Page 3 FOTileEl symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. First Edition 09/2002 1,104pages HONDA MOTOR CO., LTD. All Rights Reserved Service Publication Office Specifications apply to U.S.A. end Canada A3 s€clions with *includ6 SRS compon€nts;...
Page 11 General Information Chassis and Paint Codes- ....2 0 0 0 M o d e l 1 - 2 Chassis and Paint Codes- 2 0 0 1 M o d e l .
Page 12: Model
[[rrtltr c d e f g h a , Manutacturer, Make and Type of Vehicle a. Engine Type JHM: HONDA MOTOR CO., LTD F20C1i 2.0 A DOHC VTEC Sequential Multiport HONDA Passenger vehicle Fuel-injected engine Line, Body and Engine Type b.
Page 13 Manutacturer, Make and Type of Vehicle a. Engine Type F2,C'li 2.0 A DOHC VTEC Sequenlial Multiport JHM: HONDA MOTOR CO.. LTD Fuel-injected engine HONDA Passenger vehicle Line, Body and Engine Type b. Serial Number U .
Page 14 F20C1 rrttirt c d e f g h Manutacturer, Make and Type of Vehicle a. Engine Type JHM: HONDA MOTOR CO.. LTD F20C1: 2.0 0 DOHC VTEC Sequential Multiport Fuel-injected engine HONDA Passenger vehicle Line, Body and Engine Type b. Serial Number AP1: S2000/F20C1 U .
Page 15 F20C1: 2.0 0 DOHC VTEC Sequential Multiport J H M : H O N D A M O T O R C O . , L T D Fuel-injected engine HONDA Passenger vehicle b. Serial Number Line, Body and Engine Type U .
Page 16 General Information ldentification Number Locations Engine Numbel Vehicle ldentilication Numbel lVlN) Transmission Numbe. (located under transmission)
Page 17 Warning/Caution Label Locations DRIVER MODULE DANGER CABLE REEL CAUTION EXPLOSIVE/FLAMMABLE INSTALLATION OF THE SRS CABLE REEL IS MUST NOT EXCEED STORAGE TEMPERATURES CRITICAL TO THE PROPER OPERATION OF THE SRS SYSTEM. 2OO'F I93'CI, FOR PROPER HANDLING STORAGE REFER TO THE SERVICE MANUAL FOR DETAILEO ANO DISPOSAL PROCEDURES, REFER TO SERVICE INSTALLATION INSTRUCTIONS.
Page 18 General Information Warning/Caution Label Locations (cont'dl SRS WARNING INFORMATION SRS INFORMATION U,S,A, model Canada model : t \ \ t I r ! I a CAUTION TO AVOID SERIOUS INJURY: DEATH OR SERIOUS INJURY CAN OCCUR. . FOR MAXIMUM SAFETY PROTECTION .
Page 19 SRS WARNING {HOOD) SUPPLEMENTAL RESTRAINT SYSTEM (SRSI THIS VEHICLE IS EOUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. TAMPERING WITH, DISCONNECTING, OR USING ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIOENTAL FIRING OF THE INFLATOR.
Page 20 General Information Warning/Caution Label Locations (cont'd) 1 - 1 0...
Page 21 Under-hood Emission Control Label (2000-2002 Modelsl Engine and Evaporative Families: Emission Group ldentilication Engine Family: Example: O R M A T I O N V E H I C L E E M I S S I O N C O N T R O L 2 HNX V 02.0 DYC r [ t - r OATALYST lili;81.lll;...
Page 22 NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2003 MODEL YEAR 2 HNX B O13O AAA NEW LEV PASSENGER CARS. T f t r I Model Year 3: 2003 Manutacturer Subcode HNX: HONDA Family Type R: EVAP/ORVR Canister Work Capacity Sequence Characters 1-12...
Page 23: Lift And Support Points
Lift and Support Points Floor Jack lf you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, 1. Block the rear wheels when raising the front of the first suooort the front of the vehicle with a tall safety vehicle;...
Page 24 General lnformation Towing lf the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. lt is very dangerous. . This vehicle can only be transported on a flat-bed. .
Page 25 Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number {VlN). Original parts have sell-adhesive labels. Replacement body parts will have self-adhesive labels, and the replacement engine and transmission will have the VIN plate attached with a break-off bolt. NOTE: Be careful not to damage the parts marking labels during body repair.
Page 26 General Information Service Precaution Adhesive Wheel Balance Weight The wheels of this model are not designed to mount the balance weight on the outer side of the wheel. Instead, mount the self-adhesive balance weight on the inner side of the wheels. Note the following service tips and install the weights securely.
Page 27 J 1 9 3 0 . l f y o u f i n d a t e r m o r a b b r e v i a t i o n i n a ' 0 1 o r l a t e r m a n u a l t h a t i s u n f a m i l i a r t o y o u , c h e c k t h i s l i s t . I f a term is not listed below, it did not change. '01 or Later odels '00 and Earlier Models New Abbreviations Description Honda Abbreviations Description SAE recommendation Heated Oxygen Sensor (for A,/F SENSOR HO2S...
Page 28 General Information Revised Component Terms (cont'd) '00 and Earlier Models '01 or Later odels Description Honda Abbreviations Description New Abbreviations SAE recommendation Intake Air Bypass Control IAB Control Solenoid Intake l\4anifold Runner I M R C S o l e n o i d V a l v e...
Page 29 Specifications...
Page 30 Standards and Service Limits Electrical Item Measurement Standard or New Service Limit Oualification l g n i t i o n c o i l R a t e d v o h a g € 1 2 V Firing order 1 3 4 2 Spark plug Tvpe...
Page 31 nder Head Service Limit Stand.rd or New Measurement Oualificetion 0.05 mm {0.002 in.) H e a d 104.95' 105.05 mm (4.132- 4.136 in.) H e i g h t 0.05 0.15 mm (0.002 0.006 in.) 0.30 mm (0.012 in.) E n d p l a v C a m s h a f t 0.'15 mm (0.006 in.) Camshaft -to-holder oil clearance...
Page 32 Standards and Service Limits Enqine Block Item Measuremont Clualification Standard or New Service Limit B l o c k 0.07 mm (0.003 in.)max. 0 . 1 0 m m ( 0 . 0 0 4 i n . ) Bore diameter 87.010 87.020 mm (3.4256 3.4260 in.
Page 33 Standard or New Servic€ Limit Measurement Item Oualification 7 . 6 0 ( 8 . 0 U S q t , 6 . 7 l m p q 0 C o o l a n t c a p a c i t y ( i n c l u d e s e n g i n e , E n g i n e o v e r h a u l R a d i a t o r 6 .
Page 34 Standards and Service Limits Manual Transmission Measurement Standard or New Service Limit Oualitidtion 1 . 4 8 0 ( 1 . 5 6 U S q t . , 1 . 3 0 l m p q t ) Transmission A t f l u i d c h a n q e C a p a c i t y 1 .
Page 35 Service Limit Measuremenl Standard or New item Oualification 50.009 50.025 mm Countershaft reverse gear {1.9689 1.969s in.) 26.38 26.46 mm (1.039 1.042 in.) 26.26 mm 11.034 in.i Thickness 0.3 mm (0.012 in.) End play 0.04- 0.22 mm {0.002 0.009 in.) o.D.
Page 36 Standards and Service Limits Differential itom Measurement Oualification Slenderd or New Service Limit Capacity 0 . 7 4 0 ( 0 . 7 8 U S q t . , 0 . 6 5 l m p q t ) D i f f e r e n t a a l o i l A t o i l c h a n o e 0.77 4 (0.81 US qt., 0.68lmp qt)
Page 37 Brakes Standard or New Service Limit Measurement Ouelificetion llem Parking brake Distance traveled wh€n 1 3 c l i c k s s h o u l d l o c k t h e b r a k € s pulled with 196 N (20 kgf, 44 lbfl oI lever Pedal height (carpet removed)
Page 38 Design Specifications Item M€a3uremeift Ouelilicetion Specificstion O I M E N S I O N S 4 , 1 2 0 m m ( 1 6 2 . 2 i n . ) O v e r a l l l e n g t h '1,750 mm (68.9 in.) O v e r a l l w i d t h O v o r a l l h e i g h t...
Page 39 Clualification Specmcetion Measurement Item Electric, oowerassisted rack and pinion STEERING Type O v e r a l l r a t i o 2 . 4 Turns, lock-to-lock 3 6 0 m m ( 1 4 . 1 i n . ) S t e e r i n g w h e e l d i a m e t e r Independent double wishbone, coil spring with stabilizer Front...
Page 40 Specilication Itsm Moasuroment Clualificetion 12V 36 AH/s hours ELECTRICAL Battery 1 2 V - 1 . 0 k W RATIN GS Starter 1 2 V 1 0 5 A Alternator Fuses 100A, 40A, 30A, 20A, 15A, r0A,7.5A UndeFhood fuse/relay box 70A, 604, 30A, 20A Underhood sub fuse/relay 20A, 15A, 10A,7.5A...
Page 41 Body Specifications Unit mm lin.l 2-13...
Page 42 Maintenance Lubricants and Fluids ....Maintenance Schedule for Normal Conditions (2000 Modell Listed by Distance/Time ..... Maintenance Schedule for Severe Conditions {2000 Model) Listed bv Distance/Time ..... Maintenance Schedule for Normal and Severe Conditions (2000 Modell Listed by Maintenance/ltem.......... Maintenance Schedule for Normal Conditions t2001-2003 Modelsl Listed by Distance/Time .....
Page 43 * 1: Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the Drooer additives. * 2:Always use Honda DOT 3 Brake Fluid. Using a non Honda brake fluid can cause corrosion and decrease the life of the system.
Page 44 NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 45 Replace brake fluid (see page 19 8). Use Honda DOT 3 Brake Fluid. Fillto between marks on reservoir. Replace coolant (see page 10'8) Capacity: 6.5 q {6.9 US qt, 5.7 lmp qt}. Use Honda All Season Antifreeze/coolant Type 2. mi/144,000 km/ 6 y€ars Reolace transmission tluid.
Page 46 Do the items in pans A, B, and C as required for mileage/time interval listed. R e p l a c e e n g i n e o i l ( s e e p a g e 8 - 5 ) . C a p a c i t y w i t h o u t { i l t e r c h a n g e : 4 . 5 0 ( 4 . 8 U S q t , 4 . 0 l m p q t ) , w i t h f i l t e r c h a n g e : 4 . 8 0 ( 5 . 1 U S q t , 4 . 2 l m p q t ) .
Page 47 According to state and lederal rogulations, tailure to do the maintenance items marked with asterisk ( * ) will not void customer's emissions warranties. Howevet. Honda r€commends that allmaintenance services be done at the recommended interval to ansure long-tetm reliability.
Page 48 Check parking brake adjustment. Should be fully applied within I to 13 clicks Lubricate locks, latches, and hinges with Honda white lithium grease. Inspect brake hoses and lines (in;luding ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage {see page 19-26).
Page 49 Maintenance Schedule for Normal and Severe Conditions (2000 Modell Listed by Maintenance ltem Service at the indicated distance or time, whichever comes first. . lf driven in normal conditions, do items with a dot (a). . l f d r i v e n i n s e v e r e c o n d i t i o n s o r n o r m a l l y d r i v e n i n C a n a d a , d o t h e c i r c l e ( O l a n d d o t ( O l i t e m s . miles x 1000 3.75 1.5 11.25 15 1 8 7 5 22.5 26.25 30...
Page 50 93.75 97.5 101.25105 108.75 112.5 11.25 15 78.75 86.25 90 41.25 15 18.75 56.25 60 63.75 187 't92 61t2 7 1t2 4112 5112 31t2 Normal Conditions: Every 7,500 miles (12,000 kmlor 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil change A d j u s t o n l y i l n o i s y .
Page 51 Replace transmission fluid. 1.48 0 11.56 US qt, 1.30 lmp qt). Use Honda MTF (see page '13-3). 120,000 years, then replace every 60,000 mi/96,000 km/5 years BeDlace enqine coolant (see page 10-8). Capacitv:6.5 4 (6.9 US qt,5.7 lmp at). Use Honda All Season Antifreeze/coolant Tvpe 2. 3 - 1 0...
Page 52 Do the items in parts A, B, C, and D as tequired for mileage/time interval listed ( 5 . 1 u S q t , 4 . 2 R e p l a c e e n g i n e o i t ( s e e p a g e 8 - 5 ) . , . C a p a c i t y w i r h o u t { i l t e r c h a n g e : 4 . 5 0 ( 4 . 8 u s q t , 4 . 0 l m p q t ) , w i t h f i l t e r c h a n g e : 4 . 8 0 l m p q t ) C h e c k t i r e i n f l a t i o n a n d c o n d i t i o n .
Page 53 E Replace transmission fluid. '1.48 011.56 US qt, 1.30lmp qt). UseHonda MTF {see page 13-3). 120,000 mi/1 years, then every 60,000 mi/ 96,000 km/ 5 years lf Beolace enqine coolant (see paqe 1O 8)- Capacitv: 6.5 0 (6.9 US qt.5.7 lmo qt). Use Honda Allseason Antifreeze/coolant Tvoe 2. 3-12...
Page 54 Check parking brake adiustment. lt should be fully applied within I to 13 clicks. Lubricate all hinges,locks and latches with Honda white lithium grease. Inspect brake hoies and lines (including ABSi. Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage (see page 19-26)- checli fluid leveis and condition of fluids;...
Page 55 'According to state and tederal regulations, failure to dothe maintenance items marked with an asterisk 1'lwill notvoid customer's emissions warranties, However. Honda recommends that all maintenance services be done atthe recommended intervalto ensure long,term reliability. NOTE: l lfthe vehicle is driven in d usty cond itions, replacethe air cleaner element every l5,000 miles 124,000 kml, if not, replace itevery 30,0OO miles (a8,O00 km).
Page 56 93.75 97.5 10125 105 108.75 112.5 78.75 82.5 86 25 67.5 71.25 15 41.25 45 48.75 52.5 5625 1 6 8 1 8 1 1 4 4 1 0 8 t 1 4 5112 6 1 1 2 4112 Normal Conditions: Everv 7,500 miles (12,000 km) ot 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every 15,000 miles 124,000 km)or 1 year Severe Conditions: Every oil change...
Page 57: Table Of Contents
Engine Electrical Engine Electrical SoecialTools Starting System Component Location Index ..,..Circuit Diagram Starter Circuit Troubleshooting Clutch lnterlock Switch Test Starter Solenoid Test ....Starter Performance Test StarterReplacement ....,.. 4-10 Starter Overhaul .,...,....lgnition System 4-16 Component Location Index ....4-' tl Circuit Diagram 4- 18...
Page 58 Engine Electrical SpecialTools Number Tool Number Description 07746-0010400 Attachment, 52 x 55 mm 07749-0010000 Driver -"-FJ ..-NN {^-''...
Page 59: Component Location Index ........,
Starting System Component Location Index CLUTCH INTERLOCK SWITCH est, page 4-6 ENGINE CONTROL MODULE IECMI IGNITION SWITCH ENGINE START SWITCH STARTER Troubleshooting, page 4-5 Solenoid Test, page 4-7 Performance. page 4-7 Replacement, page 4'8 Overhaul, page 4-10...
Page 60: Circuit Diagram
Starting System Circuit Diagram...
Page 61: Starter Circuit Troubleshooting
Starter Circuit Troubleshooting 4. Check the battery condition. Check electrical NOTE: . Air temperature must be between 59'and 100"F (15' connections at the battery, the negative battery cable to body, engine ground cables, and the a n d 3 8 " C ) d u r i n g t h i s p r o c e d u r e . .
Page 62: Clutch Lnterlock Switch Test
Starting System Starter Circu it Troubleshootin g Clutch lnterlock Switch Test (cont'dl 1. Disconnect the connector from the clutch interlock switch, then remove the clutch interlock switch. 6. Check the following wires in the order listed until you find the open circuit. .
Page 63: Starter Solenoid Test
Starter Performance Test Starter Solenoid Test Disconnect the wires from the S terminal and the 1. Check the hold-in coilfor continuity between the S M t e r m i n a l . terminal and the armature housing lground). There should be continuitv.
Page 64: Starterreplacement ............,
Starting System Stafter Performance Test {cont'dl Starter Replacement ' 1 . Make sure you have the anti-theft code for the radio, 5. Disconnectthe battery from the starter body. lfthe pinion retracts immediately, it is working properly. then write down the frequencies for the radio's preset buttons.
Page 65 Disconnect the 4P connector (A) from the alternator 7. Disconnect the starter cable from the B terminal on the staner solenoid (A), then disconnect the (B), and disconnect the BLK wire from the alternator B lerminal (C). BLK,^/VHTwire from the S terminal (C). E x 1 .
Page 66: Starter Overhaul .,...,
Starting System Starter Overhaul Disassembly/Reassembly I x 1.25 mm 8 r '1.25 mm 9 N.m (0.9 kgf m,7 lbt.ft) STARTER SOLENOID PINION DRIVE LEVER WASHER "'j@ ,/,.",o,^,,. 6x1omm 8 3 N m 1 o 8 8 k s r m ' @ n / #ffi #.,\ o u .
Page 67 1. Remove the staner (see page 4-8). 5. Check the commutator diameter, lf the diameter is below the service limit, reDlace the armature. 2. Disassemble the staner. Commutator Diameter Standard {New}:28.0-28.1 mm {1.102 1.106 in.l Armature Inspection and Test 27.5 mm (1.083 in.l Seryice Limit: 3.
Page 68 Starting System Starter Overhaul (cont'dl 7. Check the mica depth (A). lf the mica is too high (B), 9 . Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. undercut the mica with a hacksaw blade to the proper depth.
Page 69 Starter Brush Holder Test Starter Brush Inspection 14. Check that there is no continuity between the (+ ) 11. lvleasure the brush length. lf it is not within the b r u s h h o l d e r { A ) a n d ( ) b r u s h h o l d e r ( B ) . l f t h e r e service limit, replace the brush holder assembly.
Page 70 Starting System Stafter Overhaul (cont'dl '16. Pry 1 8 . Install the starter end cover (A) to retain the brush back each brush spring with a screwdriver. then h o l d e r ( B ) . position the brush about halfway out of its holder, and release the spring to hold it there.
Page 71 Overrunning Clutch Inspection ,|9. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. 20. Hold the planetary gear shaft (A), and turn the overrunning clutch assembly (B) both ways. lf it does not lock in either direction or it locks in both directions, reDlace it.
Page 72 lgnition System Gomponent Location Index IGNITION COIL/IGNITION CONTROL MODULE (ICMIASSEMBLIES '.ilt, -i\l;.,,,t1.'.---l t\]. SPARK PLUGS Inspection, page 4-19 4-16...
Page 73 Circuit Diagram MAIN UNDIR- H@D FUST/iEIAY 4-17...
Page 74 Aim the light toward the pointer {A). Check the ignition timing under no load conditions: Connect the Honda PGM Tester to the data link headlights, blower fan, and alr conditioner are not connector {DLC), and check for DTC's. lf a DTC is operating.
Page 75 Spark Plug Inspection 2 . D o n o t a d j u s t t h e g a p o f p l a t i n u m t i p p l u g s ( A ) ; Inspect the electrodes and ceramic insulator.
Page 76: Component Location Index
Charging System Component Location Index INDICATOR CHARGING SYSTEM IGNITION SWITCH _ . - '_=__=;:==,,,ii _1. i\ _:-- = , , ! : r l i \ ' \ \,\ \. -ai- - -----*\ - - - - - - - - r - l ' - .
Page 77 Circuit Diagram MAINUNDER HOODfUSE/RTLAYEOX N o . { 1 { l O A l / : : \ N o l 2 i O A l G202 4-21...
Page 78: Charging Circuit Troubleshooting
Gharging System Charging Circuit Troubleshooting 8. Connect the alternator 4P connector terminal No. 3 lf the charging system indicator does not come on or t o b o d y g r o u n d w i t h a j u m p e r w i r e . T u r n t h e does not go off, or the battery is dead or low, test the i g n i t i o n s w i t c h O N ( l l ) .
Page 79 Alternator and Regulator Circuit Test L Raise the engine speed to 2.000 rpm, and hold it t h e r e . l. Be sure the battery connections are good, and that ls there voltage Iess than 13.5 V? the battery is sufficiently charged and in good condition (see page 22 39).
Page 80 Charging System Charging Circuit Troubleshooting (cont'd) Alternator Control System Test 7. Check for continuity between the ECM connector C t e r m i n a l N o . 2 a n d b o d y g r o u n d . 1 .
Page 81 Alternator-compressor Belt Inspection and Replacement 1. Check that the pointer (A) onthe auto-tensioner housing is not beyond the edge of the indicator rib {B} on the tensioner base. Move the auto-tensioner (A) to relieve tension from the alternator belt (B), and remove the alternator- compressor belt.
Page 82 Charging System Alternator Replacement 1. Make sure you have the anti-theft code for the radio, 5. Remove the mounting bolts, then remove the then write down the frequencies for the radio's alternator. preset buftons. 10 x 1.25 mm 44 N.m 14.5 kgf.m,33lbf.ft) 2.
Page 83: Auto-Tensioner Inspection/Replacement
Auto-Tensioner Inspection/Replacement Attach a torque wrench (A) to the pulley bolt. 1 . Check whether there is a change in the position of M e a s u r e t h e t o r q u e o n t h e t e n s i o n e r i n t e r n a l s p r i n g the auto-tensioner before starting the engine and with moving the torque wrench in the direction after starting the engine, lf there is a change in the...
Page 84 Charging System Auto-Tensioner Inspection/Replacement (cont'dl 8. Remove the pulley bolt (left-hand threads), and 6. Remove the auto-tensioner. replace the tensioner pulley, (i1.3 kgf.m.31 lbl.ftl 8 x 1.25 mm 22 N.m {2.2 kgf.m, 16lbl'ft) 8 x 1.25 mm 22 N.m (2.2 kgt.m, 16lbf ftl 7.
Page 85: Alternator Overhaul
Alternator Overhaul Exploded View STATOR BEARING DRIVE.END COVER RETAINER FRONT BEARING " (,D GJ_ 'sl:'d !0ii^> *-!/ | u/ // ''-:t _ \ i i J.F^FI, \:iii -"..- -\\- 'sraroa BRUSH HOLDER - '--.- - .. IBt9uo* Xi.Altfi"" PULLEY LOCKNUT l 1 1 N .
Page 86 Charging System Alternator Overhaul (cont'd) 5. Remove the washer nut (A) and insulator (B) from Special Tools Required the "B" terminal, then remove the end cover (C) . Driver 07749-0010000 . Attachment, 52 x 55 mm 07746-0010400 a n d d u s t s e a l ( D ) . NOTE: Refer to the Exploded View as needed during t h i s p r o c e d u r e .
Page 87 7. Remove the voltage regulator. JThJF. R:i-.. /rss56\ (Y'W-s\ PH]{{]d I l l l l / € l r \n""^- \!)Lbl h o u s i n g ( B ) , 10. Remove the four insulators (A), rear 8. Remove the four screws (A), then remove the a n d w a s h e r ( C ) .
Page 88 Charging System Alternator Overhaul (cont'dl 11. (lf you are not replacing the front bearing and/or 14. With a hammer and commercially available tools rear bearing, go to step 18). Remove the rotorfrom shown, install a new rear bearing on the rotor shaft. the stator drive end housino.
Page 89 '16. Rectifier Test Supportthe stator housing in a vise, and drive out the front bearing with a brass drift (A) and hammer. 18. Check for continuity in each direction, between the B terminal and P terminals, and between the E t e r m i n a l a n d P t e r m i n a l s o f e a c h d i o d e p a i r , All diodes should have continuity in only one direction.
Page 90 Charging System Alternator Overhaul (cont'd) Alternator Brush Inspection Stator Test 19. Measure the length of both brushes (A) with a 22. Check that there is continuity between each pair of v e r n i e r c a l i p e r ( B ) . leads (A).
Page 91 Cruise Control Component Location Index CRUISE CONTROL INDICATOR LIGHT BRAKE PEDAL POSITION SWITCH Test, page 4 47 Adjustment, page 19'6 CONTROL SET/RESUME SWITCH Test, page 4 42 Beplacement, page 4-42 CRUISE CONTROL MAIN SWITCH Test, page 4 40 page 4-41 Replacement, CRUISE CONTROL UNIT Input Test, page 4 38...
Page 92 Cruise Control Circuit Diagram cnu$ coMtot i ir $[rdr rG BUrcSW mAxtSW MA SYr cxutsE @flxo( uul MoroB loloR acruAToi otfN cr05r cl,uTor cnustm s|€tooilftB ctu.Totsw BmlY$ lliffi* 4-36...
Page 93 Symptom Troubleshooting Index N O T E : ' T h e n u m b e r s i n t h e t a b l e s h o w t h e t r o u b l e s h o o t i n g s e q u e n c e . .
Page 94: Cruise Control Unit Input Test
Gruise Gontrol Cruise Control Unit Input Test SRS components are located in this area, review the SRS component locations, precautions, and procedures in the SRS section (24) before performing repairs or service. 1 . R e m o v e t h e k n e e b o l s t e r u n d e r t h e s t e e r i n g c o l u m n . 2 .
Page 95 Test: Desired result Cavity Wire color Test condition Possible cause it result is not obtained Blown No. 47 (10 A) ( No. 47 Check for voltage to ground: LT GRN/ l g n i t i o n s w i t c h O N ( l l ) , m a i n s w i t c h O N ( 1 5 A ) ) f u s e i n t h e m a i n There should be battery voltage.
Page 96: Main Switch Test
Cruise Gontrol Main Switch Test 1 . C a r e f u l l y p r y t h e c r u i s e c o n t r o l m a i n s w i t c h o u t o f Check for continuity betlveen the No.2 and No.3 t h e i n s t r u m e n t p a n e l , t h e n d i s c o n n e c t t h e t e r m i n a l s .
Page 97: Main Switch/Lndicator/Lllumination Test
Main Switch/lndicator/lllumination Main Switch/lndicator Bulb Test Replacement 1. Carefully pry the cruise control mainswitch(A) out 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . T u r n t h e l i g h t i n g of the instrument oanel, then disconnect the switch and the cruise control main switch {A) ON.
Page 98 Gruise Control Set/Resume Switch Replacement Set/Resume Switch Test 1 . Remove the two screws securing the seVresume 1. Remove the two screws securing the sevresume switch, then remove the switch. switch, then remove the switch. . : - Disconnect the connector from the switch. SWITCH CONNECTOR SET/RESUME Replace the switch.
Page 99 Cruise Gontrol Actuator Test With power and ground slill connected as in step 3, 1. Disconnect the 4P connector from the cruise connect battery power to the No. 4 terminal and control actuator. ground to No. 3 terminal, and check that the output linkage starts to turn from full closed position and stops at full opened position by the motor in the actuator.
Page 100: Cruise Control Actuator Replacement
Cruise Gontrol Cruise Control Actuator Replacement 3. Remove the cruise control actuator assembly. 1 . Remove the actuator cover. and disconnect the 4P connector from the cruise control actuator. 7.2 rbr.ft r {./3;k?#ff'ksr.m. Disconnect the actuator cable end (A) from the o u t p u t l i n k a g e ( B ) .
Page 101 Actuator Gable Replacement 3. Remove the accelerator pedal assembly. Remove the actuator cover, and disconnect the 4P conneclor from the cruise control actuator. 6 x 1 . 0 m m 1 3 N . m (1.3 kgf.m, 9.4 tbf.ftl 4. Disconnect the actuator cable end (A) from the arm (B) on the accelerator pedal assembly {C).
Page 102: Actuator Cable Adjustment ............'
Cruise Control Actuator Cable Adjustment 5. Turn the adjusting nut {A) until it is I mm (0.35 in.) Hold the cable sheath, removing all slack from the away from lhe actuator cable bracket when the throttle cable. throftle linkage starts open. Turn the adjusting nut (A) until it is 3 mm (1/8 in, ) away from the throttle cable bracket, 9 mm {0.35 in.)
Page 103: Clutch Pedal Position Switch Test '
Clutch Pedal Position Switch Test Brake Pedal Position Switch Test 1. Disconnect the connector from the clutch Dedal 1. Disconnectthe brake pedal position switch Dosition switch, then remove the switch. connector, and remove the switch. 2. Check for continuity between the No. 1 and the Checkthe clutch Dedal oosition switch connector No.
Page 105 Engine Assembly Engine Removal 6. Disconectthe engine control module (ECM) N O T E : connectors (A) from the EcM. . Use fender covers to avoid damaging painted surfaces. . To avoid damage, unplug the wiring connectors carefully while holding the connector portion. .
Page 106 9. Remove the throttle cable (A) by loosening the 1 1. Remove the battery cable (A) from the main locknut (B), then slipping the cable end out of the under-hood fuse/relay box, then remove the harness clamos (B). accelerator linkage. Take care not to bend the cable when removing it.
Page 107 Engine Assembly Engine Removal (cont'dl Relieve the fuel pressure (see page 11-105). 1 4 . 17. Remove the two bolts securing the engine stop bracket. Remove the fuel feed hose (A), fuel return hose (B) t 5 . and brake booster vacuum hose (C). 1 8 .
Page 108 23. Remove the engine stop bracket cushion (A), then remove the engine stop bracket (B). *----/-,:' rl\l 24. Lower the hoist. 25. Remove the heater hoses (A) and lower radiator h o s e ( B ) . (cont'd)
Page 109 Engine Assembly Engine Removal (cont'd) 28. Remove the support nut from the left side engine 2 1 . Attach the chain hoist to the engine as shown. Take care not to damage the VTEC solenoid valve. mount bracket. Remove the support nut (A) and four mounting bolts (B), then remove the right side engine mount bracket {C).
Page 110 Engine Installation 1. Installthe accessory brackets, and tighten their bolts to the specified torques. 10 x 1.25 mm i*il N.m 14.5 kgf.m,33 lbf.ftl 10 x 1.25 mm 38 N.m (3.9 kgf.m,28 lbt.ftl Green bolts. 8 x 1 .25 mm 22 N.m 12.2 kgt.m, 16lbt.ftl (cont'd)
Page 111 Engine Assembly Engine Installation (cont'd) 2. Install the engine into position in the vehicle. 4. Tighten the support nut on the left side engine mount bracket. /12 x 1.25 rnfi Reinstall the mounting bolts/support nuts in / 54N m 15.5 ksrni, a0 '}t.ttl the sequence given.
Page 112 6. lnstall the heater hoses (A) and lower radiator hose Install the front tires/wheels. ( B ) . 1 0 . Lower the hoist. 1 1 . Tighten the two bolts securing the engine stop bracket. " f f i t 12.
Page 113 Engine Assembly Engine Installation (cont'dl Install the brake booster vacuum hose (A), fuel 16. Connect the ECM connectors (A) andmainwire 1 3 . harness connector (B), return hose (B) and fuel feed hose (C), using new washers (D). 14. Push the engine control module {ECM) connectors through the bulkhead, then installthe grommet (A).
Page 114 20. Install the throttle cable (see page 11-125), then 1 8 . I n s t a l l t h e e l e c t r i c a l p o w e r s t e e r i n g ( E P S ) c o n t r o l a d j u s t t h e c a b l e ( s e e p a g e 1 1 - 1 2 4 ) .
Page 115 Engine Mechanical Cylinder Head ..... 6-2 Soecial Tobls Comoonent Location lndex ....,,....... 6-6 DTC Troubleshooting ........ VTEC Solenoid Valve Test ..... 6-10 VTEC Rocker Arms Test ..... 6-12 Valve Clearance Adjustment Crankshaft Pulley Removal and lnstallation ....6-14 .
Page 116 Cylinder Head SpecialTools Ref.No. Tool Number Description OTHAH-PJ7O,1OB V a l v e G u i d e R e a m e r , 5 . 5 m m 07JAA-001020A Socket, 19 mm 07JAB-001020A H o l d e r H a n d l e 07JAB-001040A Holder Attachment, 50 mm 07LAK-PR30r...
Page 117 Component Location Index TDC1 SENSOR o-*'"o E ,"'*o"' RUBBER sEAL Bl------ Installation, page 6-53 'ii'ti' lS...''.-. i :-=-'J @,^-r5 \..-:@ DOWEL PIN EXHAUST CAMSHAFT InspecIron, page 6-36 RUBBER SEAL INTAKE CAMSHAFT GEAR DOWEL PIN i--\_.. EXHAUST CAMSHAFT s)'.i\ ROCKER ARM GEAR ASSEMBLY Overhaul,...
Page 118 Cylinder Head Component Location Index (cont'd) EXHAUST VALVE GUIDE Inspection, page 6-39 Replacement, page 6 40 VALVE KEEPERS EXHAUST VALVE SEAL VALVE WASHER WASHER CAM CHAIN AUTO-TENSIONER EXHAUST VALVE v" Removal, page 6-38 Installation, page 6 44 DOWEL PIN INTAKE VALVE Removal, page 6 38 Inslallation, page 6-44...
Page 119 CAM CHAIN Removal, page 6-15 Installation, page 6-19 CAM CHAIN GUIDE CHAIN CASE ICKPI SENSOR IDLER PULLEY BASE IDLER PULLEY COLLAR IDLER PULLEY PULLEY BOLT page 6-'14 Eeplacement, CRANKSHAFT PULLEY page 6-14 Replacement, CHAIN CASE OIL SEAL Installation, page 6-24...
Page 120 Cylinder Head DTC Troubleshooting DTC P1259: A problem in the WEC Oil 6. Disconnecl the VTEC oil pressure switch 2P Pressure Switch circuit or VTEC Solenoid connector. Valve circuit. 7. Check for continuity on the VTEC oil pressure SpecialTools Bequired switch between the pressure switch 2P connector .
Page 121 14. Remove the VTEC oil pressure switch (A) and 10. Measure voltage across the VTEC oil pressure i n s t a l l t h e s p e c i a l t o o l s a s s h o w n , t h e n r e i n s t a l l t h e switch harness 2P connector.
Page 122 Gylinder Head DTC Troubleshooting (cont'd) With the battery positive terminal still connected to 27. Check for continuity between the VTEC solenoid the VTEC solenoid valve, measure voltage between valve 1P connector terminal and body ground. C 1 0 a n d b o d y g r o u n d . VTEC SOLENOID VALVE HARNESS 1P CONNECTOR ECM CONNECTOR C {13P)
Page 123 VTEC Solenoid Valve Test ' 1 . 4. lf the filter is not clogged. push the VTEC solenoid Disconnect the 1 P connector from the VTEC valve with your finger and check its movement. s o l e n o i d v a l v e . lf the VTEC solenoid valve is normal, check the e n g i n e o i l p r e s s u r e , Measure resistance between the terminal and body...
Page 124 Gylinder Head WEC Rocker Arms Test Check that the air pressure on the shop air Special Tools Required . Gauge joint adapter 07LAK-PR30100 compressor gauge indicator is over 400 kPa . WEC air adapter 07ZAJ-PNAA100 (4 kgflcm',57 psi). Make sure no water in the air hose and air compressor tank.
Page 125 9. With the specified air pressure applied and the piston at TDC, move the secondary rocker arm (A). The mid rocker arm (B). primary rocker arm (C) and secondary rocker arm should move together. lf the three rocker arms do not move together, replace the rocker arms as a set.
Page 126 Cylinder Head Valve Clearance Adjustment 4. Insert the feeler gauge (A) between the adjusting NOTE; Adjust the valves only when the cylinder head temoerature is less than 100'F (38"C). screw and the end ofthe valve stem and slide it b a c k a n d f o r t h ; y o u s h o u l d f e e l a s l i g h t a m o u n t o f d r a o .
Page 127 '180'clockwise (camshaft 7. Rotatethe crankshaft 180' clockwise (camshaft 11. Rotate the crankshaft gears turn 90") gears turn 90') Check and. if necessary, adjust the valve clearance Check and, if necessary, adjust the valve clearance o n N o . 3 c y l i n d e r . o n N o .
Page 128 Cylinder Head Crankshaft Pulley Removal and lnstallation Installation Special Tools Required . H o l d e r h a n d l e 0 7 J A B - 0 0 1 0 2 0 A . Holder attachment, 50 mm 07JAB-0010404 1 .
Page 129 Cam Chain Removal Special Tools Required 6. Remove the vacuum tank. . Holder handle 07JAB-0010204 . Holder attachment, 50 mm 07JAB-0010404 . Socket, 19 mm 07JAA-0010204 or a commercially available 19 mm socket NOTE: . Use fender covers to avoid damaging painted surfaces.
Page 130 Cylinder Head Cam Chain Removal (cont'dl 9. Remove the water bypass hose (A), then remove Remove the auto-tensioner (see page 4-27! - 1 1 . the three bolts (B) securing the water bypass tube {c). 1 2 . Remove the alternator {see page 4-26). Remove the idler pulley (A), then remove the idler p u l l e y b a s e ( B ) , 1 0 .
Page 131 21. Remove the engine wire harness connectors and Thread a nut onto the 5 x 0.8 mm bolt, then thread w i r e h a r n e s s c l a m p s f r o m t h e c y l i n d e r h e a d a n d the bolt into the maintenance hole in the cam chain auto-tensioner (see step 24 on page 6-29).
Page 132 Gylinder Head Gam Chain Removal (cont'dl 40. Hold the pulley with holder handle (A) and holder 4 3 . R e m o v e t h e o i l p u m p c h a i n g u i d e . attachment (B).
Page 133 Cam Chain Installation Special Tools Required 2. Install the cam chain with the colored piece (A) . Holder handle 07JAB-0010204 aligned with the punch mark (B) on the crankshaft . Holder attachment,50 mm 07JAB-0010404 sDrocKel. . Socket, 19 mm 07JAA-001020A or a commercially available '19 mm socket 1.
