents Adjust the timing belt (see page 6-14). 10. If a camshaft is not positioned at TDC, remove the timing belt and adjust the positioning following the Install the lower cover and middle covers. procedure on page 6-18, then reinstall the timing belt.
Page 437 Main Menu Table of Contents CKP/CYP Sensor Replacement Install the CKP/CYP sensor in the reverse order of NOTE: Turn the crankshaft so that the No. 1 piston is at top dead center (see page 6-19). removal. • Refer to page 6-18 and 6-19, when installing the timing belt.
Page 438 Main Menu Table of Contents Cylinder Heads Illustrated Index CAUTION: To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing the cylin- der head. NOTE: Use new O-rings and gaskets when reassembling. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. CAMSHAFT HOLDER PLATE CAMSHAFT HOLDER...
Page 439 Main Menu Table of Contents Cylinder Heads Illustrated Index (cont'd) CAUTION: To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing the cylin- der head. NOTE: Use new O-rings and gaskets when reassembling. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. EXHAUST GAS RECIRCULATION (EGR) VALVE REAR VARIABLE VALVE TIMING...
Page 440: Cylinder Head/Valve Train
Main Menu Table of Contents INTAKE VALVE VALVE KEEPERS SPRING OUTER CYLINDER HEAD BOLTS SPRING RETAINER M/T: 11 x 1.5 mm INTAKE VALVE 96 N-m (9.8 kgf-m, 71 Ibf-ft) CYLINDER HEAD BOLT SPRING INNER A/T: 11 x 1.5 mm M/T: 11 x 1.5 mm 76 N-m (7.8 kgf-m, 56 Ibf-ft) VALVE SPRING 96 N-m (9.8 kgf-m, 71 Ibf-ft)
Page 441 Main Menu Table of Contents Cylinder Heads Removal Engine removal is not required for this procedure. Remove the front exhaust manifold (M/T). Make sure jacks and safety stands are -1. Remove the center rod assembly and under placed properly and hoist brackets are attached to cor- guard (see page 5-7).
Page 442 Main Menu Table of Contents Remove the rear exhaust manifold (M/T). 7. Remove the engine under guard, then remove the front exhaust pipe A (A/T). -1. Remove the muffler (see page 5-9). -2. Remove the rear beam rod B. GASKETS Replace.
Page 443 Main Menu Table of Contents Cylinder Heads Removal (cont'd) 12. Remove the engine cover stay from the strut brace, 17. Remove the hoses, then remove the expansion tank then set the engine cover stay between the engine (see page 5-5). cover and rear hatch latch (NSX-T open top).
Page 444 Main Menu Table of Contents 22. Remove the breather hose, positive Crankcase venti- 24. Remove the water bypass hoses. lation (PCV) hose and vacuum hose. VACUUM HOSE WATER BYPASS BREATHER HOSES PCV HOSE HOSE 25. Remove the harness covers and ground cables from 23.
Page 445 Main Menu Table of Contents Cylinder Heads Removal (cont'd) 26. Remove the engine wire harness connectors and 29. Loosen the adjusting nut and idler pulley center nut, wire harness clamps from the cylinder head and then remove the air conditioning compressor belt intake manifold.
Page 446 Table of Contents Main Menu 32. Remove the water passage. 34. Remove the alternator bracket stiffener (see page 6-16). 35. Remove the alternator bracket. O-RINGS ALTERNATOR Replace. BRACKET CONNECTING PIPE WATER PASSAGE 33. Remove the cylinder head covers. 36. Remove the timing belt (see page 6-15). 37.
Page 447 Table of Contents Main Menu Cylinder Heads Removal (cont'd) 41. Remove the cylinder head bolts, then remove the 38. Remove the front and rear back covers. cylinder head. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence REAR BACK COVER until all bolts are loosened.
Page 448 Table of Contents Main Menu Rocker Arms and Shafts Removal Screw a 5 mm bolt into each rocker shaft oil control Bundle the rocker arms with rubber bands to keep them together as sets. orifice, then pull out the rocker shaft oil control ori- fices.
Page 449 Main Menu Table of Contents Rocker Arms and Shafts Disassembly/Reassembly CAUTION: After installing the rocker shaft orifice, try to turn the rocker shaft to make sure that the orifice has been inserted in the hole of the rocker shaft correctly. If the orifice is in place, it should not turn. NOTE: •...
Page 450 Main Menu Table of Contents Rocker Arms and Lost Motion Assemblies Inspection NOTE: When reassembling the primary rocker arm, care- Remove the lost motion assembly from the cylinder fully apply air pressure to the oil passage of the rocker head and inspect it. Pushing it gently with the finger arm.
Page 451 Main Menu Table of Contents Rocker Arms and Shafts Clearance Measure both the intake rocker shafts and exhaust rocker Measure inside diameter of rocker arm, and check for shafts. out-of-round condition. Measure diameter of shaft at first rocker location. Rocker Arm-to-Shaft Clearance (Intake and Exhaust): Standard (New): Primary and Secondary: 0.025-0.052 mm (0.0010-0.0020 in)
Page 452 Main Menu Table of Contents Camshafts Inspection NOTE: Seat the camshaft by pushing it toward the left end of • Do not rotate the camshaft during inspection. cylinder head. • Remove the rocker arms and rocker shafts. Put the camshafts, the camshaft holders and holder Zero the dial indicator against the left end, then push plates on the cylinder head, and then tighten the the camshaft back and forth, and read the end play.
Page 453 Main Menu Table of Contents Camshafts Inspection (cont'd) 9. Remove the camshaft holders and measure widest 11. Check cam lobe height wear. portion of plastigage on each journal. Cam Lobe Height Standard (New): Camshaft-to-Holder Oil Clearance: Standard (New): 0.050 - 0.089 mm (0.002 - 0.004 in) Service Limit: 0.15 mm (0.006 in)
Page 454 Main Menu Table of Contents FRONT BANK CYLINDER ' NUMBER...
Page 455 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Replacement NOTE: Identify valves and valve springs as they are removed so that each item can be reinstalled in its origi- nal position. Using an appropriate-sized socket and plastic mallet, lightly tap the valve retainer to loosen the valve keep- ers before installing the valve spring compressor.
Page 456 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Replacement (cont'd) Install the valve guide seal remover as shown. VALVE GUIDE SEAL REMOVER VALVE SEAL (Commercially available) LISLE P/N 57900 or KD3350 M/T: SEAL Intake Valve Dimensions PULLER A Standard (New): 35.9 - 36.1 mm (1.413 - 1.421 in) B Standard (New): 111.10 - 111.40 mm...
Page 457 Main Menu Table of Contents A/T: Intake Valve Dimensions A Standard (New): 34.9 - 35.1 mm (1.374 - 1.382 in) B Standard (New): 111.10-111.40 mm (4.374 - 4.386 in) C Standard (New): 5.475-5.485 mm (0.2156-0.2159 in) C Service Limit: 5.445 mm (0.2144 in) 1.05—1.35 mm D Standard (New): (0.041-0.053 in)
Page 458 Main Menu Table of Contents Cylinder Heads Warpage NOTE: If camshaft-to-holder oil clearances (see pages 6-35, 6-36) are not within specification, the cylinder head cannot be resurfaced. If camshaft-to-holder oil clearances are within specifica- tions, check the cylinder head for warpage. •...
Page 459 Main Menu Table of Contents Valve Seats Reconditioning Renew the valve seats in the cylinder head using a After resurfacing the seat, inspect for even valve valve seat grinder. seating: Apply Prussian Blue compound to the valve face, and insert valve in original location in the head, then lift it and snap it closed against the seat sever- NOTE: If guides are worn (see page 6-41), replace them (see page 6-42) before grinding the valve seats.
Page 460 Main Menu Table of Contents Valve Guides Valve Movement Measure the guide-to-stem clearance with a dial indicator NOTE: An alternate method of checking guide to while rocking the stem in the direction of normal thrust stem clearance is to subtract the O.D. of the valve (wobble method).
Page 461 Main Menu Table of Contents Valve Guides Replacement As illustrated below, use a commercially available Working from the camshaft side, use the driver and air-impact valve guide driver attachment modified to an air hammer to drive the guide about 2 mm (0.1 in) fit the diameter of the valve guides.
Page 462 Main Menu Table of Contents 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. If you have all 12 guides to do, you may have to reheat the head.
Page 463 Main Menu Table of Contents Reaming NOTE: For new valve guides only. Coat both reamer and valve guide with cutting oil. Rotate the reamer clockwise the full length of the valve guide bore. Continue to rotate the reamer clockwise while removing it from the bore.
Page 464 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Installation Sequence NOTE: Exhaust and intake valve seals are NOT interchangeable. VALVE KEEPERS INTAKE VALVE SPRING VALVE SPRING RETAINER VALVE SPRING EXHAUST VALVE SEAL (BLACK SPRING) Replace. NOTE: Place the end of valve spring with closely wound coils toward the cylinder head.
Page 465 Main Menu Table of Contents Valve Installation NOTE: Tap the valve stem only along its axis so you do not bend the stem. • When installing valves in the cylinder head, coat valve stems with oil before inserting into valve guides, and make sure all valves move up and down smoothly.
Page 466 Main Menu Table of Contents Cylinder Heads Installation Install the cylinder heads in the reverse order of removal: • Always use new head gaskets. • Cylinder heads and engine block surface must be clean. • Turn the crankshaft so that No. 1 piston is at TDC (see page 6-19).
Page 467 Main Menu Table of Contents Cylinder Heads Installation (cont'd) REAR PRIMARY Rear: Tighten the cylinder head bolts sequentially in two HEATED OXYGEN SENSOR or three steps. (REAR PRIMARY HO2S) 8 x 1.25 mm • Apply clean engine oil to the bolt threads and 44 N-m (4.5 kgf-m, 22 N-m (2.2 kgf-m, washer contact surfaces.
Page 468 Main Menu Table of Contents Rocker Arms Installation Install the rocker arms in the reverse order of removal: • Valve adjusting locknuts should be loosened and adjusting screws backed off before installation. • The component parts must be installed in the original locations.
Page 469 Main Menu Table of Contents Camshafts Installation CAUTION: Valve locknuts should be loosened and ad- justing screws backed off before installation. After wiping down the camshaft and journals in the cylinder head, lubricate both surfaces and install the camshafts and rubber caps. NOTE: Apply liquid gasket around the rubber cap.
Page 470 Main Menu Table of Contents Camshafts Installation (cont'd) Apply liquid gasket to the head mating surfaces of Install the camshaft holder plates. the No. 1 and the No. 4 camshaft holders. Tighten each bolt two turns at a time in the sequence 5.
Page 471 Main Menu Table of Contents 9. Install the CKP/CYP sensor on the front cylinder 11. Insert the dowel pins in the camshaft pulley. head. 12. Install the camshaft pulleys, then tighten the retain- ing bolts to the torque specified. CKP/CYP SENSOR CAMSHAFT PULLEYS RETAINING BOLTS 10 x 1.25 mm...
Page 472 Main Menu Table of Contents Camshafts Installation (cont'd) 17. Apply liquid gasket to the head cover gasket at the 19. Tighten the nuts in two or three steps. In the final step, eight corners of the recesses. tighten all nuts, in sequence, to 12 N-m (1.2 kgf-m, 8.7 Ibf-ft).
Page 473 Main Menu Table of Contents Special Tools 7-18 7-18...
Page 474: Engine Block
Main Menu Table of Contents Engine Block Illustrated Index Lubricate all internal parts with engine oil during reassembly. NOTE: • Apply liquid gasket to the mating surfaces of the left • If the bottom of the oil pan is deformed, it should side cover and oil pump case before installing them.
Page 475 Main Menu Table of Contents Engine Block Illustrated Index (cont'd) Lubricate all internal parts with engine oil during reassembly. 11 x 1.5 mm 65 N-m (6.6 kgf-m, 48 Ibf-ft) Apply engine oil to the bolt threads and the washers. NOTE: After torquing each cap, turn crankshaft MAIN BEARING to check for binding.
Page 476 Main Menu Table of Contents CAUTION: NOTE: New rod bearings must be selected by matching • The piston skirt is coated with molybdenum; connecting rod assembly and crankshaft identification handle the piston carefully to prevent any markings (see page 7-8). damage.
Page 477 Main Menu Table of Contents Connecting Rods and Crankshaft Flywheel and Drive Plate Replacement End Play Manual Transmission: Connecting Rod End Play: Remove the eight flywheel bolts, then separate the Standard (New): 0.15-0.30 mm flywheel from the crankshaft flange. After installation, (0.006-0.012 in) tighten the bolts in the sequence shown.
Page 478 Main Menu Table of Contents Connecting Rod Bearings Main Bearings Clearance Clearance To check main bearing-to-journal oil clearance, Remove the connecting rod cap and bearing half. remove the main caps and bearing halves. Clean each main journal and bearing half with a Clean the crankshaft rod journal and bearing half clean shop towel.
Page 479 Main Menu Table of Contents Connecting Rod Bearings Main Bearings Selection Selection CAUTION: If the codes are indecipherable because of CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Page 480 Main Menu Table of Contents Piston/Connecting Rod Assemblies and Crankshaft Removal Remove the left side cover. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer. Follow reamer manufacturer's instructions.
Page 481 Main Menu Table of Contents Piston/Connecting Rod Assemblies and Crankshaft Removal (cont'd) • Remove the connecting rod caps after setting 12. Remove the bearing cap bolts and bearing cap side the crank pin at BDC for each cylinder. Remove bolts, then remove the bearing caps. the piston assembly by pushing on the connec- BEARING CAP ting rod.
Page 482 Main Menu Table of Contents Crankshaft Inspection • Clean the crankshaft oil passages with pipe Out-of-Round and Taper cleaners or a suitable brush. • Measure out-of-round at the middle of each rod • Check the keyway and threads. and main journal in two places. Alignment •...
Page 483 Main Menu Table of Contents Cylinder Block Inspection Measure wear and taper in directions X and Y at Bore Taper three levels in each cylinder as shown. Limit: (Difference between first and third measure- ment) 0.05 mm (0.002 in) • If measurements in any cylinder are beyond Oversize Bore Service Limit, replace the block.
Page 484 Main Menu Table of Contents Bore Honing (A/T) NOTE: Only scored or scratched cylinder bores must be honed. Measure cylinder bores as shown on page 7-12. If the block is to be reused, hone the cylinders and remeasure the bores. Hone cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern.
Page 485 Main Menu Table of Contents Piston/Connecting Rod Assemblies Inspection Check the piston for distortion or cracks. NOTE: If cylinder is bored, an oversized piston must be used. Measure piston diameter at a point 17 mm (0.67 in) from the bottom of the skirt. NOTE: There are two standard-size pistons (A = no letter and B).
Page 486 Main Menu Table of Contents Piston/Connecting Rod Assemblies Inspection (cont'd) Calculate the difference between cylinder bore diam- eter on page 7-12 and piston diameter.
Page 487 Main Menu Table of Contents Connecting Rods Selection Each rod is sorted into one of four tolerance ranges (from O to 0.024 mm, in 0.006 mm increments) depen- ding on the size of its big end bore. It's then stamped with a number (1, 2, 3 or 4) indicating that tolerance.
Page 488 Main Menu Table of Contents Piston Rings Replacement End Gap Using a ring expander, remove the old piston rings. Using a piston, push a new ring into the cylinder bore 15-20 mm (0.6 - 0.8 in) from the bottom. Clean all ring grooves thoroughly. NOTE: Measure the piston ring end-gap with a feeler •...
Page 489 Main Menu Table of Contents Piston Rings Ring-to-Groove Clearances After installing a new set of rings, measure ring-to-groove clearances: Top Ring Clearance M/T: Standard (New): 0.035 - 0.065 mm (0.0014-0.0026 in) Service Limit: 0.13 mm (0.005 in) A/T: Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 in) Service Limit: 0.13 mm (0.005 in)
Page 490 Main Menu Table of Contents Piston Rings Alignment Install the rings as shown. NOTE: • The top ring has an R1 or R mark. • The second ring has an R2 or RN mark. NOTE: The manufacturing marks must be facing upward.
Page 491 Main Menu Table of Contents Rotate the rings in their grooves to make sure they do not bind. Position the ring end gaps as shown:...
Page 492 Main Menu Table of Contents Piston/Connecting Rod Assemblies Installation Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. If the crankshaft is already installed: • Guide the piston carefully to prevent damage. •...
Page 493 Main Menu Table of Contents Piston/Connecting Rod Assemblies Installation (cont'd) If the crankshaft is not installed: • Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
Page 494 Main Menu Table of Contents Oil Seal Installation The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and to the lip of the seal. Using the special tools, drive in the flywheel-end seal until the driver bottoms against left side cover.
Page 495 Main Menu Table of Contents Crankshaft Installation Before installing the crankshaft, apply a coat of NOTE: engine oil to the main bearings and rod bear- • Guide the piston carefully to prevent damage. ings. • Fit long rubber hoses (about 30 cm long) to con- necting rod bolts to protect the crankshaft.
Page 496 Main Menu Table of Contents Crankshaft Installation (cont'd) Check the rod bearing clearance with plastigage BEARING CAP BOLTS TORQUE SEQUENCE (see page 7-7), then torque the connecting rod cap nuts. NOTE: Reference numbers on connecting rods are for big-end bore tolerance and do NOT indicate the posi- tion of piston in engine.
Page 497 Main Menu Table of Contents OIL PUMP SIDE: BEARING CAP BRIDGE 6 x 1.0 mm CAP BRIDGE BOLT 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 11 x 1.5 mm 65 N-m (6.6 kgf-m, OIL SCREEN BAFFLE PLATE 48 Ibf-ft) 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) SIDE BOLT...
Page 498 Main Menu Table of Contents Crankshaft Installation (cont'd) LEFT SIDE COVER Apply liquid gasket along the broken line. OIL PUMP Apply liquid gasket along the broken line. • Do not install the parts if five minutes or more have elapsed since applying liquid gasket. Instead reapply liquid gasket after removing old residue.
Page 499 Main Menu Table of Contents Special Tools...
