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INTRODUCTION General Info

1. Wire Dia O D T Free Length No of Coils 3 4 orifice control valve spring 1 0 0 039 6 6 0 260 49 6 1 953 26 8 4 3 shift timing valve spring 0 7 0 028 7 1 0 280 35 0 1 378 20 4 Modulator valve spring A 1 5 0 059 9 4 0 370 30 6 1 205 9 9 Modulator valve spring A B 1 4 0 055 9 4 0 370 33 0 1 299 10 5 4 1st accumulator spring 2 9 0 114 18 0 0 709 75 5 2 972 11 5 5 2nd accumulator spring A 3 6 0 142 22 0 0 866 96 7 3 807 13 0 6 2nd accumulator spring B 2 0 0 079 6 6 0 260 80 0 3 150 19 6 Inside Diameter 14 20 Reverse Accumulator 1st hold Accumulator Disassembly Inspection Reassembly NOTE Clean all parts thotoughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages Replace the O rings Check all pistons for free movement If any fail to slide freely see Valve Body Repair on page Coat all parts with ATF before reassembly GS qu SNAP RING c O RINGS Replace SS REVERSE ACCUMULATOR SLEEVE 25 REAR COVER S SZ SE TR S SF O RING V Replace REVERSE ACCUMULATOR Qa PISTON wv O RIN Ka Replace SEALING BOLT 8 x 1 25 mm 18 N m 1 8 kg m 13 Ib ft E z SS SEALING WASHER ONE WAY BALL Replace STEEL BALL O RING Replace 1ST HOLD ACCUMULATOR PISTON O RING Replace
2. Alternator 110 Reduction Permanent magnet 2 0 0 5 0 8 0 020 0 031 0 0 05 0 0 002 31 9 32 1 1 256 1 264 18 0 0 709 29 7 36 3 2 97 3 63 6 55 8 00 Starting motor MITSUBISHI Mica depth Commutator runout Commutator O D Brush length Brush spring tension N kg Ibs When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 14 Design Specifications meme mamen wes DIMENSIONS WEIGHT ENGINE STARTER CLUTCH Overall Length 4 950 mm 194 9 in Overall Width 1 810 mm 71 3 in Overall Height 1 410 mm 55 5 in Wheelbase 2 910 mm 114 6 in Track Front Rear Except KY 1 550 1 540 mm 61 0 60 6 in KY 1 545 1 535 mm 60 8 60 4 in Seating Capacity Five Max Permissible Weight for European Max Loaded Vehicle Weight ADR Type 2 150 kg 4 740 Ibs 1 993 kg 4 394 Ibs Water cooled 4 stroke SOHC gasoline engine 90 V6 cylinder 90 0 x 84 0 mm 3 54 x 3 31 in 3 206 cm 196 cu in 9 6 1 9 0 1 Curb Weight MT 1 590 kg 3 505 Ibs A T European type 1 610 kg 3 549 Ibs KO 1 625 kg 3 582 Ibs KY 1 635 kg 3 605 Ibs KU 1 590 kg 3 505 Ibs Weight Distribution MT 960 630 kg 2 116 1 389 lbs A T European type 975 635 kg
3. 2000098000 BALL BEARING MAINSHAFT REVERSE GEAR MAINSHAFT REVERSE GEAR DISTANCE COLLAR MAINSHAFT DISC SPRING 28 mm Replace 2ND CLUTCH ASSEMBLY O RING Replace THRUST WASHER 29 mm THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR NEEDLE BEARING THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR COLLAR COUNTERSHAFT LOCKNUT 24 x 1 25 mm Replace WASHER 24 mm Replace BALL BEARING THRUST WASHER 25 mm THRUST NEEDLE BEARING COUNTERSHAFT REVERSE GEAR THRUST NEEDLE BEARING NEEDLE BEARING COUNTERSHAFT REVERSE GEAR COLLAR REVERSE CLUTCH ASSEMBLY COUNTERSHAFT DISC SPRING 29 mm Replace REVERSE CLUTCH DISTANCE COLLAR PARKING GEAR THRUST NEEDLE BEARING THRUST WASHER 45 5 x 60 mm Selective part NEEDLE BEARINGS 2ND GEAR ONE WAY CLUTCH COUNTERSHAFT 2ND GEAR BALL BEARING SNAP RING ONE WAY CLUTCH HUB PARKING BRAKE PAWL SHAFT SLEEVE PARKING BRAKE PAWL PARKING BRAKE PAWL SPRING PARKING BRAKE PAWL SHAFT LOCK PLATE Replace PARKING BRAKE ROD HOLDER PARKING BRAKE ROD GUIDE ATF COOLER PIPES SEALING WASHERS Replace JOINT BOLTS BREATHER PIPE TRANSMISSION SUB HARNESS O RING Replace ATF LEVEL GAUGE PIPE ATF LEVEL GAUGE DIPSTICK O RING Replace Bolt Size Remarks 6 x 1 0 mm 8 x 1 25 mm 8 x 1 25 mm Sealing Bolt 24 x 1 25 mm Mainshaft Locknut 24 x 1 25 mm Countershaft Locknut Lefthand threads 14 x 1 5 mm Joint Bolt 14 13 Illustrated Index Housing Lower Va
4. Brake fluid and hydraulic components When replenishing the system use extreme care to prevent dust and dirt from entering the system Do not mix different brands of fluid as they may not be compatible Do not reuse drained brake fluid Brake fluid can cause damage to painted surfaces Wipe up spilled fluid at once e After disconnecting brake hoses or pipes be sure to plug the openings to prevent loss of brake fluid Clean all disassembled parts only in clean BRAKE FLUID Blow open all holes and passagas with com pressed air Keep disassembled parts from air borne dust and abrasives Check that parts are clean before assembly The following symbols stand for Apply engine oil Apply brake fluid Apply grease Apply Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON II Automatic Transmission Fluid Apply Power Steering Fluid Apply or check vacuum e id oi i n rubber parts and tubes eS peau SES SES Sequence for removal or installation unless specified Upon assembling check every part for proper instal lation and operation SS 1 27 Abbreviations ABS Anti lock Brake System PGM FI Programmed Fuel Injection Air Conditioner P S Power Steering American Petroleum Institute R Right AIT Automatic Transmission RHD Right Hand Drive ATF Automatic Transmission Fluid SAE Socie
5. Connect a voltmeter between the No 2 terminal of the 7 P con nector and body ground DASHBOARD WIRE HARNESS 7 P CONNECTOR Turn the ignition switch ON Il Measure the voltage between the No 2 terminal and body ground Short in BLU wire of the dash board wire harness Replace the dashboard wire harness Is there less than 8 5V with ignition switch ON il YES UN View from terminal side To page 23 58 BLU Less than 8 5V cont d 23 57 Supplemental Restraint System SRS Troubleshooting cont d From page 23 57 Turn the ignition switch OFF Connect the voltmeter between the No 3 terminal and the No 1 terminal of the dash board wire harness 7 P connector Turn the ignition switch ON Il L Measure the voltage between the No 3 terminal and the No 1 terminal DASHBOARD WIRE HARNESS 7 P CONNECTOR Battery voltage V BLK YEL View from terminal side NO Check for continuity between the gt 2 d lt Is there battery voltage No 1 terminal and body ground YES Turn the ignition switch OFF To page 23 59 Repair open in the BLK wire No 1 terminal between the gauge a Is there continuity assembly and body ground or look for a YES poor ground G521 LHD G402 RHD Repair open in the
6. Q SRS UNIT 18 P CONNECTOR gt lt s fro ope aep e s 23 41 Supplemental Restraint System SRS Wiring Locations LHD CAUTION Make sure all SRS ground locations are clean and grounds are securely attached NOTE All SRS electrical wiring harnesses are covered with yellow outer insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring CABLE REEL to DRIVER S AIRBAG 3 P Connector DASHBOARD WIRE HARNESS See Ceci i FRONT to INDICATOR LIGHT in PC GAUGE ASSEMBLY P Connector 7 P Connector RIGHT DASH SENSOR to SRS MAIN HARNESS 2 P Connector SRS MAIN HARNESS to MAIN WIRE HARNESS 3 P Connector MAIN WIRE HARNESS MAIN WIRE HARNESS to SRS MAIN HARNESS 5 P Connector MAIN WIRE HARNESS to DASHBOARD WIRE HARNESS 20 P Connector DA FRONT PASSENGER S SEAT BELT PRETENSIONER to MAIN WIRE HARNESS 3 P Connector SRS MAIN HARNESS to UNDER DASH FUSE BOX 2 P Connector SRS MAIN HARNESS SRS UNIT GROUND to SIDE WIRE HARNESS SIDE WIRE 3 P Connector HARNESS DRIVER S SEAT BELT PRETENSIONER to LEFT DASH SENSOR to SIDE WIRE SRS MAIN HARNESS HARNESS 2 P Connector 3 P Connector CABLE REEL to SRS MAIN HARNESS 7 P Connector TEST HARNESS SRS MAIN SOCKET HARNESS SOCKET 16 P Connector 18 P Connector 23 42 SRS Wiring Locations RHD CAUTION Make sure all SRS ground locations are clea
7. SPECIAL BOLT 12 x 1 25 mm 60 N m 6 0 kg m 43 Ib ft Replace 10 x 1 25 mm 39 N m 3 9 kg m 29 Ib ft LOWER PLATE 10 x 1 25 mm 39 N m 3 9 kg m 28 ib ft CORROSION RESISTANT BOLT 5 18 Cylinder Head Valve Train Special Tools 6 2 Timing Belt Illustrated Index 6 3 Inspection cernere 6 4 Tension Adjustment 6 4 Removal eoe Drei 6 5 Installation 6 7 CRANK CYL Sensor Replacement 6 9 Outline of Model Changes The center mount center bracket and damper have been added Special Tools Too Number Description 07JAA 0010200 07JAB 0010200 07MAB PY30100 6 2 Socket Wrench 19 mm Handle Pulley Holder Attachment HEX 50 mm Page Reference el Timing Belt aed Illustrated Index NOTE Turn the crankshaft so that the No 1 piston is at TDC page 6 7 e Replace rubber seals if damaged or deteriorated e Remove the damper the center bracket and the center mount before removing the crankshaft pulley ADJUSTING BOLT 10 x 1 25 mm TIMING BELT 43 N m 4 3 kg m 31 Ib ft Inspection page 6 4 For adjustment only Adjustment page 6 4 do not remove Remove any oil RUBBER SEAL Replace when damaged or deteri
8. ps e v C 5 3 15 bag inflator is faulty Replace the airbag assem bly and recheck the voltages according to the 0 2 kQ chart on page 23 61 If resistance is less than O 2 the cable reel is If resistance is more than 0 2 go to step 4 faulty Replace it and recheck the voltages according to the chart on page 23 61 If resistance is less than 0 2 the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages according to the chart on page 23 61 23 69 Supplemental Restraint System SRS Troubleshooting cont d 4 Disconnect the front passenger s airbag 3 P connec tor from the SRS main harness then connect Test Harness C to the front passenger s airbag side of the connector FRONT PASSENGER S SRS MAIN AIRBAG ASSEMBLY HARNESS TEST HARNESS C 07MAZ SPO0600 5 Measure the resistance between the No 9 terminal and the No 10 terminal TEST HARNESS C 07MAZ SPO0600 If resistance is more than 0 2 the front pas senger s airbag inflator is faulty Replace the front passenger s airbag assembly and recheck the voltages according to the chart on page 23 61 If resistance is less than 0 2 the SRS main har ness is faulty Replace it and recheck the voltages according to the chart on page 23 61 23 70 Mode G Open in seat belt pretensioner driver s side or front p
9. WARNING TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY ALWAYS INSTALL THE PROTECTIVE SHORT CONNECTOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS IS DISCONNECTED S R S 4225 3 pall gb ell LAY dons SI ai Ap AGI Logo je paidi Jrogt ss pis Laits ad Ay I 1 9 Warning Caution Label Locations cont d G INFLATOR BAM LABEL KF KG KX only TRW Safety Systems manufactured inflator Air Bag Gas Genertor 150028 TRW Safety Systems Mesa Herstellungsjahr 1989 Elnf hrer Honda Deutschland Gmbh offenbach BAM PT 0358 Gasgenertor dart nur f r Insassen R ckhaltesysteme mit Luftsack in Kraftfahrzeuge montiert werden Die Montage und Demontage des Gasgenerators darf nur von daf r geschultem Personal vorgenommen CAUTION The gas generator should only be in Contains stalled in vehicles equipped with the Flammable airbag system The gas generator is Solids US to be installed and or disassembled DOT E 8236 only by trained personnel ATTENTION Le g n rateur de gaz ne peut tre in Content De stall que sur des v hicules quip s Solides Flam d un syst me airbag Le montage et le mable US d montage du g n rteur de gaz ne DOT E B8236 peut tre effactu que par un person nel qualifie NIPPON KOKI manufactured in flator Air Bag Gas Generator NK8 NIPPON KOKI SHIRAKAWA JAPAN Herstellungsjahr 1991 Elnf hrer Honda Deutschland GmbH Offenbach BAM P
10. Stator shaft needle bearing contact I D Wear or damage torque converter side Valve body Startor shaft needle bearing contact LD 31 000 31 013 1 220 1 221 oil pump side Oil pump driven gear I D 14 016 14 034 0 552 0 553 Wear or damage Oil pump driven gear shaft O D 13 980 13 990 0 550 0 551 Wear or damage 0 03 0 05 0 001 0 002 0 210 0 265 0 008 0 010 0 070 0 125 0 003 0 005 37 000 37 025 1 457 1 458 0 07 0 003 Oil pump gear side clearance Oil pump gear to body clearance Drive Driven 37 05 1 459 Sealing ring contact LD Regulator valve body Accumulator body Shfting device and parking brake control Sealing ring contact 1 0 42 000 42 030 1 654 1 655 42 05 1 656 Wear or other defect Parking brake cone Parking brake pawl Parking gear Wear or other defect 25 95 26 05 1 022 1 026 3 95 4 00 0 156 0 157 35 00 35 05 1 378 1 380 31 06 31 09 1 223 1 224 Transmission Mainshaft reverse gear distance collar length Wear or damage 2nd clutch thrust washer 29 mm thickness Mainshaft 2nd gear collar length A Lidh Countershaft reverse gear thrust washer thickness Countershaft reverse gear collar length A SEI Reverse clutch distance collar length Thrust washer 45 5 x 60 thickn
11. 2 SRS indicator light stays on constantly see page 23 60 SRS INDICATOR LIGHT 3 SRS indicator light comes on in combination with a failure of another electrical system brake system light check engine light etc Check for damage corrosion at the under dash fuse box connector NOTE Before starting the applicable troubleshooting check the condition of all SRS connectors and ground points f the fault is not found after completing the ap plicable troubleshooting substitute a known good SRS unit and check whether the SRS indicator light goes off If it does the original SRS unit must be faulty replace it As a system check the SRS indicator light also comes on when the ignition is first turned to the ll position If the light goes off after approximately six seconds the System is OK If the SRS indicator light remains on or fails to come on in the system check mode one of the SRS components or the wiring connectors in between is faulty Troubleshooting Precautions Always use the test harness Do not use test probes directly on component connector termi nals or wires you may damage them or the SRS unit When connecting any of the test harnesses to the system push the connectors straight in do not bend the connector terminals Before disconnecting the airbag connectors turn off the ignition switch and wait for at least three minutes to let the capac
12. Differential pinion gear 0 15 0 006 Adjust with a shim Adjust with a shim Drive pinion gear and ring gear Drive pinion Backlash At inspection hole At ring gear circumference Preload starting toque N m kg cm Ib in Adjust with a shim M T New bearing Reused bearing A T New bearing Reused bearing 0 93 1 57 9 3 15 7 8 1 13 6 0 72 1 21 7 2 12 1 6 2 10 5 1 86 2 54 18 6 25 4 16 1 22 0 1 45 1 95 14 5 19 5 1 26 16 9 Drive pinion Total preload starting torque Adjust with a shim and differen N m kg cm 1 tial unit MIT D Tp 0 55 0 78 5 5 7 8 4 8 6 8 0 55 0 78 5 5 7 8 4 8 6 8 Tp 0 65 0 79 6 5 7 9 5 6 6 9 0 65 0 79 6 5 7 9 5 6 6 9 AIT D 1 06 1 28 10 6 12 8 9 2 11 1 Tp 1 06 1 28 10 6 12 8 9 2 11 1 Tp 0 96 1 09 9 6 10 9 8 3 9 5 0 96 1 09 9 6 10 9 8 3 9 5 D Pinion and ring gear bearings are new Ring gear bearing is new Pinion bearing is new Pinion and ring gear bearings are reused Tp Actual measurement of pinion preload Steering Section 17 MEASUREMENT STANDARD NEW Steering wheel Play at steering wheel circumference 0 10 0 0 4 Starting load at steering wheel circumference kg Ibs Engine stopped 200 20 44 max Engine running 3
13. For all normal driving For hot climates or continu ous high speed driving For cold climate driving Without Catalytic Converter Engine type C32A4 and C32A5 Adjust the gap with a suitable gapping tool Electrode Gap 1 0 1 1 mm 0 039 0 043 in 1 1 mm 0 043 in Use only the plugs listed below BKR6E 11 NGK K20PR U11 BKR7E 11 NGK K22PR U11 ND BKR5E 11 K16PR U11 ND For all normal driving For hot climates or continu ous high speed driving For cold climate driving Power Rear Passenger s Seat KY KQ and KT models Component Location Index LEFT REAR POWER SEAT SWITCH Removal Test page 23 35 on E 4 D RIGHT REAR POWER SEAT SWITCH A Removal Test page 23 35 RIGHT REAR RECLINE MOTOR Test page 23 36 LEFT REAR RECLINE MOTOR Test page 23 36 23 33 Power Rear Passenger s Seat KY KO and KT models Circuit Diagram UNDER HOOD FUSE RELAY BOX No 31 120A No 34 50A BATTERY WHT BLK UNDER DASH FUSE BOX LHD No 8 20A RHD No 5 20A LHD No 11 20A RHD No 1 20A LHD BLU YEL LHD BLK GRN RHD RED YEL RHD BLU YEL BLU YEL BLK GRN BACKWARD FORWARD FORWARD BACKWARD B LEFT REAR POWER SEAT SWITCH E RIGHT REAR POWER SEAT SWITCH GRN RED RED YEL RED YEL
14. 104 F keep away from open flame Refrigerant although 5 If you find any leaks tighten the joint nuts and non flammable will produce poisonous gas if bolts to the specified torque burned work in well ventilated area Refrigerant evaporates 6 Recheckthe system for leaks using a leak detector quickly and can force all the air out of a small enclosed area 7 If you find leaks that require the system to be open ed to repair or replace hoses fittings etc release any charge in the system 8 After checking and repairing leaks the system must be evacuated see System Evacuation THREE VALVE GAUGE LOW PRESSURE EVACUATION VALVE TWO VALVE GAUGE HIGH PRESSURE HIGH PRESSURE EVACUATION STOP VALVE LOW PRESSURE cl Y e VALVE VACUUM PUMP CHECK VALVE CHECK VALVE 22 4 H i t 1 HIGH PRESSURE QUICK JOINT HIGH PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT LOW PRESSURE 4 QUICK JOINT INNER DIAMETER 130 mm 22 8 Performance Test The performance test will help determine if the air con ditioning system is operating within specifications NOTE Only use a gauge set for refrigerant R 134a Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pu
15. AIRBAG ACCESS CONNECTOR PANEL SHORT CONNECTOR RED Connect the SRS short connector special tool to the cable reel connector CABLE REEL CONNECTOR SHORT CONNECTOR RED SRS SHORT CONNECTOR 07MAZ SPO0200 cont d 20 21 Dashboard Replacement cont d NOTE To prevent damage to the steering column wrap it with a shop towel STEERING COLUMN 8 x 1 25 mm 8 x 1 25 mm 22 N m 2 2 kg m 16 N m 1 6 kg m 12 Ib ft 16 lb ft Replace 3 Remove the nuts and screw then remove the airbag brackets passenger s To avoid accidental deployment and possible injury always install the short connector on the airbag connector when the SRS wire harness is disconnected NOTE Disconnect the connector between the front passenger s airbag and SRS wire harness Connect the short connector RED to the front passenger s airbag connector FRONT PASSENGER S m ae CONNECTOR HOLDER FRONT PASSENGER S AIRBAG CONNECTOR SHORT CONNECTOR RED Connect the SRS short connector special tool to the SRS wire harness connector FRONT PASSENGER S AIRBAG CONNECTOR SHORT CONNECTOR RED P SRS WIRE HARNESS SRS SHORT CONNECTOR CONNECTOR 07MAZ SP0O0200 FRONT PASSENGER S AIRBAG NUT pium 6 x 1 0 X 10 N m 1 0 kg m 7 2 lb ft SRS WIRE NS GL HARNESS Oy eS i REIN e E S SCREW te AIRBAG BRACKETS 4 Remove the right glov
16. Eege 31 7 1 248 28 3 1 114 Until grooves worn out Until grooves worn out Discoloration 1 95 2 05 2 55 2 65 Clutch end plate thickness Mark 1 2 05 2 10 0 081 0 083 1st 2nd 3rd 4th Mark 2 2 15 2 20 0 085 0 087 Mark 3 2 25 2 30 0 089 0 091 Mark 4 2 35 2 40 0 093 0 094 Mark 5 2 45 2 50 0 096 0 098 Mark 6 2 55 2 60 0 100 0 102 Mark 7 2 65 2 70 0 104 0 106 Mark 8 2 75 2 80 0 108 0 110 Mark 9 2 85 2 90 0 112 0 114 Clutch end plate thickness Mark L1 2 05 2 10 0 081 0 083 1st hold Mark L2 2 15 2 20 0 085 0 087 Mark L3 2 25 2 30 0 089 0 091 Mark L4 2 35 2 40 0 093 0 094 Mark L5 2 45 2 50 0 096 0 098 Mark L6 2 55 2 60 0 100 0 102 Mark L7 2 65 2 70 0 104 0 106 Mark L8 2 75 2 80 0 108 0 110 Mark L9 2 85 2 90 0 112 0 114 Clutch end plate thickness Mark R1 4 05 4 10 0 159 0 161 Reverse Mark R2 4 15 4 20 0 163 0 165 Mark R3 4 25 4 30 0 167 0 169 Mark R4 4 35 4 40 0 171 0 173 Mark R5 4 45 4 50 0 175 0 177 Mark R6 4 55 4 60 0 179 0 181 Mark R7 4 65 4 70 0 183 0 185 Mark R8 4 75 4 80 0 187 0 189 Mark R9 4 85 4 90 0 191 0 193 Discoloration cont d 3 7 Standards and Service Limits Automatic Transmission cont d Section 14 MEASUREMENT STANDARD NEW 28 000 28 021 1 102 1 103 SERVICE LIMIT
17. Valve spring Free length Valve guide LD Installed height Arm to shaft clearance Camshaft to holder oil clearance 1 350 kPa 13 5 kg cm 192 psi 1 000 kPa 10 0 kg cm 142 psi 200 kPa 2 0 kg cm 28psi 99 95 100 05 3 935 3 939 0 05 0 15 0 002 0 006 0 050 0 089 0 0020 0 0035 0 03 0 001 40 118 1 5794 37 766 1 4868 40 005 1 5750 37 766 1 4868 O Hydraulic tappets Auto adjuster type O Hydraulic tappets Auto adjuster type 5 48 5 49 0 2157 0 2161 5 45 5 46 0 2146 0 2150 0 02 0 05 0 001 0 002 0 05 0 08 0 002 0 003 1 25 1 55 0 049 0 061 1 25 1 55 0 049 0 061 46 935 47 425 1 8478 1 8671 47 885 48 375 1 8852 1 9045 Except KY KT 2 KQ KY KT 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring 3 2 EX IN and EX IN and EX 50 16 1 9748 1 50 17 1 9752 50 36 1 9827 5 51 5 53 0 217 0 218 15 75 16 25 0 620 0 640 0 018 0 054 0 0007 0 0021 STANDARD NEW SERVICE LIMIT 0 05 0 002 0 15 0 006 0 10 0 004 0 04 0 002 5 55 0 219 0 08 0 003 Engine Block Section 7 MEASUREMENT Cylinder block Warpage of deck surface 0 07 0 003 max 0 10 0 004 Bore diameter 90 00 90 02 3 543 3 544 90 07 3 546 Bore taper 0 05 0 002 Reboring limit 0 5
18. 22 1 Outline of Model Changes Due to the introduction of new refrigerant R 134a part descriptions warnings and handling information were rewritten accordingly Automatic Climate Control Description OUEN nes ee Compressor Relief Valve Replacement AIC Service Tips A C System Service Discharge Evacuation 1 ge ENKEN Reeg Charging ec eebe ee LeakTest ege ees Description Outline The air conditioning system delivers cooled air into the passenger compartment by circulating refrigerant through the system as shown below High temperature High temperature High temperature high pressure gas high pressure liquid Traps debris high pressure liquid Suction and compression Radiation of heat and removes moisture COMPRESSOR Si gt CONDENSER m RECEIVER DRYER Less liquefied More liquefied low pressure vapor low pressure vapor Absorption of heat EVAPORATOR Sd EXPANSION VALVE EVAPORATOR EXPANSION VALVE SUCTION LINE RECEIVER DRYER CONDENSER This car uses R 134a refrigerant which does not contain chlorofluorocarbons Pay attention to the following service items Do not mix refrigerants R 12 and R 134a They are not compatible Use only the recommended polyalkyleneglycol PAG refrigerant oil ND OIL 8 P N 38899 PR7 003 designed for the R 134a compressor Intermixing the recommended PAG refrigera
19. Before installing the slide motor and slide gear box apply grease to the slide lead screws as shown SLIDE MOTOR SLIDE LEAD cd SLIDE LEAD SCREW GEARBOX Before installing the slide motor and slide gear box align the 9 portion as shown SLIDE MOTOR SLIDE GEARBOX SU SLIDE GEARBOX SLIDE MOTOR Check the slide lead screw for bending 20 10 When installing the slide joint cable set the in ner cable securely SLIDE JOINT CABLE INNER CABLE Make sure the connectors are connected properly SLIDE SENSOR CONNECTOR SLIDE MOTOR Gray 2 P CONNECTOR CONNECTOR Green Yellow Black wire Gray SLIDE MOTOR SLIDE GEARBOX Check the slide motor and slide gearbox opera tions Front and Rear Elevation Motors Replacement CAUTION Wear gloves to remove and install the front and rear elevation motors NOTE Take care not to scratch the seat covers To remove the rear elevation motor elevate the seat cushion at the rear Remove the front seat Remove the seat cushion 1 Remove the harness protector from the slide eleva tion adjuster gt Clip locations 2 1 2 Detach the clip by pulling it Push here Detach the connectors from the harness protector SLIDE ELEVATION ADJUSTER HARNESS PROTECTOR cont d 20 11 Front Seat Linkage Front and Rear Elevation Motors Replacem
20. K NEEDLE BEARING THRUST NEEDLE BEARING 2ND GEAR COLLAR Replace TURHST WASHER 43 x 74 mm Selective part THRUST NEEDLE BEARING PEA TRANSMISSION GN HOUSING BEARING Al cw 4TH GEAR A CUBE rd 2 NEEDLE BEARING mt eC 98 THRUST NEEDLE BEARING 3RD GEAR EI c NEEDLE BEARING SET RING PB 14 22 Countershaft Disassembly Inspection Reassembly NOTE Lubricate all parts with ATF during reassembly Install the thrust needle bearings with unrolled edge of bearing retainer facing washer Inspect the thrust needle bearings and the needle bearings for galling and rough movement Before installing the O rings wrap the shaft splines with tape to prevent damage to the O rings Locknut has left hand threads LOCKNUT 24 x 1 25mm WASHER 24 mm Replace Replace 2ND GEAR COLLAR SE threads Se BALL BEARING THRUST NEEDLE 4 13 0 kg m BEARING 94 Ib ft Gy SE THRUST WASHER 25 mm SET PLATE 5 THRUST NEEDLE BEARING 1ST GEAR E REVERSE GEAR ONE WAY CLUTCH E 1ST GEAR NEEDLE BEARING THRUST NEEDLE 4 BEARING 1ST GEAR COLLAR 1ST HOLD CLUTCH COUNTERSHAFT Check splines for excessive wear or damage Check bearing surface for scoring scratches or excessive wear 9 GEAR T 4 CH NEEDLE BEARING THRUST NEEDLE BEARING 3RD GE
21. Be sure to install the harness wires so that they are senger s airbag connector and from the SRS main not pinched or interfering with other car parts harness connector Carefully inspect the new dash sensor s for signs of being dropped or improperly handled such as dents 9 Reconnect the front passenger s airbag 3 P connec cracks or deformation tor to the SRS main harness connector For the SRS to function properly the right and left sen sors must be installed on the proper sides 10 Remove the short connectors from the driver s air bag connector and from the cable reel 3 P connector 6 Install the sensor securely 11 Reconnect the driver s airbag 3 P connector to the cable reel 3 P connector Attach the short connec tor RED to the access panel then reinstall the panel on the steering wheel DASH SENSOR 12 Remove the short connectors RED from the seat belt pretensioners then attach them to their holders 13 Reconnect the side wire harness 3 P connector to the driver s seat belt pretensioner and the main wire harness 3 P connector to the front passenger s seat belt pretensioner 14 Reinstall the B pillar lower panel 15 Reconnect the battery positive cable then the nega tive cable 16 After installing the dash sensor confirm proper sys DASH SENSOR tem operation Turn the ignition ON Il The instru MOUNTING BOLTS ment panel SRS indicator light should go on for about 8 mm x 1 25 six se
22. SPECIAL NUT D 10 x 1 25 mm 10 1 25 mm 39 N m 3 9 kg m 49 N m 4 9 kg m 28 Ib ft 35 Ib ft Replace OX 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft NS d x 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft CORROSION RESISTANT BOLT 5 14 10 x 1 25 mm 39 N m 3 9 kg m AH 28 ib ft WT 10x 125 rnm Install the bolt 39 N m 3 9 kg m 10x 1 25 mm 39 N m 3 9 kg m 10 x 1 25 mm 39 N m 3 9 kg m 28 lb ft 28 Ib ft 28 Ib ft 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft D 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft SPECIAL NUT 8 8x 1 25 mm x 10 x 1 25 mm 22 N m 2 2 kg m 10 x 1 25 mm 49 N m 4 9 kg m 39 N m 3 9 kg m 35 Ib ft Pas 28 Ib ft 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft 10 x 1 25 mm 39 N m 3 9 kg m 28 lb ft 6 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft x 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft d cont 5 15 Engine Removal Installation cont d Mount and Bracket Bolts Nuts Torque Value Specifications CAUTION After loosening the special nuts be sure to replace them with new ones 12 x 1 25 mm REAR TRANSMISSION 55 Nm 5 5 kg m REAR TRANSMISSION 10 x 1 25 mm MOUNT BRACKET 40 Ib ft MOUNT 39 N m 3 9 kg m 28 Ib ft M T MID MOUNT BRACKET TRANSMISSION BEAM 12 x 1 25 mm MID MOUNT 55 N m 5 5 kg m SPECIAL NUT 10 x 1 25
23. quickly 7 Check the system for leaks using a leak detector proper to refrigerant R 134a NOTE Particularly check for leaks around the compressor condenser and receiver dryer TWO VALVE GAUGE HIGH PRESSURE VALVE EVACUATION STOP VALVE VACUUM PUMP HIGH PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT INNER DIAMETER mm 22 7 A C System Service Leak Test NOTE 1 Close the evacuation valve in case of two valve Only use a gauge set for refrigerant R 134a gauge close the evacuation stop valve Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum 2 Open the cans pump oil 3 Open the high pressure valve to charge the system When handling refrigerant R 134a to about 100 kPa 1 0 kg cm 14 psi then close always wear eye protection it do notlet refrigerant get on your skin or in your eyes If it does NOTE Close the low pressure valve do not rub your eyes or skin splash large quantities of cool water into your 4 Check the system for leaks using a leak detector eyes or on your skin proper to refrigerant R 134a rush to a physician or hospital for immediate treatment Do not attempt to treat it yourself NOTE Particularly check for leaks around the keep refrigerant containers cans of R 134a stored compressor condenser and receiver dryer below 40