Page 134 Gylinder Head Cam Chain Installation (cont'd) Remove old liquid gasket from the oil pan mating 4. Remove old liquid gasket from the chain case surfaces, bolts and bolt holes. mating surfaces, bolts and bolt holes, Clean and dry the oil pan mating surfaces. 5.
Page 135 12. Clean the bolt (A), washer (B), pulley (C)and 14. Measure the diameter of each cylinder head bolt at crankshaft (D). Lubricate as shown below. point A and point B (see step 1 on page 6-45). lf either diameter is less than 1 1.5 mm (0.45 in.), O: Clean replace the cylinder head bolt.
Page 136 Gylinder Head Cam Chain Installation (cont'dl 29. Apply engine oil to the idler gear center bolt 26. Installthe cam chain on the sprocketwith the punch mark (A) aligned with the center of the two threads. Install a new O-ring on the bolt. colored pieces (B).
Page 137 Installthe alternator (see page 4-26). Installthe exhaust manifold using new gaskets and new self-locking nuts {see step 3'l on page 6-50). Installthe auto-tensioner {see page 4-27). 5 7 . Installthe exhaust manifold bracket. Make sure the Install the water pump pulley. smooth sides of the washers face the exhaust manifold bracket (see step 32 on page 6-50).
Page 138 Gylinder Head Cam Chain Installation (cont'dl Chain Case Oil Seal Installation Special Tools Required Install the alternator-compressor belt. . Driver 07749-0010000 . Attachment, 52 x 55 mm 07746-0010400 6 1 . lnstall the vacuum tank. 1. Use the specialtools to drive a new oil seal squarely into the chain case to the specified installed height.
Page 139 Cylinder Head Removal NOTE: 6. Move the auto-tensioner (A) to remove tension ' U s e f e n d e r c o v e r s t o a v o i d d a m a g i n g p a i n t e d from the alternator belt (B), then remove the su rfaces.
Page 140 Cylinder Head Cylinder Head Removal (cont'd) 1 1. Remove the bolt (A) securing the intake manifold 8. Relieve fuel pressure. bracket, and remove the air hose (B). 9. Remove the fuelfeed hose (A), fuel returnhose{B) and brake booster vacuum hose (C). tt',,;Z:i ".':::-G i..€-.
Page 141 13. Remove two bolts (A) securing the intake manifold 1 5 . Remove the four bolts securing the exhaust bracket, and remove the water bypass hose (B). manifold cover. " \ , , ) , l - i 16. Remove the three bolts (A). and loosen the bolt {B), t h e n r e m o v e t h e h e a t s h i e l d ( C : .
Page 142 Gylinder Head Cylinder Head Removal (cont'dl 17. Remove the exhaust manifold cover, then remove 1 9 . R e m o v e t h e i g n i t i o n c o i l c o v e r { A ) , t h e n r e m o v e t h e the exhaust manifold bracket (A) and the exhaust manifold (B).
Page 143 Remove the end cover (A) and nozzle (B) from the 21. Remove the cylinder head cover, cam chain auto-tensioner. Thread a nut {A) onto a 5 x 0.8 mm bolt that is at least 40 mm long (B), then thread the bolt into the maintenance hole in the cam chain auto-tensioner.
Page 144 Cylinder Head Cylinder Head Removal (cont'dl 26, Remove the cam chain auto-tensioner. Remove the camshaft holders and camshafts. Insert the bolts (A) into the rocker shaft holder. then remove the rocker arm assembly {B). 27. Loosen the rocker arm adjusting screws (A). 30.
Page 145 Camshaft Gear Removal 1 . Remove the dipstick, positive crankcase ventilation 31. Remove the cylinder head bolts. To prevent (PCV) hose and breather hose (see step 18 on page warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all the bolts are 6-28).
Page 146 Cylinder Head Cylinder Head Inspection for Warpage 1 . Remove the cylinder head (see page 6-25). Inspect the camshaft (see page 6-36). Check the cylinder head for warpage. Measure along the edges. and three ways across the center. . lf warpage is less than 0.05 mm (0.002 in.) cylinder head resurfacing is not required.
Page 147 Rocker Arms and Shafts Disassembly/Reassembly NOTE: . l d e n t i f y p a r t s a s t h e y a r e r e m o v e d t o e n s u r e r e i n s t a l l a t i o n i n t h e i r o r i g i n a l l o c a t i o n s .
Page 148 Cylinder Head Rocker Arms and Shafts Inspection 1 . Remove the dipstick, positive crankcase ventilation 9. Measure the inside diameter of the rocker arm. and {PCV) hose and breather hose (see step 18 on page check it for an out-of-round condition, 6-28).
Page 149 11. Inspect the rocker arm pistons (A). Push each piston manually. lf it does not move smoothly, replace the rocker arm assemDry. NOTE: . When reassembling the primary rocker arm (B), carefully apply air pressure to its oil passage. . Apply oil to the pistons when reassembling. 6-35...
Page 150 Cylinder Head Camshaft Inspection NOTE: Do not rotate the camshaft during inspection. 1 0 . Z e r o t h e d i a l i n d i c a t o r a g a i n s t t h e e n d o f t h e camshaft, then push the camshaft back and forth 1.
Page 151 1 8 . M e a s u r e c a m l o b e h e i g h t . 16. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. Cam Lobe Height Standard (New): .
Page 152 Cylinder Head Valves, Springs, and Valve Seals Removal Special Tools Bequired 4. Installthe valve guide seal remover. Valve spring compressor attachment 077 57 -P J'1010A ldentify the valves and valve springs as they are removed so that each item can be reinstalled in its o r i g i n a l p o s i t i o n .
Page 153 Valve Stem-to-Guide Clearance Valve Inspection lnspection 1 . Remove the valves (see page 6-38) 1 . Remove the valves (see page 6-38) Measure the valve in these areas. Slide the valve out of its guide about 10 mm, then Intake Valve Dimensions measure the guide-to-stem clearance with a dial A Standard lNewl: 35.90-36.10 mm ( 1 .
Page 154 Cylinder Head Valve Guide Replacement Special Tools Requir6d 5. Working from the camshaft side, use the driver and . Valve guide driver, 5.5 mm 07742-0010'100 a n a i r h a m m e r t o d r i v e t h e g u i d e a b o u t 2 m m .
Page 155 1 0 . Coat both reamer and valve guide with cutting oil. 9 . A p p l y a t h i n c o a t o f c l e a n e n g i n e o i l t o t h e o u t s i d e of the new valve guide.
Page 156 Cylinder Head Valve Seat Reconditioning 1 . Inspect valve stem-to-guide clearance (see page 6- 6, After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the 39). lf the valve guides are worn, replace them (see page 6-40) before cutting the valve seats.
Page 157 8. Insert the inlake and exhaust valves in the head and measure valve stem installed height (A). Intake Valve Stem Installed Height: Standard (New): 44.1 - 44.4 mm {1.736 - 1.748 in.) Service Limit: 44.7 mm 11.760 in.) Exhaust Valve Stem Installed Height: Standard (New): 44.2 44.5 mm {1.740 - 1.752 in.) 44.8 mm (1.764 in.)
Page 158 Gylinder Head Valves, Springs, and Valve Seals Installation 5 . I n s t a l l t h e v a l v e s p r i n g a n d v a l v e r e t a i n e r . P l a c e t h e Special Tools Required end of the valve spring with closely wound coils Valve spring compressor attachment 07757-PJ1010A...
Page 159 Camshaft Gear Installation Cylinder Head Installation 1. Installthe camshaft gear (A). 1. Measure the diameter of each cylinder head bolt at ooint A and ooint B. lf either diameter is less than 1 . 5 m m ( 0 . 4 5 i n . ) , r e p l a c e t h e c y l i n d e r h e a d b o l t . B 50 mm {2.0 in.) A 45 mm 11.8 in.) *'h,i...
Page 160 Cylinder Head Gylinder Head Installation (cont'd) Installthe dowel pins (A) and the new cylinder head Install the cylinder head on the block. gasket (B). A p p l y e n g i n e o i l t o t h e t h r e a d s a n d u n d e r t h e h e a d s o f a l l t h e c y l i n d e r h e a d b o l t s .
Page 161 1 1 . Make sure the crankshaft pulley is at top dead 14. Install the cam chain on the sprocket, then fitthe center (TDC). Align the TDC mark (A) on the idler gear collar into the cylinder head. crankshaft pulley with the pointer (B) on the chain 15.
Page 162 Gylinder Head Cylinder Head Installation (cont'd) 21. lnstallthe cam chain auto-tensioner (A) in the 18. Clamp the cam chain auto-tensioner in a soft-iawed cylinder head with new O-rings (B). v i s e . 19. Turn the 5 x 0.8 mm bolt (A) clockwise to compress the bottom of the auto-tensioner, then insert the set p i n ( B ) , P / N 1 4 5 1 1 - P C X - 0 0 5 .
Page 163 lnstall the rocker arm assembly. 28. Make sure the camshaft gears are at TDC. Check the alignment of the TDC marks {A) on the cam chain sprocket with the cylinder head surface. Adjust the valve clearance (see page 6-12). Install the cylinder head cover (see page 6-53). 25.
Page 164 Gylinder Head Cylinder Head Installation (cont'd) Install the exhaust manifold (A) using new gaskets Put the exhaust manifold cover on the exhaust 3 1 . (B) and new self-locking nuts (C). manifo ld. 10 x 1 ,25 mm lnstall the heat shield. 44 N.m (4.5 kgf.m.33lbt.ftl Install the exhaust manifold bracket (D).
Page 165 36. Installthe intake manifold (Alwith a new gasket (B). 37. Installthe water bypass hose (A), and tighten the two bolts (Bl securing the intake manifold bracket. 8 x 1.25 mm 22N.n kgl.m, 16 lbl ft) t\-.-- 10 x 1.25 mm il4 N.m {,1.5 kgf.m,33 lbf.ft}...
Page 166 Cylinder Head Cylinder Head Installation (cont'd) 41. Installthe brake booster vacuum hose (A), tuel Installthe air hose (A), and tighten the bolt (B) return hose (B) and fuel feed hose (C). using new securing the intake manifold bracket. w a s h e r s ( D ) . '10 x 1.25 mm 44 N.m {,1.5 kgf.m.33 lbt.ftl...
Page 167 Cylinder Head Cover Installation 44. Installthe throttle cable (see page 11-125), then Install the head cover gasket in the groove of the adjust the cable (see page 11-1241. cylinder head cover. 45. After installation. check that alltubes, hoses and Set the spark plug seal (A) on the spark plug tube. connectors are installed correctly.
Page 168 Gylinder Head Cylinder Head Cover Installation (cont'dl 8 . I n s t a l l t h e i g n i t i o n c o i l s ( A ) , t h e n i n s t a l l t h e i g n i t i o n 3.
Page 169 Engine Mechanical Engine Block SpecialTools ..... 7-2 Component Location Index ....,..,..,,.., Flywheel Removal and Installation ......Connecting Rod and Crankshaft End Play Inspection ....Crankshaft Main Bearing Replacement ...... Connecting Rod Bearing Replacement ...... 7 -11 Crankshaft and Pistons Removal ....-....Crankshaft Inspection ......
Page 170 Engine Block Special Tools Description Tool Number Ref.No. R i n g G e a r H o l d e r 07LAB-PV00100 S e a l D r i v e r O7LAD.PT3O1OA 07749-0010000 Driver 07948-SB00101 Driver Attachment...
Page 171 Component Location Index LOWER BLOCK OOWEL PIN WASHER *i'h ' " h \ : \-lY, 'ri .;:-':1// MAIN BEARINGS Oilclearance, page 7-7 Selection, FLYWHEEL step 1 on page 7 8 CRANKSHAFT OIL SEAL Installation, page 7 26 CRANKSHAFT THRUST WASHERS End play, page 7-6 Runout, Taper and Out-of-Round, p a g e i 1 3...
Page 172 Engine Block Component Location Index (cont'dl ( a:x t > : < SNAPRNG \ffi (': l/ ra?-.-.',, ^-,0 \prsroN \g< Removal, page 7-'17 Installation, step 1 on page 7-'19 Inspection, step 1 on page 7-18 PISTON R e m o v a l , p a g e 7 - 1 1 page 7'14 Measurement, CONNECTING ROD...
Page 173 Flywheel Removal and Installation Special Tools Required Ring gear holder 07LAB-PV00100 1. Rem ove the tra nsm ission (see page 13-5), 2. Remove the pressure plate and clutch disk {see page 12-7). 3. Remove the eight flywheel bolts.then separate the flywheel from the crankshaft flange.
Page 174 Engine Block Connecting Rod and Crankshaft End Play Inspection 1 . Remove the oil pump (see page 8-9). 4. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft.
Page 175 Crankshaft Main Bearing Replacement Main Bearing Clearance Inspection 6. lf the plastigage measures too wide or too narrow, (remove the engine if it's still in the vehicle), remove the crankshaft, and remove the upper half To check main bearing-to-journal oil clearance, remove the lower block and bearing halves.
Page 176 Engine Block Crankshaft Main Bearing Replacement {cont'd) Main Bearing Selection Main Journal Code Location 2. The main journal codes are stamped on the No. 1 Crankshaft Bore Code Location weo. 1. Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the 5 main journal bores.
Page 177 Connecting Rod Bearing Replacement Rod Bearing Clearance Inspection Rod Bearing Selestion 1. Inspect each connecting rod for cracks and heat 1. Remove the connecting rod cap and bearing half ( s e e p a g e 7 - ' 1 1 ) . damage.
Page 178 Engine Block Connecting Rod Bearing Replacement (cont'd) Use the big end bore codes and rod journal codes Connecting Rod Journal Code Location to select appropriate replacement bearings from 3. The connecting rod journal codes are stamped on the following table. t h e N o .
Page 179 Crankshaft and Piston Removal 1. Remove the cam chain (see page 6-15). 5. Remove the lower block and bearings. Keep all bearings in order. 2. Remove the oil pump (see step 1 on page 8-9). 3. Remove the 8 mm bolts. 'ffff$ll: 6 .
Page 180 Engine Block Crankshaft and Piston Removal (cont'dl lf you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. lf the ridge is not removed, it may damage the piston as it is pushed out, 9 .
Page 181 Crankshaft Inspection Straightness Out-of-Round and Taper 6. Place the cylinder block on the surface plate. 1. Remove the crankshaft from the cvlinder block (see p a g e 7 - 1 1 ) . 7 . C l e a n a n d i n s t a l l t h e b e a r i n g s o n t h e N o . 1 a n d No.
Page 182 Engine Block Block and Piston Inspection 1 . Remove the crankshaft and pistons (see page 7-1 1). 4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. lf Check the Diston for distortion or cracks. measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block.
Page 183 7. Calculate the difference between the cylinder bore Scored or scratched cylinder bores must be honed. diameter and the piston diarneter. lf the clearance is near or exceeds the service limit, inspect the Check the top of the block for warpage. Measure Diston and cvlinder block for excessive wear.
Page 184 Engine Block Cylinder Honing The cylinder liners are made wlth FRM ({iber rein{orced metal). Hone the cylinders only as described here. 1. Measure the cylinder bores (see step 3 on page 7- 14). lf the engine block is to be reused, hone the cVlinders and remeasure the bores.
Page 185 Piston, Pin, and Connecting Rod Replacement Disassembly 4, Heat the piston and connecting rod assembly to '158"F {70'C), then remove the approximately 1. Remove the piston from the cylinder block (see p i s t o n p i n . p a g e 7 1 1 ) .
Page 186 Engine Block Piston, Pin, and Connecting Rod Replacement {cont'd) Inspection 3. Check the difference between the Diston Din diameter and piston pin hole diameter in the piston. NOTE: Inspect the piston, piston pin and connecting rod when they are at room temperature. Piston Pin-to-Piston Clearance: Standard {New): 0.0030 to +0.0060 mm 1 .
Page 187 4. Installthe piston pin (A). Assemble the piston (B) Reassembly "lN" mark and connecting rod (C)with the {D) and the reference mark (E) on the same side. 1 . I n s t a l l a n e w p i s t o n p i n s n a p r i n g ( A ) . Coat the piston pin bore in the piston and the connecting rod, and the piston pin with engine oil.
Page 188 Engine Block Piston Ring Replacement Remove the piston from the cylinder block (see 4. Using a piston, push a new ring (A) into the c y l i n d e r b o r e 1 5 2 0 m m ( 0 . 6 0 . 8 i n . ) f r o m t h e p a g e 7 - 1 1 ) .
Page 189 6. Installthe rings as shown. The top ring (A) has a R1 7 . Rotate the rings in their grooves to make sure they mark and the second ring (B) has a R2 mark. The do not bind. manufacturing marks (C) must be facing upward. Position the ring end gaps as shown: About 90' OIL RING GAP...
Page 190 Engine Block Piston Installation lf the crankshaft is already installed 6, Checkthe connecting rod bearing clearance with plastigage {see page 7-9). 1. Set the crankshaft to bottom dead center (BDC) for 7 . A p p l y e n g i n e o i l t o t h e t h r e a d s o f t h e c o n n e c t i n g e a c h c y l i n d e r .
Page 191 lf the crankshaft is not installed Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. Position the arrow (A) facing the timing chain side o f t h e e n g i n e . Position the piston in the cylinder.
Page 192 Engine Block Crankshaft Installation 1 0 . Special Tools Required Tighten the connecting rod bolts in sequence to 25 . Driver 07749-0010000 N.m (2.5 kgf m, 18 ibf ft). . Driver attachment 07948-S800101 1 1 . Tighten the connecting rod bolts an additional 90'. 1 .
Page 193 1 3 . Put the lower block on the cvlinder block. 17. Use the sDecialtools to drive a new oil seal squarely into the block to the specified installed 1 4 . Tighten the bearing cap bolts is sequence to height.
Page 194 Engine Block Pulley End Crankshaft Seal Transmission End Crankshaft Seal Installation - In Car lnstallation - In Car Special Tools Required Special Tools Required ' Seal driver 07LAD-PT3o10A . Driver 07749-0010000 . Driver attachment 07948-S800101 1. Dry the crankshaft oil seal housing. 1.
Page 195 Engine Mechanical...
Page 196 Engine Lubrication SpecialTools Number Tool Number Description 0 7 9 1 2 - 6 1 1 0 0 0 1 O i l F i l t e r W r e n c h...
Page 197 Component Location Index OIL PAN BAFFLE PLATE +DRAINBOLT OIL PUMP Overhaul, page 8-8 Inspection, step 6 on page 8-10 KNOCK SENSOR page 8.7 OIL PUMP CHAIN TENSIONER CRANKSHAFT ENGINE OIL COOLER ENGINE OIL COOLER CENTEN BOLT OIL PUMP CHAIN GUIDE CHAIN CASE ENGINE OIL PRESSURE SWITCH Circuit Diagram, page 22-47...
Page 198 1. Connect a tachometer or a Honda PGN4 Tester. 2 . R e m o v e t h e e n g i n e o i l p r e s s u r e s w i t c h , a n d i n s t a l l a n o i l p r e s s u r e g a u g e ( A ) .
Page 199 Engine Oil Replacement NOTE: Under normal conditions, the oilfilter should be replaced at every other oil change. Under severe conditions. the oil filter should be reolaced at each oil c n a n g e . Change interval Evory 7,500 miles (12.000 kml or 12 months (Normal conditions) Every 3,750 miles (6.000 kml or 6 months {Severe conditionsl.
Page 200 Engine Lubrication Engine Oil Filter Replacement 5. lf eight numbers (1 to 8) are printed around the SpecialTools Required outside of the filter, use the following procedure to Oil Filter Wrench 07912-61 1000'1 tighten the filter. . Spin the filter on until its seal lightly seats against 1.
Page 201 OilJet Inspection 1 . R e m o v e t h e o i l i e t , a n d i n s p e c t i t a s f o l l o w s . M a k e s u r e t h a t a 1 .
Page 202 Engine Lubrication OilPump Overhaul Exploded View PUMP COVER DOWEL PIN OUTER ROTOR PUMP HOUSING DOWEL PIN RELIEF VALVE Valve must slide treely in housing bore. Replace if scored. SEALING BOLT 39 N.m (i0.0 kgl.m,29lbf.ltl 6 x 1 . 0 m m 12 N.m DOWEL PINS (1.2 kgf.m,8.7 lbf.ftl...
Page 203 4. Remove the three bolts securing the oil pump. Removal 1. Remove the cam chain (see page 6-'15). 2 , R e m o v e t h e o i l p u m p c h a i n t e n s i o n e r . 5.
Page 204 Engine Lubrication Oil Pump Overhaul (cont'd) Inspection 9. Check the housing-to-outer rotor radial clearance between the outer rotor (A) and pump housing (B). 6. Remove the DumD cover. lf lhe housing-to-outer rotor radial clearance exceeds the service limit, reolace the outer rotor a n d o i l p u m p h o u s i n g .
Page 205 13. Tighten the bolts on the oil pump. Installation x 1.25 mm 1 1 . S q u e e z e t h e n e w o i l p u m p c h a i n t e n s i o n e r ( A ) , t h e n 22 N.m (2.2 ksf.m, 16 lbl ft) i n s t a l l t h e s e t c l i p ( B ) o n i t a s s h o w n .
Page 206 Engine Lubrication Oil Pump Overhaul (cont'dl Set the crankshaft sprocket so that the No. 1 piston 1 1 . I n s t a l l t h e o i l p u m p c h a i n g u i d e ( A ) a n d o i l p u m p is at top dead center (TDC).
Page 207 Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal/lnstallation ..........Exhaust Manifold Removal/lnstallation Exhaust Pipe and Muffler Replacement .....
Page 208 Intake Manifold and Exhaust System Intake Manifold RemovaUlnstallation NOTE: Use new O-rings and gaskets when reassembling. 5 x 0 . 8 m m 6 N . m AIR CONTROL VALVE tbf.ft) {0.6 kgf m, TNTAKE AtR TEMPERATURE {rAT)SENSOR 8 x 1 . 2 5 m m 22 N.m 8 x 1 .
Page 209 Exhaust Manifold RemovaUlnstallation NOTE: Use new gaskets and self-locking nuts when reassembling. 8 x 'l.25 mm 22 N.m (2.2 ksf.m, 16 lbt ftl 6 x 1 . 0 m m 1 2 N . m {1.2 kg{ m, 8.7 rbf.ftt 0 f o '14 N.m {1.4 kgf.m, 10 lbt ft}...
Page 210 Intake Manifold and Exhaust System Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self{ocking nuts when reassembling. SELF.LOCKING 6 x 1 , 0 m m 10 x 1.25 mm 1 2 N . m 33 N.m (1.2 kgl.m,8.7 lbf.ftl (3.,1kgf.m,25 lbl'ft) Replace.
Page 211: Comoonent Location Index
Engine Cooling Cooling System 10-2 Comoonent Location Index ...,..,..10-5 Radiator Cao Test ....1 p - 5 Radiator Test 10-6 Fan Motor Test ThermostatTest ...... 10-6 Water Pump Inspection tu- I Water Pump Replacement 10-7 Coolant Replacement ..... 10-8 1 0 - 1 0 Thermostat ReDlacement Radiator and Fan Reolacement .....
Page 212 Cooling System Component Location Index RADIATOR Replacement, page 10'1 1 RADIATOR CAP UPPER RADIA COOLANT /'-' RESERVOIR .""*oY LOWER O-RING FAN MOTOR RADIATOR FAN SWITCH Test, page'10-6 Test, page 10-18 Replacement, DRAIN PLUG p a g e 1 0 - 1 1 RADIATOR FAN SHROUD Replacement, page 10-1 1 TOR HOSE...
Page 213 IDLE AIR CONTROL IIAC) VALVE HEATER VALVE OIL COOLER BYPASS HOSE BYPASS TUBE WATER THERMOSTAT COVER HEATER HOSES -.,!,'jj uppenmDrAroRHosE LOWER RADIATOR HOSE (cont'd) 10-3...
Page 214 Cooling System Component Location Index {cont'd) - - i ' - : ' f . ENGINE COOLANT TEMPERATURE l r r € _ ' , {ECTI SENSOR O.RING WATER OUTLET COVER THERMOSTAT page 10-'l0 Replacement, Inspection, page 10-6 THENMOSTAT COVER l) o'\, RUBBER SEAL THERMOSTAT...
Page 215 Radiator Cap Test Radiator Test 1. Remove the radiator cap (A). wet its seal with 1. Wait until the engine is cool, then carefully remove engine coolant, then install it on the pressure tester the radiator cap and fill the radiator with engine ( B ) ( c o m m e r c i a l l y a v a i l a b l e ) .
Page 216 Cooling System Fan Motor Test Thermostat Test 1. Disconnect the 2P connectors from the radiator fan Replace the thermostat if it is open at room motor (A) and condenser fan motor (B). temperature. To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of the hot container.
Page 217 Water Pump Replacement Water Pump Inspection Loosen the water pump pulley bolts. Loosen the water pump pulley bolts. Move the auto-tensioner to remove tension from fMove the auto-tensioner to remove tension from the alternator-compressor belt. then remove the the alternator-compressor belt, then remove the alternator-compressor belt (see step 8 on page 6- alternator-compressor belt (see step 8 on page 6- 1 5 ) .
Page 218 7 . R e m o v e , d r a i n , a n d r e i n s t a l l t h e r e s e r v o i r . F i l l t h e maximum heat. tank to the MAX mark with Honda All Season Antifreeze/Coolant Type 2 (P/N O1999-9001).
Page 219 With the radiator cap off, start the engine and let it run until warmed up {radiator fan comes on at least twice). Then, if necessary, add more Honda All Season Antifreeze/Coolant Type 2 to bring the level back up to the bottom of the filler neck.
Page 220 Cooling System Thermostat Replacement Y r t --/./ /';-'s, "1,'-'lt' ../...
Page 221 Radiator and Fans Replacement UPPEF RADIA TOR HOSE LOWER CUSHION 6 x 1 . 0 m m 7 N.m (0.7 kgf.m,5lbf.ftl RADIATOR FAN SHROUD ASSEMBLY 1 . 0 m m 7 N.m {0.7 kgl.m, 5 lbf ftl A/C CONDENSER FAN RADIATOR SHROUD ASSEMBLY swtTcH...
Page 222 Fan Controls Component Location Index UNDER-HOOD FUSE/RELAY A/C CONDENSER FAN RELAY Test, step 10 on page 23-41 RADIATOB FAN RELAY Test, step 10 on page 23-41 RADIATOR FAN SWITCH RADIATOR FAN ASSEMBLY Test, page 10 18 Motor Test, page 10 6 A/C CONDENSER FAN ASSEMBLY Motor Test, page 10-6 10-12...
Page 223 Symptom Troubleshooting Index Before performing any troubleshooting procedures check: . Fuses . Grounds . Cleanliness and tightness of all connectors SYMPTOM PROCEDURE Radiator Fan Circuit Troubleshooting {see page 10-15). Radiator tan does not run at all Radiator Fan Switch Circuit Troubleshooting (Open) Radiator fan does not run for engine cooling.
Page 224 Fan Controls Circuit Diagram MAIfl UNOEE-HOOD FUSE/8ETAY GflnoN swtTcH / 8AT \ \ c 2 8 l IG2 HOT h ON II|| G201 G301 -mhrito 1 0 - 1 4...
Page 225 Radiator Fan Gircuit Troubleshooting 1 . C h e c k t h e N o . 5 7 { 2 0 A } f u s e i n t h e m a i n u n d e r - h o o d 4.
Page 226 Fan Gontrols Radiator Fan Circuit Troubleshooting (cont'd) 9 . Reinstall the radiator fan relay. Disconnect the radiator fan motor 2P connector. 1 0 . Disconnect the radiator fan switch 2P connector. Check for continuity between the No. 2 terminal of the radiator fan relay 4P socket and the No.
Page 227 Radiator Fan Switch Circuit Radiator Fan Switch Circuit Troubleshooting (Openl Troubleshooting (Shon) 1. Disconnect the radiator fan switch 2P connector. 1, Remove the radiator fan relay from the main under- hood fuse/relay box, and test it (see page22-401. 2. Turn the ignition switch ON (ll). ls the rclay OK? 3.
Page 228 Fan Gontrols Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-81. 1. Remove the radiator fan switch from the radiator ( s e e p a g e ' ! 0 - 1 1 ) . 2.
Page 229 Fuel and Emissions Fuel and Emissions Systems Fuel Pressu re Regulator S p e c i a l T o o l s ......R e p 1 a c e m e n t 1 1 - 2 .
Page 230 Fuel and Emissions Systems SpecialTools Description Tool Number Ref. No. A973X-O41.XXXXX Vacuum Pump/Gauge, 0 30 in.Hg Vacuum/Pressure Gauge. 0 4 in.Hg 07JAz-0010008 07sAz-001000A Backprobe Set 07vAJ-0040100 Fuel Pressure Gauge Adapter 07406-004000A F u e l P r e s s u r e G a u o e ---) Aitt".' M"...
Page 231 1 . S t a r t t h e e n g i n e a n d c h e c k t h e M l L . NOTE; . Freeze data indicates the engine conditions when 2. lf the l\4lL stays on, connect the Honda PGM Tester the first malfunction, misfire or fuel trim (A) or an OBDII scan tool to the data link connector malfunction was detected.
Page 232 2 . R e m o v e t h e l e f t s i d e k i c k p a n e l ( A ) t o e x p o s e t h e manual that came with the scan tool or Honda PGM E C M ( B ) .
Page 233 How to Troubleshoot Circuits at the ECM How to Substitute the ECM for Testing Purposes Special Tools Required Use this procedure if you need a known-good ECM to . Digital multimeter KS-AHfvl-32-003 (1)or a test a vehicle. lt allows you to swap a ECM from a "donor"...
Page 234 D T C S a r e i n d i c a t e d b y a b l i n k i n g l v l a l f u n c t i o n I n d i c a t o r L a m p ( M l L ) w h e n t h e S C S s e r v i c e s i g n a l l i n e i s jumped with the Honda PGM Tester.
Page 235 ( s e e p a g e 1 1 - 4 5 ) Hiqher Than Exoected These DTCS are indicated by a blinking lvllL when the SCS service signal line is jumped with the Honda PG fvl Tester. (cont'd)
Page 236 ( s e e p a g e 1 1 - 8 0 ) l\4alfunction These DTCs are indicated by a blinking MIL when the SCS service signal line is jumped with the Honda PGM Tester. 1 1 - 8...
Page 237 Symptom Troubleshooting Index These symptoms DO NOT trigger Diagnostic Trouble Codes (DTCs) or cause the Malfunction Indicator Lamp (MlL) to come on. lf the MIL is reported on, check for DTCS. lf the vehicle has one of these symptoms, do the diagnostic procedure for it, in the sequence listed, until you find the cause.
Page 238 Fuel and Emissions Systems System Descriptions Elestronic Control System The functions of the fuel and emissions control systems are managed by the engine control module (ECM). Fail-safe Function When an abnormality occurs in the signal from a sensor, the ECM ignores the signal and assumes a pre-programmed value for the sensor that allows the enqine to continue to run.
Page 239 EGM Data You can retrieve data from the ECM by connecting the OBD ll scan tool or the Honda PGM Tester to the Data Link Connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGlvl Tester also reads data beyond that recommended by SAE to help you find the causes of intermittent problems.
Page 240 5'+ 5" BTDC with the conditions. S C S s e r v i c e s i g n a l l i n e jumped with the Honda P G M Calculated CLV is the engine load calculated from the lvlAp data.
Page 241 EGM Electrical Connections To ECTGAUGE To fiADIATOB FAN aELAY, MDIATOR FAN SWITCH OBATTERY{lOOA}'A OBACK UP ACC(3OA)*A osroP{10A)*A IMMOBIIEEN INDICAIOR LIGIIT OIGl MAINI4OA)'A Oacc snsAl*A To IMMOaILIZER RECEIVER @AIR PUMP{60A}*B Io TMMOBIUZEF RECETvER ONo.25 EAcK uPl7.5A).c .IEST OrNo.6 ACGnsAl.c O I N o , 5 I N S T R U M E N T L I G H T B A C K U P L I G H T { 7 . 5 A ) * C @ N o .
Page 242 Fuel and Emissions Systems System Descriptions (cont'dl ECM Electrical Connections (cont'dl No.2 IGNITION COIL AIR CONTiOL SOLENOID VALVE VIECPNESSURE 11-14...
Page 243 ECM Inputs and Outputs at Connector A (32P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. Description Signal ferminal name Terminal Wire color With ignition switch ON (ll): duty controlled Sends ECT signal to ECT YEUGBN W i t h i g n i t i o n s w i t c h O N ( l l ) : b a t t e r y v o l t a g e SAVS (AIR CONTROL VALVE D r i v e s a i r c o n t r o l v a l v e...
Page 244 Fuel and Emissions Systems System Descriptions (cont'dl EGM Inputs and Outputs at Connector A (32P) Wire side of female terminals NOTEr Standard battery voltage is 12 V. Terminal Wire color ferminal name Description Signel K L I N E S e n d s a n d r e c e i v e s s c a n t o o l W i t h i g n i t i o n s w i t c h O N { l l ) : b a t t e r y v o t t a g e s t q n a l , BLU/ORN STS {STARTER SWITCH...
Page 245 ECM Inputs and Outputs at Connector B (25P1 Wire side of female terminals NOTE: Standard battery voltage is 12 V. Description Signel Terminsl Wire color Terminal name numb6r Power source for ECM control With ignition switch ON (ll): battery voltage YEUBLK IGPl (POWER SOURCE) With ionition switch OFFi about 0 V Ground for ECM control...
Page 246 Fuel and Emissions Systems System Descriptions (cont'd) ECM Inputs and Outputs at Connector C (31P} W i r e s i d e o f f e m a l e t e r m i n a l s PO2SHTC (PRIMARY HEATED Drives primary heared oxygen OXYGTN SENSOF HFATER...
Page 247 Terminalname D6c.iption Signal Terminal Wire color numoel Detects CMP (TDC) sensor A. With engine running: pulses TDClP (CAMSHAFT POSITION G B N (CMP) SENSOR (TOP DEAD CENTEF {TDC) SENSORiA P S I D F ) Ground for CMP (TDC) sensor TDClM (CAMSHAFT POSITION (CMP}SENSOR (TOP DEAD CENTER (TDC) SENSOR)A M...
Page 248 Fuel and Emissions Systems System Descriptions (cont'd) Vacuum Hose Routing FUEL PRESSURE REGULATOR AIR CONTROL VALVE VACUUM CONTROL SOLENOID VALVE AIR CONTROL VALVE FRONT OF VEHICLE PURGE JOINT {i,Z?\''AW'*7 EVAPORATIVE EMtSStON IEVAP} CANISTER PURGE VALVE AIR CONTROL VACUUM RESERVOIR 11-20...
Page 249 Vacuum Distribution 1 PRIMARY HEATEO OXYGEN SENSOR (PRIMARY HO2S) O EVAPoRATIVE EMISSIoN {EVAP} CANISTER FILTER (SENSOR 1) EMISSION {EVAP) CANISTER PURGE @0 EVAPORATIVE VALVE i, SECONDARY HEATED OXYGEN SENSOR {SECONDARY EMISSION (EVAPI CANISTER VENT 4!] EVAPORATIVE HO2SI TSENSOR 2l SHUT VALVE MANIFOLD ABSOLUTE PRESSURE {MAP) SENSOR EMISSION (EVAP) TWO WAY VALVE €E EVAPORATIVE...
Page 250 Fuel and Emissions Systems System Descriptions (conf d) PGM-FI System Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor The Programmed Fuel Injection (PGM-Fl) system is a (thermistor). The resistance of the thermistor decreases sequential multiport fuel injection system. as the engine coolant temperature increases.
Page 251 Primary and Secondary Heated Oxygen Sensors Iniector Timing and Duration The ECM contains the memory for basic discharge {HO2Sl duration at various engine speeds and manifold The heated oxygen sensors detect the oxygen content pressures. The basic discharge duration, after being in the exhaust gas, then sends a signal to the ECM which varies the duration of injeclion accordingly.
Page 252 Fuel and Emissions Systems System Descriptions (cont'd) Throttle Position (TPl Sensor ldle Control System The TP sensor is a potentiometer connected to the thronle valve shaft. As the throttle position changes. the When the engine is cold, the A,,/C compressor is on. the sensor varies the signal voltage to the ECM.
Page 253 Fuel Supply System Intake Air System Fuel Cut-off Control Refer to the System Diagram to see the functional During deceleration with the throttle valve closed, layout ofthe system. current to the injectors is cut off to improve fuel economy at speeds over 1,050 rpm Throttle Body Fuel cut-off action also occurs when engine speed The throttle body is a single-barrel side draft type.
Page 254 Fuel and Emissions Systems System Descriptions (cont'dl Evaporative Emission (EVAPI Control Positive Crankcase Ventilation {PCV} System System The PCV valve prevents blow-by gases from escaping Refer to the System Diagram to see the functional into the atmosphere by venting them into the intake lavout of the system.
Page 255 ldle Control System The idle speed of the engine is controlled by the ldle Air Control (lAC) valve: . After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle soeed.
Page 256 Fuel and Emissions Systems System Descriptions (cont'dl Pulsed Secondary Air Injection The Pulsed Secondary Air Injection advances the activation of the catalytic converter and reduces the hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas. The system operates after the engine starts under the followig conditions: .