Page 500: Engine Lubrication
Main Menu Table of Contents Engine Lubrication Illustrated Index NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. • Use liquid gasket, Part No. 08718-0001 or 08718- 0003. • If the bottom of the oil pan is deformed, it should be repaired or the oil pan should be replaced to retain proper clearance between the screen and the bottom.
Page 501 Main Menu Table of Contents Engine Oil Inspection Check engine oil with the engine off and the car parked on level ground. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. If the level has dropped close to the lower mark, add oil until it reaches the upper mark.
Page 502 Main Menu Table of Contents Replacement CAUTION: Remove the drain plug carefully while the en- gine is hot, the hot oil may cause scalding. Warm up the engine. Drain the engine oil. Reinstall the drain plug with a new washer, and refill with the recommended oil.
Page 503 Main Menu Table of Contents The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: An oil with a viscosity of 10W-30 is preferred for improved fuel economy and year-round protection in the vehicle.
Page 504 Main Menu Table of Contents Oil Filter Replacement CAUTION: Loosen the oil filter carefully while the engine is hot, the hot oil may cause scalding. Remove the oil filter with the special tool as shown. OIL FILTER WRENCH 07912-6110001 Torque: One turn (22 N-m (2.2 kgf-m, 16 Ibf-ft)) Inspect the threads and rubber seal on the new filter.
Page 505 Main Menu Table of Contents Oil Pressure Testing If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: Remove the engine oil pressure switch, and install an oil pressure gauge. Start the engine.
Page 506 Main Menu Table of Contents Oil Pump Overhaul NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. PUMP COVER 6 x 1.0 mm Inspection, page 8-8, 6 N-m (0.6 kgf-m, 4 Ibf-ft) PUMP HOUSING Inspection, page 8-8, OIL SEAL Installation, page Replace.
Page 507 Main Menu Table of Contents Oil Pump Removal/lnspection/lnstallation 1. Drain the engine oil. 11. Remove the nine screws from the pump housing, then separate the housing and cover. 2. Remove the timing belt (see page 6-15). 12. Check the inner-to-outer rotor radial clearance. 3.
Page 508 Main Menu Table of Contents 14. Check the housing-to-outer rotor radial clearance. 18. Reassemble the oil pump. Apply liquid thread-lock to the pump housing screws. Housing-to-Rotor Radial Clearance Standard (New): 0.11 - 0.20 mm 19. Check that the oil pump turns freely. (0.004 - 0.008 in) Service Limit: 0.21 mm (0.008 in)
Page 509 Main Menu Table of Contents Oil Pump Removal/lnspection/lnstallation (cont'd) 23. Install the oil pump on the cylinder block. 27. Apply liquid gasket to the oil pump and left side cover mating areas as shown below. 24. Install the oil pass pipe and joint. 25.
Page 510 Main Menu Table of Contents 29. Tighten bolts and nuts finger tight at six points as shown below. 30. Starting with nut torque all bolts and nuts, in a clockwise pattern in three steps. NOTE: Excessive tightening can cause distortion of oil pan gasket and oil leakage.
Page 511 Main Menu Table of Contents Oil Cooler, Oil Filter Base Illustrated Index NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. OIL COOLER CENTER BOLT • Use liquid gasket, Part No. 08718-0001 or 08718-0003. 49 N-m (5.0 kgf-m, 36 Ibf-ft) 2 mm PIN SPRING RELIEF VALVE...
Page 512 Main Menu Table of Contents Special Tools 9-4, 9-5, 9-6,...
Page 513: Intake Manifold/Exhaust System
Main Menu Table of Contents Intake Manifold Replacement NOTE: Use new O-rings and gaskets when reassembling. CAUTION: • Check for folds or scratches on the surface of the gasket. • Replace with a new gasket if damaged. 6 x 1.0 mm INTAKE MANIFOLD 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) PLATE...
Page 514 Main Menu Table of Contents Exhaust Manifold Replacement NOTE: Use new gaskets and self-locking nuts. M/T: GASKET Replace. FRONT EXHAUST MANIFOLD COVER 8 x 1.25 mm 8 x 1.25 mm 22 N-m (2.2 kgf-m, 22 N-m (2.2 kgf-m 16 Ibf-ft) 16 Ibf-ft) COVER FRONT PRIMARY HEATED...
Page 515 Main Menu Table of Contents A/T: FRONT PRIMARY HO2S 44 N-m (4.5 kgf-m, 33 Ibf-ft) • Be careful not to damage. • Use the special tool when removing and installing. GASKET Replace. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) REAR PRIMARY HO2S...
Page 516 Main Menu Table of Contents Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. M/T: LONG BOLT REAR SECONDARY HEATED 8 x 1.25 mm OXYGEN SENSOR (REAR 22 N-m (2.2 kgf-m, 16 Ibf-ft) SECONDARY HO2S) Replace.
Page 517 Main Menu Table of Contents A/T: REAR SECONDARY HO2S 44 N-m (4.5 kgf-m, 33 Ibf-ft) GASKETS SELF-LOCKING NUTS • Be careful not to 10 x 1.25 mm Replace. damage. 33 N-m (3.4 kgf-m, 25 Ibf-ft) • Use the special tool Replace.
Page 518: Cooling
Main Menu Table of Contents Cooling Illustrated Index NOTE: System is under high pressure when the • Check all cooling system hoses for damage, engine is hot. To avoid danger of releasing scalding leaks or deterioration and replace if necessary. engine coolant, remove the cap only when the engine is •...
Page 519 Main Menu Table of Contents ENGINE OIL COOLER EXPANSION TANK Refilling and bleeding, page 10-5 Leak Test, page 10-8 Test, page 10-8 ENGINE OIL COOLER PIPE AUTOMATIC TRANSMISSION FLUID (ATF) COOLER...
Page 520 Main Menu Table of Contents Radiator Replacement Remove the spare tire. Install the radiator in the reverse order of removal: Drain the radiator (see page 10-5 thru 10-7). NOTE: • Set the upper and lower cushions securely. Disconnect the fan motor connector and the •...
Page 521 Main Menu Table of Contents Engine Coolant Refilling and Bleeding Open the hood, the rear window and the engine CAUTION: When pouring engine coolant, be sure to cover. shut the relay box lid and not let coolant spill on the electrical parts or the paint.
Page 522 • Always use Genuine Honda Antifreeze/Coolant. engine drain bolts. Using a non-Honda coolant can result in corro- • Be sure to replace the water pipe drain bolt sion, causing the cooling system to malfunction washers with new ones.
Page 523 Main Menu Table of Contents 10. Fill the expansion tank with engine coolant. As 14. Install the expansion tank cap, and turn it 60 degrees (where it engages the first lock tab of filler neck). coolant starts to run out in a steady stream without bubbles, tighten the bleeders in sequence: thermo cover bleed bolt, radiator bleed plug, heater pipe 1 5.
Page 524 Main Menu Table of Contents Expansion Tank Cap Testing Remove the expansion tank cap, wet its seal with engine coolant, then install it on the pressure tester. Apply a pressure of 93-123 kPa (0.95 - 1.25 kgf/cm 14-18 psi). PRESSURE TESTER Check for a drop in pressure.
Page 525 Main Menu Table of Contents Thermostat Replacement NOTE: Use new gaskets and O-rings when reassem- bling. COOLANT TEMPERATURE GAUGE SENDING UNIT 9 N-m (0.9 kgf-m, 7 Ibf-ft) Apply liquid gasket to the threads. WATER PASSAGE 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) BLEED BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft)
Page 526 Main Menu Table of Contents Water Pump Illustrated Index NOTE: Use new O-rings and new special bolts when reassembling. COOLANT RADIATOR FAN TEMPERATURE GAUGE CONTROL SENSOR SENDING UNIT 27 N-m (2.8 kgf-m, 9 N-m (0.9 kgf-m, 7 Ibf-ft) 20 Ibf-ft) Apply liquid gasket to the threads.
Page 527 Main Menu Table of Contents Replacement Inspection Remove the timing belt (see page 6-15). Remove the timing belt (see page 6-15). Turn the water pump pulley counterclockwise. Check Unscrew the bolts, then remove the water pump. that it turns freely. NOTE: Inspect and clean the O-ring groove and Check for signs of seal leakage.
Page 528 Main Menu Table of Contents Special Tools Note: Refer to page 11-2c 11-2g for further page references 11-151,11-155, 11-163, 11-164, 11-172, 11-173, 11-175, 11-178, 11-139 11-173 11-38, 11-60, 11-62, 11-64, 11-81,11-91,11-129,11-160, 11-162, 11-163, 11-38c 11-40 11-133, 11-137...
Page 529 Main Menu Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. THROTTLE POSITION (TP) SENSOR EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUEL TANK PRESSURE SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR EVAPORATIVE EMISSION CRANKSHAFT POSITION/...
Page 530 Main Menu Table of Contents Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-52. CLUTCH SWITCH (M/T only) Troubleshooting, page 11-125 ACCELERATOR POSITION (AP) SENSOR THROTTLE CABLE Inspection/Adjustment, page 11-150 Installation, page 11-150 PGM-FI MAIN RELAY Relay Testing, page 11-143...
Page 531 Main Menu Table of Contents For Troubleshooting of DTC related components, see chart on page 11-52. FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE FUEL PUMP Testing, page 11-142 Replacement, page 11-142 FUEL FEED PIPE FUEL FILTER Replacement, page 11-138 FUEL PRESSURE REGULATOR Testing, page 11-137 Replacement, page...
Page 532 Main Menu Table of Contents Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-52. THROTTLE BODY (TB) Inspection, page 11-151 Disassembly, page 11-152 AIR CLEANER (ACL) Disassembly, page 11-149 INTAKE AIR DUCT INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM Troubleshooting, page 11-155 INTAKE AIR BYPASS (IAB) VALVE BODY ASSEMBLY...
Page 533 Main Menu Table of Contents System Description Vacuum Connections For Troubleshooting of DTC related components, see chart on page 11-52. CONTROL page 11-8 EVAP CONTROL CANISTER VENT SHUT VALVE EVAP PURGE CONTROL SOLENOID EVAP CONTROL VALVE CANISTER To EVAP TWO-WAY VALVE INTAKE BYPASS...
Page 534 Main Menu Table of Contents System Description Vacuum Connections (cont'd) Control Box For Troubleshooting of DTC related components, see chart on page 11-52. EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INTAKE AIR BYPASS (IAB) CONTROL SOLENOID VALVE...
Page 535 Main Menu Table of Contents INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM FRONT PRIMARY HEATED OXYGEN SENSOR (HO2S) FRONT THREE WAY CATALYTIC CONVERTER (TWO (BANK 2, SENSOR 1) REAR THREE WAY CATALYTIC CONVERTER (TWO REAR PRIMARY HEATED OXYGEN SENSOR (HO2S) POSITIVE CRANKCASE VENTILATION (PCV) VALVE (BANK 1, SENSOR 1) EXHAUST GAS RECIRCULATION (EGR) VALVE FRONT SECONDARY HEATED OXYGEN SENSOR (HO2S)
Page 536 Main Menu Table of Contents System Description Electrical Connections FUSES BRAKE LIGHTS HORN (20 A)* THL MOTOR (20 A)** CLOCK (7.5 A)* ACG (120 A)** ACG(S) (20 A)** IG COIL (30 A)** No. 2 FUEL PUMP SRS2 (15 A)*** No. 5 BACK-UP LIGHTS ALTERNATOR In the under-hood fuse/relay box TURN SIGNALS (15 A)**»...
Page 537 Main Menu Table of Contents...
Page 538 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 539 Main Menu Table of Contents...
Page 540 Main Menu Table of Contents System Description Electrical Connections (cont'd) (To page 11-15)
Page 541 Main Menu Table of Contents (From page 11-14)
Page 542 Main Menu Table of Contents System Description Electrical Connections (cont'd) (To page 11-17)
Page 543 Main Menu Table of Contents (From page 11-16)
Page 544 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 545 Main Menu Table of Contents...
Page 546 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 547 Main Menu Table of Contents...
Page 548 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 549 Main Menu Table of Contents...
Page 550 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Right Side)]...
Page 551 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). : Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 552 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Left Side)] (cont'd)
Page 553 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 554 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 555 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 556 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 557 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 558 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 559 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 560 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd) FLOOR WIRE HARNESS UNDER-HOOD FUSE/RELAY UNDER-DASH FUSE FRONT COMPARTMENT WIRE HARNESS SIDE WIRE HARNESS...
Page 561 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEU/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 562 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd) UNDER-HOOD FLOOR FUSE/RELAY WIRE HARNESS SIDE WIRE HARNESS UNDER-DASH FUSE SUB RELAY BOX A FRONT COMPARTMENT WIRE HARNESS...
Page 563 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEU/BLK and YEU/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 564 When the Malfunction Indicator Lamp (MIL) has been reported on, or there is a driveability problem, use the appropri- ate procedure below to diagnose and repair the problem. A. When the MIL has come on: MALFUNCTION 1. Connect the Honda PGM Tester or an OBD II INDICATOR scan tool to the 16P Data Link Connector (DLC) LAMP...
Page 565 The ECM is part of the immobilizer system. If you substitute a known-good ECM, the ECM will have a different immo- bilizer code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester.
Page 566 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures (cont'd) If the inspection for a particular code requires voltage or resistance checks at the ECM connectors, remove the bulkhead panels. Unbolt the ECM. Check the system according to the procedure described for the appropriate code(s) listed on the following pages.
Page 567 Main Menu Table of Contents CAUTION: Puncturing the insulation on a wire can cause poor or intermittent electrical connections. Bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with the tester probe and do not insert the probe. TESTER PROBE RUBBER SEAL WIRE HARNESS...
Page 568 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures (cont'd) Symptom Chart Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL was reported on, go to page 11-38. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated.
Page 569 Main Menu Table of Contents Probable Cause List (For the DTC chart, see page 11-52.) Probable Cause Page System Engine Control Module (ECM) 11-61, 11-62 11-132, 11-139 Fuel pressure and fuel pump relay 11-143 PGM-FI main relay Section 23 Ignition system See DTC chart Crankshaft Position/Cylinder Position sensor circuit See DTC chart...
Page 570 ECM Data By connecting the OBD II scan tool or the Honda PGM Tester to the 16P data link connector (DLC), various data can be retrieved from the ECM. The items listed in the table below conform to the SAE recommended practice.
Page 571 Main Menu Table of Contents Data Description Operating Value Freeze Data HO2S At idle speed: closed Loop status is indicated as "open" or "closed". Feedback Closed: Based on the H02S output, the ECM deter- Loop Status mines the air/fuel ratio and controls the amount of (Bank 1: Rear) injected fuel.
Page 572 Main Menu Main Menu Table of Contents Table of Contents Troubleshooting Engine Control Module Terminal Arrangement ECM CONNECTOR A (26P) Wire side of female terminals ECM CONNECTOR A (26P) NOTE: Standard battery voltage is 12 V. Terminal Wire Description Terminal name Signal number color...
Page 573 Main Menu Main Menu Table of Contents Table of Contents Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR B (16P) *: M/T Terminal Wire Terminal name Description Signal number color With engine at low rpm: 0 V VTP SWF (FRONT VTEC Detects VTEC pressure switch With engine at high rpm:...
Page 574 Main Menu Main Menu Table of Contents Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) ECM CONNECTOR C (12P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR C (12P) *: M/T Terminal Wire Terminal name Description...
Page 575 Main Menu Main Menu Table of Contents Table of Contents ECM CONNECTOR D (22P) Wire side of female terminals ECM CONNECTOR D (22P) NOTE: Standard battery voltage is 12 V. Terminal Wire Terminal name Decription Signal number color VBU (VOLTAGE BACK UP) Battery voltage at all times Power source for the ECM con- WHT/YEL...
Page 576 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR F (26P) *: M/T Terminal Wire Terminal name Description Signal number color VCC1 Provides sensor voltage With ignition switch ON (II): about 5 V YEL/WHT With ignition switch OFF: 0 V...
Page 577 Main Menu Table of Contents ECM CONNECTOR G (12P) Wire side of female terminals ECM CONNECTOR G (12P) NOTE: Standard battery voltage is 12 V. Terminal Wire Terminal name Description Signal number color IGM1 (POWER SOURCE) Power source for throttle With ignition switch ON (II): GRN/RED valve control motor...
Page 578 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart Note: Refer to page 11-48c 11-9g for DTCs not listed on this chart. Detection Item Probable Cause Page (MIL indication*) Manifold Absolute • Open or short in MAP sensor circuit •...
Page 579 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) • Short in Rear Secondary HO2S (Bank 1, Rear Secondary Heated Oxygen Sensor 2) circuit Sensor P0137 (64) 11-82 • Rear Secondary H02S (Bank 1, Sensor 2) Circuit Low Voltage (Bank 1, Sensor 2) •...
Page 580 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Detection Item Probable Cause Page (MIL indication) System Too Lean • Fuel supply system [Front Bank (Bank 2)] • Front Primary H02S (Bank 2, Sensor 1) • MAP sensor 11-87 P0174 (45)
Page 581 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) P0700 Automatic P0715 Transaxle P0720 P0725 (70)* Section 14 P0730 P0740 P0753 P0758 Barometric • ECM (Baro sensor) Pressure Circuit P1106 (13) 11-103 Range/Performance Problem Barometric • ECM (Baro sensor) P1107 (13) Pressure Circuit...
Page 582 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Probable Cause Page (MIL indication) Detection Item VTEC System • Open or short in Front VTEC Solenoid Malfunction Valve circuit [Front Bank (Bank 2)] • Front VTEC Solenoid Valve •...
Page 583 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) Evaporative Emission Control • Vacuum connection System Leak Detected (Fuel Tank • Fuel tank Area) • Fuel tank pressure sensor • Fuel fill cap P1456 (90)** • EVAP bypass solenoid valve 11-172 ('97-99) •...
Page 584 Main Menu Table of Contents Troubleshooting How to Read Flowcharts A flowchart is designed to be used from start to final repair. It's like a map showing you the shortest distance. But beware: if you go off the "map" anywhere but a "stop" symbol, you can easily get lost. Describes the conditions or situation to start a troubleshooting flowchart.