24. 7 1ST HOLD ACCUMULATOR SLEEVE SNAP RING Unit mm in SPRING SPECIFICATIONS Standard New Free Length 115 5 4 547 68 4 2 693 14 0 0 551 No of Coils Spring Wire Dia 18 6 0 732 25 0 0 984 4 0 0 157 Reverse accumulator spring 3 5 0 138 1st hold accumulator spring 4 0 0 157 One way ball spring 0 29 0 011 Mainshaft Disassembly Inspection Reassembly NOTE Lubricate all parts with ATF during reassembly Install the thrust needle bearings with unrolled edge of bearing retainer facing washer Inspect the thrust needle bearings and the needle bearings for galling and rough movement Before installing the O rings wrap the shaft splines with tape to prevent damage to the O rngs LOCKNUT 24 x 1 25 mm Replace 130 Nem 13 0 kg m 94 Ib ft e WASHER 24 mm 4 a Replace eer D BALL BEARING SNAP RING E REVERSE GEAR THRUST WASHER a E C REVERSE GEAR M DISTANCE COLLAR 227 e EE ES DISC SPRING 28 mm SE N Replace 2ND CLUTCH 1ST GEAR Ee ASSEMBLY NEEDLE BEARINGS DEA nnes Ge THRUST NEEDLE ic Replace eck splines for excessive BEARING e THRUST WASHER wear or damage 29 mm Check bearing surface for 1ST GEAR z THRUST NEEDLE scoring scratches or excessive SLA a DISTANCE COLLAR BEARING wear i j 2ND GEAR Ir Ee 1ST GEAR COLLAR 1ST ATH CLUTCH ASSEMBLY
25. GRN RED LEFT REAR RIGHT REAR RECLINE MOTOR RECLINE MOTOR BLK BLK LHD G521 LHD G404 RHD G404 RHD G521 G522 23 34 4 Check for continuity between the terminals in each switch position according to the table Switch Removal Test 1 Remove the rear door panel see section 20 2 Remove the eight screws then remove the armrest NOTE Left rear door panel is shown Right rear door panel is similar ARMREST FORWARD NEUTRAL O BACKWARD SCREW DOOR PANEL 3 Remove the rear power seat switch from the armrest NOTE Left rear armrest is shown Right rear arm REAR POWER rest is similar SEAT SWITCH REAR POWER SEAT SWITCH 23 35 Power Rear Passenger s Seat KY KO and KT models Motor Teat 1 Remove the rear seat cushion see section 20 3 Test the motor in each direction by connecting pow er and ground according to the table 2 Remove the four screws and disconnect the 2 P con nector under the rear power seat rail assembly then remove the rear power seat rail assembly Terminal 2 Direction NOTE Left rear power seat rail assembly is shown o Right rear power seat rail assembly is similar FORWARD BACKWARD CAUTION When the motor stops running discon nect one lead immediately BOLT 22 Nem 2 2 kg m 16 Ib ft REAR POWER SEAT RAIL ASSEMBLY 2 P CONNECTOR REAR RECLINE MOTOR 23 36 Supplemental Restraint System SR
26. Including cow sensor Replacement page 23 90 DRIVER S SEAT BELT PRETENSIONER Replacement page 23 92 Disposal page 23 80 23 38 SRS Component Location Index RHD To CRUISE CONTROL SET RESUME CANCEL CABLE REEL SWITCH Replacement page 23 84 SRS INDICATOR LIGHT In the gauge assembly Troubleshooting page 23 52 To DRIVER S AIRBAG ASSEMBLY To RADIO REMOTE ESS SWITCH To HORN SWITCH To GROUND FRONT PASSNGER S AIRBAG ASSEMBLY Airbag and Inflator Replacement page 23 76 LEFT DASH SENSOR Disposal page 23 79 Replacement page 23 88 UNDER DASH FUSE BOX FRONT PASSENGER S SEAT BELT PRETENSIONER Replacement page 23 92 Disposal page 23 80 RIGHT DASH SENSOR Replacement page 23 88 SRS UNIT P ES Including cowl sensor Replacement page 23 90 DRIVER S AIRBAG ASSEMBLY Airbag and Inflator Replacement page 23 76 Disposal page 23 79 DRIVER S SEAT BELT PRETENSIONER Replacement page 23 92 Disposal page 23 80 23 39 Supplemental Restraint System SRS Description SRS Airbag System The SRS is a safety device which when used in conjunction with the seat belt is designed to protect the driver in a frontal impact exceeding a certain set limit The system consists of left and right dash sensors the SRS unit including cowl sensor the cable reel driver s airbag and front passenger s airbag Seat Belt Pretensioner The seat belt pretensioner is linked with the SRS airbags to f
27. JUMPER WIRE RHD RHD JUMPER WIRE SERVICE CHECK CONNECTOR 2P YELLOW LED if yellow LED is off Do not adjust idle adjusting screw Go on to step 6 If yellow LED is blinking Adjust idle adjusting screw 1 4 turn clockwise If yellow LED is on Adjust idle adjusting screw 1 4 turn counter clockwise NOTE new engine less than km or 310 miles the yellow LED may light even though the idle adjusting screw is properly set However no adjust ment should be make cont d 11 3 Idle Control System Idle Speed Setting cont d IDLE ADJUSTING Ke CZ TS PX S CA me Check that the yellow LED goes off after approx imately seconds If it does not go off rotate the idle adjusting screw by 1 4 turn in the same direction and repeat the same operation until the yellow LED goes off Check the idle speed in the following conditions With headlights Hi and rear window defogger ON While the steering wheel is turning With air conditioner compressor on Idle speed should be 650 50 min rpm 600 50 1 rpm N or P position If applicable with automatic transmission in gear except N or P position Idle should remain stable at 600 50 min rpm Remove the jumper wire from the service check con nector terminal NOTE When there is no code stored the Check En gine
28. the engine and burned B Vapor Purge Control System Canister purging is accomplished by drawing fresh air through the canister and into a port on the throttle body The purging vacuum is controlled by the purge control diaphragm valve and the purge control solenoid valve PURGE CONTROL SOLENOID VALVE OFF CANISTER IS BEING PURGED AFTER STARTING ENGINE AND COOLANT TEMPERATURE ABOVE 70 C 158 F E AIR CONDITIONER COMPRESSOR ON C Fuel Tank Vapor Control System When fuel vapor pressure in the fuel tank is higher than the set value of the two way valve the valve opens and regulates the flow of fuel vapor to the canister 11 6 FUEL CUT OFF VALVE FUEL FILLER CAP FUEL TANK PURGE CONTROL SOLENOID VALVE PURGE VARIOUS SENSORS CONTROL DIAPHRAGM VALVE al Jr TWO WAY CHARCOAL VALVE CANISTER FRESH AIR cont d 11 7 Emission Control System Evaporative Emission Controls cont d Troubleshooting Flowchart Inspection of Evaporative Emis sion Controls LHD RHD 6 VACUUM HOSE 6 VACUUM HOSE valve on the charcoal canister and connect a vacuum pump gauge to the hose Disconnect 6 vacuum hose PS ff from the purge control diaphragm La VACUUM PUMP GAUGE PURGE CONTROL VACUUM PUMP the engine and allow it to DIAPHRAGM VALVE PURGE CONTROL GAUGE NOTE Engine coolant tempera DIAPHRAG
29. 13 2 15 0 084 0 085 16 2 18 0 085 0 086 19 2 21 0 086 0 087 22 2 24 0 087 0 088 25 2 27 0 0886 0 0894 28 2 30 0 090 0 091 31 2 33 0 091 0 092 34 2 36 0 092 0 093 37 2 39 0 093 0 094 40 2 42 0 094 0 095 43 2 45 0 0957 0 0965 STANDARD NEW SERVICE LIMIT Wear or damage Wear or damage Adjust with a washer Adjust with a washer Adjust with a washer Wear or damage Unit of length mm in STANDARD NEW Automatic Transmission Section 14 MEASUREMENT Free Length One way ball spring 0 29 0 011 4 0 14 0 0 551 13 0 Secondary spring 0 2 21 099 0 831 4 0 4 3 kick down valve spring 7 1 51 3 2 020 22 5 Regulator valve spring A 4 7 86 5 3 406 16 5 Regulator valve spring B 6 0 43 0 1 693 13 5 Stator reaction spring 6 4 30 3 1 193 1 9 Modulator valve spring A 9 4 30 6 1 205 9 9 Modulator valve spring A B 9 4 33 0 1 299 10 5 Torque converter check valve spring 8 4 41 8 1 646 15 7 Relief valve spring 8 4 56 5 2 224 22 4 Cooler relief valve spring 8 4 46 8 1 843 17 0 3 4 orifice contro valve spring 6 6 49 6 1 953 Throttle valve spring 7 6 28 3 1 114 1 2 shift valve spring 7 6 55 5 2 185 2 3 3 4 shift valve spring 6 6 42 1 1 657 4 3 shift timing valve spring 7 1
30. BOLTS Use a TORX T30 bit DRIVER S AIRBAG ASSEMBLY 6 Disconnect the connectors from the horn and cruise control set resume cancel switch then remove the cable reel 3 P connector from its clips CRUISE CONTROL SET RESUME CANCEL HORN SWITCH SWITCH CONNECTOR CONNECTOR GROUND CONNECTOR RADIO REMOTE SWITCH CONNECTOR CABLE REEL 3 P CONNECTOR 7 Remove the steering wheel from the column 8 Remove the upper and lower column covers UPPER COLUMN COVER LOWER COLUMN COVER 9 Disconnect the 7 P connector between the cable reel and SRS main harness then remove the connector holder from the steering column CABLE REEL CANCEL SLEEVE CABLE REEL 7 P CONNECTOR CONNECTOR HOLDER 10 Remove the cable reel from the column CAUTION Before installing the steering wheel the front wheels should be aligned straight ahead Be sure to install the harness wires so that they are not pinched or interfering with other car parts After reassembly confirm that the wheels are still turned straight ahead and that steering wheel spoke angle is correct If minor spoke angle adjustment is necessary do so only by adjusting of the tie rods not by removing and repositioning the steering wheel 11 Align the cancel sleeve grooves with the cable reel projections CANCEL SLEEVE GROOVES PROJECTIONS 12 Carefully install the cable reel on the steering column shaft Then attach the connector ho
31. Transmission Installation cont d 23 Install the control lever to the control shaft with a new lock plate Bend the lock plate after installing the bolt CAUTION Take care not to bend the cable when removing installing it 24 Install the shift cable holder on the shift cable holder base 25 Install the shift cable cover 26 Connect the ATF cooler hoses to joint pipes 27 Connect the shift control solenoid valve linear sole noid connector to the transmission sub harness con nector Then install the connector on the shift cable cover 28 Install the ATF level gauge pipe in the torque con verter housing with a new O ring 6 x 1 0 mm SHIFT CABLE 12 Nm HOLDER 1 2 kg m 9 Ib ft CONTROL LEVER LOCK PLATE Replace 6 x 1 0 mm ID FLOATING nom WASHERS SHIFT CABL An HOLDER BASE O RING Replace JOINT PIPES 6 x 1 0 mm 12 Nem SHIFT CABLE 1 2 kg m 9 Ib ft COVER 29 Install the heat shields HEAT SHIELD 30 Install the exhaust pipe A exhaust pipe A cover and catalytic converter with new self locking nuts NOTE Nuts in figure below are all self locking replace them when installing 8 x 1 25 mm 22 Nem 10 x 1 25 mm 2 2 kg m 16 lb ft 34 10 x 1 25 mm 3 4 kg m 25 lb ft 34 Nem 3 4 kg m 25 lb ft F7 GASKET Replace CATALYTIC CONVERTER GASKET Replace EXHAUST EXHAUST PIPE A V PIPE A COVER 8 x 1 25 mm EXHAUST 22 N m 2 2 kg m 16 lb
32. leys at TDC CRANKSHAFT PULLEY INSPECTION HOLE After checking install the rubber POINTER ON THE LOWER COVER cap RIGHT CAMSHAFT PULLEY POINTER ON THE UPPER COVER TDC MARK TDC MARK WHITE CRANKSHAFT PULLEY INSPECTION HOLE After checking install the rubber cap 10 If the camshaft pulleys are not positioned at remove the timing belt and adjust the positioning following the procedure on page 6 7 then reinstall the timing belt NOTE Refer to page 6 5 for timing belt removal 11 After installation adjust the tension of each belit rotation 6 8 Sn CRANK CYL Sensor Replacement 1 Turn the crankshaft so that the No 1 piston is at top 7 install the CRANK CYL sensor in the reverse order dead center page 6 7 of removal e Refer page 6 7 when installing the timing belt 2 Remove the upper covers 3 Remove the timing belt from the right and left cam shaft pulleys 4 Remove the left camshaft pulley 5 Remove the left back cover 6 Remove the CRANK CYL sensor from the left cylin der head RIGHT UPPER COVER 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft RUBBER SEALS Replace when damaged or deteriorated CRANK CYL 8 x 1 25 mm SENSOR 32 N m 3 2 kg m 23 Ib ft 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft CAMSHAFT PULLEY RUBBER SEAL Replace when damaged or deteriorated UPPER COVER 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 6 9 Fu
33. registration O Under severe driving conditions service these items more often Severe Driving Conditions Items marked O need service more often if you drive in these conditions The conditions are Repeated short distance driving Dusty conditions Severe cold weather Areas with road salt or other cor rosive materials Rough or muddy roads Towing a trailer gt mm The services are Replace engine oil and oil filter every 5 000 km 3 000 miles or 3 months under condition A B or F Clean the air cleaner element every 20 000 km 12 000 miles or 12 months and replace every 40 000 km 24 000 miles or 24 months under condition B or E for European type KO and KU Clean the air cleaner element every 10 000 km 6 000 miles or 6 months and replace every 20 000 km 12 000 miles or 12 mon ths under condition B or E for other than European type KQ and KU Replace transmission oil and front differential oil every 20 000 km 12 000 miles or 12 months under condition F Inspect front brake discs and calipers every 10 000 km 6 000 miles or 6 months under condition A B D E or F Inspect rear brake discs calipers and pads every 20 000 km 12 000 miles or 12 months under condition A B D E or F Inspect power steering system every 10 000 km 6 000 miles or 6 months under condition B C or E 4 5 Engine Engine Removal Installation 5 1 Cylinder Head Valve
34. to the ex tension shaft splines Install the secondary spring in the differential side of the extension shaft Place the transmission on a transmission jack and raise to the engine level 14 x 20 mm DOWEL PIN O RING Replace 14 x 20 mm N L SECH SECONDARY TORQUE SPRING CONVERTER 5 Install the transmission housing mounting bolt and 26 mm shim 6 Attach the torque converter covers to the drive plate with six bolts and torque to 27 Nem 2 7 kg m 20 Ib ft Rotate the crankshaft as necessary to tight en the bolts 1 2 of specified torque then final tor que in a crisscross pattern After tightening the last bolt check that the crankshaft rotates freely 7 install the torque converter covers 8 Install the engine stiffener NOTE Loosely install the engine stiffener 8 mm mounting botls then torque to specified torque af ter installing the transmission housing mounting 12 mm bolt on th engine stiffener 12 x 1 25 mm 8 x 1 25 mm 65 N m 6 5 kg m 27 N m 2 7 kg m 20 Ib ft 47 b ft ENGINE STIFFENER SSSA SOs GE 6 x 1 0 MMA lt 12 N m 1 2 e 8 x 1 25 mm 9 Ib ft 3 m 22 N m rp 2 2 kg m H 16 Ib ft Dum TORQUE CONVERTER COVERS TRANSMISSION HOUSING MOUNTING BOLT 12 x 1 25 mm 65 N m 6 5 kg m 47 16 cont d 14 25 Transmission Installation cont d 9 Install the three transmission housing mounting bolts 10 Install the mid mounts and tighten the s
35. 0 02 Piston Skirt OD at 17 0 mm 0 67 in from bottom of skirt No Letter A 89 980 89 990 3 5425 3 5429 89 970 3 5421 B 89 970 89 980 3 5421 3 5425 89 960 3 5417 Clearance in cylinder 0 02 0 04 0 001 0 002 0 08 0 003 Groove width for ring Top 1 22 1 23 0 0480 0 0484 1 25 0 0492 Second 1 22 1 23 0 0480 0 0484 1 25 0 0492 Oil 2 805 2 820 0 1104 0 1110 2 85 0 1122 Piston ring Ring to groove clearance Top 0 035 0 060 0 0014 0 0024 0 13 0 005 Second 0 030 0 055 0 0012 0 0022 0 13 0 005 Ring end gap Top 0 25 0 40 0 010 0 016 0 70 0 028 Second 0 40 0 55 0 016 0 0221 0 85 0 033 Cil 0 20 0 70 0 008 0 028 0 80 0 031 0 20 0 50 0 008 0 020 0 80 0 031 Piston Pin O D 21 994 22 000 0 8659 0 8661 Pin to piston clearance 0 012 0 024 0 0005 0 0009 Connecting rod Pin to rod interference 0 013 0 032 0 0005 0 0013 Small end bore diameter 21 968 21 981 0 8649 0 8654 Large end bore diameter Nominal 57 00 2 244 End play installed on crankshaft 0 15 0 30 0 006 0 012 Small end bore to large end bore parallelism 0 12 100 max 0 15 100 Crankshaft Main journal diameter Rod journal diameter Taper Out of round End play Total runout Bearings Main bearing to journal oil clearance Rod bearing to journal oil clearance 1 RIKEN manufactured piston ring 2 TEIKOKU PISTON RING
36. 07MAZ SPO0500 f resistance is more than the dash sensor is faulty Replace it and recheck the voltages according to the chart on page 23 61 f resistance is less than 5kQ the SRS main har ness is faulty Replace it and recheck the voltages according to the chart on page 23 61 if resistance is more than 5 for either set of terminals go to step 3 If resistance is less than 5 for both sets of ter minals the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages accord ing to the chart on page 23 61 cont d 23 67 Supplemental Restraint System SRS Troubleshooting cont d Mode E Open in driver s airbag inflator or cable reel 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 2 Connect Test Harness B between the SRS unit and the SRS main harness 18 P connector SRS UNIT TEST HARNESS B 07MAZ SP00500 SRS MAIN HARNESS 3 Reconnect the driver s airbag connector then mea sure the resistance between the B1 and the B7 ter minals TEST HARNESS B 07MAZ SP00500 if resistance is more than O 2 kQ go to step 4 If resistance is less than 0 2 the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages according to the chart on page 23 61 4 Disconnect the cable reel 7 P connector from the SRS main harness then connect Test
37. 2 After installing the anchors check for free movement es when servicing the retractor on the anchor bolts If necessary remove the anchor Remove the short connector RED from the con bolts and check that the washers and other parts are nector holder and disconnect the SRS wire har not damaged or improperly installed ness connector then connect the short connector RED to the pretensioner connector 3 Check the seat belts for damage or discoloration Clean with a shop towel if necessary NOTE To prevent contamination wrap the SRS wire harness connector with a protective cover CAUTION Use only soap and water to clean CONNECTOR r HOLDER NOTE Dirt built up in the metal loops of the upper anchors can cause the seat belts to retract slowly PRETENSIONER Wipe the inside of the loops with a clean cloth damp CONNECTOR ened in isopropyl alcohol RETRACTOR if PROTECTIVE 4 Check that the seat belt does not lock when pulled COVER out slowly The seat belt is designed to lock only dur SRS WIRE ing a sudden stop or impact HARNESS CONNECTOR 5 Make sure that the seat belt will retract automati cally when released SHORT EN SRS WIRE 6 Replace the seat belt with a new one if there is any HARNESS abnormality Retractor Inspection 1 Before installing the retractor check that the seat belt can be pulled out freely 2 Make sure that the seat belt does not lock when the retractor is leaned slowly up to 15 from
38. 2 149 1 400 Ibs KO 965 660 kg 2 127 1 455 Ibs KY 970 665 kg 2 138 1 466 Ibs Cylinder Arrangement Bore and Stroke Displacement Compression Ratio Except European type and KU Valve Train Lubrication System Oil Pump Displacement At oil temp 120 C 248 F Fuel Required C32A2 Engine Belt driven SOHC Forced and wet sump trochoid pump 42 3 t min 44 7 US qt min 37 2 Imp qt min PREMIUM UNLEADED gasoline with research octane number of 95 or higher UNLEADED gasoline with research octane number of 91 or higher LEADED gasoline with research octane number of 91 or higher at 6 000 pump min 1 rpm European type and KU KQ C32A3 Engine C32A4 C32A5 Engines KY KT Unleaded gasoline with R O N of 91 or higher may also be used at 5 760 pump min 7 rpm Water Pump Displacement At coolant temp 25 C 77 F 178 min 188 US qt min 157 Imp at min Type Makes Gear reduction permanent magnet MITSUBISHI Normal Output 2 0 kW Nominal Voltage 12V Hour Rating 30 seconds Direction of Rotation Clockwise as viewed from gear end Weight Clutch Type Single plate dry diaphragm spring Torque converter Clutch Living Area 3 15 Design Specifications TRANSMISSION ITEM METRIC ENGLISH Transmission M T Synchronized 5 speed forward 1 reverse A T Electronically control
39. 21 Reconnect the front passenger s airbag 3 P connec tor to the SRS main harness connector SRS MAIN HARNESS SHORT CONNECTOR RED HOLDER FRONT PASSENGER S AIRBAG 3 P CONNECTOR GLOVE BOX 22 Reinstall the glove box 23 86 23 Remove the short connectors RED from the driver s airbag connector and from the cable reel 3 P con nector 24 Reconnect the driver s airbag 3 P connector to the cable reel 3 P connector Attach the short connec tor RED to the access panel then reinstall the panel on the steering wheel CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG CONNECTOR ACCESS PANEL 25 Remove the short connectors RED from the seat belt pretensioners then attach them to their holders 26 Reconnect the side wire harness 3 P connector to the driver s seat belt pretensioner and the main wire harness 3 P connector to the front passenger s seat belt pretensioner SHORT CONNECTOR RED SEAT BELT PRETENSIONER CONNECTOR ASSEMBLY HOLDER SIDE WIRE HARNESS 3 P CONNECTOR Driver s side MAIN WIRE HARNESS 3 P CONNECTOR Front passenger s side 27 28 29 Reinstall the B pillar lower panel Reconnect the battery positive cable then the nega tive cable After installing the cable reel confirm proper system operation Turn the ignition ON Il The instrument panel SRS indicator light should go on for about six seconds and then go off Make sure both horn
40. Desired result INTERLOCK CONTROL UNIT 8 P CONNECTOR GRN WHT WHT RED YEL BLK BLK dd GRN WHT BLK RED View from wire side Possible cause if result is not obtained Blown No 39 20 A fuse Faulty brake switch An open in the wire 2 GRN WHT Shift lever in P Check for continuity to ground There should be continuity Faulty shift lever position switch Poor ground G521 G522 An open in the wire 3 YEL BLK Ignition switch ON II Check for voltage to ground There should be battery voltage Key Interlock System No Wire Test condition Test Desired result Blown No 17 7 5 A fuse Faulty shift lock solenoid An open in the wire BLK Under all conditions Check for continuity to ground There should be continuity Poor ground G402 G403 An open in the wire 2 GRN WHT Shift lever in P Check for continuity to ground There should be continuity Poor ground G521 G522 Faulty shift lever position switch An open in the wire pushed in all the way WHT RED Ignition switch turned Check for voltage to ground Blown No 39 20 A fuse to ACC 1 and the key There should be battery voltage Faulty steering lock assembly key interlock solenoid An open in the wire pushed in all the way 4 BLK RED Ignition switch turned Check for voltage to ground Blo
41. GRN WHT A SHIFT ig KEY BRAKE LIGHTS 2 Built into ON Unlock steering lock INTERLOCK CU CRUISE CONTROL SOLENOID NIT ABS CONTROL UNIT WHT RED BLK RED GRN WHT YEL BLK KEY INTERLOCK CIRCUIT SHIFT LOCK CIRCUIT INTERLOCK CONTROL UNIT BLK GRN WHT SHIFT LEVER POSITION INDICATOR GRN WHT _Y GRN WHT SHIFT LEVER POSITION SWITCH ON In position P 1 6521 6522 23 18 Control Unit Input Test Disconnect the 8 P connector from the control unit Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it NOTE If the shift lock solenoid clicks when you step on the brake pedal with the ignition switch ON 1I the shift lever is in P the shift lock system is electroni cally OK If the shift lever cannot be shifted from P see shift lever position indicator system and section 14 Shift Lock System No Wire Test condition 1 GRN WHT Ignition switch ON Il Check for voltage to ground There should be battery voltage brake pedal pushed Test
42. Harness C only to the cable reel side of the 7 P connector CABLE REEL 7 P CONNECTOR TEST HARNESS C 07MAZ SPO0600 5 Measure the resistance between the No 4 terminal and the No 5 terminal e 07MAZ 5 00600 If resistance is more than O 2 go to step 6 If resistance is less than 0 2 the SRS main har ness is faulty Replace it and recheck the voltages according to the chart on page 23 61 23 68 6 Disconnect the driver s airbag 3 P connector from the cable reel then connect Test Harness C to the driver s airbag 3 P connector 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 Mode F Open in front passenger s airbag inflator 2 Connect Test Harness B between the SRS unit and m SRS main harness 18 P connector CABLE REEL 7P CONNECTOR SRS UNIT DRIVER S AIRBAG 3 P CONNECTOR TEST HARNESS B TEST 07MAZ SP00500 HARNESS C 07MAZ SP00600 7 Measure the resistance between the No 9 terminal and the No 10 terminal SRS MAIN HARNESS TEST HARNESS C 07MAZ SPO0600 3 Reconnect the front passenger s airbag connector then measure the resistance between the No 2 ter minal and the No 8 terminal TEST HARNESS B 07MAZ SPO0500 f resistance is more than 0 2 the driver s air a fejelte eTe o
43. Light will stay on if the service check connec tor is jumped 11 4 6 Emission Control System Tailpipe Emission Inspection Do not smoke during this procedure Keep any open flame away from your work area 1 Starting the engine and warm it up to normal oper ating temperature the cooling fan comes on by driv ing the car on the road Connect a tachometer see page 11 2 Check idle speed and adjust the idle speed if neces sary see page 11 2 Warm up and calibrate the CO meter according to the meter manufacturer s instructions Check idle CO with the headlights heater blower rear window defogger cooling fan and air condition er off Specified CO96 The cars with CATA 0 1 96 maximum The cars without CATA 1 0 1 0 96 If unable to obtain this reading On with CATA models see ECU troubleshooting guide On without CATA models adjust by turning the adjusting screw of the IMA sensor ADJUSTING SCREW IMA SENSOR If unable to obtain a CO reading of specified 96 by this procedure check the engine tune up con dition 11 5 Emission Control System Evaporative Emission Controls Description The evaporative controls are designed to minimize the amount of fuel vapor escaping to the atmosphere The system consists of the following components A Charcoal Canister A canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the canister into
44. N m 0 1 kg m 0 7 Ib ft of torque to turn the nut on the bolt NOTE Adjust the tool so the jaws are parallel to each other a zs CASTLE NUDU 70 80 7 0 8 0 kg m 51 58 lb ft BALL JOINT REMOVER 32 mm 07MAC SL00100 COTTER PIN Replace 37 Remove the driveshafts Suspend them with a rope as shown CAUTION Do not pull on the driveshaft as the CV joint may come apart e Use care when prying out the assembly and pull it straight to avoid damaging the differential oil seal or intermediate shaft dust seal NOTE Coat all precision finished surfaces with clean engine oil or grease Tie plastic bags over the driveshaft ends DRIVESHAFT 38 Raise the hoist to full height cont d 5 9 Engine Removal Installation cont d P PY 39 Remove the lower plate from the rear beam then 42 Remowve the heat shields retighten the steering gearbox mounting bolts STEERING GEARBOX MOUNTING BOLTS Retorque these bolts 10 x 1 25 mm gt REAR e lt gt S A y 2 Ve o 10 x 1 25 mm LOWER PLATE HEAT SHIELDS 39 N m 3 9 kg m 28 Ib ft 6 x 1 0 mm 7 CORROSION RESISTANT BOLT 10 N m 1 0 kg m 6 x 1 0 mm 7 lb ft 10 N m 1 0 kg m 7 lb ft 40 Remove the power steering speed sensor Do not disconnect the hoses 43 Remove the exhaust pipe A covers exhaust pipe A and joint pipe assembly Do not dis