Page 257 Evaporative Emission {EVAP} Control Diagram The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the canister into the engine and burneo. ' T h e E V A P c a n i s t e r i s p u r g e d b y d r a w i n g f r e s h a i r t h r o u g h i t a n d a p o r t o n t h e i n t a k e m a n i f o l d .
Page 258 Fuel and Emissions Systems System Descriptions [cont'd) ECM Circuit Diagram u""' "r./neo :Ffl - G R N / h E D M A P S E N S O R lf-- ECTSENSOR L - l IATS€NSOF H t l TPSENSOF HO2S(SENSOBI) SECONDARY HO2S ISENSOR 2)
Page 259 __fffil YEL/BtU -.1 fFq!l elulwrlt _,_{9M_erutwrr -1f-- - B R N / Y E L AIR PUMP ELECTRIC CUNfiENTSENSOR G30r T f-l -S'.Er".f- -i"\ VAfVE --t-1 T t---_--------_---1 l l l i - , . , - . - . 1 t i t i ( A ) l I l r v l [ F l...
Page 260 Fuel and Emissions Systems System Descriptions {cont'd) ECM Circuit Diagram (cont'dl T--- L p l No.2INJECIoR No.3III|JECTOR L____9 | No.alNJECToR To EPS CONISO! UNr 11-32...
Page 261 No,1 IGNITION COIL Tr--.-.----------- iYEr --- r--l_l ," r/GRN ----l ff-------tr-|.---)SpaFx rcM I L-rftr\ PLUG I I ll ------Lf: No.2lGNlllON COIL F-----,------t lfr---+sPARKl I LjTF- PruG I No.3lGNlTlON COlt PIUG No.4 lGNlllON COt! eurrr ---!-auler t q l l - l AN CONTFOL SOI.ENOIDVALVE ---f---r...
Page 262 Fuel and Emissions Systems System Descriptions (cont'd) ECM Circuit Diagram (cont'd) r Y E L COOLANT GAUGE TACHOMETER c303 J l--Btu---------------l TACHOMETER -CONNECTOR 1 1 - 3 4...
Page 263 VTEC OIL PR€SSURE c102 JUNCTION CONNECTOR -caoa -ctot |-8tK.-------l}-B|.I-.--l}_Btx DATALIN( CONNECTOR (cont'd) 1 1 - 3 5...
Page 264 Fuel and Emissions Systems System Descriptions (cont'd) ECM Circuit Diagram (cont'dl F U S E S A:No.21 STARTEF SIGNAUt.5A) B:No.2 FUEL PUMP SBS(t5A) c : N o . 6 A C G ( 1 5 A ) DrNo.5 INSTAUMENT LrGHT __,__\r_ aacK uPticttllT.5A) E : N o .
Page 265 "-'_ PBESSURESWITCH n.o --95;--""rr"ro UNDEB,DASH FUSE/REUYAOX _w|lfler-x ________J$l _w"T/u*" _______{f"v BBAKE PEDA! POSTTTONSWITCH "o,ur,rr"roa a l- c20t- ---- -]-wHr/GRN CONNECTORC CONNECTOS A WHT/G8N WHT/GRN BLK/YEL LK,/YEI" CONNECIOS D FUSES F:No,25 AACK UP{7.5A1 G : S T O P ( r 0 A l FTBACK UPACC(3OA) lrlGl MAIN(aoA) J : A C G S ( l 5 A l...
Page 266 In some states, pan disconnected or when the ECM is cleared with the OBD ll scan tool or Honda PGM Tester. of the emissions testing is to make sure these codes are . Low ambient temperatures or excessive stop-and-go set to complete.
Page 267 ECM is cleared with the proceoure. . All readiness codes are cleared when the battery is OBD ll scan tool or Honda PGM Tester. . The enable criteria musl be repeated ifthe intake air disconnected or when the ECM is cleared with the temperature (lAT) drops lower then 36'F (20'C) from OBD ll scan tool or Honda PGM Tester.
Page 268 Fuel and Emissions Systems How to Set Readiness Codes (cont'dl Misfire Monitor and Readiness Code ' This readiness code is always setto available because misfiring is continuously monitored . Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road .
Page 269 PGM-Fl System Gomponent Location Index CAMSHAFT POSITION {CMPI SENSOR {TOP DEAD CENTER (TDC)2 SENSOR) B page 1 1-7'1 Troubleshooting, CAMSHAFT POSITION (CMP) SENSOR {TOP DEAD CENTER {TCD) SENSOR} A TroLrbleshooting. p a g e 1 1 - 7 1 INTAKE AIR TEMPERATURE IIATI SENSOR Troubleshooting, p a g e 1 1 ' 4 6...
Page 270 PGM-FI System Component Location Index (cont'd) il-..:-- DATA LINK CONNECTOR IDLCI ('02-03 models) General Troubleshootino lnformation. p a g e 1 1 - 3 11-42...
Page 271 DTG Troubleshooting DTC P0107: MAP Sensor Circuit Low Voltage 8. Turn the ignition switch OFF. 9. Disconnect the ECM connector C (31P). 1. Turn the ignition switch ON (ll) 10. Check for continuity between MAP sensor 2. Check the MAP with the scan tool. connector terminal No, 3 and body ground.
Page 272 PGM-FI System DTC Troubleshooting (cont'dl DTC P0108: MAP Sensor Circuit High Voltage 9. l\4easure voltage between MAP sensor connector t e r m i n a l s N o . 1 a n d N o . 2 . 1.
Page 273 DTC Pl129: MAP Sensor Signal Higher Than DTC Pl128: MAP Sensor Signal Lower Than Expected Expected Start the engine. Hold the engine at 3,000 rpm with 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . no load (in neutral) until the radiator fan comes on, then let it idle.
Page 274 IAT and ECT will have the same value. 2. Checkthe lATwith the scan lool. ls the cortect ambient temperature indicated? ls302"F (150"C)or higher (or H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES Intermittent failure, system is OK at this time.
Page 275 Turn the ignition switch ON (ll) ECM CONNECTOR C {3IP) 2. Check the IAT with the scan tool. ls " 4"F ( 20'C) ot less (or L-Limit in Honda 9 1 0 mode ot PGM Tester) or 5 V indicated?
Page 276 2. Check the ECT with the scan tool. then reckeck for DTC P0116. ls 302"F (150"C) or higher (or H-Limit in Honda 1. Start the engine. Hold the engine at 3,000 rpm with mode of PGM Tester) or 0 V indicated? no load (in neutral) until the radiator fan comes on, then let it idle.
Page 277 2. Check the ECT with the scan tool. ECM CONNECTOR C {31P) 4"F ( 20"C) or less (or L-Limit in Honda mode ot PGM Tester) or 5 V indicated? 9 1 0 YES Go to step 3.
Page 278 PGM-FI System DTC Troubleshooting (cont'dl DTC P0122: TP Sensor Circuit Low Voltage 8. At the sensor side, measure resistance between TP sensor 3P connector terminals No. 1 and No. 2 with 1. Turn the ignition switch oNfll) the throttle {ully closed. TP SENSOR 3P CONNECTOR 2.
Page 279 DTC Pl121: TP Sensor Signal Lower Than Turn the ignition switch ON (ll). 1 1 . Expected fMeasure voltage between ECM connector 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) t e r m i n a l s C 1 8 a n d C 2 7 .
Page 280 PGM-FISystem DTG Troubleshooting (cont'd) DfC P1122:TP Sensor Signal Higher Than ExDected 1. Turn the ignition switch oN (ll). 2. Check the thronle position with the scan tool. ls 14.1o/o ot Iess indicated when the throttle is f ullv clo6ed? YES - Intermittent failure, system is OK at this t r m e .
Page 281 DTC P0123: TP Sensor Circuit High Voltage 7. Measure voltage between ECM connector t e r m i n a l s C ' 1 8 a n d C 2 8 , 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . ECM CONNECTOR C {31P) 2.
Page 282 PGM-FI System DTC Troubleshootihg (cont'd) DTG P0128: Cooling System Malfunction ('02-03 modelsl NOTE: lf the DTCS listed below are stored at the same time as DTC P0128. troubleshoot those DTCs first. then recheck for P0128. P0107, P0108, P1128, P1129t Manifold Absolute Pressure (MAP) Sensor P 1 1 0 6 , P ' 1 1 0 7 , P 1 1 0 8 : B a r o m e t r i c P r e s s u r e ( B A R O ) Sensor...
Page 283 DTC P0131: Primary HO2S (Sensor 1) Circuit 1 1. Check for continuity between primary HO2S Low Voltage ( S e n s o r 1 ) 4 P c o n n e c t o r t e r m i n a l N o , 1 a n d b o d y g rou nd.
Page 284 PGM-FI System DTC Troubleshooting (cont'd) DTC P0132: Primary HO2S (Sensor llCircuit Turn the ignition switch ON (ll). High Voltage Check the primary HO2S (Sensor output voltage 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . with the scan tool.
Page 285 DTC P0133: Primary HO2S (Sensor 1) Circuit Slow Response NOTE: lf DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCS first, then recheck for DTC P0133. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 | . 2.
Page 286 PGM-FI System DTG Troubleshooting (cont'dl DTC P0137: Secondary HO2S (Sensor 2) 10. Check for continuity between secondary HO2S Circuit Low Voltage (Sensor 2) 4P connector terminal No. 2 and body g rou nd. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . HO2S SECONDARY ISENSOR 2l irP CONNECTOR...
Page 287 DTC P0138: Secondary HO2S (Sensor 2) Turn the ignition switch ON (ll). Circuit High Voltage Check the secondary HO2S (Sensor 2) output 1. Reset the Eclvl (see page 1 1-41. voltage with the scan tool. 2. Start the engine. Hold the engine at 3,000 rpm with ls there 0.6 V or more? no load (in neutral) until the radiator fan comes on.
Page 288 PGM-Fl System DTC Troubleshooting (cont'd) DTG P0139: Secondary HO2S (Sensor 2) Slow Resoonse 1 . R e s e t t h e E C M { s e e p a g e 1 1 - 4 1 . 2.
Page 289 DTC P0135: Primary HO2S (Sensor 1) Heater 6. At the HO2S side, check continuity be&veen body Circuit Malfunction ground and HO2S 4P connector terminals No. 3 a n d N o . 4 i n d i v i d u a l l y . DTC P0141: Secondary HO2S(Sensor Heater Circuit Malf unction PRIMARY HO2S (Sonsoi'll...
Page 290 PGM-FISystem DTG Troubleshooting (cont'dl 13. Turn the ignition switch OFF. Turn the ignition switch OFF. 14. Reconnect the HO2S 4P connector. 1 0 . Disconnect ECM connector C {31P) 15. Disconnect the ECM connector C (31P)' 1 1 . Check for continuity between the connector t e r m i n a l C 1 ( C 1 1 ) * a n d b o d y g r o u n d .
Page 291 DTC P0171: Fuel System Too Lean 4. Turn the ignition switch OFF. DTC P0172: Fuel System Too Rich 5. With a vacuum pump, apply vacuum to the EVAP canister purge valve from the intake manifold side. NOTE: lf some of the DTCS listed below are stored at the same time as DTCP0171 and/or P0'172, Does it hold vacuum? troubleshoot those DTCS first, then recheck for P0171...
Page 292 PGM-FISystem DTC Troubleshooting (cont'd) DTC P0300: Random Misfire and Any Combination of the Following: DTC P0301: No. 1 Cylinder Misfire DTG P0302: No. 2 Cylinder Misfire DTG P0303: No. 3 Cylinder Misfire DTC P0304: No. 4 Cylinder Misfire NOTE: . l f t h e m i s f i r i n g i s f r e q u e n t e n o u g h t o t r i g g e r d e t e c t i o n o f i n c r e a s e d e m i s s i o n s d u r i n g t w o c o n s e c u t i v e d r i v i n g c y c l e s , the MIL will come on, and DTC P0300 {and some combination of P0301 through P0304) will be stored.
Page 293 DTC P0301: No. 1 Cylinder Misfire 7 . Determine which cylinder(s) had the misfire. DTC P0302: No. 2 Cylinder Misfire Does the misfire occut in the othet cylinder wherc the ignition coil was exchanged? DTC P0303: No. 3 Cylinder Misfire Y E S R e p l a c e t h e f a u l t y i g n i t i o n c o i l .
Page 294 PGM-FI System DTC Troubleshooting {cont'd) 24. Check for continuity between ignition coil 3P 17. Check for a DTC or Temporary DTC with the scan connector terminal No. 2 and body ground. r o o l . IGNITION COIL 3P CONNECTOR ls DTC P0301, P0302, P0303 ot P0304, ol Temporary DTC P1399 indicated? YES'- Go to step 18.
Page 295 26. Check for continuity between body ground and the 27. Con nect the a ppropriate ign ition coil 3P connector ECM connector terminal (see table). to body ground wilh a jumper wire terminal No. {see table). ECM CONNECTOR C {31P) IGPLSl {WHT} IGNITION COIL 3P CONNECTOR IGPL33...
Page 296 PGM-FI System DTC Troubleshooting (cont'd) 29. Check the engine compression (see page 6-32). 36. Measure resistance betvveen iniector 2P connector t e r m i n a l s N o . 1 a n d N o . 2 . ls the engine compression OK? INJECTOR 2P CONNECTOR YES Substitute a known-good ECM and recheck...
Page 297 45, Measure voltage between injector 2P connector 48. Connect injector 2P connector terminal No. I to t e r m j n a l N o . 2 a n d b o d y g r o u n d . body ground with a jumper wire (see table).
Page 298 PGM-FI System DTC Troubleshooting (cont'd) DTC P0325: Knock Sensor Circuit Malfunction 7. Connect knock sensor connector terminal No. 1to body ground with a jumper wire. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . KNOCK SENSOR 1P CONNECTOR 2.
Page 299 DTC P1361: CMP (TDC) Sensor A ,ntermittent 6. Checkfor continuity to body ground on all Interruption t e r m i n a l s i n d i v i d u a l l y . DTC Pl362: CMP (TDC) Sensor A No Signal CMP (TDC} SENSOR A 2P CONNECTOR DTC P1366: CMP (TDC) Sensor B Intermittent CMP (TDC) SENSOR B 2P CONNECTOR*...
Page 300 PGM-FISystem DTC Troubleshooting {cont'd) '10. 7 . Reconnect CMP {TDC) sensor A and CMP (TDC) Check for continuity between body ground and ECM connector teminal C20 (C29) * . sensor B * 2P connectors. ECM CONNECTOR C (31P) Disconnect ECI\4 connector C (31P). lvleasure resistance between ECM connector TDC lP IGRNI t e r m i n a l s C 2 0 a n d C 2 1 ( C 2 9 a n d C 3 0 ) * .
Page 301 DTC P0335: CKP Sensor No Signal 5. Check for continuity between CKP sensor 3P connector termlnal No. I and body ground and DTC P0336: CKP Sensor lntermittent t e r m i n a l N o . 2 a n d b o d y g r o u n d i n d i v i d u a l l y . Interruption CKP SENSOR 3P CONNECTOR 1 .
Page 302 PGM-FI System DTC Troubleshooting (cont'dl 8. Check for continuity between ECM connector terminal C8 and body ground. ECM CONNECTOR C 13,IP) CKP+ (BLU} Wire side of female terminals ls therc continuity? YES Repair short in the wire between ECM t e r m i n a l C 8 a n d t h e C K P s e n s o r . I NO Substitute a known-good ECM and recheck (see page 1 1-5).
Page 303 DTC P0500: VSS Circuit Malfunction 10. Measure voltage between ECM connector terminal C 2 8 a n d b o d y g r o u n d . 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) ECM CONNECTOR C {31P} 2.
Page 304 PGM-FI System DTC Troubleshooting (cont'dl 12. Turn the ignition switch OFF. 21. Measure voltage between ECM connector terminals A9 and B20. 13. Reconnect the VSS 3P connector. ECM CONNECTORS 1 4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . B (25P) 1 5 .
Page 305 DTC Pl107: BARO Sensor Circuit Low Voltage DTC Pl106: BARO Sensor Range/Perfoma Problem DTC Pl108: BARO Sensor Circuit High Voltage 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) 1 .
Page 306 PGM-FI System DTC Troubleshooting (cont'd) DTC P1297: ELD Circuit Low Voltage 8. Turn the ignition switch OFF. 1. Reset the ECI\4 (see page 11-4). 9. Disconnect ECM connector A (32P). 2. Stan the engine. 10. Check for continuity between ECM connector t e r m i n a l A 3 0 a n d b o d y g r o u n d .
Page 307 DTC P1298: ELD Circuit High Voltage 9. Connect ELD 3P connector terminal No. 3 to body g r o u n d w i t h a j u m p e r w i r e . 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) ELD 3P CONNECTOR 2 .
Page 308 PGM-FI System DTC Troubleshooting {cont'd) DTC Pl607: ECM Internal Circuit Malfunction 12. Check for continuity between ELD 3P connector t e r m i n a l N o , 2 a n d b o d y g r o u n d . 1 .
Page 309 MIL Circuit Troubleshooting 3. Try to stan the engine. 1 . Turn the ignition switch ON { ll), and watch the M a l f u n c t i o n I n d i c a t o r L a m p ( M l L ) . n ^ a .
Page 310 PGM-FI System MIL Circuit Troubleshooting (cont'd) 1 . Turn the ignition switch OFF. 1 0 . D i s c o n n e c t E C N 4 c o n n e c t o r C { 3 1 P ) . I n s p e c t t h e A C G S ( 1 5 A ) f u s e i n t h e m a i n u n d e r - Check for continuity between body ground and 1 1 .
Page 311 B 2 2 l . a Turn the ignition switch OFF. 2 1 . Connect an OBD ll scan tool/Honda PGM Tester ( s e e p a g e 1 1 - 3 ) . Turn the ignition switch ON (ll).
Page 312 PGM-FI System MIL Circuit Troubleshooting (cont'dl 24. Turn the ignition switch OFF. Turn the ignition switch ON (ll). 25. Disconnect ECM connector A (32P). Measure voltage between ECM connector terminal 4 1 0 a n d b o d y g r o u n d . 26.
Page 313 DLC Circuit Troubleshooting lf the ECM does not communicate with the OBD ll scan 3. Measure voltage between DLC terminals No.8 and tool, Honda PGM Tester, or l/M test equipment, do this N o . 1 3 . troubleshooti ng procedure.
Page 314 DLC Circuit Troubleshooting (cont'd) 7 . Disconnect ECM connector A (32P). Make sure the ls there continuity? OBD ll scan tooi or Honda PGM Tester is disconnected from the DLC. YES Substitute a known-good ECM and recheck (see page 11-5). lfthe symptom/indication goes Check for continuity between DLC terminal No.
Page 315 lnjector Replacement Relieve the fuel pressure (see page'11-105). Remove the fuel rail cover (A), then disconnect the connectors from the injectors (B). 1 2 N . m (1.2 kgf,m, 8.7lbf.ft) {1.2 kgf m, 8.7 rbf.ftl 3 . D i s c o n n e c t t h e v a c u u m h o s e a n d f u e l r e t u r n h o s e f r o m t h e f u e l p r e s s u r e r e g u l a t o r { C ) . P l a c e a r a g o r s h o p t o w e l over the hoses before disconnecting them.
Page 316 PGM-FISystem Injector Replacement (cont'dl 9. Slide new cushion rings (A) onto the injectors (B). 12 N.m 11.2 kgf.m,8.7 lbt ft) 10. Coat new O-rings (C)with clean engine oil, and put them on the iniectors. 11. Insert the injectors into the fuel rail (D). 1 2 .
Page 317 Primary HO2S Replacement Secondary HO2S Replacement 1. Disconnect the primary HO2S 4P connector (A). l. Dlsconnect the secondary HO2S 4P connector (A). 2. Remove the primary HO2S (B). 2. Remove the secondary HO2S (B). ___1-l ,/' .,' ,' ., 'i>1-:l .
Page 318 ldle Gontrol System Component Location Index t-'t'tt' -- -''"-- - - "";t 1 1 - 9 0...
Page 319 DTC Troubleshooting DTC P0505: ldle Control System Malfunction 7. Block both the upper and the lower ports (A) in the throttle body with your fingers. NOTE: lf DTC Pl519 is stored atthe same time as DTC P0505, troubleshooting DTC P1519 first, then recheck for DTC P0505.
Page 320 ldle Control System DTC Troubleshooting (cont'd) DTC Pl519: IAC Valve Circuit Malfunction 8. Check for continuity between body ground and IAC v a l v e 3 P c o n n e c t o r t e r m i n a l N o . 1 . 1 .
Page 321 13. Remove the jumper wire from the IAC valve 3P 1 1. Connect IAC valve 3P connector terminals No. 1 and No. 3 with a iumoer wire. connector, then reconnect the IAC valve 3P connector. 't4. Turn the ignition switch ON (ll). IAC VALVE 3P CONNECTOR 1 5 .
Page 322 ldle Control System A/C Signal Circuit Troubleshooting 8. Momentarily connect ECM connector terminals A17 1. Turn the ignition switch OFF. and B20 with a iumoerwire several tames. 2. Disconnect the A/C pressure switch connector. ECM CONNECTORS A (32P) 3 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 4.
Page 323 '16. 14. Check for continuity between body ground and Measure voltage between ECM connector ECM connector terminal 427. t e r m i n a l s A 2 7 a n d 8 2 0 . ECM CONNECTORS ECM CONNECTOR A (32P) A (32P) 1 8 19 20 21 25 26 21...
Page 324 ldle Control System Alternator FR Signal Circuit Troubleshooting 1 1 , Connect alternator 4P connector terminal No 4 to 1. Disconnect the alternator 4P connector. body ground with a jumPer wire. 2. Turn the ignition switch ON (ll) ALT 4P CONNECTOR 3.
Page 325 Starter Switch Signal Circuit Troubleshooting 15. Check for continuity between body ground and ECM connector terminal C5. NOTE: The clutch pedal must be pressed. ECM CONNECTOR C 13lPI 1. Measure voltage between Eclvl connector terminals A24 and 820 with the lgnition switch in ALTF {WHT/RED) the ON {ll) position and the engine start button pressed.
Page 326 ldle Gontrol System Electrical Power Steering (EPS) Signal Circuit Troubleshooting T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 9, Measure voltage between EPS control unitterminal N o .
Page 327 Brake Pedal Position Switch Signal Circuit Troubleshooting 13. lMeasure voltage between EPS control unit terminal N o . 1 3 a n d b o d y g r o u n d . 1 , C h e c k t h e b r a k e l i g h t s . EPS CONTROL UNIT 14P CONNECTOR Are the brake lights on without prcssing the brake pedal?
Page 328 . Replace the ECM or disconnect its connector' - Spark plugs . Reset the ECM. - Ail cleaner NOTE. Eras\ng DTCS N\th Honda PGM Testei does - PC\ system require the idle learn procedure to be done again. ' On Canadian models. pullthe parking brake lever up.
Page 329 Fuel Supply System Component Location Index FUEL PRESSURE REGULATOR Replacement, page 1 1-1 13 FUEL RAIL FUEL FILL CAP FUEL TANK page 11 115 Replacement, FUEL PUMP T e s t , p a g e 1 1 l 0 7 Replacement, page 11 114 FUEL FILTER Replacement, page 11-1 13...
Page 330 Fuel Supply System PGM-Fl Main Relay Circuit Troubleshooting 4 . Check for a blown ACG S (15 A) fuse in the under- Turn the ignition switch OFF, then disconnect the hood fuse/relay box. PGM-Fl main relay 7P connector. Check for continuity between body ground and ls the luse blown? PGM-Fl main relay 7P connector terminal No.
Page 331 7. Push the clutch pedal in, then turn the ignition 10. Check for continuity between PGM-FI mainrelayTP switch ON (ll), and press the engine start bufton. connector terminal No. 1 and ECM connector Measure voltage between body ground and PGM-Fl t e r m i n a l A 1 5 .
Page 332 Fuel Supply System PGM-Fl Main Relay Circuit Troubleshooting (cont'd) 1 3 . T u r n t h e i g n i t i o n s w i t c h O F F , t h e n O N ( l l ) a g a i n , 15.
Page 333 Fuel Pressure Test Fuel Pressure Relieving Special Tools Required Before disconnecting fuel lines or hoses, release . Fuel pressure gauge 07406-004000A pressure from the system by loosening the fuel . Fuel pressure gauge adapter 07VAJ-0040100 pulsation damper on top of the fuel rail. 1, Make sure you have the anti-theft code for the radio, 1.
Page 334 FuelSupply System Fuel Pressure Test {cont'd) Remove the fuel pulsation damper from the fuel 1 4 . W i t h t h e e n g i n e r u n n i n g , u n p i n c h a n d r e c o n n e c t the vacuum hose and read the gauge again.
Page 335 Fuel Pump Test Turn the ignition switch ON (ll). lf you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is ON, you will hear some noise if you listen to the fuel fill port with the fuel Check that banery voltage is available between fuel fill cap removed.
Page 336 Fuel Supply System Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, or deterioration, and replace parts as needed. 22 N.m (2.2 kgt.m, 16lbf.ft) 37 N.m (3.8 kgt m, 27 lbf.ft) 1 1 - 1 0 8...
Page 337 Check all hose clamps and retighten if necessary. : Do not disconnect the hose from the line at these ioints. Clamo in the middle. 1 0 - 1 5 m m {0.39-0.59 in.) Clamp in the middle. 1 1 - 1 0 9...
Page 338 Fuel Supply System Fuel Line/Ouick-Connect Fittings Fuel Line/Ouick-Connect Fittings Precautions Removal 1 . R e l i e v e f u e l p r e s s u r e ( s e e p a g e 1 1 - 1 0 5 ) . The fuel tube/qulck-connect fittings assembly connects the in-tank fuel DumD to the fuel feed line and the fuel r e t u r n l i n e .
Page 339 Fuel Line/Ouick-Connect Fittings lnstallation 4. Checkthe contact area (A) o{ the line (Bl for dirt and o a m a g e . 1. Check the contact area (A) of the line (B) for dirt and . lf the surface is dirty, clean it.. .
Page 340 Fuel Supply System Fuel Line/Ouick-Connect Fittings Installation (cont'dl 3. Before connecting a new fuel tube/quick-connect Reconnection to existing retainer: fitting assembly {A), remove the old retainer from t h e m a t i n g l i n e . 5.
Page 341 Fuel Filter Replacement Fuel Pressure Regulator Replacement The fuel filter should be reDlaced whenever the fuel pressure drops belowthe specified value (320 370 kPa, 3 . 3 3 . 8 k g f l c m ' , 4 7 5 4 p s i w i t h t h e f u e l p r e s s u r e 1.
Page 342 Fuel Supply System Fuel Pump/Fuel Gauge Sending Unit Replacement 9. Remove the bracket (A), the fuelfilter (B), the fuel 1. Remove the reartray (see page 20-71). g a u g e s e n d i n g u n i t ( C ) , t h e h o s e ( D ) , a n d t h e w i r e h a r n e s s ( E ) .
Page 343 Fuel Tank Replacement Removal 7, Disconnect both ABS rear wheel sensors2P connectors (A), and push the connectors out (B). 1 . R e m o v e t h e f u e l f i l l c a p . 2 .
Page 344 FuelSupply System Fuel Tank Replacement (cont'd) 13. Disconnect both parking brake cables (A), and 11. Remove the bolts from both ABS rear wheel sensor move them out of the way harness brackets (A). 6 x 1 . 0 m m 9.8 N.m {1.0 kgf.m,7.2 lbf.ft) NoTE: Left side is shown 12.
Page 345 15. Remove the flange bolt (A)from both rear dampers 17. Remove the muffler {A). ( B ) . - '')/,. '|d:<;.:'.f: 6 i . - / g - J : f : 10 x 1,25 mm 33 N.m {3.4 kgf.m,25 lbt.ftl NOTE: Left side is shown.
Page 346 Fuel Supply System Fuel Tank Replacement (cont'd) 19. Disconnect the fueltank vapor vent tube (A). then 21. Place a jack or other support under the rear remove the bolt (B) and the EVAP canister (C). suspension subframe (A). Remove the mounting bolts (B) and the rear suspension subframe (A).
Page 347 Fuel Gauge Sending Unit Test Installation NOTE: For the fuel gauge system circuit diagram, refer t o t h e G a u g e s C i r c u i t D i a g r a m ( s e e p a g e 2 2 - 4 4 ) . 1 .
Page 348 FuelSupply System Fuel Gauge Sending Unit Test Low Fuel Indicator Test (cont'd) Do the fuel gauge sendlng unit test (see page 1 1- 1 1 9 ) . 6. Turn the ignition switch OFF. . lf the system is OK, go to step 2. .
Page 349 Intake Air System Component Location Index ,,.,,,r,,?i-. AIR CLEANER Replacement, page 1 1-123 THROTTLE CABLE Adiustment, page I 1-'124 p a g e 1 1 - 1 2 5 R e m o v a l / l n s t a l l a t i o n , THROTTLE BOOY Test, page 11-122 Removal/lnstallat;on, paqe 1 1-126...
Page 350 hake Air System Throttle Body Test NOTE; Do not adjust the throftle stop screw. lt is preset al the factory. 1. Wlth the engine off, check the throttle cable operation.The cable should operate without b i n d i n g o r s t i c k i n g . .
Page 351 Air Cleaner Element Replacement CLEANER HOUSING COVER AIR CLEANER ELEMENT / , 1 ,// i ,. /// 2,1.:^ I l'.. , - l ' \ L|u",,..'/ t..:-+:'-.'::9 AIR CLEANER HOUSING 11-123...
Page 352 Intake Air System Throttle Cable Adjustment Check cable free play at the throttle linkage. Cable f r e e p l a y ( A ) s h o u l d b e 4 6 m m ( 3 / 1 6 - l i a i n . ) . l f f r e e p l a y ( A ) i s n o t w i t h i n s p e c ( 4 - 6 m m , 3 / 1 6 1 / 4 in.) loosen the locknut (B), turn the adjusting nut (C) until the free play (A) is as specified, then...
Page 353 Throttle Cable Removal/lnstallation 1. Fully open the throttle valve, then remove the 5. Remove the throttle cable (A) and the actuator throttle cable {A)from the throttle link (B). cable (B) from the accelerator pedal bracket (C). 6. Install in the reverse order of removal. 7.
Page 354 Intake Air System Throttle Body Removal/lnstallation NOTE; . Do not adiust the throttle stop screw. . After reassem bly, adju st the cru ise co ntrol actuator ca ble (see page 4-46), a nd the th rottle cable (see page 1 1- 124). .
Page 355 Throttle Body Disassembly/Reassembly 2 1 N m 10.21 kgf m. 1.5 lbt.ft) MAP SENSOR TP SENSOR 11-127...
Page 356 Catalytic Converter System DTC Troubleshooting DTC P0420: Catalytic System Efficiency Below Threshold NOTE: lf some of the DTCS listed below are stored at the same time as DTC P0420, troubleshoot those DTCS first, then recheck for DTC P0420. P0137, P0138: Secondary Heated oxygen Sensor (secondary H02S) (Sensor 2) P0141: Secondary H02S (Sensor 2) heater 1 .
Page 357 PCV System PCV Valve Inspection and Test 1 . Check the PCV valve (A), hoses (B), and connections for leaks or restrictions. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched {A)with your f i n g e r s o r p l i e r s .
Page 358 EVAP System Component Location Index (FTP} SENSOR FUEL TANK PRESSURE FUEL TANK VAPOR CONTROL VALVE Test, page l1'146 Replacement, page 11 147 : - - " ( t'",. :';':" - -.,,,, t ,.-;;../tttt EMISSION (EVAP) EVAPORATIVE | ..- - . . : BYPASS SOLENOID VALVE ' .
Page 359 Ait973X-041- 2. Turn the ignition switch ON(ll). 3. Monitor FTP sensor voltage with the Honda PG lvl Tester, or measure voltage between ECM c o n n e c t o r t e r m i n a l s A 2 9 a n d C 1 8 .
Page 360 4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 5. Monitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between body ground and EClvl connector terminal A29.
Page 361 4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . Is there about 5 V? 5. lvlonitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between body ground YES Replace the FTP sensor.I...
Page 362 EVAP System DTC Troubleshooting (cont'd) 11. Measure voltage between FTP sensor 3P connector Turn the ignition switch OFF. t e r m i n a l s N o . 2 a n d N o . 3 . Reinstall the fuel fill cap. FTP SENSOR 3P CONNECTOR Disconnect the FTP sensor 3P connector.
Page 363 DTC Pl456: EVAP Control System Leakage EVAP Canister Purge Valve Test (Fuel Tank Svstem) 3. Disconnect the vacuum hose from the EVAP purge joint (A), and connect a vacuum pump to the hose. The fuel system is designed to allow specified maximum vacuum and pressure conditions.
Page 364 EVAP System DTC Troubleshooting (cont'd) Check for continuity between EVAP canister purge EVAP Bypass Solenoid Valve Test v a l v e 2 P c o n n e c t o r t e r m i n a l N o . 2 a n d b o d y g r o u n d . 1 1.
Page 365 Turn the ignition switch ON (ll). 1 8 . Turn the ignition switch OFF. t t . 1 9 . Measure voltage between EVAP bypass solenoid Disconnect the EVAP bypass solenoid valve 2P t o . valve 2P connector terminal No. 1 and body ground. connector.
Page 366 A973X-041- While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring the voltage between ECM connector terminals A29 and C18, slowly pump the vacuum pump until the voltage drops to about 1.5 volts. Turn the ignition switch ON (ll).
Page 367 NO - Replace the fuel tank vapor control valve.I "clicks". then monitor the Tighten the fuel cap 3 5 t . FTP readings with the Honda PGM Tester. Start the engine, and let it idle for 5 minutes. ls there continuity? Check the FTP sensor reading.
Page 368 EVAP System DTC Troubleshooting (cont'dl DTC Pl457: EVAP Control System Leakage 2. Connect ECM connector terminal 46 to bodv (EVAP Canister Svstem) g r o u n d w i t h a j u m p e r w i r e . ECM CONNECTOR A I32P) The fuel system is designed to allow specified maximum vacuum and pressure conditions.
Page 369 Turn the ignition switch ON (ll). EVAP Bypass Solenoid Valve Test 10. Disconnect both vacuum hoses from the EVAP two Measure voltage between EVAP purge canister way valve {A), and connect a vacuum pump to the valve 2P connector terminal No. 1 and body ground. canister port on the two way valve.
Page 370 EVAP System DTC Troubleshooting {cont'd) EVAP Canister Vent Shut Valve Test 18. Disconnect the vacuum hose from the EVAP canister vent filter, and connect a vacuum pumo to the hose. 4973X-041-XX) ls therc continuity? YES- Go to step 16. NO-Replace the EVAP bypass solenoid valve (A) a n d o - r i n g s ( B ) .
Page 371 Turn the ignition switch ON (ll). While monitoring FTP sensor voltage with the J t . Honda PGM Tester, or measuring voltage between ls there battety voltage? ECM connector terminals A29 and C18, slowly p u m p t h e v a c u u m p u m p .
Page 372 While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring voltage between E C M c o n n e c t o r t e r m i n a l s A 2 9 a n d C 1 8 , s l o w l y T u r n t h e i g n i t i o n s w i t c h O N ( l l ) .
Page 373 EVAP Two Way Valve Test 5. Slowly pressurize the vapor line while watching the R e m o v e t h e f u e l f i l l c a p . gauge. The pressure should stabilize momentarily a b o v e 1 .
Page 374 EVAP System Fuel Tank Vapor Control Valve Test Valve Test SpecialTools Required V a c u u m p u m p / g a u g e , 0 3 0 i n . H g A 9 7 3 X - 0 4 1 - X X X X X 1 .
Page 375 Fuel Tank Vapor Control Valve Replacement 7. Connect a second vacuum pump to the fuel tank vapor signal hose (A). R e m o v e t h e f u e l t a n k ( s e e p a g e 1 1 - 1 1 5 ) . Remove the fuel tank vapor control valve (A) from t h e f u e l t a n k ( B ) .
Page 376 Pulsed Secondary Air Injection System Component Location Index AIR CONTROL VALVE VACUUM CONTROL SOLENOIO VALVE page 1 1-'153 Troubleshooting, AIR CONTROL VALVE page 1 1-153 Troubleshooting, ,/':: \i,\ - = - 'l-i '' ---=\-: ..'.':. \r.. ELECTRICAL CURRENT SENSOR AIR PUMP Removal/lnstallation, page 1 1-160 Removal/lnstallation, page'1 1-159 Troubleshootjng, page 1 1-156...
Page 377 DTC Troubleshooting DTC P0410: Air Pump Circuit Malfunction 1 1. At the left engine compartment wire harness side, measure voltage between air pump electrical 1 . R e s e t t h e E C I M ( s e e p a g e 1 1 - 4 ) . current sensol 2P connector terminal No.
Page 378 Pulsed Secondary Air Injection System DTC Troubleshooting (cont'd) 21. Connect large air pump relay 2P connector 14. Reconnect the air ou m o electrical current sensor. t e r m i n a l s N o . 1 a n d N o . 2 w i t h a i u m o e r w i r e . 15.
Page 379 Disconnect ECM connector A (32P). 29. Check for continuity between ECM connector terminal A28 and body ground 2 7 . Check for the continuity betvveen ECM connector terminal A28 and body ground. ECM CONNECTOR A I32PI A (32P) ECM CONNECTOR 12 13 17 1 8 19 20 21 12 13...
Page 380 Pulsed Secondary Air lnjection System DTC Troubleshootang (cont'd) 33. Check for continuity between large air pump relay 2 Turn the ignition switch OFF. P c o n n e c t o r t e r m i n a l N o . 2 a n d a i r p u m p 2 P D o t h e a i r p u m p r e l a y t e s t ( s e e p a g e 1 1 - 1 6 0 ) .