Page 585 Main Menu Table of Contents PGM-FI System System Description INPUTS ENGINE CONTROL MODULE (ECM) OUTPUTS Front Primary H02S Fuel Injectors Rear Primary HO2S PGM-FI M.ain Relay (Fuel Pump) Front Secondary HO2S Malfunction Indicator Lamp Rear Secondary H02S Throttle Valve Control Motor MAP Sensor A/C Compressor Clutch Relay CKP/CYP Sensor...
Page 586 Main Menu Table of Contents PGM-FI System System Description (cont'd) Fuel Cut-off Control During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over 1,500 rpm. Fuel cut-off action also takes place when engine speed exceeds 8,300 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving.
Page 587 Main Menu Table of Contents Engine Control Module (ECM) The Malfunction Indicator Lamp NOTE: If this symptom is intermittent, check for a loose No. 5 BACK-UP LIGHTS, ALTERNATOR, (MIL) never comes on (even for TURN SIGNALS (15 A) fuse in the under-dash fuse/relay box, a poor connection at ECM terminal two seconds) after ignition is A7, or an intermittent open in the BLU wire between the ECM (A7) and the gauge assembly.
Page 588 — An intermittent short in the wire between the ECM (F14) and accelerator position sensor tool or Honda PGM Tester. • See the OBD II scan tool or Honda PGM Tester user's manuals for specific operating instruc- tions. Go to troubleshooting proce-...
Page 589 Main Menu Table of Contents (From page 11-62) Check for a short in the wire (MIL line): 1. Turn the ignition switch OFF. 2. Disconnect the ECM connec- tor A (26P). 3. Turn the ignition switch ON (II). Repair short to body ground in Is the MIL ON? the wire between the ECM (A7) and MIL.
Page 590 Main Menu Table of Contents PGM-FI System Engine Control Module (ECM) (cont'd) (From page 11-63) Check for a short in the AP sen- sor: 1. Turn the ignition switch OFF. 2. Connect the SCS service con- nector. 3. Disconnect the AP sensor 3P connector.
Page 591 Main Menu Table of Contents Drive By Wire System System Description The Drive By Wire System is an electronic throttle control system. This system consists of the throttle valve control motor and Throttle Position (TP) sensor assembled in Throttle Body (TB), the accelerator position sensor, and the Engine Control Module (ECM).
Page 592 Main Menu Table of Contents Drive By Wire System System Description (cont'd) Cruise Control Function The ECM controls the throttle valve control motor to maintain the set speed when the cruise control system is operating. The throttle valve control motor takes the place of the cruise control actuator. Traction Control System (TCS) Function If wheel spin occurs during acceleration or cornering, the TCS control unit requests the ECM to reduce the engine power by retarding the ignition timing and closing the throttle valve.
Page 593 Main Menu Table of Contents Idle Control System Air Conditioning Signal This signals the ECM when there is a demand for cooling from the air conditioning system. Inspection of Air Conditioning Signal. Check for a short in the wire (ACS line): 1.
Page 594 Main Menu Table of Contents (From page 11-118) Check for an open in the wire: Momentarily connect the No. 4 ter- Is there a clicking noise from the minal of the 4P connector on the A/C compressor clutch? A/C clutch relay to body ground several times.
Page 595 Main Menu Table of Contents Idle Control System Alternator (ALT) FR Signal This signals the ECM when the Alternator (ALT) is charging. Inspection of ALT FR Signal. Check for a short in the wire (ALTF line): 1. Disconnect the GRN 4P con- nector from the ALT.
Page 596 Main Menu Table of Contents (From page 11-120) Check for an open in the wire (ALTF line): 1. Turn the ignition switch OFF. 2. Disconnect the negative battery cable from the battery. 3. Disconnect the ECM connec- tor D (22P) from the ECM. 4.
Page 597 Main Menu Table of Contents Idle Control System Automatic Transaxle (A/T) Gear Position Signal This signals the ECM when the transmission is in position. Inspection of A/T Gear Position Signal. Check the operation of the A/T gear position switch: 1. Turn the ignition switch ON (II). 2.
Page 598 Main Menu Table of Contents (From page 11-122) Check for an open in the wire (ATF PN line): 1. Turn the ignition switch OFF. 2. Reconnect the 30P (C412) con- nector to the gauge assembly. 3. Reconnect the 26P connector to the TCM.
Page 599 Main Menu Table of Contents Idle Control System Neutral Switch Signal (M/T) This signals the ECM when the transmission is in neutral. Inspection of neutral switch signal. Check for an open in the wire (NTSW line): 1. Turn the ignition switch ON (II). 2.
Page 600 Main Menu Table of Contents Clutch Switch Signal (M/T) This signals the ECM when the clutch is engaged. Inspection of clutch switch signal. Check for an open in the wire (MTCLS line): 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM connector terminals C4 and A26.
Page 601 Main Menu Table of Contents Idle Control System Clutch Switch Signal (M/T) (cont'd) (From page 11-125) Check the clutch switch: 1. Turn the ignition switch OFF: 2. Disconnect the 3P connector from the clutch switch. Is there approx. 5 V? 3.
Page 602 Main Menu Table of Contents Brake Switch Signal This signals the ECM when the brake pedal is depressed. Inspection of Brake Switch Signal. Are the brake lights on without Inspect the brake switch (see depressing the brake pedal? section 19). Depress the brake pedal.
Page 603 Main Menu Table of Contents Idle Control System Starter Switch Signal This signals the ECM when the engine is cranking. Inspection of Starter Switch Sig- NOTE: nal. • M/T: Clutch pedal must be depressed. • A/T: Transmission in position. Check for an open or short in the wire (STS line): Measure voltage between ECM connector terminals C6 and A26...
Page 604 Main Menu Table of Contents Idle Speed Setting Inspection/Adjustment Restart the engine. NOTE: Before setting the idle speed, check the these Check idling in no-load conditions in which the items: headlights, blower fan, rear defogger, cooling fan, The MIL has not been reported on. and air conditioner are not operating.
Page 605 Main Menu Table of Contents Fuel Supply System Fuel Lines Check fuel system lines, hoses, connections and components for damage, leaks or deterioration, and replace if necessary. 27 N-m (2.8 kgf-m, 21 Ibf-ft) 27 N-m (2.8 kgf-m, 21 Ibf-ft) 27 N-m (2.8 kgf-m, 21 Ibf-ft) 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Page 606 Main Menu Table of Contents Check all hose clamps and retighten if necessary.
Page 607 Main Menu Table of Contents Fuel Supply System System Description The fuel supply system consists of a fuel tank, in-tank high-pressure fuel pump, fuel pump relay, fuel pump resistor PGM-FI main relay, fuel filter, fuel pressure regu- lator, fuel injectors, injector resistor (A/T), and fuel deliv- ery and return lines.
Page 608 Main Menu Table of Contents Fuel Pressure Relieving Before disconnecting fuel pipes or hoses, release pres- sure from the system by loosening the 6 mm service bolt on top of the fuel filter. Do not smoke while working on the fuel system. Keep open flames or sparks away from your work area.
Page 609 Main Menu Table of Contents Inspection If the fuel pressure is not as specified, first check the fuel pump (see page 11-142). If the fuel pump is OK, 1. Relieve fuel pressure (see page 11-132) check the following: Remove the service bolt on the fuel filter while If the fuel pressure is higher than specified, inspect for: holding the banjo bolt with another wrench.
Page 610 Main Menu Table of Contents Fuel Supply System Fuel Injectors Replacement Do not smoke during the work. Keep open flames away from your work area. 1. Relieve fuel pressure (see page 11-132). 2. Remove the intake manifold covers. 3. Disconnect the connectors from the fuel injectors and the IAT sensor. 4.
Page 611 Main Menu Table of Contents 13. To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake mani- fold. FUEL RAILS FUEL RAIL INSULATOR 14. Align the center line on the connector with the mark on the fuel rail. FUEL RAIL 15.
Page 612 Main Menu Table of Contents Fuel Supply System Fuel Injector Resistor (A/T) Description Testing Disconnect the fuel injector resistor connector. The fuel injector resistor lowers the current supplied to the fuel injectors to prevent damage to the fuel injector Check for resistance between each of the fuel injec- coils.
Page 613 Main Menu Table of Contents Fuel Pressure Regulator Description Testing The fuel pressure regulator maintains a constant fuel pressure to the fuel injectors. When the difference Do not smoke during the test. Keep open between the fuel pressure and manifold pressure flames away from your work area.
Page 614 Main Menu Table of Contents Fuel Supply System Fuel Pressure Regulator (cont'd) Replacement Do not smoke while working on fuel sys- tem. Keep open flame away from your work area. Place a shop towel under fuel pressure regulator, then relieve fuel pressure (see page 11-132). Disconnect the vacuum hose and fuel return hose.
Page 615 Main Menu Table of Contents Fuel Supply System Fuel Filter Replacement Do not smoke while working on fuel sys- tem. Keep open flame away from your work area. The fuel filter should be replaced every 4 years or 60,000 miles (96,000 km), whichever comes first, or whenever the fuel pressure drops below the specified value [324 - 363 kPa (3.3 - 3.7 kgf/cm , 47 - 53 psi) with the fuel pres-...
Page 616 Main Menu Table of Contents Fuel Supply System Fuel Pump Testing Replacement Do not smoke while working on fuel sys- Do not smoke during the test. Keep open flame away from your work area. tem. Keep open flames away from your work area. If you suspect a problem with the fuel pump, check that 1.
Page 617 Main Menu Table of Contents PGM-FI Main Relay Description Relay Testing The PGM-FI main relay actually contains two individual NOTE: If the car starts and continues to run, the PGM-FI relays. main relay is OK. The relay is located behind the passenger's seat back panel.
Page 618 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay (cont'd) Troubleshooting Engine will not start. Inspection of PGM-FI main relay and relay harness. PGM-FI MAIN RELAY 8P CONNECTOR Check for an open in the wire (PG1 line): 1. Turn the ignition switch OFF. 2.
Page 619 Main Menu Table of Contents (From page 11-144) Check for an open in the wire (IGSW line): Measure voltage between the PGM-FI main relay 4P connector terminal No. 4 and body ground. Replace the IG COIL (30 A) fuse in the engine compart- ment fuse/relay box.
Page 620 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay (cont'd) (From page 11-145) Check for an open in the wires (IGP lines): 1. Reconnect the ECM connector A (26P). 2. Reconnect the PGM-FI main relay 4P and 8P connectors. 3.
Page 621 Main Menu Table of Contents Fuel Tank Replacement Do not smoke while working on fuel system. Keep open flame away from your work area. Make sure lifts are placed properly (see section 1. Raise the vehicle. 2. Remove the drain bolt, and drain the fuel into an approved container. 3.
Page 622 Main Menu Table of Contents Intake Air System System Description The system supplies air for all engine needs. It consists of the intake air pipe. Air Cleaner (ACL), intake air duct, throttle body, and intake manifold. A resonator in the intake air duct provides additional silencing as air is drawn into the system. IAB CONTROL SOLENOID VALVE To No.
Page 623 Main Menu Table of Contents Air Cleaner (ACL) ACL Element Replacement ACL HOUSING COVER ACL ELEMENT Normal conditions: Replace air cleaner element every 30,000 miles (48,000 km) or 24 months whichever comes first. Severe conditions: Clean air cleaner element every ACL HOUSING 15,000 miles (24,000 km) or 12 months and replace every 30,000...
Page 624 Main Menu Table of Contents Intake Air System Throttle Cable ——— Inspection/Adjustment Installation Remove the accelerator position sensor cover. Rotate the throttle linkage counterclockwise, then install the throttle cable in the throttle linkage and Check that the throttle cable operates smoothly with install the cable housing in the cable bracket.
Page 625 Main Menu Table of Contents Throttle Body Description Inspection The throttle body is of the single-barrel side-draft type. The lower portion of the throttle valve is heated by CAUTION: Do not adjust the throttle stop screw. It is engine coolant which is fed from the cylinder head. The preset at the factory.
Page 626 Main Menu Table of Contents Intake Air System Throttle Body (cont'd) Disassembly THROTTLE BODY IDLE ADJUSTING SCREW O-RING Replace. TP SENSOR THROTTLE VALVE CONTROL MOTOR INTAKE AIR DUCT...
Page 627 Main Menu Table of Contents Fuel Injection Air (FIA) Control System Description The Fuel Injection Air (FIA) Control system enables fresh air to be drawn through the throttle body and fuel injector port. AIR FLOW FUEL INJECTOR IDLE ADJUSTING THROTTLE SCREW BODY...
Page 628 Main Menu Table of Contents Intake Air System Intake Air Bypass (IAB) Control System Description Satisfactory power performance is achieved by closing and opening the intake air bypass (IAB) control valves. High torque at low engine speed is achieved when the valves are closed, whereas high power at high engine speed is achieved when the valves are opened.
Page 629 Main Menu Table of Contents Troubleshooting Inspection of IAB Control System. VACUUM PUMP/GAUGE, 0-30 in.Hg A973 - 041 - XXXXX Check for vacuum at idle: 1. Start the engine and allow it to idle. 2. Remove the No. 3 vacuum hose from the IAB control diaphragm and connect a vac- uum gauge to the hose.
Page 630 Main Menu Table of Contents Intake Air System Intake Air Bypass (IAB) Control System (cont'd) (From page 11-155) (From page 11-155) Repair open in the wire between the control box 6P connector and Is there battery voltage? Check for vacuum at 5,000 rpm: No.
Page 631 Main Menu Table of Contents Intake Air Bypass (IAB) Control Valve Testing CAUTION: Do not adjust the IAB control valve full-close screw. It was preset at the factory. Check the IAB control valve shaft for binding or sticking. Check the IAB control valve for smooth movement. Check that of the IAB control valve is in close contact with the stop when the vacuum hose is dis-...
Page 632 Main Menu Table of Contents Emission Control System System Description Tailpipe Emission The emission control system includes two Three Way Inspection Catalytic Converters (TWCs), Exhaust Gas Recirculation (EGR) system, Positive Crankcase Ventilation (PCV) sys- Do not smoke during this procedure. Keep any open flame away from your work area.
Page 633 Main Menu Table of Contents Three Way Catalytic Converter (TWC) Description The Three Way Catalytic Converter (TWC) is used to convert hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO2), dinitrogen (N2) and water vapor. SECONDARY HEATED OXYGEN SENSOR (SENSOR 2) THREE WAY CATALYST...
Page 634 Main Menu Table of Contents Exhaust Gas Recirculation (EGR) System The EGR system is designed to reduce oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers. It is composed of the EGR valve, EGR vacuum control valve, EGR control solenoid valve, ECM and various sensors.
Page 635 Main Menu Table of Contents Emission Control System Positive Crankcase Ventilation (PCV) System Description Inspection The Positive Crankcase Ventilation (PCV) system is designed to prevent blow-by gas from escaping to the 1. Check the PCV hoses and connections for leaks and atmosphere.
Page 636 Main Menu Table of Contents Evaporative Emission (EVAP) Controls Description The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system consists of the following components: A. Evaporative Emission (EVAP) Control Canister An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP control canister into the engine and burned.
Page 637 Main Menu Table of Contents EVAP Control Canister Removal/Installation EVAP CONTROL Remove the air cleaner housing. CANISTER Remove the engine compartment fuse/relay box mounting bolts and harness clip. AIR CLEANER HOUSING EVAP CONTROL DUST FILTER CANISTER BRACKET BRACKET HARNESS CLIP DUST FILTER Remove the EVAP control canister bracket mount- ing bolts.
Page 638 Main Menu Table of Contents Emission Control System Evaporative Emission (EVAP) Two Way Valve Testing Remove the fuel fill cap. Remove the vapor line from the EVAP two way valve (located under the engine compartment fuse/relay box), and connect it to a T-fitting from a vacuum gauge and a vacuum pump as shown.
Page 639 Main Menu Table of Contents Special Tools 12-8, 12-12,12-13 12-8, 12-13 12-12 12-12 12-8, 12-13...
Page 640 Main Menu Table of Contents Description Dual Mass Flywheel The dual mass flywheel is designed to reduce the noise and vibrations produced by the engine, clutch, and transmission during acceleration and cruising. The flywheel assembly is actually two flywheels in one, which raises the inertia mass on both the engine and transmis- sion.
Page 641 Main Menu Table of Contents Illustrated Index NOTE: • Whenever the transmission is removed, clean and grease the release bearing sliding surface. • If the parts marked * are removed, the clutch hydraulic system must be bled. • Bleed the clutch hydraulic system (see page 12-7). •...
Page 642 Main Menu Table of Contents Clutch Pedal Adjustment NOTE: 4. Thread in the clutch pedal switch A in until it con- • To check the switch, see section tacts the clutch pedal. • The clutch is self-adjusting to compensate for wear. 5.
Page 643 Main Menu Table of Contents Clutch Master Cylinder Installation Removal CAUTION: Install the clutch master cylinder in the reverse • Avoid spilling brake fluid on paint as it may damage order of removal. the finish. • Plug the end of the clutch line and reservoir hose NOTE: Bleed the clutch hydraulic system (see with a shop towel to prevent fluid from flowing out page 12-7).
Page 644 • Refill the master cylinder fluid when done. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corro- sion and decrease the life of the system.
Page 645 Main Menu Table of Contents Pressure Plate, Clutch Disc Removal 1. Remove the transmission (see section 13). Remove the clutch disc and special tools. Install the special tools. HANDLE HANDLE 07936-3710100 07936-3710100 CLUTCH ALIGNMENT SHAFT CLUTCH ALIGNMENT SHAFT 07MAF-PR80100 07MAF-PR80100 RING GEAR HOLDER 07LAB-PV00100 07924-PD20003...
Page 646 Main Menu Table of Contents Clutch Disc Inspection Inspect the lining of the clutch disc for signs of slip- Measure the depth from the lining surface to the page or oil. Replace it if it is burned black or oil rivets, on both sides.
Page 647 Main Menu Table of Contents Pressure Plate Release Bearing Inspection Inspection Inspect the pressure plate surface for wear, cracks, Check the release bearing for excessive play by and burning. spinning it by hand. Do not wash it in solvent. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area.