45. PROPRE ET SEC WAARSCHUWING BINNENIN BEVINDEN ZICH GEEN OHDERDELEN DIE AAN ONDERHOUD ONDERHEVIG ZIJH DEMONTEER NIETS EN KNCE AAN DE S R S LAAT DE S R S NIET VALLEN ACHTUNG WARTUNGSFREIES BAUTEIL NICHT FFNEN ZERLEGEN ODER VERANDERN NICHT WERFEN TROCKEN UND GESCH TZT LAGERN CAUTION NO SERVICEABLE PARTS INSIDE DO NOT DISASSEMBLE OR TAMPER DO NOT DROP STORE IN A CLEAN DRY AREA OBSERVERA DET FINNS INGA INRE DELAR DU SJAJV KAN REPARERA F RS K INTE TA IS R ELLER ANDRA TAPPA INTE 1 GOLVET e F RVARA P EN REN OCH TORR PLATS Varoitus Fi huollettavia osia sis ll e l pura l k tuki e l pudota Varastoi puhtaassa kuivassa paikassa S R S oos JSL iile Sas eld 2295 Y Sani gl ciis Alagus Y Ug bald l A 6555 Lift and Support Point Lift 1 Place the lift blocks as shown 2 Raise the lift until the tyres are slightly off the ground and rock the car to be sure it is firmly supported 3 Raise the lift to full height and inspect lift points for solid support TSS NS S SE FRONT SUPPORT POINT LIFT BLOCKS REAR SUPPORT POINT 1 19 Lift and Support Points Floor Jack 1 Setthe parking brake and block the wheels that are FS not being lifted Always use safety stands when working on or under any vehicle that is supported by onl
46. SC GH LL SEAT BELT REMINDER LIGHT GRN YEL GRN WHT BLU YEL INTERMITTENT DWELL TIMER CONTROLLER DRIVER S POWER EAT BELT WINDOW 2 RELAY With the seat 23 23 Integrated Control Unit KY model Input Test Remove the left kick panel cover and under dash fuse CAUTION box then disconnect the 22 P connector from the in AII SRS wiring harnesses are covered with yellow out tegrated control unit Remove the integrated control unit er insulation from the under dash fuse box Before disconnecting any part of the SRS wire har ness install the short connectors see page 23 54 Inspect the connector and socket terminals to be sure Replace the entire affected SRS harness assembly if they are all making good contact i has an open circuit or damaged wiring e If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector and the under dash fuse box socket f any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it NOTE Different wires with the same color have been given a number suffix to distinguish them for example WHT GRN and WHT GRN are not the same SRS MAIN HARNESS Covered with yellow outer insulation INTEGRATED CONTROL U
47. SOLENOID THROTTLE VALVE BODY 2ND ACCUMULATOR COVER O RINGS Replace 1ST ACCUMULATOR COVER DOWEL PIN THROTTLE SEPARATOR PLATE FILTER Replace SECONDARY VALVE BODY DOWEL PIN FILTER Replace CHECK BALLS MAIN SEPARATOR PLATE FILTER Replace MAIN VALVE BODY DOWEL PIN FILTER Replace OIL PASS BODY SEPARATOR PLATE OIL PASS BODY ATF STRAINER O RING Replace SHIFT CABLE HOLDER BASE CONNECTOR STOPPER DETENT SPRING FIX PIN DETENT SPRING DETENT SPRING PLATE LOCK WASHER Replace OIL PAN GASKET Replace DOWEL PIN ATF MAGNET OIL PAN DRAIN PLUG SEALING WASHER Replace CHOKE e 699999e99959e9 9 99999999 e e u1 eee ee 999 o TORQUE SPECIFICATIONS Torque Value Bolt Size 12 Nem 1 2 kg m 9 Ib ft 6 x 1 0 mm 6 N m 0 6 kg m 4 Ib ft 5 x 0 8 mm Flange Nut 50 Nem 5 0 kg m 36 Ib ft 18 x 1 5 mm Drain Plug 14 15 Illustrated Index Transmission Housing ARK d AS Sy 2 or 9 7 14 16 SNAP RING THRUST WASHER THRUST NEEDLE BEARING MAINSHAFT 1ST GEAR NEEDLE BEARINGS THRUST NEEDLE BEARING MAINSHAFT 1ST GEAR DISTANCE COLLAR MAINSHAFT 1ST GEAR COLLAR 1ST 4TH CLUTCH ASSEMBLY O RING Replace THRUST WASHER 43 x 74 mm Selective part THRUST NEEDLE BEARING MAINSHAFT 4TH GEAR NEEDLE BEARING THRUST NEEDLE BEARING MAINSHAFT 3RD GEAR MAINSHAFT SEALING RINGS 37 mm NEEDLE BEARING SET RING COUNTERSHAFT 2ND GEAR COLLAR THRUST NEEDLE BEARING S
48. SWITCH ASSEMBLY TRAY RADIO REAR REMOTE REAR ARMREST SWITCH SCREWS CAP 4 Check for continuity between the terminals in each Switch position according to the table Ne omm 3 Disconnect the 10 P connector and remove the two screws then remove the radio rear remote switch from the switch panel POWER SWITCH PANEL o seca o mme Jo SCREWS Es BE EE RADIO REAR REMOTE SWITCH 10 P CONNECTOR 23 31 Stereo Sound System KO model Bulb Replacement Remove the radio rear remote switch see page 23 31 Turn the bulb counterclockwise to remove it from the switch then replace the bulb BULB 0 84 W RADIO REAR REMOTE SWITCH 23 32 ignition System Spark Plug Inspection With Catalytic Converter Engine type C32A2 and C32A3 Make sure that the 1 3 mm 0 051 in plug gauge does not fit into the gap of the platinum tip plug If the gauge fits into the gap do not attempt to adjust the side elec trode Replace the plug Electrode Gap 1 0 1 1 mm Standard 0 039 0 043 in Service Limit 1 3 mm 0 051 in Platinum tip plug Check and confirm that the 1 3 mm 0 051 in plug gauge does not fit into the gap Use only the plugs listed below PFR6G 11 NGK PZFR6F 11 NGK PK20PR L11 ND PKJ2OCR L11 ND PFR7G 11 NGK PK22PR L11 ND PFR5G 11 NGK PK16PR L11 ND
49. WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY VARING DETTA FORDON HAR EN LUFTKUDDE F R FORARSATET SOM ETT KOMPLETTERANDE SKYDDSSYSTEM SRS SAMTLIGA ELLEDNINGAR OCH KONTAKTER SRS SYSTEMET AR GULFARGADE ANV ND INTE ELEKTRISK PROVUTRUSTNING F R DESSA KRETSAR OM DU NDRAR ELLER LOSSAR EN SRS LEDNING KAN DET RESULTERA EN OAVSIKTLIG UTL SNING AV TRYCKPUMPEN ELLER G RA ATT SYSTEMET SLUTAR FUNGERA D KAN EN ALLVARLIG OLYCKA UPPST VAROITUS T SS AUTOSSA ON YLIMAARAISENA TUKIJARJESTELMANA AJAJAN ILMATYYNY SRS KAIKKI SRS S HK JOHDOT JA LITTIMET OVAT KELTAISET L K YT S HK KOELAITTEITA N ISS VIRTAPIIREISA SRS JOHTOJEN TUKKEAMINEN TAI IRROTAAMINEN SAATTAA SYTYTT VAHINGOSSA PUMPUN TAI TEHD J RJESTELM N K YTT KELVOTTOMAKSI T ST TAAS SAATTAA AIHEUTUA VAKAVIA VAURIOITA S R S CS EU Fill Late ilga Se Slow gt S R S 35 S R S BLSY ca Slt alas 0310 9g S M SNY phe agli Ligle gh Sadi yl Le eG w l Lad lane Ba rl 5058 Of Say 5 8 5 SUSY res SI alias Lad d ody Lao Jandi Op aalt Juan A caesaris gi BLU da l JH pol gas cont d 1 11 Warning Caution Label Locations cont d SUNVISOR 1 J Refer to page 1 13 K Refer to page 1 14 L Refer to page 1 15 M Refer to page 1 15 and 16 N O Refer to pag
50. YEL wire No 3 terminal of the dashboard wire harness between the gauge as sembly and the No 13 7 5 A LHD or No 17 7 5 A RHD fuse 23 58 NOTE Make sure you reinstall the socket plug in From page 23 58 the SRS unit after testing Reconnect each connector to the gauge assembly and SRS unit SRS UNIT then connect Test Harness A to the SRS unit SRS MAIN HARNESS Measure the voltage between the No 13 terminal and body ground for six seconds after igni tion is first turned on TEST HARNESS A s 7 2 5100500 More than 8 5 V NO GER ig there more than BV The SRS indicator circuit in the gauge assembly is faulty YES The SRS unit is faulty cont d 23 59 Supplemental Restraint System SRS Troubleshooting cont d NOTE Before troubleshooting make sure that battery voltage is 12 V or more Otherwise you ll obtain wrong test readings 1 Make a photocopy of the chart on page 23 61 2 Connect Test Harness A to the SRS unit as shown SRS UNIT TEST HARNESS A 07MAZ SLOO500 3 Turn the ignition switch ON Il Voltages in the chart assume the car s battery voltage is about 12 volts Less than 12 volts will result in different or possibly false readings Do not disconnect the airbags from the circuit when checking SRS unit
51. air le tenir la verticale Suivre attentivement les instructions du manuel d en tretien tact flush eyes with water for 15 minutes If gases from acid or water contact are inhaled seek fresh air in every case get prompt medical attention KEEP OUT OF REACH OF CHILDREN WARNING The airbag inflator is explosive and if accidentally deployed can seriously hurt or kill you Do not use electrical test equipment or probing devices They can cause accidental deployment No serviceable parts inside Do not disassemble Place airbag upright when removed Follow Service Shop Manual instructions carefully 1 16 N INFLATOR CAUTION LABEL KF KG KX ACHTUNG AUM SCHUTZ VOR UNBEABSICHTIGTER AUSLOSUNG UND MOGLICHEN VERLETZUNGEN BEI ANSCHLUSS DES KURZSCHLUSSICHERUNGES STECKERS AN DEN GASGENERATORSTECKER IMMER DEN KABELBAUM ABTRENNEDN WAARSCHUWING OM TE VOORKOMEN DAT HET SYSTEEM PER ONGELUK IN BEDRIJF WORDT GESTELD EN OM VERWONDINGEN TE VOORKOMEN DIENT U DE BESCHERMENDE KORTE CONNECTOR OP DE VULINRICHTINGCONNECTOR UITSLUITEND TE INSTALLEREN WANNEER DE DRAADBOOM 15 LOSGEKOPPELD KE KT KU A WRNING Accidental airbag deployment can seriously hurt or kill you Install the red service connector when the inflator harness is disconnected A ATTENTION Tout d ploiement accidentel du coussin d air risqu
52. body can be seriously damaged if this method of towing is attempted TOWING HOOK and If the LEGEND cannot be transported by flat bed it should TIE DOWN BRACKETS be towed with the front wheels off the ground If due to damage the car must be towed with the front wheels on the ground do the following Release the parking brake Shift the 5 speed transmission to Neutral if the car has an automatic transmission start the en gine Shift the transmission to position then into N position then shut off the engine NOTICE Improper towing preparation will damage the transmission Follow the above procedure exact ly If you cannot shift the transmission the car must be transported on a flat bed itis best to tow the car no farther than 80 km 50 miles and keep the speed below 55 km h 35 mph NOTICE Trying to lift or two the car by the bum pers will cause serious damage The bumpers are not designed to support the car s weight 1 22 Preparation of Work Handling of Special Nuts and Bolts Because the front sub frame sections on this car are con structed with aluminum alloys use only the special Dacro type nuts and bolts recommended by Honda NOTE Dacro finish can be identified by gray plating Some Dacro finish bolts have a green coating on the thread section of the bolt for easier applica tion This type of bolt is called a Torquer bolt Use of other
53. buttons work Make sure the headlight and wiper switches work Take a test drive and make sure the cruise con trol set resume cancel switch works Rotate the steering wheel counterclockwise to make sure the yellow gear tooth lines up with the alignment mark on the cover ALIGNMENT MARK YELLOW GEAR TOOTH 23 87 Supplemental Restraint System SRS Dash Sensor Replacement CAUTION 4 Front passenger s side Do not damage the sensor wiring Remove the door sill molding and pull back the car Do not install used SRS parts from another car When peting Remove the ECU repairing an SRS use only new parts Replace a sensor if it is dented cracked or deformed p orir ieie dented cracked ed DASH SENSOR SRS MAIN HARNESS 2 P CONNECTOR 1 Disconnect the battery negative cable then the posi tive cable 2 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 3 Driver s side Remove the footrest and door sill molding then pull the carpet back and remove the sensor cover SENSOR COVER DASH SENSOR MOUNTING BOLTS b Remove the two dash sensor mounting bolts then remove the left or right dash sensor DASH SENSOR DASH SENSOR DASH SENSOR 2 P CONNECTOR DASH SENSOR MOUNTING BOLTS 8 mm x 1 25 23 88 SRS CAUTION 8 Remove the short connectors from the front pas
54. ces r parables l int rieur Ne pas d monter Quand on retire le coussin d air le tenir la verticale Suivre attentivement les instructions du manuel d entretien F INFLATOR CAUTION LABEL KF KG KX ACHTUNG AUM SCHUTZ VOR UNBEABSICHTIGTER AUSLOSUNG UND MOGLICHEN VERLETZUNGEN BEI ANSCHLUSS DES KURZSCHLUSSICHERUNGES STECKERS AN DEN GASGENERATORSTECKER IMMER DEN KABELBAUM ABTRENNEN WAARSCHUWING OM TE VOORKOMEN DAT HET SYSTEEM PER ONGELUK IN BEDRIJF WORDT GESTELD EN OM VERWONDINGEN TE VOORKOMEN DIENT U DE BESCHERMENDE KORTE CONNECTOR OP DE VULINRICHTINGCONNECTOR UITSLUITEND TE INSTALLEREN WANNEER DE DRAADBOOM IS LOSGEKOPPELD KE KT KU WARNING Accidental aribag deployment can seriously burt or kill you Install the red service connector when the inflator harness is disconnected ATTENTION Tout d ploiement accidentel du coussin d air risque de provoquer des blessures graves ou de tuer Quand le faisceau de fils du gonfleur est d connect installer le connecteur d entretlen rouge KS VARNING F R ATT F RHINDRA OAVSIKTLIG UTL SNING OCH TANKBARA SKADOR S TT ALLTID DET SKYDDANDE KORT SLUTNINGSSTIFTET PA TRYCKPUMPSKONTAKTEN N R KABELN TET LOSSAS Varoitus Est vahingollisen k yt n ja mahdollisen vahingoittumisen Asenna aina suojaava lyhyt liitin pumpun liittimeen silloin kun haarniska on irti
55. cont d 23 73 Supplemental Restraint System SRS Troubleshooting cont d 7 Check for continuity between the B11 terminal of Test Harness B and the No 10 terminal of the main wire harness 20 P connector TEST HARNESS B 07MAZ SPO0500 Continuity MAIN WIRE HARNESS 20 P CONNECTOR sl else STITT Eo s pe v e s n n View from terminal side If there is continuity the SRS unit is faulty Replace it and recheck the voltages according to the chart on page 23 61 f there is no continuity there is an open in the SRS main harness Replace the SRS main harness and recheck the voltages according to the chart on page 23 61 23 74 8 Reconnect the dashboard wire harness 20 P connec tor to the main wire harness Disconnect the dash board wire harness 7 P connector from the gauge assembly DASHBOARD WIRE HARNESS 7 P CONNECTOR 9 Turn the ignition switch ON 11 and wait for six se conds Measure the voltage between the No 2 ter minal and body ground More than 8 5 V Less than 8 5 V is faulty BLU View from terminal side f voltage is more than 8 5 V the SRS indicator circuit is faulty in the gauge assembly Replace the gauge assembly and recheck the voltages according to the chart on page 23 61 9 If voltage is less than 8 5 V the dashboard wire harness or the main wire harness is faulty Replace it and recheck the voltages accor
56. or damaged wiring 3 N m 0 3 kg m 2 Ib ft SRS MAIN Appry non hardening SELECT LEVER HARNESS thread lock sealant Nem 0 3 kg m 2 Ib ft SHIFT INDICATOR SELECT LEVER ASSEMBLY PANEL nnd ee crease y SILICONE GREASE SHIFT INDICATOR DETENT SPRING B qmump 3 Q LEVER COVER BEE SILICONE GREASE SHIFT LOCK DETENT PLATE SOLENOID DETENT HOLDER q ES AT SHIFT POSITION SELF LOCKING NUT i beten CONSOLE SWITCH 6 x 1 0 mm A ES S dn S 10 N m 1 0 kg m Va ASS NE 7 lb ft SILICONE m 0 7 kam 5 lb ft GREASE 7 N m 0 7 kom 5 Ib ft CONTROL SEAL x 1 2b mm 2 N m 2 2 kg m 16 Ib ft BRACKET D SHIFT CABLE BRACKET SHIFT CABLE 14 32 Suspension Wheel Alignment Camber Caster gauge Installation For 16 inch aluminum wheel models 18 2 Turning Angle For KE KG KX KF KS models 18 2 Front Suspension Front Spindle Nut Installation 18 3 Outline of Model Change The camber caster gauge installation procedures have been changed on the 16 inch aluminum wheel models Turning angle specifications have been changed for the KE KG KX KF KS models The front spindle nut installation procedures have been changed Wheel Alignment Camber Caster Gauge Installation For 16 inch aluminum wheel models 1 Remove the wheel Turning Angle For KE KG KX KF KS models Turning angle Inward
57. s seat belt switch UNDER DASH FUSE BOX Integrated control unit Turn signal hazard relay aa Power window relay IAS Sunroof and cruise control switches HA Gauges and indicator lights Rear window defogger switch 6402 Dash lights brightness control unit To page 23 6 Clock y Climate control unit is BLK Rear fog light switch European model E BLK E BLK AE Lights on chime HE BLK Starter cut relay Without security system M T 16 BLK YEL Shift lever position switch Without security system A T EE BLK BLK Power window master switch Power mirror switch Driver s door key cylinder switch With security system m BLK Driver s window motor Left mirror defogger Driver s door lock knob switch Driver s door switch Driver s door lock switch E BLK rT u BLK E Blower motor high relay Blower motor relay Power transistor A C E BLK Service check connector BLK BLK Jk BLK E Front passenger s door key cylinder switch Right mirror defogger Front passenger s door lock knob switch Front passenger s door switch E BLK BLK ABS pressure switch ABS front fail safe relay ABS rear fail safe relay G403 E BLK E BLK Cigarette lighter relay E BLK Seat heater relay BLK Ceiling light relay Q G401 E Main wire harness Front passenger
58. shift cable bracket CAUTION Take care not to bend the cable when removing installing it SHIFT CABLE BRACKET 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft 7 Remove the shift cable guide from the transmission beam SHIFT CABLE GUIDE 8 x 1 25 mm 22 N m 2 2 kg m SHIFT CABLE TRANSMISSION BEAM 8 Remove the shift cable cover 9 Remove the shift cable holder from the shift cable holder base and from the shift cable 10 Remove the control lever from the control shaft 11 Remove the shift cable 30 N m SHIFT CABLE ine HOLDER 6 x 1 0 mm 12 Nem C 1 2 kg m 9 Ib ft XS v CO S KO A WT A O Y 6 Vie s SHIFT CABLE LOCK PLATE CS E dam 14 Nem A 1 4 kg m MAN 10 Ib ft _ SA SHIFT CABLE HOLDER BASE CONTROL LEVER S us Ke d g 5 Lely XA i N SCH ae 4 Po SHIFT CABLE COVER CONTROL SHAFT 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 12 Install the shift cable in the reverse order of removal 13 Check the cable adjustment on reassembly 14 31 Gearshift selector KQ model SRS electrical wiring harnesses are routed near the gearshift selector CAUTION All SRS electrical wiring harnesses are covered with yellow outer insulation Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 Replace the entire affected SRS harness assembly if it has an open circuit
59. to return it for disposal Deployment Tool Check Procedure 1 Connect the yellow clips to both switch protector handles on the tool connect the tool to a battery Push the operation switch green means the tool is OK red means the tool is faulty Disconnect the battery and the yellow clips 23 83 Supplemental Restraint System SRS Cable Reel Replacement Store a removed airbag assembly with the pad surface up If the airbag is improperly stored face down accidental deployment could propel the unit with enough force to cause serious injury CAUTION Carefully inspect the airbag assembly before install ing it Do not install an airbag assembly that shows signs of being dropped or improperly handled such as dents cracks or deformation Always keep the short connectors on the airbags and seat belt pretensioners when the harness is discon nected Do not disassemble or tamper with any airbag as sembly 1 Disconnect the battery negative cable and then the positive cable 2 Make sure the wheels are aligned straight ahead 3 Remove the dashboard lower cover and glove box GLOVE BOX DASHBOARD LOWER COVER 23 84 4 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 5 Remove the driver s airbag assembly from the steer ing wheel two T30 TORX bolts then remove the steering wheel nut STEERING WHEEL NUT TORX
60. types of nuts and bolts may cause electrolysis and corrosion which in turn could cause the bolt to loosen Gray plating Green coating on the threads of some bolts Gray plating Dacro type Gray plating Green coating on the threads Torquer type When replacing nuts and bolts use only the same type Tighten the nuts and bolts with a torque wrench to the specifications provided in this manual Clean all thread ridges with a non wire type bristle brush Foreign matter in the threads may cause the bolt to loosen Sections on this car requiring the use of Dacro nuts and bolts wilkl be indicated by a x in this manual 7 DLA IS 1 23 Preparation of Work Special Caution Items for This Car Anti lock brake piping system servicing Disassemble the Anti lock brake piping system after relieve the high pressured brake fluid Otherwise the high pressured brake fluid will burst out and it is very dangerous Refer to the Base Shop Manual 62SP000 section 19 how to relieve the high pressured brake fluid BLEEDER T WRENCH 07HAA SG00100 or 07HAA SG00101 RED CAP MAINTENANCE BLEEDER 8 x 1 25 mm 5 5 N m 0 55 kg m 4 0 Ib ft Fuel Line Servicing Relieve fuel pressure by loosening the service bolt provided on the top of the fuel filter before discon necting a fuel hose or a fuel pipe SERVICE BOLT 12 N m 1 2 kg m 9
61. wheel 40 2 Outward wheel 33 Remove the wheel center cap On the rear wheel remove the hub cap Insert the special tool into the wheel from inside of the wheel Hold the special tool and install the wheel with the wheel nuts Tighten the wheel nuts securely Install a camber caster gauge on the special tool cor rectly Front gt WHEEL ALIGNMENT GAUGE ATTACHMENT 07MGK 0010100 WHEEL NUT WHEEL CENTER CAP CAMBER CASTER GAUGE EQUIVALENT COMMERCIALLY AVAILABLE lt Rear gt WHEEL ALIGNMENT GAUGE ATTACHMENT 07MGK 0010100 WHEEL NUT WHEEL CENTER CAP CAMBER CASTER GAUGE EQUIVALENT COMMERCIALLY AVAILABLE 18 2 Front Suspension Front Spindle Nut Installation Apply engine oil to the seating surface of the new front spindle nut then install the spindle nut Tighten the spindle nut to specified torque then stake the spindle nut shoulder against the spindle STAKE POINT FRONT SPINDLE NUT 26 x 1 5 mm 335 N m 33 5 kom 242 Ib ft Replace 18 3 Anti lock Brake System ABS Change in the ABS Control Unit Control System 19 2 NOTE The name of ALB was changed to ABS When you refer to the LEGEND Shop Manual No 62SPOOO for the changes in the ABS control unit control system read by substituting a word of ALB to ABS Outline of Model Changes As the control system of the ABS control unit was partially revised the chang
62. your eyes or on your skin rush to a physician or hospital for immediate treatment Do not attempt to treat it yourself keep refrigerant containers cans of R 134a stored below 40 104 keep away from open flame Refrigerant although non flammable will produce poisonous gas if burned work in well ventilated area Refrigerant evaporates quickly and can force all the air out of a small enclosed area CAUTION Do not overcharge the system the com pressor will be damaged 1 After the leak test check that the high pressure valve is closed and start the engine THREE VALVE GAUGE LOW PRESSURE VALVE EVACUATION VALVE HIGH PRESSURE VALVE CHECK VALVE HIGH PRESSURE QUICK JOINT 134a 134a LL LOW PRESSURE QUICK JOINT LOW PRESSURE VALVE Bal TA NOTE Run the engine below 1500 rpm 1 2 Open the front door Turn the A C switch ON Set the temperature control dial to MAX COOL Push the mode control button to VENT Push the fan switch to MAX 3 Open the low pressure valve and charge with R 134a refrigerant Do not open the high pressure valve Do not turn the cans upside down 4 Charge the system with refrigerant capactiy Refrigerant capacity 750 2 g 26 5 9 4 oz 5 When fully charged close the low pressure valve and the refrigerant cans Check the system 6 Stop the engine and disconnect the charge hose
63. 0 3 771 86 487 86 513 3 405 3 406 79 107 79 120 3 114 3 115 69 833 69 846 2 749 2 750 6 97 6 98 0 274 0 275 11 47 11 48 0 4516 0 4520 7 018 7 030 0 276 0 277 11 500 11 518 0 4528 0 4535 1 980 1 995 0 078 0 079 1 980 1 995 0 078 0 079 2 025 2 060 0 080 0 081 2 025 2 060 0 080 0 081 24 980 24 993 0 983 0 984 53 968 53 984 2 1247 2 1254 34 975 34 991 1 377 1 378 34 975 34 991 1 377 1 378 34 975 34 991 1 377 1 378 38 505 38 515 1 5159 1 5163 47 975 47 991 1 8888 1 8894 38 975 38 991 1 534 1 535 38 975 38 991 1 534 1 535 33 975 33 991 1 3376 1 3382 13 99 14 00 0 5508 0 5512 Unit of length mm in SERVICE LIMIT Wear or damage Wear or damage Wear or damage Wear or damage 7 045 0 277 11 53 0 454 1 80 0 071 0 082 1 8 2 0 2 08 0 082 Co Wear or damage Wear or damage cont d 3 9 Standards and Service Limits Automatic Transmission cont d Section 14 MEASUREMENT Transmission LD cont d Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 1st gear Countershaft 3rd gear Countershaft 2nd gear Countershaft 1st gear Countershaft reverse gear Reverse idler gear End play Mainshaft 4th gear 1st 4th clutch Mainshaft 2nd gear Mainshaft 1st gear Countershaft 3rd gear Countershaft 4th gear C
64. 0 3 6 6 max Gear box Angle of rack guide screw loosened from locked position 0 Pump pressure with shut off valve closed 8 000 9 000 80 90 1 138 1 280 kPa kg cm psi Fluid capacity Reservoir 0 53 0 56 0 47 US ot Imp qt System 1 7 1 8 1 5 Deflection with 100 N 10 kg 22 Ibs between pulleys 11 5 13 5 0 45 0 53 with used belt 7 5 9 5 0 30 0 37 with new belt 350 550 35 55 77 121 with used belt 700 900 70 90 154 198 with new belt Pump Power steering fluid Power steering belt Belt tension N kg Ibs Measured with belt tension gauge When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 12 Unit of length mm in Suspension Section 18 MEASUREMENT STANDARD NEW SERVICE LIMIT Wheel Camber Front 0 00 1 0 15 1 alignment Rear 0 20 1 0 5 1 1 Caster Front 3 45 1 3 30 1 1 Total toe Front Out 1 2 0 04 0 08 Rear IN 2 2 0 08 0 08 Front wheel turning angle Inward wheel 449 2 40 t29 2 Outward wheel 35 33 2 Side slip Front Out 1 2 0 04 0 08 Rim runout Wheel bearing End play 5 0 0 002 5 0 0 002 1 KY only 2 KF KG KX KE KS Brakes Section 19 MEASUREMENT S
65. 1 185 76 0 80 0 169 176 88 7 91 3 192 196 82 0 86 0 180 187 MEASUREMENT Radiator Coolant capacity US qt Imp qt including engine heater cooling line and reservoir Reservoir capacity 0 65 0 69US qt 0 57 Imp qt Radiator cap Opening pressure kPa kg cm 2 psi Thermostat Start to open C F Fully open C F Valve lift at fully open Cooling fan Radiator fan control sensor ON temperature LOW C F Radiator fan control sensor OFF temperature LOW C F Radiator fan control sensor ON temperature HIGH C F Radiator fan control sensor ON temperature HIGH C F r Fuel and Emission Section 11 MEASUREMENT SERVICE LIMIT STANDARD NEW 230 7 78 8 10 min 450 600 4 5 6 0 64 0 85 3 270 320 2 7 3 2 38 46 130 4 40 4 58 Fuel pump Displacement m fl oz Imp oz in 10 seconds Relief valve opening pressure kPa kg cm2 psi Pressure regulator Pressure with regulator vacuum hose disconnected kPa kg cm 2 psi Capacity US gal Imp gal Fast idle speed min rpm at 25 C 77 F Idle speed min 1 rpm with headlight and cooling fan off 68 18 0 15 0 1 500 200 650 A T 600 50 or P position With CATA 0 1 max Without CATA 1 0 1 0 Fuel tank Engine I
66. 14 Suspension 16 inch aluminum wheel added European type Turning angle specifications changed European type 18 Brake ABS ABS control unit changed 19 Body Front seats modified Rear power seat added KO KY KT Air Conditioning System for new refrigerant R 134a changed Electrical Power supply circuit changed Added Interlock system KQ Key in reminder system Rear power seat KQ KT KY and Spark plug for models without catalytic converter Supplemental Restraint SRS unit changed Troubleshooting procedure modified System SRS Front seat passenger s airbag and Seat belt pretensioner added General Informaiton Chassis and Engine Numbers 1 2 Identification Number Locations 1 3 Warning Caution Label Locations 1 5 Lift and Support Points B pne TS 1 19 Floot ET edo ye E Eee pet cR 1 20 Safety Stands 1 21 TOWING veu anes 1 22 Preparation of Work 1 23 Symbol Marks 1 27 Abbreviations 1 28 Chassis and Engine Numbers Vehicle Identification Number SS r Engine Number JHMKA7ES00C200001 C32A2 3000001 Engine Type Serial Number lt KF KG KS KX KE KU gt C32A2 3000001 Manufacturer Make and Type of Vehicle JHM HONDA MO
67. 14 5 Disassembly Inspection Reassembly 14 21 Lower Valve Body Assembly Mainshaft Disassembly Reassembly 14 8 Disassembly Inspection Reassembly 14 22 Transmission Countershaft Removal 14 9 Disassembly Inspection Reassembly 14 23 Illustrated Index Oil Seal Rear Cover 14 12 Installation eet crede 14 24 Housing Lower Valve Body 14 14 Transmission Transmission Housing 14 16 Installation eese 14 25 Shift Cable Removal Installation 14 30 Gearshift Selector 14 32 Outline of Model Changes The hydraulic flow circuit has been modified The A T speed sensors have been modified The shift points has been changed The transmission rear mount mount bracket and heat shields have been changed Torque value of mainshaft and countershaft locknuts has been changed The main valve body secondary valve body and rear cover have been modified nstalled depth of transmission housing oil seal has been changed The gearshift selector has modified model Special Tools Tool Number O7LAC PW50101 or O7LAC PW50100 O7LAD SM40100 Oil Seal Driver Attachment O7LAJ PT30100 or Test Harness O7LAJ PT3010A 07MAF PY 40101 or Exte