Page 381 DTC P0411: SecondaryAir Injection System 9. Disconnect the vacuum hose from the air control lncorrect Flow valve (A), and connect a vacuum gauge to the hose. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . 2.
Page 382 Pulsed Secondary Air Iniection System DTC Troubleshooting (cont'dl Disconnect the air control valve vacuum control 1 8 . Disconnect ECM connector A {32P), 1 4 . solenoid valve 2P connector. Check for continuity between air control valve 1 5 . Turn the ignition switch ON (ll).
Page 383 DTC Pl410: Air Pumo Malfunction 1 . R e s e t t h e E C M { s e e p a g e 1 1 - 4 ) . 2. Make sure the engine coolant temperature is over 32 'F (0"C) and below 158 'F (60'C) with the scan tool.
Page 384 Pulsed Secondary Air Iniection System DTC Troubleshooting (cont'd) DTC Pl415: Air Pump Electrical Current 8. Turn the ignition switch OFF. Sensor Circuit Low Voltage 9. Disconnectthe ECIM connector C (31P). 1 . R e s e t t h e E C M ( s e e p a g e 1 1 4 ) . 10.
Page 385 12. Check for continuity betlveen ECM connector 16. Measure voltage between body ground and ECM t e r m i n a l s C 2 4 a n d C 1 8 . connector terminal C24. ECM CONNECTOR C (31P) ECM CONNECTOR C {3IP} 9 10 2A 21...
Page 386 Pulsed Secondary Air lniection System DTC Troubleshooting (cont'd) DTC Pl416: Air Pump Electric Current Sensor Measure voltage between ECM connector Circuit High Voltage t e r m i n a l s C 1 8 a n d C 2 8 . C (31PI ECM CONNECTOR 1 .
Page 387 Air Pump/Air Pump Relay Removal/lnstallation Remove the front bumper (see page 20-92). R e m o v e t h e a i r p u m p ( A ) , a n d t h e a i r p u m p r e l a y ( B ) . 8 x 1.25 mm 22N.m 12.2 kgt m, 15 tbf.ft)
Page 388 Pulsed Secondary Air Injection System Air Pump Electrical Current Sensor Air Pump Relay Test RemovaUlnstallation Check for continuity between the terminals according to t h e t a b l e . 1. Pull away the left inner fender as necessary {see .
Page 390 Transaxle Glutch SpecialTools ..12-2 Component Location Index ........12-3 Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment ..... 12-4 Clutch MasterCylinder Replacement ..... 12-5 Slave Cylinder Replacement ..12-6 Cf utch Replacement ......12-l...
Page 391 Clutch SpecialTools Description Ref. No. Tool Number o) (a R i n g G e a r H o l d e r 1 00 or 07924-PD20003 07LAB-PVO0 Clutch Alignment Shaft 07LAF-PT00110 Attachment, 32 x 37 mm 07746-0010200 Driver 07749-0010000 R e m o v e r H a n d l e 0 7 9 3 6 - 3 7 1 0 1 0 0 .a )/...
Page 392 Gomponent Location Index CLUTCH PEOAL Adjustment, page l2-4 RESERVOIR RELEASE FORK M/T ASSEMBLY LOCK PIN CLUTCH LINE RELEASE FORK BOOT CLUTCH HOSE CLIP Replace. SLAVE CYLINDER Replacement, page 12-6 CLUTCH HOSE CLUTCH DISC Removal, page 12 7 s t e p I o n p a g e 1 2 - 1 1 l n s t a l l a t i o n , BANJO BOLT RELEASE BEARING...
Page 393 Glutch Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment 5. Turn the clutch pedal position switch {B) in an NOTE: . To checkthe clutch pedal position switch (see page 4- additional 3/4 to 1 turn. 4 7 ) . 6.
Page 394 Clutch Master Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle; it may 4. Bemove the clutch master cylinder (A). damage the paint; if brake fluid does contact the paint. wash it off immediately with water -.--1i:,.'1. 1. The brake fluid may be sucked out through the top ,-_-::-:-:=---_-,;.,1,'a) of the master cylinder reservoir (A) with a syringe.
Page 395 . Refill the clutch master cylinder with fluid when d o n e . . Always use only Honda DOT 3 brake fluid. . Confirm clutch operation, and check for leaking f l u i d . (Brake Ass€mbly Lubel A p p l y s u p e r h i g h t e m p u r e a g r e a s e t o t h e t i p o f t h e s l a v e c y l i n d e r r o d .
Page 396 Clutch Replacement 5. Inspect the fingers of the diaphragm spring (A) lor Special Tools Required . Clutch alignment shaft 07LAF-PToo110 wear at the release bearing contact area. . R e m o v e r h a n d l e 0 7 9 3 6 - 3 7 1 0 1 0 0 .
Page 397 Glutch Clutch Replacement (cont'd) 8. Remove the clutch disc and sDecial tools. 11. Measure the rivet depth from the lining surface (A) to rivets (B), on both sides. lf the rivet depth is less than the service limit, replace the clutch disc. Standard lNew): 1.2 1.7 mm {0.047-0.067 in.) 0.2 mm (0.00e in.l...
Page 398 Flywheel Replacement Flywheel lnspection 1. lnspect the ring gear teeth for wear and damage. 1 . I n s t a l l t h e s p e c i a l t o o l . 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
Page 399 Clutch Clutch Replacement (cont'dl Release Bearing Inspection 4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface. Check the release bearing for excessive play by spinning it by hand.
Page 400 Clutch Disc and Pressure Plate Installation 6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent w a r p i n g t h e d i a p h r a g m s p r i n g . 1 .
Page 401 Transaxle Countershaft Reassembly ..13-41 Manual Transmission Secondary Shaft Disassembly ... 13-45 13-2 S o e c i a l T o o l s Secondary Shaft Inspection ..13-45 Transmission Fluid Inspection Secondary Shaft Reassembly ..13-46 13-3 a n d R e o l a c e m e n t ..... 13-3 Shift Forks Clearance Back-up Light Switch Test ..
Page 402 Manual Transmission SpecialTools Ref.No. Tool Number Description " q 0 7 G A J - P G 2 0 1 1 0 M a i n s h a f t H o l d e r "(9 07GAJ-PG20130 M a i n s h a f t B a s e 07JAB-0010204 H o l d e r H a n d l e 07LAD-PW5060'r...
Page 403 Back-Up Light Switch Test Transmission Fluid Inspection and Replacement 1. Disconnectthe back-up light switch (A) 2P connector, 1 . P a r k t h e v e h i c l e o n l e v e l g r o u n d , a n d t u r n t h e e n g i n e O F F .
Page 404 Manual Transmission Gearshift Mechanism Replacement t'vER KN.B .ttt"''n LOCKNUT 1 0 x 1 . 2 5 m m 9 N.m {0.9 kgf.m,7lbf ft) BOOT HOLDER SEIFT BOOT //-'/'-" SHIFT LEVER BOOT C 6 x 1 . 0 m m 9.8 N m 11.0 kgf m, 7.2tbf.tt) SHIFT LEVER SPRING '"...
Page 405 Transmission Removal Remove the center console (seepage20-76). NOTE: Use fender covers to avoid damaging painted surfaces, Remove the boot holder {A) and the shift boot (B). 1 . D i s c o n n e c t t h e n e g a t i v e ( ) c a b l e f i r s t , t h e n t h e positive (+ ) cable from the battery.
Page 406 Manual Transmission Transmission Removal (cont'd) 6 . R e m o v e t h e a i r c l e a n e r h o u s i n g a s s e m b l y . Remove the alternator-comDressor belt and the alternator (see page 4-25).
Page 407 14. Disconnect the TDC1 (A) and TDC2 {B) sensor 12. Remove the heat shield (A), then remove the connectors. exhaust manifold cover. ' 1 5 . R e m o v e t h e s D l a s h s h i e l d . 13.
Page 408 Manual Transmission Transmission Removal (cont'dl 16. Disconnect the 2P connector (A) from the steering 1 9 . Disconnect the heated oxygen sensor (HO25) {A), secondary heated oxygen sensor {secondary HO2S) (B), and the back-up light switch (C) connectors, then remove the wire harness from the transmission.
Page 409 24, Remove the release fork boot (A), then carefully 21. Remove the exhaust manifold bracket (A) and the remove the slave cylinder (B). Do not operate the e x h a u s t m a n i f o l d ( B ) . clutch pedal once the slave cylinder has been removed.
Page 410 Manual Transmission Transmission Removal (cont'dl Remove the five lower transmission mounting Lower the front subframe in until it touches the four bolts. loosened mounting bolts. Place the floor jack under the transmission, and remove the three transmission rear mount bolts. 1 .
Page 411 33. Remove the three upper tra nsm ission mounting bolts. Pull the transmission away from the engine until it clears the mainshaft, then lower the transmission o n t h e j a c k . Remove the transmission rear mount from the t r a n s m i s s i o n h o u s i n g .
Page 412 Manual Transmission Transmission Disassembly Exploded View-Rear Cover @)--"'' x_=----' -"'t-': 7*_-3 =--D ----=P=\ -\.1) t--rr-.._ --=-g t\if5 8'... q- ,/-- f1 \ l l . ' o*--.-- \a'o 13-12...
Page 413 (D 27 mm LOCKNUT O 8 mm SPECIAL BOLT Replace. 31 N.m {3.1 kgf.m,22lbf.ttl '162 * 0 - 162 N.m (16.5 - 0 * 16.5 kgt.m, @ SHIFT LEVER HOUSING 1 1 9 * 0 * ' l 1 9 l b f . f t l (} 6 mm FLANGE BOLT O 27 mm SPRING WASHER 12 N m 11.2 kgf.m,8.7 lbf.ft)
Page 414 Manual Transmission Transmission Disassembly (cont'd) Exploded View-Transmission Housing @---'-r..^ ,,--t\ o \-:) t //// rA d , ( 9 H ,./ G) @ x\,, -cr\\-_- 13-14...
Page 415 .]) 29 mm LOCKNUT {Left-hand threads) Q]) FILLER PLUG Replace. 44 N.m (4.5 kgt.m,33lbf ft) 172 *0 * 172 N.m (17.5 - 0 * 17.5 kgf,m, @ WASHER 127-0-127lbf.ltl Replace. (2) 29 mm SPRING WASHER @ SET SCREW O 30 x 64x20 mm NEEDLE BEARING @ SPRING L.
Page 416 Manual Transmission Transmission Disassembly (cont'd) Exploded View-Clutch Housing 61 - \ 1-----.-' S:.-------t trE) ^Qg- -.'A ^-- -,--@ @--=-ssR-'-, " e.., €- -.-e FJ-.- *--"-"*9 1 3 - 1 6...
Page 417 O coUNTERSHAFTASSEMBLy ( l 8 x , l 0 P l N O 68 mm SNAP RING (} SELECT RETURN SPRING 1O MAINSHAFT ASSEMBLY @ CLUTCH RELEASE HANGER O 64 mm SPRING WASHER ED RELEASE HANGER SPRING O otL GUrDE TUBE (} 8 mm SPECIAL BOLT 27 N.m {2.8 kgf m.20 lbf.ft} G] REVERSE SHAFT HOLDER...
Page 418 Manual Transmission Transmission Disassembly (cont'd) 3. Remove the I mm flange bolts in a crisscross Special Tools Required . F l a n g e h o l d e r 0 7 R A B - T B 4 0 1 0 8 pattern in several stePs, .
Page 419 6. Raise the 27 mm locknut tab from the qroove in the 8. Remove the 27 mm locknut (A), spring washer (B). secondarv shaft. b a c k - u p r i n g ( C ) , a n d O - r i n g { D ) , Install the special tool onto the companion flange, and loosen the 27 mm locknut.
Page 420 Manual Transmission Transmission Disassembly {cont'd} 13. Remove the bearing outer race (A) and shim (B) 1 0 . R e m o v e t h e o i l s e a l . from the rear cover (C). 1 l.
Page 421 Transmission Housing Removal 3 . I n s t a l l t h e s p e c i a l l o o l o n t o t h e m a i n s h a f t s p l i n e , and loosen the 29 mm locknut (left-hand threads).
Page 422 Manual Transmission Transmission Disassembly (cont'd) Remove the needle bearing (A) using a 7. Remove the 6 mm flange bolts, then remove the oil pump plate (A), spring, steel ball, and oil pump c o m m e r c i a l l y a v a i l a b l e b e a r i n g p u l l e r ( B ) a s s h o w n . rotors (B).
Page 423 '12. Remove the bearing outer race (A) usingthe special tool as shown, then remove the shim (B) a n d o i l g u i d e p l a t e S . 3/8" .16 SLIDE HAMMER (commerciallv available) 07736-A010008 Remove the 8 mm tlange bolts in a crisscross oattern in several steos.
Page 424 Manual Transmission Transmission Disassembly (cont'dl Remove the circlip (A). then remove the suction 1 6 . R e m o v e t h e o i l g u i d e t u b e ( A ) a n d m a g n e t ( B ) . 1 4 .
Page 425 1 8 . R e m o v e t h e 1 0 m m f l a n g e b o l t , t h e n r e m o v e t h e I 2 1 .
Page 426 Manual Transmission Transmission Disassembly (cont'dl Remove the 6 mm flange bolts and release bearing g u i d e ( A ) . Remove the I mm special bolts, clutch release h a n g e r ( B ) a n d r e l e a s e h a n g e r s p r i n g ( C ) . 2 7 .
Page 427 Mainshaft Assembly Clearance Inspection 2. lvleasure the distance of the distance collar. NOTE: . lf replacement is required, always replace the . lf distance is notwithin the standard, replace the synchro sleeve and hub as a set. distance collar with a new one .
Page 428 Manual Transmission Mainshaft Assembly Clearance Inspection {cont'd) 4. Measure the clearance between 4th gear (A) and 6. fMeasure the thickness of 4th gear. d i s t a n c e c o l l a r ( B ) . l f t h e c l e a r a n c e i s m o r e t h a n t h e service limit, go to step 5.
Page 429 10. Measure the clearance between 6th gear (A) and 8, Measure distance O on the distance cotrar. the mainshaft (B). lf the clearance is more than the service limit, go to step 11. . l f d i s t a n c e O i s n o t w i t h i n t h e s t a n d a r d , r e p l a c e the distance collar with a new one.
Page 430 Manual Transmission Mainshaft Disassembly Support ball bearing (A) with a commercially Remove the 42 x 47 x 30.5 mm needle bearing, available bearing separator, and remove the ball distance collar,sth gear, synchro ring, and synchro bearing using a press as shown. s p r i n g .
Page 431 Mainshaft Inspection 3. Inspect for runout by supporting both ends of 1. Inspect the gear surface and the bearing surface for mainshaft. Rotate the mainshaft two complete w e a r a n o o a m a g e . revolutions when measuring the runout.
Page 432 Manual Transmission Mainshaft Reassembly Exploded View ANGULAR BALL BEARING Check for wear and operation. Thin edge of the outer Note the direction of race faces 3rd gear installation. RING /,,,sYNcHRo GEAR SYNCHRO '//,,.3RD SPRING 3 5 x 4 0 x 3 5 m m 5TH/6TH SYNCHRO NEEOLE BEARING...
Page 433 4. Press the 5th/6th synchro hub using the specialtool Special Tools Required as shown. After installing, checkthe operation of . D r i v e r , 4 0 m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 the 5th/6th svnchro hub and sleeve.
Page 434 Manual Transmission Mainshaft Reassembly (cont'd) Installthe 3rd/4th synchro hub (A) and sleeve (B) by 9. Install the double cone synchro (A)and synchro aligning the stops (C). sprlng (B) as shown. 1 0 . I n s t a l l t h e d i s t a n c e c o l l a r ( A ) , 3 5 x 4 0 x 3 5 m m Press the 3rd/4th synchro hub using the special tool n e e d l e b e a r i n g ( B ) , a n d 3 r d g e a r ( C ) .
Page 435 Shift Arm Rod Assembly Disassembly/Reassembly 1 1 . I n s t a l l t h e a n g u l a r b a l l b e a r i n g ( A ) w i t h t h e t h i n edge of the outer race facing 3rd gear (B).
Page 436 Manual Transmission Gountershaft Assembly Glearance Inspection NOTE: lf replacement is required, always replace the 2. Measure the thickness of 2nd gear. synchro sleeve and hub as a set. . l f t h e t h i c k n e s s o f 2 n d g e a r i s l e s s t h a n t h e service limit, replace 2nd gear with a new one.
Page 437 6. Measure the clearance between reverse gear (A) 4. Measure distance O on the distance cottar. and the distance collar {B). lf the clearance is more than the service limit, go to step 7. . lf distance O is notwithinthe standard, replace the distance collar wilh a new one.
Page 438 Manual Transmission Countershaft Assembly Clearance Countershaft Disassembly lnspection (cont'dl 1. Remove the needle bearing. 8. fvleasure the thickness of reverse gear. . lf the thickness of reverse gear is less than the service limit, replace reverse gear with a new one. .
Page 439 6. Remove the ball bearing using a press as shown. 3. Raise the 27 mm locknut tab from the groove in the countershaft. PRESS 7. Remove the remaining parts from the countershaft. 4. Securely clamp the 4th and 5th gears in a bench vise with wood blocks (A).
Page 440 Manual Transmission Gountershaft lnspection 1. Inspect the gear surface and the bearing surface for 3. Inspectfor runout by supporting both ends of w e a r a n d d a m a g e . countershaft. Rotate the countershaft two complete revolutions when measuring the runout.
Page 441 Countershaft Reassembly Exploded View lST/2ND SYNCHRO HUS /R\ i.wj------=..-34 x s7 x 20 mm sYNcHRo SPRTNG :|::513;:*|.""0 DOUBLE CONE SYNCHRO FRICTION DAMPER lST GEAR 5 1 x 5 7 x 2 3 m m NEEDLE BEARING Check for wear and operation.
Page 442 Manual Transmission Countershaft Reassembly (cont'd) Special Tools Required 4 . I n s t a l l t h e s y n c h r o s p r i n g ( A ) a n d d o u b l e c o n e .
Page 443 I n s t a l l t h e 5 l x 5 7 x 2 3 m m n e e d l e b e a r i n g , d i s t a n c e 1 0 .
Page 444 Manual Transmission Gountershaft Reassembly (cont'd) 14. Stake the locknut tab into the groove. 16. lnstall the needle beafl ng. bearing inner race (A) using the 1 5 . l n s t a l l t h e n e e d l e a press as shown.
Page 445 Secondary Shaft Disassembly Secondary Shaft Inspection '1. Inspect the gear surface and the bearing surface lor Remove the tapered roller bearings using a commercially available bearing separator and a w e a r a n d d a m a g e . press as shown.
Page 446 Manual Transmission Secondary Shaft Inspection (cont'd) Secondary Shaft Reassembly Special Tools Requir€d lnspect for runout by supporting both ends of . Attachment. 45 mm 07947-6890300 secondary shaft. Rotate the secondary shaft two . Bearing attachment 07LAD-PW50601 complete revolutions when measuring the runout. lf the runout is more than the service limit, replace ' 1 .
Page 447 Shift Forks Clearance Inspection NOTE: lf replacement is required. always replace the 3. Measure the clearance between each shift fork, reverse shift piece and shift arm A. lf the clearance synchro sleeve and hub as a set. exceeds the service limit, go to step 4. 1.
Page 448 Manual Transmission Shift Forks Clearance Inspection (cont'dl Measure the clearance between the 1-2 shift lever REVERSE SHIFT PIECE and each shift fork and shift piece. lf the clearance exceeds the service limit, go to step 6. Standard: 0-0./r mm (0-0.016 in.l Service Limit: 0.5 mm (0.020 in.) 6 .
Page 449 Shift Forks Disassembly/Reassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. s-6 sHtFT 3-4 SHTFT 1.2 SHIFT FORK !=n6.+ 3-,1SHIFT PIECE x 22 SPRING PIN Replace. REVEFSE SHIFT PIECE 13-49...
Page 450 Manual Transmission Synchro Ring and Gear Inspection 1. Inspect the inside of the synchro ring (A) for wear. 4. Inspect the gear hub thrust surface 1A) for wear. Inspect the cone surface (B) for wear and Inspect the synchro sleeve teeth and matching rougnness, teeth on the synchro ring (B) for wear (rounded off).
Page 451 Synchro Sleeve and Hub lnspection and Reassembly Double Cone Synchro-to-Gear Clearance Standard: O: Outer Synchro Fing to Synchro Cone 1. lnspect gear teeth on all synchro hubs and synchro 1st,2nd, gear:0.70 1.09 mm (0.028 0.043 in.) sleeves for rounded off corners, which indicate 3rd.4th gear:0.90 1.39 mm (0.035 0.055 in.) w e a r .
Page 452 Manual Transmission Oil Pump Glearance Inspection 3 . M e a s u r e t h e a x i a l c l e a r a n c e o n t h e p u m p r o t o r . l f 1 .
Page 453 Secondary Shaft Preload Adjustment 1 . I n s t a l l t h e o i l g u i d e p l a t e S , s h i m ( A ) a n d t h e 5.
Page 454 Manual Transmission Mainshaft Thrust Clearance Adiustment 5. Seat the mainshaft fully by tapping its end with a Special Tools Required . M a i n s h a f t h o l d e r 0 7 G A J ' P G 2 0 1 1 0 p l a s t i c h a m m e r .
Page 455 Transmission Reassembly 82 mm Shim Special Tools Required . Driver 07749-0010000 . Attachment, 42 x 47 mm 07746-0010300 Parts Number Thickness 23931-PR8-F000 0 . 6 0 m m ( 0 . 0 2 3 6 i n . Attachment,62 x 68 mm 07746-0010500 23932-PR8-F000 0 .63 mm (0.0248 .
Page 456 Manual Transmission Transmission Reassembly (cont'd) 6 . I n s t a l l t h e 1 - 2 s h i f t p i e c e . Install the thrust washer (A) and 64 mm spring washer (B).
Page 457 9 . I n s t a l l t h e s h i f t r o d ( A ) i n t o t h e i n t e r l o c k a s s e m b l y 12.
Page 458 Manual Transmission Transmission Reassembly (cont'd) Install the oil pump strainer (A), suction guide (B), 1 7 . I n s t a l l t h e o i l g u i d e p l a t e S a n d s h i m { A ) , t h e n t 5 .
Page 459 21. Apply liquid gasket (P/N 08718-0001) to the threads 1 9 . I n s t a l l t h e 1 4 x 2 0 d o w e l p i n s ( A ) , t r a n s m i s s i o n of the set screws (A), then install the steel balls and h o u s i n g ( B ) .
Page 460 Manual Transmission Transmission Reassembly {cont'dl Installthe oil pump outer rotor S, steel ball (A), 27. Installthe needle bearing (A) on the countershaft s p r i n g { B ) , o i l p u m p p l a t e ( C ) . using the special tool as shown.
Page 461 31. Install the oil pump gear and oil pump gear shaft. 29. Install the special tool on the mainshaft, then tighten the 29 mm locknut (left-hand threads) to the specified value. Torque 172- 0 -- 172 N.m ( 1 7 . 5 - 0 - * 1 7 . 5 k 9 1 . m , 127- o - 127 lbf.ttl .
Page 462 Manual Transmission Transmission Reassembly (cont'dl Rear Cover Installation 3. Installthe secondary shaft assembly into the rear cover, NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricate to any contact su rfaces. 1 . I n s t a l l t h e b e a r i n g o u t e r r a c e ( A ) u s i n g t h e s p e c i a l tools as shown.
Page 463 7 . I n s t a l l t h e O - r i n g ( A ) , b a c k - u p r i n g ( B ) , s p r i n g 5 .
Page 464 Manual Transmission Transmission Reassembly (cont'd) '11, 9. Stake the 27 mm locknut tab into the oroove. Remove the dirty oil fromthe rear cover sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil r e a K a g e .
Page 465 1 5 . I n s t a l l t h e s h i f t l e v e r h o u s i n g . 13. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
Page 466 Manual Transmission Transmission Installation 1 . I n s t a l l t h e t r a n s m i s s i o n r e a r m o u n t l A i . 4 .
Page 467 9. Place a floor jack under the front subframe and the 7 . I n s t a l l t h e w i r e h a r n e s s ( A ) t o t h e t r a n s m i s s i o n , then connect the Dick-uo sensor connector (B).
Page 468 Manual Transmission Transmission Installation (cont'd) Install the propeller shaft (see page 16-18). Remove the shop towel, and install the release fork 1 5 . onto the release hanger, Install the gasket {A), exhaust manifold (B), and the t o . Apply super high urea greese (P/N 08798-9002)to exhaust manifold bracket (C).
Page 469 20. Reconnect the torque sensor 3P connector (A), and 18. Install the wire harness (A) onto the transmission, i n s t a l l t h e w i r e h a r n e s s c l a m p ( B ) . then connect the heated oxygen sensor (H02S) (B), secondary heated oxygen sensor (secondary HO2S) {C), and the back-up light switch (D)
Page 470 Manual Transmission Transmission lnstallation (cont'd) 23. Connect the TDC1 (A) and TDC2 (B) sensor 25. Install the heat shield. connectors. Installthe upper intake manifold bracket mounting 6 x 1 . 0 m m bolt (A) and upper starter motor mounting bolt (B). 9.8 N.m (1.0 kgf.m, 7.2lbf.ftl Connect the hose (C) to the suction varve.
Page 471 3 0 . I n s t a l l t h e a i r c l e a n e r h o u s i n g a s s e m b l y . 27. Install the Ay'C compressor, then connect the 1 P connecror.
Page 472 Manual Transmission Transmission Installation (cont'd) Install the battery. Connect the positive (+ ) cable 32. Installthe shift boot and the boot holder. first, then the negative ( ) cable to the battery. Check the transmission fluid {see page l3-3). 3 7 . Test-drive the vehicle.
Page 473 Transaxle Rear Differential ..... 15-2 Soecial Tools Precautio ns for Torsen Type Limited Slip Differential (LSD) ......... 15-3 Torsen Type Limited Slip Differential (LSD) Operation Check ......15-3 ... 15-4 System Description ....Differential Oil Inspection and Replacement ..... 15-6 Differential Removal ......
Page 474 Rear Differential SpecialTools Ret. No. Tool Number Description 07JAD-P190100 Oil Seal Driver 07JAB-001020A H o l d e r H a n d l e 07LAD-PW50601 Attachment, 40 x 50 mm l.D. 07MAC-S100200 Ball Joint Remover. 28 mm 07MAD-PR90100 Attachment, 45 x 55 mm l.D. 07NAD,PX40100 Attachment, 78 x 80 mm OTRAB-TB4O,1OB...
Page 475 Precautions for Torsen Type Torsen Type Limited Slip Limited Slip Differential (LSD) Differential (LSDI Operational Check . The Torsen differentials are mechanical limited slip The Torsen type limited slip differential (LSD) differentials which deliver the available Dower to the distributes optimum power between the two driving wheels and axles with the most grip or resistance as axles according to the difference in torque demanded the engine torque output increases.
Page 476 Rear Differential System Description The vehicle uses the Torsen type limited slip differential (LSD) which is rubber mounted to the sub-frame Construct'ron . The Torsen type LSD assembly consists of the two side gears, eight planetary gears, three side washers, tvvo center washers, a gear case cover and a gear case.
Page 477 Operation . Straight-road driving The differential carriel and gears rotate together as a unit when both wheels rotate at the same speed. Turning eflort from the final driven gears are directlv transmitted to both wheels. . When rounding a curve When the vehicle rounds a curve, the differential allows the outer wheel to rotate a little faster than the Inner wheel.
Page 478 Rear Differential Differential Oil Inspection and Replacement 5 . C l e a n t h e d r a i n p l u g , t h e n r e i n s t a l l w i t h a n e w With the vehicle on level ground, inspect the w a s h e r , a n d r e f i l l t h e d i f f e r e n t i a l w i t h t h e differential oil with engine OFF.
Page 479 Differential Removal Special Tools Required 5. Make a reference marks (A) across the inboard ioint Ball joint remover,2S mm 07N4AC-S100200 (B) and the rear differential (C). 1. Make a reference marks across the propeller shaft, the transmission, and the rear differential, then remove the propeller shaft (see page 16-17).
Page 480 Rear Differential Diff erential Removal (cont'd) 1 1. Remove the four differential mount A mounting 8. Remove the canister cover. bolts, '12. Lower the rear differential onthefloorjack. Place a floor jack under the rear differential Remove the four differential mount bracket B 1 0 .
Page 481 Differential Case Assembly Removal and Installation 1. Remove the output shafts {A) from the differential 3. Remove the dirt and oilfrom the sealing surfaces. c a s e a s s e m b l y u s i n g t h e p r y b a r s ( B ) . Apply liquid gasket (P/N 08718-0001) to the sealing surface.
Page 482 Rear Differential OilSeal Replacement 3 . l n s t a l l t h e o i l s e a l u s i n g t h e s p e c i a l t o o l s a s s h o w n . Special Tools Required Oil seal driver 07JAD-P190100 07JAO-P190100...
Page 483 Backlash Inspection 1. Remove the output shafts and differential case 4. Measure the backlash of the ring gear, assembly (see page 15-9). . S e t t h e d i a l g a u g e t i p a t a r i g h t a n g l e t o t h e r i n g 2 .
Page 484 Rear Differential Differential Disassembly Exploded View I O D t \ l ,,df#w\, :\g/ X \ w \ \ , , w^@m '@ (fr'a BGA. f l t * \ rP,.l \, @ @ @ @ ) ?q6) \ (i*?
Page 485 A:24 N.m 12.4 kgf m, 17 lbf.ft) B: 45 N.m (4.6 kqt.m,33 lbt.ft) C:22 N.m {2.2 kgf.m, '16lbf.ftl D: 75 N.m (7.6 kgt.m,55lbf.ft) E: 11 N m (1.1 kgf.m.8lbt.ft) O LOCKNUT @ BEARING CAP Reolace. @ LOCK PLATE _ 127-284 N.m (r3.0-29.0 kgf.m, 94-210 lbf.ftl @ OUTPUT SHAFT (a)DRIVE PINION WASHER @CLIP...
Page 486 Rear Differential Differential Disassembly (cont'dl 3. Remove the output shafts. Special Tools Bequired . H o l d e r h a n d l e 0 7 J A B - 0 0 1 0 2 0 A . C o m p a n i o n J l a n g e h o l d e r 0 7 R A B ' T 8 4 0 1 0 8 1.
Page 487 7. Remove the adjustment screws (A), bearing outer 5. Make a mark on the bearing cap. adjust screw, and races (B), and Torsen LSD assembly (C). differential carrier case. Remove the lock plates and beari n g c a p s . 8.
Page 488 Rear Differential Differential Disassembly (cont'dl 1 1. Remove the bearing outer race (A), tapered roller Remove the companion flange using a bearing (B), thrust washer (C), and oil seal (D) from commercially available bearing puller as shown. the differential carrier housing. Remove the drive pinion (A) and pinion spacer (B) 1 0 .
Page 489 13. Remove the tapered roller bearing (A) andthrust 15. Remove the ten mounting bolts in a crisscross washer (B) from the drive pinion (C) using a pattern in several steps, then remove the ring gear. commercially available bearing separator and a Dress as snown.
Page 490 Rear Differential Differential Disassembly (cont'd) Differential Reassembly Special Tools Required 1 7 . R e m o v e t h e o i l s e a l s . . Attachment, 40 x 50 mm l.D. 07LAD-PW50601 . D r i v e r , 4 0 m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 .
Page 491 5. Installthe bearing outer races {A) into the 3. Install the tapered roller bearing using the special differential carrier housing using the special tools tools and a Dress as shown. a s s h o w n , lnstall the standard thrust washer 3.47 mm {0.1366 in.) (A) onto the drive pinion (B).
Page 492 Rear Differentaal Differential Reassembly (cont'd) 6. Apply lubricant to the tapered roller bearing, then 8 . I n s t a l l t h e o i l s e a l u s i n g t h e c o m p a n i o n f l a n g e a n d install the drive pinion and pinion spacer into the soecial tool as shown.
Page 493 1 2 . T i g h t e n t h e l o c k n u t t o 1 2 7 N . m ( 1 3 . 0 k g f . m . 1 0 . I n s t a l l t h e s p e c i a l t o o l t o t h e c o m p a n i o n f l a n g e , then tighten the locknut to 20 N.m (2.0 kgf.m, 94 lbf.ft), then remove the sDecial tool.
Page 494 Rear Differential Differential Reassembly (cont'dl Install the Torsen LSD assembly (A), bearing outer 16. Measure the backlash of the ring gear. 1 4 . races (B), adjustment screws (C) onto the Set the dial gauge tip at a right angle to the ring differential carrier housing.
Page 495 20. Check the tooth contact, and adjust it if needed. 17. Tighten the bearing cap mounting bolts. 45 N.m {4.6 kgt.m,33lbf.ftl . Toe Contact: Use a thinner thrust washer to move the drive pinion away from the ring gear. . Heel Contact: Use a thicker thrust washer to move the drive pinion toward from the ring gear.
Page 496 Rear Differential Differential Reassembly (cont'dl 21. Rotate the Torsen LSD assembly several timesto Heel Contact assure proper tapered roller bearing contact. Measure the Torsen LSD assembly preload using t h e p u s h / p u l l g a u g e . .
Page 497 25. Remove the dirty oilfrom the differential case 2 3 . I n s t a l l t h e o i l s e a l u s i n g t h e s p e c i a l t o o l s a s s h o w n . sealing surface.
Page 498 Rear Differential Differential Reassembly (cont'd) Differential lnstallation 2 7 . Tighten the 10 mounting bolts in a crisscross Install the right and left differential mount bracket A to the rear differential (see page 15-29). pattern in several steps. Place the rear differential on the floor jack, and 24 N.m {2.4 kgf.m, 17 lbf.ft) raise it to the mounting level.
Page 499 6. Install the rear suspension stiffener, 4. Installthe right and left differential mountbracketA mounting bolts. 10 x 1.25 mm 6 x 1 . 0 m m 4 5 N m 1 4 . 6 k g f . m , 1 0 x 1 .
Page 500 Rear Differential Differential Installation (cont'dl Install the ball joints onto the lower arms (A), then installthe castle nuts (B) and new cotter pins. NOTE: Make sure the ball joint boot is not damage or cracks. .a=:\ \mr{-B 69-78 N.m 6< {7.0-8.0 kgf.m.
Page 501 Differential Mount Replacement NOTE: lf the installing the rear differential and mount assembles, tighten the differential mount bracket B mounting nuts first, then the differential mount bracket A mounting bolts, 12 x 1,25 mm 12 x'1.25 mm 64 N.m 16.5 kst.m, 47 lbt.ftl 75 N.m (7.6 kgf.m,55lbt.ft) 10 x 1.25 mm 4 5 N m...
Page 502 Transaxle Driveline/Axle ..... 16-2 SpecialTools ......16-3 Driveshaft lnsoection ......16-3 Driveshafts Removal 16-5 Driveshafts Disassembly ........16-8 Driveshafts Reassembly ...... 16-15 Driveshafts lnstallation ....16-16 Propeller Shaft Inspection 16-17 Propeller Shaft Removal ....16-18 Propeller Shaft Installation ..........
Page 503 Driveline/Axle SpecialTools Ref. No. Tool Number Descriotion 0TrvtAc-s100200 B a l l J o i n t R e m o v e r , 2 8 m m 07xAc-001020A Threaded Adaoter. 24 x 1.5 mm 16-2...
Page 504 Driveshafts Removal Driveshaft Inspection Check the inboard boot (A) and outboard boot (B) Special Tools Required on the driveshaft (C) for cracks, damage, leaking Balljoint remover, 28 mm 07MAC-S100200 grease, and loose boot bands (D). lJ any damage is found, reDlace the boot and boot bands. 1.
Page 505 Driveline/Axle Driveshafts Removal (cont'dl 7. Remove the ABS sensor harness (A) from the 1 1 . P u l l t h e k n u c k l e o u t w a r d , a n d r e m o v e t h e driveshaft outboard joint from the wheel hub using u p p e r a r m , a plastic hammer.
Page 506 Driveshafts Disassembly 2 . M a k e a m a r k ( A ) o n e a c h r o l l e r ( B ) a n d i n b o a r d j o i n t Special Tools Required .
Page 507 Driveline/Axle Driveshafts Disassembly (cont'd) Outboard Joint Side: Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 1. Pry up the three tabs (A)with a screwdriver, then lift up the end of the band. Be careful not to damage the boot.
Page 508 3. Wipe offthe grease to expose the driveshaft and 8. Remove the stop ring from the driveshaft. the outboard joint inner race. 4. Make a mark (A) on the driveshaft {B) at the same position of the outboard joint end (C). Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.
Page 509 Driveline/Axle Driveshafts Reassembly Exploded View clRcLlP INBOARD BOOT o99 lt Use the grease included in the inboard boot set. ," spioen g Use the grease included in the inboard boot set. --------_l STOP RING Replace. DRIVESHAFT tu@a t----..\ BANDS - --.1 OUTBOARD JOINT 16-8...
Page 510 Special Tools Required 5. Fit the rollers (A) onto the spider (B) asshown,and . Boot band tool, KD-3191 or equivalent, commercially note these items; a v a i l a b l e . Boot band pincers, Kent-Moore J-35910 or equivalent, .
Page 511 Driveline/Axle Driveshafts Reassembly (cont'd) 10. lnstall the boot bands with the band end toward to 7. Fit the inboard joint onto the driveshaft, and note front of the vehicle. these items: . Reinstallthe inboard ioint onto the driveshaft by a l i g n i n g t h e m a r k s ( A ) o n t h e i n b o a r d j o i n t a n d the rollers.