Page 648 Main Menu Table of Contents Flywheel, Flywheel Bearing Inspection Inspect the ring gear teeth for wear and damage. Turn the inner race of the flywheel bearing with your finger. The flywheel bearing should turn Inspect the clutch disc mating surface on the fly- smoothly and quietly.
Page 649 Main Menu Table of Contents Flywheel, Flywheel Bearing Replacement Remove the flywheel mounting bolts in a crisscross Drive the new flywheel bearing into the flywheel pattern in several steps, then remove the flywheel. using the special tools. DRIVER 07749-0010000 ATTACHMENT, 37 x 40 mm 07746-0010200 RING GEAR HOLDER 07LAB-PV00100...
Page 650 Main Menu Table of Contents Pressure Plate, Clutch Disc Installation Install the ring gear holder. Apply grease to the splines of the clutch disc, then install the clutch disc using the special tools as shown. HANDLE 07936-3710100 CLUTCH ALIGNMENT SHAFT 07MAF-PR80100 Torque the mounting bolts in a crisscross pattern as shown.
Page 651 Main Menu Table of Contents Special Tools 13-47 13-47 13-45 13-44 13-45 13-47 13-47 13-44, 13-45...
Page 652 Reinstall the oil filler plug with a new washer. NOTE: The drain plug washer should be replaced at every oil change. Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives.
Page 653 Main Menu Table of Contents Reverse Lockout System Component Location REVERSE LOCKOUT RELAY section 23...
Page 654 Main Menu Table of Contents Description At a vehicle speed of 19 mph (30 km/h) or more, a signal from the vehicle speed sensor (VSS) activates the reverse lockout solenoid, which causes the select lock pin to extend. As a result, the interlock cannot rotate to the reverse shift piece mak- ing it impossible to select reverse gear.
Page 655 Main Menu Table of Contents Troubleshooting Perform the indicated PGM-FI system troubleshooting (see section 11). Remove the reverse lockout relay from the under-hood relay box A, and test the relay (section 23). (To page 13-8)
Page 656 Main Menu Table of Contents Reverse Lockout System Troubleshooting (cont'd) (From page 13-7) Measure the voltage between ECM connector terminal A17 and body ground. (See section 11 how to use the Backprove Sets.) (To page 13-9)
Page 657 Main Menu Table of Contents (From page 13-8) (To page 13-10) Check the reverse lockout sole- noid (see page 13-11). Replace the reverse lockout solenoid (see page 13-11).
Page 658 Main Menu Table of Contents Reverse Lockout System Troubleshooting (cont'd) (From page 13-9) Remove the reverse lockout sole- noid (see page 13-11). Replace the reverse lockout sole- noid (see page 13-11).
Page 659 Main Menu Table of Contents Solenoid Test Solenoid Replacement Disconnect the 3P connector of the reverse lockout Disconnect the 3P connector. solenoid. Measure the resistance between No. 1 and No. 3 terminals. Remove the reverse lockout solenoid from the trans- mission.
Page 660 Main Menu Table of Contents Transmission Assembly Removal Make sure lifts are placed properly, and 6. Remove the connectors from the control box, and hoist brackets are attached to correct positions (see remove the control box. Do not remove the vacuum section tubes from the control box.
Page 661 Main Menu Table of Contents 12. Remove the parking brake cable holders from the rear beam rod. 13. Remove the rear beam rod. 14. Remove the parking brake cable holder from the rear sub frame, and the wheel sensor wire clamp from the lower control arm.
Page 662 Main Menu Table of Contents Transmission Assembly Removal (cont'd) 19. Remove the intermediate shaft heat cover and the intermediate shaft mounting bolts. 20. Pry the intermediate shaft out of the differential. Pull and remove it. Coat all precision finished surfaces with clean engine oil or grease.
Page 663 Main Menu Table of Contents 26. Remove the one of the upper control arm mounting bolt. 27. Remove the lower cover, change wire bracket and upper cover. 28. Remove the shift cable and select cable. 29. Remove the slave cylinder from the transmission. Do not operate the clutch pedal once the slave cylinder has been removed.
Page 664 Main Menu Table of Contents Illustrated Index NOTE: • This transmission uses no gaskets between the major housings; use liquid gasket (P/N 08718-0001). If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings and allow it to cure at least 30 minutes after assembly before filling the transmission with oil.
Page 665: Oil Guide Plate
Main Menu Table of Contents BEARING OUTER RACE STRAINER SET SPRING 12 mm SEALING BOLT 75 mm THRUST SHIM OIL PUMP STRAINER 22 N-m (2.2 kgf-m, 16 Ibf-ft) Selection. 14 mm SEALING BOLT STEEL BALL (5/16 in) CLAMP 32 N-m (3.3 kgf-m, 24 Ibf-ft) SHIFT LEVER ASSEMBLY BACK-UP LIGHT SWITCH SPRING (L.
Page 666 Main Menu Table of Contents Transmission Housing Removal Place the clutch housing on two pieces of wood Expand the snap ring on the countershaft ball bear- thick enough to keep the mainshaft from hitting the ing, and remove it from the groove using a pair of workbench.
Page 667 Main Menu Table of Contents Reverse Shift Arm, Reverse Shift Fork Clearance Inspection Measure the clearance between the reverse shift Measure the clearance between the reverse shift arm and reverse shift fork. arm and the reverse shift piece. If the clearance exceeds the service limit, measure If the clearance exceeds the service limit, measure the width of the reverse shift arm.
Page 668 Main Menu Table of Contents Reverse Shift Arm, Reverse Shift Fork Clearance Inspection (cont'd) Measure the clearance between the reverse shift fork and reverse synchro sleeve. If the clearance exceeds the service limit, measure the thickness of the shift fork fingers. If the trickiness is less than the standard, replace the reverse shift fork with a new one.
Page 669 Main Menu Table of Contents Reverse Idler Gear Shaft Assembly Removal Remove the reverse shift arm from the clutch hous- ing. Shift the reverse shift fork to the driven gear side. Remove the reverse shift fork assembly.
Page 670 Main Menu Table of Contents Remove the reverse idle gear shaft assembly.
Page 671: Needle Bearing
Main Menu Table of Contents Disassembly/Reassembly NOTE: • The thrust needle bearings are the same size. • The needle bearings are the same size. Prior to reassembling, clean all the parts in sol- vent, dry them, and apply lubricant to any con- tact surface.
Page 672 Main Menu Table of Contents Reverse Shift Fork Assembly Disassembly/Reassembly NOTE: The spring pin grooves should be 180° apart. REVERSE SHIFT FORK Inspection, page 13-20 Disassembly: Remove the 3 mm spring pin and 5 mm spring pin. Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.
Page 673 Main Menu Table of Contents Mainshaft, Countershaft, Differential Assemblies Removal Remove the change holder assembly from the clutch housing. Tape the mainshaft splines to protect them, then remove the mainshaft assembly and countershaft assembly with the shift fork from the clutch housing.
Page 674 Main Menu Table of Contents Remove the differential assembly from the clutch housing.
Page 675 Main Menu Table of Contents Shift Lever, Select Lever Removal Remove the shift spring set plate and shift detent spring from the transmission housing. Remove the bolt and spring washer. Pull out the shift lever, then remove the shift arm.
Page 676 Main Menu Table of Contents Shift Lever, Select Lever Removal (cont'd) Remove the bolt and spring washer. Pull out the select lever, then remove the select arm.
Page 677 Main Menu Table of Contents Change Holder Assembly Disassembly/Reassembly NOTE: Make sure the return springs are installed properly. Prior to reassembling, clean all parts in solvent, dry them, and apply lubricant to any contact surfaces.
Page 678 Main Menu Table of Contents Change Holder Assembly, Shift Fork Clearance Inspection Measure the clearance between the shift piece and Measure the clearance between the interlock and select arm. shift arm. Standard: 0.03 - 0.15 mm (0.001 - 0.006 in) If the clearance exceeds the service limit, measure If the clearance exceeds the standard, measure the width of the interlock finger.
Page 679 Main Menu Table of Contents Measure the clearance between the shift fork and shift piece. If the clearance exceeds the service limit, measure the width of the shift piece. If the width of the shift piece is less than the stan- dard, replace the shift piece with a new one.
Page 680 Main Menu Table of Contents Shift Fork, Synchro Sleeve Clearance Inspection Measure the clearance between each shift fork and its matching synchro sleeve.. If the clearance exceeds the service limit, measure the width of the shift fork fingers. If the width of the shift fork fingers is less than the standard, replace the shift fork with a new one.
Page 681: Disassembly/Reassembly, Page
Main Menu Table of Contents Shift Fork Assembly Disassembly/Reassembly NOTE: Install the spring pins so their grooves are 180° apart. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. Disassembly: Remove the 3 mm spring pin and 5 mm spring pin. Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.
Page 682 Main Menu Table of Contents Mainshaft Assembly Index NOTE: The 3rd/4th and 5th/6th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th/6th synchro hubs, however, should be installed with a press before lubricating them. OUTER SYNCHRO RING Inspection, page 13-41...
Page 683 Main Menu Table of Contents Mainshaft Assembly Clearance Inspection Measure the clearance between 2nd and 3rd gears. Measure the clearance between 4th gear and the spacer collar. Standard: 0.06 - 0.19 mm Standard: 0.06 - 0.19 mm (0.002 - 0.007 in) Service Limit: 0.3 mm (0.012 in) (0.002 - 0.007 in) Service Limit: 0.3 mm (0.012 in)
Page 684 Main Menu Table of Contents Measure the clearance between the spacer collar 9. Measure the clearance between the distance collar and 5th gear. and 6th gear. 10. If the clearance exceeds the service limit, measure If the clearance exceeds the service limit, measure on the spacer collar.
Page 685 Main Menu Table of Contents Mainshaft Assembly Disassembly Support ball bearing on steel blocks as shown, and Support 5th gear on steel blocks as shown, and press the shaft out of the ball bearing. Use of a jaw- press the shaft out of the 5th/6th synchro hub. type puller can damage the gear teeth.
Page 686 Main Menu Table of Contents Mainshaft Assembly Inspection Inspect the gear surface and bearing surface for Support the mainshaft at both ends, and inspect for wear and damage, then measure the mainshaft at runout. points A, B, and C. If the runout exceeds the service limit, replace the mainshaft with a new one.
Page 687 Main Menu Table of Contents Mainshaft Assembly Reassembly Install the 5th/6th synchro hub using a press. CAUTION: • Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. • Press the 3rd/4th and 5th/6th synchro hubs on the mainshaft without lubrication.
Page 688 Main Menu Table of Contents Countershaft Assembly Index NOTE: The 3rd, 4th, 5th and 6th gears are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd, 4th, 5th and 6th gears should be installed without lubrication using a press. OUTER SYNCHRO RING Inspection, page 13-41...
Page 689 Main Menu Table of Contents Countershaft Assembly Clearance Inspection Measure the clearance between 2nd and 3rd gear. Measure the clearance between 1st and reverse gear. Standard: 0.04 - 0.10 mm (0.002 - 0.004 in) If the clearance exceeds the standard, select the If the clearance exceeds the standard, select the appropriate spacer collar for the correct clearance appropriate thrust washer for the correct clearance...
Page 690 Main Menu Table of Contents Disassembly NOTE: Remove the gears using a press and steel blocks. Support 4th gear on steel blocks, and press the Use of a jaw-type puller can damage the gear teeth. shaft out of 5th and 4th gears. Securely clamp the countershaft assembly in a bench vise with wood blocks.
Page 691 Main Menu Table of Contents Countershaft Assembly Inspection Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A and B inspect oil passages for clogging. If any part of the countershaft is less than the ser- vice limit, replace it with a new one.
Page 692 Main Menu Table of Contents Countershaft Assembly Reassembly CAUTION: • Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. • Press the 3rd, 4th, 5th and 6th gears on the counter- shaft without lubrication.
Page 693 Main Menu Table of Contents Install the ball bearing using a press. Install 5th gear using a press. Install 6th gear using a press. Securely clamp the countershaft assembly in a bench vise with wood blocks. Install the needle bearing using a press then install the bearing outer race.
Page 694 Main Menu Table of Contents Synchro Sleeve, Synchro Hub Installation Inspection Inspect gear teeth on all synchro hubs and synchro Each synchro sleeve has three sets of longer teeth (120 sleeves for rounded off corners, which indicates degrees apart) that must be matched with the three wear.
Page 695 Main Menu Table of Contents Synchro Ring, Gear Inspection Inspection the synchro ring and gear. A : Inspect the inside of the synchro ring for wear. B : Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). C : Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off).
Page 696: Disassembly/Reassembly, Page
Main Menu Table of Contents Oil Pump Disassembly/Reassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
Page 697 Main Menu Table of Contents Clearance Inspection Check the radial clearance on the pump rotor. Check the clearance between the transmission mat- ing surface of the clutch housing and the oil pump Inner Rotor-to-Outer Rotor Radial clearance gear. Standard: 0.14 mm (0.006 in) max. Service Limit: 0.2 mm (0.008 in) Standard: 0.3 - 0.8 mm (0.012 - 0.031 in)
Page 698 Main Menu Table of Contents Mainshaft Oil Seal (Clutch Housing) Replacement Remove the release bearing guide cover, and Drive a new oil seal from the clutch side using the release bearing guide. special tools as shown. ATTACHMENT, Remove the oil seal. DRIVER 52 x 55 mm 07749-0010000...
Page 699 Main Menu Table of Contents Countershaft Bearing (Clutch Housing) Replacement Remove the bearing retaining plate. Position the oil guide plate and new needle bearing in the bore of the clutch housing. Position the nee- dle bearing with the oil hole facing up. Drive the needle bearing using the special tools.
Page 700 Main Menu Table of Contents Mainshaft Thrust Shim Adjustment Select the proper thrust shim on the basis of the Remove the thrust shim and oil guide plate from the transmission housing. following calculations. Do not use more than two thrust shims. Install the mainshaft in the transmission housing.
Page 701 Main Menu Table of Contents NOTE: Clean all the parts thoroughly before installation. • Back-out the mainshaft holder bolt and loosen the two hex bolts. 6. Install the oil guide plate and thrust shim into the • Fit the holder over the mainshaft so its lip is transmission housing.
Page 702 Main Menu Table of Contents Transmission Reassembly Install the oil seal, shift arm, and shift lever in the Install the oil seal, select arm, and select lever in the transmission housing. clutch housing. Install the shift detent spring and spring set plate. Install the differential assembly into the clutch housing.
Page 703 Main Menu Table of Contents Install the spring washer, then insert the mainshaft Install the reverse idle gear shaft assembly. and countershaft into the shift forks and install them as an assembly. Tape the mainshaft splines before installation. Install the change holder assembly in the clutch housing.
Page 704 Main Menu Table of Contents Transmission Reassembly (cont'd) 9. Install the reverse shift arm. 11. Install the dowel pins on the clutch housing. 12. Place the transmission housing over the clutch housing, being careful to line up the shafts. 10. Apply liquid gasket to the surface of the transmis- sion housing mating with the clutch housing as shown, and note those items: Use liquid gasket (P/N 08718 - 0001).
Page 705 Main Menu Table of Contents b. Lower the transmission housing, then place the 13. Lower the transmission housing with snap ring shift arm in the groove of the shift piece by turn- pliers, and set the snap ring in the groove of the ing the shift lever.
Page 706 Main Menu Table of Contents Transmission Reassembly (cont'd) 15. Tighten the transmission housing attaching bolts 18. Apply liquid gasket (P/N 08718-0001) to the in a crisscross pattern in several steps as shown threads, and install the back-up light switch below. and neutral position switch.
Page 707 Main Menu Table of Contents Transmission Assembly Installation MOTE: Use only Super High Temp Urea Grease (P/N 08798 - 9002). 1. Place the transmission on the transmission jack, and raise it to the engine level. Check that the two dowel pins are installed in the clutch housing. 2.
Page 708 Main Menu Table of Contents Transmission Assembly Installation (cont'd) 12. Install a new set ring on the end of the left driveshaft and intermediate shaft. 13. Install the left driveshaft (see section 16). 14. Install the lower control arm to the side beam (see section 18).
Page 709 Main Menu Table of Contents 20. Install the right driveshaft onto the intermediate shaft. 21. Install the lower control arm to the side beam (see section 18). Align the reference marks on the adjusting bolt, adjust- ing cam and lower control arm. 22.
Page 710 Main Menu Table of Contents Transmission Assembly Installation (cont'd) 27. Install the transmission mount and two transmission 31. Install the air cleaner assembly. housing mounting bolts. 32. Install the strut bar. 28. Install the starter motor, and connect the starter 33.
Page 711 Main Menu Table of Contents Gearshift Mechanism Overhaul NOTE: • Inspect rubber parts for wear and damage when disassembling. • Check that the new cotter pin is seated firmly.
Page 712 Main Menu Table of Contents Special Tools 14-149, 14-152 14-121 14-149, 14-152 14-106 14-106 14-51, 14-5a 14-53, 14-102, 14-7a 14-106 14-106 14-157 14-156, 14-157 14-155, 14-156, 14-157 14-155, 14-156, 14-157 14-120, 14-163 14-156...
Page 713 Main Menu Main Menu Table of Contents Table of Contents Description The automatic transmission is a combination of a 3-element torque converter and a triple-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 speed reverse. The entire unit is positioned in line with the engine.
Page 714 Main Menu Table of Contents Description (cont'd) Gear Selection Rear wheels locked; parking pawl engaged with parking gear on countershaft. All clutches released. Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch locked. All clutches released. General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speed and throttle position.
Page 715 Main Menu Table of Contents TORQUE CONVERTER LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY ATF COOLER 4TH CLUTCH 1ST CLUTCH 3RD CLUTCH 1ST-HOLD CLUTCH DIFFERENTIAL ASSEMBLY [LIMITED SLIP DIFFERENTIAL (LSD)] 2ND CLUTCH...
Page 716 Main Menu Table of Contents Description Clutches The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum, the clutch piston is applied. This presses the friction discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to its hub-mounted gear.