68. 20A 30A 7 5 A 10 A 15 A 20 A 30 A 40 A 50 A 120A 12 V 55 60 W 12 V 55 65 W 12 V 21 12 V 45 CP 1 12V 5W 12 5 W 2 12 V 21 W 12 V 32 CP 12 V 32 2 CP 12 V 21 W 12 V 10 W 12 V 4 CP 12 5 W 12 V 3 CP 12 V 21 W 12 V 32 CP 1 12 V 21 W 12 V 45 CP 12 V 5 W 12 8 W 1 12 V 3 0 W 1 4 W 12 V 1 12 W 1 4 W 12 V 1 4 W 12 V 5 W 12 V 1 6 W 12 V 3 4 W 12 V 3 4 W 12 V 1 4 W 1 12 W 0 84 12 V 0 91 W 0 56 W L 12 V 1 4 W 12V 5W o 4 Except European type and KU Parking brake KU KO KY KT KF KG KX KE KS 3 17 Maintenance Lubrication Points 4 2 Maintenance Schedule 4 4 Lubrication Points For the details of lubrication points and types of lubricants to be applied refer to the Illustrated Index and various work procedures such as Assembly Reassembly Replacement Overhaul Installation etc contained in each section LUBRICANT API Service Grade SF or SG Fuel Efficient Oil SAE Viscosity See chart below API Service Grade SF or SG SAE Viscosity 10 W30 or 10 W40 Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON II Automatic Transmission Fluid Brake fluid DOT3 or DOT4 Brake fluid DOT3 or DOT4 Ste
69. 35 0 1 378 1st accumulator spring 8 0 75 5 2 972 4th accumulator spring 6 5 80 8 3 181 2nd accumulator spring A 2 0 96 7 3 807 2nd accumulator spring B 6 6 80 0 3 150 1st hold accumulator spring 5 0 68 4 2 693 3rd accumulator spring 9 0 78 4 3 087 Reverse accumulator spring 8 6 115 5 4 547 Lock up shift valve spring 7 6 73 7 2 902 Lock up timing valve spring 6 6 61 2 2 409 Lock up control valve spring 6 6 36 3 1 429 6 6 37 5 1 476 6 6 38 5 1 516 CPC valve spring A B 6 8 34 3 1 350 LD 3 11 Standards and Service Limits Differential Section 15 MEASUREMENT STANDARD NEW SERVICE LIMIT Differential Capacity US qt Imp qt 1 10 1 16 0 97 for overhaul oil 1 05 1 11 0 92 for oil change Differential Pinion shaft contact area LD 20 000 20 021 0 7874 0 7882 0 1 0 004 0 013 0 050 0 0005 0 0020 32 025 32 045 1 2608 1 2616 carrier Carrier to pinion shaft clearance Driveshaft and intermediate shaft contact area I D Carrier to driveshaft clearance Carrier to intermediate shaft clearance Backlash LD Pinion gear to shaft clearance 0 045 0 086 0 0018 0 0034 0 080 0 116 0 0031 0 0046 0 05 0 15 0 002 0 006 20 042 20 066 0 7891 0 7900 0 055 0 095 0 0022 0 0037 0 06 0 14 0 002 0 006 0 08 0 18 0 003 0 007 0 120 0 0047 0 120 0 0047 0 30 0 012
70. 4 P N 41211 PY5 305 as shown 17 Install a new set ring in the extension shaft groove SSH HONDA GENUINE GREASE UM264 P N 41211 PY5 305 SET RING 20 Apply liquid gasket P N 0Y740 99986 to the 36 mm sealing bolt threads 21 Install the 36 mm sealing bolt and secondary cover on the transmission housing NOTE Shift to position rotating the control shaft HONDA GENUINE SECONDARY GREASE UM264 COVER P N 41211 PY5 305 12 14 g 0 4 0 5 oz EXTENSION SHAFT GROOVE zm 4 18 Install the extension shaft using the special tool as CRE shown NOTE Make sure that the secondary spring is in stalled and the extension shaft locks securely in the zn secondary gear shaft 5 EATEN SHAFT 36 mm SEALING BOLT INSTALLE Apply liquid gasket 07MAF PY40101 or 60 100 N m 07MAF PY40100 x 6 0 10 0 kg m 43 72 Ib ft 22 Remove the steering gearbox mounting bolts then install the lower plate NOTE LHD is shown The location of the steering gearbox mounting bolts on the RHD are symmetrical Corrosion resistant bolt Remove these bolts before installing the lower plate 10 x 1 25 mm 60 Nem 6 0 kg m 43 Ib ft SECONDARY 36 mm SEALING BOLT COVER SD A 7 SET RING DID LOWER PLATE EXTENSION SHAFT EXTENSION 10 x 1 25 mm INSTALLER SHAFT 39 N m 3 9 kg m 28 Ib ft 07MAF PY40101 or cont d 07MAF PY40100 14 27
71. 56 1 4961 44 080 1 735 29 32 1 154 0 30 0 012 44 080 1 735 29 32 1 154 0 30 0 012 31 050 1 2224 37 940 1 494 29 54 1 163 Thickess of needle bearing contact area 29 56 29 61 1 164 1 166 Countershaft 1st LD 53 010 53 029 2 0870 2 0878 gear Thickness 35 92 36 00 1 414 1 417 0 04 0 10 0 002 0 004 53 010 53 029 2 0870 2 0878 35 92 36 00 1 414 1 417 0 04 0 10 0 002 0 004 53 081 2 0898 35 85 1 411 Adjust with a shim 53 081 2 0898 35 85 1 411 Adjust with a collar cont d 3 5 Standards and Service Limits Manual Transmission Section 13 MEASUREMENT Distance collar countershaft 2nd gear STANDARD NEW 37 950 37 960 1 4941 1 4945 46 989 47 000 1 8500 1 8504 36 03 36 05 1 419 1 419 36 07 36 08 1 420 1 421 SERVICE LIMIT 38 008 1 496 46 940 1 848 Adjust with a collar O D Countershaft reverse Thickness gear Synchro ring gear Ring to gear clearance ring pushed against 46 989 47 000 1 8500 1 8504 50 45 50 55 1 986 1 990 0 85 1 10 0 033 0 043 46 94 1 848 50 38 1 983 0 4 0 02 Double cone synchro ring Clearance ring pushed against gear Outer synchro ring to gear Synchro cone to g
72. 9 22 174 191 108 119 3rd 2nd 169 186 105 116 2nd 1st 3rd 1st Throttle angle sensor voltage 2 175 2 325 V 3 5 8 throttle When car is slowed by increased grade wind etc Full throttle When car is slowed by increased grade wind etc Upshift 96 105 2 60 65 162 178 152 168 KG model with Austria Ds Position 101 111 1st 2nd 94 104 2nd 3rd 3rd 4th Lock up Clutch ON Full throttle Acceleration from a stop 9 Downshift Throttle angle sensor voltage 0 822 0 878 V 0 5 8 throttle Coasting or braking to a stop Lock up Clutch OFF 4th 3rd mph 19 22 70 78 108 119 Throttle angle sensor voltage km h 15 19 30 35 42 49 32 37 0 822 0 878 V 0 5 8 throttle Coasting down hill from a stop mph 9 12 19 22 26 30 20 23 Throttle angle sensor voltage km h 34 40 61 69 93 102 n 120 129 2 175 2 325 V 3 5 8 throttle Acceleration from a stop mph 21 25 SR 38 43 58 63 75 80 km h 63 71 112 125 174 191 169 186 3rd 2nd 105 116 2nd 1st 3rd 1st Throttle angle sensor voltage 2 175 2 325 V 3 5 8 throttle When car is slowed by increased grade wind etc Full throttle Whe
73. AIN HARNESS SHORT CONNECTOR Driver s Airbag Place the driver s airbag assembly in the RED HOLDER steering wheel and secure it with new TORX bolts TORX BOLT 10 N m 1 0 kg m 7 2 ib ft Replace Use a TORX T30 bit TORX BOLT 10 N m 1 0 kg m 7 2 lb ft Replace Use a TORX T30 bit DRIVER S AIRBAG ASSEMBLY Front Passenger s Airbag Place the front passenger s airbag assembly in the dashboard Install the front passenger s airbag assembly in the reverse order of removal FRONT PASSENGER S AIRBAG 3 P CONNECTOR GLOVE BOX FRONT PASSENGER S AIRBAG 6 Reconnect the front passenger s airbag 3 P connec tor to the SRS main harness connector N Reinstall the glove box 62 box MOUNTING 7 NUTS 10 Nem 1 0 kom 7 2 lb ft Replace MOUNTING MOUNTING E SCREWS BOLTS 10 N m 1 0 kg m 7 2 Ib ft cont d Replace 23 77 Supplemental Restraint System SRS Airbag Assembly Replacement cont d 8 Remove the short connectors from the driver s air 12 Reinstall the B pillar lower panel bag 3 P connector and from the cable reel 3 P con nector 13 Reconnect the battery positive cable then the nega tive cable 9 Reconnect the driver s airbag 3 P connector to the cable reel 3 P connector Attach the short connec 14 After installing the airbag assembly confirm proper tor RED to the access panel then reinstall the panel Syste
74. AR COLLAR 3RD CLUTCH ASSEMBLY ke O RINGS Replace SEALING RINGS 42 mm ASSEMBLY E 1 O RINGS 7 THRUST NEEDLE BEARING NEEDLE BEARING REVERSE GEAR COLLAR A REVERSE CLUTCH ASSEMBLY O RINGS Replace DISC SPRING 29 mm Replace REVERSE CLUTCH S Replace DISTANCE COLLAR em Ji UST a PARKING GEAR V THR A 4 WASHER 38 8 x 47 mm 3 2 Selective part D sf THRUST NEEDLE 2 1ST HOLD CLUTCH TL BEARING DISTANCE COLLAR D THRUST WASHER N 45 5 x 60 mm d ns ZIP GEAR Selective part uo THRUST NEEDLE NEEDLE BEARINGS sn BEARING 2ND GEAR ONE WAY CLUTCH 2ND GEAR BALL BEARING SNAP RING ONE WAY CLUTCH HUB 14 23 Oil Seal Installation 1 Install the oil sea in the transmission housing us ing the special tools DRIVER 07749 0010000 OIL SEAL DRIVER ATTACHMENT 07LAD SM40100 Ch 10 5 11 5 mm 0 41 0 45 in TRANSMISSION HOUSING OIL SEAL 2 Install the oil seal in the torque converter housing using the special tools as shown 3 Install the snap ring in the torque converter housing DRIVER 07749 0010000 TORQUE CONVERTER HOUSING ATTACHMENT 72 x 75 mm 07746 0010600 OIL SEAL 14 24 Transmission Installation Install the torque converter with a new O ring and two 14 x 20 mm dowel pins in the torque converter housing Set the extension shaft and apply HONDA GENUINE GREASE UM284 P N 41211 PY5 305
75. CENTER PUNCH GEARBOX REAR ELEVATION FRONT ELEVATION SENSOR CONNECTOR SENSOR CONNECTOR BUSH Gray Blue 3 Flatten the bush using a flat tip screwdriver as shown METAL a PLATE FLAT TIP SCREWDRIVER REAR ELEVATION MOTOR BUSH Make sure the slide joint cable is connected se curely see page 20 15 REAR ELEVATION MOTOR CONNECTOR Brown FRONT ELEVATION MOTOR FRONT ELEVATION MOTOR CONNECTOR Green Check the recline adjuster and slide elevation ad juster operations 20 6 Recline Motor Replacement CAUTION Wear gloves to remove and install the recline 2 Installation is the reverse of the removal procedure motor NOTE NOTE Before installing the recline motor apply greace Take care not to scratch the seat cover molybdenum grease to the gear portion Remove the front seat Remove the seat cushion and seat back 1 Remove the switch plate and recline motor from the RECLINE recline adjuster gt Nut locations RECLINE MOTOR RECLINE MOTOR HARNESS After installing the recline motor apply liquid RECLINE thread lock to locations then tighten the nuts S ADJUSTER MEMORY SWITCH PN gt Nut locations HARNESS 5 x 0 8 mm N m 0 3 kg m 2 2 Ib ft gt J 2 SWITCH PLATE MEMORY SWITCH Disconnect the connector HARNESS CLIP 2 PLATE NOTE When removing
76. Continuity If there is continuity at either terminal the driver s airbag inflator is faulty Replace it and recheck the voltages according to the chart on page 23 61 f there is no continuity at either terminal the cable reel is faulty Replace it and recheck the voltages according to the chart on page 23 61 23 64 11 Disconnect the front passenger s airbag 3 P connec tor from the SRS main harness then connect Test Harness C to the airbag side of the connector SRS MAIN HARNESS FRONT PASSENGER S AIRBAG ASSEMBLY FRONT PASSENGER S AIRBAG 3 P CONNECTOR TEST HARNESS C 07MAZ SPO0600 12 Check continuity between the No 9 terminal and body ground and between the No 10 terminal and body ground TEST HARNESS C 07MAZ SPO0600 Continuity If there is continuity at either terminal the front passenger s airbag inflator is faulty Replace it and recheck the voltages according to the chart on page 23 61 If there is no continuity at either terminal the SRS main harness is faulty Replace it and recheck the voltages according to the chart on page 23 61 13 Disconnect the connector between the SRS main harness and the side wire harness 3 P connector driver s side and between the SRS main harness and the car main wire harness 3 P connector front passenger s side First connect Test Harness C to the side wire harness side of the driver s pretensioner 3 P connector and check
77. D 23 54 7 Connect another SRS short connector A special tool to the SRS main harness side of the 3 P con nector FRONT PASSENGER S AIRBAG CONNECTOR SHORT CONNECTOR RED SRS SHORT CONNECTOR A 07MAZ SP0020A SRS MAIN HARNESS 3 P CONNECTOR 8 Remove the right B pillar trim panel 9 Remove the short connector RED from the short connector holder 10 Disconnect the seat belt pretensioner 3 P connec tor then connect the short connector RED to the pretensioner side of the connector SHORT CONNECTOR RED SHORT SEAT BELT CONNECTOR PRETENSIONER HOLDER ASSEMBLY RHD SIDE WIRE HARNESS 3 P CONNECTOR LHD MAIN WIRE HARNESS 3 P CONNECTOR 11 Repeat steps 8 9 and 10 on the left side 12 After completing repair work be sure to remove the short connectors and reconnect all SRS connectors 23 55 Supplemental Restraint System SRS Troubleshooting The SRS Indicator Does Not Light CAUTION Use only a digital circuit tester to check the system NOTE Before troubleshooting make sure that battery voltage is 12 V or more Otherwise you ll obtain wrong test readings Turn the ignition switch off and wait for at least three minutes Disconnect the battery negative cable and then the positive cabie Connect the short connectors see page 23 54 D Reconnect the battery positive ca ble and then the negative cable Turn the ignition sw
78. Distribution LHD Circuit Identification cont d E BLK SEENEN ELE Headlight washer control unit European Engine oil level unit model E BLK NI BLK Power window main switch E BLK Combination light switch Ignition key switch Keyless power door lock control unit Security control unit E BLK 1i u Bk E aee ceiling light E BLK E BLK Speed alarm unit KY model E BLK Clutch switch Cruise control E BLK AT kick down switch E BLK Fan control unit E Fan timer unit Cruise control unit G403 G402 To page 23 7 BLK Driver s seat heater switch Front passenger s seat heater switch Headlight washer switch European model BLK 0 BLK Right rear door lock knob switch Right rear door switch Right rear power seat switch KY model BUR BIK d T HOC Front passenger s power seat switch Seat heater control unit Right rear ashtray light G404 F High mount brake light BLK r 3 45 BLK I Sunroof close relay Sunroof open relay 6405 BLK e Fuel pump BLK Fuel gauge sending unit G406 E Main wire harness IN Driver s door wire harness D Side wire harness Right rear door wire harness 1 Roof wire harness Front passenger s power seat wire harness Sunroof wire harness 23 6 BLK Driver
79. ESS CONTROL UNIT DASH LIGHTS 23 22 RED BLK RED BLK COMBINATION LIGHT SWITCH IGNITION SWITCH BLK YEL 2 WHT YEL CEILING LIGHT FOOT LIGHT RELAY UNDER DASH FUSE BOX WHT BLK WHT YEL ENTRY LIGHT CONTROL CIRCUIT GRN YEL GRN WHT GRN RED LEFT RIGHT FRONT REAR REAR PASSENGER S DOOR DOOR DOOR SWITCH SWITCH SWITCH BLK BLK BLK G404 G402 G403 GRN WHT GRN BLU IGNITION KEY LIGHT WHT BLK 2 DRIVER S DOOR SWITCH G402 G403 Description This multi function control unit located on the left kick panel integrates on one circuit board the functions of the entry light control key in reminder lights on reminder seat belt reminder power window key off timer and intermittent wiper onto one circuit board sharing common circuit functions NOTE Different wires with the same color have been given a number suffix to distinguish them for example YEL GRN and YEL GRN are not the same BEEPER De LIGHTS ON KEY IN SEAT BELT REMINDER REMINDER REMINDER CIRCUIT CIRCUIT BLU BLU WHT BLU YEL LIGHTS ON IGNITION CHIME KEY SWITCH G402 G403 BLU YEL SWITCH belt unbuckled WINDSHIELD WIPER WASHER SWITCH INTERMITTENT WIPER RELA INT WASHER BLU WHT BLU WHT GRN WINDSHIELD WIPER MOTOR BLU RED BLK YEL AS A9 POWER WINDOW i INTERMITTENT KEY OFFTIMER WIPER CIRCUIT CIRCUIT x EXER m
80. ET PLATE 1ST GEAR ONE WAY CLUTCH COUNTERSHAFT 1ST GEAR NEEDLE BEARING THRUST NEEDLE BEARING SET RING Replace TAPERED ROLLER BEARING SECONDARY GEAR SHAFT TAPERED ROLLER BEARING SECONDARY GEAR SHAFT OIL SEAL Replace EXTENSION SHAFT SECONDARY SPRING LOCK WASHER Replace DETENT LEVER SEALING RINGS 42 mm PARKING BRAKE ROD HARNESS STAY TRANSMISSION HANGER CONTROL SHAFT OIL SEAL Replace SEALING WASHER Replace SPEED SENSOR CONNECTOR STAY TRANSMISSION HOUSING O RINGS Replace NM SPEED SENSOR NC SPEED SENSOR TRANSMISSION HOUSING OIL SEAL Replace SEALING BOLT SECONDARY COVER SEALING WASHER Replace THRUST WASHER 75 mm Selective part BEARING OUTER RACE COUNTERSHAFT 1ST GEAR COLLAR SNAP RING 1ST HOLD CLUTCH ASSEMBLY TRANSMISSION HOUSING MAINSHAFT BEARING O RING Replace DOWEL PIN THRUST WASHER 38 8 x 47 mm Selective part 1ST HOLD CLUTCH DISTANCE COLLAR COUNTERSHAFT 4TH GEAR THRUST NEEDLE BEARING TRANSMISSION HOUSING GASKET Replace BEARING OUTER RACE WASHER TORQUE CONVERTER HOUSING OIL SEAL Replace COUNTERSHAFT 3RD GEAR TORQUE CONVERTER HOUSING NEEDLE BEARING NC SPEED SENSOR WASHER THRUST NEEDLE BEARING NOTE KY KQ KT models COUNTERSHAFT 3RD GEAR COLLAR SNAP RING 3RD CLUTCH ASSEMBLY NM SPEED SENSOR WASHER O RING Replace NOTE KE KU KG KF KS KX models e699999e9e9 9e99999999999e9o9e99999999e9oee 9 9 o COUN
81. F YOUR SRS INDICATOR LIGHTS WHILE DRIV ING SEE YOUR AUTHORIZED HONDA DEALER SRS ANV ND ALLTID BILB LTET OETTA FORDOM AR FORSETTMED EN LUFT KUDDE FORARSATET OCH EN LUFKUDDE FOR PASSAGERASATET FRAM SOM ETT KOMPLET TERANCE SKYDDSSYSTEM S R S DET AR AMNAT ATT KOMPLETTERA BILBALTET OM SRS INDIKATORN TANDS UNDER KORNING SKALL DU KONTAKTA EN AUKTORISERAD HONDA ATERFORSALJARE SRS K YT AINA TURVAVYOTA TAMA AUTO OM VARUSTETTU AJAJAN IL MATYYNYLLA JA ETUMATKUSTAJAN ILMATY Y NYLL JOTKA TOIMIVAT YLIMAARAISENA TUKIJAJESTELMAMA SE ON SUUNNITELTU TAYDENTAMAAN TUR VAVYOTA JOS SRS MERKKIVALO SYTTYY AJON AIKANA OTTAKAA YHTEYS VALTUUTETTUUN HONDA MYYJAAN all gt Laits Jari S R S TS PUALS Lg ilga Zell odd jp ai 5 3001 sl JaaSi data ai a Soll gt g 5135 329291 Sault 1 51 Sula L e L INFLATOR BAM LABEL KF KG KX only Air Bag Gas Generator UT11873 Morton International Inc Automotive Safety Products Herstellungs jahr Elnf hrer Honda Deutschland Gmbh 6050 offenbach BAM PT 0437 Gasgenerator dart nur f r Insassen R ckhaltesysteme mit Luftsack in Kraftfahrzeuge montiert werden Die Montage und Demontage des Gasgenerators darf nur von daf r geschultem Personal vorgenommen werden CAUTION The gas generator should only be in Contains stalled in vehicles equipped with the Flammabl
82. FRONT PASSENGER S SEAT BELT PRETENSIONER DRIVER S AIRBAG INFLATOR FRONT PASSENGER S AIRBAG INFLATOR SELF DIAGNOSIS CIRCUIT RIGHT DASH SENSOR E LEFT DASH SENSOR Self diagnosis system A self diagnosis circuit is built into the SRS unit when the ignition switch is turned ON the SRS indicator light comes on and goes off after about six seconds if the system is operating normally If the light does not come on or does not go off after six seconds or if it comes on while driving it indicates an abnormality in the system The system must be inspected and repaired as soon as possible 23 40 SRS Circuit Diagram UNDER DASH FUSE BOX SRS INDICATOR CIRCUIT In the gauge Assembly SRS UNIT SRS SELF DIAGNOSIS CIRCUIT VOLTAGE REGULATOR BACK UP POWI EE BLK YEL Q d ignition 5521 RAD BAT A SWITCH d WHT CABLE REEL No 35 gt 50 DRIVER S AIRBAG d D INFLATOR S d BACK UP POWER CIRCUIT No 31 RELAY E SEAT BELT PRETENSIONER TRIGGER CIRCUIT BATTERY SADH SAPH BUC3 FRONT 2 PASSENGER S AIRBAG INFLATOR O DRIVER S 9 SEAT BELT PRETENSIONER PA vcc 5 CCHK1 M3 CONNECTOR SPDH 16 FRONT 10 PASSENGER S SEAT BELT PRETENSIONER e POWER SOURCE 18 SPPH BUCH BUC2 GND IDC MI DASH SENSOR Q Q
83. GE nmm CENTER ANCHOR BOLT 7 16 20 UNF 33 Nem 3 3 kg m 24 Ib ft ANCHOR TRIM LOWER ANCHOR BOLT 7 16 20 UNF Remove the center 33 N m 3 3 kg m 24 Ib ft cover 20 18 Anchor bolt construction TOOTHED UPPER ANCHOR LOCK WASHER LOCK COLLAR WASHER UPPER ANCHOR ae De TOOTHED Ge BOLT SCH WASHER 6 BEARING PLAIN BEARING WASHERS Se WAVE WASHER 3 Check that the retractor locking mechanism functions as described on page 20 20 NOTE When storage of the seat belts is necessary store them in a place free from water oil grease heat and direct sunlight 4 Installation is the reverse of the removal procedure NOTE Make sure you assemble the washers and collars on the upper center and lower anchor bolts as shown Before reinstalling the center pillar lower trim make sure there are no twists or kinks in the seat belts On reassembly replace the upper and center anchor bolts and use liquide thread lock 20 19 Front Seat Belt Inspection SRS wire harnesses are routed near the retractor 3 Replace the seat belt with a new one if there is any abnormality ENS AI SRS wire harnesses and connec tors are colored yellow Do not use electrical test On the Car Seat Belt Inspection equipment on these circuits 1 Check that the seat belt is not twisted or caught on anything CAUTION Be careful not to damage the SRS wire harness
84. GNMENT Rear Caster Toe BRAKE SYSTEM Front Rear Pad and Lining Surface Area Front Rear Parking Brake Kind and Type ELECTRICAL Battery Starter Alternator Fuses In the Under Dash Fuse Box In The Under Hood Relay Fuse Box Headlights Low High Front Turn Signal Lights Front Position Lights Side Turn Signal Lights Rear Turn Signal Lights Stop Taillights Stop Lights 2 Taillights Side Marker Lights Front Rear Backup Lights Rear Fog Light 3 High Mount Brake Light License Plate Lights Gauge Lights Indicator Lights Warning Lights Interior Light Vanity Mirror Light Boot Lights Door Courtesy Lights Illumination and Pilot Lights Heater Illumination Light Manual A C Spot Light Front and rear 2 Except KY 3 European type and KU 1 KY only Independent double wishbone coil spring with stabilizer Independent double wishbone coil spring with stabilizer Telescopic hydraulic nitrogen gas filled 0 00 0 15 0 20 0 5 3 45 3930 Out 1 0 mm Out 0 04 in In 2 0 mm In 0 08 in Power assisted self adjusting ventilated disc Power assisted self adjusting solid disc with parking brake drum 58 0 cm2 8 99 sq in 28 0 49 0 cm2 4 34 7 60 sq in Mechanical expanding drums rear two wheels 205 65 ZR 15 205 60R15 91V 205 60R15 90V 215 55ZR 16 12 V 72 AH 20 HR 12 V 2 0 kw 12 110 7 5 A 10A 15
85. INTRODUCTION How to Use This Manual This supplement contains informaiton for the 1993 LEGEND Refer to following shop manuals for service procedures and data not in cluded in this supplement Description LEGEND MAINTENANCE REPAIR AND CONSTRUCTION 91 LEGEND SUPPLEMENT 92 62SP000 62SP020 The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page You can quickly find the first page of each section without looking through a full table of contents The symbols printed at the top corner of each page can also be used as a quick reference system Special Information MZ Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information CAUTION Detailed descriptions of standard workshop procedures safety principles and service operations are not included Please note that this manual contains warnings and cautions against some specif ic service methods which could cause PERSONAL INJURY damage a vehicle or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by HONDA might be done or of the possible hazardous consequences of every conceivable way no
86. IPE STAY TRANSMISSION ber 8 Remove the catalytic converter 9 Remove the exhaust pipe A cover then remove the exhaust pipe A NOTE All nuts shown in this figure are self locking replace them when installing GASKET Replace CATALYTIC CONVERTER v x a SS GASKET EXHAUST Replace COVER PIPE A EXHAUST PIPE A COVER EXHAUST PIPE A COVER HOLDER 10 Remove the heat shields Loosen these bolts HEAT SHIELD HEAT SHIELD cont d 14 9 Transmission Removal cont d 11 Remove the ATF cooler hoses at the joint pipes Turn the ends up to prevent ATF flowing out NOTE Check for any signs of leakage at hose joints 12 Remove the tramsmission sub harness connector from the shift cable cover then remove the shift ca ble cover 13 Remove the shift cable holder from the shift cable holder base 14 Remove the control lever from the control shaft 15 Remove the bolt securing the ATF level gauge pipe then remove the ATF level gauge pipe from the tor que converter housing SHIFT CABLE HOLDER 29 3 CONTROL LEVER S SHIFT CABLE SV GO ATF LEVER AS PIRE BE FLOATING G S WASHERS e SO e Ke jw SHIFT CABLE d HOLDER BASE 25 BOLT ANY i I JOINT PIPES 9 b ATF COOLER HOSES SHIFT CABLE COVER CONTROL SHAFT 16 Remove the lower plate and reinstall the steering gearbox mounting botls NOTE LHD is shown The locations of the s
87. IRBAG F R FAHRER UND BEIFAHRER ALS ZUSAT ZLICHES R CKHAL TESYSTEM S R S DAS R CKHALTESYSTEM IST EINE ERGANZUNG ZUM SICHERHEITSGURT e SOLLTE WAHREND DER FAHRT DIE SRS KONTROLLEUCHTE AUFLEUCHTEN SUCHEN SIE BITTE UNGEHEND EINEN HONDA HANDLER SUF DRAAG ALTIJD UW VEILIGHEIDSGORDEL DIT VOERTUIG IS UITGERUST MET AIRBAG SRS AAN BESTUURDERSZIJDE EN PASSAGIERSZIJDE VOOR EXTRA VEILIGHEID ONTWORPEN ALS EXTRA BESCHERMING NAAST DE VEILIGHEIDSGORDELS ALS HE SRS WAARSCHUWINGSLAMPJE GAAT BRANDEN ONDER HET RIJDEN NEEM DAN KON TAKT OP MET EEN HONDA DEALER KE KT ALWAYS WEAR YOUR SET BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT IF YOUR SRS INDICATOR LIGHTS WHILE DRIV ING SEE YOUR AUTHORIZED HONDA DEALER 1 14 KU SRS ALWAYS WEAR YOUR SET BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT e IF YOUR SRS INDICATOR LIGHTS WHILE DRIV ING SEE YOUR AUTHORIZED ACURA DEALER KS KY SRS ALWAYS WEAR YOUR SET BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT I
88. Ib ft 15 Remove air cleaner assembly and air flow tube 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft AIR CLEANER ASSEMBLY AIR FLOW TUBE 16 Remove the igniter unit connector harness clamp and engine ground cable 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft IGNITER UNIT CONNECTOR ENGINE GROUND CABLE 17 Disconnect four engine wire harness connectors and clamp LHD ENGINE WIRE 6 x 1 0 mm HARNESS CONNECTORS 10 N m 1 0 kg m p gt CP RHD 6 x 1 0 mm 10 N m 1 0 kg m 7 ENGINE WIRE HARNESS CONNECTORS XE es Je 2x PN pea LHD 18 Disconnect three connectors then remove the emis sion control box Do not disconnect the vacuum hoses EMISSION CONTROL BOX CONNECTORS 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft 19 Relieve fuel pressure by slowly loosening the ser vice bolt on the fuel filter about one turn Do not smoke while working on the fuel system Keep open flame away from work area Drain fuel only into an approved container CAUTION e Before disconnecting any fuel line the fuel pres sure should be relieved as described above Place a shop towel over the fuel filter to prevent pressurized fuel from spraying over the engine cont d 5 5 Engine Removal Installation cont d PN 20 Remove the fuel feed hose and the fuel return hose 23 Remove the purge hose and vacuum hose from the fuel pressure reg
89. Ib ft FUEL FILTER 1 24 Be sure to replace washers O rings and rubber seals with new ones when servicing fuel line parts Always apply oil to the surfaces of O rings and seal rings before installation Never use brake fluid radi ator fluid vegetable oils or alcohol based oils RUBBER SEAL Ye O RING A CUSHION RING FUEL INJECTOR When assembling the flare joint of the high pressure fuel line clean the joint and coat with new engine oil When installing an injector check angle of the cou pler The center line of the coupler should align with the setting mark on the injector holder FUEL PIPE MARKINGS INJECTOR Inspection for fuel leakage After assembling fuel line parts turn ON the igni tion switch do not not operate the starter so that the fuel pump is operated for approximately two seconds and the fuel is pressurized Repeat this operation two or three times and check whether any fuel leakage has occurred in any of the vari ous points in the fuel line Installation of an amateur radio for cars equipped with PGM F1 Care has been taken for the Fuel Injection A T Cruise control and Anti lock brake system control units and its wiring to prevent erroneous operation from exter nal interference but erroneous operation of the con trol units may be caused by entry of extremely strong radio waves Attention must be paid to the following items to prevent e
90. Ib ft CENTER 10 x 1 25 mm BRACKET 39 N m 3 9 kg m 28 Ib ft 10 x 1 25 mm CENTER MOUNT SK 39 N m 3 9 kg m 28 Ib ft 7 CORROSION RESISTANT BOLT 3 Remove the wire harness covers 4 Remove the engine wire harness 5 Remove the breather pipe 6 Remove the vacuum pipe bracket BREATHER PIPE OIL PRESSURE SN ENGINE GROUND CABLE WIRE HARNESS COVER SWITCH CONNECTOR iem 7 Loosen the mounting nut bolt and adjusting rod then remove the alternator belt MOUNTING NUT 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft ADJUSTING ROD 8 N m 0 8 kg m 6 Ib ft MOUNTING BOLT ALTERNATOR 10 x 1 25 mm BELT 45 N m 4 5 kg m 33 Ib ft 8 Loosen the idler pulley center nut and adjusting bolt then remove the A C compressor belt ADJUSTING BOLT 8 N m 0 8 kg m 6 Ib ft IDLER PULLEY CENTER NUT 10 x 1 25 mm SS 45 N m 4 5 kg m A C COMPRESSOR BELT 33 Ib ft 9 Loosen the mounting bolt nut and adjusting bolt then remove the P S pump belt ADJUSTING BOLT 8 N m 0 8 kg m 6 Ib ft MOUNTING NUT 8x 1 25 mm 22 N m 2 2 kg m 16 Ib ft P S PUMP BELT MOUNTING BOLT 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft cont d Timing Belt Removal cont d 10 Remove the upper covers CAUTION Do not crimp or bend the timing belt more than 90 or less than 25 mm 1 in in diame 11 Remove the crankshaft pulley ter 12 Remove the A C adjusting pulley 13 Remove th