Page 512 13. Thread the free end ofthe band through the nose 16. Unwind the boot band tool, and cut off the excess free end ofthe band to leave a 5 .. 10 mm (0.2 0.4 section ofthe commercially available boot band tool KD-3191 or equivalent (A), and into the slot on in.)tail protruding from the clip.
Page 513 Driveline/Axle Driveshafts Reassembly (cont'dl 5. lnse rt the driveshaft (A) into the outboard joint (B) Outboard Joint Side: until the stop ring (C) is close to the joint. 1 . Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the outboard boot. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 Install the new ear clamp band (B) and outboard...
Page 514 7. Check the alignment of the paint mark (A) with the 9. Adjust the length of the driveshafts to the figure o u t b o a r d j o i n t e n d ( B ) . below, then adjust the boots to halfway between full compression and full extension.
Page 515 Driveline/Axle Driveshafts Reassembly (cont'd) Check the clearance between the closed ear portion Set the new ear clamp band (A) by threading the 1 1 . of the band. lf the clearance is not within the tab (B) into holes (C) of the band. standard.
Page 516 Driveshafts Installation 1 . P u l l t h e k n u c k l e o u t w a r d . a n d i n s t a l l t h e o u t b o a r d 3.
Page 517 Driveline/Axle Driveshafts Installation (cont'dl Propeller Shaft Inspection Install a new spindle nut (A), then tighten the nut. 1 . Shift into neutrai position. After tightening, use a drift to stake the spindle nut Raise the vehicle off the ground, and suppon it with shoulder (B) against the driveshaft.
Page 518 Propeller Shaft Removal Raise the vehicle off the ground, and make sure it's 5. lMake a reference mark (A) across the propeller shaft (B) and the rear differentialflange (C). securely supported. Remove the propeller shaft protector. 't-rt, Make a reference mark (A) across the propeller shaft (B) and the transmission flange (C).
Page 519 Driveline/Axle Propeller Shaft Installation ' t . 3. Installthe propeller shaft protector (A). Install the propeller shaft (A) onto the rear differential (B) by aligning the reference marks (C). NOTE: When the propeller shaft is replaced, align the white marks (D) on the new propeller shaft with the white mark on the differential, SPECIAL BOLTS Replace.
Page 520 Steering Steering ..... 17 -2 Speciaf Tools Component Location Index ......... 17-3 Steering Wheel Rotational Play Check ....... 17-4 Power Assist Check ......17-4 Steering Linkage and Gearbox Inspection ....17-5 Steering Wheel Removal ..........l7-6 Steering Wheel Disassembly and Reassembly ..17-7 Steering Wheel Installation .........
Page 521 Steering Special Tools Tool Number DescriDtion Ref.No. Locknut Wrench, 43 mm 071\4AA-S10020A...
Page 522 Component Location Index AIRBAG ASSEMBLY Removal/lnstallation. page 23-65 STEERING WHEEL Removal, page 17-6 Disassembly/Reassembly, p a g e 1 1 - j Installation, page 17-8 STEERING COLUMN Steering Column Removal and Installation, page 17-9 Steering Column Inspection, page 17-12 Steering Lock Replacement, p a g e ' 1 1 - 1 3 STEERING SHAFT Steering Shaft Removal and Installation,...
Page 523 Steering Steering Wheel Rotational Play Power Assist Check Gheck ' 1 . Stan the engine, let it idle. 1. Turn the front wheels to the straight ahead position. Attach a commercially available spring scale to the steering wheel. With the engine idling and the v e h i c l e o n a c l e a n , d r y f l o o r , p u l l t h e s c a l e a s 2, lvleasure how fa r you can turn the steering wheel left and right without moving the front wheels.
Page 524 Steering Linkage and Gearbox Inspection STEERING COLUMN lnspect for loose column mountinq bolts and nuts. STEERING JOINTS Check for loose ioint bolts. TIE.ROD LOCKNUT Check for loose locknut. \r,.-*oo a"o,o,-,-,o,", lnspect Ior faulty movement STEERING GEARBOX ano oamage. Inspect lor loose mounting bolts. GEARBOX MOUNTING CUSHIONS Inspect lor deterioration.
Page 525 Steering Steering Wheel Removal SRS components are located in this area, Review the 5 . I n s t a l l a c o m m e r c i a l l y a v a i l a b l e s t e e r i n g w h e e l puller (A) on the steering wheel (B).
Page 526 Steering Wheel Disassembly/Reassembly STEERING WHEEL WHEEL LOWER COVER SLIDE SCREWS \ i** t Ag> {?'%\-l @ { ( # Y ' - / \ .o"{.,,*,. HORN PLATE HORN PLATE COVEB ACCESS PANEL CRUISE CONTROL SWITCH 17-7...
Page 527 Steering Steering Wheel Installation 1. Before installing the steering wheel, make sure the 3. lnstallthe steering wheet bolt and tighten it. front wheels are aligned straight ahead, then center 39 N m {4.0 kgf m,29lbf.ft} the cable reel (A). Do this by first rotating the cable reel clockwise unlil it stoos.
Page 528 Steering Column Removal and Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-10). Removal 1. Record the radio station presets, and disconnect the battery. 2.
Page 529 Steering Steering Column Removal and Steering Shaft Removal and Installation (cont'dl Installation lnstallation Removal Remove the steering column (see page 17-9). 1 . I n s t a l l t h e s t e e r i n g c o l u m n , a n d m a k e s u r e t h e wires are not caught or pinched by any parts.
Page 530 steering shaft (B) (from the engine companment). lnstallation Be sure the steering joint and steering shaft are aligned with the serrations; the joint should slip on 1, Apply multipurpose grease to the inside surface of t h e p i n i o n d u s t s e a l ( A ) . freelv.
Page 531 Steering Steering Column/Steering Shaft Inspection Check the steering column ball bearing {A) and the steering joint bearings (B) for play and proper movement. lf any bearing is noisy or has excessive play, replace the steering column as an assembly. Check the retaining collar (C) for damage. lf it is damaged, replace the steering column as an assembly. Check the absorbing plates {D) for distortion or breakage.
Page 532 Steering Lock Replacement 1. Remove the steering column (see page 17-9), 2. Center DUnch each of the two shear bolts, and drill their heads off with a 5 mm {3/16 in.) drill bit. Be careful not to damage the switch body when removing the shear bolts.
Page 533 Steering Rack Guide Adjustment 7. Tighten the locknut to 25 N.m (2.5 kgf.m, 18lbfft) Special Tools Roquired Locknut wrench, 43 mm 07MAA-S100204 while holding the rack guide screw. 1. Set the wheels in the straight ahead position. 8. Install the lower radiator clamp. 2.
Page 534 Electrical Power Steering (EPSI EPS Gomponents S o e c i a l T o o l s t / - t o Component Location Index ....17-17 17 -18 General Troubleshooting Information DTC Troubleshooting Index 1 7 - 2 2 17-23 Symptom Troubleshooting Index ....
Page 535 EPS Components Special Tools Description Ref.No. Tool Number 07MAC-S100200 B a l l J o i n t R e m o v e r , 2 S m m 07746-0010100 Attachment. 32 x 35 mm 07749-0010000 Driver 07974-6790000 O i l S e a l D r i v e r 17-16...
Page 536 Component Location Index DATA LINK UNDER-HOOD FUSE BOX CONNECTOR I16PI GAUGE ASSEMBLY UNDEB.DASH FUSE/RELAY BOX MAIN UNDER-HOOD FUSE/RELAY BOX TOROUE SENSOR page 17-54 Torque Sensor Beplacement, EPS CONTROL UNIT EPS Control Unit Bemoval/ Installation, page 17-59 STEERING GEARBOX Steering Gearbox Removal and lnstallation, page 17-46 Steering Gearbox Ov€rhaul, page 17-53 Rack Guide Bemoval/lnstallation, page 17-54...
Page 537 EPS Gomponents General Troubleshooting Information EPS Indicator The EPS control unit performs the following functions when a problem is detected by self-diagnosis: Under normal conditions. the EPS indicator comes on when the ignition switch is turned to the ON (ll) position, Turns on the EPS indicator.
Page 538 Service Check Signal Circuit Method: connectors with a double outline. 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P data link connector (DLC) 1. Ouestion the customer about the conditions when...
Page 539 Add the long and short blinks together to determine the DTC. After determining the DTC. refer to the 1. With the ignition switch OFF, connect the Honda DTC troubleshooting index, PGM Tester (A) to the 16P data link connector (DLC)
Page 540 OFF. This will return the svstem to the alert m o o e . 10. Disconnect the Honda PGM Tester from the DLC. Whith the vehicle on the ground, set the front wheels in the straight ahead driving position.
Page 541 DTC Troubleshooting Index Note Detection ltem (see page 17-28) DTC: 1 Power relay stuck ON (see page l7-28) Drc 2 Fail-sate relay stuck ON {see page 17-28) LOW FET (Motor drive transistor) stuck ON DTC: 3 (see page '17-29) UP FET (Motor drive transistor) stuck ON DTC: 4 (see page 17-30) Open to body ground in the motor circuit...
Page 542 Symptom Troubleshooting Index Diagnostic procedure Symptom Also check for EPS Indicator Circuit Troubleshooting (see page 17'42) EPS indicator does not come on EPS Indicator Circuit Troubleshooting (see page 17-42) EPS indicator does not go off and no DTC is stored EPS indicator does not stay 1.
Page 543 EPS Components System Description EPS Control Unit lnputs and Outputs for Connector A (2P) EPS CONTROL UNITCONNECTOR A {2P} W i r e s i d e o f f e m a l e t e r m i n a l s . Terminel sign Description Tormanal...
Page 544 EPS Control Unit Inputs and Outputs for Connector C (2P) EPS CONTROL UNIT CONNECTOR C I2PI W i r e s i d e o f f e m a l e t e r m i n a l s . Terminal Wire color Terminal sign...
Page 545 EPS Components Circuit Diagram UNDER-OASH FUSE/RELAY AOX TOROU€ SENSOF GAUGE ASSEMBLY CONNECTOR A (1'P) TOROUE SENSOF 3P CONNECTOR GAUGE ASSEMELY CONNECTOA A (T2PI Term nal side of female tef minals GAUGE ASSEMBTY CONNECTOF C {2OP) Wre side oi le male rermina ls W i r e s i d e o i f e m a l e r e r m n a l s 17-26...
Page 546 .L---r-_r CONTBOI UNIT CONNECTOR A (2P) EPSCONTEO! UNITCONNECTOR C {2P) MOTOA CONNECTOR I2P) l i ; c o n n a t o r ) l a : /-+' tllu t 2 t l l t 2 t 1 l e r m n a l s i d e o l f e m a l e l e r m i h a l s W r e s i d e o t i e m a e t e r m i n a l s T e r m i n a s i d e o f f e m a e t e r m n a l s...
Page 547 EPS Components DTC Troubleshooting DTC 3: Lower FET Stuck ON DTC 1: Power Relay Stuck ON 1, Disconnect EPS control unit connector A (2P) and DTG 2: Fail-safe Relay Stuck ON the motor 2P connector. 1 . C l e a r t h e D T C . 2.
Page 548 DTC 4: Upper FET Stuck ON 4. Check for continuity between EPS control unit c o n n e c t o r A ( 2 P ) t e r m i n a l s N o . 2 a n d N o . 1 . 1.
Page 549 EPS Gomponents DTC Troubleshooting (cont'd) 7. Measure the voltage between terminal No. 2 and DTC 5: Open In The Motor Wire Harness body ground. 1 . C l e a r t h e D T C . EPS CONTROL UNIT 2.
Page 550 10. Check for continuity between EPS control unit 12. Check for continuity between EPS control unit connector A (2P) terminal No. 2 and motor 2P c o n n e c t o r A ( 2 P ) t e r m i n a l N o . 1 a n d b o d y g r o u n d . c o n n e c t o r t e r m i n a l N o .
Page 551 EPS Components DTC Troubleshooting (cont'd) DTC 11, 13: Torque Sensor 7. Check for continuity between the appropraate torque sensor 3P connector terminal and body g r o u n d ( s e e t a b l e ) . 1.
Page 552 DTC 12: Torque Sensor PVF 9. Check for continuity between the appropriate EPS control unit connector B (14P) and torque sensor 3P 1 . C l e a r t h e D T C . connector terminals {see table). Torque 2.
Page 553 EPS Components DTG Troubleshooting (cont'd) DTC 14: Torque Sensor (Resistance) 7, Check for continuity between torque sensor 3P c o n n e c t o r t e r m i n a l s N o . 2 a n d N o . 3 . 1 .
Page 554 DTC 21:Voltage For lG1 9. On the sensor side, check for resistance between the torque sensor 3P connector terminals No. 1 and ' 1 . c h e c k t h e I N S T R U M E N T L I G H T ( 7 . 5 A ) f u s e i n t h e No.2, and between terminal No.
Page 555 EPS Components DTG Troubleshooting (cont'dl DTC 22: Vehicle Speed Signat 6. Block the right rear wheel, and slowly rotate the left rear wheel and measure the voltage between EPS NOTE: control unit connector B {14P) terminal No. 2 and . lf the l\4lL indicator is ON, troubleshootthe PGM-Fl body ground.
Page 556 DTC 23: Engine Speed Signa 8. lvleasure the voltage between the No. 5 terminal and body ground. NOTE: lf the MIL indicator is on, troubleshootthe PGM- Fl problem first, 1. Start the engine and check the tachometer. ls the tachometer working correctly? YES Go to step 2.
Page 557 EPS Gomponents DTC Troubleshooting (cont'dl DTC 30: Su b-Microcomputer DTC 31, 32, 33: Motor Current Sensor 1 . C l e a r t h e D T C . 1. Clear the DTC. 2 . S t a n t h e e n g i n e . 2.
Page 558 DTC 36: Charge of the Motor Voltage DTC 34,35: EPS Control Unit lnternal Circuit 1 . C l e a r t h e D T C . 1 . C l e a r t h e D T C . 2.
Page 559 EPS Gomponents DTC Troubleshooting (cont'dl DTC 37: Motor Voltage 7. Measure the voltage between terminal No.2 and body ground. 1 . C h e c k t h e E P S { 7 0 A ) f u s e i n t h e a u x i l i a r y u n d e r - hood fuse box, and reinstallthe fuse if it is OK.
Page 560 6. Check for continuiw between EPS control unit 4. Check for continuity between EPS control unit connector A {2P) terminal No. 1 and body ground. connector A (2P) terminal No. 2 and motor 2P c o n n e c t o r t e r m i n a l N o . 1 . EPS CONTROL UNIT CONNECTOR A (2PI FPS CONTROL UNIT...
Page 561 EPS Components DTC Troubleshooting (cont'd) EPS Indicator Circuit Troubleshooting DTC 50 to 62: Central Processing Unit (CPU) 1. Clear the DTC. 1 . T u r n t h e i g n i t l o n s w i t c h O N ( l l ) , s t a r t t h e e n g i n e , and watch the EPS indicator.
Page 562 6, Connect gauge assembly connector A (14P) 11. Check for continuity between body ground and EPS terminal No. 14 to body ground with a jumper wire. control unit connector B {14P} terminals No. 4 and N o . 6 i n d i v i d u a l l y . EPS CONTROL UNIT GAUGE ASSEMBLY CONNECTOR A {14PI CONNECTOR...
Page 563 NO - Go to step 17. Does the EPS indicator go off? 17. Turn the ignition switch OFF. then remove the Honda PGM Tester. YES Go to step 25. 18. ConnectEPS control unit connector B ('14P). NO Repair short to body ground in the wire between the EPS indicator and the EPS control unit.
Page 564 11. Disconnect the Honda PG M Tester from the DLC. S h o r t t h e S C S c i r c u i t t o b o d y g r o u n d u s i n g t h e Honda PGM Tester.
Page 565 EPS Components Steering Gearbox Removal and Installation 9. From the underthe dashboard; loosen the joint bolt Special Tools Required Ball joint remover, 28 mm 07MAC-S100200 (A) on the column, and pull the steering shaft (B) fullv to the column side. Removal Note these items during removalr .
Page 566 '11. Remove and discard the cotter pin (A)Jrom the 14. Remove the stabilizer bar holder brackets {A) from the frame, and lower the stabilizer bar (B). 12 mm nut (B). then remove the nut. 12 x 1.25 mm Disconnect the ground cable (A) and motor 2P 07MAC-S100200 connector (B).
Page 567 EPS Components Steering Gearbox Removal and Installation (cont'dl 16. Disconnect the torque sensor 3P connector (A). 18. Pullthe steering gearbox toward the front. Move After disconnecting the connector, put a piece of the steering gearbox to the passenger's side and tape over the steering gearbox connector to protect remove it.
Page 568 lnstallation 3. Installthe four gearbox mounting bolts. 1. Before installing the gearbox, centerthe steering Right side: rack within its stroke. 10 x 1.25 mm (3 N.m 2. Pass the driver's side of the steering gearbox {4.4 kof m,32 lbf.ft) \_ll through the left wheel housing.
Page 569 EPS Components Steering Gearbox Removal and Installation (cont'dl 4, Connect the torque sensor 3P connector (A). 6. Raise the stabilizer bar (A) to the original position, a n d i n s t a l l t h e s t a b i l i z e r b a r h o l d e r b r a c k e t { B ) . Connect the motor 2P connector (A) and ground cable (B).
Page 570 8. Wipe off any grease contamination f rom the ball 11. From the under the dashboard, push the steering joint tapered section and threads. Then reconnect shaft (A) fully to engine compartment side, but do the tie-rod ends (A)to the steering knuckles (B), and not push excessively on the steering shaft.
Page 571 EPS Gomponents Steering Gearbox Removal and Installation (cont'd) 1 3 . i n s t a l l t h e s t e e r i n g w h e e l ( s e e p a g e 1 7 - 8 ) . 1 4 .
Page 572 Steering Gearbox Overhaul Exploded View MOUNTING BUSHING Inspect for damage and BOX BRACKET deterioration. ,o-RtNG ^"'"""' ., RACK GU|DE @ , / ou,,, E(/" 9' --,,*,"o STEERING GEARBOX ASSEMBLY {MOTOR) ll the gearbox is faulty, replace it as an assembly. TOROUE SENSOR ASSEMBLY lf the torque sensor is faulty, replace it as an assemblv.
Page 573 EPS Components Rack Guide Removal/lnstallation Torque Sensor Replacement NOTE: During removal/installation, do not allow dust, Note these items during replacement: din, or other foreign materials to enter the gearbox. . Do not allow dust, din, or other foreign malerials to enter the gearbox.
Page 574 Rack End Removal and Installation Special Tools Required 2. Unbend the lock washer. . Attachment, 32 x 35 mm 07746-0010100 . Driver, 07749-0010000 Removal Note these items during removal/installation: . Do not allow dust, dirt, or other foreign materials to enter the gearbox.
Page 575 EPS Components Rack End Removal and Installation (cont'd) lnstallation 4, Check the rubber stop (A) for damage or deterioration. lf the rubber stop is damaged or 1 . l n s t a l l t h e n e w l o c k w a s h e r { A ) o n t h e r a c k s h a f t . deteriorated, reolace it.
Page 576 Apply multipurpose grease to the circumference 8. lnstallthe new boot band (A) by aligning the tabs (A) of the rack end joint housing. (B) with holes (C) of the band. o-Gr a'.RE-As!x (P/N: 08733-B070El Apply a light coat of silicone grease to the boot Close the ear portion (A) of the band with grooves {B) on the rack ends.
Page 577 EPS Components Ball Joint Boot Replacement Gearbox Bracket RemovaU lnstallation SpecialTools Required Oil seal driver, 07974-6790000 1. Remove the bracket clamo bolt (A) from the 1. Remove the boot from the tie-rod end, and wipe the gearbox bracket (B), then pry open the bracket to old grease off the ball pin.
Page 578 EPS Control Unit Removal/lnstallation 1 . Make sure you have the anti,theft code for the radio, then write down the frequencies for the radio preset buttons. Remove the battery. Remove the EPS control unit. 3. Disconnect the EPS control unit connectors. 4.
Page 579 Suspension Front and Rear Suspension Special Tools ..... 18-2 Component Location Index ......... 18-3 W h e e l A l i g n m e n t ..... .
Page 580 Front and Rear Suspension SpecialTools Description Tool Number Ref.No. Hub Dis/Assembly Tool, 42 mm 07GAF-SD40100 Hub Dis/Assembly Tool 07GAF-SD40200 B a l l J o i n t B o o t C l i p G u i d e . 4 2 x 4 4 m m 07GAG-SD40700 B u s h i n g B a s e 07JAF-SH20330...
Page 581 Component Location Index Front Suspension: Removal, step 1 on page 18-23 step 1 on page 18-24 Disassembly/lnspection, Reassembly, step 1 on page 18-25 Installation, step 1 on page 18-26 Replacement, page 18'20 STABILIZER LINK Removal/lnstallation, page 18'18 STABILIZER BAR Replacement, page 18 17 KNUCKLE/HUB page 18-l 1 Replacement,...
Page 582 Front and Rear Suspension Component Location Index {cont'dl Rear Suspension: Replacement, page 18-34 REAR DAMPER Removal, step 1 on page 18-40 step'l on page 18-41 Disassemblv/lnspection, Reassembly, step 1 on page 18-41 Installation, step 1 on page 18-42 UPPER ARM page 18-37 Removal/lnstallation, LOWER ARM...
Page 583 Wheel Alignment The suspension can be adjusted for caster, camber, and Bounce the suspension up and down several times. toe. However, each of these adjustments are interrelated to each other, For example, when you Check the height of each suspension. Make sure adjust toe, lhe camber changes.
Page 584 Front and Rear Suspension Wheel Alignment (cont'dl Front Camber Inspection/Adiustment Front Caster Inspection/Adiustment Use commercially available computerized four wheel Use commerciallv available computerized four wheel alignment equipment to measure wheel alignment alignment equipment lo measure wheel alignment (caster. camber, toe, and turning angle) Followthe {caster, camber, toe, and turning angle) Followthe equipment manuJacturer's instructions.
Page 585 Front Toe Inspection/Adjustment Rear Camber Inspection/Adjustment U s e c o m m e r c i a l l y a v a i l a b l e c o m p u t e r i z e d f o u r w h e e l Use commerciallv available comDuterized four wheel a l i g n m e n t e q u i p m e n t t o m e a s u r e w h e e l a l i g n m e n t a l i g n m e n t e q u i p m e n t t o m e a s u r e w h e e l a l i g n m e n t...
Page 586 Front and Rear Suspension Wheel Alignment (cont'd) Rear Toe Inspection/Adiustment Turning Angle Inspection Use commercially available computerized four wheel Use commerciallv available comouterized four wheel alignment equipment to measure wheel alignment alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the {caster, camber, toe.
Page 587 Wheel Runout Inspection Wheel Bearing End Play lnspection ' 1 . Raise the vehicle, and support it with safety stands 1 . Raise the vehicle, and suppon it with safety stands in the proper locations (see page 1-13). in the proper locations (see page 1-13). Check for a bent or deformed wheel.
Page 588 Front and Rear Suspension Ball Joint Removal 4. Once the special tool is in place, turn the adjusting Special Tools Required bolt (A) as necessary to make the jaws parallel. Balljoint remover, 28 mm 07MAC-S100200 Then hand-tighten the pressure bolt (B), and 1.
Page 589 Front Suspension Knuckle/Hub Replacement Exploded View 7 HUB CAP Checktot delormation and damaqe. d^^/q BEARING Replace. ,-,----{g /Y / Check lor deformation a n o o a m a g e , SPINDLE NUT 24 x 1.5 mm 329 N.m SCREW (33.5 kgf.m.2,|2 lbf.ft) 5 m m...
Page 590 Front Suspension Knuckle/Hub Replacement (cont'd) 5. Remove the flange bolts (A) and wheel sensor (B) SpecialTools Required . Ball joint remover, 28 mm 07MAC-S100200 from the knuckle (C). Do not disconnect the wheel . Bearing driver attachment, T2 x 75 mm 07746-0010600 sensor connector.
Page 591 14. Remove the lock pin (A) from the upper arm ball 10. Remove the cotter pin (A)from the tie-rod end ball ioint, and remove the castle nut (B). joint, then remove the nut (B). 12 x '1.25 mm 54 N.m 15.5 kgf m.,l0 lbf ft) 12 x 1.25 mm 49-59 N m...
Page 592 Front Suspension Knuckle/Hub Replacement (cont'dl Separate the hub (A)from the knuckle (B) using a 2 1 . P r e s s t h e w h e e l b e a r i n g ( A ) o u t o f t h e k n u c k l e { B } 1 9 .
Page 593 Wash the spindle thoroughly in high flash point 2 7 . W a s h t h e k n u c k l e a n d h u b t h o r o u g h l y i n h i g h f l a s h point solvent before reassembly.
Page 594 Front Suspension Knuckle/Hub Replacement (cont'dl Ball Joint Boot Replacement Installthe knuckle in the reverse order of removal, Special Tools Required paying particular attention to the following items: Balljoint boot clip guide, 07GAG-SD40700 . Be careful not to damage the ball joint boot when Remove the boot clip and the boot.
Page 595 Stabilizer Bar Replacement 4. Remove the bolts (A) and bushing holders (B). then Raise the front of the vehicle, and support it with remove the bushings (C) and the stabilizer bar (D). safety stands in the proper locations ( s e e p a g e 1 - 1 3 ) . R e m o v e t h e f r o n t w h e e l . 1 0 x 1 .
Page 596 Front Suspension Stabilizer Link Removal/lnstallation 5. lnstall the self-locking nut and flange nut, and 1 . Raise the front of the vehicle, and support it with safety stands in the proper locations lightly tighten. (see page 1-13). Remove the front wheel. 6, Place a jack under the lower arm, and raise the Remove splash guard (see page 18-17).
Page 597 Lower Arm Removal/lnstallation 4. Remove the cotter pin (A)from the lower arm ball Special Tools Required ioint, and remove the castle nut (B). . Ball joint remover, 28 mm 07MAC-S100200 1. Raise the front of the vehicle, and support it with safety stands in the proper locaions {see page 1-13).
Page 598 Front Suspension Upper Arm Replacement Lower Arm Removal/lnstallation {cont'd) Special Tools Required . Ball joint remover,23 mm 07MAC-S100200 7 . l n s t a l l t h e l o w e r a r m i n t h e r e v e r s e o r d e r o f 1.
Page 599 5. Remove the flange bolts {A). and the upper arm. 1 2 x 1 . 2 5 m m 103 N.m (10,5 kgt.m, 75.9lbt.ftl I n s t a l l t h e u p p e r a r m i n t h e r e v e r s e o r d e r o f removal paying particular attention to the following items: Be careful not to damage the ball joint boot when...
Page 600 Front Suspension Damper/Spring Replacement Exploded View SELF.LOCKING 10 x 1.25 mm 29 N.m (3.0 kgf.m,22lbf.ftl Beplace. DAMPER MOUNTING coLLAR n-.' SPRING MOUNTING CUSHION Check for deterioration and damage. COVER PLATE _.-ousr covER SLEEVE unecK ror oenorng ano oamage' Check for bending and damage. [:gl' -,or.r aou., ."o Check for deformation and damage.
Page 601 5. Remove the flange nuts (A)trom the top of the Special Tools Required Strut spring compressor, Branick MST-580A or Model o a m p e r . 7200, or equivalent. commercially available. Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-13).
Page 602 Front Suspension Damper/Spring Replacement (cont'd) Disassembly/lnspection 1 . Lower the lower arm, and remove the damper assembly (A). 1. Compress the damper spring with the commercially available strut spring compressor {A) according to the manufacturer's instructions, then remove the self-locking nut {B). Do not compress the spring more than necessary to remove the nut.
Page 603 Reassembly Compress the damper spring with the spring compressor. 1. Assemble all of the damper components except the Install a new self-locking nut (A) on the damper self-locking nut onto the damper unit. Align the spring bottom end (A), the stepped pan of the shaft.
Page 604 Front Suspension Damper/Spring Replacement (cont'dl 3. Position the damper bottom on the lower arm (A), lnstallation and connect the lower arm and the lower ball ioint 1. Lower the lower arm, and position the damper { B ) . assembly {A) in the body. -\1, 1 0 x 1 .
Page 605 9. Tighten the flange nuts on the top of the damper to the soecified toroue. 10. Installthe brake hose mounting bracket (A) and the flange bolt (B)to the damper, and tighten the bolt to the specified torque. E x 1 . 2 5 m m 22 N.m (2.2 kgf.m, 16lbf.ftl 18-27...
Page 606 Rear Suspension Knuckle/Hub Replacement Exploded View KNUCKLE WHEEL BEARING Replace. SNAP RING SPLASH GUARD Check for delormation and damage. SCREW 5 m m 4 . 9 N m l0.s kgf.m,3.6lbf.ft) iAri LOWER ARM BALL JOINT 12 x 1,25 mm 64 N.m (6.5 kgf.m,47 lbf.ft) BALL JOINT BOOT Replace.
Page 607 Special Tools Required 4 . R e m o v e t h e f l a n g e b o l t ( A ) a n d w h e e l s e n s o r ( B ) .
Page 608 Rear Suspension Knuckle/Hub RePlacement (cont'dl 1 1 . R e m o v e t h e l o c k p i n ( A ) f r o m t h e c o n t r o l a r m b a l l Remove the 6 mm brake disc retalning flat-head ioint, and remove the castle nut (B) screws (A).
Page 609 '16. Remove the lock pin (A) from the upper arm ball 19. Separate the hub (A)from the knuckle (B) using the joint, and remove the castle nut (B). special tool and a hydraulic press. Be careful notto deform the splash guard. Hold the hub to keep it from falling when pressed clear.
Page 610 Rear Suspension Knuckle/Hub Replacement (cont'dl Press the wheel bearing (A) out of the knuckle (B) 23. Wash the knuckle and hub thoroughly in high flash 2 1 . point solvent before reassembly. u s i n g t h e s p e c i a l t o o l s a n d a p r e s s , Pross 2 4 .
Page 611 Ball Joint Boot Replacement 2 7 . I n s t a l l t h e h u b { A ) o n t o t h e k n u c k l e ( B ) u s i n g t h e Special Tools Required Ball joint boot clip guide, 07cAG-SD40700 specialtools and a hydraulic press.
Page 612 Rear Suspension Stabilizer Link Removal/lnstallation Stabilizer Bar Replacement ' 1 . Raise the rear of the vehicle, and suppon it with 1 . Raise the rear of the vehicle, and support it with safety stands in the proper locations safety stands in the proper locations ( s e e p a g e 1 - 1 3 ) .
Page 613 Lower Arm Removal/lnstallation 4. Install the self-locking nut and flange nut. and Special Tools Required . Ball joint remover. 28 mm 07MAC-SL00200 lightly tighten. 5. Place a jack under the lower arm, and raise the 1. Raise the rear of the vehicle, and support it with suspension to load the stabilizer bar.
Page 614 Rear Suspension Lower Arm Removal/lnstallation (cont'd) 4 . Remove the cotter pin (A) from the lower arm ball lnstall the lower arm in the reverse order of joint, and remove the castle nut (B). removal paying panicular attention to the following t r e m s : r-----'------ - \ .
Page 615 Upper Arm Removal/lnstallation 5. Remove the flange bolts (A), and the upper arm. Special Tools Required . Ball joint remover. 28 mm 07MAC-S100200 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations ( s e e p a g e 1 - 1 3 ) .
Page 616 Rear Suspension Control Arm Replacement 6. Installthe control arm in the reverse order of Special Tools Required . Ball joint remover, 28 mm 07MAC-S100200 removal paying particular attention to the following rrems: 1. Raise the rear of the vehicle. and support it with .
Page 617 Damper/Spring Replacement Exploded View SELF.LOCKING NUI 1 0 x 1 . 2 5 m m 49 N.m 15.0 kgf m,36 lbf.ftl Replace. H'*,' DAMPER MOUNTING COLLAR \-,2 11--,----- RUBBER MOUNTING BUSHING Check for deterioration and damage. COVER PLATE .,,/"DUSf /,i-:\ /DUST COVER SLEEVE Check for bending and damage.
Page 618 Rear Suspension Damper/Spring Replacement (cont'dl 5. Lower the lower arm, and remove the damper SpecialTools Required assembly (A). Strut spring compressor, Branick MST-580A or Model 7200, or equivalent. commercially available Removal 1. Raise the rear of the vehicle, and support it with safety stands in the proper Iocations (see page 1-13).
Page 619 Reassembly Disassembly/lnspection 1. Assemble all of the damper components except the 1, Compress the damper spring with the self'locking nut onto the damper unit. Align the commercially available strut spring compressor {A) spring bottom end (A), the stepped part of the according to the manufacturer's instructions, then remove the self-locking nut (B).
Page 620 Rear Suspensiton Damper/Spring Replacement (cont'd) lnstallation 5. lnstall a new self-locking nut (A) on the damper shaft. 1. Lower the lower arm. and position the damper assembly (A) in the body. ,'-_\ 10 x 1.25 mm 29 N.m (3.0 kgl.m,22 lbl.ftl Hold the damoer shaft with a hex wrench (B), and tighten the self-locking nut to the specified torque.
Page 621 3. Position the bottom ofthe damper on the lower a r m ( A ) . Install the flange bolt (B), and lightly tighten. Raise the suspension until the vehicle just lifts off the safety stand. Tighten the flange bolt (B) to the specified torque. Tighten the flange nuts on the top of the damper to the specified torque.
Page 622: Soecialtools
Brakes Conventional Brake Components ..... 19-2 SoecialTools 1 9 - 3 C o m o o n e n t L o c a t i o n I n d e x ......... 19-4 Brake System Inspection and Tests ......
Page 623 Conventional Brake Components SpecialTools Description Rel.No. Tool Number Pushrod Adiustment Gauqe 07JAG-SD40100...
Page 624 Component Location Index INDICATOR Brake System Indicator Circuit D i a g r a m , p a g e l 9 - 1 0 Parking Brake Switch Test, page 19-11 Brake Fluid Level Switch Test, page 19-11 BRAKE PEDAL Erake Pedal and Brake PedalPosition Switch Adjustment, page 19-6 REAR BRAKES...
Page 625 Gonventional Brake Components Brake System Inspection and Tests M a s t e r C y l i n d e r Bulging seal at reservoir cap, This is a Look for damage or signs of fluid leakage at: . Reservoir or reservoir grommets s i g n o f f l u i d c o n t a m i n a t i o n .
Page 626 Rapid brake pad wear, Vehicle vibration (after a long Loosen the hydraulic lines at the master cylinder, drive), or High, hard brake pedal then spin the wheels to check for brake drag. ls there brake dtag at any of the wheels? 1 .
Page 627 Gonventional Brake Components Brake Pedal and Brake Pedal Position Switch Adiustment Pedal Height 3. Loosen the pushrod locknut {A), and screwthe pushrod in or out with pliers until the standard ' t . pedal height from the floor is reached. After Disconnect the brake Dedal Dosition switch connector, loosen the brake pedal position switch adjustment, tighten the locknut firmly.
Page 628 Parking Brake Check and Adiustment Check Pedal Free Play 1 . P u l l t h e p a r k i n g b r a k e l e v e r ( A ) w i t h 1 9 6 N ( 2 0 k g f , 1.
Page 629 . D o n o t r e u s e t h e d r a i n e d f l u i d . . Always use Honda DOT 3 Brake Fluid. P u l l t h e p a r k i n g b r a k e l e v e r u p o n e c l i c k .
Page 630 Have someone slowly pump the brake pedal Bleed Screw Locations severaltimes, then apply steady pressure. FRONT: Starting at the left-front, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid.
Page 631 Conventional Brake Components Brake System Indicator Circuit Diagram UNDEN.OASH FUSE/ REIAYBOX GAUGE ASSEMALY .CONVEBTAALE TOP CONIAOL UNrI .DAYTIME RUNNING IIGHTS CONTROI UNIT (Canad. 6od€l onlvl EAAKEFI.UID PANKING BRAKE SwlTCH LEVEL SWTTCH CIOSEO: ldor up G30t 1 9 - 1 0...
Page 632 Parking Brake Switch Test Brake Fluid Level Switch Test Remove the center console, and disconnect the Check for continuity between the terminals (A) with the connector (A)from the switch (B). float in the down position and the up position. . Remove the brake fluid completely from the reservoir. With the float down, there should be continuity.
Page 633 Conventional Brake Components Front Brake Pads Inspection/Replacement 4. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not i n c l u d e t h e p a d b a c k i n g p l a t e ( A ) t h i c k n e s s . Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your Brake Pad Thickness:...
Page 634 9. Apply Molykote M77 grease or Daikalub 528D 1 1 .Push in the piston (A) so that the caliper will fit over grease to the pad side of the shims (A) and back of the pads. N4ake sure the piston boot is in position to the pads (B).
Page 635 Conventional Brake Components Front Brake Disc Inspection Thickness and Parallelism Runout 1. Loosen the front wheel nuts slightly, then raise the 1. Loosen the front wheel nuts slightly, then raise the vehicle, and support it with safety stands in the vehicle, and support it with safety stands in the proper locations (see page 1-13).
Page 636 When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Always use Honda DOT 3 Brake Fluid. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
Page 637 Conventional Brake Gomponents Master Cylinder/Brake Booster Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; lf brake fluid does contact the paint, wash it off immediately with water. 1. Disconnect the brake fluid level switch connectors. 2.