Page 717 Main Menu Table of Contents COUNTERSHAFT 2ND GEAR COUNTERSHAFT 3RD GEAR MAINSHAFT 3RD GEAR 3RD CLUTCH 4TH CLUTCH DRIVE PLATE MAINSHAFT 4TH GEAR MAINSHAFT REVERSE GEAR MAINSHAFT 1ST GEAR 1ST CLUTCH MAINSHAFT COUNTERSHAFT LOCK-UP 1ST-HOLD CLUTCH CLUTCH SECONDARY SHAFT ONE-WAY CLUTCH COUNTERSHAFT 1ST GEAR PARKING GEAR COUNTERSHAFT REVERSE GEAR...
Page 718 Main Menu Table of Contents Description Power Flow...
Page 719 Main Menu Table of Contents 1st Speed in Position position, hydraulic pressure is applied to the 1st clutch and to the 1st-hold clutch. The power flow when accelerating is as follows; Hydraulic pressure is applied to the 1st clutch on the mainshaft, and power is transmitted via the 1st clutch to the mainshaft 1st gear.
Page 720 Main Menu Table of Contents Description Power Flow (cont'd) 1st Gear in positions position, the optimum gear is automatically selected from the gear ratios of 1st, 2nd, 3rd, and 4th speeds, according to conditions such as the balance between throttle opening (engine load) and vehicle speed. 1.
Page 721 Main Menu Table of Contents 2nd Gear in Positions 1. Power from the mainshaft 3rd gear drives the countershaft 3rd gear. Since there is no hydraulic pressure to the 3rd clutch, the countershaft 3rd gear turns freely and drives the secondary shaft 3rd gear. 2.
Page 722 Main Menu Table of Contents Description Power Flow (cont'd) 3rd Gear in Positions 1. Hydraulic pressure is applied to the 3rd clutch. Power from the mainshaft 3rd is transmitted to the countershaft 3rd gear. 2. Power is transmitted to the final drive gear and drives the final driven gear. NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of the 3rd gear exceeds 1st gear speed, power from 1st gear is cut off at the one-way clutch.
Page 723 Main Menu Table of Contents 4th Gear in Positions 1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, and the mainshaft 4th gear. 2. Power is transmitted through countershaft 4th gear to the countershaft. 3.
Page 724 Main Menu Table of Contents Description Electronic Control System The electronic control system consists of the Transmission Control Module (TCM), sensors, a linear solenoid and four solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The TCM is located on the insulator center bulkhead, behind the driver's seat.
Page 725 Main Menu Table of Contents Shift Control Engine torque controls shifting through the linear solenoid. The linear solenoid is controlled by the TCM, and it is used to operate the throttle valve. The TCM instantly determines which gear to select by various signals sent from sensors, and actuates shift control solenoid valves A and B to control shifting.
Page 726 Main Menu Table of Contents Description Electronic Control System (cont'd) • Automatic shifting control in Sport Shifting mode This position also has automatic shifting areas: • 1-2 upshift • 4-3 downshift, 3-1 downshift, 2-1 downshift depending on vehicle speed. To prevent engine over-revving, the transmission has a 1-2 automatic upshift speed, and 4-3, 3-1, 2-1 downshift allowable speeds.
Page 727 Main Menu Table of Contents Description Hydraulic Control The valve bodies include the main valve body, the regulator valve body, the lock-up valve body, the secondary valve body, the servo body, the throttle valve body and the 2nd accumulator body. The ATF pump is driven by splines on the left end of the torque converter which is attached to the engine.
Page 728 Main Menu Table of Contents Throttle Valve Body The throttle valve body is mounted on the servo valve body with the throttle valve built in. Throttle Valve B, Linear Solenoid Throttle valve B converts changes in the throttle opening to changes in transmission hydraulic pressure, to determine transmission shift quality and lock-up operation.
Page 729 Main Menu Table of Contents Description Hydraulic Control (cont'd) Regulator Valve Body The regulator valve body is mounted on the main valve body with the regulator valve, the lock-up control valve and the cooler relief valve built in. The stator shaft arm contacts the regulator valve spring cap. The hydraulic pressure (line pressure) is controlled by the regulator valve.
Page 730 Main Menu Table of Contents Regulator Valve The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, while also furnishing fluid to the lubricating system and the torque converter. Fluid from the ATF pump flows through B and B'. The regulator valve has a valve orifice. The fluid entering from B flows through the orifice to the A cavity.
Page 731 Main Menu Table of Contents Description Hydraulic Control (cont'd) Main Valve Body The main valve body is located on the torque converter housing. The main valve body houses the ATF pump gears, the torque converter check valve, the manual valve, the 1-2, 2 - 3 , 3 - 4 shift valves, the relief valve and the one-way relief valve.
Page 732 Main Menu Table of Contents ATF Pump The external tooth gear type ATF pump consists of a housing together with the main valve body, a pump drive gear, a pump driven gear, and a pump shaft. The ATF pump is installed on the torque converter housing. The pump's driving force is transmitted by the torque converter pump (directly connected to the engine) to the pump shaft.
Page 733 Main Menu Table of Contents Description Hydraulic Control (cont'd) Secondary Valve Body The secondary valve body is also mounted on the main valve body with the 3-2 kick-down valve, the CPC valve, the 2nd orifice control valve, the 3rd orifice control valve, the modulator valve, the 4th exhaust valve, the 2nd exhaust valve, the servo control valve and the 4-3 kick-down valve built in.
Page 734 Main Menu Table of Contents Modulator Valve The modulator valve uses line pressure from the regulator (to shift control solenoid valves A/B) and the lock-up control solenoid valves A/B, to maintain accurate shift and lock-up characteristics. 2nd Orifice Control Valve For smooth shifting between the 2nd and 3rd gear, the open pressure on the 2nd gear side is relieved through a fixed ori- fice.
Page 735 Main Menu Table of Contents Description Hydraulic Control (cont'd) Servo Body The servo body is mounted on the secondary valve body with the servo valve, the 1st accumulator piston, the 3rd accu- mulator piston, and the 4th accumulator piston built in to it. The primary functions of the servo body are to switch the direction foward and reverse, and to control hydraulic pressure reduction for shifting shock.
Page 736 Main Menu Table of Contents Lock-up Valve Body The lock-up valve body is mounted on the regulator valve body with the lock-up shift valve and the lock-up timing B valve built in. The capacity of the lock-up clutch is controlled by the lock-up shift valve and the lock-up timing B valve.
Page 737 Main Menu Table of Contents Description Hydraulic Flow General Chart of Hydraulic Pressure Distribution of Hydraulic Pressure...
Page 738 Main Menu Table of Contents position As the engine turns, the ATF pump also starts to operate. The ATF is drawn from (99) and discharged into (1). Then, ATF flowing from the ATF pump becomes the line pressure (1). The line pressure (1) is regulated by the regulator valve. The torque converter inlet pressure (92) enters (94) of torque converter through the orifice and discharges into (90).
Page 739 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Position Line pressure (1) becomes line pressure (4), (18), and (25) as it passes through the manual valve. Also, line pressure (1) goes to the modulator valve through the filter and becomes modulator pressure (6). Modulator pressure (6) is supplied to the 1-2 shift valve and 2-3 shift valve.
Page 740 Main Menu Table of Contents Position Line pressure (1) becomes the line pressure (4), (25) as it passes through the manual valve. Line pressure (1) goes to the modulator valve and becomes the modulator pressure (6). The modulator pressure (6) is sup- plied to the 1-2 shift valve and 3-4 shift valve.
Page 741 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Positions 1. 1st Gear The flow of fluid through the torque converter circuit is the same as in position. Line pressure (1) becomes line pressure (4) and 1st clutch pressure (10). The 1st clutch pressure is applied to the 1st clutch and 1st accumulator, and the vehicle will move as engine power is transmitted.
Page 742 Main Menu Table of Contents 2. 2nd Gear The flow of fluid to the 1-2 and 2-3 shift valves is the same as in 1st gear. As the speed of the vehicle reaches the pre- scribed value, solenoid valve A is turned ON by the TCM. As a result, the 1-2 shift valve is moved to the left side and uncovers the port leading to the 2nd clutch, and the 2nd clutch is engaged.
Page 743 Main Menu Table of Contents Description Hydraulic Flow (cont'd) 3. 3rd Gear The flow of fluid to the 1-2, 2-3, and 3-4 shift valves is the same as in 2nd gear. As the speed of the vehicle reaches the prescribed value, shift control solenoid valve B is turned OFF (Shift control solenoid valve A remains ON). The 2-3 shift valve is then moved to the left side, uncovering the fluid port leading to the 3rd clutch.
Page 744 Main Menu Table of Contents 4. 4th Gear The flow of fluid to the 1-2, 2-3, and 3-4 shift valves is the same as in 3rd gear. When the speed of the vehicle reaches the prescribed valve, shift control solenoid valve A is turned OFF (Shift control solenoid valve B remains OFF). As this takes place, the 3-4 shift valve is moved to the left side and uncovers the fluid port leading to the 4th clutch.
Page 745 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Position The flow of fluid through the torque converter circuit is the same as in the position. Fluid (1) from the ATF pump flows through the manual valve and becomes line pressure (3). It then flows through the 1-2 shift valve to the servo valve (3), moving the shift fork shaft to the reverse position.
Page 746 Main Menu Table of Contents Position The flow of fluid through the torque converter circuit is the same as in position. Line pressure (1) becomes line pressure (3) as it passes through the manual valve. Line pressure (3) flows through the 1-2 shift valve, to the servo valve, and to the servo control valve, moving the shift fork to the reverse position as in the position.
Page 747 Main Menu Table of Contents Description Lock-up System Lock-up Clutch 1. Operation (clutch on) With the lock-up clutch on, fluid in the chamber between the converter cover and lock-up piston is discharged, and the converter fluid exerts pressure through the piston against the converter cover. As a result, the converter turbine is locked on the converter cover firmly.
Page 748 Main Menu Table of Contents position and position (2nd, 3rd, and 4th gear), pressurized fluid is drained from the back of the torque converter through a passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the main- shaft rotates at the same speed as the engine crankshaft.
Page 749 Main Menu Table of Contents Description Lock-up System (cont'd) No Lock-up Pressurized fluid regulated by the modulator works on both ends of the lock-up shift valve and on the left side of the lock- up control valve. Under this condition, the pressure on both ends of the lock-up shift valve are equal, and the shift valve is moved to the right side by valve spring tension.
Page 750 Main Menu Table of Contents Partial Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: OFF The TCM switches solenoid valve A ON to release modulator pressure in the left cavity of the lock-up shift valve. Modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force, and the lock-up shift valve is moved to the left side.
Page 751 Main Menu Table of Contents Description Lock-up System (cont'd) Half Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON Modulator pressure is released by solenoid valve B, causing modulator pressure in the left cavity of the lock-up control valve to lower.
Page 752 Main Menu Table of Contents Full Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON When the vehicle speed further increases, the throttle B pressure is increased in accordance with the throttle opening. The lock-up timing valve B overcomes the spring force and moves to the left side. Also this valve closes the fluid port leading to the torque converter check valve.
Page 753 Main Menu Table of Contents Description Lock-up System (cont'd) Deceleration Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: Duty Operation The TCM switches the solenoid valve B to ON and OFF alternately at high speeds under certain conditions. The slight lock-up and half lock-up regions are maintained so as to lock the torque converter properly.
Page 754 Main Menu Table of Contents ATF Cooler The radiator is mounted at the front of the vehicle. The ATF cooler is installed directly on the transmission housing. The ATF is cooled by the engine coolant.
Page 755 Main Menu Table of Contents Component Locations...
Page 756 Main Menu Table of Contents <Engine Compartment> LOCK-UP CONTROL SOLENOID ENGINE COOLANT TEMPERATURE (ECT) VALVE ASSEMBLY SENSOR MAINSHAFT SPEED SENSOR LINEAR SOLENOID SHIFT CONTROL SOLENOID VALVE ASSEMBLY THROTTLE POSITION (TP) SENSOR COUNTERSHAFT SPEED VEHICLE SPEED SENSOR (VSS) SENSOR TRANSMISSION CONTROL MODULE (TCM) TCS CONTROL UNIT ENGINE CONTROL MODULE...
Page 757 When the 16P Data Link Connector (DLC) (located to the lower left of the glove compartment) is connected to the OBD II Scan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
Page 758 Main Menu Table of Contents Checking the Diagnostic Trouble Code (DTC) with the Service Check Connector and Special Toot When the TCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. When the Service Check Connector (2P) (located to the lower right of the glove compartment) is connected with the special tool as shown, the indicator light will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned on (II).
Page 759: Remove The Connector Holder From The Tcs Control Unit, And Disconnect The Antenna Lead
Main Menu Table of Contents Troubleshooting Procedures SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or service. Remove the seat back panels (see section 20). Remove the connector holder from the TCS control unit, and disconnect the antenna lead.
Page 760 • The TCM memory cannot be cleared by using the OBD II scan Tool or Honda PGM Tester; be sure to remove the CLOCK fuse to reset the TCM.
Page 761 Main Menu Table of Contents Linear Solenoid Test Remove the linear solenoid connector. Measure the resistance between the A and B terminal. STANDARD: 5.0-5.5 Ω (at 70°F, 20°C) LINEAR SOLENOID TERMINAL SIDE OF MALE TERMINALS Replace the linear solenoid if resistance is out of specification.
Page 762 Main Menu Table of Contents Linear Solenoid Replacement NOTE: Select the appropriate shim when the linear sole- noid is replaced. Remove the linear solenoid and shim from the trans- mission housing. Clean the mounting surface. Measure the distance between the mounting surface of the linear solenoid and the throttle valve body.
Page 763 Main Menu Table of Contents Select a new shim from the chart below. Apply liquid gasket to both sides of the linear solenoid shim as shown. Use liquid gasket Part No. NOTE: Identification color is painted on the side of 08718-0001.
Page 764 Main Menu Table of Contents Mainshaft/Countershaft Speed Sensors Replacement Remove the 6 mm bolt from the transmission hous- ing, then remove the mainshaft and countershaft speed sensors. Replace the O-ring with a new one before reassem- bling the mainshaft and countershaft speed sensors. Install the washer only on the countershaft speed sensor.
Page 765: Remove The Tcs Control Unit
Main Menu Table of Contents Transmission Control Module (TCM) Replacement SRS components are located in this area. Review the Disconnect the A (26P) and B (22P) connectors from SRS component locations, precautions, and procedures the TCM, then remove the TCM. in the SRS (section 24) before performing repairs or ser-...
Page 766 Main Menu Table of Contents Symptom-to-Component Chart Hydraulic System...
Page 767 Main Menu Table of Contents PROBABLE CAUSE...
Page 768 Main Menu Table of Contents Symptom-to-Component Chart Hydraulic System (cont'd)
Page 769 Main Menu Table of Contents...
Page 770 Table of Contents Main Menu Road Test position SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. 1. Apply parking brake and block the wheels. Start the engine, and warm up the engine to normal operating temperature (the cooling fan comes on).
Page 771 Main Menu Table of Contents Upshift Downshift 3. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from position to position. The vehi- cle should immediately begin slowing down from engine braking. CAUTION: Do not shift from position to position at speeds over 76 mph (123 km/h) or from position to...
Page 772 Main Menu Table of Contents Stall Speed Test CAUTION: • To prevent transmission damage, do not test stall speed for more than 10 seconds at a time. • Do not move the shift lever while raising the engine speed. • Be sure to remove the pressure gauge before testing stall speed. Engage the parking brake and block all four wheels.
Page 773 Transmission Fluid (ATF)* mark. *Always use Genuine Honda Premium Formula Insert the dipstick back into the transmission. Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality.
Page 774 Main Menu Table of Contents Pressure Testing • Line Pressure/Clutch Pressure Measurement • While testing, be careful of the rotating rear wheels. • Make sure lifts are placed properly (see section 1. Allow the rear wheels to rotate freely. CAUTION: 2.
Page 775 Main Menu Table of Contents 1ST-HOLD CLUTCH PRESSURE INSPECTION HOLE 2ND CLUTCH PRESSURE INSPECTION HOLE 4TH CLUTCH PRESSURE INSPECTION HOLE LINE PRESSURE/1ST CLUTCH PRESSURE INSPECTION HOLE 3RD CLUTCH PRESSURE INSPECTION HOLE...
Page 776 Main Menu Table of Contents Pressure Testing (cont'd) • Clutch Low/High Pressure Measurement With the engine idling, press down the accelerator pedal approximately 1/2 of its possible travel and While testing, be careful of the rotating increase the engine rpm until pressure is indicated rear wheels.
Page 777 Main Menu Table of Contents • Throttle B Pressure Measurement While testing, be careful of the rotat- ing rear wheels. 1. Allow the rear wheels to rotate freely. 2. Disconnect the linear solenoid connector. 3. Shift to position. 4. Run the engine at 2,000 rpm. 5.
Page 778 Main Menu Table of Contents Transmission Removal Make sure lifts are placed properly, and 4. Remove the strut bar. hoist brackets are attached to correct position (see section 5. Remove the air cleaner housing. CAUTION: Use fender covers to avoid damaging painted 6.
Page 779 Main Menu Table of Contents 11. Remove the parking brake cable holders from the rear beam rod. 12. Remove the rear beam rod. 13. Remove the front exhaust pipe A. 14. Remove the parking brake cable holder and the wheel sensor wire clamp. 1 5.
Page 780 Main Menu Table of Contents Transmission Removal (cont'd) 20. Remove the intermediate shaft heat shield cover and the intermediate shaft mounting bolts. 21. Pry the intermediate shaft out of the differential. Pull and remove it. NOTE: • Coat all precision finished surfaces with clean engine oil. •...
Page 781 Main Menu Table of Contents 28. Remove the one upper arm mounting bolt shown. 29. Remove the shift cable cover and shift cable holder. 30. Remove the shift cable from the control lever. 31. Remove the torque converter cover, then remove the drive plate bolts. 32.
Page 782 Main Menu Table of Contents Illustrated Index Left Side Cover/Transmission...
Page 783 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 784 Main Menu Table of Contents Illustrated Index Transmission Housing...
Page 785 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 786 Main Menu Table of Contents Illustrated Index Torque Converter Housing/Valve Body...