91. LISEZ PAS UN EQUIPMENT D ESSAIS ELECTRIQUE SUR CES CIRCUITS NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME S R S CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU RENDRE LE STSTEME INOPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES WARNING DIESES FAHRZEUG IST MIT EINEM FAHRERAIRBAG SRS ALS ZUSATZLICHEM R CKHALTESYSTEM AUSGERUSTET ALLE ELEKTRISCHEN KABEL SOWIE DEI ZUGEHORIGEN STECKVERBINDER DES S R S SYSTEMS SIND IN GELBER FARBE AUSGEFUHRT KEINE ELEKTRISCHEN PRUFGERATE AN DIE S R S VERKABELUNG ANSCHLIEBEN VERANDERN ODER UNTERBRECHEN DER S R S VERKABELUNG KANN UNKONTROLLIERTES Z NDEN DES GASGENERATORS AUSL SEN ODER DAS SYSTEM AUBER FUNKTION SETZEN WAS ZU ERNSTHAFTEN VERLETZUNGEN F HREN KANN WAARSCHUWING DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMINT S R S ALLE ELEKTRISCHE LEIDINGEN EN AANSLUTINGEN VAN DE S R S ZIJN GEEL GEKLEURD GEBRUIK GEEN ELEKTRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS KNOEIEN MET OF LOSKOPPELEN VAN DE S R S LEIDINGENN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKELEN VAN HET SYSTEEM DIT KAN TOT ERNSTIGE ONGELUKKEN LEIDEN WARNING THIS VEHICLE IS EOUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE S R S
92. LK D BLK e D BLK 6201 D BLK UN EE ras See 6202 D BLK eme D BLK D BLK M E D BLK i D BLK e D BLK e D BLK aH D BLK D BLK D BLK a EY UNDER HOOD ii FUSE RELAY BOX D BLK G301 G302 1 Engine wire harness 23 10 Engine compartment wire harness Igniter unit Right front parking light Right front turn signal light Right headlight low Right horn Left horn Without security system AIC triple pressure switch MID Washer fluid level switch Right headlight adjuster KE and KU models Headlight washer motor Hood switch With security system Left front turn signal light Windshield washer motor Windshield wiper motor Brake fluid level switch Right side turn signal light Radiator fan main relay Windshield wiper intermittent realy Windshield wiper high relay Cruise actuator Radiator fan motor Left front parking light Left side turn signal light Security horn Left headlight low Left headlight adjuster KE and KU models Dimmer relay ABS pump motor BLK Cigarette lighter relay Ceiling light relay BLK ABS pressure switch ABS front fail safe relay ABS rear fail safe relay UNDER DASH FUSE BOX E BLK BLK 1l 4 BLK H ele ceiling light BLK AIT kick down switch Integrated contro unit Turn signal h
93. LVE GAUGE LOW PRESSURE VALVE EVACUATION VALVE HIGH PRESSURE Own VALVE d 4 VACUUM PUMP VALVE Rn R R 134a 134a PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT TWO VALVE GAUGE LOW PRESSURE HIGH PRESSURE VALVE EVACUATION STOP VALVE VACUUM PUMP 134a 134a HIGH PRESSURE L QUICK JOINT LOW PRESSURE QUICK JOINT cont d INNER DIAMETER mm 22 9 System Service Performance Test cont d 284 kPa kg cm DELIVERY psi C PRESSURE F 1500 400 4 30 ee as 30 15 4 86 213 157 80 DELIVERY PRESSURE 1000 300 25 10 77 80 142 43 INTAKE 3096 PRESSURE 200 20 INTAKE PRESSURE 100 15 41 DELIVERY TEMPERATURE DELIVERY TEMPERATURE 25 30 35 40 c 77 86 95 104 F INTAKE AIR TEMPERATURE 22 10 Read this before you do any electrical work on the car The Legend Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in this shop manual Items marked with an asterisk on the contents page include or are located near SRS components Servic
94. M VALVE ture must be below 70 C 158 F and air conditioner OFF YES Is there vacuum S Turn the ignition switch OFF NO Disconnect the 2P connector from purge control solenoid valve RHD PURGE CONTROL SOLENOID VALVE Start the engine PURGE CONTROL SOLENOID VALVE Measure voltage between BLK YEL terminal and LT GRN terminal Inspect vacuum hose routing If OK replace purge control solenoid valve Is there battery voltage Measure voltage between BLK YEL terminal and body ground To page 11 9 To page 11 9 11 8 From page 11 8 Warm up the engine to normal operating temperature the cool ing fan comes on From page 11 8 Repair open in BLK YEL wire between NO 22 Is there battery voltage fuse and the 2P con nector A C switch ON Check for vacuum at 6 vacuum hose Is there manifold vacuum when air conditioner compressor ON YES Reconnect the hose Remove fuel filler cap To page 11 10 Inspect LT GRN wire for an open to body ground between ECU A20 and the 2P connector If wire is OK substitute a known good ECU and recheck If sym ptom goes away replace the original ECU Disconnect the 2P connector from purge control solenoid valve Is there manifold vacuum Inspect for a short in LT GRN wire be
95. NESS es CLAMP FILTER Replace SECONDARY VALVE BODY 5 x 0 8 mm 6 Nem 6 x 1 0 mm 12 Nem 1 2 kg m 9 Ib ft 0 6 kg m A 4 ib ft MAIN A 6 x 20 mm 2 Bolts SEPARATOR B 6 x 30 mm 2 Bolts C 6 x 35 mm 1 Bolt D 6 x 60 mm 6 Bolts E 6 x 70 mm 4 Bolts F 6 x 95 mm 2 Bolts k 6 x 65 mm 8 Bolts DOWEL PIN No Mar SHIFT CONTROL Replace FILTER SOLENOID VALVE B ELTER eplace SHIFT CONTROL Replace Y CHECK BALL SOLENOID VALVE A MAIN VALVE BODY FILTER Replace OIL PASS BODY SEPARATOR PLATE 14 8 Transmission Removal Make sure lifts jacks and safety stands are placed properly and hoist brackets are attached to the correct position on the engine see section 1 1 Disconnect the battery negative and positive cables from the battery 2 Remove the strut bar 3 Remove the control box LHD only CAUTION Do not remove the vacuum tubes from the control box 4 Disconnect the transmission sub harness connector and remove the transmission sub harness clamp 5 Remove the bolt s securing the ATF level gauge pipe stay 6 Remove the transmission housing mounting bolts 7 Drain automatic transmission fluid ATF Reinstall the drain plug with a new sealing washer LHD TRANSMISSION SUB HARNESS TRANSMISSION HOUSING CONNECTOR MOUNTING BOLTS ATF LEVEL GAUGE RHD CONTROL BOX TRANSMISSION HOUSING ATF LEVEL MOUNTING BOLTS GAUGE P
96. NIT 22 P CONNECTOR View from wire side GRN YEL2 GRN WHT2 GRN WHT GRN WHT BLK WHT BLK UNDER DASH FUSE BOX E BLK YEL A1 A7 BLU RED BLU BLU WHT GRN RED GRN YEL BLU YEL GRN WHT Een A8 A14 23 24 A1 A2 A3 A4 Ab A6 A7 HE A8 A9 A10 11 A12 A13 14 All Systems No Terminal Test condition Key in Reminder System No Terminal Test condition Driver s door open Under all conditions Under all conditions Ignition switch ON Il GRN WHT GRN WHT BLK BLK YEL GRN YEL GRN WHT WHT BLK View from wire side BLU RED BLU BLU WHT GRN YEL BLU YEL GRN WHT Test Desired result Possible cause if result is not obtained Poor ground G402 G403 An open in the wire Blown No 56 7 5 A fuse An open in the wire Blown bulb or No 13 7 5 A fuse An open in the wire Check for continuity to ground There should be continuity Check for voltage to ground There should be battery voltage Check for voltage to ground There should be battery voltage Test Desired result Possible cause if result is not obtained Check for continuity to ground Faulty driver s door switch There should be continuity An open in the wire NOTE Before testing remove No 57 15 A fuse BLU WHT Ignition key inserted all the way into the ignition switch Ligh
97. ORT PLUG Terminal Wire Connects to Don t remove with power ON A1 RED GRN Driver s door speaker A2 BLU GRN Front passenger s door speaker pe RED BLK A4 WHT YEL Lights on signal Constant power Tuning memory A5 YEL RED ACC Main stereo power supply Radio switched power To antenna A6 TYEUWHT A7 BLU YEL RED YEL BRN BLK A10 GRY BLK Left rear speaker Right rear speaker Driver s door speaker Front passenger s door speaker A11 exu NGtused A12 LT GRN Security OUT A13 GRN WHT Security IN A14 BLK Ground G601 A15 GRY WHT Left rear speaker Tri A16 BRN WHT Right rear speaker Terminal Wire Connects to B1 RED GRN Radio rear remote switch Power supply B2 RED WHT Radio rear remote switch Vol down GRN Radio rear remote switch Vol up To mast antenna 1 A8 A9 A16 Radio rear remote switch Seek Not used 23 30 Radio Rear Remote Switch Removal Test 1 Pull out the rear armrest then remove the two Not used B Not used screws and the cap AE Not used F G I J 2 Remove the four screws then remove the radio rear remote switch assembly from the tray RADIO REAR REMOTE
98. S Component Location Index 23 38 Description 23 40 Circuit Diagram 23 41 Wiring Locations 23 42 Precautions Procedures 23 44 Troubleshooting 23 52 Airbag Assembly Replacement 23 76 Disposal seseris aree iiaeaa eaa 23 79 Cable Reel Replacement 23 84 Dash Sensor Replacement 23 88 SRS Unit Replacement 23 90 Seat Belt Pretensioner Replacement 23 92 Disposal nn Suede ZEE a Tet 23 80 Supplemental Restraint System SRS Component Location Index LHD To CRUISE CONTROL CABLE REEL SET RESUME CANCEL SRS INDICATOR LIGHT In the gauge assembly Replacement SWITCH Troubleshooting page 23 52 page 23 84 d To DRIVER S AIRBAG ASSEMBLY To HORN SWITCH To RADIO REMOTE SWITCH To GROUND FRONT PASSENGER S AIRBAG ASSEMBLY Airbag and Inflator Replacement page 23 76 Disposal page 23 79 RIGHT DASH SENSOR Replacement page 23 88 UNDER DASH FUSE BOX gt LEFT DASH SENSOR Replacement page 23 88 FRONT PASSENGER S SEAT BELT PRETENSIONER Replacement page 23 92 DRIVER S AIRBAG ASSEMBLY Disposal page 23 80 Airbag and Inflator Replacement page 23 76 Disposal page 23 79 SRS UNIT
99. S BULT TAS BORT Varoitius SRS kaapelin ja rullan vahingoittumisen est miseksi jotts j rjestelm ei menisi k ytt kelvottomaksi irrote taan ohjauspy r enne kuin irrotetaan ohjausvarren liit timen pultti KY CAUTION TO AVOID DAMAGING THE S R S CABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT S R S p35 941 55611 gi 5 5 Loy TaS alas JuS SMG SI in EX Ja Ssi Ale gyal aUa paii Haas Oe Sa 980 gt Jaga J LABEL cont d 1 13 Warning Caution Label Locations cont d DRIVER INFORMATION LABEL SUNVISOR KG KX ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT e IF YOUR SRS INDICATOR LIGHTS WHILE DRIV ING SEE YOUR AUTHORIZED HONDA DEALER ATTACHEZ TOUJOURS VOTRE CEITURE CE VEHICULE EST EQUIPE D UN COUSSIN D AIR POUR LE PASSAGER AVANT QUI CONSTITUENT UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S CE COUSSIN D AIR COMPLETE LA FONCTION DE LA CEINTURE DE CECURITE SI LE TEMOIN SRS S ALLUME PENDANT LA CON DUITE ADRESSEZ VOUS A VOTRE CONSSION NARIE HONDA OFFICIEL SICHERHEITSUGRTE BEI JEDER FAHRT ANLEGEN e DIESES FAHRZEUG BESITZT JE EINEN A
100. SE FUEL FEED HOSE CONNECTOR 30 Remove the purge hose and vacuum hose PURGE HOSE VACUUM HOSE cont d 5 7 Engine Removal Installation cont d 6 x 1 0 mm 10 N m 1 0 kg m 7 b ft pui UPPER BRACKET Er D Je Si EN R Da COOLER 4 A Y Ni RADIATOR ASSEMBLY LOWER CUSHION CONNECTORS 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft AIR SUCTION BYPASS LOW BYPASS HIGH CONTROL 31 Disconnect the radiator hoses the thermosensor SOLENOID VALVES connector and the radiator fan motor connectors P S FLUID RESERVOIR Disconnect and plug the ATF cooler hoses Remove VACUUM the radiator assembly 32 Remove vacuum pipe air suction bypass low bypass high control solenoid valves vacuum tank A and B Do not disconnect the P S hoses FRONT OF VEHICLE VACUUM TANK B 33 Loosen the adjusting bolt and remove the mounting bolt nut then remove the power steering P S pump belt and pump Do not disconnect P S hoses MOUNTING NUT POWER STEERING 8 x 1 25 mm PUMP 22 2 2 kg m 16 Ib ft MOUNTING BOLT P S PUMP ADJUSTING 10 x 1 25 mm BELT BOLT 45 N m 4 5 kg m 33 Ib ft 34 Remove the front tires wheels 35 Remove the damper forks 36 Disconnect the suspension lower arm ball joints with the special tool CAUTION Replace the self locking bolts if you can easily thread a non self locking nut past their nylon locking inserts It should require 1
101. SHANDBOEK KE KO KT WARNING TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE IN INJURY ALWAYS INSTALL THE PROTECTIVE SHORT CON NECTOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS IS DISCONNECTED UNDER NO CIRCUMSTANCES SHOULD DIAGNOSIS BE PERFORMED USING ELECTRICAL TEST EQUIP MENT OR PROBING DEVICES NO SERVICEABLE PARTS INSIDE DO NOT DISASSEMBLE OR TAMPER STORE THE REMOVED AIRBAG ASEMBLY WITH THE PAD SURFACE UP FOR SPECIAL HANDLING OR STORAGE REFER TO THE HONDA SHOP MANUAL DISPOSE OF THE ENTIRE UNIT AS DIRECTED KS KY WARNING REFER TO THE SHOP MANUAL SE VERKSTADSHANDBOKEN KATSO TYOKASIKIRJAA Audi yoll 8 ela Jala Luis Aa g gt ya mi e E DRIVER MODULE WARNING LABEL KU WARNING The airbag inflator is explosive and if accidentally deployed can seriously hurt or kill you Do not use electrical test equipment or probing devices They can cause accidental deployment No serviceable parts inside Do not disassemble Place airbag upright when removed Follow Service Shop Manual instructions carefully ATTENTION Le gonfleur de conssin d air est explosible et s il se d ploie accidentellement il risque de provoquer des blessures graves ou de tuer Ne pas utiliser de mat riel d essai lectrique ni de sonde lls pourraient provoquer un d ploiment accidentel du coussin d air n y a pas de pi
102. SRING SPECIFICATIONS Unit nit mm in Standard New O D Free Length 7 1 0 280 51 3 2 020 No of Coils 4 3 kick down valve spring 1 1 0 043 3 2 3 shift valve spring 3 4 shift valve spring 0 8 0 031 6 6 0 260 42 1 1 657 0 8 0 031 6 6 0 260 42 1 1 657 1 2 shift valve spring 0 9 0 035 7 6 0 299 55 5 2 185 CPC valve spring 1 0 0 039 6 8 0 268 34 3 1 350 14 19 Secondary Valve Body Disassembly Inspection Reassembly NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages Check all valves for free movement If any fail to slide freely see Valve Body Repair on page Coat all parts with ATF before reassembly 2ND ACCUMULATOR COVER 1ST ACCUMULATOR COVER 3 4 ORIFICE CONTROL VALVE O RING O RING Replace Replace FILTER Replace RS VALVE CAP ROLLER VALVE SLEEVE MODULATOR VALVE 4 3 SHIFT TIMING VALVE SPRING SEAT Ne Q SHIFT CONTROL SOLENOID VALVE FILTERS Replace O RING ec Replace 2ND ACCUMULATOR PISTON 1ST ACCUMULATOR PISTON 1 O RING Replace O RING Replace SPRING SPECIFICATIONS Unit mm in Standard New
103. T CUSHION Disconnect the NO LEFT SEAT connectors CUSHION HOOK 9 8 x 1 25 mm D 6 x 1 0 mm 22 N m 2 2 kg m 10 N m 1 0 kg m 16 ib ft 7 2 lb ft HOOK Seat cushion side ue LT COLLAR 8 x 1 25 mm 22 Nem 2 2 kg m 16 Ib ft NOTE Before installing the seat back apply grease to the sliding portion gt locations Before attaching the seat back and seat cushion make sure there are not twists in the rear seat belts When installing the seat cushion slip the slits in the seat cushion over the seat belt buckles 20 16 Slide Adjuster Disassembly NOTE Before installing the slide motors and seat tracks apply grease to the sliding and gear portion Make sure the connector is connected properly Check the slide motors operations RIGHT SEAT CUSHION FRAME LEFT SEAT CUSHION FRAME 8 x 1 25 mm 22 Nem 2 2 kg m 16 b ft RIGHT OUTER SEAT TRACK RIGHT INNER SEAT TRACK N Ng AE V 8 1 25 mm 22 Nem m 16 Ib ft 2 2 kg LEFT OUTER SEAT TRACK LEFT INNER SEAT TRACK RIGHT SLIDE MOTOR 8 x 1 25 mm LEFT SLIDE MOTOR 2 Nem 0 2 kom 1 4 Ib ft 20 17 Front Seat Belt Replacement SRS wire harnesses are routed near the retractor SRS wire tors colored yellow Do not use electrical test equip
104. T1 0379 Der Gasgenertor dart nur f r Insassen R ckhaltesysteme mit Luftsack in Kraftfahrzeuge montiert werden Die Montage und Demontage des Gasgenerators darf nur von daf r geschultem Personal vorgenommen werden CAUTION The gas generator should only be in Contains stalled in vehicles equipped with the Flammable airbag system The gas generator is Solids to be installed and or disassembled only by trained personnel ATTENTION Le g n rateur de gaz ne peut tre in Content De stall que sur des v hicules quip s Solides d un syst me airbag Le montage et le Flammable d montage du g n rateur de gaz ne peut tre effactu que par un person nel qualifie LHD RHD Refer to page 1 11 1 10 ENGINE HOOD WARNIHG LABEL Except KS KY WARNING THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE S R S WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY ATTENTION CE VEHICULE EST EQUIPE D UN COUSSIN D AIR DU COTE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYSTEME DE RETENUE COMPLEMENTAIRE S R S SONT DE COULELUR JAUNE N UTI
105. TANDARD NEW SERVICE LIMIT Parking brake Play in stroke at 200 N 20 kg 44 Ibs lever force lever LHD Parking brake Play in stroke at 300 N 30 kg 66 Ibs pedal force pedal RHD To be locked when pulled 8 12 notches To be locked when pushed 6 8 notches Foot brake Pedal height with floor mat removed LHD 213 8 39 min pedal RHD 210 8 27 min Free play 1 5 0 04 0 20 Master cylinder Disc brake Piston to pushrod clearance Disc thickness Front 0 0 2 0 0 008 23 0 0 91 28 0 1 10 9 0 0 35 Rear Disc runout Front Rear Disc parallelism Front and rear Pad thickness Front 11 0 0 43 Rear Parking brake LD Rear drum Lining thickness Rear Brake booster Characteristics at 200 N 20 kg 44 Ibs pedal force 9 0 0 35 170 0 6 69 2 5 0 10 Line pressure kPa kg cm2 psi O mm 0 in Hg 700 7 0 100 min 820 8 2 117 min 300 mm 11 8 in Hg 6 230 62 3 886 min 6 190 61 9 880 min 500 mm 19 7 in Hg 9 920 99 2 1 411 min 9 780 97 8 1 391 min 1 Dual pot caliper type 2 Rear disc brake with drum parking brake type 3 13 Standards and Service Limits Air Conditioner Section 22 MEASUREMENT STANDARD NEW Air conditioner Lubricant capacity Condenser 30 1 1 06 system m fl oz Imp oz Evaporator 60 2 2 11 Li
106. TEE 23 37 Read SRS precautions on page 23 54 then install the short connectors on the airbags before working in these areas Outline of Model Changes Ground Distribution The ground distribution has partly changed Interlock System The interlock system has been added to the KO model integrated Control Unit The key in reminder system has been added to the KY model Stereo Sound System A radio rear remote switch has been added to the KO model Ignition System The spark plug list for models without catalytic converter has been added Power Rear Passenger s Seat The rear passenger s power seat has been added to the KY KT models SRS The front passenger s airbag and seat belt pretensioners have been added Special Tools Tool Number Description O7MAZ SLOOBO0 Test Harness Page Reference O7MAZ SP00500 Test Harness B 07MAZ SPOO600 Test Harness C 07 L AZ SL40400 Test Harness D 07HAZ SGO0500 Deployment Tool 07MAZ SP00200 Short Connector A Set 23 2 Troubleshooting Schematic Symbols BATTERY GROUND FUSE In COIL SOLENOID CIGARETTE LIGHTER Ground terminal Component ground ON O RESISTOR VARIABLE RESISTOR THERMISTOR IGNITION SWITCH BULB HEATER MOTOR PUMP CIRCUIT BREAKER HORN DIODE SPEAKER BUZZER ANTENNA TRANSISTOR Tr Mast Window Wire Color Codes Y ien The following abbreviations ar
107. TERSHAFT TORQUE SPECIFICATIONS No Torque Value 12 Nem 1 2 kg m 9 ib ft 14 Nem 1 4 kg m 10 lb ft 34 Nem 3 4 kg m 26 Ib ft 18 N m 1 8 kg m 13 Ib ft 6 x 1 0 mm 6 x 1 0 mm 8 x 1 25 mm 8 x 1 25 mm Special Bolt Oil Pressure Check Bolt 14 17 Main Valve Body Disassembly Inspection Reassembly NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages Replace valve body as an assembly if any parts are worn or damaged Check all valves for free movement If any fail to slide freely see Valve Body Repair on page Coat all parts with ATF before reassembly CAUTION Do not use a magnet to remove the check balls it may magnetize the balls SPRING SEAT 4 3 KICK DOWN 3 4 SHIFT VALVE VALVE 2 3 SHIFT VALVE CHECK BALLS 9 pcs G CHOKE i dh 1 FILTER Replace gt f ES MANUAL VALVE 1 2 SHIFT o LCR VALVE MAIN VALVE BODY QC 2 4 e FILTER On Replace CPC VALVE VALVE CAP ROLLER 14 18 CHECK BALL ze CHECK BALLS ig ia SLT Q A RSS pen ASSEN SL NN ASS O XK NN Ss Ce Li 5 173 Ww E b Ei T CHECK BALLS e AR 2 42 Es FILTERS MAIN VALVE BODY Sectional View
108. THE SHOP MANUAL e DANGER EXPLOSIF ET INFLAMMABLE POISON SE REPORTER AU MANUEL D ATELIER GEFAHR EXPLOSIV ENTZ NDBAR GIFT WERKSTATTHANDBUCH LESEN GEVAAR EXPLOSIEGEVAAR BPANDBAAR GIFTIG LEES HET WERKPLAATSHANDBOEK KE KT DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVYMETALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERA TURES MUST NOT EXCEED 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCE DURES REFER TO THE HONDA SHOP MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EV ERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN KS KY DANGER EXPLOSIVE FLAMMABLE POISON REFER TO THE SHOP MANUAL FARLIGT EXPLOIVT VATTANTANDLIGT GIFTIGT SE VERK STADSHANDBOKEN VAARA HELPOSTI RAJAHTAVA SYTTYVA MYRKKY GIFT KATSO TYOKASIKIRJAA Am 5 ala Salo SUES LG 3 paiia Salo dol Sule aalt A plais Yt July iS dao ya 5 Colegial Ca cont d 1 7 Warning Caution Label Locations cont d D DRIVER MODULE DANGER LABEL KU AA DANGER EXPLOSIVE FLAMMABLE Contact with acid water or heavymetals such as cop per lead or m
109. TOR CO LTD HONDA Passenger car for except KU KO JH4 HONDA MOTOR CO LTD C32A3 3800001 ACURA Passenger car KY for KU C32A4 3000001 Body Type KT KA7 LEGEND 4 Door Sedan Body and Transmission Type 5 4 Door Sedan 5 speed Manual 6 4 Door Sedan 4 speed Automatic Vehicle Grade 5 With SRS AIRBAG Fixed Code Auxiliary Number Factory Code C Saitama Factory in Japan Sayama Model Year 2 1993 Serial Number C32A5 3000001 Transmission Number Manual Transmission K4E6 3000001 Transmission Type Serial Number Transmission Number Automatic Transmission MPYA 3000001 Transmission Type Serial Number Identification Number Locations EN Transmission Number Vehicle Identification Number VIN r Automatic Transmission Number Manual cont d Identification Number Locations VIN and ENGINE No EC and KU VIN and ENGINE No KT BUILD DATE and VEHICLE TYPE No PLATE KO CERTIFICATION PLATE KY Warning Caution Label Locations EB SRS CAUTION LABELS Refer to page 1 6 thru 18 ANTI LOCK BRAKE SERVICE SYSTEM CAUTION INFORMATION LHD KS KQ COOLANT CAUTION ANTI LOCK BRAKE SYSTEM CAUTION AIR CLEANER OIL RHD OIL FILTER and SPARK PLUG SERVICE FROZEN BATTERY FLUID CAUTION RADIATOR CAP CAUTION TYRE INFORMATION cont
110. Train 6 1 Engine Removal Installation Special Tools 5 2 Engine Removal Installation 5 3 Outline of Model Changes The engine mounts have been changed Special Tools 5 2 Tool Number Description Oty Page Reference 07KAK SJ40101 3l Engine Tilt Hanger Set 1 5 13 07MAC SL00100 Ball Joint Remover 32 mm 1 5 9 07MAK PY30100 Engine Sub Hanger Stay 1 5 13 a 07MAK PY30200 Sub Hanger Belt 1 5 13 07744 0010600 Pin Driver 8 0 mm 1 5 11 Cie n 2 Engine Removal Installation a Drain the engine coolant Make sure jacks and safety stands are placed proper ly and hoist brackets are attached to the correct positions on the engine see section 1 Make sure the car will not roll off stands and fall while you are working under it CAUTION Use fender covers to avoid damaging painted sur faces Unspecified items are common Unplug the wiring connectors carefully while holding the coupler and the connector portion to avoid dam age Mark all wiring and hoses to avoid misconnection Also be sure that they do not contact other wiring or hoses or interfere with other parts Disconnect the battery negative terminal first then the positive terminal Remove the battery Remove the radiator cap Use care when removing the radiator cap to avoid scalding
111. air 20 ml 2 3 fl oz O 7 Imp oz Compressor On compressor replacement subtract the volume of oil drained from the removed compressor from 180 mi 6 fl oz 6 34 Imp oz and drain the calculated volume of oil from the new compressor 180 ml 6 fl oz 6 34 Imp oz Volume of removed compressor Draining volume NOTE Even if no oil is drained from the removed compressor don t drain more than ml 1 2 3 fl oz 1 8 Imp oz from the new compressor REMOVED NEW COMPRESSOR COMPRESSOR DRAINING VOLUME 180 ml 6 fl oz 6 34 Imp oz SAME LEVEL 22 4 System Service Discharge j 4 Slowly open the high pressure valve slightly to let Keep away from open flames The refrigerant refrigerant flow from the center hose only Do not although nonflammable will produce a poisonous open the valve too wide Check the shop towel to gas if burned make sure no oil is being discharged with the Work in a well ventilated area Refrigerant refrigerant evaporates quickly and can force all the air out of a small enclosed area CAUTION If you allow refrigerant to escape too fast compressor oil will be drawn out of the NOTE Only use a gauge set for refrigerant R 134a system 1 Connect the R 134a gauges as shown 5 After the high pressure gauge reading has dropped below 1000 kPa 10 kg cm 142 psi open the low side valve to discharge bot
112. al tool to the airbag side of the connector FRONT PASSENGER S AIRBAG CONNECTOR SHORT CONNECTOR RED SRS MAIN HARNESS 3 P CONNECTOR SRS SHORT CONNECTOR A 07MAZ SP0020A 8 Remove the right B pillar trim panel 23 48 9 Remove the short connector RED from the short connector holder SHORT CONNECTOR RED SEAT BELT PRETENSIONER SHORT ASSEMBLY CONNECTOR HOLDER RHD SIDE WIRE HARNESS 3 P CONNECTOR LHD MAIN WIRE HARNESS 3 P CONNECTOR 10 Disconnect the seat belt pretensioner 3 P connec tor then connect the short connector RED to the pretensioner side of the connector 11 Repeat steps 8 9 and 10 on the left side 12 After completing repair work be sure to remove the short connectors and reconnect all SRS connectors Disconnecting the SRS Connector at the Fuse Box CAUTION Avoid breaking the connector it s double locked First lift the connector lid with a thin screwdriver then press the connector tab down and pull the connector out UNDER DASH FUSE BOX SRS MAIN HARNESS TAB LID To reinstall the connector push it into position until it clicks then close its lid 23 49 Supplemental Restraint System SRS Sensor Inspection CAUTION Take extra care when painting or doing body work on any part of the dashboard lower panel Avoid direct exposure of the sensors or wiring to heat guns welding or spraying equipment A WARNING Disco
113. andling storage and disposal procedure refer to Service Shop Manual SRS supplement POISON DANGER EXPLOSIBLE INFLAMMABLE Tout contact avec l acide l eau ou des m taux lourds com me le cuivre le plomb ou le mercure risque de produire des gaz nocifs et irritants ou des compos s explosifts Les tem p ratures de rangement ne devront pas d passer 200 F 100 Pour les proc dures de manipulation de range ment et de mise au rebut voir le supl ment SRS du manuel d entrien Contains poisonous sodium azide and potassium nitrate POISON FIRST AID Renferme de l acide de soude et du nitrate de potassium If contents are swallowed induce vomiting For eye con toxiques PREMIERS SECOURS Si le contenu est absorb induire un vomissement En cas de contactavec les yeux laver grande eau pendant un quart d heure En cas d inhalation des gaz par contact avec l acide ou l eau Aller l air frais Dans tous le cas ob tenir promptement des soins m dicaux TENIR HORS DE PORT E DES ENFANTS ATTENTION Le gonfleur de conssin d air est explosible et s il se d ploie accidentellement il risque de provoquer des blessures graves ou de tuer Ne pas utiliser de mat riel d essai lectrique ni de sonde Ils pourraient provoquer un d ploiment accidentel du coussin d air Il n y a pas de pi ces r parables l int rieur Ne pas d monter Quand on retire le coussin d