Page 638 Master Cylinder Inspection Master Cylinder Pushrod Clearance Adjustment NOTE: . Before reassembling, checkthat all parts are free of dust and other foreign particles. Special Tools Required . Do not try to disassemble the master cylinder Pushrod adjustment gauge 07JAG-SD40'100 assembly. Replace the master cylinder assembly with a new Dart if necessarv.
Page 639 Conventional Brake Components Master Cylinder Pushrod Clearance Adiustment (cont'd) 9. Check the pushrod length (A) as shown if the 5, With a feeler gauge {A), measure the clearance booster is removed. lf the length is incorrect, between the gauge body and the adjusting nut (B) loosen the pushrod locknut (B), and turn the clevis as shown.
Page 640 Brake Booster Test Functional Test 3. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster (B). With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the pedal hard and hold it for 15 seconds. lf the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, proportioning valve, or...
Page 641 Gonventional Brake Components Rear Brake Pads Inspection/Replacement 4. Remove the pad shims (A) and brake pads (B). Frequent inhalation of brake pad dust. regardless of material composition, could be hazardous to your health. ' Avoid breathing dust Particles. . Never use an air hose or brush to clean brake assemblies.
Page 642 6. Remove the pad retainers. 12. Rotate the caliper piston (A) clockwise into the cylinder, then align the cutout (B) in the piston with the tab (C) on the inner pad by turning the piston ..back.
Page 643 Gonventional Brake Components Rear Brake Disc Inspection Thickness and Parallelism Runout 1. Loosen the rear wheel nuts slightly, then raisethe 1. Raise the rear of the vehicle. and support it with vehicle, and support it with safety stands in the safety stands in the proper locations (see page proper locations (see page 1-13).
Page 644 Rear Brake Caliper Removal/lnstallation 6. Remove the cabls clip (A) from the parking brake c a b l e ( B ) . Frequent inhalalion of brake pad dust, regardless of material composition, could be hazardous to your health. . Avoid breathing dust particles. .
Page 645 . Make sure no grease or oil gets on the brake discs or pads. . Do not reuse drained brake fluid. . Always use Honda DOT 3 Brake Fluid. . Coatthe piston, pistonseal groove, and caliper bore with clean brake fluid.
Page 646 :Honda caliper grease (P/N 08c30-Bo234M) #:!@ PAD SPRING 6 x ' l 0 m m 8 x 1.25 mm RETAINER 9.8 N m {1.0 ktq.m,7.2 lbf.ft) 23 N.m (2.3 kts.m, 17 lbl.ft) PAD SHIM CALIPER SHIELD BRAKE PADS CALIPER BODY ourER PAD sHrM / l3il,l"fu.,"...
Page 647 Conventional Brake Components Brake Hoses and Lines Inspection 1, Inspectthe brake hoses for damage, deterioration, leaks, interference, and twisting. 2 . C h e c k t h e b r a k e l i n e s f o r d a m a g e , r u s t i n g , a n d l e a k a g e . A l s o c h e c k f o r b e n t b r a k e l i n e s . 3.
Page 648 Brake Hose Replacement 6 . l n s t a l l t h e b r a k e h o s e { A ) o n t h e k n u c k l e a n d NOTE;...
Page 649 Conventional Brake Gomponents Parking Brake Cable Replacement Exploded View PARKING BRAKE CABLE Check for faulty movement. 22 N.m (2.2 kgf.m, 16 lbt.ftl BIGHT PARKING BRAKE CABLE Check for faulty movement. PARKING BRAKE SWITCH 22 N.m (2.2 kgf.m, 16 lbt.ftl -------- --------..- CABLE ADJUSTING NUT CABLE EOUALIZER...
Page 650 NOTE: . The parking brake cables must not be bent oI distorted. This will lead to stiff operation and premature failure. . Refer to the Exploded View as needed during this proceoure. 1 . R e m o v e t h e c a l i p e r s h i e l d . 2.
Page 651 Brakes 19-1 Conventional Brake Gomponents ....ABS (Anti-lock Brake Systeml Components 19-32 Component Location Index ......... 19-33 General Troubleshooting Information ....... DTC Troubleshooting Index ....19-37 19-38 Index ....... Symptom Troubleshooting ... 19-39 System Description ......19-46 Circuit Diagram ..
Page 652 ABS Components Component Location lndex UNDER-DASH FUSE/RELAY BOX DATA LINK CONNECTOR {16P} MAIN UNDER.HOOD FUSE/RELAY BOX LEFT.REAR WHEEL SENSOR Inspection, page 19-60 page 19-60 Replacement, RIGHT-REAR WHEEL SENSOR RIGHT-FRONT WHEEL SENSOR Inspection, page 19-60 Inspection, page'19-60 Replacement, page 19-60 Replacement, page 19-60 ABS MODULATOR.CONTROL UNIT Removal and Installation, page 19-59...
Page 653 General Troubleshooting Information Diagnostic Trouble Code (DTCI ABS lndicator . The memory can hold any number oJ DTCS. However, . l f t h e s y s t e m i s O K , t h e A B S i n d i c a t o r g o e s o f f 2 seconds after turning the ignition switch ON (ll) when the same DTC is detected more than once.
Page 654 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P data link connector (DLC) lB) under the passenger's side oi the dashboard.
Page 655 1 0 s h o r t b l i n k s . A d d t h e l o n g a n d 1. With the ignition switch OFF, connect the Honda shon blinks together to determine the DTC.
Page 656 Turn the ignition switch OFF. After the ABS indicator goes off, release the brake 1 0 . Disconnect the Honda PGM Tester from the DLC. p e o a r . You cannot clear the DTC unless these conditions are met;...
Page 657 DTC Troubleshooting I ndex Note Detection ltem (see paqe 19-48 Rioht-front wheel sensor {oDen/short to bodv qround/short to power) D T C : 1 1 (see Daoe 19-49 Rioht-front wheel sensor (electrical noise/intermittent interruption) Df Ci'\2 Left-front wheel sensor (open/short to body qround/short to power) see oaqe 19-48 D T C : 1 3 Left-f ront wheel sensor (electrical noise/intermittent interruption)
Page 658 ABS Components Symptom Troubleshooting Index Diacnostic procedure symptom Also check for ABS Indicator Circuit Troubleshooting {see page ABS indicator does not come on 1 9 - 5 6 ) ABS Indicator Circuit Troubleshooting (see step 1 ABS indicator does not go off and no DTC is stored on oaoe 19-57) 19-38...
Page 659 System Description ABS Control Unit Inputs and Outputs for 25P Gonnector -'-.._.- STOF G|\D1 Wire side of female terminals Measurement (Disconnect the ABS control unit Wire Terminalsign Description Terminal (Terminal connector) color number Voltage Terminals Conditions namel AC: 0.053 V or F R W { ) 2 1 8 W h e e l S p i n w h e e l...
Page 660 System Description (cont'dl Terminal Wire Terminalsign Measurement {Disconnect the ABS control unit Description numDer color (Terminal connector, namel Terminals Conditions Voltaoe B R N / F L W H Detects left-front Wheel S p i n w h e e l AC: 0.053 V or wheel sensor signal {Frontleft...
Page 661 Features When the brake pedal is pressed during driving, the wheels can lock before the vehicle comes to a stop. In such an event, the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if the rear wheels are locked, creating an extremely unstable condition.
Page 662 System Description (cont'dl COMPONENTS MAIN FUNCTION Wheel sensor The wheel sensor outputs the speed signal to the ABS control unit accordinq to the Dulser's rotation soeed. The ABS control unit processes the signal from the wheel sensor, Modulator- ABS control unit control unit then outouts the ABS control sional to the modulator unit.
Page 663 The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding, and checking wheel sensor signals. use the Honda PGM Tester. See the Honda PGM Tester user's manuals for specific operating instructions.
Page 664 ABS Components System Description (cont'd) ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressu re directly. lt is a circulating-type modulator h a s b e c a u s e t h e b r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r , T h e h y d r a u l i c c o n t r o l three modes: pressure intensifying, pressure retaining, and pressure reducing.
Page 665 Wheel Sensors The wheel sensors are the magnetic contactless type. As the gear pulser teeth rotate past the wheel sensor's magnetic coil. AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed.
Page 666 ABS Gomponents Circuit Diagram WHEEL SENSOB MAIN UNDER-HOOD FUSE/RELAY BOX GAUGE ASSEMBLY CONNECTORS BRAKE SWITCH 4P CONNECTOR 2P CONNECTOR CONNECTOBS 16P coNNEcroR {Cnumber) FRONT 18P CONNECTOR {Onumbe'} IEIL ( 1 r l 2 F ) 1 1 1 1 4 7P CONNECTOR ([number) REAR...
Page 667 -r!rr0' ABS CONTROL UNIT25P CONNECTOR 2 l 3 i 4 l s l 6 i 7 l a W i r e s i d e o f f e m a l e t e r m i n e l s 19-47...
Page 668 ABS Gomponents DTC Troubleshooting DTC 11, 13,15,17: Wheel Sensor 5. Check for continuity between the appropriate (Open/Short to Body Ground/Short to Power) w h e e l s e n s o r ( + ) c i r c u i t t e r m i n a l a n d b o d y g r o u n d { s e e t a b l e ) .
Page 669 DTC 12, 14, 16, 18i Wheel Sensor (Electrical 7. Check the resistance between the appropriate w h e e l s e n s o r ( + ) a n d ( - ) c i r c u i t t e r m i n a l s ( s e e Noise/lntermittent Interruption) t a b l e ) .
Page 670 ABS Components DTC Troubleshooting (cont'd) 4. Check for continuity between the appropriate Measure the resistance between the appropriate wheel sensor ( + ) circuit terminal and other wheel w h e e l s e n s o r ( + ) a n d ( - ) c i r c u i t t e r m i n a l s ( s e e s e n s o r ( + ) c i r c u i t t e r m i n a l s ( s e e t a b l e ) .
Page 671 DTC 21, 22, 23, 24: Pulser DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid 1 . C l e a r t h e D T C ( s e e s t e p 1 o n p a g e 1 9 - 3 5 ) . 1.
Page 672 ABS Components DTC Troubleshooting (cont'd) DTC 51: Motor Lock DTC 41, 42,t|(|, 44: Wheel Lock 1 . Check the ABS MOTOR (30 A) fuse in the main 1 . L i f t u p t h e v e h i c l e s o a l l f o u r w h e e l s a r e o f f t h e under-hood fuse/relay box, and reinstallthe fuse if ground, and release the parking brake.
Page 673 DTC 52: Motor Stuck OFF DTC 53: Motor Stuck ON Check the ABS MOTOR (30 A)fuse in the main 1. Clear the DTC (see step 1 on page 19-35). under-hood fuse/relay box, and reinstall the fuse if it is OK. 2, Test-drive the vehicle.
Page 674 ABS Components DTC Troubleshooting (cont'dl DTC 61, 62: FSR * B Voltage DTC 54: ABS Fail-safe Relay 1. Clearthe DTC (see step 1 on page 19-35). 1. Clear the DTC (see step 1 on page 19-35). 2 . T e s t - d r i v e t h e v e h i c l e a t 6 m p h { 1 0 k m / h ) o r m o r e . 2.
Page 675 DTC 81: Central Processing Unit (CPU) DTC 71: Different Diameter Tire Diagnosis, and ROM/RAM Diagnosis 1. Clear the DTC (see step 1 on page 19-35). 1. Clear the DTC (see step 1 on page 19-35). 2. Test-drive the vehicle. 2. Test-drive the vehicle. Does the ABS indicator come on, and is DTC 71 indicated? Does the ABS indicatot come on, and is DTC 81...
Page 676 ABS Components ABS lndicator Circuat Troubleshooting ABS indicator does not come on Disconnect the gauge assembly 16P connector. 1. Turn the ignition switch ON (ll), and watch the ABS Check for continuity between the gauge assembly 1 0 . 1 6 P c o n n e c t o r t e r m i n a l N o . 8 a n d b o d y g r o u n d . indicator.
Page 677 ABS indicator does not go off 6. Measure the voltage between the ABS control unit 2 5 P c o n n e c t o r t e r m i n a l N o . 1 6 a n d b o d y g r o u n d . ' 1 , C h e c k t h e A B S + B ( 2 0 A ) f u s e i n t h e m a i n u n d e r - hood fuse/relay box, and reinstall the fuse if it is OK.
Page 678 ABS Components ABS Indicator Circuit Troubleshooting (cont'd) Turn the ignition switch ON (ll). 1 0 . Connect the ABS control unit 25P connector t e r m i n a l N o . 7 a n d b o d y g r o u n d w i t h a j u m p e r w i r e . ABS CONTROL UNIT 25P CONNECTOR WALP N E U...
Page 679 ABS Modulator-Control Unit Removal and Installation NOTE: . Donotspill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. . Take care not to damage or deform the brake lines during removal and installation. .
Page 680 ABS Components Wheel Sensor Inspection Wheel Sensor Replacement Inspect the front and rear pulsers for chipped or NOTE; Install the sensors carefully to avoid twisting the damaged teeth. wires. Measure the air gap between the wheel sensor and Front: pulser all the way around while rotating the pulser. Remove the rear brake disc to measure the gap on 6 mm BOLT 9.8 N m {1.0 kgl.m, 7.2 lbf ft)
Page 681 Body Doors Convertible Top Motor Comoonent Location lndex ..20-2 R e p l a c e m e n t . . 2 0 - 5 0 Door Panel Removal/ Convertible Too Striker Installation 20-4 Reolacement .. 20-50 Door Outer Handle A-Pillar-Header Weatherstrio Replacement...
Page 682 Fuel Fill Door Gonsoles 20-100 Adjustment Center Console Removal/ 20-76 Installation Exterior Trim Wind Defector Replacement ..20-77 Cowl Cover Replacement ..20-101 Rear Console Removal/ Rear Tray Opening Molding 20-78 lnstallation 20-102 Reolacement Rear Console Box Rear Window Lower Molding 20-79 Replacement 20-102...
Page 683 Doors Component Location Index WEDGE HOLOER Replacement, page 20-17 GLASS OUTER WEATHERSTRIP Replacement, page 20-16 ts+a DETENT ROD DooRwEDGE #'*e e^/ Replacement, page 20-17 w> €@(hJ"te i.%-. DOOR Position Adjustment, page 20'18 ADAPTER SPEAKER TWEETER GRILLE ('02-03 models) \\..- DOOR GLASS INNER WEATHERSTRIP TWEETER PLASTIC...
Page 684 GLASS Replacement, page 20-8 Adjustment, page 20-l'l FRONT LOWER /DOOR SASH HOLDER CHANNEL / Replacement, I page 20-15 \ o Q / Adjustment, Page 20'16 DOOR GLASS GLASS STOP REGULATOB o trF Beplacement, page 20-8 LOCK CYLINDER REGULATOR LOWER PATCH DOOR OUTER HANDLE page 20-5 Replacement,...
Page 685 Doors Door Panel RemovaUlnstallation SpecialTools Required Trim pad remover, Snap-on A 177A, or equivalent, commercially available. NOTE: . Take care not to scratch the door panel anddoor, . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. ' 1 .
Page 686 Door Outer Handle Replacement N O T E : . Put on gloves to protect your hands. . Take care not to scratch the door . Take care not to bend each rod. ' 1 . Remove these items: . D o o r o a n e l .
Page 687 Doors Door Outer Handle Replacement (cont'd) Fastener Locations CO : Nut, 1 > : Bolt, 2 F > : S c r e w . 1 : Bolt, 1 G ) : S c r e w , 2 I" f)'-'---,-'- I i lllllrr--1 I i I \tF,----:\...
Page 688 Door Latch Replacement NOTE: . Put on gloves to protect your hands. . Take care not to scratch the door. . Take care notto bend each rod. 1 . R e m o v e t h e o u t e r h a n d l e ( s e e p a g e 2 0 - 5 ) . 2.
Page 689 Doors Door Glass and Regulator Replacement NOTE: . Put on gloves to protect your hands. . Take care notto scratch the door. . Take care not to drop the window glass inside the door. 1. Remove these items: . l n n e r h a n d l e a n d r o d c r a n k ( s e e p a g e 2 0 - 7 ) .
Page 690 Faslenel Locations B > : B o l t . 3 O Carefully move the glass down Llntil you can see the bolts. €) Remove the glass from the requlator. 6 x 1 . 0 m m I N.m {0.8 kgf m, 6 rbt.ft) 'tt'"-' '"' @ Scribe a line around the bolls...
Page 691 Doors Door Glass and Regulator Replacement (cont'd) Fastener Locations C a : N u t , 2 o O : N u t . 2 E > : Bolt,3 F > : B o l t . 2 l r l @ (' Scribe a line around the nuts.
Page 692 Door Glass Adiustment NOTE: . Check the A-pillar-header weatherstrip, roof Measuring Point A weatherstrips and B-pillar weatherstrip for damage or deterioration. and replace them if necessary. . Wipe each weatherstrip and the front lower channel clean with a shop towel. .
Page 693 Doors Door Glass Adjustment (cont'dl 9. Adjust clearance "H" as follows: -1 Loosen the bolts (A) securing the stop plates (B). -2 Loosen the bolts (Clsecuring the glass {D). -3 Move the glass up or down, as well as, forward and rearward to align it with the retainer and molding. Move the glass until clearcnce "H"...
Page 694 10. Adjust clearance "8" as follows: Push the glass (A) outward 10 mm (0.39 in.), then lightly push the stabilizer (B) against the glass. Tighten the bolt (C) securing the stabilizer. Check thatthe glass moves smoothly. Loosen the locknuts (D). Turn the adjusting bolts (E) until the clearance "8"...
Page 695 Doors Door Glass Adjustment {cont'd) ' l t . Attach the plastic cover, and installthe door panel A l i g n t h e d o o r s a s h h o l d e r w i t h t h e g l a s s u s i n g t h e t c .
Page 696 Door Sash Holder Replacement NOTE: . Put on gloves to protect your hands. . Take care not to scratch the door. Remove these items: . Door glass (see page 20-8) . Door weatherstrip, as necessary {see page 20-171 Remove the door sash holder in numbered sequence; .
Page 697 Doors Door Sash Holder Adjustment Door Glass Outer Weatherstrip Replacement R a i s e t h e g l a s s f u l l y . L o o s e n t h e l o c k n u t ( A ) w h i l e h o l d i n g t h e a d j u s t i n g NOTE: .
Page 698 Door Weatherstrip Replacement Door Wedge and Door Wedge Holder Replacement NOTE: . Take care not to scratch the door. . Use a clip remover, to remove the clips. NOTE: Take care not to scratch the door and body. 1 . R e m o v e t h e d o o r p a n e l { s e e p a g e 2 0 - 4 ) . 1.
Page 699 Doors Door Position and Door Striker Adjustment NOTE: . A f t e r i n s t a l l i n g t h e d o o r , c h e c k f o r a f l u s h f i t w i t h t h e b o d y , t h e n c h e c k f o r e q u a l g a p s b e t w e e n t h e t r o n t , r e a r , a n d bottom door edges and the body.
Page 700 5. Adjust the striker (A); . Move the striker In or Out to make the latch fit tighter or looser. . Move the striker Up or Down to align it with the latch opening. 8 x 1 . 2 5 m m 1 8 N m ( 1 .
Page 701 Mirrors Component Location Index POWER MIRROR Replacement, page 20-21 , . . , 1 , r !'.:;r, POWEB MIRROR ACTUATOR page 22-106 Replacement, LOCK BOLT TOOTHED LOCK WASHER g .'' HoLD SPRING /'=,-\2 =---'. HOOK PLATE t-- 1 q . " \,/v BRACKET COVER REARVIEW...
Page 702 Power Mirror Replacement Mirror Holder Replacement NOTE: To avoid scratching the door, be sure to hold the NOTE: Put on gloves to protect your hands- m i r r o r w h i l e r e m o v i n g o r i n s t a l l i n g t h e n u t s . 1.
Page 703 Mirrors Rearview Mirror RePlacement NOTE: . Take care not to scratch the cover and mirror stay. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage 1. Remove the rearview mirror as shown 2. Installthe mirror in the reverse order of removal. MOUNTING LUG REARVIEW MIRROR...
Page 704 Glass Component Location Index WINDSHIELD MOLDING i{rin FASTENER, 2 (Clip type, body side) / i / _. MoLD|NG stDEsEAL,2 ill/. LOWER RUBBER DAM 20-23...
Page 705 Glass Component Location Index (cont'dl Removable Hardtop MOLDING RUBBER DAM p-... { 2 \ ,-o*ri'ro.rr"..(Self'adhesive{YPe, olass side) LOWER FASTENER, 2 (Self-adhesive-type, rooJ side) SPACER, SIDE RUBBER DAM,2 REAR WINDOW Glass Replacemenl Process, page 20-25 page 20-32 Replacement, 20-24...
Page 706 Glass Replacement Process NOTE: Using an awl, make a hole through the adhesive . This procedure is a general description ofthe glass from inside the vehicle at the corner portion of the replacement process. For details about fastener and glass, windshield (see page 20-29), rear window rubber dam locations, windshield {see page 20-29), (see page 20-32).
Page 707 Glass Glass Replacement Process (cont'd) 14. Glue the molding (A) with adhesive tape (B) to the 9. Carefully remove the glass. edge ofthe glass (C), windshield (see p age 20-291, '10. With rear window (see page 20-32). Be careful not to a knife, scrape the old adhesive smooth to a touch the glass where adhesive will be applied.
Page 708 16. lf the new glass is to be installed, set the glass (A) 19. With a sponge, apply a light coat of body primerto in the opening, and center it. Make alignment t h e o r i g i n a l a d h e s i v e r e m a i n i n g a r o u n d t h e marks (B) across the glass and body with a grease windshield opening flange, windshield (see page pencil at the four ooints shown.
Page 709 Glass Glass Replacement Process (cont'd) 25. Reinstall atl remaining removed parts. Installthe 21. Pack adhesive into the cartridge without air pockets rearview mirror after the adhesive has dried to ensure continuous delivery. Putthe cartridge in a thoroughly (windshield) caulking gun, and run a bead of adhesive (A) around the edge oJ the glass (B) between the NOTE: Advise the customer notto do the following rubber dam (C) and molding (D) as shown,...
Page 710 Windshield Replacement NOTE: Familiarize yourself with the glass replacement process (see page 20-25). Parts Removal First remove these items: . Rearview mirror {see page 20-22) . Front roof rail trim (see page 20-68) . Windshield wiper arms (see page 22-1 14) .
Page 711 Glass Windshield Replacement (cont'd) Rubber Dams and Fastener Installation, and Primer Application . Be sure the rubber dams and fasteners line up with the alignment marks, ' G l u e t h e r u b b e r d a m s w i t h a d h e s i v e t a p e { N | T T O 5 0 1 l \ i l , o r e q u i v a l e n t ) , a n d g l u e t h e f a s t e n e r w i t h a d h e s i v e t a p e (3M 4215, or equivalent).
Page 712 Fastener (body sidel Installation/Body Primer Application 16 mm : Apply bodv primer here. (0.63 in.) 6 mm {0.24 in,l 16 mm 10.63 in.l 5 m m 10.2 in.) Glass Primer and Adhesive Application .l',,jli : Apply glass prime. here. 9 mm 10.35 in.l 13 mm (0.51 in.) M.LD'NG rnsiae I...
Page 713 Glass Rear Window Replacement Removable Hardtop NOTE: . To remove and install the rear window, remove the roof from the body. . Place the roof on padded supports to prevent damage. . Have an assistant helo vou remove and install the rear window. .
Page 714 Rubber Dams, Fasteners, and Spacers Installation . Be sure the rubber dams, fasteners, and spacers line up with the alignment marks. . G l u e t h e u p p e r f a s t e n e r w i t h a d h e s i v e t a p e ( 3 M 4 2 1 5 , o r e q u i v a l e n t ) a n d t h e l o w e r f a s t e n e r w i t h a d h e s i v e t a D e ( 3 M 5 3 1 2 , o r e q u i v a l e n t ) .
Page 715 Glass Rear Window Replacement {cont'd) Fastoner {roof side} lnstallation/Body Primer Application Glue the lower fasteners with adhesive tape (3M 4256, or equivalent). li/i,i/tt I t ppty bodr p.im€f. h?r'.e. U n i t m m { i n . ) ( T w o p l a c e s ) 1610.631 31 {1.21...
Page 716 Convertible Top Component Location Index '00-01 Models CONVERTIBLE TOP CLOTH page 20 40 Replacement, Repair, page 20 48 wtNDow R e p l a c e m e n t , CONVERTIBLE TOP page 20-43 COVER LINK STOP RUBBER SPACER (With removable hardtopi CONVERTIBLE TOP PLATE B...
Page 717 Convertible Top Component Location Index (cont'd) '02-03 Models CONVERTIBLE TOP CLOTH page 20-40 Replacement, Repair, page 20-48 REAR WINOOW HARNESS HOLDER COVER REAR WINDOW CONVERTIBLE TOP LOWER MOLDING COVER Replacement, page 20-47 REAR WINDOW REAR WINDOW HARNESS HOLDER Replacement, Daae 20 47 REAR WINDOW DEFOGGER LINK STOP RUBBER SPACER...
Page 718 ., coNvERTIBLE TOP -STRIKER Re?lacement' Page 20'50 B-PILLAR ///' OUTER WEATHERSTRIP page 20-52 Replacement, -43t \=,,., PIPE page ase 20-52 DRAIN VALVE A.PILLAR MOLDING page 20-51 Replacement, 20-37...
Page 719 Convertible Top Convertible Top Assembly Replacement NOTE: . Have an assistant help you remove the convertible top assembly. . Take care not to scratch the top cloth and body. . Put on gloves to protect your hands. ' l f t h e t o p d o e s n o t m o v e w i t h t h e c o n v e r t i b l e t o p s w i t c h , d i s c o n n e c t t h e e m e r g e n c y c o n n e c t o r n e a r t h e p a s s e n g e r ' s kick panel lsee page 22-'147l., and move the top by hand.
Page 720 Fatten6r Locations F > : C t i p . 2 G > : C l i p , 2 E > : B o l t , 1 0 '00 model '01-03 models /Gt\ Flk.. -4E5- tE,]urPrr'rr !/4)E\'4 V t o {!i!]!!r MOLDING REAR WINDOW...
Page 721 Convertible Top Convertible Top Cloth Replacement NOTE: . Take care notto scratch the top frame. . Put on gloves to protect your hands. . Wear eye protection when removing the rivets with a drill. . When removing the rivets, drill holes in the rivets with a 4 mm {0.16 in.) drill. ' T h i s i l l u s t r a t i o n s h o w s t h e l e f t s i d e o f t h e v e h i c l e , r e p e a t t h e p r o c e d u r e o n t h e r i g h t s i d e i n t h e s a m e m a n n e r .
Page 722 Fastener Locations RIVET C > : S c r e w , 4 E F - : R i v e t , 6 ) : Screw , . . . O u t e r d i a m e t e . 4 m m ( 0 . 1 6 i n . ) (Silver) Removal Installation...
Page 723 Convertible Top Convertible Top Cloth Replacement (cont'dl Reinstalling the Cloth to each Bow Make sure the alignment notch ofthe cloth is in the center portion ofthe retainer. After reinstalling, press on the relarners securety. Center Donion: RETAINERS ALIGNMENT NOTCH RETAINER Cloth and Weatherstrip Check The weatherstrip should fit flush.
Page 724 Rear Window Replacement '00-01 Models 6. Open the roof, and lift up the center console (see page 20-761. NOTE: . Take care not to scratch the top frame. 7. Remove the rear console and the rear console box . Wear eye protection when removing the rivets with a (see page 20-78).
Page 725 Convertible Top Rear Window Replacement (cont'd) 1 0 . Open the roof half-way, and remove the two clips 14. Pull the rain rail {A) up. and turn it inside-out. With (A, B) on each side of the top between the quarter the rain rail resting on the roof (B), drill out the r i v e t s ( C ) w i t h a 4 m m ( 0 .
Page 726 17. Release the fasteners (A) to expose the zipper (B), 19. Zip the new window (A) onto the roof (B), making and remove the end stops (C) from both ends of the sure the alignment notches (C) are lined up. z i D D e r .
Page 727 Convertible Top Rear Window Replacement (cont'd) 22. Secure the lower part of the rear window (A) to the 2 4 . Setthe rain rail in position, and install the clips between the quarter panel and the roof. lower part of the convertible top cloth (B) with new two-piece brass rivets (C).
Page 728 Rear Window Lower Molding/Rear Window Harness Holder Replacement '02-03 Models 4. Apply primer (3M N-200, or equivalent) to the areas of the rea r window (A) where the molding and h a r n e s s h o l d e r w i l l b e g l u e d , a n d a p p l y p r i m e r ( 3 M NOTE: .
Page 729 Convertible Top Conveftible Top Cloth Repair Clean the repair cloth where adhesive will be 1. The following tools and supplies are required to repair the top cloth. a p p l i e d . . Repair cloth Apply the adhesive (A) to the repair cloth (B) and .
Page 730 Conveftible Top Lock Handle Convertible Top Lock Handle Replacement Operation Load Adiustment NOTE: Take care not to scratch the top frame. NOTE: Take care not to scratch the interior parts. Remove the convertible top lock handle as shown. 1. Remove both reartray side trim (see page 20-7'1). 2.
Page 731 Convertible Top Gonvertible Top Striker Convertible Top Motor Replacement Replacement NOTE: Take care not to scratch the interior parts. NOTE: . Take care not to scratch the interior parts. 1. Remove the windshield header interior trim (see . Put on gloves to protect your hands. page 20-68).
Page 732 A-Pillar-Header Weatherstrip and A-Pillar Molding Replacement NOTE: . Take care not to scratch the body. . Use a clip remover, to remove the clips. 1. Remove the A-pillar-header weatherstrip and A-pillar-molding as shown. 2. Installthe weatherstrip and molding in the reverse order of removal, and note these items: .
Page 733 Gonvertible Top Drain Tank and Lower Drain Hose B-Pillar Outer Weatherstrip Replacement Replacement NOTE: NOTE: . Take care not to scratch the body . Take care notto scratch the body . Take care not to drop the screw. . Use a clip remover. to remove the clips. 1.
Page 734 Convertible Top Cover Snap Replacement NOTE: Take care not to scratch the convertible top cover. Using a snap ring pliers (A), remove the nut (B) from the snap (C). then remove the snap from the convertible top cover (D). Install the cover snap in the reverse order of removal, 20-53...
Page 735 Removable Hardtop Component Location Index ROOF wrNDow REAR WINDOW Position Adjustment, Component Location Index, page 20-24 DEFOGGER GROUND page 20-65 Glass Beplacement Process, page 20-25 HARNESS Replacemenl, page 20 32 WEATHERSTRIP Replacement, page 20'60 wtNDow DEFOGGER HARNESS ROOF FRONT TRIMS Replacement, page 20-61 WINDOW LOWER TRIM...
Page 736 Interior Trim Removal/lnstallation NOTE: . Put on gloves to protect your hands. . To remove and install the interior trim, remove the roof from the booy. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. .
Page 737 Removable Hardtop Headliner RemovaUlnstallation NOTE: . Put on gloves to protect your hands. . To remove and install the headliner, remove the roof from the body. . Have an assistant help you remove and installthe headliner. . Take care notto bend or scrach the headliner. 1.
Page 738 Roof Molding Replacement NOTE: . Put on gloves to protect your hands. . To remove and install the roof molding, remove the roof from the body. . Take care not to scratch the roof. . Use a clip remover to remove the clip. .
Page 739 Removable Hardtop Roof Molding Replacement (cont'd) lnstallation Install the roof molding in the numbered sequence, and note these items: Before reinstalling the roof molding, clean the roof surface where the sealant will be applied. W h e n r e i n s t a l l i n g t h e r e t a i n e r . a l i g n i t w i t h t h e m a r k s f o r t h e o r i g i n a l p o s i t i o n s . Check that the weatherstrip is securely installed to the retainer.
Page 740 Weatherstrip Check NOTE: . Make sure the hardtop is locked securely with both lock handles and both roof side locks. . Check that the weatherstrip is securely installed to the retainer. . R a i s e t h e g l a s s f u l l y . .
Page 741 Removable Hardtop Hardtop Lower Weatherstrip Replacement NOTE: . To remove and install the hardtop lower weatherstrip, remove the roof from the body . Take care not to scratch the roof, . Use a clip remover to remove the cllps. 1. Remove the rear window lower trim (see page 20-55). 2, Remove the hardtop lower weatherstrip as shown.
Page 742 Hardtop Lock Handle Replacement Roof Front Trim Replacement NOTE: NOTE: . To remove and install the rooffronttrim. remove the . To remove and installthe hardtop lock handle, roof from the body. remove the roof from the body. ' Take care not to scratch the roof. .
Page 743 Removable Hardtop Roof Side Lock Replacement NOTE: Grease Application . Put on gloves to protect your hands. . To remove and installthe roof side lock, remove the roof from the body. . Take care not to scratch the roof. . l f t h e o l d l o c k i s t o b e i n s t a l l e d , s c r i b e a l i n e a r o u n d the mounting bolts before removing the lock.
Page 744 Hardtop Striker Replacement Body Side Catch Assembly Replacement NOTE: ' To remove and install the hardtop striker, removethe NOTE: Put on gloves to protect your hands. roof from the body. . Take care not to scratch the interior parts. 1. Remove the roof from the body. Take care not to 1.
Page 745 Removable Hardtop Body Side Catch Assembly Body Side Catch Replacement Replacement (cont'dl 1 . Remove the body side catch assembly from the body (see page 20-63). Remove the lower clip (A) fastening the B-pillar outer weatherstrio (B) from outside of the front Remove the body side catch as shown.
Page 746 Roof Position Adjustment NOTE: Have an assistant help you adjust the roof position. 1. Remove the B-pillar trim from both sides (see page 20-55), and make sure both lock handles (A) androofside 6 x 1 . 0 m m 9.8 N.m (1.0 kgf m,7.2lbt ftl 8 x 1.25 mm 22 N.m...
Page 747 Removable Hardtop Roof Position Adjustment (cont'dl 4. lf the roof alignment is still not within specification, unlock the roof, and repeat the preceding steps. 5. lf the roof alignment is not within specification, check the body side catches, and check for body de{ormation. 6.
Page 748 Interior Trim Component Location Index CONVERTIBLE TOP COVER PIN p a g e 2 0 - 7 0 REAR TRAY page 20-71 ROLL BAR UPPER TRIM page 20-71 REAR TRAY REAR TRIM page 20-71 REAR TRAY SIDE TRIM page 20-71 A-PILLAR INTERIOR CONVERTIBLE TOP COVER TRIM...
Page 749 lnterior Trim Trim Removal/lnstallation - Front Roof Area NOTE: . Put on gloves to protect your hands. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to bend or scratch the trim and oanels. 1.
Page 750 Trim Removal/lnstallation - Door Area NOTE: . Put on gloves to protect your hands. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to bend or scratch the trim and Danels. ' 1 .
Page 751 Interior Trim Trim Removal/lnstallation - Seat Side Area NOTE: . Put on gloves to protect your hands. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to bend or scratch the trim and panels. 1.
Page 752 Trim Removal/lnstallation - Rear Tray Area NOTE: . Put on gloves to protect your hands. ' When prying with a flat-tip screwdriver. wrap it with protective tape to prevent damage. . Take care not to bend or scratch the top cloth, rear window, trim and panels. 1 , R e m o v e t h e t r i m i n n u m b e r e d s e q u e n c e .
Page 753 lnterior Trim Trim Removal/lnstallation - Rear Tray Area (cont'dl O ROLL BAR AND UPPER TRIM ASSEMBLY Fastener Locations First remove the these items: .Rear console C > : B o l t , 8 D > : S c r e w , 4 .Rear side trim 6] SEAT BELT UPPER ANCHOR BOLT 7/16-20UNF...
Page 754 Trim Removal/lnstallation - Trunk Area NOTE: . Put on gloves to protect your hands. . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to bend or scratch the trim and panels. 1 .
Page 755 lnterior Trim Carpet Replacement N O T E : . Put on gloves to protect your hands, . Take care not to damage. wrinkle, or twist the carpets. . B e c a r e f u l n o t t o d a m a g e t h e d a s h b o a r d o r o t h e r i n t e r i o r t r i m p i e c e s . 1.
Page 756 Center Carpet Replacement SRS components are located in this area. Reviewthe SRS component locations {see page 23-9) and the precautions and procedures (see page 23-10) in the SRS section before performing repairs or service, NOTE: . Put on gloves to protect your hands. .
Page 757 Consoles Center Console RemovaUlnstallation NOTE: . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to scratch the front seat, dashboard and related parts. . Remove the shift knob by turning it counterclockwise. 1.
Page 758 Wind Deflector Replacement '01-03 Models NOTE: . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care notto scratch the rear console upper lid and related parts. 1. Remove the wind deflector as shown. 2.
Page 759 Consoles Rear Console Removal/lnstallation NOTE: . When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. . Take care not to scratch the front seat and related parts. 1. Remove these items: ' Center console (see page 20-76) .
Page 760 Rear Console Box Replacement NOTE: Take care not to scratch the front seat and related parts. Remove these items, then remove the rear console box as shown; . Roll bar upper trim, both sides (see page 20-71] ' S p a r e t i r e 2.
Page 761 Dashboard Radio Panel RemovaUlnstallation Instrument Panel Removal/ Installation NOTE: . When prying with a flat-tip screwdriver, wrap lt with protective tape, and apply protective tape around the NOTE: related parts, to prevent damage. . When prying with a flat-tip screwdriver, wrap it with .