Page 787 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 788 Main Menu Table of Contents Left Side Cover Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Cut the lock tabs of each shaft locknut using a chisel, then remove the locknuts and conical spring washers from each shaft.
Page 789 Main Menu Table of Contents Transmission Housing Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • The (7/32) #7 steel ball in the reverse idler gear shaft is under spring pressure. Take care not to let it pop out. 1.
Page 790 Main Menu Table of Contents Valve Body Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. • Accumulator covers are spring loaded; to prevent stripping the threads in the torque converter housing, press down on the accumulator covers while unscrewing the bolts in a crisscross pattern.
Page 791 Main Menu Table of Contents Repair NOTE: This repair is only necessary if one or more Remove the #600 paper and thoroughly wash the of the valves in a valve body do not slide smoothly entire valve body in solvent, then dry with com- in their bores.
Page 792 Table of Contents Main Menu Valve Assembly • Set the spring in the valve, and install it in the valve NOTE: Coat all parts with ATF before assembly. body. Push the spring in with a screwdriver, then install the spring seat. •...
Page 793 Main Menu Table of Contents • Set the spring in the valve, and install it in the valve • Install the valve, spring and cap in the valve body. body. Install the spring with a screwdriver, then Push on the cap, then install the stopper seat. install the valve cap with the cutout aligned with the screwdriver.
Page 794 Main Menu Table of Contents Valve Caps Description • Caps with one projected tip and one flat end are in- • Caps with hollow ends are installed with the hollow stalled with the flat end toward the spring. end away from the spring. •...
Page 795 Table of Contents Main Menu ATF Pump Inspection Remove the shaft, then measure the thrust clear- Install the pump gears and shaft in the main valve ance of the driven gear-to-valve body. body. Drive/Driven Gear thrust (Axial) Clearance: Standard (New): 0.03-0.05 mm (0.001-0.002 in.) Service Limit: 0.07 mm (0.0028 in.)
Page 796 Main Menu Table of Contents Main Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement.
Page 797 Main Menu Table of Contents NOTE: All check balls are the same size (7/32) #7.
Page 798 Main Menu Table of Contents Secondary Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 799 Main Menu Table of Contents NOTE: All check balls are the same size (7/32) #7.
Page 800 Main Menu Table of Contents Servo Body/Throttle Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement.
Page 801 Main Menu Table of Contents NOTE: • After disassembly of the ATF strainer, check that it is in good condition, and the inlet opening is not clogged. Replace the strainer with a new one if it is clogged or damaged. •...
Page 802 Main Menu Table of Contents Regulator Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 803 Main Menu Table of Contents Lock-up Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 804 Main Menu Table of Contents 2nd Accumulator Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 805 Table of Contents Main Menu Mainshaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 806 Main Menu Table of Contents Countershaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 807 Main Menu Table of Contents Inspection/Installation NOTE: Lubricate all parts with ATF during assembly. Hold the 2nd gear against the 3rd gear. Measure the clearance between the 3rd gear and thrust needle Assemble the parts below on the countershaft. bearing with a feeler gauge. NOTE: Do not install the O-rings during inspection.
Page 808 Main Menu Table of Contents Countershaft Inspection/Installation (cont'd) If the clearance is out of tolerance; If the clearance is out of tolerance, select and install a new cotters. Select and install a new 3rd gear collar, and recheck the clearance. If the clearance is still out of tolerance, replace the two thrust needle bearings, and recheck the clearance.
Page 809 Main Menu Table of Contents 10. Measure the clearance between 4th gear and reverse selector hub with a feeler gauge. NOTE: Take measurements in at least three places, and take the average as the actual clearance. STANDARD: 0.05 - 0.11 mm (0.002 - 0.004 in) 12.
Page 810 Table of Contents Main Menu One-way Clutch/Parking Gear Disassembly/lnspection/Reassembly Separate countershaft 1 st gear from the parking Inspect the parts as follows: gear by turning the parking gear in the direction shown. Remove the one-way clutch by prying it up with the end of a screwdriver.
Page 811 Main Menu Table of Contents Secondary Shaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 812 Main Menu Table of Contents Secondary Shaft Inspection/Installation NOTE: Hold the 2nd clutch assembly against the 3rd gear. • Lubricate all parts with ATF during assembly. Measure the clearance between the 2nd gear and • Before installing the O-rings, wrap the shaft splines thrust needle bearing using a feeler gauge.
Page 813 Main Menu Table of Contents If the clearance is out of tolerance, select and in- stall a new thrust washer. After replacing the thrust washer, make sure that the clearance is within tolerance.
Page 814 Main Menu Table of Contents Clutch Illustrated Index...
Page 815 Main Menu Table of Contents 1ST-HOLD CLUTCH 3RD CLUTCH...
Page 816 Table of Contents Main Menu Clutch Illustrated Index (cont'd) 2ND CLUTCH...
Page 817 Table of Contents Table of Contents Main Menu Main Menu Disassembly Remove the snap rings, then remove the clutch end Install the special tools as shown. plate, clutch discs and plates. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 07HAE - PL50100 Remove the disc spring.
Page 818 Table of Contents Table of Contents Main Menu Main Menu Clutch Disassembly (cont'd) Compress the clutch return spring. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the pis- ton. Place a finger tip on the other end while apply- ing air pressure.
Page 819 Main Menu Table of Contents Reassembly NOTE: Install the piston in the clutch drum. Apply pressure • Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seating. cleaner, and dry with compressed air. • Blow out all passages. NOTE: Lubricate the piston O-ring with ATF before •...
Page 820 Main Menu Table of Contents Clutch Reassembly (cont'd) Install the special tools as shown. Compress the clutch return spring. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 07HAE-PL50100 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE - PG40200 07GAE - PG4020A CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsup-...
Page 821 Main Menu Table of Contents 10. Install the disc spring. 13. Install the snap ring. NOTE: • For 1st-hold and 2nd clutches. • Install the disc spring in the direction shown. 11. Soak the clutch discs thoroughly in ATF for a mini- mum of 30 minutes.
Page 822 Main Menu Table of Contents Clutch Reassembly (cont'd) 14. Measure the clearance between the clutch end plate 15. If the clearance is not within the service limits, select and top disc with a dial indicator. Zero the dial indi- a new clutch end plate from the following table. cator with the clutch end plate lowered, and lift it up to the snap ring.
Page 823 Table of Contents Main Menu 1st-hold Clutch Bearing Replacement Remove the 1st-hold clutch bearing using a bearing puller. Install a new bearing using the special tools as shown. NOTE: Drive in the bearing until it is fully seated. DRIVER 07749-0010000 ATTACHMENT, 72 x 75 mm 07746-0010600...
Page 824 Main Menu Table of Contents Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement Install the new oil seal flush with the housing using Drive out the mainshaft bearing and oil seal using the special tools as shown. the special tools as shown. DRIVER DRIVER 07749-0010000...
Page 825 Main Menu Table of Contents Secondary Shaft Bearing Countershaft Bearing Replacement Replacement Remove the countershaft bearing using the special 1. Remove the secondary shaft bearing using the spe- tools as shown. cial tools as shown. ADJUSTABLE BEARING PULLER, 25 - 40 mm 07736-A01000B 07736-A01000A ADJUSTABLE...
Page 826 Table of Contents Main Menu Transmission Housing Bearings Replacement To remove the mainshaft, countershaft and secondary Expand each snap ring with the snap ring pliers, insert shaft bearings from the transmission housing, expand the new bearing part-way into it, then release the pli- each snap ring with the snap ring pliers, then push the ers.
Page 827 Main Menu Table of Contents Reverse Idler Gear Installation Install the reverse idler gear. Install the reverse idler shaft holder into the transmis- sion housing, then tighten the bolts. Set the spring in the reverse idler shaft. Push the spring in with the steel ball, then install the needle bearing.
Page 828 Main Menu Table of Contents Parking Brake Stopper Manual Valve Detent Spring Inspection/Adjustment Replacement/Adjustment Set the parking brake lever in the position. NOTE: Select the appropriate manual valve detent spring when these parts are replaced: Measure the distance between the face of the park- •...
Page 829 Main Menu Table of Contents Transmission Reassembly NOTE: Coat all parts with ATF. Reassemble the valve bodies in the following numbered sequence. CAUTION: To prevent stripping the threads, press down on the accumulator cover while installing the bolts. NOTE: Install the ATF pump driven gear with its chamfered side facing down.
Page 830 Main Menu Table of Contents Transmission Reassembly (cont'd) Assemble the transmission housing in the following numbered sequence. NOTE: See page 14-159 when installing the reverse idler gear. NOTE: Install the three shafts together. NOTE: Align the control shaft spring pin with the groove in the transmission housing.
Page 831 Main Menu Table of Contents Assemble transmission following Set the parking brake lever in the position, then numbered sequence. verify that the parking brake pawl engages the parking gear. NOTE: Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O- If the pawl does not engage fully, check the parking rings.
Page 832 Main Menu Table of Contents Transmission Reassembly (cont'd) Install a new conical spring washer and a new lock- 10. Stake each locknut into its shaft using a 3.5 mm nut on each shaft. punch. CAUTION: Install the conical spring washers in the direction shown.
Page 833 Main Menu Table of Contents 13. Install the left side cover. 15. Install the control lever, new lock washers, change shaft, and change shaft cap on the other end of the TORQUE: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) control shaft. Tighten the bolts, then bend the tab against the bolt head.
Page 834 Main Menu Table of Contents Torque Converter/Drive Plate...
Page 835 Main Menu Table of Contents Transmission Installation 1. Place the transmission on a transmission jack, and raise it to engine level. 2. Check that the 14 mm and 10 mm dowel pins are installed in the torque converter housing. 3. Install the three transmission housing mounting bolts. 4.
Page 836 Main Menu Table of Contents Transmission Installation (cont'd) 11. Install a new set ring on the end of the left driveshaft and intermediate shaft. Apply a light film of grease around the set ring grooves, then center the new set ring on the shafts. The grease keeps the set ring centered, making shaft installation easier.
Page 837 Main Menu Table of Contents 19. Install the right driveshaft on the intermediate shaft. 20. Install the lower control arm to the side beam. CAUTION: Line up the reference marks on the adjusting bolt, adjusting cam, and lower control arm. 21.
Page 838 Main Menu Table of Contents Transmission Installation (cont'd) 27. Install the three transmission mounting bolts and 34. Refill the transmission with ATF. the two transmission housing mounting bolts. 35. Connect the positive (+) and negative (-) cables to 28. Install the starter motor, and tighten the starter the battery.
Page 839 Main Menu Table of Contents Shift Cable Adjustment Raise the vehicle (see section 6. Check that the hole in the control lever is perfectly aligned with the hole in the shift cable. Shift to the position. Remove the shift cable cover. Remove the control lever pin and lock pin from the control lever.
Page 840 Main Menu Table of Contents Shift Cable Removal/Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. Make sure lifts are placed properly (see section Remove the center console panel (see section...
Page 841 Table of Contents Main Menu Shift Lever SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service.
Page 842 Main Menu Main Menu Table of Contents Table of Contents Shift Indicator Panel Adjustment SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice. Check that the index mark of the indicator aligns with the N mark of the shift indicator panel with the transmission in NEUTRAL.
Page 843 Table of Contents Main Menu Special Tools 15-12 15-5 15-14 15-4, 15-6, 15-9, 15-11, 15-13 15-12 15-13 15-12, 15-13, 15-14 15-14 15-14...
Page 844 Table of Contents Main Menu Differential Illustrated Index NOTE: • If the parts marked with an asterisk ( * ) are replaced, the bearing preload must be adjusted (see page 15-12). • If replacement is required, always replace the limited slip differential clutch set. *75 mm THRUST SHIM Selection, Adjustment, page 15-13...
Page 845 Main Menu Table of Contents Preset Torque Inspection On-Vehicle: Assembly: Block the front wheels. Place one special tool in a vise. Place the left side of the differential assembly on the special tool, then Shift to low gear. preset the differential with 3 - 5 r o t a t i o n s , counter clockwise.
Page 846 Main Menu Table of Contents Bearing Replacement NOTE: Install the tapered roller bearings using a special • The bearing and outer race should be replaced as a tool and a press. Press the tapered roller bearings set. squarely until they bottom against the case. •...
Page 847 Table of Contents Main Menu Differential Disassembly Hold the differential in a bench vise using a special Remove the 112 mm shim, clutch discs, clutch tool, then remove the differential housing mounting plates, and 102 mm washer. bolts in a crisscross pattern in several steps. 112 mm SHIM CLUTCH DISCS...
Page 848 Main Menu Table of Contents Screw two 8 x 1.0 mm bolts into the threaded holes in the differential housing cover to push it away from the final driven gear. Turn eacr bolt two turns at a time to prevent cocking the differential housing cover excessively.
Page 849 Table of Contents Main Menu Reassembly NOTE: • If the limited slip differential clutch set was replaced, the 65 mm shim (differential housing cover side) and 1 1 2 mm shim (differential housing cover side) must be adjusted. • Reassemble the parts in the same order and direction they were before disassembly.
Page 850 Table of Contents Main Menu Differential Reassembly Install the carrier assembly. Install the washers, thrust needle bearing, and cen- tral gear. CARRIER CENTRAL GEAR ASSEMBLY THRUST NEEDLE DIFFERENTIAL BEARING WASHERS HOUSING Install the final driven gear. Align the mark on the differential housing cover with the mark on the final driven gear.
Page 851 Table of Contents Main Menu Install the washer, thrust needle bearing, 65 mm Tighten the mounting bolts in a crisscross pattern shim, 112 mm shim, clutch disc, and spring plate. in several steps. Be careful not to move the plastigauge when installing the washer.
Page 852 Main Menu Table of Contents Differential Reassembly 11. Measure the widest part of the plastigauge. • After installing a thinner shim: If the measured value is less than 0.18 mm, select Standard: 0.18-0.229 mm the next thinner shim, and recheck. If the new value is more than 0.229 mm, the selected shim is OK.
Page 853 Main Menu Table of Contents 16. Tighten the mounting bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 39 N-m (4.0 kgf-m, 29 Ibf-ft) BENCH VISE DIFFERENTIAL INSPECTION TOOLS 07MAJ-PR90100 17. Measure the preset torque (see page 15-4). Standard: 59-137 N-m (6-14 kgf-m, 43-101 Ibf-ft) 112 mm SHIM...
Page 854 Main Menu Table of Contents Oil Seal Removal Remove the differential assembly. Remove the oil seal from the transmission housing. OIL SEAL Replace. TRANSMISSION HOUSING Remove the oil seal from the clutch housing. OIL SEAL CLUTCH HOUSING Replace.
Page 855 Main Menu Table of Contents Bearing Outer Race Replacement (Clutch Housing Side) NOTE: • The outer race and bearing should be replaced as a set. • Inspect and adjust the bearing preload whenever the bearing is replaced. Remove the bearing outer race, 90 mm washer, and oil guide ring using the special tools.
Page 856 Table of Contents Main Menu Bearing Preload Adjustment If any of the items listed below are replaced, the bearing preload must be adjusted. • TRANSMISSION HOUSING • CLUTCH HOUSING • DIFFERENTIAL • TAPERED ROLLER BEARING and OUTER RACE • 75 mm THRUST SHIM •...
Page 857 Main Menu Table of Contents Install the standard shim and bearing outer race Lubricate the tapered roller bearing with transmis- into the transmission housing using the special sion oil, then install the differential. tools. Install the bearing outer race squarely, and check that there is no clearance between the bear- Install the transmission housing.
Page 858 Main Menu Table of Contents Oil Seal Installation Install the oil seal into the transmission housing Install the oil seal into the clutch housing using the using the special tools. special tools. SEAL DRIVER BEARING ATTACHMENT DRIVER DRIVER ATTACHMENT 07947 - SD90100 07749 - 0010000 07965 - SA00600 DRIVER...
Page 859 Main Menu Table of Contents 15-26 15-20, 15-24 15-20, 15-24 15-20, 15-24 15-19 15-28 15-18, 20, 25, 28 15-26 15-27 15-26, 15-27, 28 15-28 15-28...
Page 860 Table of Contents Main Menu Differential Illustrated Index NOTE: If the parts marked with an asterisk ( * ) are replaced, the bearing preload must be adjusted (see page 15-26). 75 mm THRUST SHIM Selection, Adjustment, page 15-27 FINAL DRIVEN GEAR TAPERED ROLLER BEARING Inspect for wear and damage.
Page 861 Table of Contents Main Menu Preset Torque Inspection Assembly: On-Vehicle: Place one special tool in a vise. Place the left side of Lift up right rear wheel, and place the safety stand. the differential assembly on the special tool, then (Lift and Support Points, see section preset the differential with 3 —...
Page 862 Main Menu Table of Contents Bearing Replacement Install the tapered roller bearings using a special NOTE: • The bearing and outer race should be replaced as a tool and a press as shown. Press the tapered roller set. bearings squarely until they bottom against the •...
Page 863 Table of Contents Main Menu Compress the spring plate. Hold the differential in a bench vise using a special tool, then remove the differential housing mounting bolts in a crisscross pattern in several steps. DIFFERENTIAL HOUSING BENCH VISE DIFFERENTIAL INSPECTION TOOLS 07MAJ - PR90100 Remove the differential housing, then install the Remove the stop clip.
Page 864 Main Menu Table of Contents Remove the 112 mm thrust shim, clutch discs, Screw two 8 x 1.0 mm bolts into the threaded holes clutch plates, and 102 mm washer. in the differential housing cover to push it away from the final driven gear. Turn each bolt two turns at a time to prevent cocking the differential housing cover excessively.
Page 865 Table of Contents Main Menu Clutch Disc, Clutch Plate Replacement NOTE: The clutch discs and clutch plates should be replaced as a set. Remove the clutch discs and clutch plates (see page 15-20). Soak the clutch discs for five minutes in transmis- 112 mm THRUST SHIM sion oil.
Page 866 Main Menu Table of Contents Differential Reassembly Install the 102 mm washer, clutch discs, clutch Install the clutch disc, clutch plate, central gear, and plates, and 112 mm thrust shim. Lubricate the carrier assembly. Lubricate the clutch disc surface with transmission fluid. clutch discs with transmission fluid.