114. areils de v rification approuv s pour le diagnostic du circuit Consulter le Manuel d entretien pour les directives coml tes cont d 1 17 Warning Caution Label Locations cont d P PRETENSIONER POWER SOURCE CAUTION LABEL R SRS MONITOR CAUTION LABEL Except KS KY A XO Rv ik 71 H E Rv 3 SEAT BELT TENSIONER Do not tamper Refer to service shop manual for complete in structions ENROULEUR DE CEINTURE DE S CURIT Ne pas modifier Consulter le Manuel d entretien pour les direc tives compl tes Q PRETENSIONER POWER SOURCE BAM LABEL Except KY P T PWR SOURCE BGO NIPPON KOKI SHIRAKAWA JAPAN Herstel lungsjahr 1991 Einf hrer Honda Deutschland Gmbh offenbach BAM PT 0380 Der Gasgenertor darf nur f r Insassen R ckhaltesysteme mit Gurstraffereinhelten in Kraft fahrzeuge montiert werden Die Montage und Demontage des Gasgenertors darf nur von daf r geschuitem Personal vorgenommen werden 1 18 KS KY CAUTION e NO SERVICEABLE PARTS INSIDE e DO NOT DISASSEMBLE OR TAMPER e DO NOT DROP STORE IN A CLEAN DRY AREA ik X EA 0 BELAEV LEW TK HEN ATTENTION AUCUN POINT D INTERVENTION A L INTERIEUR NE PAS DEMONTER OU TOUCHER NE PAS FAIRE TOMBER RANGER DANS UN ENDROIT
115. assenger s side 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 2 Connect Test Harness B between the SRS unit and SRS main harness 18 P connector SRS UNIT TEST HARNESS B 07MAZ SPO0500 SRS MAIN HARNESS 3 Reconnect the seat belt pretensioner 3 P connector then measure the resistance between the driver s seat belt pretensioner terminals B9 and B17 and be tween the front passenger s seat belt pretensioner terminals B10 and B18 TEST HARNESS B 07MAZ SPO0500 if resistance is more than O 2 go to step 4 if resistance is less than 0 2 the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages according to the chart on page 23 61 4 Disconnect the connector between the SRS main harness and the side wire harness 3 P connector driver s side and between the SRS main harness and the car main wire harness 3 P connector front passenger s side First connect Test Harness C to the side wire harness side of the driver s pretensioner 3 P connector and check resistance then connect it to the car main wire harness side of the front pas senger s pretensioner 3 P connector and check resistance again SRS MAIN HARNESS FRONT PASSENGER S SIDE TEST HARNESS C 07MAZ SPOO600 SIDE WIRE HARNESS 3 P CONNECTOR MAIN WIRE HARNESS 3 P CONNECTOR 5b Measure the resistance between the No 9 term
116. at there is a clearance of 2 5 0 5 mm 0 098 0 020 in between the top corner of the shift lock lever and the side of the lock pin see clearance check on this page When the shift lock solenoid is OFF make sure that the lock pin is blocked by the top of the shift lock lever If it is not blocked adjust the position of the shift lock solenoid Replacement 1 2 Remove the E ring and the solenoid pin Remove the self locking nuts and shift lock solenoid SOLENOID PIN SELF LOCKING NUTS Replace 10 Nem 1 0 kg m 7 2 Ib ft 3 Install the new shift lock solenoid in the reverse order of removal and adjust its position When the shift lock solenoid is ON check that there is a clearance of 2 5 0 5 mm 0 098 0 020 in between the top corner of the shift lock lever and the side of the lock pin then tighten the self locking nuts Use brand new self locking nuts 2 5 0 5 mm 0 098 0 020 in LOCK PIN SHIFT LOCK LEVER When the shift lock solenoid is OFF make sure that the lock pin is blocked by the shift lock lever NOTE Test the solenoid after you assemble it LOCK PIN SHIFT LOCK LEVER 23 21 Integrated Control Unit KY model Circuit Diagram UNDER HOOD FUSE RELAY BOX No 31 120A No 35 50 RED GRN RED BLK FRONT PARKING LIGHTS SIDE MARKER LIGHTS RIGHT TAILLIGHT LICENSE PLATE LIGHTS DASH LIGHTS BRIGHTN
117. azard relay Power window relay BLK Power window main switch BLK Cruise main switch Sunroof switch Gauge and indicator lights BLK Rear window defogger switch Dash lights brightness control unit Coin box light E BLK Engine oil level unit KE and KU models E BLK Headlight washer control unit KE and KU models E BLK E BLK Security control unit With security system Interlock control unit model 16 23 12 E Main wire harness 1 Roof wire harness Dashboard wire harness N Driver s door wire harness cont d 23 11 Ground Distribution RHD Circuit Identification cont d E BLK DEEE Fan control unit Fan timer unit Keyless power door lock control unit E BLK Combination light switch Ignition key switch Windshield wiper washer switch Cruise control unit M BLK Left mirror defogger Front passenger s door lock knob switch Front passenger s key cylinder switch Front passenger s door switch Lg BLK Power window master switch Right mirror defogger Driver s window motor Driver s door switch Driver s door lock knob switch Driver s key cylinder switch Power mirror switch Driver s door lock switch Except KE G402 BLK BLK a BLK Blower motor high relay E Blower motor relay Power transistor A C G403 E Main wire harness N Driver s door wire
118. by hot engine coolant or steam Raise the hoist to full height Remove the engine splash shield CLIP 2 places 6 x 1 0 mm eee 10 N m 1 0 kg m 7 Ib ft Loosen the drain plug in the radiator Drain transmission and differential oil or fiuid Reinstall the drain plugs using new washers Drain the engine oil Reinstall the drain bolt using a new washer CAUTION Do not overtighten the drain bolt Lower the hoist Remove the hood support mount bolts then fix the engine hood in a vertical position Remove the strut bar and bracket 8 x 1 25 mm 22 N m 2 2 kg m STRUT BAR 16 Ib ft BRACKET cont d Engine Removal Installation cont d 11 Remove the battery base 12 Disconnect the engine wire harness connectors then remove the under hood fuse relay box e Remove the ground cable from cylinder block e Remove the battery cable from starter motor B terminal UNDER HOOD FUSE RELAY BOX 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft BATTERY BASE 13 Remove the throttle cover 14 Remove the throttle cable and cruise control cable by loosening the locknuts then slip the cable ends out of the throttle bracket and throttle linkage NOTE e Take care not to bend the cable when removing it Always replace any kinked cable with a new one e Adjustthe throttle cable when installing THROTTLE CABLE THROTTLE COVER CRUISE CONTROL 6 x 1 0 mm CABLE 10 N m 1 0 kg m 7
119. can be reused Deploying the Airbag s Out of car NOTE If an intact airbag assembly has been re moved from the scrapped car or has been found defective or damaged during transit storage or serv ice it should be deployed as follows Position the airbag assembly face up outdoors on flat ground at least 10 meters 30ft from any obstacles or people Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool box label Remove the short connector from the airbag con nector Follow steps 6 7 and 8 of the in car deployment procedure 23 82 Damaged Airbag or Pretensioner Special Procedure If an airbag or pretensioner cannot be deployed or triggered it should not be treated as normal scrap it should still be considered a potentially explosive device that can cause serious injury T If installed in a car follow the removal procedure on page 23 76 In all cases make sure a short connector is properly installed on the airbag or pretensioner connector Package the airbag or pretensioner in exactly the same packaging that the new replacement part came in Mark the outside of the box DAMAGED AIRBAG or PRETENSIONER NOT DEPLOYED so it does not get confused with your parts stock If applicable also note on the box the VIN of the car from which it was removed Contact your Honda or Acura District Service Manager for how and where
120. cedures for disposing of the damaged airbag SRS Seat Belt Pretensioner Handling and Storage Do not try to disassemble the seat belt pretensioner as Follow these precautions below during removal of a sembly It has no serviceable parts Once an seat belt pretensioner pretensioner has been operated it cannot be repaired or Install its short connector RED as soon as the reused pretensioner connector is disconnected Use only the test equipment specified in the Electrical section Do not disassemble the pretensioner or allow any CYLINDER impact to it SHORT Se E For proper disposal see page 23 79 POWER SOURCE SEAT BELT WEBBING PRETENSIONER ASSEMBLY Store the removed seat belt pretensioner assembly on a secure flat surface away from any high heat source exceeding 1009 C 2129 F and free of any oil grease detergent or water 23 45 Supplemental Restraint System SRS Steering related Precautions Steering Wheel and Cable Reel Alignment Steering Column Removal NOTE To avoid misalignment of the steering wheel or CAUTION airbag on reassembly make sure the wheels are turned Before removing the steering column first disconnect straight ahead before removing the steering wheel the connector between the cable reel and the SRS main harness If the steering column is going to be removed without dismounting the steering wheel lock the steering by turning the igni
121. chor bolt SHOULDER HARNESS ANCHOR BOLT 33 N m 3 3 kg m 23 9 Ib ft 7 Remove the short connectors RED from the seat belt pretensioners then attach them to their holders 8 Reconnect the side wire harness 3 P connector to the driver s seat belt pretensioner and the main wire harness 3 P connector to the front passenger s seat belt pretensioner 9 Reinstall the B pillar lower panel door opening trim and door sill molding SEAT BELT PRETENSIONER ASSEMBLY DOOR OPENING TRIM B PILLAR LOWER PANEL DOOR SILL MOLDING 10 11 12 13 14 15 Remove the short connectors from the front pas senger s airbag connector and from the SRS main harness connector Reconnect the front passenger s airbag 3 P connec tor to the SRS main harness connector Remove the short connectors from the driver s air bag connector and from the cable reel 3 P connector Reconnect the driver s airbag 3 P connector to the cable reel 3 P connector Attach the short connec tor RED to the access panel then reinstall the panel on the steering wheel Reconnect the battery positive cable then the nega tive cable After installing the SRS unit confirm proper system operation Turn the ignition ON 11 The instrument panel SRS indicator light should go on for about six seconds and then go off Make sure the seat belt retractor work 23 93
122. clutch distance collar length Countershaft 3rd gear l ls A collar length 1 Diameter or one way clutch contact area Countershaft 1st gear LD Countershaft 2nd gear LD One way clutch hub O D Parking gear one way clutch contact area O D Feed pipe A O D Feed pipe B O D Mainshaft and countershaft bushings 7 0 1 0 Mainshaft and countershaft bushings 11 5 Mainshaft sealing ring 37 mm thickness Countershaft sealing ring 42 mm thickness Mainshaft sealing ring groove width Countershaft sealing ring groove width Diameter of needle bearing contact area Mainshaft stator shaft Mainshaft 3rd gear Mainshaft 1st gear collar Mainshaft 151 gear distance collar Mainshaft 2nd gear collar Countershaft torque converter housing Countershaft 3rd gear collar Countershaft 1st gear collar Countershaft 2nd gear collar Countershat reverse gear collar Reverse idler gear shaft STANDARD NEW 35 95 36 00 1 415 1 417 27 95 28 05 1 100 1 104 23 50 23 55 0 925 0 927 2 97 3 00 0 117 0 118 3 02 3 05 0 119 0 120 3 07 3 10 0 121 0 122 3 12 3 15 0 123 0 124 3 17 3 20 0 125 0 126 2 3 25 0 127 0 128 7 3 30 0 129 0 130 2 3 35 0 131 0 132 7 3 40 0 133 0 134 2 3 45 0 135 0 136 7 3 50 0 137 0 138 68 95 69 05 2 715 2 718 28 95 2 05 1 140 1 144 24 02 24 05 0 946 0 947 3 3 3 3 3 3 ERR 95 764 95 790 3 77
123. conds and then go off 22 Nem 2 2 kg m 16 Ib ft Replace Reinstall all other removed parts 23 89 Supplemental Restraint System SRS SRS Unit Replacement CAUTION 4 Remove the four SRS unit TORX bolts then Before disconnecting any part of the SRS wire har remove the SRS unit ness connect the short connectors on the airbags and seat belt pretensioners Do not damage the SRS unit terminals or connectors Do not disassemble the SRS unit it has no servicea pen ble parts SRS UNIT Store the SRS unit in a clean dry area Do not use any SRS unit which has been subjected to water damage or shows signs of being dropped or improperly handled such as dents cracks or defor mation 1 Disconnect the battery negative cable then the posi tive cable 2 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 3 Remove the center armrest then disconnect the SRS main harness 18 P connector from the SRS unit CENTER ARMREST TORX BOLTS 6 mm Use a TORX T30 bit SRS UNIT SRS MAIN HARNESS 18 P CONNECTOR 23 90 CAUTION Be sure to install the SRS wiring so that it is not pinched or interfering with other car parts 5 Install the new SRS unit TORX BOLTS 6 mm 10 N m 1 0 kg m 7 2 Ib ft Replace Use a TORX T30 bit SRS UNIT TORX BOLTS 6 mm 10 N m 1 0 kg m 7 2 Ib ft Replace Us
124. connect EXHAUST hoses PIPE A GASKET Replace POWER STEERING SPEED SENSOR 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft EXHAUST PIPE A COVERS 6 x 1 0 mm 10 N m 1 0 kg m 7 lb ft SELF LOCKING NUT 41 Remove the catalytic converter or exhaust chamber 10 x 1 25 mm 55 N m 5 5 kg m 40 Ib ft Replace 5 10 44 Loosen the idler pulley center nut and adjusting bolt then remove the air conditioning A C com pressor belt and compressor IDLER PULLEY CENTER NUT 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft ADJUSTING BOLT Do not disconnect A C COMPRESSOR 8 x 1 25 mm 22 2 2 kg m 16 lb ft Manual transmission M T equipped cars 45 Remove the slave cylinder from transmission hous ing Do not disconnect the clutch hose 46 Disconnect the shift rod and shift lever torque rod as shown M T SHIFT LEVER TORQUE ROD 222 8 mm SPRING PIN SHIFT ROD PIN DRIVER 8 0 mm 07744 0010600 RETAINER Automatic transmission A T equipped cars 47 Disconnect the shift control cable CONTROL CABLE AIT HOLDER 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft CONTROL CABLE HOLDER BASE LOCK WASHER Replace a 6 x 1 0 mm 4 J 14 N m 1 4 kg m 10 Ib ft DC gt 6 x 10 mm 23527 12 N m 1 2 kg m 9 Ib ft cont d 5 11 Engine Removal Installation cont d 48 Remove the engine mid mount nuts and bolts 49 Remove rear transmiss
125. continuity then connect it to the car main wire harness side of the front pas senger s pretensioner 3 P connector and check con tinuity again SRS MAIN HARNESS FRONT PASSENGER S DRIVER S SIDE TEST HARNESS C 07 2 SPOO600 SIDE WIRE HARNESS 3 P CONNECTOR MAIN WIRE HARNESS 3 P CONNECTOR 14 Check continuity between the No 9 terminal and body ground and between the No 10 terminal and body ground TEST HARNESS C 07MAZ SPO0600 Continuity f there is continuity at either terminal go to step 15 If there is no continuity at either terminal the SRS main harness is faulty Replace it and recheck the voltages according to the chart on page 23 61 TEST HARNESS C 07MAZ SPO0600 15 Disconnect the 3 P connector from the driver s and front passenger s seat belt pretensioners then con nect Test Harness C to the seat belt pretensioner side of the connector first on the driver s side then on the passenger s side SEAT BELT PRETENSIONER ASSEMBLY SEAT BELT PRETENSIONER 3 P CONNECTOR LI STE S AS SIDE WIRE HARNESS 3 P CONNECTOR Driver s side MAIN WIRE HARNESS 3 P CONNECTOR Front passenger s side 16 Check continuity between the No 9 terminal and body ground and between the No 10 terminal and body ground TEST HARNESS C 07MAZ SPO0600 Continuity if there is continuity at either terminal the seat belt pretensioner is fau
126. d Warning Caution Label Locations cont d D Refer to pages 1 7 and 8 E Refer to pages 1 7 and 9 F Refer to page 1 9 G Refer to page 1 10 A CABLE REEL CAUTION A LABEL Except KS KY CAUTION REFER TO THE SHOP MANUAL ATTENTION SE REPORTER AU MANUAL D ATELIER ACHTUNG WERKSTATTHANDBUCH LESEN WAARSCHUWING LEES HET WERKPLAATSHANOBOEK KS KY AUTION REFER TO THE SHOP MANUAL OBSERVERA LAS IGENOM INSTRUKTIONSBOKEN Lue huoltokirjanen Varoitus JS Los uisi e B CABLE REEL CAUTION B LABEL Except KS KY sas CAUTION REFER TO THE SHOP MANUAL ATTENTION SE REPORTER AU MANUAL D ATELIER ACHTUNG WERKSTATTHANDBUCH LESEN WAARSCHUWING LEES HET WERKPLAATSHANOBOEK KS KY SRS CAUTION REFER TO THE SHOP MANUAL OBSERVERA LAS IGENOM INSTRUKTIONSBOKEN Varoitus Lue huoltokirjanen 523 aalt e C STEERING WHEEL WARNING LABEL Except KS KY WARNING e REFFER TO THE SHOP MANUAL SE REPORTER AU MANUEL D ATELIER WERKSTATTHANDBUCH LESEN LEES HET WERKPLAATSHANDBOEK KS KY WARNING REFER TO THE SHOP MANUAL SE VERKSTADSHANDBOKEN KATSO TYOKASIKIRJAA Balai als iS Angle gt gt i Gloglall a Aal duds agli D INFLATOR COVER LABEL KF KG KX DANGER EXPLOSIVE FLAMMABLE POISON REFER TO
127. ding to the chart on page 23 61 1 Poor ground at SRS unit or unit mounting bolts Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 Connect Test Harness B between the SRS unit and SRS main harness 18 P connector SRS UNIT TEST HARNESS B 07 2 SPO0500 SRS MAIN HARNESS 1 2 1 o v a rose e e o 2 lele fs 3 Check for continuity between the B5 terminal body ground and the B15 terminal and body ground TEST HARNESS B 07MAZ SPO0500 f there is continuity at either terminal the SRS unit is faulty Replace and recheck the voltages according to the chart on page 23 61 If there is no continuity at either terminal the SRS unit ground the SRS unit component grounds or the SRS main harness is faulty Check the grounds check wire and control unit mounting bolts and if necessary replace the SRS main har ness Recheck the voltages according to the chart on page 23 61 23 75 Supplemental Restraint System SRS Airbag Assembly Replacement Store a removed airbag assembly with the pad surface up if the airbag is improperly stored face down accidental deployment could propel the unit with enough force to cause serious injury CAUTION Do not install used SRS parts from another car When repairing use only new SRS parts Carefully inspect the a
128. ding to the chart on page 23 61 Mode B T HARNESS B Short to driver s or passenger s airbag inflator body OM AZ SPO00500 ground Short to driver s or passenger s seat belt pretension A L 2 s s e 7 o oo n u o e os e lo oo er body ground B 2 3 4 8 2 17 18 Short in dash sensor i O Open in both cowl sensor contacts Continuity 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 2 Connect Test Harness B between the SRS unit and if there is continuity at either terminal go to SRS main harness 18 P connector 9 7 If there is no continuity at either terminal go to step 4 4 Reconnect the front passenger s airbag connector SRS UNIT then check continuity between the B2 terminal and body ground and between the B8 terminal and body ground TEST HARNESS B TEST HARNESS B 07MAZ SPO0500 07 2 SPO0500 SRS MAIN HARNESS If there is continuity at either terminal go to step 11 If there is no continuity at either terminal go to step 5 23 62 5 Reconnect the seat belt pretensioner 3 P connector then check continuity between body ground and each terminal of both seat belt pretensioners TEST HARNESS B 07MAZ SPO0500 2 o o v zoo s o v Te Eed If there is conti
129. dle CO Clutch Section 12 MEASUREMENT STANDARD NEW SERVICE LIMIT Clutch pedal _ Clutch pedal height to floor 199 5 7 85 Stroke at pedal 139 5 47 Total clutch pedal free play include the pedal play 9 15 0 35 0 59 Pedal play 1 0 7 0 0 04 0 28 Disengagement height to floor 90 3 5 min Flywheel Clutch surface runout 5 0 002 max 0 15 0 006 Clutch disc Rivet head depth 1 5 0 06 min 0 5 0 02 T Surface runout O 6 0 02 max 0 8 0 03 Thickness 9 6 10 3 0 38 0 41 6 8 0 27 Pressure plate Warpage 0 03 0 001 max 0 15 0 006 Hi 3 4 Manual Transmission Section 13 MEASUREMENT US qt Imp at Transmission oil Capacity STANDARD NEW 2 6 2 7 2 3 for overhaul 2 3 2 4 2 0 for oil change Mainshaft End play Diameter of bearing contact area Clutch housing side Transmission housing side Transmission cover side 3rd gear needle bearing Runout End play Diameter of bearing contact area Clutch housing side Transmission housing side Transmission cover side Runout Countershaft Reverse idler shaft Diameter bearing contact area Reverse drive gear V D Thickness Mainshaft 3rd gear 1 0 Thickness End play when tightening by specified torque 1 0 Thickness End play when tightening by specified torque LD Thickness End play when tightening by spec
130. e Mode A Open in one cowl sensor contact Short to driver s or passenger s inflator body ground Short to driver s or passenger s seat belt pretensioner body ground Short in dash sensors Open in both cowl sensor contacts Short in one cowl sensor contact or open in both dash sensors Open in one dash sensor Voltage 10 5 10 5 14 5 14 5 12 0 10 5 14 0 14 5 Open in driver s airbag inflator or cable reel 10 5 10 5 14 5 14 5 4 5 4 5 12 0 10 5 14 0 14 5 10 5 14 5 10 5 5 1 5 1 7 0 7 0 5 5 1 7 0 7 0 4 5 5 5 12 0 14 0 14 5 10 5 Open in front passenger s airbag inflator Open in driver s seat belt pretensioner Open in front passenger s seat belt pretensioner 10 5 10 5 14 5 14 5 Short in seat belt pretensioner trigger transistor Blown SRS fuse No 7 10 LHD No 16 10 A RHD or open in the wire Short or open in SRS indicator wire harness cont d 23 61 Supplemental Restraint System SRS Troubleshooting cont d Mode A Open in one cowl sensor contact 3 Reconnect the driver s airbag connector then check continuity between the B1 terminal and body ground The SRS unit is faulty Substitute a known good SRS unit and between the B7 terminal and body ground and recheck the voltages accor
131. e de provoquer des blessures graves ou de tuer Quand le faisceau de fils du gonfleur est d connect installer le connecteur d entretien rouge KS VARNING FOR ATT FORHINDRA OAVSIKTLIG UTLOSNING OCH TANKBARA SKADOR S TT ALLTID DET SKYDDANDE KORT SLUTNINGSSTIFTET PA TRYCKPUMPSKONTAKTEN N R KABELAN TET LOSSAS Varoitus Est vahingollisen k yt n ja mahdollisen vahingoittumisen Asenna aina suojaava lyhyt liitin pumpun liittimeen silloin kun haarniska on irti KY WARNING TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY ALWAYS INSTALL THE PROTECTIVE SHORT CONNECTOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS IS DISCONNECTED S R s 4245 bail y s ll gl oo yall LEY dus ara SI ASL rage AE prod Jrogt Lans is Leila ad daa O PRETESIONER ELR CAUTION LABEL WARNING EXPROSIVE MATERIAL INSIDE You can be seriously hurt or burned Install red short connector when wire harness is disconnected Do not tamper or disassemble No serviceable parts inside Use only approved electrical testers for circuit diagnosis Refer to Service Shop Manual for complete instractions ATTENTION MAT RIEL EXPROSIF L INT RIEUR Vous pouvez subir des blessures ou des br lures graves Mettre le connecteur rouge court en place quand le faisceau de fils est d branch Ne pas modifier ou demonter Ne comprend aucune pl ce interne 4 entretenir N utiliser que des app
132. e 1 17 P Q R Refer to page 1 18 1 12 I STEERING COLUMN CAUTION LABEL KF KG KX CAUTION TO AVOID DAMAGING THE S R S CABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT ATTENTION POUR NE PAS RISQUER D ENDOMMAGER LE CABLE OU L ENROULEUR DU S R S ET DE RENDRE AINST LE SYSTEME INOPERANT RETIREZ LE VOLANT AVANT DE DEVINSSER LE BOULON D ACCOUPLE MENT D ARBRE DE DIRECTION ACHTUNG UM BESCHADIGUNGEN DER S R S KABELROLLE ODER DES KABELS WELCHE DAS S R S SYSTEM AUBER FUNKTION SETZEN W RDEN ZU VERMEI REN VOR ARBEITEN AN DER LENKSPINDEL DAS LENKRAD AUSBAUEN WAARSCHUWING OM TE VOORKOMEN DAT DE S R S KABEL OF HASPEL BESCHADIGO WORDEN HETGEEN ERTOE ZOU LEIDEN DAT HET SYSTEEM UITVALT DIENT U HET STUUR TE VERWIJDEREN VOORDAT U DE STUURSHACHT CONNECTORBOUT VERWIJDERT KE KT CAUTION TO AVOID DAMAGING THE S R S CABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT ATTENTION POUR NE PAS RISQUER D ENDOMMAGER LE CABLE OU L ENROULEUR DU S R S ET DE RENDRE AINST LE SYSTEME INOPERANT RETIREZ LE VOLANT AVANT DE DEVISSER LE BOULON D ACCOUPLE MENT D ARBRE DE DIRECTION KS OBSERVERA F R ATT UNDVIKA SKADOOR PA SRS SYSTEMETS KABEL ELLER TRUMMA NAGOT SOM KAN G RA ATT SYSTEMET INTE FUNGERAR SKALL RATTEN TAS BORT INNAN RATTAXELN
133. e a TORX bit 6 Connect the SRS main harness 18 P connector to the SRS unit push it into position until it clicks 7 Install the center armrest CENTER ARMREST SRS UNIT 10 11 12 13 14 15 18 Remove the short connectors from the front pas Reconnect the front passenger s airbag 3 P connec senger s airbag connector and from the SRS main harness connector tor to the SRS main harness connector Remove the short connectors from the driver s air bag connector and from the cable reel 3 P connector Reconnect the driver s airbag 3 P connector to the cable reel 3 P connector Attach the short connec tor RED to the access panel then reinstall the panel on the steering wheel Remove the short connectors RED from the seat belt pretensioners then attach them to their holders Reconnect the side wire harness 3 P connector to the driver s seat belt pretensioner and the main wire harness 3 P connector to the front passenger s seat belt pretensioner Reinstall the B pillar lower panel Reconnect the battery positive cable then the nega tive cable After installing the SRS unit confirm proper system operation Turn the ignition ON Il The instrument panel SRS indicator light should go on for about six seconds and then go off 23 91 Supplemental Restraint System SRS Seat Belt Pretensioner Replacement CAUTION Do not install used SRS parts
134. e airbag system The gas generator is Solids to be installed and or disassembled only by trained personnel ATTENTION Le g n rateur de gaz ne peut tre in Content De stall que sur des v hicules quip s Solides d un syst me airbag Le montage et le Flammable d montage du g n rateur de gaz ne peut tre effactu que par un person nel qualifie M PASSENGER MODULE DANGER LABEL KF KG KX DANGER EXPLOSIVE FLAMMABLE POISON WARNING REFER TO THE SHOP MANUAL DANGER EXPLOSIF ET INFLAMIMABLE POISON ATTENTION SE REPORTER AU MANUEL D ATELIER GEFAHR EXPLOSIV ENTZ NDBAR GIFT WARNUNG WERKSTATTHANDBUCH LESEN GEVAAR EXPLOSIEGEVAAR BRANDBAAR GIFTIG WAARSCHUWING LEES HET WERKPLAATSHANDBOEK KS KY DANGER EXPLOSIVE FLAMMABLE POISON REFER TO THE SHOP MANUAL FARLIGT EXPLOIVT VATTANTANDLIGT GIFTGT SE VERKSTADBOKEN e ATTENTION SE VERKSTADBOKEN e VAARA HELPOSTI RAJAHTAVA SYTTYVA MYRKKY KATSO LIIKEOHJETTA SRS ae eol asus isl aus ER NA CS EE cont d 1 15 Warning Caution Label Locations cont d M PASSENGER MODULE DANGER LABEL KE KT KU DANGER EXPLOSIVE FLAMMABLE Contact with acid water or heavymetals such as copper lead or mercury may produce harmful and irritating gases or explosive compounds Storage temperatures must not exceed 200 F 100 C For proper h
135. e box side cover and dash board side cover 5 Disconnect the connectors 6 Disconnect the opener cable from the hood release handle 20 22 7 Remove the six mounting bolts then lift and remove the dashboard CAUTION Use protective tape on the bottom of the front pillar trim When prying with a flat tip screwdriver wrap it with protective tape to prevent damage NOTE Take care not to scratch the dashboard FRONT PILLAR EE UIDE PIN ENGER S S DASHBOARD AIRBAG FRONT PILLAR PROTECTIVE y pee TRIM ims PROTECTIVE X TAPE Disconnect the connectors Gr ec d s DASHBOARD MOUNTING BOLTS 6 x 1 0 mm 10 Nem DASHBOARD 1 0 kg m 7 2 Ib ft MOUNTING BOLTS 6 x 1 0 mm 10 Nem 1 0 kg m 7 2 Ib ft HOOD RELEASE HANDLE DASHBOARD GROUND CABLE MOUNTING BOLTS To install tighten the dashboard 6 x 1 0 mm 10 Nem mounting bolt with the ground cable 1 0 kg m 7 2 Ib ft SHOP TOWEL Driver s Passenger s DASHBOARD SIDE COVER HOOD PT OPENER Ge CABLE UNDER DASH FUSE BOX Disconnect the connectors Disconnect the connectors RIGHT GLOVE BOX SIDE COVER Installation is the reverse of the removal procedure NOTE Make sure the dashboard fits onto the guide pin correctly Before tightening the dashboard mounting bolts make sure the dashboard wire harnesses are not pinched 20 23 Heater and Air Conditioning Automatic Climate Control