Page 762 Front Console Cover Removal/ Passenger's Dashboard Lower Installation Gover Removal/lnstallation NOTE: NOTE: . When prying with a flat-tip screwdriver. wrap it with . When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the protective tape, and apply protective tape around the related parts, to prevent damage.
Page 763 Dashboard Dashboard RemovaUlnstallation Passenger's Side Vent Removal and lnstallation SRS comoonents are located in this area. Review the SRS component locations (see page 23-9) and the precautions and procedures (see page 23-10) in the SRS 1. Wrap a flat-tip screwdriver with protective tape, section belore performing repairs or service.
Page 764 4. Disconnect the engine wire harness connector (A), engine compartment wire harness connectors (B), door wire harness connectors (C), rear wire harness connector (D), steering hanger beam wire harness connectors (E), SRS main harness connector {F), radio antenna harness connector (G), ECM connector (H}. keyless entry control unit connector ( l), and convertible toD control unit connector (J).
Page 765 Dashboard Dashboard Removal/lnstallation (cont'd) 7. From outside the doors. remove the caps (A), then remove the bolts (8, C, D) and screws {E), and lift up on the dashboard (F) to release it from the guide pins (G ). Take care not to scratch the center console and shift knob. Fasten6r Locations >...
Page 766 Component Location Index Removal/lnstallation, paqe 20-86 Disassembly/Reasseniblt Driver's, page 2O-87 Disassembly/Reassembly Passenger's,page2O-88 Seat Cover Replacement; page 2O-8r-9...
Page 767 Seats Seat Removal/lnstallation NOTE: Take care not to scratch the body or tear lhe seat covers. 1 . Remove the seat as shown. Install the seat ln the reverse order of removal, and note these items: . Slip the seat belt through the slits in the seat belt guide properly .
Page 768 Seat Disassembly/Reassembly - Driver's NOTE: . Make sure the bushing and pivot washer are installed correctly. . Apply multipurpose grease to the moving portion of th€ seat track. . To prevent wrinkles in the seat-back cover, stretch the malerial evenly over the pad, .
Page 769 Seats Seat Disassembly/Reassembly - Passenger's NOTE: . lMake sure the bushing and pivotwasher are installed correctly. . Apply multipurpose grease to the moving portion of the seat track. e v e n l y o v e r t h e p a d ' ' T o p r e v e n t w r i n k l e s i n t h e s e a t - b a c k c o v e r , s t r e t c h t h e m a t e r i a l .
Page 770 Seat Cover Replacement NOTE: . Take care not to tear the seams or damage the seat covers. . Put on gloves to protect your hands, Seat-back Cover 1. Remove the seat-back cover in numbered sequence. 2. Install the cover in the reverse order of removal, and note these items: ' T o p r e v e n t w r i n k l e s w h e n i n s t a l l i n g a s e a t - b a c k c o v e r , m a k e s u r e t h e m a t e r i a l i s s t r e t c h e d e v e n l y o v e r t h e p a d before securing the clips, fasteners and hooks.
Page 771 Seats Seat Cover Replacement (cont'dl O CLIP Pull back the edge of the cover on the center pad allthe way around, and release the clips. back the center Pad --/""11 CLIP Release from underthepenter pad. FASTENER i.{. @SEAT.BACK COVER i . r \ \ .
Page 772 Seat Cushion Cover 1. Remove the seat (see page 20-86). 2, Remove the seat cushion, driver's {see page 20-87), passenger's (see page 20-88). 3. Remove the seat cushion cover in numbered sequence. 4. Installthe cover in the reverse order of removal, and note these items; ' T o p r e v e n t w r i n k l e s w h e n i n s t a l l i n g a s e a t c u s h i o n c o v e r , m a k e s u r e t h e m a t e r i a l i s s t r e t c h e d e v e n l y o v e r t h e p a d b e f o r e s e c u r i n g t h e c l i p s .
Page 773 Bumpers Front Bumper Removaulnstallation NOTE: . Have an assistant help you remove and install the front bumper. . Take care notto scratch the front bumper and body. . Put on gloves to protect your hands. 1. Remove the front bumoer as shown. 2.
Page 774 Rear Bumper Removal/lnstallation NOTE: . Have an assistant help you remove and install the rear bumper. . Take care notto scratch the rear bumoer and bodv. . Put on gloves to protect your hands. 1 . R e m o v e t h e r e a r b u m D e r a s s h o w n . 2.
Page 775 Hood Adjustment Slightly loosen each hood hinge bolt. Adjust the hood alignment: . A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e l l a s f o r w a r d a n d r e a r w a r d , b y u s i n g t h e e l o n g a t e d h o l e s o n t h e h o o d h i n g e (A).
Page 776 Check that the hood opens properly and locks securely. Apply body paint to the hinge mounting bolts and around the hinges. Remove the air guide plate cover (see page 20-1 1 1), then remove the latch cover (A). Apply multipurpose grease to each location of the hood latch (B) and hood hinge (C) as indicated by the arrows.
Page 777 Hood Hood Insulator Replacement NOTE: . Take care notto scratch the hood. . Use a clip remover to remove the clips. 1. Remove the hood insulator in numbered sequence. 2. lnstallthe insulator in the reverse order of removal. and note these items: .
Page 778 Trunk Lid Adjustment Slightly loosen each bolt. A d j u s t t h e t r u n k l i d a l i g n m e n t : . Adjust the trunk lid right and left, as well as forward and rearward, by using the elongated holes on the trunk lid h i n g e s ( A ) .
Page 779 Trunk Lid Trunk Lid Torsion Bar Replacement NOTE: . Take care not to scratch the bodv. . Put on gloves to protect your hands. . U s e a t o r s i o n b a r t o o l t o r e m o v e a n d i n s t a l l t h e t o r s i o n b a r s . .
Page 780 Trunk Lid Rubber Protector Trunk Lid Weatherstrip Replacement Replacement NOTE; 1. Remove the trunk lid weatherstrip by pulling it off. . Take care not to scratch the trunk lid. . Use a clip removerto remove the clips. 2 . L o c a t e t h e p a i n t e d a l i g n m e n t m a r k ( A ) o n t h e t r u n k lid weatherstrip (B).
Page 781 Fuel Fill Door Adjustment 1. Slightly loosen the hinge mounting bolts (A). 5. Apply multipurpose grease to each location indicated by the arrows. _ _1---. I l , t 1 - l Apply body paint to the hinge mounting bolts and around the hinges.
Page 782 Exterior Trim Cowl Cover Replacement N O T E ; . Take care not to scratch the body. . Use a clip remover to remove the clips. 1. Remove the windshield wiper arms lsee page 22-112). 2 . R e m o v e t h e c o w l c o v e r a s s h o w n . Installthe cover in the reverse order of removal, and note these items: .
Page 783 Exterior Trim Rear Window Lower Molding Rear Tray Opening Molding Replacement Replacement NOTE: Take care not to scratch the body. NOTE: . Take care not to scratch the body. . Be careful not to pry too far or you may bend the 1.
Page 784 Emblem Replacement NOTE: When removing the emblems. take care not to scratch the body. Apply the emblems where shown, and note these items: . Clean the body surface with a sponge dampened in alcohol. . After cleaning. keep oil, grease and water from getting on the surface. Adhesive tape: 3M ,12'13E, or equivalent Thickness 0.8 mm 10.03 in.) Unit mm {in.)
Page 785 Exterior Trim A-pillar Exterior Trim Replacement N O T E : . Keep dust away from the working area. . When working at lower temperatures, heat the body and trim with a hair dryer. Body: about 59'F ( 15"C) Trim: about 86"F (30'C) .
Page 786 Fenderwell Inner Fender Replacement NOTE: Take care not to scratch the body. 1. Remove the front wheel. 2 . R e m o v e t h e i n n e r f e n d e r a s s h o w n . 3 .
Page 787 Fenderwell Strakes Replacement NOTE: Take care not to scratch the body. 1. Remove the strakes as shown. 2. lnstall the strakes in the reverse order of removal Fastener Locations C > : S c r e w . 3 B > : B o l t , 4 A >...
Page 788 Fenderwell Trim Replacement Rear Air Outlet Replacement NOTE:The steel core in the fenderwelltrim cannot be NOTE: Take care not to scratch the body. restored to it original shape once it is bent. Replace the fenderwelltrim when the steel core is bent. 1.
Page 789 Openers Component Location Index TRUNK LID LOCK CYLINOER Replacement, page 20-1 13 TRUNK LID LATCH Replacement, page 20-112 FUEL FILL OOOR OPENER CABLE Replacement, page 20 1'10 FUEL FILL DOOB OPENER page 20-110 .::._': HOOD RELEASE HANOLE Replacement, page 20'1 1 1 HOOD LATCH Replacement, page 20 111 HOOD OPENER CABLE...
Page 790 Hood Opener Cable Replacement NOTE: . Put on gloves to protect your hands. . Take care not to scratch the body and related parts. . Take care notto bend the cable. 1. Remove these items: . Inner fender (see page 20-105) .
Page 791 Openers Fuel Fill Door Opener Cable Replacement NOTE: . Put on gloves to protect your hands . Take care not to scratch the body and related parts . Take care not to bend the cable. '1. Remove these items: . Rear side trim (see page 20-70) .
Page 792 Hood Release Handle Replacement Hood Latch Replacement NOTE: Take care not to bend the caore. NOTE: Take care not to bend the cable. 1. Remove the kick panel (see page 20-69). Replacement 2, Remove the hood release handle as shown, 1.
Page 793 Openers Hood Latch Replacement (cont'd) Trunk Lid Latch Replacement Grease Application NOTE: ' P u t o n g l o v e s t o p r o t e c t y o u r h a n d s . .
Page 794 Trunk Lid Lock Cylinder Replacement NOTE: . Take care notto scratch the body. . Take care notto bend the cylinder rod. 1 . R e m o v e t h e t r u n k l i d l o c k c y l i n d e r a s s h o w n . 2.
Page 795 Frame Front Subframe Replacement After loosening the subframe mounting bolts, be sure to replace them with new ones' Reference holes alignment: SUBFRAME INSTALLATION REFERENCE HOLE {Subframe side) I x 1.25 mm 22N.m l2.2kgl..n, 8 x 1.25 mm 16 rbf.ftl INSTALLATION 22N.m 12.2kgl.m, REFERENCE HOLE 16 rbf.ftl...
Page 796 Rear Subframe Replacement After loosening the subframe mounting bolts, be sure to replace them with new ones. Reference holes alignment: (Body side) SUBFRAME SCREWORIVER or TAPERED PUNCH INSTALLATION REFERENCE HOLE INSTALLATION REFERENCE HOLE REAR SUBFRAME To body. To body. - / , _ \ \ , t t , L , t - - 7 - - J ) i A t \ o f i...
Page 797 Frame Frame Repair Chart Top View POINT POINT For upper arm 613 {0.5) Unitrmm (in.) For bumper beam 010 {0.4) For tie down s23 x 30 (0.9 x 1 21 For subframe s17 10.7) d: lnner diameter For subframe 617 {0.7) For stabilizer d24 {0.91 Locate hole o25 (1.01 For stabilizer d24 {0.9}...
Page 798 POINT Locate hole o15 10.59) For rear subframe 11610.63l For rear subtrame 616 {0.631 Rear dampe. c€nter 650 12.01 For rear subfr.rne 616 10.6i|l Locate hol6 r20 {0.81 (cont'd) 20-117...
Page 799 Frame Frame Repair Chart {cont'd) SideView POINT P O I N T F o r u p p e r a r m s 1 3 { 0 5 1 Unit mm (in.) For bumper beam o10 {0.41 F o r s u b f r a m e o 1 7 { 0 . 7 ) For tie down o23 x 30 {0.9 x 1 2) o: lnner diameter For subframe s17 {0.7)
Page 800 POINT Locate hole s15 10.59) Cs\ rsar s\bhaNsd$\$S3\ For rear subframe 016 {0.631 R€er damper centor ,50 (2.0) For rear Bublramo 116 lo.fill Locale hole s20 {0.8} SECT|O OO 20-119...
Page 801 HVAC (Heating, Ventilation, and Air Conditioningl Heating and Air Conditioning Speciaf Tools ..... 21-2 C o m p o n e n t L o c a t i o n I n d e x ......... 2 1 - 3 A,/C Service Tips and Precautions .......
Page 838 Blower/Evaporator Unit Components Replacement Note these items when overhauling the blower/evaporator unit: . The recirculation control motor (A), the powertransistor (B), and the blower motor (C)can be replaced without removing the blower/evaporator unit. . l f y o u ' r e i n s t a l l i n g a n e w e v a p o r a t o r c o r e ( D ) , a d d r e f r i g e r a n t o i l ( K E I H I N S P - 1 0 ) ( s e e p a g e 2 l - 6 ) .
Page 839 Heating and Air Conditioning Heater Unit/Core Replacement Remove the mounting bolt from the heater valve. SRS comoonents are located in this area. Review the Slide the hose clamps (A) back, then disconnect the SRS component locations, precautions, and procedures inlet heater hose (B) and the outlet heater hose {C) in the SRS section before performing repairs or service (see page 23-10).
Page 840 Disconnect the connectors (A) from the mode 8. Remove the dashboard {see page 20-82). control motor and the air mix control motor, then 9. Remove the blower/evaporator unit remove the wire harness clip {B). Remove the ( s e e p a g e 2 1 - 3 8 ) . mounting nuts, the mounting bolt, and the heater u n i t ( C ) .
Page 841 Heating and Air Conditioning Dust and Pollen Filter Replacement Heater Unit/Core Replacement (cont'dl The dust and pollen filter should be replaced every 30,000 miles under normal conditions, or every 15,000 15. Installthe heater core in the reverse order of miles under extremely dusty or sooty conditions. Reolace the filter more often if the air flow is less than removal.
Page 842 Heater Valve Cable Adjustment 1 . From under the hood, open the cable clamp (A), From under the hood, turn the heater valve arm (C) then disconnect the heater valve cable (B) from the to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve heater valve arm (C).
Page 843 Heating and Air Conditioning Compressor Replacement 1. lf the compressor is marginally operable. run the 8, Disconnect the compressor clutch connector, then remove the mounting bolts and the compressor. engine at idle speed, and let the air conditioning work for a lew minutes, then shut the engine off. 2.
Page 844 1 0 . l n s t a l l t h e c o m D r e s s o r i n t h e r e v e r s e o r d e r o f removal, and note these items: .
Page 845 Heating and Air Conditioning Compressor Clutch Check 1 . Check the armature plate for discoloration, peeling, 4. Release the field coil con nector f rom the ho lder, then disconnect it. Check the thermal protector for or other damage. lf there is damage, replace the clutch set (see page 21-47).
Page 846 Kent-Moore J37872, pulley (B). Be careful not to damage the pulley and or Honda Tool and Equipment KMT-J33939, c o m m e r c i a l l y a v a i l a b l e compressor.
Page 847 Heating and Air Conditioning Compressor Clutch Overhaul (cont'd) 5. Reassemble the clutch in the reverse order of disassembly, and note these items: ' l n s t a l l t h e f i e l d c o i l w i t h t h e w i r e s i d e f a c i n g down, and align the boss on the field coil with the hole in the compressor.
Page 848 Compressor Thermal Protector Compressor Relief Valve Replacement Replacement ' 1 . 1 . R e m o v e t h e b o l t , t h e g r o u n d t e r m i n a l { A ) , a n d t h e Recover the refrigerant with a recove rylrecycling/ holder (B).
Page 849 Heating and Air Conditioning Condenser Replacement 5. Remove the bolts and the upper mount brackets (A), Recover the refrigerant with a recovery/recycling/ c h a r g i n g s t a t i o n ( s e e p a g e 2 1 - 5 1 ) . then remove the condense.
Page 850 Refrigerant Recovery 1. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high'pressure service port (B) and the Iow-pressure service port (C) (see Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. p a g e 2 ' 1 - 3 ) , a s s h o w n . f o l l o w i n g t h e e q u i p m e n t Be carefulwhen connecting service equipment.
Page 851 Heating and Air Conditioning System Evacuation 2. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (B) and the low-pressure service port {C) (see . Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. page 2l-3), as shown, following the equipment ' Be careful when connecting service equipment.
Page 852 System Charging 2. Evacuate the system (see page 21-52). . Air conditioning refrigerant or lubricant vapor 3. Add the same amount of new refrigerant oil to the can irritate your eyes, nose. or throat. system that was removed during recovery. Use ' Be careful when connecting service equipment.
Page 853 Special Tool Required charging station (A) to the high-pressure service Leak detector. Honda Tool and Equipment YGK-H-10PM port (B) and the low-pressure service port (C) (see c o m m e r c i a l l y a v a i l a b l e page 21-3), as shown, following the equipment manufacturer's instructions.
Page 854 A/C System Tests Pressure Test Test results Related svmDtoms Probabls causo Remedv Discharge (high) Atter stopprng compressor, Hecover, evacuate (see page 2l-51), Air in system pressure pressure drops to about 196 kPa (2.0 and recharge with specified amount abnormally high kgt/cm', 28 psilquickly, and then (see page 21-53).
Page 855 Heating and Air Conditioning A/C System Tests (cont'dl Performance Test Remove the passenger's dashboard lower cover (see page 20-81). lnsert a thermometer (A) in the center vent, and place another thermometer {B) near the blower unit. Compressed air mixed with R-134a forms a combustible vapor.
Page 856 7. To complete the charts: . Markthe delive ry tem peratu re along the vertical line. . Mark the intake temperature (ambient air temperalure) along the bottom line. . Draw a line straight up from the air temperature to the humidity. .
Page 857 Body Electrical *Audio System Body Electrical Keyless/Power Door Locks G e n e r a l T r o u b i e s h o o t i n g ComponentLocation Index ..22-A7 Component Location Index ..22 130 I n f o r m a t i o n 22-2 CircuitDiagram .....
Page 858 Body Electrical General Troubleshooting Information . Some connectors have a clip on their side used to Tips and Precautions attach lhem to a mount bracket dn the body or on another component. This clip has a pull type lock. Betore Troubleshootin g .
Page 859 Check for loose retainer (A) and rubber seals (B). Handling Wires and Harnesses . Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. . Remove clips carefully; don't damage their locks (A). The backs of some connectors are packed wilh dielectric grease.
Page 860 . . lf possible, insertthe probe of the testerfrom thewire side (except waterproo{ connector). Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. 22-4...
Page 861 Five-step Troubleshooting Wire Color Codes 1. Verify The Complaint The following abbreviations are used to identify wire Turn on all the components in the problem circuit colors in the circuit schematics: to verify the customer complaint. Note the W H T ........W n r r e symptoms.
Page 862 Relay and Control Unit Locations Engine Gompartment INTERMITTENT WIPER RELAY {'02-03 models) AUXILIARY ABS MODULATON UNIT UNDER-HOOD FUSE BOX EPS CONTROL UNIT AIR PUMP RELAY BLOWER MOTOR RELAY MAIN UNDER.HOOD FUSE/RELAY BOX CONDENSER FAN RELAY RADIATOR FAN RELAY A/C COMPRESSOR CLUTCH RELAY HORN RELAY ELD UNIT...
Page 863 Dashboard l{lGH BEAM CUT RELAY lcanadal f Wire colors: RED/BLU, ORN, I LBLU and BLU/RED INTERMITTENT WIPER RELAY {'00-01 modelsl DOOR LOCK CONTROL UNIT IWire colors: GRN/REO, CAru, I L GRN/BLK, BLK and BLUAr'YHT .l REAR wlNDOW DEFOGGER RELAY CRUISE CONTROL UNIT {'02-03 modelsl f Wire colors: WHT/GBN, ELIVRED, L YEVBLU, and YEUBLK...
Page 864 Relay and Control Unit Locations Dashboard and Door IG2 RELAY OAYTIME RUNNING LIGHTS fwire colors: BLK/RED, CONTROL UNIT LLT BLU, BLUAVHT and YEL I (Canadal POWER SOCKET RELAY Wire colorsr WHT/RED, LT BLU, YEURED and BLU,lwHT CONVERTIBLE TOP CONTROL UNIT POWER WINDOW MASTER SWITCH (Has built-in control unit)
Page 865 Connectors and Harnesses Connector Index Tl, T6 end (+ ) ( s e e p a g 6 2 2 1 4 ) C204, C303 and C402 through C404, C451 C501 through C504 . 2:'02-03 models 22-9...
Page 866 Gonnectors and Harnesses Connestor to Harness Index EPS Subharness Connects to Notes Location Cavities Connector or Terminal Right side oI engine companment EPS control unit connector C Left engine compartment wire Left side of engine compartment harness (see oaoe 22-16) Right side of engine companment M a i n u n d e r h o o d f u s e / r e l a y Left side o{ engine compartment...
Page 867 BATTERY GROUND CABLE EPS SUBHARNESS STARTER CABLE EPS GEARBOX GROUND CABLE ENGINE GROUND CABLE 22-11...
Page 868 Gonnectors and Harnesses Connector to Harness Index (cont'dl Engine Wire Harness Notes Connector or Terminal C.vitie3 Location Connecis to IVC compressor clutch Left side ofengine compartment Left side ofengine compartment Alternator Back-up light switch Middle oftransmission CKP sensor N,liddle ofengine CMP {TDC) sensor A Middle oI engine CMP {TDC) sensor B...
Page 869 \-1...-- ENGINE WIRE HARNESS 22-13...
Page 870 Gonnectors and Harnesses Connector to Harness Index (cont'dl Bight Engine Compartment Wire Harness Notes Connects to Location Connector or Terminal Cavitie3 Right side of engine compartment ABS right front wheel sensor Ay'C pressure switch Middle of engine companment Left side of engine compartment Condenser fan motor Underhood fuse/relay box ELD unit lsee page 22-321...
Page 871 ENGINE COMPARTMENT WIRE HARNESS 22-15...
Page 872 Connectors and Harnesses Connector to Harness Index (cont'd) Left Engine Compartment Wire Haness Location Connects to Notes Connec-tor or Terminal Cavities Left side ol engine compaftment ABS left front wheel sensor ABS modulator unit Left side ofengine compartment Air pump electric current sensor Left side of engine compartment Air pump electric current sensor Lett side ofengine companment...
Page 873 LEFT ENGINE COMPARTMENT WIRE HARNESS ' 1 6 'ftt|--'-' "t; r'1;i$ /i'; -r.,ffi-...' 22-17...
Page 874 Gonnectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness B (Left branch) Connec't3 to Notes Connector or Terminal Cavities Location Brake pedal position switch Under left side of dash Cable reel Under left side of dash Clutch pedal position switch L,nder lett side of dash Clutch interlock switch Under left side of dash...
Page 875 1 4 1 5 't', 1? ( C o n t i n u e s t o r i g h t b r a n c h ) UNDER.DASH FUSE/RELAY DASHBOARO WIRE HARNESS B ( c o n t ' d ) 22-19...
Page 876 Connectors and Harnesses Connector to Harness Index {cont'dl Dashboard Wire Harness B (Right branch) Connector orTorminal Cavitios Location Connects to Notes Accessory power socket relay Under middle of dash Air mix control motor Under middle of dash Blower motor Under right side of dash Convertible top motor emergency Under right side of dash Convertible top motor emergency...
Page 877 (Continues to left branch) 1 2 1 3 DASHBOARD WIRE HARNESS B 22-21...
Page 878 Connectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness A Connectsto Notes Conn6ctor or Teraninal Cavitie3 Location Antenna amplifier Behind audio unit Audio unit Behind audio unit Convertible top control unit connector Under right side of dash Cruise control main switch Under left side of dash ECM connector A Behind left kick panel...
Page 879 1 1 1 2 1 3 1 4 o 1 o OASHBOARD WIRE HABNESS A 22-23...
Page 880 Gonnectors and Harnesses Connector to Harness Index (cont'd) Rear Wire Harness {Left blanch) Connector orT€rminal Cevitios Locetion Connocts to Notes ABS left rearwheel sensor '02,03 Left side oltrunk Condenser mooels '02-03 Diode Left side oltrunk models Behind left corner gusset Driver's door switch Driver's seat belt switch Under driver's seat...
Page 881 (Continues to right branch) ( C o n t i n u e s t o r i g h t b r a n c h ) (cont'd) 22-25...
Page 882 Gonnectors and Harnesses Connector to Harness Index (cont'd) Rear Wire Harness (Right branch) Notes Location Connects to Connector or Terminal Cavities Bjght side oftrunk ABS right rear whee, sensor Accessory power socket Behind rear console betlveen seat- License plate light Behind rear bumper Behind right corner gusset Passenger's door switch...
Page 883 SRS Main Hamess Connector or Terminal C.vitie3 Location Connects to Notes Cable reel Under left side ot dash Driver's seat belt tensioner Behind driver's seat-back Memory erase signal (MES) connector Under-dash fuse/relay box Passenger's airbag inflator Und€r right side of dash Passenger's seat belt tensioner Behind passenger's seat-back Middle offloor...
Page 884 Gonnectors and Harnesses Connector to Harness Index (cont'd) Driver's Door Wire Harness Connocts to Notos Connector or Terminal Cavities Locltion Driver's door Driver's door key cylinder switch Driver's door Driver's door lock actuator Driver's door lock knob switch Driver's door Driver's door Driver's door speaker Driver's door...
Page 885 Passenger's Door Wire Harness Connoctor or Torminal Cavitios Localion Connects to Notes Passenger's door lock actuator Passenger's door Passenger's door speaker Passenger's door Passenger's window motor Passenger's door Pass6nger's window switch Passenger's door Right power mirror actuator Pass€nger's door '02,03 Righttweeter Passenger's door c504...
Page 886 Connectors and Harnesses Connector to Harness Index (cont'd) HARDTOP: Rearwire harness {see page 22 241 R e a r w i n d o w d e f o g g e r c o n n e c t o r ( + ) REAR WINDOW DEFOGGER GROUND WIRE HARDTOP SUBHARNESS...
Page 887 CONVERTIBLE TOP: Left side ot rear wandow Left sideoftrunk ::-2'/ REAR WINDOW DEFOGGEN SUBHARNESS 22-31...
Page 888 Fuse/Relay Boxes Connector to Fuse/Relay Box Index Main Under-hood Fuse/Relay Box Connects to Socket Terminal Right engine compartment wire harness (see page 22-14) Ay'C compressor clutch relay Right engine compartment wlre harness (see page 22-14) Blower motor relay R i g h t e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 2 2 - 1 4 ) Condenser fan relay Right engine compartment wire harness (see page 22-14) Diode...
Page 889 Under-dash Fuse/Relay Box Socket Terminal Connects to SRS main harness (see page 22-27) lgnition switch harness (see page 22-27) Optional connector Optional connector Optional connector Memory erase signal (MES) SRS main harness (see page 22-27) connector Rear window defogger relay ('00-01 models) Staner cut relay Taillight relay...
Page 890 Fuse/Relay Boxes Connector to Fuse/Relay Box lndex (cont'dl Auxiliary Under-hood Fuse Box Ret Terminal Connects to Socket L e f t e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 2 2 - 1 6 ) L e f t e n q i n e c o m D a r t m e n t w i r e h a r n e s s ( s e e p a q e 2 2 - 1 6 ) 22-34...
Page 891 Power Distribution Fuse to Components Index Main Under-hood Fuse/Relay Box Fuse Amps Wire Color Component{s} or Circuit{s} Protected Number 100 A Battery, Power distribution 4 0 A lgnition switch {BAT} B E DAr'r'HT 2 0 4 Daytime running lights control unit (Canada), Right headlight (high/low o e a m , Not used 2 0 A '...
Page 892 Power Distribution Fuse to Components Index (cont'dl Under-dash Fuso/Relay Box system light, Cruise control unit, 8 L f i E L 1 5 A Cruise control main switch, ELD unit, EVAP bypass solenoid valve' EVAP canister vent Condenser fan relay, Heater control "l@lay, --pr"".- A-udio-unit light, Cruise control main switch light, Front parking lights, Gauge l'ghts'...
Page 893 Auxiliary Under.hood Fuse Box Fuse Amps Wire Color Component(s) or Circuit(s) Protected Numbor 6 0 A Air pump electric current sensor 7 0 A WHT/RED EPS control unit 2 0 ^ ' WHT/GRN Rear window defogger Not used Not used 22-37...
Page 894 Ground Distribution Ground to Components Index Component or circuit grounded Ground Battery E n g i n e b l o c k E n q i n e b l o c k EPS qearbox C K P s e n s o r . D a t a l i n k c o n n e c t o r ( D L C ) , E C M ( P G 1 a n d P G 2 a r e B L K ; L G l a n d L G 2 a r e B H N / Y E L ) , I A U G 1 0 1 valve, lqnition coils, lmmobilizer receiver unit, PGM-Fl main relay, vss, vTEc oil pressure switch shelilng between the EcM these components have BRNryEL wires: cKP sensor, TDC sensor 1 and 2...
Page 895 Battery Battery Test A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby. Follow all procedures carefully and keep sparks and open flames away from the battery. Use either a JCI or Bear ARBST tester, and follow the manufacturer's procedures.
Page 896 Relays Power Relay Test Normally-open type A: Use this chart to identlfy the type of relay, then do the test listed for it. Check for continuity between the terminals. NOTE: For the turn signal/hazard reiay input test (see . There should be continuitv between the No. 1 and page 22-781.
Page 897 Five-terminal type B: Check for continuity between the terminals. . There should be continuity between the No, 1 and N o . 2 t e r m i n a l s w h e n p o w e r a n d g r o u n d a r e connected to the No.
Page 898 Relays Power Relay Test (cont'd) Five-terminal type A: Normally-open type B: Check for continuily between the terminals. Check for continuity between the terminals. . There should be continuity between the No. 1 and ' There should be continuity between the No. 1 and No.
Page 899 lgnition Switch rest SRS components are located in this area. Review the 4. Check for continuity between the terminals in each SRS component locations, precautions, and procedures switch position according to the table. "t+, in the SRS section before performing repairs or service (see page 23-10).
Page 900 Gauges Component Location Index VEHICLE SPEED SENSOR {VSS} Troubleshooting, page 22-53 Replacement, page 22 52 GAUGE ASSEMBLY Bulb Feplacement, page 22 46 Replacement, page 22 52 FUEL GAUGE SENDING UNIT p a g e 1 1 - 1 1 9 PARKING BRAKE SWITCH page 19''l I BRAKE FLUID LEVEL SWITCH...
Page 901 Gauge/Tarminal Location Index: CONNECTOR D CONNECTOR A A 1 . . . - - - . . - . > A 6 A 7 ..> A 1 4 D9''..--> D16 . > c 1 0 >...
Page 902 Gauges Gauge Bulb Replacement GAUGE LIGHTS 13.O W) GAUGE LIGHTS {2,0 W} LIGHT (3.0 W x 3) SEAT BELT REMINDER LTGHT {1.12 W) LEFT TURN SIGNAL INDICATOR LIGHT t 1 . 1 2 W ) ABS INDICATOR SRS INDICATOR LIGHT {1.12 WI LTGHT 11.12 Wl BRAKE SYSTEM LTGHT (1.12 Wl...
Page 903 Circuit Diagram MAINUNDER HOOD fUSE/BILAY BOX !DrcATON UGI{T l1.r2w) DAvllME RUNNING IIGHTS CONTEOL . . u ! L . . _ . . - J (cont'd) 22-47...
Page 904 Gauges Circuit Diagram (cont'dl l " . E?S c0rvn0t UI{IT ' co[vEFn&t c0Nnot . cSulsE MMIOL UI{IT G501 22-48...
Page 905 rcYESS DOOF LOCK CONIFOL UI\IIT RED/l{r{r lcl'llllol'l /'F\ [ - l ] r G Y SWITCH 1 1 q o $ d . 8Ll( Gr01 G6o1 ( c o n t ' d ) 22-49...
Page 906 Gauges Circuit Diagram (cont'd) GAUCE ASSEMEIY MODUIATOS UI{II UI{IT 22-50...
Page 907 I'{0.6{1541 FUSE - EUNr'ltNG | ucHrs ^Di,,orn _,2 CONTBOT {Cdrdal 22-51...
Page 908 Gauges VSS Replacement Gauge Assembly Replacement Raise the vehicle, and make sure it is securely Lower the steering column, and remove the driver's su pported. airbag, steering wheel. steering column covers cable reel, and combination switch assembly {see Disconnect the 3P connector from the vehicle p a g e 1 7 - 9 ) .
Page 909 Vehicle Speed Signal Circuit Troubleshooting Note; lf the MIL indicator is ON, troubleshoot the PGM- 5. Measure voltage between the VSS 3P connector Fl problem first. N o . 1 t e r m i n a l a n d b o d y g r o u n d 1 .
Page 910 Gauges Vehicle Speed Signal Circult Maintenance Required Indicator Troubleshooting (cont'dl Reset Procedure How to Reset: Reconnect the VSS 3P connector, and put the car in neutral with the ignition switch ON (ll). Push and hold the trip button. turn the ignition switch O N ( l l ) , a n d c o n t i n u e h o l d i n g t h e t r i p b u t t o n I o r m o r e Slowly rotate the propeller shaft.
Page 911 Tachometer Circuit Coolant Temperature Gauge Circuit Troubleshooting Troubleshooting NOTE: lf the MIL indicator is on, troubleshoot the PG lM- 1 . Check for PGM-Fl DTCS. Fl Droblem first. l s D T C P 0 1 1 6 , P 0 1 1 7 , o r P 0 1 1 8 i n d i c a t e d ? 1.
Page 912 Lights-on, Key-in, Seat Belt Reminder System Circuit Diagram MAIN UNOEi.IIOOO FUSARELAY EOX IGNIIION SWITCH ORIVEBS OFIVEF'S SEAT 6ELT swrTcH stvtlcS fc56.d: I fctcad: Looo. opan J L',Ylrn unhctLd J 22-56...
Page 913 System lnput Test Remove the gauge assembly (see page 22-52). Inspectthe allconnectors and socket terminals to be surethey are all making good contact. . l f t h e t e r m i n a l a r e b e n t , l o o s e , o r c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y . a n d r e c h e c k t h e s y s t e m . .
Page 914 Lights-on, Key-in, Seat Belt Reminder System System Input Test (cont'dl With the connectors connected, back probe the connectors and make these input tests. . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m . .
Page 915 Exterior Lights Component Location lndex r ) A f - , - - - - i ; n n l L r L = r L r L L J t _ I L HEADLIGHT RELAY 1 {Rightl Test, page 22-40 MAIN UNDER-I{OOD FUSE/RELAY HEADLIGHTS/FRONT PARKING LIGHTS...
Page 916 Exterior Lights Component Location Index (cont'd) DASH LIGHTS BRIGHTNESS CONTROLLER Input Test, page 22-85 BEAM INOICATOR LIGHT Bulb Locations, page 22 46 DRL INDICATOR LIGHT {Canada) Bulb Locations, page 22-46 COMBINATION LIGHT swtTcH DAYTIME RUNNING TesVReplacement, page 22-65 LIGHTS CONTROL UNIT {Canadal HIGH BEAM CUT RELAY (Canadal Input Test, page 22-66...
Page 917 Circuit Diagram - USA fff* ;15s199 HEl0!o1T LlGNI li$*) ,.,?'d5-i 22-61...
Page 918 Exterior Lights Circuit Diagram - Canada MA N UNO€R-HOOO FUSE/FELAY NEAOLIGHT FELAY 1 INDICATOF LIGIII UNOER-OASH FIJSE/RELAY SLUN.|.iHI OAYTIME FUNN NG LIGNTS CONTROL UN]T .CONVERTIBLE I iHh*' I i,lfltu I ^ L GRNWHI G8I']]WF]I I*-I R G N T HEADLIGHT @isu+, (Hioh beaml i5sw)
Page 919 UNOER DASH FUSE/REUYEOX ''"-'T;_: ED/BLK 8ED/BLK R€O/8I( RED/BIK BEO/AIX 8EI ( 9 ( 9 ( 9 ( 9 ( t ) ( ,,r\ ( P ] I RIGHT I L]CENSE liF[* l:A'd; lh',[ llt"^{ l!i['o'., I TA LIIGHT I PTITE p^R!|iG I P^8(NG I I SD!
Page 920 Exterior Lights Circuit Diagram - Back-up Lights Circuit Diagram - Brake Lights t{A|t ut{0ln-8000 MAIN UMEN HOOO FUSE/8ELIY FUSE/BELAY 1 RGHT BAC(-UP _/ ucxr LIGHT i {21W1 i i21wl 22-64...
Page 921 Combination Light Switch Test/Replacement Remove the steering column covers (see page 17-9). Disconnectthe 16P connector (A)trom the combination light switch {B). Remove the two screws, then pull out the combination light switch. Inspect the connector terminals to be sure they are all making good contact. .
Page 922 Exterior Lights Daytime Running Lights Control Unit Input Test - Canada 1. Disconnectthe 14P connector (A) from the daytime running lights control unit (B). RED/BLU BLU/RED YEL/BLK Wire side of {emale terminals Inspect the connector and socket terminals to be sure they are all making good contact' .
Page 923 3. Make these input test at the connecror. . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m , .
Page 924 Exterior Lights HID Lamp System Troubleshooting 5 . C h e c k f o r v o l t a g e b e t w e e n t h e N o . l t e r m i n a l o f t h e inverter unit 2P connector and bbdy ground.
Page 925 HID Bulb Removal 1. Make sure you have the anti-theft code for the radio. then write down the frequencies for the radio,s A transient high tension (25,000 V) occurs at the preset buttons. bulb sockets of the high intensity discharge (HlD) lamps when the combination light switch is turned 2.
Page 926 Exterior Lights HID Bulb Removal (cont'dl 10. lnstallthe new bulb in the reverse order of removal. 8. Pull the retaining spring (A) away from the bulb (B), then remove the socket and the bulb (C). 11. After reconnecting the battery, enter the anti-theft code for the radio, then enter the customer's radio statron Dresets.