Page 867 Table of Contents Main Menu Differential Reassembly Install the special tools on the stop plate. Install the differential housing. Align the fingers of the clutch plates and clutch discs. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 DIFFERENTIAL HOUSING STOP PLATE CLUTCH SPRING Align the fingers.
Page 868 Table of Contents Main Menu Hold the differential in a bench vise using a special tool, then install the differential housing mounting bolts. Tighten the bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 39 Nm (4.0 kgf-m, 29 Ibf-ft) BENCH VISE DIFFERENTIAL...
Page 869 Table of Contents Main Menu Oil Seal Removal 1. Remove the differential assembly. 2. Remove the oil seal from the transmission housing. OIL SEAL TRANSMISSION Replace. HOUSING Remove the oil seal from the torque converter housing. OIL SEAL TORQUE CONVERTER Replace.
Page 870 Main Menu Table of Contents Bearing Outer Race Replacement (Torque Converter Housing Side) NOTE: • The outer race and bearing should be replaced as a set. • Inspect and adjust the bearing preload whenever the bearing is replaced. Remove the bearing outer race, 90 mm washer, and oil guide ring using the special tools.
Page 871 Table of Contents Main Menu Bearing Preload Adjustment NOTE: If any of the items listed below are replaced, the bearing preload must be adjusted. TRANSMISSION HOUSING TORQUE CONVERTER HOUSING DIFFERENTIAL TAPERED ROLLER BEARING and OUTER RACE 75 mm THRUST SHIM 90 mm WASHER OIL GUIDE RING Remove the bearing outer race and 75 mm thrust...
Page 872 Table of Contents Main Menu Install the standard shim and bearing outer race 75 mm THRUST SHIM: into the transmission housing using the special tools as shown. Install the bearing outer race squarely. Check that there is no clearance between the bear- ing outer race, shim, and transmission housing.
Page 873 Main Menu Table of Contents Bearing Preload Adjustment (cont'd) Measure the starting torque of the differential assembly with a special tool and a torque wrench. Measure the bearing preload at normal room tem- perature in both directions. Standard: 3.3 - 4.5 N-m (33 - 45 kgf-cm, 29 - 39 Ibf-in) TORQUE WRENCH DIFFERENTIAL...
Page 874 Main Menu Table of Contents Oil Seal Installation Install the oil seal into the transmission housing using the special tools. DRIVER 07749 - 0010000 OIL SEAL Replace. BEARING DRIVER ATTACHMENT 07965 - SA00600 PILOT, 32 x 50 mm 07MAD - PR90200 Install the oil seal into the torque converter housing using the special tools.
Page 875 Main Menu Table of Contents Special Tools 16-13, 16-14, 16, 17 16-16 16-16 16-16 16-17 16-14 16-14, 16-16, 16-17...
Page 876: N-M (1.0 Kgf-M, 7.2 Ibf-Ft
Table of Contents Main Menu Driveshafts Removal Inspection Raise the vehicle, and place safety stands in the proper locations (see section Driveshaft Boot Check the boots on the driveshaft for cracks, damage, Remove the rear wheels. leaking grease or loose boot bands. If any damage is found, replace the boot Drain the transmission fluid (see section 13...
Page 877 Main Menu Table of Contents Driveshafts Removal Remove the wheel sensor from the knuckle and the 9. Hold the damper lower mount of stabilizer link with rear of the lower arm, then secure the wheel sensor a wrench, and remove the damper mounting nut. wire to the suspension arm.
Page 878 Table of Contents Main Menu 12. Remove the self-locking nut and flange bolt. 15. Pry the driveshaft assembly with a screwdriver as shown to force the set ring past the groove. Corrosion resistant bolt/nut SELF-LOCKING NUT 14 x 1.5 mm SCREWDRIVER Replace.
Page 879 Table of Contents Main Menu Driveshafts Disassembly To remove the boot band, pry up the locking tabs Remove both joints. with screwdriver, and raise the end of the band. Outboard joint side only: Remove the circlip from NOTE: Carefully clamp the driveshaft in a vise with the outboard joint groove, then remove the out- soft jaws.
Page 880 Table of Contents Main Menu Inspection Grease Quantity: : Thoroughly pack the inboard joint and outboard joint with joint grease included in the new joint boot set. NOTE: Mark the rollers and roller grooves during disassembly to ensure proper positioning during reassembly.
Page 881 Table of Contents Main Menu Driveshafts Reassembly Outboard joint side Fit the rollers to the spider with their high shoulders facing outward. NOTE: Wrap the splines with vinyl tape to prevent CAUTION: damage to the boot. • Reinstall the rollers in their original positions on the spider.
Page 882 Main Menu Table of Contents Install the spring and cap, then fit the outboard joint Inboard joint side onto the driveshaft. NOTE: Wrap the splines with vinyl tape to prevent damage to the boot. CAUTION: Reinstall the outboard joint in the origi- nal position on the rollers.
Page 883 Main Menu Table of Contents Driveshafts Reassembly 1 3. Fit the rollers to the spider with their high shoulders 15. Fit the inboard joint onto the driveshaft. facing outward. CAUTION: Reinstall the inboard joint in the original CAUTION. position on the rollers. •...
Page 884 Table of Contents Main Menu 17. Install new boot bands on the boots, then bend both 19. Install the new set rings in the driveshaft groove and intermediate shaft groove. sets of locking tabs. 20. Apply a light film of grease around the set ring groove 1 8.
Page 885 Main Menu Table of Contents Intermediate Shaft Replacement Drain the fluid from the transmission The bearing support assembly is a light press fit in (see section 13 M/T or section 14 A/T). the support base. To remove the bearing support assembly, remove the 8 x 1.25 mm flange bolts with 2.
Page 886 Table of Contents Main Menu Disassembly CAUTION: The bearing support and support base are Press the intermediate shaft out of the shaft bearing made of aluminum. Be careful not to damage them using the special tool and a press. when servicing. Remove the intermediate shaft outer seal from the bearing support.
Page 887 Table of Contents Main Menu Intermediate Shaft Disassembly (cont'd) Press the intermediate shaft bearing out of the bear- ing support using the special tools and & press. Press DRIVER 07749 - 0010000 ATTACHMENT, BEARING 52 x 55 mm 07746 - 0010400 HUB DIS/ASSEMBLY BASE 07GAF - SD40700...
Page 888 Main Menu Table of Contents Index/Inspection CAUTION: • The bearing support and support base are made of aluminum. Be careful not to damage them when servicing. • The bearing support and support base are a matched set and must be replaced as an assembly. Corrosion resistant bolt/nut SUPPORT BASE Check for damage.
Page 889 Main Menu Table of Contents Intermediate Shaft Reassembly Press the intermediate shaft bearing into the bear- Press the intermediate shaft inner seal into the ing support using the special tools and a press. bearing support using the special tools and a press. Press DRIVER 07749 - 0010000...
Page 890 Main Menu Table of Contents Seat the external circlip in the groove of the in- termediate shaft. CAUTION: Install the circlip with the radiused side facing out. EXTERNAL CIRCLIP Press the outer seal into the bearing support using the special tools and a press. Press DRIVER 07749-0010000...
Page 891 Main Menu Table of Contents Special Tools 17-53 17-61 17-23 17-59, 17-42 17-58...
Page 892: Removal, Page
Main Menu Table of Contents Component Locations Index NOTE: • If an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged during transit, storage or service, it should be deployed (see section 24).
Page 893 Main Menu Table of Contents System Description Steering Column The NSX/NSX-T has a tilt/telescopic steering column. The tilt/telescopic mechanism makes it possible to adjust the steer- ing wheel in fore and aft, and up and down directions. Tilt Mechanism In the upper portion of the steering column is a joint on the steering shaft. This joint allows the steering wheel to be adjusted up or down.
Page 894 Main Menu Table of Contents Telescopic Mechanism The upper steering shaft is divided into two shafts, connected by splines, making it possible for the shaft to telescope while transmitting the rotation of the steering wheel. When the telescopic lever is lowered, the lever pivot turns in a direc- tion to loosen the stop shim at the tip of the lever pivot, allowing the shaft to telescope.
Page 895 Main Menu Table of Contents System Description Energy-absorbing Steering Column/Wheel Both the steering column and steering wheel are designed to absorb impact energy during a collision. Steering Wheel The steering wheel absorbs the energy of a collision through the deformation of the spoke portion. Should the impact absorbing capacity of the column side decrease due to the deformation of the vehicle body during a collision, the steering wheel will help absorb the impact.
Page 896 Main Menu Table of Contents Electrical Power Steering (EPS) Outline The NSX/NSX-T uses an electric motor-driven power steering, which possesses the characteristics best suited for a mid- engine automobile. This system is a power-assisted steering device, with a motor inside the steering gearbox driven by the EPS control unit.
Page 897 Main Menu Table of Contents System Description Major Components The Electrical Power Steering system is composed of the following major components: • A steering gearbox that converts rotary operation of the steering wheel into transverse operation via a rack and pinion mechanism.
Page 898 Main Menu Table of Contents System Operation Manual Steering Operation Steering wheel input rotates the pinion of the gearbox through a universal joint. Due to the rack and pinion mechanism, the rotation of pinion is converted into a transverse motion at the rack, which steers the front wheels throught the tie-rods and knuckles the same as an ordinary rack and pinion system.
Page 899 Main Menu Table of Contents System Description Function and Operation Steering Sensor The steering sensor consists of a torque sensor, an interface. Torque Sensor The torque sensor converts steering torque input and its direction to voltage signals, in conjunction with the interface.
Page 900 Main Menu Table of Contents Interface Circuit The interface circuit is housed inside the steering gearbox near the pinion. It rectifies and amplifies the signals from the torque sensor, and transmits the steering signals to the EPS control unit.
Page 901 Main Menu Table of Contents System Description Function and Operation (cont'd) EPS Control Unit The control unit receives input signals from the vehicle speed sensors, torque sensor. It performs a multitude of control functions, including a circuit which can detect troubles in each functional part of the system and the control unit itself. The control unit operates the system while the engine is in the process of starting, on receipt of voltage generated by the alter- nator.
Page 902 Main Menu Table of Contents Self-Diagnosis Function The EPS control unit monitors the system inputs and outputs, and the driving current of the motor. If there is a problem in the system, the control unit turns the system off by actuating the relay. Power assist stops and normal manual steering operation resumes.
Page 903 Main Menu Table of Contents System Description Function and Operation (cont'd) The power module in the EPS control unit consists of a driving circuit, current sensor, field effect transistor (FET) bridge circuit, and two relays. It receives control signals from the central processing unit (CPU) and controls the driving current of the motor.
Page 904 Main Menu Table of Contents Steering Gearbox Motor and Power Assist Mechanism A motor is housed inside the gearbox housing. It consists of a yoke with a permanent magnet fixed in it, a rotor with a field coil, and brushes which pass electricity to rotor commutators. The motor is on the rack shaft of the steering gearbox. The drive current from the control unit flows through the power relay and fail-safe relay to the brushes of the motor.
Page 905 Main Menu Table of Contents Component Locations...
Page 906 Main Menu Table of Contents...
Page 907 Main Menu Table of Contents EPS Control Unit Terminal Arrangement 18P CONNECTOR WIRE SIDE OF FEMALE TERMINALS...
Page 908 Main Menu Table of Contents 3P CONNECTOR (LEFT SIDE) VB: Battery voltage IG SW: Ignition switch 3P CONNECTOR (RIGHT SIDE) VB: Battery voltage IG SW: Ignition switch PULSE UNIT 7P CONNECTOR (MT) 6P CONNECTOR...
Page 909 Main Menu Table of Contents Troubleshooting Precautions EPS Indicator Light Under normal conditions, the EPS indicator light in the gauge assembly 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 circuits are operating cor- rectly.
Page 910 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Indication Connect the SCS service connector to the service check connector under the glove box. SERVICE CHECK SCS SERVICE CONNECTOR CONNECTOR (2P) 07PAZ-0010100 Turn the ignition switch ON (II), but do not start the engine. Record the blinking frequency of the EPS indicator light.
Page 911 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Symptom-to-System Chart 17-27 17-29 17-36 17-31 17-36 17-38 • Initial diagnosis: Performed right after the engine starts until the EPS indicator light goes off. • Regular diagnosis: Continuously performed (under some conditions) after the EPS indicator light goes off until the engine stops.
Page 912 Main Menu Table of Contents Troubleshooting Hard Steering Refer to the Symptom-to-System Chart (see page 17-25). Power Assist Check with Car Parked: Connect a spring scale to the steering wheel and turn the wheel. Read the measurement when the front wheels start to move.
Page 913 Main Menu Table of Contents Inspection Steering Wheel Rotational Play Steering Gearbox Adjustment Place the front wheels in a straight ahead position, Serious burns may result if you touch any and measure the distance the steering wheel can be cooling components when the cooling system is hot. turned without moving the front wheels.
Page 914 Main Menu Table of Contents Steering Wheel Removal Remove the Torx bolts using a Torx T30 bit, then Airbag Removal remove the driver's airbag assembly. Store a removed airbag assembly with the pad surface up. If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury.
Page 915 Main Menu Table of Contents Steering Wheel Removal (cont'd) Remove the steering wheel nut. Disconnect the connectors from the horn and cruise control set/resume switches, then remove the cable reel 3P connector from its clips. Remove the steering wheel by rocking it slightly from side-to-side as you pull steadily with both hands.
Page 916 Main Menu Table of Contents Steering Wheel Disassembly/Reassembly Store a removed airbag assembly with the CAUTION: pad surface up. If the airbag is improperly stored face * Carefully inspect the driver's airbag assembly before down, accidental deployment could propel the unit with installing.
Page 917 • Do not replace the original steering wheel with any other design, since it will make it impossible to prop- erly install the airbag. (Use only genuine Honda replacement parts.) • After reassembly, confirm that the wheels are still straight ahead and that steering wheel spoke angle is correct.
Page 918 Main Menu Table of Contents Steering Wheel Installation (cont'd) Install the airbag assembly with new Torx bolts. 9. Connect the battery positive terminal, and then con- nect the negative terminal. 10. After installing the airbag assembly, confirm proper system operation: •...
Page 919 Main Menu Table of Contents Steering Column Removal SRS components are located in this area. Review the Remove the column covers. SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- NOTE: Be careful not to damage the column covers. vice.
Page 920 Main Menu Table of Contents Steering Column Removal (cont'd) Remove the combination switch assembly from the 10. Remove the steering joint bolts and toothed lock column shaft. washers from the steering joint. NOTE: The combination switch can be removed by disconnecting only the TCS sensor connector.
Page 921 Main Menu Table of Contents Inspection NOTE: • Check the telescopic mechanism, tilt mechanism, and steering joint bearings or steering shaft for movement and damage. Replace as an assembly if damaged or faulty. • If either the steering column assembly or TCS sensor is removed, select the appropriate shim and adjust the distance between the steering shaft and TCS sensor.
Page 922 Main Menu Table of Contents Steering Column Installation SRS components are located in this area. Review the Install the column holder with the 8 mm bolts. SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice.
Page 923 Main Menu Table of Contents Install the combination switch assembly over the 9. Install the column covers. column shaft. NOTE: Be careful not to damage the column covers. 10. Insert the cable reel 3P connector through the col- umn lower panel, and attach it to the column lower panel with the connector holder.
Page 924 Main Menu Table of Contents Steering Column Installation (cont'd) 12. Install the dashboard brace and dashboard lower pad. 13. Connect the foot well light harness and light-on warning chime to the dashboard lower panel, then install the dashboard lower panel. 14.
Page 925 Main Menu Table of Contents Steering Gearbox Removal/Installation NOTE: Before removing the steering gearbox, make 7. Install the 10 mm hex nut on the ball joint. Be sure sure the front wheels are straight ahead. that the 10 mm hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin Remove the steering joint cover.
Page 926 Main Menu Table of Contents Steering Gearbox Removal/Installation (cont'd) 12. Disconnect the connectors from the EPS wire har- 16. Remove the radiator pipe bracket at the front com- ness. partment bulkhead. 13. Remove the ground cable by removing the EPS wire harness bracket.
Page 927 Main Menu Table of Contents NOTE: Before removing the gearbox, place a stand jack 19. Lower the gearbox and front crossbeam with care under the gearbox and front crossbeam to lightly sup- so as not to hit or damage the radiator pipe. port them.
Page 928 Main Menu Table of Contents Steering Gearbox Removal/Installation (cont'd) 21. Install the gearbox in the reverse order of removal. NOTE: When connecting the steering joint, make sure that the cable reel of airbag system is centered. 22. Set the steering rack in the center of its stroke. 23.
Page 929 Main Menu Table of Contents Steering Gearbox Illustrated Index CAUTION: Do not try to disassemble the power steering gearbox. If the gearbox is faulty, replace it as an assembly.
Page 930 Main Menu Table of Contents Steering Gearbox Inspection Carefully clamp the gearbox in a vise with soft jaws. • Preload inspection: Remove the boot bands. Slide the steering rack in the cylinder until the end of the rack projects 60 mm (2.4 in) from the cylinder end.
Page 931 Main Menu Table of Contents Retighten the locknut while holding the rack Tie-rod installation: guide screw with a wrench. Screw each rack end into the rack while holding the lock washer so its tabs are in the slots in the rack end.
Page 932 Main Menu Table of Contents Steering Gearbox Inspection (cont'd) Install the boots on the rack end with the tube clamps. 9. If the tie-rod ends were removed, install the tie-rods on the right and left rack ends and screw them in until the threaded section is 11 mm (7/16 in) in NOTE: •...
Page 933 Main Menu Table of Contents Ball Joint Boot Replacement Remove the set ring and the boot. Insert the special tool into the threads in the ball pin, and align the end of the tool with the groove in the CAUTION: Do not contaminate the boot installa- boot.
Page 934 Main Menu Table of Contents EPS Control Unit Replacement SRS components are located in this area. Review the Disconnect the connectors from the EPS control SRS component locations, precautions, and procedures unit, then remove it. in the SRS (section 24) before performing repairs or ser- vice.