136. e connectors 2 Separate the recline adjuster and slide elevation adjuster BUSHS Replace Disconnect the connectors SLIDE ELEVATION ADJUSTER BUSH 20 4 3 Remove the slide joint cable see page 20 15 4 Remove the seat memory control unit and harness protector from the slide elevation adjuster Disconnect the connectors gt Clip locations 2 1 2 Detach the clip by pulling it Push here SLIDE MOTOR CONNECTOR SEAT MEMORY CONTROL UNIT gt TA connector A ls fe ka 4 SEA 2402 T KING eg eu X EE d ea HARNESS N PROTECTOR SLIDE ELEVATION ADJUSTER FRONT ELEVATION SENSOR CONNECTOR REAR ELEVATION SENSOR CONNECTOR REAR ELEVATION MOTOR CONNECTOR FRONT ELEVATION MOTOR CONNECTOR b Remove the lower caps on both sides LOWER CAP SLIDE ELEVATION ADJUSTER cont d 20 b Front Seat Linkage Recline Adjuster Slide Elevation Adjuster Replacement cont d 6 Installation is the reverse of the removal procedure Make sure the connectors are connected properly NOTE Replace the bushs with new ones as follows SLIDE SENSOR CONNECTOR SLIDE MOTOR Gray 2 CONNECTOR CONNECTOR 1 Install the bush Green Yellow Black wire Gray a g nie 2 Hold the bush down against a metal plate then flare the edge of the bush using a center punch as shown
137. e dashboard wire harness 20 P con nector from the main wire harness DASHBOARD WIRE HARNESS 20 P CONNECTOR RHD 5S CPL G ZE iv U SESCH ile ER A A a LAURE VS JN 222278 Ki DASHBOARD WIRE HARNESS 20 P CONNECTOR MAIN WIRE HARNESS 20 P CONNECTOR 2 Turn the ignition switch ON Il and wait for six se conds Measure the voltage between the No 10 ter minal and body ground on the main wire harness 20 P connector side MAIN WIRE HARNESS 20 P CONNECTOR sl pooo Monog 17 More than 8 5 V View from terminal side f voltage is more than 8 5 V go to step 8 f voltage is less than 8 5 V go to step 3 3 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 4 Connect Test Harness B between the SRS unit and the SRS main harness 18 P connector SRS UNIT TEST HANRESS B 07MAZ SPO0500 SRS MAIN HARNESS 5 Reconnect the battery positive cable and negative cable 6 Check for continuity between the B11 terminal and body ground TEST HANRESS B 07MAZ SPO0500 2 2141 617 o w uw we v o o 12 2 14 Continuity f there is continuity the SRS main harness is shorted Replace the SRS main harness and recheck the voltages according to the chart on page 23 61 If there is no continuity go to step 7
138. e dipstick pipe 14 Remove the lower cover 15 Loosen the timing belt adjusting bolt 180 16 Push the tensioner to release tension from the belt then retighten the adjusting bolt TIMING BELT ADJUSTING BOLT Do not remove When 17 Remove the timing belt from the pulleys adjusting loosen it 180 RUBBER SEALS RIGHT Replace when damaged UPPER COVER or deteriorated UPPER COVER DIPSTICK PIPE 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft O RING Replace 12 Nm 1 2 kam LOWER COVER 9 Ib ft Y JJ CRANKSHAFT PULLEY P PULLEY BOLT d i vu 15mm Remove any oil amp 240 N m 24 0 kg m EOM 174 Ib ft 8 x 1 25 mm Apply engine oil to the bolt threads 22 N m 2 2 kg m and the surface that contacts the washer 16 Ib ft A C ADJUSTING PULLEY 6 6 Installation CAUTION Do not rotate the crankshaft or camshafts with the timing belt removed The pistons may hit the valves and cause damage When installing the timing belt turn the crankshaft pulley clockwise 15 past No 1 cylinder TDC After adjusting the left and right camshaft pulleys to TDC turn the crankshaft pulley counterclockwise back to TDC Top Dead Center Inspect the water pump when replacing the timing belt Install the timing belt in the reverse order of re moval Only key points are described here Remove all spark plugs Position t
139. e used to identify wire colors in the circuit schematics RELAY In normal position Normally open relay Normally closed relay SWITCH In normal position Normally open Switch CONNECTION Input Output Normally closed switch CONNECTOR CONDENSER 1 T LIGHT EMITTING DIODE LED M REED SWITCH LT BLU LT GRN Light Blue Light Green The wire insulator has one color or one color with another color stripe The second color is the stripe WHT BLK 23 3 Ground Distribustion LHD Circuit Identification BLK Battery Engine cylinder block G1 m EM E BLK Right valve cover G2 ECU BRN BLK L4 BRN BLK BRN BLK BLK Engine oil temperature sensor Neutral position switch M T BLK BLK ECU main relay ECU BLK BRN BLK ECU G101 Right heated oxygen RED BLU sensor Left heated oxygen WHT sensor LS nes mua ecrit BLU YEL BLU GRN CYL sensor WHT BLU ECU ORN BLU L wes em me oo zem o rm mm zl pew em e mm mm rr e e rm mm em len re wm e zm e e mm WHT BLU Crank angle Se ORN BLU sensor C ORN mem rm em zm mm NM speed sensor r ECU NC speed BLU GRN sensor BLU YEL Ka e SEN et lee e Battery ground cables 0 Engine compartment wire harness S
140. ear Outer synchro ring to synchro cone Shift fork Finger thickness 1st 2nd Finger to synchro sleeve clearance 3rd Ath and 5th 95 1 68 0 037 0 066 5 1 0 0 02 0 04 0 0 5 1 0 0 02 0 04 7 o 4 7 6 0 29 0 30 35 0 65 0 014 0 026 1 00 0 039 Reverse shift fork Finger thickness Finger to reverse synchro sleeve clearance Groove width Fork to reverse shift arm clearance 6 4 6 6 0 25 0 26 0 35 0 65 0 014 0 026 13 20 13 30 0 520 0 524 0 20 0 50 0 008 0 020 1 00 0 039 0 8 0 031 Shift fork shaft Shat to shift piece clearance Shift arm Diameter at the contact point with the change piece Arm to change piece clearance Diameter at the contact point with the shift piece Arm to shift piece clearance Groove width of the shift piece contact point 0 25 0 55 0 010 0 022 12 20 12 40 0 480 0 488 0 85 0 033 7 9 8 0 0 311 0 315 0 1 0 3 0 004 0 012 7 9 8 0 0 311 0 315 0 1 0 3 0 004 0 012 0 55 0 022 0 55 0 022 Change piece Groove width of the shift arm contact point 8 1 8 2 0 319 0 323 Groove width of the shift fork shaft or shift fork contact point Diameter at the contact point with the Shift piece 0 25 0 55 0 010 0 022 11 85 11 95 0 467 0 470 L shift fork s
141. ecting any part of the SRS wire har ness connect the short connectors see page 23 54 Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring SRS MAIN HARNESS Covered with yellow outer insulation Throttle Angle Sensor Voltage Throttle Opening 0 822 0 878 V 0 5 8 Throttle 2 175 2 325 V 3 5 8 Throttle 011 00000000000001000000001000000100000000000 DIGITAL CIRCUIT 1 0000000000000 00000000 000000 00000000009 TESTER 022 c TEST HARNESS 07LAJ PT30100 or 07LAJ PT3010A NOTE LHD is shown RHD is similar cont d 14 5 Road Test cont d Upshift KE KU KG KF KS KX models Position 1st 2nd 2nd 3rd 3rd 4th Lock up Clutch ON 2 175 2 325 V 3 5 8 throttle Acceleration from a stop Throttle angle sensor voltage km h 30 35 42 49 32 37 0 822 0 878 V 0 5 8 throttle Coasting down hill from a stop mph 9 12 19 22 26 30 20 23 Throttle angle sensor voltage km h 34 40 61 69 93 102 120 129 21 25 38 43 58 63 75 80 Full throttle Acceleration from a stop 9 Downshift Throttle angle sensor voltage 0 822 0 878 V 0 5 8 throttle Coasting or braking to a stop 112 125 39 43 Lock up Clutch OFF 31 36 4th 3rd 1
142. el and Emissions idle Control System Idle Speed Setting pe 11 2 Emission Control System Tailpipe Emission Evaporative Emission Controls 11 6 SUPPLEMENTAL RESTRAINT SYSTEM SRS The Legend Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in this shop manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda or Acura dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda or Acura dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do n
143. emory Switch Replacement CAUTION Wear gloves to remove and install the front seat NOTE Take care not to scratch the seat covers 1 Remove the front seat 2 Remove the cushion front cover recline cover and height cover Disconnect the connector and detach the wire ties RECLINE MEMORY SWITCH WIRE TIES CONNECTOR P SEAT COVER 4 Pull back the seat cover Remove the recline memory switch 3 3 0 kg m 0 2 4 Ib ft RECLINE MEMORY SWITCH 3 5 Ib ft m 3 0 kg m lb ft NO AU Installation is the reverse of the removal procedure NOTE After installing the recline memory switch apply liquid thread lock to locations then tighten the nuts Make sure the connector is connected properly Check the recline memory switch operation 20 15 Rear Power Seat KY KO KT models Replacement Disassemble in the numbered sequence NOTE Take care not to split the seams or damage the seat covers ARMREST 6 LEFT HEADREST LEFT RIGHT SEAT BACK HEADREST 6 x 1 0 mm 10 Nem 1 0 kg m 7 2 Ib ft 0 6 x 1 0 mm 10 N m 1 0 kg m 7 2 lb ft ARMREST LID TRIM PANEL 0 6 x 1 0 mm 10 N m 1 0 kg m 7 2 lb ft 6 3 6 x 1 0 mm 10 N m 1 0 kg m 7 2 Ib ft RIGHT SEAT BACK 6 x 1 0 mm 10 N m 1 0 kg m 7 2 lb ft 35 b RLA 2 RIGHT SEA
144. ent cont d 2 Remove the springs SPRINGS 3 Remove the plate from the slide elevation adjuster gt Bolt locations 4 5 x 0 8 mm Comm 3 N m 0 3 kg m 2 2 Ib ft Pd SLIDE ELEVATION ADJUSTER 20 12 4 Disconnect the connectors then detach the rear ele vation sensor connector and front elevation motor connector on the motor side as shown REAR ELEVATION FRONT ELEVATION SENSOR CONNECTOR SENSOR CONNECTOR Motor side REAR ELEVATION REAR ELEVATION SENSOR CONNECTOR REAR ELEVATION MOTOR CONNECTOR FRONT ELEVATION MOTOR CONNECTOR FRONT ELEVATION MOTOR CONNECTOR Motor side FRONT ELEVATION MOTOR 5 Remove the nuts and bolts gt Nut bolt locations 6 x 1 0 mm 6 x 1 0 mm 5 N m 0 5 kg m 5 Nem 0 5 kg m 3 6 Ib 3 6 Ib ft p REAR ELEVATION FRONT ELEVATION MOTOR MOTOR 6 Remove the nuts from the slide elevation adjuster gt Nut locations 4 SLIDE ELEVATION ADJUSTER 7 Slide the pipe brackets inward then remove the front and rear elevation motors as shown REAR ELEVATION BUSH MOTOR Replace Replace PIPE BRACKETS FRONT ELEVATION MOTOR cont d 20 13 Front Seat Linkage Front and Rear Elevation Motors Replacement cont d 8 Installation is the reverse of the removal procedure Replace the bushs see page 20 13 with new ones as described on page 20 6 NOTE Before installi
145. er igniter The pretensioner should take up the slack in the belt pop the clip off and lock the belt in its retracted position If the pretensioner works and the green light on the tool goes on continue with this procedure if the pretensioner doesn t work yet the green light goes on its igniter is defective Go to Damaged Airbag or Pretensioner Special Procedure During activation the pretensioner can become hot enough to burn you Wait thirty minutes after activation before touching it Dispose of the complete pretensioner assembly No part of it can be reused Repeat steps 3 through 8 on the other side if that pretensioner has not been triggered Simultaneously Deploying Airbags and Trigger ing Seat Belt Pretensioners 1 Disconnect both the negative cable and positive ca ble from the battery Confirm that the special tool is functioning properly by following the check procedure on the label of the tool box or on page 23 83 Disconnect the SRS main harness 18 P connector from the SRS unit SRS UNIT Cut and twist together 4 wires Cut and twist toghther 4 wires Cut eight wires at the SRS main harness 18 P con nector four on Sach side as shown Strip the end of the wires then twist them together to make each set of four wires into one Connect the alligator clips of the deployment tool to the ends of the twisted wires cont d 23 81 Supplemental Restraint System SRS A
146. ercury may produce harmful and irritat ing gases or explosive compounds Storage temperatures must not exceed 200 F 100 C For proper handling storage and disposal procedure refer to Service Shop Manual SRS supplement POISON Contains poisonous sodium azide and potassium nitrate FIRST AID If contents are swallowed induce vomiting For eye contact flush eyes with water for 15 minutes If gases from acid or water contact are inhaled seek fresh air in every case get prompt medical attention DANGER EXPLOSIBLE INFLAMMABLE Tout contact avec l acide l eau ou des m taux lourds comme le cuivre Le plomb ou le mercure risque de produire des gaz nocifs et irritants ou des compos s explosifts Les temp ratures de rangement ne devront pas d passer 200 F 100 Pour les proc dures de manipulation de rangement et de mise au rebut voir le supl ment SRS du manuel d entrien POISON Renferme de l acide de soude et du nitrate de potas sium toxiques PREMIERS SECOURS Si le contenu est absorb En cas de contact avec les yeux laver grande eau pendant un quart d heure En cas d inhalation des gaz par contact avec l acide ou l eau Aller l air frais Dans tous les cas obtenir promptement des soins m dicaux 1 8 E MODULE WARNING LABEL KF KG KX WARNING REFER TO THE SHOP MANUAL SE REPORTER AU MANUEL D ATELIER e WERKSTATTHANDBUCH LESEN LEES HET WERKPLAAT
147. ering grease P N 08733 BO70E Grease with molybdenum disulfide Multi purpose grease Silicone grease Honda power steering fluid No LUBRICATION POINTS 1 Engine 2 Transmission Manual Automatic 3 Brake Line 4 Clutch Line 5 Power steering gearbox 6 Shift lever pivots Manual transmission 7 Release fork Manual transmission 8 Steering boots 9 Throttle cable end 10 Steering ball joints 11 Select lever Automatic transmission 12 Pedal linkage 13 Intermediate shaft 14 Brake master cylinder pushrod 15 Trunk hinges 16 Door hinges upper and lower 17 Door opening detents 18 Fuel filler lid 19 Engine hood hinges and engine hood latch 20 Clutch master cylinder pushrod Manual transmission 21 Change rod joint Manual transmission 22 Caliper Piston seal Dust seal Caliper pin Piston 23 Power steering system 24 Differential Air conditioner compressor oil Recommended Engine Oil API Service Grade SF or SG Fuel Efficient oil 15W 40 15W 50 20W 40 20W 50 RER 10 20 30 40 C 1 a a a oes 20 20 40 60 80 100 F 30 20 10 L 1 For cars with catalytic converter 2 For cars without catalytic converter Differential oil Hypoid gear oil classified GL4 or GL5 Viscosity SAE90 above 18 C O F SAE 80 W90 below 18 O F ND OIL8 P N 38899 PR7 003 CAUTION Used engine oil may cause
148. es were described in this section Anti lock Brake System ABS Change in the ABS Control Unit Control System 1 ABS Pump Motor Operation Conditions Before change After change The ABS control unit activates the ABS pump mo tor when it detects the pressure switch OFF signal The ABS control unit activates the ABS pump mo tor when it detects the pressure switch OFF signal and the vehicle speed being 6 mph 10 km h or above NOTE The ABS pump motor can operate for a short time at the initial diagnosis right after the engine start Note there is no change in the conditions of this ABS pump motor operation 2 ABS Pump Motor Over run Warning Conditions Before change After change 5 seconds or more 20 seconds or more When the pressure switch is ON at the initial di No conditions agnosis 20 seconds or more When the pressure switch is OFF at the initial di agnosis and the over run warning was activated during the previous self diagnosis 15 seconds or more When the ABS is not activated at the regular di agnosis 3 ABS Control Unit Reset Condition after Warning of the Accumulator Gas Leak Problem Code 1 8 Before change After change The ABS control unit holds the ABS indicator The ABS has no holding function of the problem light ON at the restart of the engine when the code 1 8 T
149. ess countershaft 2nd gear parking gear 3 95 4 05 0 156 0 159 26 95 27 05 1 061 1 065 23 05 23 09 0 907 0 909 35 45 35 55 1 396 1 400 1 27 1 30 0 050 0 051 1 32 1 35 0 052 0 053 1 37 1 40 0 054 0 055 1 42 1 45 0 056 0 057 1 47 1 50 0 058 0 059 1 52 1 55 0 060 0 061 1 57 1 60 0 062 0 063 1 1 1 1 1 1 Wear or damage 62 1 65 0 064 0 065 67 1 70 0 066 0 067 72 1 75 0 068 0 069 77 1 80 0 070 0 071 82 1 85 0 072 0 073 87 1 90 0 074 0 075 3 45 3 55 0 136 0 140 34 05 34 08 1 341 1 342 33 90 33 97 1 335 1 337 30 05 30 10 1 183 1 185 Mainshaft 1st gear thrust washer thickness Wear or damage Mainshaft 1st gear distance collar length Mainshaft 1st gear collar length A mri Wear or damage 9 67 9 70 0 381 0 382 9 72 9 75 0 383 0 384 9 77 9 80 0 385 0 386 9 82 9 85 0 387 0 388 9 87 9 90 0 389 0 390 9 92 9 95 0 391 0 392 9 97 10 00 0 393 0 394 j 4th clutch collar 3 8 Automatic Transmission Section 14 MEASUREMENT Transmission cont d Countershaft 2nd gear collar length Countershaft 1st gear collar length B Thrust washer 38 8 x 47 thickness 1st hold clutch front side 1st hold
150. eters 30 ft away from the airbag DRIVER S AIRBAG FRONT PASSENGER S AIRBAG ALLIGATOR CLIPS ALLIGATOR Yellow CLIPS Yellow OPERATION SWITCH 12 VOLT BATTERY DEPLOYMENT TOOL 07HAZ 5600400 cont d 23 79 Connect a 12 volt battery to the tool If the green light on the tool goes on the airbag igniter circuit is defective and cannot be deployed Go to Damaged Airbag Special Procedure f the red light on the tool goes on the airbag is ready to be deployed Push the tool s deployment switch The airbag should deploy deployment is both highly audible and visible a loud noise and rapid inflation of the bag followed by slow deflation If deployment happens and the green light on the tool goes on continue with this procedure If the airbag doesn t deploy yet the green light goes on its igniter is defective Go to Damaged Airbag Special Procedure During deployment the airbag as sembly can become hot enough to burn you Wait thirty minutes after deployment before touching the assembly Dispose of the complete airbag assembly No part of it can be reused Place it in a sturdy plastic bag and seal it securely CAUTION Wear a face shield and gloves when handing a deployed airbag Wash your hands and rinse them well with water after handling deployed airbag STURDY AIRBAG PLASTIC ASSEMBLY al C Lee 23 80 Supplemental Restraint S
151. from another car use only new SRS parts Carefully inspect the seat belt pretensioner before in stalling it Do not install a pretensioner that shows signs of being dropped or improperly handled such as dents cracks or deformation The shoulder harness anchor bolt must be removed before you remove the pretensioner After completing repair work be sure to remove SRS short connector A 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 2 Remove the B pillar trim panel 3 Disconnect the 3 P connector from the seat belt pretensioner then connect the short connector RED to the seat belt pretensioner 3 P connector SHORT CONNECTOR RED SEAT BELT PRETENSIONER SHORT ASSEMBLY CONNECTOR HOLDER MOUNTING SIDE WIRE HARNESS 3 P CONNECTOR BOLTS MAIN WIRE HARNESS 3 P CONNECTOR 4 Remove the shoulder harness anchor bolt then remove the two seat belt pretensioner mounting bolts and pretensioner SHOULDER HARNESS ANCHOR BOLT CAUTION Be sure to install the harness wires so that they are not pinched or interfering with other parts 5 Install the new seat belt pretensioner MOUNTING BOLT 10 Nem 1 0 kg m 7 2 Ib ft SEAT BELT PRETENSIONER ASSEMBLY MOUNTING BOLT 33 N m 3 3 kg m 23 9 Ib ft SIDE WIRE HARNESS 3 P CONNECTOR MAIN WIRE HARNESS 3 P CONNECTOR 23 92 6 Reinstall the shoulder harness an
152. ft PIPE A COVER 6 x 1 0 mm COVER 10 Nem 1 0 kg m 7 lb ft HOLDER 14 28 31 Install the transmission housing mounting bolts 32 Install the ATF level gauge pipe stay bolt s 33 Connect the transmission sub harness connector 34 Install the control box LHD only LHD ATF LEVEL GAUGE PIPE STAY BOLTS 6 x 1 0 mm TRANSMISSION 12 N m 1 2 kg m 9 Ib ft SUB HARNESS CONNECTOR TRANSMISSION HOUSING MOUNTING BOLTS 6 x 1 0 mm 12 x 1 25 mm 12 Nm 65 N m 6 5 kg m 1 2 kg m 9 Ib ft 47 Ib ft CONTROL BOX RHD TRANSMISSION HOUSING MOUNTING BOLTS 6 x 1 0 mm 12 x 1 25 mm 12 N m 65 N m 6 5 kom 1 2 kg m 47 lb ft ATF LEVEL GAUGE PIPE TT TRANSMISSION SUB HARNESS CONNECTOR TRANSMISSION HOUSING MOUNTING BOLT 12 x 1 25 mm 65 Nem 6 5 kg m 47 ib ft 35 Install the strut bar 36 37 38 39 40 8 x 1 25 mm 22 Nem 2 2 kg m 16 lb ft STRUT BAR BRACKET Refill the transmission with ATF Connect the battery positive and negative cables to the battery Start the engine Set the parking brake and shift the transmission through all gears three times Check for proper shift cable adjustment Let the engine reach normal operating temperature the radiator fan comes on with the transmission in N or P position then turn it off and check fluid level Road test as described on pages 14 5 thru 7 14 29 Shift Cable Removal Installati
153. ght Control System No Terminal Test condition Test Desired result Possible cause if result is not obtained Driver s door open Check for continuity to ground Faulty door switch There should be continuity An open in the wire GRN RED Front passenger s door open GRN YEL Left rear door open GRN WHT Right rear door open 2 WHT BLK Under all conditions Attach to ground Foot well light Blown No 57 15 A fuse should come on Blown bulb An open in the wire Blown No 57 15 A fuse Blown bulb open in the wire Blown No 57 15 A fuse Blown bulb Faulty ceiling light relay An open in the wire NOTE Before testing remove No 57 15 A fuse 3 WHT BLK Under all conditions Attach to ground Ignition key light should come on GRN WHT Ceiling light switch at Attach to ground Ceiling lights MIDDLE position front and rear courtesy lights should come on 23 26 Power Window Key off Timer System No Terminal Test condition Driver s door open GRN RED Front passenger s door open Test Desired result Check for continuity to ground There should be continuity NOTE Before testing remove No 57 15 A fuse Possible cause if result is not obtained Faulty door switch An open in the wire Connect the A4 terminal to the A14 terminal Intermittent Wiper System No Termi
154. gine cold e Do not rotate the crankshaft when adjusting bolt is loose NOTE Tensioner is spring loaded to apply proper tension to the belt automatically after making the following adjustment e Inspect the timing belt before adjusting the belt ten sion Always rotate the crankshaft clockwise when viewed from the pulley side Rotating it counterclockwise may result in improper adjustment of the belt ten sion 1 Remove the left upper cover 2 Remove the damper from the center bracket as shown in left column 3 Setthe No 1 piston at TDC page 6 7 4 Rotate the crankshaft clockwise 9 teeth on camshaft pulley The blue mark on crankshaft pulley should line up with the pointer on lower cover 5 Loosen the timing belt adjusting bolt 180 6 Tighten the adjusting bolt torque to 43 N m 4 3 kg m Direction of rotation ADJUSTING BOLT 43 N m 4 3 kg m 31 Ib ft POINTER ON LOWER COVER BLUE MARK Removal CAUTION Inspect the water pump when replacing the timing belt NOTE e Turn the crankshaft so that the No 1 piston is at top dead center page 6 7 e Before removing the timing belt mark direction of rotation if it is to be reused 1 Disconnect the negative terminal from the battery 2 Remove the damper center bracket and center mount 10 x 1 25 mm DAMPER 39 N m 3 9 kg m 16 Ib ft 8 x 1 25 mm 22 N m 2 2 kg m 16
155. gnose Connecting the short connectors CAUTION Before disconnecting the airbag connector be sure to completely discharge the capacitor in the back up circuit by turning off the ignition switch and allow ing three minutes to elapse to prevent a malfunction of the seat belt pretensioners 1 Disconnect the battery negative cable then discon nect the positive cable 2 Remove the access panel from the steering wheel then remove the short connector RED from the panel DRIVER S AIRBAG ASSEMBLY CABLE REEL 3 P CONNECTOR ACCESS PANEL DRIVER S AIRBAG SHORT CONNECTOR 3 P CONNECTOR RED 3 Disconnect the 3 P connector between the driver s airbag and the cable reel then connect the short con nector RED to the airbag side of the connector cont d 23 47 Supplemental Restraint System SRS Wiring Precaution cont d 4 Connect an SRS short connector A special tool to the cable reel side of the connector DRIVER S AIRBAG ASSEMBLY CABLE REEL 3 P CONNECTOR SHORT CONNECTOR RED SRS SHORT CONNECTOR A 07MAZ SPO020A 5 Remove the glove box then disconnect the 3 P con nector between the front passenger s airbag and SRS main harness 6 Connect the short connector RED to the airbag side of the connector FRONT PASSENGER S AIRBAG ASSEMBLY SRS MAIN HARNESS FRONT PASSENGER S AIRBAG 3 P CONNECTOR SHORT CONNECTOR RED 7 Connect another SRS short connector A speci
156. h high and low sides of the system 2 Disconnect the center hose of the gauge set and place the free end in a shop towel 3 Open the evacuation valve in case of two valve 6 Note the gauge reading and as system pressure gauge open the evacuation stop valve drops gradually open both high and low side valves fully until both gauges indicate kPa kg cm2 O psi THREE VALVE GAUGE TWO VALVE GAUGE EVACUATION VALVE LOW PRESSURE HIGH PRESSURE LOW PRESSURE HIGH PRESSURE VALVE VALVE VALVE VALVE EVACUATION STOP VALVE EE EECH LOW PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT HIGH PRESSURE QUICK JOINT HIGH PRESSURE QUICK JOINT INNER DIAMETER mm 22 5 A C System Service Evacuation NOTE gauge open the evacuation stop valve Run the Only use a gauge set for refrigerant R 134a pump for about 15 minutes Close both pressure Use a vacuum pump adapter which is equipped with valves and the evacaution valve in case of two a check valve to prevent the backflow of the vacuum valve gauge close the evacuation stop valve and pump oil stop the pump The low pressure gauge should in dicate above 700 mmHg 27 in Hg and remain 1 When an A C System has been opened to the at steady with the valves closed mosphere such as during installation or repair it must be evacuated using a R 134a refrigerant NOTE If low pressu
157. haft R everse shift holder Diameter at the contact point with the reverse shift fork Diameter at the contact point with the bth reverse shift fork shaft 12 80 13 00 0 504 0 512 12 80 13 00 0 504 0 512 0 85 0 033 Backlash Preload starting torque N m kg cm Ib in Diameter of bearing contact area Clutch housing side Transmission housing side Diameter of oil seal contact area Clutch housing side Transmission housing side Secondary gear Diameter of oil seal contact area 37 438 37 500 1 4739 1 4764 Oil pump Clutch housing to outer rotor clearance Inner to outer rotor clearance Clutch housing to rotor axial clearance 0 061 0 121 0 0024 0 0048 1 4 2 6 14 26 12 2 22 6 55 002 55 021 2 1654 2 1662 45 002 45 018 1 7717 1 7724 54 894 54 940 2 1612 2 1630 44 911 44 950 1 7681 1 7697 0 03 0 13 0 001 0 005 0 14 0 006 0 10 0 20 0 004 0 008 0 18 0 007 0 2 0 01 0 22 0 009 Automatic Transmission Section 14 Transmission fluid MEASUREMENT Capacity US ot Imp qt STANDARD NEW 8 7 9 2 7 7 for overhaul 3 3 3 5 2 9 for oil change Hydraulic pressure kPa kg cm psi Stall speed min rpm Clutch Line pressure at 2 000 min rpm N or P position iz clutch pressure at 2 000 rpm Ds Da or 1 position Unit of
158. harness Front passenger s door wire harness Blower wire harness 23 12 BLK BLK Front passenger s power seat switch Service check connector BLK fa BLK Left rear door lock knob switch Left rear door switch Left rear power seat switch and KT models a OQ BLK Left rear door ashtray light G404 BLK lb BLK Sunroof open relay Sunroof close relay BLK G405 Fuel pump Fuel gauge sending unit BLK Radio rear remote switch model G406 E Main wire harness a Left rear door wire harness Sunroof wire harness Front passenger s power seat wire harness cont d 23 13 Ground Distribution RHD Circuit Identification cont d Rear cigarette lighter Driver s power seat switch Power seat control unit Right rear door lock knob switch Right rear door switch Right rear power seat switch KQ and KT models Shift lever position switch Shift lever position switch Without security system Headlight adjuster switch KE and KU models High mount brake light Except KE and KU 6522 Side wire harness s Driver s power seat wire harness Right rear door wire harness Floor sub harness 23 14 G551 BLK nr _ BLK E G601 o BLK MM G602 6701 LR BLK R BLK Q G801 6 Dashboard wire harness H Rear wire harness P Rear wi