Page 927 Headlight Replacement Install the headlight in the reverse order of removal. Headlights become very hot during use; do not After replacement, adjust the headlights to local t o u c h t h e m o r a n y a t t a c h i n g h a r d w a r e i m m e d i a t e l y requirements (see page 22-721.
Page 928 Exterior Lights Headlight Adiustment Park the vehicle 7.5 m (25 ft) awa.y from a wall or a scr€en (A). Headlights become very hot during use; do not touch them or any attaching hardware immediately 7.5 m (25 ftl after thev have been turned off. Betore adiusting tho headlights: ' Parkthe vehicle on a level surface.
Page 929 Turn the low beams on. 6. lf necessary, adjust the he,adlights to local requirements by turning the vertical adjuster (A). Determine if the headlights are aimed properly. Vertical adiustment: Measure the height ofthe headlights (A). The lights should reflect 52 mm (2.1 in.) below headlight h e i g h r { B ) .
Page 930 Exterior Lights Taillight Replacement Side Turn Signal Light Replacement NOTE; For bulb replacement, see the owner's manual. 1 . P u s h t h e s i d e t u r n s i g n a l l i g h t ( A ) f o r w a r d , t h e n remove it from the fender.
Page 931 High Mount Brake Light License Plate Light Replacement Replacement 1 . Remove the license plate light assembly, and disconnect the 2P connector from it. O p e n t h e t r u n k l i d . License Plate Light Bulb;5 W Disconnect the 2P connector (A) from the high m o u n t b r a k e l i g h t ( B ) .
Page 932 Turn Signal/Hazard Flasher Component Location Index TURN SIGNAL INDICATOR LIGHTS (ln the gauge assembly) Bulb Locations, page 22 46 -i\ - - . r ' \ r , - 9 \ " ' = COMBINATION LIGHT/ TURN SIGNAL SWITCH Test, page 22-65 HAZARD WARNING SWITCH Test, page 22 79 TURN SIGNAL/HAZARD RELAY...
Page 933 Circuit Diagram UND€R.OASH MAIN UNOEF-HooO 'USAREL^Y 80X FUSE/F€LAY BOX t * " , . 1 v|ni< o-;LN';LT=r-t \:-/ ",,.., N0.23 (r0A) DASH LIGHTS LEFTIURN SIGM! LIGHT BRIGNTI{ESS co.lTRol.lER /{n th. ga'{6\ BI-K c:301 G3OJ G501 Cr20r c20r c6o2...
Page 934 Turn Signal/Hazard Flasher Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay {A)from the under-dash fuse/relay box (B) InsDect the connector and socket terminals to be sure they are all making good contact. . lf the terminals are bent, loose, orcorroded, repairthem as necessary, and recheckthe system .
Page 935 Hazard Warning Switch Test 1. Remove the center console (see page 20-76), 2. Disconnect the I0P connector (A) from the hazard warning switch (B). Remove the two screws and the hazard warning S W I T C N . Check for continuity between the terminals in each switch position according to the table.
Page 936 Interior Lights Component Location Index DOOR SwlTCH DRIVER'S DOOR SWTCH TRUNK LATCH SWITCH Test, page 22-83 22-80...
Page 937 Circuit Diagram UNDEB.DASIT MA N UNDEB HOOD FUSE/BELAYEOX FUSE/FELAY BOX '.r.'Fl-wHrBruT I s*t,"^ | ,Y" MIDDLE gIU/ALK O S I V E B S TBUNK 000R LAICFl SW]TCN swtTcH f cbs€d: fobsed L lrunk lid oten.J B L K G60t 22-81...
Page 938 Interior Lights Ceiling/Spotlight Test 5. Check for continuity between the terminals in each Turn the ceiling/spotlights switch OFF. switch position according to thdtable. Pry off the lens {A). ---tl\ Terminal 2 BODY Ceiling/Spotlight Bulb: 5W ;il; GROUND re'o MIDDLE CEILING LIGHT ----o o r @ - - o...
Page 939 Trunk Light Test Trunk Lid Latch Switch Test O p e n t h e t r u n k l i d . 1 . O p e n t h e t r u n k l i d . P r y o u t t h e t r u n k l i g h t a s s e m b l y .
Page 940 Dash Lights Brightness Controller Circuit Diagram UiIDER DASH FUS[/NELAYEOX MAIN UItDEfi HOOOFUSE/BEIAY | /,il\ L-+r >F 8rx/YEL \ lc1-r/ c{01 22-84...
Page 941 Controller Input Test 1. Remove the gauge assembly (see page 22-52). m a k i n g g o o d c o n t a c t . 2 . I n s p e c t t h e g a u g e a s s e m b l y c o n n e c t o r B ( 1 2 P ) t e r m i n a l s t o b e s u r e t h e y a r e a l l .
Page 942 Dash Lights Brightness Gontroller Controller Input Test (cont'dl 3. Reconnect the connectors to the gauge assembly. 4. Back probe the connector and make these input tests. . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m . .
Page 943 Audio System Gomponent Location Index ACCESSORY POWER SOCKET RELAY [Wi.e colors: WHT/BED, LT BLU;l and BLUAVHT LYEL/RED Test, page 22-40 ':.r ,.,\ r,, ',-4 AUDIO UNIT Removal, page 22-89 page 22-89 Connector Beplacement, RADIO REMOTE SWITCH Test, page 22-90 LEFT TWEETER {'02-03 modelsl Replacement, page 22-91 TWEETER ('02-03 modelsl...
Page 944 Audio System Circuit Diagram MAINUNOEN HOOD FUSgffIAY 8OX E SIE srAiT slvtTcH AUOIOUl{T ftGHITWEEIIS' LINTWEETEB' DRIVEI'S PASSEIGETS 0008 sPflxES Doons'urcn lu' ]lnu ]l:r*" ll"', LIGHT l0.55wril DlsH Lictlls BB|GHflESS c0f{Ti0tun G502 22-88...
Page 945 Audio Unit Removal Audio Unit Connector Replacement Make sure you have the anti-theft code for the radio. When replacing an audio unit connector, match the then write down the frequencies for the radio's w i r e s t o t h e c a v i t i e s l i s t e d i n t h e f o l l o w i n g t a b l e . preset buttons.
Page 946 Audio System Radio Remote Switch Test Remove the instrument panel (see page 20-80). 5. Check for continuity between the terminals in each switch position according to the table. Disconnect the 6P connector (A) from the switch. lf the continuity is not as specified, replace the illumination bulb{s) (B) or the switch.
Page 947 Speaker Replacement Speaker: Tweeter ('02-03 modelsl: 1. Remove the door panel (see page 2O-4). 1. Remove the door panel (see page 20-4). 2. Remove the three mounting screws. 2. Remove the two screws. 3. Disconnect the 2P connector from the soeaker. 3.
Page 948 Audio System Mast Antenna Replacement 4. Remove the antenna (A). Open the trunk lid. Remove the right side trunk trim panel (see page 20-731. Disconnect the 2P connector from the antenna a m p l i f i e r . Remove the antenna nut (B) and spacer (C).
Page 949 Accessory Power Socket Component Location Index ACCESSORY POWER SOCKET TesVReplacement, page 22-95 ACCESSORY POWER SOCKET RELAY [Wire colors: WHT/RED, YEURED, J LBLUMHT and LT BLU Test, page 22-40...
Page 950 Accessory Power Socket Gircuit Diagram IGN TION SW TCH MAIN UNDER,HOOO FUSE/ RELAY BOX 6;\\ afrl WHT/8LK WHT.+ ENGINE SIART swlTcH WHTi REO 8LU,'WHT 8LU/WIiT ELUAVHT - IG? R€LAY ' SIARTEF CUI BEL^Y WBT/NED LT BLU CLU]CH INTERLOCK swtTcH ACCESSOFY POWER SOCKET G50t...
Page 951 Test/Replacement Remove the rear console (see page 20-78). 5. Remove the housing and socket. Disconnect the 2P connector. Inspect the connector terminals to be sure they are all making good contact. . lf the terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
Page 952 Horn Component Location Index MAIN UNDER.HOOD FUSE/RELAY BOX l l l l r r ('02-03 models) HORN{low) TesVReplacement, page 22-97 ('00-03 models) Test/Beplacement, page 22'97 22-96...
Page 953 Circuit Diagram Horn Test/Replacement 1 . Remove the front bumper (see page 20-92) ('00-03 models). Open the hood ('02-03 models). Disconnect the 1P connector (A), and remove the h o r n ( B ) . Test the horn by connecting battery power to the terminal (A) and grounding to the bracket {B).
Page 954 Horn Horn Switch Test Remove the driver's airbag (see page 23-65). R e m o v e t h e s t e e r i n g c o l u m n u p p e r a n d l o w e r cover {see page 17-9).
Page 955 Trunk Lid Opener Component Location Index TRUNK OPENER SWITCH Test, page 22-'101 f ,_, ':':'t':' ltt " -'t' TRUNK OPENER SOLENOIO/ LATCH SWITCH Solenoid Test, paqe 22 101 Latch Switch Testpage 22-83 ( . , "-'-..-=- - r...
Page 956 Trunk Lid Opener Circuit Diagram UNOER.DASH FUSAFEUY 8OX MAIN UNDER.HOOO FUSE/BEUY 8OX KEYLESS D@N L@K co.{?Rol TRUNK INDICATOR BLfiEL BIfiEL uGHl T R U N K L I G H T 8L&YEL SLU/8LK soLENo,D jl :*sl- G601 22-100...
Page 957 Trunk Opener Switch Test Trunk Opener Solenoid Test Remove the rear console (see p age 20-78||. Open the trunk lid. Disconnect the 2P connector from the switch. Disconnect the 3P connector from the trunk latch. Termihal side of male terminals 3.
Page 958 Power Mirrors Component Location Index POWER MIRROR SWITCH Test, page 22-105 POWER MIRROR Function Test, Page 22-104 Actuator Test, Page 22-105 Daqe 20-21 Reolacement, Aciuator Replacehent, Page 22 106 22-102...
Page 959 Circuit Diagram MAiN UNO€R HooD 'USE/BEUY BOX UNDEE.DASH FUSE/8ELAY EOX LEFT I 22-103...
Page 960 Power Mirrors Function Test Remove the driver's door panel (see page 20-4). 5. Check for continuity between the No. 10 terminal and body ground. Move the mirror selector switch to the left or right Disconnect the 10P connector {A) from the power and hold down the mirror switch in any direction mirror switch (B), and inspect the terminals.
Page 961 Power Mirror Switch Test Power Mirror Actuator Test 1 . R e m o v e t h e d r i v e r ' s d o o r p a n e l ( s e e p a g e 2 0 - 4 ) . 1.
Page 962 Power Mirrors Power Mirror Actuator Replacement ' t . 6. Remove the screws and the actuator from the Remove the power mirror from the door (see page h o u s r n g . 20-21). Record the terminal locations and wire colors. Cutthe wire harness with a wire cutter.
Page 963 Wiper/Washer Component Location Index WINDSHIELO WIPER ARMS and LINKAGE WINOSHIELD WASHER TUBE page 22-1 14 Replacement, Replacement, page 22-1 15 WIPER/WASHER SWITCH TesVReplacement, page 22-l 1 1 INTERMITTENT WIPER RELAY {'00-01 models) fwire colors: GRN/BLK, I I G R N , B L K , G R N / R E D I Land BLU/WHT Test, page 22 40 INTERMITTENT WIPER CIRCUIT...
Page 964 Wiper/Washer Circuit Diagram I\1A N UNDER NOOD FUSE/RELAY BOX UNOEE OASFl FUSE/BELAY BOX No4r (r00aj No 12 {rcA) GBNTBLK GRN/8LK tr.$fl6:rtunr G5N/BLK BLKryfiI l - F - - + - - J \ o o l " ' I d l u t f o u u , WINDSIIIELD WIPEN MOTOR UNDEF OASH...
Page 965 UNOER DASH FUSE/FELAYEOX !"'l,T.i9J .'*., D>- f33loo^) G50r 22-109...
Page 966 Wiper/Washer Intermittent Wiper Control Circuit Input Test 1. Remove the gauge assembly {see page 22'52). 2. lnspect the all connectors and socket terminals to be sure they are all making good contact. . lf the terminals are bent, loose, or corroded, repa ir th em as necessa ry, and recheck the system .
Page 967 Wiper/Washer Switch Test/Replacement 1. Lower the steering column, and remove the steering column covers (see page 17-9). '14P 2. Disconnect the connector from the wiDer/washer switch. 3. Remove the two screws, then pull out the wiper/washer switch. 4. Check for continu ity betwee n the term ina ls in each switch position accord ing to the ta ble. lf the continuity is not as specified, replace the switch.
Page 968 Wiper/Washer Washer Motor Test Wiper Motor Test Remove the right inner tender {see page 20-105). 1. Open the hood and remove the cap nuts and the wiper arms (see page 22-1'14]-. Disconnect the 2P connector (A) from the washer 2. Remove the hood seal and cowl cover (see page m o t o r ( B ) .
Page 969 Washer Reservoir Replacement 1. Pull away the right inner fender. 2. Disconnect the washer tube (A) and washer motor 2P connector (B). USA: 9 . 8 N m 1 1 0 t g t m , 7 , 2 l b l h l 9.8 N.m (r.0tgr.ln, 7.2lbtft) 3.
Page 970 WiperlWasher Wiper Motor Replacement 5. Remove the three mounting bolts and nut from the 1 . Open the hood, and remove the cap nuts and the wiper linkage (A) to remove the wiper motor (B). wrper arms. 1 0 x 1 . 2 5 m m 18 N m {1.8 kgf.m, 13lbf.ftl {1.5 kgf.m,11lbf.ftl Remove the hood seal and cowl cover.
Page 971 Washer Tube Replacement 1. Remove the front bumper and the right inner fender (see page 20-105). 2. Remove the washer nozzles and cliDs, then remove the tube. /a- \ 3 . I n s t a l l i n t h e r e v e r s e o r d e r o f r e m o v a l , T a k e c a r e n o t t o p i n c h t h e w a s h e r t u b e . C h e c k t h e w i n d s h i e l d w a s h e r oDeraI|on.
Page 972 lmmobilizer System Component Location Index IMMOBILIZER INDICATOR LIGHT Bulb Location, page 22-46 IMMOBILIZER RECEIVER UNIT page 22-'120 Troubleshooting, page 22- 121 Replacement, TRANSPONDER (Built into the ignition key) IGNITION KEY (Master and valet keys) 22-116...
Page 973 , a n d the Honda PGM Tester equipped with an immobilizer program card with the latest version of PGM Tester software.
Page 974 lmmobilizer System System Description (cont'd) c o m e o n f o r a b o u t 2 s e c o n d s , t h e n g o o f f . . l f t h e p r o p e r k e y h a s b e e n u s e d , t h e i m m o b i l i z e r i n d i c a t o r l i g h t w i l l .
Page 975 Circuit Diagram UIDER-0ASli MAINUNOTR XOOO FUS€/RELIY FUST/8ELIY <--l fl ---1__J No5{7.54) FUST EP2 ti/toco tMotN 22-119...
Page 976 lmmobilizer System Troubleshooting Follow this procedure if the vehicle does not start. or after rewriting the ECM with the PGM-Tester and the vehicle does not start. Note these items belore troubleshooting: . Due to the action of the immobilizer svstem, the engine takes slightly more time to start than a vehicle without an immobilizer system.
Page 977 lmmobilizer Receiver Unit Replacement 6. Check for continuity between the No. 4 terminal a n d b o d y g r o u n d . Remove the steering column covers (see page 17- lsthere continuity? YES Go to step 7. Disconnect the 5P connector (A) from the i m m o b i l i z e r r e c e i v e r u n i t ( B ) .
Page 978 Power Windows Component Location Index SWITCH PASSENGER'SWINDOW page 22-128 TesVReplacement, WINDOW MOTOR PASSENGER'S Test, page 22-129 Y - . ) ' . ' i ; - \ . " \ - / ' - - . , r / POWER WINDOW MASTER swtTcH (Has built-in control unit) Input Test, page 22-125...
Page 979 Gircuit Diagram MAIN UNDEF.FiOOO FUSSRELAY 8OX IGNITION SWITCH COI{VERIIBLE 'r0P CONTROL UNIT ELLI/ORN Pou/EF WtNoow MASTEn SWTTCH IGS VgU VMPI PWOFO POWER WINOOW CONTNOL UNIT SGND REOTYEL DRIVER'S WINDOWMOTOR CONVEFfIBLE TOP COIITFOL UNII G501 22-123...
Page 980 Power Windows Master Switch Test 3. Check the master passenger's switch for continuity 1 . Remove the driver's door panel (see page 20-4). between the terminals in each switch position Disconnect the 14P connector from the power according to the table. window master switch.
Page 981 Master Switch Input Test Remove the door panel (see page 20-4). Remove the power window master switch (A) from the door panel. GRN/ALK RED/BLK Wire side of female terminals BLU/ORN GRN/WHT BLU/REO RED/WHT Disconnect the 14P connector (B) and the l Op connector (C) from the power window master switch. Inspect the connectors and socket terminals to be sure they are all making good contact.
Page 982 Power Windows Master Switch Input Test (cont'd) With the master switch still disconnected, make these input tests at the 14P connector' . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m . .
Page 983 6. Reconnect the master switch, and perform the following input tests. . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s v s t e m . .
Page 984 Power Windows Passenger's Window Switch Test/Replacement 4. Check for continuity between the terminals in each 1. Remove the switch and switch panelfrom the door switch position according to the table. p a n e l . Teiminal Position aF-r-- DOWN lf the continuity is not as specified, replace the switch.
Page 985 Driver's Window Motor Test Passenger's Window Motor Test Moior Test: Remove the passenger's door panel (see page 20- 4 t . 1. Remove the driver's door panel (see page 20-4). Disconnect the 2P connector from the window 2. Disconnect the 4P connector from the window moIor.
Page 986 Keyless/Power Door Locks Component Location Index LOCK BUTTON TRUNK BUTTON UNLOCK BUTTON PANIC BUTTON TRANSMITTER Test, page 22 138 Proqramming, page 22-'138 IGNITION KEY SWITCH Test, page 22-135 DOOR SWITCH PASSENGER'S TRUNK OPENER SOLENOIO Test, page 22-101 DRIVER'S DOOR KEY CYLINDER SWITCH Test, page 22-137 DRIVER'S DOOR LOCK ACTUATOR/ KNOB SWITCH...
Page 987 r t J Circuit Diagram UNO€I.DASH MAIN UNOER.HOOD FUSE/FELAY BOX IGNITONSWITCH FUSEiBELAYBOX /f;\' |*;"01 *"\'rj|- BL,(YEL YEL- f\-o-f - - t HoRN FFi Av o aN rF-L TBUNK OPENER swtTcH No 23 110 ) FUSE BLfiEI L ^ro^* 8LK/YEI- 0008 LocK xioB ELICYET G^ucE l-,-.-- *...
Page 988 Keyless/Power Door Locks Keyless Door Lock Control Unit Input Test 1 . D i s c o n n e c t t h e 1 8 P c o n n e c t o r f r o m t h e k e y l e s s d o o r l o c k c o n t r o l u n i t ' RED/BLK PNK/BLK GRN/YEL...
Page 989 3, Make these input tests at the connector. . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s v s t e m . .
Page 990 Keyless/Power Door Locks Keyless Door Lock Control Unit Input Test (cont'd) 4. Beconnect the connector to the control unit, and perform the following input tests at the keyless door lock control unit connector, . l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e t h e n r e c h e c k t h e s y s t e m ' ' lf all the inout tests prove OK, the control unit must be faulty;...
Page 991 lgnition Key Switch Test 1 . Remove the steering column upper and lower covers (see page 17-9). Disconnect the 7P connector. 3. Check for continuity between the No. 1 and No.3 t e r m i n a l s . .
Page 992 Keyless/Power Door Locks Driver's Door Lock Actuator Test Driver's Door Lock Knob Switch Test 1 . R e m o v e t h e d r i v e r ' s d o o r p a n e l ( s e e p a g e 2 0 - 4 ) 2.
Page 993 Passenger's Door Lock Actuator Driver's Door Key Cylinder Switch Test Test ' 1 . Remove the passenger's door panel (see page 20- Remove the door panel (see page 20-4). 4 ) . Disconnect the 2P connector (A) from the key Disconnect the 2P connector (A) from the actuator cylinder switch.
Page 994 Keyless/Power Door Locks Transmitter Programming Transmitter Test Storing transmitter codes: The codes of up to three NOTE: transmitters can be programmed into the keyless . lf the doors unlock or lock with the transmitter, but receiver unit memory. (lf a fourth code is stored, the the LED on the transmitter does not come on, the LED code which was input first will be erased.) is faulty;...
Page 995 Convertible Top Component Location Index DRIVER'S WINDOW MOTOR fest, page 22 129 TOP SWITCH Test, page 22-143 CONVERTIBLE CONTROL UNIT Input Test, page 22-'144 CONVERTIBLE TOP MOTOR EMERGENCY CONNECTOR PASSENGER'S WINOOW MOTOR fe$, page 22-129 RIGHT CONVERTIBLE TOP MOTOR Test, page22-147 LEFT CONVERTIBLE TOP MOTOR fesl, page22-147 22-139...
Page 996 Convertible Top Circuit Diagram vss srcNrl DBrV[\lG CFCUII l " C0l'IVEFTIELI TOP MOTOF EM€8GII'ICY CONNECIOR 22-140...
Page 997 UiDEN DASH FUST/8ELIY 8OX I{o.l2l1sAl FUSE f - - - 1 DEFOGGER CHANGT SEIAY MASTIF CONVERNBLT swtTc|l IOP DISASLT swIc1r lolor.d Gt01 22-141...
Page 998 Convertible Top Basic Operation System Description 1 . P u l l t h e p a r k i n g b r a k e l e v e r u P . The convertjble top can automatically be opened and closed by operating the convertible top switch 2.
Page 999 Convertible Top Switch Test 1. Removethe centerconsole (see page 20-761, 2. Disconnect the 6P connector (A) from the switch. 3. Check for continuity between the terminals in each switch position according to the table. Terminal Position OPEN CLOSE 4 . lf the continuity is not as specified, replace the i l l u m i n a t i o n b u l b ( B ) o r t h e s w i t c h , 22-143...
Page 1000 Convertible Top Convertible Top Control Unit Input Test Remove the passenger's dashboard lower cover (see page 20-81). Disconnect the 14P connector (A) and 10P connector (B) from the convertible top control unit (C). RED/WHT A4 A5 A6 Wire side of female terminals 412 A13 A l l...
Page 1001 4. With the connectors still disconnected, make these input tests at the connectors. . lf any test indicates a problem, find and correct the cause, then recheck the system. . lf all the input tests prove OK, go to step 5. Wire Test condition Test: Desired result...
Page 1002 Gonvertible Top Convertible Top Control Unit Input Test (cont'd) RED/WHT YEL BLU/ORN RED/BLU RED/BLU GRN/RED GRY/RED A2 A3 Wire side of temale terminals 87 BB B9 4 1 3 A9 41041 BLU/BLK RED/BLK BLU/RED /BLK cRN/wHT WHT/RED RED/BLU neoivel BLU/WHT Possible cause ifresult is notobtained Wire Test condition...
Page 1003 Convertible Top Motor Test Right Top Motor: 1 . Remove the passenger's dashboard lower cover ( s e e p a g e 2 0 - 8 1 ) . l. Remove the right corner gusset (see page 20-38). Disconnect the convertible top motor emergency 2.
Page 1004 Convertible Top Convertible Top Motor Test (cont'dl Left Top Motor: 7 . Remove the passenger's dashboard lower cover (see page 20-81). 1. Remove the left corner gusset (see page 20-38). Disconnect the convertible top motor emergency 2. Disconnect the 2P connector (A)from the left top 2P connector (A).
Page 1005 Removable Hardtop Component Location Index CONTROL UNIT Input Test, page 22'144 CONVERTIBLE TOP DISABLE SWITCH Test, page 22 150...
Page 1006 Removable Hardtop Convertible Top Disable Switch Test 3. Push the convertible top disable switch. NOTE: For the convertible top disable switch circut diagram, refer to the Convertible Top Circuit Diagram {see page 22-140}and the RearWindow Defogger C i r c u i t D i a g r a m ( s e e p a g e 2 2 - 1 5 3 ) . 1.
Page 1007 Rear Window Defogger Component Location Index REAR WINOOW DEFOGGER SWITCH ( ' 0 2 0 3 m o d e l s ) T e s t , p a g e 2 2 1 5 5 REAR WINDOW DEFOGGER RELAY !02-03 models) Wire colors: BL(RED, WHT/GnN, I LYEUBLU and YEUBLK...
Page 1008 Rear Window Defogger Component Location Index (cont'd) REAB WINDOW DEFOGGER Function Test, page 22-156 Defogger Wire Repait, page 22-157 CONDENSER DIODE ('02-03 models) 1'02-03 models) REAR WINDOW DEFOGGER CHANGE RELAY ('02-03 models) Test, page 22-40 22-152...
Page 1009 Circuit Diagram '00-01 models UNOEN,HooD FUSgEELAY 8OX GNtTtONSWTTCTI Nolr (r@ ) N0.12 (10 ) CLI]TCH INTESLOCK sw TcH UNDEB DASN FUSABELAY ) - l N o 2 3 ( 1 0 ) FLJSE swtTcH 22-153...
Page 1010 Rear Window Defogger Circuit Diagram (cont'd) '02-03 models MAIN UNDER.HOOO IGNITION SWITCH FUSE,NELAY BOX --l-g<lor-, wirT--F wHT/slK BUdrEo 1-,,*, l9+Jo,.^| BrK"vFl UNDEF.DASH FUSENELAY GAUGE No.A {10 ) CLUICH ASSEMELY FUSE INTEFLOCK swtTcH YE!&K REAR OEFOC€EF REUY oAsN Lto.frs BRIi]HTNESS CONIFOLLER th rho 9il4.1 BIJ( '-.E...
Page 1011 Switch Test '02-03 models: ?0-01 models: 1. Remove the center console (see page 20-55). 1 . R e m o v e t h e i n s t r u m e n t p a n e l ( s e e p a g e 2 0 - 5 7 ) . 2.
Page 1012 Rear Window Defogger Function Test Check for continuity between the negative terminal NOTE: Be careful not to scratch or damage the defogger ( B ) a n d b o d y g r o u n d . wires with the tester probe. lf there is no continuity, check for an open in the 1.
Page 1013 Defogger Wire Repair NOTE: To make an effective repair, the broken section m u s t b e n o l o n g e r t h a n o n e i n c h . Lightly rub the area around the broken section (A) with fine steel wool, then clean it with alcohol.
Page 1014 Restraints Restraints Special Tools ..... 23-2 Seat Belts Component Location Index ..,......23-3 Seat Belt Replacement ....... 23-4 f nspection ....23-7 SRS (Supplemental Restraint Systeml Component Location Index ......,....,..23-9 Precautions and Procedures ..... 23-10 General Troubleshooting lnformation ..,,,,,..,,,., 29-17 Erasing the DTC Memory ....
Page 1015 Restraints Special Tools Description Tool Number Ref.No. Deployment Tool 07HAZ-SG00500 SCS Service Connector 0 7 P A z - 0 0 1 0 1 0 0 SRS Inflator Simulator 07SAZ.TB4011A 07TM-52501 1A S R S S i m u l a t o r L e a d C Backorobe AdaDter, 17 mm aa*? 07TAZ-001020A...
Page 1016 Seat Belts Gomponent Location Index SEAT BELT page 23 4 Replacement, Inspection, paqe 23-8 SEAT BELT BUCKLE step 'l on page 23-6 23-3...
Page 1017 Seat Belts Seat Belt Replacement SRS components are located in this area. Review the iZ]UPPER ANCHOR BOLT OROLL BAR and SRS component locations {see page 23-9) and the UPPER TRIM ASSEMBLY 7 / 1 6 - 2 0 U N F 32 N m (3.3 kgf.m, 24lbf.ft) precautions and procedures (see page 23-'10) in the SRS section before performing repairs or service.
Page 1018 3. Install the belt in the reverse order of removal, and note these items: . Check that the retractor locking mechanism functions (see page 20-8). . Assemble the washers, collar and busing on the upper and lower anchor bolts. Refer to the Anchor Bolt Construction (see page 20,7).
Page 1019 Seat Belts Seat Belt Replacement (cont'd) Seat Belt Buckle 1. Remove the seat (see page 20-86). NOTE: To get to the seat belt switch connector, remove the seat cushion from the inner seat track. 2. Remove the seat belt buckle in numbered sequence 3.
Page 1020 Center anchor boh construciion: TOOTHED LOCK WASHER WAVEWASHER COLLAR TOOTHED LOCK WASHER BUSHING CENTER ANCHOR BOLT COLLAR roorneo LOCKWASHER \ q t le /IlYil "v --r LOWER SPRING BOLT ANCHOR WASHER '02-03 models WAVE WASHER CENTER ANCHOR TOOTHEO BOLT LOCK WASHER SPRING WASHER 23-7...
Page 1021 Seat Belts Inspection ln-vehicle SRS components are located in this area. Review the SRS component locations (see page 23-9) and the 1. Check that the seat belt is not twisted or caught on Drecautions and procedures (see page 23-10) in the SRS a n y l n I n g .
Page 1022 Component Location Index CAALE REEL Replacement, page 23-72 INDICATOR LIGHT Troubleshootin g, page 23-55 PASSENGER'S AIRBAG Replacement, page 23-67 Disposal, page 23-69 DATA LINK {DLCI (16PI CONNECTOR UNIT Replacement, page 23,75 PASSENGER'S SEAI BELT TENSIONER Reolacement. oaae 23-4 Diiposal, page 23'-59 DRIVER'S S€AT EELT TENSIONER Replacement, page 23-4 Disposal, page 23-69...
Page 1023 . Use only a digital multimeter to check the system lf it General Precautions is not a Honda multimeter, make sure its output is 10 mA {0.01 A) or less when switched to the lowest value Read the following precautions carefully before in the ohmmeter range.
Page 1024 Airbag Handling and Storage . Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200'F/ D o n o t d i s a s s e m b l e a n a i r b a g . l t h a s n o s e r v i c e a b l e 93'C).
Page 1025 Precautions and Procedures (cont'dl SRS Unit Precautions . Be careful not to bumo or imoact the SRS unit whenever the ignition switch is ON (ll), or for at least for 3 minutes after the ignition switch is turned OFF. . D u r i n g i n s t a l l a t i o n o r r e p l a c e m e n t , b e c a r e f u l n o t t o bump (by impact wrench, hammer, etc.) the area around the SRS unit.
Page 1026 Wring Precautions Precautions for Electrical Inspections . When using electrical test equipment, insertthe Some of the SRS wiring can be identified by a special yellow outer covering, and the SRS connectors can be Drobe of the tester into the wire side of the connector. identified bv their vellow color.
Page 1027 Precautions and Procedures (cont'd) Backprobing Sprin g-loaded Lock Connectors Spring-loaded Lock Connector When checking voltage or resistance on this type of Some SRS system connectors have a spring-loaded connector the first time, vou must remove the retainer lock. (A) to insert the tester probe from the wire side. Disconnecting To release the lock, pullthe spring-loaded sleeve (A) NOTE: lt is not necessary to reinstall the removed...
Page 1028 Disconnecting System Connectors Before removing the airbag or SRS related devices (the SRS unit, the cable reel, and the seat belt tensioner connectors), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors and seat belt tensioner connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures.
Page 1029 Precautions and Procedures (cont'd) Seat Belt Tensionar: 1. Disconnect the battery negative cable, and wait at least 3 minutes. 4. Remove the roll bar uppertrim (see page 20-7'l), then disconnect the seat belt tensioner 2P Driver's Airbag connector {A) from the SRS main harness. 2.
Page 1030 Precautions . Use only a digital multimeter to check the system. lf it is not a Honda multimeter, make sure its output is 10 mA {0.01 A) or less when switched to the smallest value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause accidental airbag deployment and possible injury.
Page 1031 "SCS" Menu Method (Retrieving the flash codes) PGM Tester The SRS indicator indicates the DTC by the number of blinks when the Honda PGM Tester is connected to the DLC (data link connector) (16P). 1. Make sure the ignition switch is OFF.
Page 1032 SRS indicator will come on. To erase the DTC(S) from the SRS unit, use a Honda PGM Tester (see the Honda PGM Tester SRS Vehicle After checking the DTC, troubleshoot as follows: System Supplement) or the following procedure.
Page 1033 DTC Troubleshooting Index Detsction ltem Notes (see Daoe 23-24) ODen in driver's airbaq inflator (see oaqe 23-241 lncreased resistance in driver's airbao inflator Short to another wire or decreased resistance in driver's airbaq inflator {see Daoe 23-26) (see Daqe 23-28) Short to oower in driver's airbaq inflator 1 - 4 Short to qround in driver's airbaq inflator...
Page 1034 Symptom Troubleshooting Index Diagnostic procedure Also check for svmptom S R S I n d i c a t o r T r o u b l e s h o o t i n g ( s e e SRS indicator doesn't come on steo 1 on Daqe 23-55) SRS lndicator Troubleshooting (see...
Page 1035 For better serviceability, the SRS unit memory stores a DTC that relales to the cause of the malfunction, and the unit is connected to the data link connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P) (see page 23-11).
Page 1036 Circuit Diagram !-'oo-oztvoo"tt MAIN UNDEN-HOOO FUSE/8ILAY MX GNITION SWTCH [,'ornooe UNDEn-oaslr lGl lOT in 0N lll) FUSE/RTLAY DASHSOAFD TEBMII{ALNUMEEB WIFEHAFNESS \ I iEldi'i DASHSOAFD : t , ' WBEHANNESS SFS T\IOICATOF CFCUIT I MAI_E I TTRIIIINAT SFS MAIN HANNtSS OASHEOAFO hASt'tEss s F s M A r N HANflESS...
Page 1037 DTG Troubleshooting DTC 1-1: Open in Driver's Airbag Inflator 6. Reconnect the battery negative cable. DTC 1-2: Increased Resistance in Driver's 7. Erase the DTC memory. Airbag Inflator 8. Read the DTC. Special Tools Requirod . SRS inflator simulator 07SAZ-T840'11A ls DTC 1-1 or DTC 1-2 indicated? .
Page 1038 17. Disconnect the SRS unit 18P connector (A) fromthe 14. Read the DTC. SRS unit. Do not disconnect the special tool from ls DTC 1-1 or DTC 1-2 indicated? t h e S R S m a i n h a r n e s s . Y E S - G o t o s t e p 1 5 , NO Open or increased resistance in the cable reel;...
Page 1039 DTG Troubleshooting (cont'd) DTC 1-3: Short to Another Wire or Decreased Read the DTC. Resistance in Driver's Airbag Inflator ls DTC 1-3 indicated? Special Tools Required . s R s i n f l a t o r s i m u l a t o r 0 7 s A z - T B 4 o 1 1 A YES Go to step 9.
Page 1040 Turn the ignition switch OFF, then disconnect the 1 7 . Disconnect the special tool from the SRS main t 5 . battery negative cable, and wait for 3 minutes. h a r n e s s . 1 6 . Disconnect the passenger's airbag 2P connector (A) Disconnect the SRS unit 18P connector (A) from the 1 8 .
Page 1042 Turn the ignition switch OFF, then disconnect the 17. Disconnect the SRS unit 18P connector {A)from the battery negative cable, and wait for 3 minutes. S R S u n i t . Disconnect the passenger's airbag 2P connector (A) 1 6 .
Page 1043 DTC Troubleshooting (cont'd) DTC 1-5: Short to Ground in Driver's Airbag Read the DTc. lnflator ls DTC 1-5 indicated? Special Tools Required YES - Go to step 9. . SRS inflator simuiator 07SAZ-T8401'lA . SRS simulator lead C 07TAZ-S25011A NO Shortto ground in the driver's airbag; replace the driver's airbag (see page 23'65).1 1.
Page 1044 14. Read the DTC. 17. Disconnect the SRS unit 18P connector (A) from the S R S u n i t . ls DTC 1-5 indicated? YES - Go to slep 15. NO Shortto ground in the cable reel; replace the cable reel (see page 23-72).I 15.
Page 1045 DTC Troubleshooting (cont'dl DTC 2-1: Open in Passenger's Airbag lnflator 6. Reconnect the battery negative cable. DTC 2-2: Increased Resistance in Passenger's 7. Erase the DTC memory. Airbag Inflator 8. Read the DTC. SpecialTools Required ls DTC 2-1 or 2-2 indicated? .
Page 1046 1 1. Disconnect the SRS unit 18P connector (A) from the DTC 2-3: Short to Another Wire or Decreased Resistance in Passenger's Airbag Inflator SRS unit. Do not disconnect the sDecial tool from the SRS main harness. Special Tools Required .
Page 1047 DTC Troubleshooting (cont'dl 1 . Disconneci the special tool from the SRS main 6. Reconnect the battery negative cable. h a r n e s s . 7. Erase the DTC memory. 'l8P connector (A) from the Disconnect the SRS unit S R S u n i t .
Page 1048 DTC 2-4: Short to Power in Passenger's 6. Reconnecl the battery negative cable. Airbag Inflator 7. Erase the DTC memory. Special Tools Required . SRS inflator simulator 07SM-TB401'1A 8. Read the DTC. . SRS simulator lead C 07TAZ-S25011A ls DTC 2-4 indicated? 1.

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