Page 935 Main Menu Table of Contents Special Tools 18-33, 18-34 18-18,18-34 18-18, 18-33 18-26, 18-39 18-21, 18-22, 18-24, 18-37 18-21, 18-36 18-26 18-18, 18-34 18-39...
Page 936 Table of Contents Main Menu Component Locations Index Front Suspension: FRONT DAMPER Removal, page 18-27 Disassembly/Inspection, page 18-27 Reassembly, page 18-29 FRONT SUSPENSION ASSEMBLY Installation, page 18-29 • Knuckle/Control Arms/ Compliance Pivot Removal, page 18-21 • Illustrated Index, page 18-20 •...
Page 937 Main Menu Table of Contents System Description Suspension Composition Outline Double wishbone independent suspension has been selected for each of the four wheels. This eliminates damper friction along the steering axis, and permits suspension geometry that takes full advantage of the performance potential of the wide, low aspect ratio tires.
Page 938 Table of Contents Main Menu (Front Compliance Mechanism) To avoid the usual compromise between ride quality and handling characteristics, a pivot-type "compliance mechanism" has been designed as an integral part of the front suspension. When one of the front wheels is subjected to a rearward movement by an uneven road surface or by heavy braking, the load produced has two separate effects.
Page 939 Table of Contents Main Menu Wheel Alignment Height NSX/NSX-T four wheel alignment requires the use of equipment designed specifically for four wheel independent suspensions and capable of immediate feedback. NOTE: For proper inspection/adjustment of the wheel alignment, check and adjust the following before checking the alignment.
Page 940 Main Menu Table of Contents Front Wheel Alignment Adjusting Procedure Adjustment NOTE: NSX/NSX-T four wheel alignment requires the use of equipment designed specifically for four wheel independent suspensions and capable of immediate feedback. The NSX/NSX-T suspension can be adjusted for camber, caster (front only), and toe. However, because each of them relates to the other, the camber changes when the toe is adjusted for example.
Page 941 Table of Contents Main Menu Wheel Alignment Front Wheel Alignment Adjustment Procedure NOTE: Camber: — Loosen the self-locking nut on the front lower • NSX/NSX-T four wheel alignment requires the use of control arm adjusting point, and adjust the equipment designed specifically for four wheel in- camber by turning the adjusting cam.
Page 942 Table of Contents Main Menu Measure the caster on the both sides, and adjust the caster to specifications. Caster: Loosen the pivot adjuster mounting nuts (self- locking nuts) under the compliance pivot, and adjust the caster by turning the adjusting cam. ADJUSTING CAM SELF-LOCKING Replace.
Page 943 Table of Contents Main Menu Wheel Alignment Front Turning Angle Inspection NOTE: • Place a vehicle on a level surface before inspection. • Release the parking brake and be sure that the vehicle is empty. • Check that the suspensions are at the standard height (see page 18-6).
Page 944 Table of Contents Main Menu Rear Wheel Alignment Adjusting Procedure Rear wheel alignment adjusting procedure TOP VIEW: Check tire pressure on both sides. Check the ride height on both sides. Adjust both camber and toe of the left side. CAMBER Adjust both camber and toe of the right side.
Page 945 Table of Contents Main Menu Wheel Alignment Rear Wheel Alignment Adjusting Procedure NOTE: NSX/NSX-T four wheel alignment requires the Camber use of equipment designed specifically for four wheel -1. Loosen the self-locking nut on the rear lower independent suspensions and capable of immediate control arm adjusting point, then adjust the feedback.
Page 946 Table of Contents Main Menu Runout Bearing End Play Raise the vehicle off the ground, and support it with Front Wheel End Play: safety stands in the proper locations (see section Standard: 0 mm (0 in) Service limit: 0.05 mm (0.002 in) max. Place the dial gauge on each front and rear wheel Rear Wheel End Play: rim, and turn the wheel slowly by hand.
Page 947 Table of Contents Main Menu Front Suspension Torque Specifications CAUTION: • Replace the self-locking nuts after removal. • Replace the self-locking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts. (It should require 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) of torque to turn the test nut on the bolt). •...
Page 948 Hub Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage the aluminum wheels. • On the aluminum wheels, remove the center cap from inside of the wheel after removing the wheel.
Page 949 Table of Contents Main Menu Front Suspension Hub Replacement Remove the wheel sensor from the knuckle and Loosen the wheel nuts slightly. front lower control arm. Raise the front of vehicle, and support it on safety NOTE: stands in proper locations (see section •...
Page 950 Main Menu Table of Contents Remove the flat head screws. Install two 8 x 12 mm Front Wheel Bearing Replacement: bolts into the disc to push it away from the hub. Raise the locking tab on the spindle nut, then remove the nut.
Page 951 Table of Contents Main Menu Front Suspension Hub Replacement Separate the wheel bearing from the hub using the NOTE: Replace the bearing with a new one after special tools and a press. removal. CAUTION: Hold onto the hub to keep it from fall- Press a new wheel bearing into the hub using the ing when pressed clear.
Page 952 Main Menu Table of Contents 7. Tighten the new spindle nut to specified torque, then stake the spindle nut shoulder against the spindle. 329 N-m (33.5 kgf-m, 242 Ibf-ft) Stake After tightening, use a drift to stake spindle shoulder against the spindle.
Page 953 Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Illustrated Index Overall Suspension NOTE: Align the white line on the stabilizer bar with the bushing end, and install the stabilizer bar. NOTE: • Wipe off the grease before tightening the nut at the ball joint. •...
Page 954 Table of Contents Main Menu Removal Remove the front wheel and bearing unit assembly NOTE: Use the ball joint removers to separate the ball (see page 18-15). joints from the suspension or steering arm. Remove the splash guard from the knuckle. CAUTION: •...
Page 955 Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Removal 9. Once the tool is in place, turn the adjusting bolt as 12. Remove the cotter pin and lower control arm ball necessary to make the jaws parallel. Then hand- joint nut. tighten the pressure bolt, and recheck the jaws to make sure they are still parallel.
Page 956 Main Menu Table of Contents 18. Remove the knuckle. 20. Hold the ball pin of the stabilizer link with a hex wrench, and loosen the self-locking nut. STABILIZER LINK LOWER CONTROL KNUCKLE HEX WRENCH 19. Separate the lower control arm and damper by removing the damper mounting bolt.
Page 957 Main Menu Table of Contents Knuckle/Control Arms/Compliance Pivot Removal 22. Remove the cotter pin and lower arm ball joint nut. 26. Remove the cotter pin and upper arm ball joint nut. CASTLE NUT CASTLE NUT 12 x 1.25 mm 12 x 1.25 mm 54 - 64 N-m 54 - 64 N-m (5.5 - 6.5 kgf-m, 40 - 47 Ibf-ft)
Page 958 Main Menu Table of Contents 31. Remove the compliance pivot assembly by remov- NOTE: ing the bolts and nuts shown. • Install the upper control arm on the frame before installing the compliance pivot assembly. SELF-LOCKING • Install the compliance pivot bolts and nuts. NUTS Torque them to the specified torque in the order.
Page 959 Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Ball Joint Boot Replacement Wipe the grease off the sliding surface of the ball NOTE: The upper control arm ball joint, lower control arm ball joint and knuckle upper ball joint are attached pin, and pack with fresh grease.
Page 960 Table of Contents Main Menu Front Damper Disassembly/Inspection Removal Remove the front wheel. Disassembly: Compress the damper spring with the spring com- Remove the brake hose mounting bolt from the pressor according to the manufacturer's instruc- damper. tions, then remove the self-locking nut. CAUTION: Do not compress the spring more than BRAKE HOSE MOUNTING BOLT necessary to remove the nut.
Page 961 Table of Contents Main Menu Front Damper Inspection SELF-LOCKING NUT 10 x 1.25 mm Replace. 29 N-m (3.0 kgf-m, 22 Ibf-ft) DAMPER MOUNTING RUBBER SELF-LOCKING DAMPER MOUNTING WASHER 10 x 1.25 mm Check for weakness. Replace. 43 N-m DAMPER MOUNTING (4.4 kgf-m, 32 Ibf-ft) COLLAR DUST COVER PLATE...
Page 962 Main Menu Table of Contents Reassembly Installation Install the damper unit on a spring compressor. Reposition the damper on the frame with the welded nut of the hose bracket facing outside. Assemble the damper in reverse order of removal BRAKE HOSE MOUNTING BOLT except the damper mounting washer and self-locking DAMPER 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Page 963 Table of Contents Main Menu Rear Suspension Torque Specifications CAUTION: • Replace the self-locking nuts after removal. • Replace the self-locking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts. (It should require 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) of torque to turn the test nut on the bolt). •...
Page 964 Hub Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage the aluminum wheels. • On the aluminum wheels, remove the center cap from inside of the wheel after removing the wheel.
Page 965 Table of Contents Main Menu Rear Suspension Hub Replacement Remove the center cap, then pry the spindle nut Remove the banjo bolt and disconnect the brake lock tab away from the spindle and loosen the nut. hose, then remove the brake hose clamp from the knuckle.
Page 966 Table of Contents Main Menu Rear Wheel Bearing Replacement: Remove the flat head screws. Install two 8 x 12 mm bolts into the disc to push it away from the hub. Separate the wheel bearing from the hub using the special tools and a press.
Page 967 Table of Contents Main Menu Rear Suspension Hub Replacement NOTE: Replace the bearing with a new one after removal. Press a new wheel bearing onto the hub using the special tools and a press. Press HUB ASSEMBLY DRIVER ATTACHMENT 07GAF - SD40200 WHEEL BEARING SUPPORT BASE HUB DIS/ASSEMBLY PIN...
Page 968 Table of Contents Main Menu Knuckle/Control Arms Illustrated Index Overall Suspension NOTE: • Wipe off the grease before tightening the nut at the ball joint. • Torque specifications, see page 18-30. • Align the white line on the stabilizer bar with the bushing end, and install the stabilizer bar. Corrosion resistant bolt/nut REAR DAMPER STABILIZER BAR...
Page 969 Table of Contents Main Menu Knuckle/Control Arms Removal Remove the rear wheel and bearing unit assembly Hold the damper lower mount of stabilizer link with (see page 18-31). a wrench, then remove the damper mounting nut. DAMPER MOUNTING NUT Remove the splash guard from the knuckle. 12 x 1.25 mm Replace.
Page 970 Main Menu Table of Contents 9. Remove the cotter pin from the castle nut of the 15. Separate the knuckle from the upper control arm lower control arm ball joint, and remove the nut. and driveshaft outboard joint. BALL JOINT NOTE: Do not remove the driveshafts from the dif- REMOVER, 32 mm ferential case or intermediate shaft.
Page 971 Main Menu Table of Contents Knuckle/Control Arms Removal 19. Remove the toe control arm. 1 7. Remove the lower control arm by removing the ad- justing bolt and flange bolt. FLANGE BOLT SELF-LOCKING NUT 12 x 1.25 mm Corrosion resistant bolt/nut 14 x 15 mm 93 N-m Replace.
Page 972 Table of Contents Main Menu Ball Joint Boot Replacement NOTE: The upper control arm ball joint is attached with Wipe the grease off the sliding surface of the ball the boot retainer to improve the sealing efficiency of the pin, and pack with fresh grease (upper ball joint boot.
Page 973 Table of Contents Main Menu Rear Damper Removal Remove the three self-locking nuts. Remove the rear wheels. Remove the lower rear hatch glass trim. SELF-LOCKING NUT 10 x 1.25 mm STRUT BRACE Replace. REAR HATCH GLASS TRIM Corrosion resistant bolt/nut Remove the rear strut brace (NSX-T model only).
Page 974 Table of Contents Main Menu Remove the self-locking nut, then remove the stabilizer link from the stabilizer bar and knuckle. REAR DAMPER SELF-LOCKING NUT 12 x 1.25 mm Replace. STABILIZER STABILIZER LINK Corrosion resistant bolt/nut...
Page 975 Main Menu Table of Contents Rear Damper Disassembly/Inspection Inspection: Disassembly: Reassemble all parts, except the spring. Compress the damper spring with the spring com- pressor according to the manufacturer's instruc- Push on the damper assembly and check for smooth tions, then remove the self-locking nut. operation through a full stroke, both compression and extension.
Page 976 Main Menu Table of Contents Inspection SELF-LOCKING NUT 10 x 1.25 Replace. DAMPER DAMPER MOUNTING MOUNTING RUBBER WASHER SELF-LOCKING DAMPER 10 x 1.25 mm MOUNTING Replace. COLLAR 54 N-m (5.4 kgf-m, 39 Ibf-ft) BUMP STOP DAMPER PLATE MOUNTING BASE DUST COVER DAMPER SLEEVE MOUNTING...
Page 977 Table of Contents Main Menu Rear Damper Reassembly Install the damper unit on a spring compressor. Assemble the damper in reverse order of removal except the damper mounting washer and self-lock- ing nut. NOTE: Align the bottom of damper spring and spring lower seat.
Page 978 Table of Contents Main Menu Installation Reposition the damper assembly between the frame and knuckle. SELF-LOCKING NUT 12 x 1.25 mm Replace. STABILIZER BAR STABILIZER LINK Corrosion resistant bolt/nut Install the stabilizer link and connect the stabilizer bar. Loosely install a new self-locking nut. Hold the ball pin of the stabilizer link with a hex wrench, then tighten the self-locking nut.
Page 979 Table of Contents Main Menu 6. Install the new self-locking nuts on the top of the damper assembly. STRUT BRACE SELF-LOCKING NUT 10 x 1.25 mm Replace. 53 N-m (5.4 kgf-m, 39 Ibf-ft) Corrosion resistant bolt/nut 7. Tighten the damper mounting nut to the specified torque.
Page 980 Main Menu Table of Contents Special Tools 19-77, 19-79, 19-80, 19-84 19-22, 19-25 19-42, 19-44, 19-79, 19-84 19-16 19-80 19-48, 19-10c 19-22, 19-25...
Page 981 Main Menu Main Menu Table of Contents Table of Contents Illustrated Index The accumulator contains high-pressure nitrogen gas; do not puncture, expose to flame or attempt to dis- assemble the accumulator or it may explode; severe personal injury may result. HYDRAULIC SYSTEM Relieving Accumulator/line pressure, page 19-77...
Page 982 Main Menu Table of Contents Inspection and Adjustment Brake System Rubber Parts and Brake Booster Brake Booster Brake Hoses Check brake operation by applying the brakes. Visually check for damage or signs of fluid leakage. If the brakes do not work properly, check the brake Replace the brake hose with a new one if it is dam- booster.
Page 983 Main Menu Table of Contents Parking Brake Pedal Height Adjustment Adjustment NOTE: After rear brake caliper servicing, loosen the 1. Loosen the brake switch locknut, and back off the brake switch until it is no longer touching the brake parking brake adjusting nut, start the engine, and pedal.
Page 984 • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 985 Main Menu Table of Contents Front Brake Pads Inspection/Replacement Remove the two brake hose mounting bolts. Remove • Never use an air hose or dry brush to clean brake the two caliper mounting bolts, and move the caliper assemblies. out of the way. Support the caliper with a piece of •...
Page 986 Main Menu Table of Contents Front Brake Pads Inspection/Replacement (cont'd) 6. Clean the caliper thoroughly; remove any rust, and 11. Push in the pistons so that the caliper will fit over check for grooves and cracks. the brake pads. 12. Set the caliper down into position, then install the 7.
Page 987 Main Menu Table of Contents Front Caliper Disassembly If necessary, apply compressed air to the caliper • Never use an air hose or dry brush to clean brake fluid inlet to get the pistons out. Place a shop rag or assemblies.
Page 988 • Replace parts with new ones whenever specified to Remove the brake disc pads (see page 19-7). do so. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and Inspect the disc surface for cracks and rust. Clean decrease the life of the system.
Page 989 Main Menu Table of Contents Thickness and Parallelism Inspection Raise each side of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the front wheels. Remove the brake disc pads (see page 19-7). Using a micrometer, measure disc thickness at eight points, approximately 45°...
Page 990 Table of Contents Bleeding CAUTION: • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Page 991 Main Menu Table of Contents Bleeding (cont'd) FRONT: REAR:...
Page 992 Main Menu Table of Contents Master Cylinder and Brake Booster Index/Torque BRAKE BOOSTER Do not disassemble. Tests, page 19-15 Pushrod Clearance Adjustment, page 19-16 MASTER CYLINDER Inspection, page 19-14...
Page 993 • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 994 Main Menu Table of Contents Brake Booster Tests Functional Test Booster Check Valve Test With the engine stopped, depress the brake pedal Disconnect the brake booster vacuum hose at the several times to deplete the vacuum reservoir, then booster or at the booster side of the valve. depress the pedal hard and hold it for 15 seconds.
Page 995 Main Menu Table of Contents Brake Booster Pushrod Clearance Adjustment NOTE: Master cylinder pushrod-to-piston clearance NOTE: If the clearance between the gauge body and adjusting nut is 0.4 mm (0.02 in), the pushrod- must be checked and adjustments made, if necessary, to-piston clearance is 0 mm.
Page 996 • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.
Page 997 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement Remove the two brake hose mounting bolts. • Never use an air hose or dry brush to clean brake Remove the two caliper mounting bolts, and the assemblies. caliper from the bracket. •...
Page 998 Main Menu Table of Contents Remove the pad shims, pads and pad retainers. 9. Install the new brake pads and pad shims on caliper bracket. Using vernier calipers, measure the thickness of each brake pad lining. • When reusing the pads, always reinstall the Brake Pad Thickness: brake pads in their original positions to prevent Standard:...
Page 999 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement (cont'd) 11. Install and tighten the two caliper mounting bolts. 12. Insert the cable through the arm, and connect the cable to the lever with the clevis pin and new lock pin.
Page 1000 Main Menu Table of Contents Rear Brake Disc Run-Out Inspection Raise each side of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the rear wheels. Remove the brake pads (see page 19-18). Inspect the disc surface for grooves, cracks, and rust.
Page 1001 Main Menu Table of Contents Thickness and Parallelism Inspection Raise both sides of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the rear wheels. Move the caliper and pads out of the way as described on the preceding page.

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