159. he SRS is included in this shop manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda or Acura dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda or Acura dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits Automatic Transmission Special Tools 14 2 Main Valve Body Description Disassembly Inspection Reassembly 14 18 Hydraulic Flow 14 3 Secondary Valve Body A T Speed Sensors Disassembly Inspection Reassembly 14 20 Replacement 14 4 Reverse Accumulator 1st hold Accumulator Road Test
160. he crankshaft and the camshaft pulleys as shown before installing the timing belt Set the crankshaft so that the No 1 piston is at top dead center Align the A mark on the teeth side of the timing belt drive pulley to the pointer on the oil pump Align the TDC mark on the left camshaft pulley to the pointer on the left back cover O Align the TDC mark on the right camshaft pulley to the pointer on the right back cover RIGHT CAMSHAFT PULLEY POINTER ON THE BACK COVER YELLOW Install the timing belt tightly in the sequence shown DTiming belt drive pulley crankshaft gt Ad justing pulley gt Left camshaft pulley gt Water pump pulley gt Right camshaft pulley e For easy installation advance the right camshaft pulley by about a half tooth from the TDC posi tion POINTER ON THE BACK COVER YELLOW TDC MARK BLUE LEFT CAMSHAFT PULLEY POINTER ON THE OIL PUMP TIMING BELT DRIVE PULLEY KEY WAY A MARK cont d 6 7 Timing Belt Installation cont d 5 Loosen the adjust bolt and retighten it after ten LEFT CAMSHAFT PULLEY sioning the belt POINTER ON TDC MARK THE UPPER COVER BLUE 6 Install the lower cover and crankshaft pulley 7 Rotate the crankshaft about 5 or 6 turns clockwise so that the belt may fit in position on the pulleys 8 Carry out timing belt tension adjustment page 6 4 9 Check the crankshaft pulley and the camshaft pul
161. he reverse order of removal After the engine is in place Torque the engine mount bolts nuts in sequence shown below CAUTION Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration and reduce bushing life check that the bushings are not twisted or offset e Check that the spring clip on the end of each driveshaft clicks into place CAUTION Use new spring clips e Bleed air from the cooling system at the bleed boit with the heater valve open e Adjust the throttle cable tension e Check the clutch pedal free play e Check that the transmission shifts into gear smoothly e Adjust the tension of the following drive belts e Clean battery posts and cable terminals with sandpaper assemble then apply grease to pre vent corrosion e Inspect for fuel leakage After assembling fuel line parts turn on the ignition switch do not operate the starter so that the fuel pump operates for approximately two seconds and the fuel is line pressurizes Repeat this operation two or three times and check for fuel leakage at any point in the fuel line REAR BEAM Mount the engine so that the rear beam does not hit the transmission Engine Mount Bolts and Nuts Tightening Sequence CAUTION After loosening the special nuts be sure to replace them with new ones NOTE Tighten the mounting bolts nuts in the num bered sequence as shown 13 Cum i 4
162. herefore when the problem code 1 8 is problem code 1 8 is memorized in the ABS con memorized in the ABS control unit it does not pre trol unit vent the ABS indicator light from going OFF at the Problem code holding function restart of the engine To reset the holding function disconnect the bat tery terminal or the ABS B2 15A fuse for more than 3 seconds 19 2 Body Dashboard Replacement 20 21 Front Seat Belt Replacement vun deos 20 18 Inspection 20 20 Front Seat Linkage Ind x eeng EE 20 3 Recline Adjuster Slide Elevation Adjuster Replacement Selen 20 4 Recline Motor Replacement 20 7 Slide Motor Slide Gearbox Replacement K ren Weste e 20 8 Front and Rear Elevation Motors Replacement 20 11 Slide Joint Cable Replacement 20 15 Recline Memory Switch Replacement 20 15 Rear Power Seat KY KO KT models Replacement eer 20 16 Slide Adjuster Disassembly 20 17 Special Tools beg 20 2 Read SRS precautions on section 1 then install short connectors on the airbags and seat belt pretensioner before working in these areas SUPPLEMENTAL RESTRAINT SYSTEM SRS if body maintenance is required The Legend Supplemental Restraint System SRS incl
163. hielded wire Engine ground wire E Main wire harness European model Engine wire harness A T sub harness 23 4 BLK Igniter unit BLK 6102 D BLK Right front parking light Se D BLK Right front turn signal light D BLK Right front side marker light E D BLK Right headlight D BLK Right horn D BLK AIC triple pressure switch MID Es D BLK Hood switch With security system D BLK Right headlight Low eu D BLK Right headlight adjuster European model D BLK Right side turn signal light Q G201 D BLK Windshield wiper motor D BLK Brake fluid level switch Left side turn signal light European model G202 D BLK D BLK Radiator fan main relay Windshield wiper intermittent relay Cruise actuator Windshield wiper high relay ee DIBLK Left horn See D BLK Radiator fan motor D BLK EE Es Left front turn signal light Windshield washer motor D BLK E Left front parking light Left headlight adjuster dei Left headlight Low rapean Left headlight KY model D BLK RE GES Left front side marker light Headlight washer motor D BLK Security horn European model UNDER HOOD Washer fluid level switch FUSE RELAY BOX S SS SE Ge Q G301 BLK ABS pump motor G302 Engine wire harness D Engine compartment wire harness cont d 23 5 Ground
164. ified torque Distance collar 1 0 Diameter of needle bearing contact area Mainshaft 4th gear Mainshaft 5th gear End paly when tightening by specified torque Countershaft 2nd LD gear Thickness End paly when tightening by specified torque 0 183 0 375 0 007 0 015 27 977 27 990 1 1015 1 1020 30 987 31 000 1 2200 1 2205 27 987 28 000 1 1018 1 1024 37 989 38 000 1 4956 1 4961 0 02 0 001 max Unit of length mm in SERVICE LIMIT 0 525 0 021 27 930 1 0996 30 940 1 2181 27 937 1 0999 37 935 1 4935 0 05 0 002 0 173 0 340 0 007 0 013 33 000 33 015 1 2992 1 2998 31 975 31 988 1 2589 1 2594 27 987 28 000 1 1018 1 1024 0 02 0 001 max 19 989 20 000 0 7870 0 7874 0 490 0 019 32 950 1 2972 31 928 1 257 27 937 1 0999 0 05 0 002 19 93 0 785 25 007 25 020 0 9845 0 9850 26 45 26 50 1 041 1 043 44 009 44 025 1 7326 1 7333 31 39 31 47 1 236 1 239 0 06 0 19 0 002 0 008 25 078 0 9873 26 38 1 039 44 080 1 735 31 32 1 233 0 30 0 012 44 009 44 025 1 7326 1 7333 29 39 29 47 1 157 1 160 0 06 0 19 0 002 0 008 44 009 44 025 1 7326 1 7333 29 39 29 47 1 157 1 160 0 06 0 19 0 002 0 008 30 992 31 002 1 2202 1 2205 37 989 38 000 1 49
165. inal and the No 10 terminal TEST HARNESS C 07MAZ SP00600 0 2 kQ f resistance is more than 0 2 go to step 6 If resistance is less than 0 2 the SRS main har ness is faulty Replace it and recheck the voltages according to the chart on page 23 61 6 Disconnect the 3 P connector from the driver s and TEST HARNESS C 07MAZ SPO0600 front passenger s seat belt pretensioners then con nect Test Harness C to the seat belt pretensioner side of the 3 P connector first on the driver s side then on the front passenger s side SEAT BELT PRETENSIONER ASSEMBLY SEAT BELT PRETENSIONER 3 P CONNECTOR SIDE WIRE HARNESS 3 P CONNECTOR Driver s side MAIN WIRE HARNESS 3 P CONNECTOR Front passenger s side 7 Measure the resistance between the No 9 terminal and the No 10 terminal TEST HARNESS C 07MAZ SPO0600 0 2 kQ If resistance is more than 0 2 kQ the seat belt pretensioner is faulty Replace it and recheck the voltages according to the chart on page 23 61 If resistance is less than 0 2 the side wire har ness driver s side or the car main wire harness front passenger s side is faulty Replace the faulty harness and recheck the voltages accord ing to the chart on page 23 61 cont d 23 71 Supplemental Restraint System SRS Troubleshooting cont d Mode H Short in seat belt pretensioner trigger transistor The SRS unit is faulty Subst
166. ing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda or Acura dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda or Acura dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits Electrical Special Tools 23 2 Integrated Control Unit Troubleshooting KY model m seesssossassessaseee 23 22 Schematic Symbols 23 3 Interlock System model 23 16 Wire Colors V Kee DT 23 3 Power Rear Passenger s Seat Index to Circuits and Systems M pa models 23 33 tereo Sound System Airbags Gedeelt cie 23 37 model 23 28 Ground Distribution 23 4 Ge Supplemental Restraint System Ignition System 23 32
167. ion mount bracket CAUTION After loosening the special nuts be sure to replace them with new ones REAR TRANSMISSION MOUNT BRACKET 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft MID MOUNT 10 x 1 25 mm SPECIAL NUT 39 N m 3 9 kg m 28 Ib ft 10 x 1 25 mm 49 N m 4 9 kg m 35 Ib ft Replace TRANSMISSION BEAM 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft Ze CORROSION RESISTANT BOLT 5 12 Lower the hoist Check that the engine transmission is completely free of vacuum hoses fuel and engine coolant 51 Remove the right and left brackets hoses and electrical wiring 52 Remove the damper and center bracket 56 Slowly raise the engine approximately 150 mm 6 in Check once again that all hoses and wires have 53 Remove the EGR passage bolt except KQ then been disconnected from the engine transmission install a special tool assembly 54 Attach a chain hoist to the engine Raise the hoist to 57 Raise the engine transmission assembly all the way remove all slack from the chain and remove it from the car ENGINE SUB Except HANGER STAY KO 07MAK PY30100 A T MOUNT BRACKET EGR PASSAGE BOLT ENGINE TILT HANGER SET 07KAK J40101 SUB HANGER BELT GL O7MAK PY30200 M T MOUNT BRACKET RIGHT BRACKET MID MOUNT CENTER LEFT BRACKET cont d BRACKET 5 13 Engine Removal Installation cont d 58 Install the engine in t
168. irbag Seat Belt Pretensioner Disposal cont d 6 Buckle the seat belt then pull out about five cen timeters two inches of slack make a loop with it and hold the loop in place with a clip as shown 5 cm 2 in of slack SEAT BELT PRETENSIONER ASSEMBLY 7 Repeat step 6 on the other front belt 8 Connect a 12 volt battery to the tool If the green light on the tool goes on an igniter circuit is defective Go to Damaged Airbag or Pretensioner Special Procedure if the red light on the too goes on the system is ready 9 Push the tool s deployment switch The airbags should deploy deployment is both highly audible and visible a loud noise and rapid inflation of the bags followed by slow deflation The seat belt pretensioners should take up the slack pop the clips off the belts and lock the belts in retracted positions If the airbags are deployed the pretensioners are triggered and the green light on the too goes on continue with this procedure If an airbag doesn t deploy or a pretensioner isn t triggered yet the green light goes on an igniter is defective Go to Damaged Airbag or Pretension er Special Procedure During airbag deployment and preten sioner activation the airbag and pretensioner assem blies can become hot enough to burn you Wait thirty minutes after activation before touching them 10 Dispose of the complete airbag and pretensioner as sembly No part of them
169. irbag assembly before you in stall it Do not install an airbag assembly that shows signs of being dropped or improperly handled such as dents cracks or deformation Do disassemble or temper with the airbag as sembly 1 Disconnect the battery negative cable then discon nect the positive cable 2 Before disconnecting any parts of the SRS wire har ness connect the short connectors see page 23 54 3 Remove the airbags Driver s Side Remove the two TORX bolts using a TORX T3O bit then remove the driver s airbag assembly CRUISE CONTROL SET RESUME CANCEL SWITCH TORX BOLTS Use a TORX T30 bit Front Passenger s Side Remove the glove box then remove the four mount ing nuts and the two mounting bolts then remove the bracket Remove the four mounting screws from the front pas senger s airbag assembly FRONT PASSENGER S AIRBAG ASSEMBLY MOUNTING MOUNTING SCREWS NUTS MOUNTING N _7 NUTS MOUNTING BOLTS Carefully lift the front passenger s airbag assembly out of the dashboard 23 76 SRS CAUTION 5 Remove the short connectors from the front pas Be sure to install the SRS wiring so that it is not senger s airbag connector and from the SRS main pinched or interfering with other car parts harness connector After completing repair work be sure to remove the SRS short connectors and reconnect all the con nectors 4 Install the new airbags SRS M
170. itch ON 11 Do any other indicator lights brake system light etc come on in the gauge assembly Inspect the No 13 7 5 A LHD or NO 17 7 5 A RHD fuse in the under dash fuse box YES NO Turn the ignition switch OFF ee LAG er AAG Replace the fuse YES SRS UNIT Disconnect the SRS main harness 18 P connector from the SRS unit Turn the ignition switch ON lI Repair open in dashboard wire harness between the No 13 LHD or No 17 RHD fuse and gauge as sembly SRS MAIN HARNESS 18 P CONNECTOR indi H YES lt Does the SRS indicator light The SRS unit is faulty Replace it come on Wa MO Turn the ignition switch OFF To page 23 57 23 b6 From page 23 56 Disconnect the dashboard wire harness 20 P connector from the main wire harness MAIN WIRE HARNESS Turn the ignition switch ON 11 DASHBOARD WIRE HARNESS 20 P CONNECTOR Is the SRS indicator light ON The SRS main harness or the car main wire harness is faulty Turn the ignition switch OFF Remove the gauge assembly then inspect the SRS indicator light bulb indi i NO lt GE SRS indicator light bulb Replace the indicator light bulb DASHBOARD p die WIRE HARNESS y MAIN WIRE HARNESS ves 20 P CONNECTOR 20 5 CONNECTOR
171. itor in the back up circuit discharge This will prevent a malfunction of the seat belt pretensioners Before disconnecting any part of the SRS wire harness connect the short connectors RED to the airbags and both seat belt pretensioners Af ter connecting the short connectors to the air bags immediately connect an SRS short connector AT special tool to the cable reel con nector for the driver s airbag and another to the SRS main harness connector for the passenger s airbag This will prevent any static electricity from triggering the seat belt pretensioners before you disconnect them see page 23 54 23 52 SRS Test Harnesses and Attachment Points SRS UNIT TEST HARNESS A 07MAZ SLOO500 S PIPPISPI sje o eT DRIVER S AIRBAG ASSEMBLY CABLE REEL 7 P CONNECTO b 22 SRS MAIN FRONT PASSENGER S HARNESS AIRBAG ASSEMBLY PASSENGER S AIRBAG 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR TEST HARNESS C 2 07MAZ SP00600 ie 7 0 SRS UNIT SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS 07MAZ SPO0500 ROW A SRS UNIT END SEAT BELT PRETENSIONER 3 P CONNECTOR SEAT BELT gt PRETENSIONER ASSEMBLY DRIVER S SIDE SIDE WIRE HARNESS FRONT PASSENGER S SIDE MAIN WIRE HARNESS SRS MAIN HARNESS DASH SENSOR 2 P CONNECTOR TEST HARNESS D 07LAZ SL40400 Supplemental Restraint Syste
172. itute a known good SRS unit and recheck the voltages according to the chart on page 23 61 Mode I Blown SRS No 7 10 LHD No 16 10 A RHD fuse or open in the wire 1 Check the SRS No 7 10 LHD No 16 10 A RHD fuse in the under dash fuse box If it s OK go to step 2 If it s blown replace it with a new 10 A fuse then turn the ignition switch ON ll If fuse doesn t blow go on to step 2 If the fuse blows troubleshoot as necessary to find the short 2 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 3 Connect Test Harness B between the SRS unit and the SRS main harness 18 P connector SRS UNIT TEST HARNESS B 07MAZ SP00500 SRS MAIN HARNESS Reconnect the positive and negative cable to the battery Measure the voltage between the B13 terminal and body ground with the ignition switch ON II TEST HARNESS B 07MAZ SP00500 A z s s lo opo es 12 5 2 Battery voltage d 16 17 18 16 17 e if there is battery voltage the SRS unit is faulty Replace it and recheck the voltages according to the chart on page 23 61 If less than battery voltage the SRS main harness is faulty Replace it and recheck the voltages ac cording to the chart on page 23 61 23 72 Mode J Short or open in SRS indicator wire harness 1 Disconnect th
173. ix bracket bolts TRANSMISSION HOUSING MOUNTING BOLT 12 x 1 25 mm 65 N m 6 5 kom 47 Ib ft TRANSMISSION MID MOUNT NUT 10 x 1 25 mm MID 49 N m 4 9 kg m MOUNT 35 bf MID MOUNT BRACKET BOLTS 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft 11 Remove the transmissin jack from the transmission 14 26 12 Loosely install the transmission beam to the rear transmission mount bracket mount with three bolts then install them with the exhaust pipe stay on the transmission rear cover and body REAR TRANSMISSION MOUNT BRACKET BOLTS 10 x 1 25 mm REAR TRANSMISSION MOUNT BRACKET MOUNT 39 N m 3 9 kg m 28 lb ft 8 x 1 25 mm 22 Nem 2 2 kg m 16 Ib ft amp SHIFT CABLE TRANSMISSION GUIDE BEAM BOLTS EXHAUST PIP ere TTT 10 1 25 MM TRANSMISSION Y BEAM BOLTS 10 x 1 25 mm 13 Tighten four transmission beam bolts 14 Tighten three rear transmission mount bracket bolts 15 Tighten three transmission beam bolts installed loosely in step 12 TRANSMISSION BEAM BOLTS 10 x 1 25 mm 39 N m 3 9 kg m 28 lb ft TRANSMISSION BEAM BOLTS 10 x 1 25 mm REAR TRANSMISSION AR 39 Num MOUNT BRACKET BOLTS 45 1 25 mm 3 9 kg m NES Inn 39 N m 3 9 kg m 28 Ib ft 39 N m 3 9 kg m 28 Ib ft 28 Ib ft 16 Install the shift cable guide on the transmission beam with the bolt 19 Fill the opening between the secondary gear shaft and extension shaft with HONDA GENUINE GREASE UM26
174. ket to the O ring grooves Do not install the parts if 20 minutes or more have elapsed since applying liquid gasket Instead reap ply liquid gasket after removing the old residue Wait at least 30 minutes before filling with appropri ate liquid engine oil coolant and similar fluids Prior to removing or disassembling parts they must be inspected carefully to isolate the cause for which service is necessary Observe all safety notes and precautions and follow the proper procedures as described in this manual cont d 1 25 Preparation of Work cont d Use the special tools when use of such is specified Use new packings gaskets O rings and cotter pins whenever reassembling Use genuine HONDA parts and lubricants or those equivalent When parts are to be reused they must be inspected carefully to make sure the are not r deteriorated and are in good usable con Mark or place all removed parts in order in a parts rack SSES SS so they can be reassembled in their original places Parts must be assembled with the proper torque ac cording to the maintenance standards established Coat or fill parts with specified grease as specified When tightening a series of bolts or nuts begin with page 4 2 Clean all removed parts with solvent upon the center or larger diameter bolts and tighten them disassembly in crisscross pattern in two or more steps 1 26 Symbol Marks
175. lder to the steer ing column CABLE REEL CANCEL SLEEVE CONNECTOR HOLDER cont d 23 85 Supplemental Restraint System Cable Reel Replacement cont d 13 Install the steering column upper and lower covers 14 Center the cable reel Do this by first rotating the cable reel clockwise until it stops Then rotate it counterclockwise approximately two turns until The yellow gear tooth lines up with the alignment mark on the cover The arrow mark on the cable reel label points straight up ARROW MARK CABLE REEL ALIGNMENT MARK LABEL YELLOW GEAR TOOTH 15 Install the steering wheel and attach the cable reel 3 P connector to the steering wheel clips GROUND CONNECTOR CRUISE CONTROL HORN SWITCH SET RESUME CANCEL CONNECTOR SWITCH CONNECTOR RADIO REMOTE SWITCH CONNECTOR CABLE REEL 3 P CONNECTOR 16 Connect the horn switch connector and cruise con trol set resume cancel switch connector SRS 17 Install the steering wheel nut 18 Install the driver s airbag assembly STEERING WHEEL NUT 50 Nem 5 0 kg m 36 Ib ft Replace DRIVER S AIRBAG ASSEMBLY TORX BOLT 10 N m 1 0 kom 7 2 Ib ft Replace Use a TORX T30 bit 19 Connect the cable reel 7 P connector to the SRS main harness then install the dashboard lower cover 20 Remove the short connectors from the front pas senger s airbag connector and from the SRS main harness connector
176. led 4 speed automatic 1 reverse Primary Reduction Direct 1 1 Type Manual Gear Ratio 1st 2 937 2 458 2nd 1 692 1 454 3rd 1 151 0 973 0 948 4th 0 868 0 630 0 688 5th 0 682 Reverse 3 186 1 826 EE Secondary Reduction Gear type Single helical gear Gear ratio 1 433 1 394 1 333 Final Reduction Gear type Spiral bevel gear AIR CONDITIONER STEERING SYSTEM 3 16 Cooling Capacity Gear ratio 3 133 3 133 4 900 K cal h 19 443 BTU h European type and KU European type and KU Compressor Type Make Swash plate type NIPPONDENSO No of Cylinder 10 Capacity 207 4 cm3 rev 12 7 cu in rev Max Speed 7 600 min rpm Lubricant Capacity 180 m 6 fl oz 6 32 Imp oz ND OIL8 Condenser Type Corrugated fin type Evaporator Type Corrugated fin type Blower Type Sirocco fan Motor Input 200 W 12 V Speed Control Infinite variable Temp control Max Capacity 480 m3 h 16 954 cu ft h Air mix type Type Overall Ratio Turns Lock to Lock Steering Wheel Diameter Compressor Type Dry single plate poly V belt drive Power Consumption 40 W 12 V Refrigerant Type R 134 a Quantity 750 9 g 26 5 9 16 7 3 24 Power assisted rack and pinion 390 mm 15 4 in nd __ SUSPENSION Type Front Rear Shcok Absorber Camber Front and Rear WHEEL ALI
177. length mm in SERVICE LIMIT 800 860 8 0 8 6 114 122 750 7 5 107 Sg clutch pressure at 2 000 min rpm 04 position 400 4 0 57 throttle fully closed 3rd clutch pressure at 2 000 min 1 rpm 02 position 4th clutch pressure at 2 000 min rpm Da position Bs hold clutch presure at 2 000 min rpm or 2 positon 2n clutch pressure at 2 000 1 rpm L or 2 positon Reverse clutch pressure at 2 000 1 rpm R position 860 8 6 122 throttle more than 1 4 opened 800 860 8 0 8 6 114 122 1 190 1 270 380 3 8 54 throttle fully closed 750 7 5 107 throttle more than 1 4 opened 750 7 5 107 1 150 11 5 164 Throttle B pressure Throttle fully closed Throttle fully open Check with car on level ground 1st hold 1st 2nd 3rd 4th Reverse Clutch return spring free length 1st hold 1st 2nd 3rd 4th Reverse Clutch disc thickness 1st hold 1st 2nd Reverse Clutch initial clearnace 3rd 4th Clutch plate thickness 1st hold 1st 2nd Reverse 3rd 4th 11 9 12 7 169 181 0 15 0 0 15 0 2 590 640 5 9 6 4 84 91 1 850 2 150 9 0 028 0 035 0 85 0 026 0 033 8 0 024 0 031 7 0 020 0 028 0 95 0 030 0 037 fools 33 7 1 327 30 3 1 193 1 88 2 00 0 074 0 079 2 28 2 40 0 090 0 094 0 077 0 081 0 100 0 104
178. lippage in the following position 1st Gear Position 1 Accelerate from a stop at full throttle Check that there is no abnormal noise or clutch slippage 2 Upshifts should not occur with the selector in this position 2nd Gear Position 1 Accelerate from a stop at full throttle Check that there is no abnormal noise or clutch slippage 2 Upshifts and downshifts should not occur with the selector in this position Reverse Position Accelerate from a stop at full throttle and check for abnormal noise and clutch slippage 6 Test in P Parking Position Park car on slope approximately 16 apply the parking brake and shift into P position Release the brake the car should not move 14 7 Lower Valve Body Assembly Disassembly Reassembly NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages Coat all parts with ATF before reassembly Replace the O rings and filters Install the filters in the direction shown CAUTION Do not use a magnet to remove the check balls it may magnetize the balls THROTTLE VALVE BODY LINEAR 34 SOLENOID ff DOWEL b d RB PIN i 2ND ACCUMULATOR COVER O RING THROTTLE d Replace SEPARATOR PLATE 1ST ACCUMULATOR COVER HAR
179. lty Replace it and recheck the voltages according to the chart on page 23 61 If there is no continuity at either terminal the side wire harness driver s side or the car main wire harness front passenger s side is faulty Replace the faulty harness and recheck the voltages ac cording to the chart on page 23 61 cont d 23 65 Supplemental Restraint System SRS Troubleshooting cont d 17 Connect Test Harness D between the dash sensor and SRS main harness 2 P connector Check con tinuity between the No 1 terminal and body ground and between the No 2 terminal and body ground SRS MAIN HARNESS DASH SENSOR DASH SENSOR 2 P CONNECTOR TEST HARNESS D 07LAZ SL40400 TEST HARNESS D 07LAZ SL40400 If there is continuity at either terminal the dash sensor is faulty Replace it and recheck the vol tages according to the chart on page 23 61 If there is no continuity at either terminal the SRS main harness is faulty Replace it and recheck the voltages according to the chart on page 23 61 18 Check the resistance between the left dash sensor terminals B12 and B16 and between the right dash sensor terminals B4 and B6 TEST HARNESS B 07MAZ SPO0500 23 66 If resistance is 3 8 4 2 for both sensors the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages according to the chart on page 23 61 If resistance is less than 3 8 for ei
180. lve Body 14 14 SUPPLEMENTAL RESTRAINT SYSTEM SRS The Legend Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in this shop manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda or Acura dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda or Acura dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits SHIFT CONTROL SOLENOID VALVE A B O RING Replace O RING Replace HARNESS CLAMP LINEAR
181. ly and can force all the air out of a small enclosed area 1 Always disconnect the negative cable from the battery whenever replacing air conditioning parts Keep moisture and dust out of the system When disconnecting any lines plug or cap the fittings immediately don t remove the caps or plugs until just before you reconnect each line 3 Before connecting any hose or line apply a few drops of refrigerant oil ND OIL 8 P N 38899 PR7 003 to the O ring When tightening or loosening a fitting use a second wrench to support the matching fitting When discharging the system don t let refrigerant escape too fast it will draw the compressor oil out of the system Add refrigerant oil ND OIL 8 P N 38899 PR7 003 after replacing the following parts ome NOTE Do not return the oil to the container once it is dispensed and never mix with other refrigerant oils to avoid contamination Immediately after using the oil replace the cap on the container and seal it to avoid moisture absorption Do not spill the refrigerant oil on the car it may damage the paint If the refrigerant oil contacts the paint wash it off immediately Condenser 30 ml 1 fl oz 1 1 Imp oz Evaporator 60 ml 2 fl oz 2 1 Imp oz Line or hose 10 ml 1 3 fl oz O 4 Imp oz Receiver Dryer 10 ml 1 3 fl oz 0 4 Imp oz Leakage rep
182. m SRS Connecting Short Connectors Connect the short connectors as follows whenever you 4 Connect an SRS short connector A special tool to are working near SRS wiring or components the cable reel side of the 3 P connector CAUTION Before disconnecting the airbag connectors turn off DRIVER S AIRBAG CABLE REEL the ignition switch and wait for at least three minutes ASSEMBLY 3 P CONNECTOR to let the capacitor in the back up circuit discharge This will prevent a malfunction of the seat belt preten sioners After completing repair work be sure to remove both short connectors SHORT 1 Disconnect the battery negative cable then discon Ce nect the positive cable 2 Remove the access panel from the steering wheel then remove the short connector RED from the panel SRS SHORT CONNECTOR A O7MAZ SP0020A DRIVER S AIRBAG CABLE REEL ASSEMBLY 3 P CONNECTOR 5 Remove the glove box then disconnect the connec tor between the front passenger s airbag SRS main harness 6 Connect the short connector RED to the airbag side of the 3 P connector FRONT PASSENGER S AIRBAG ASSEMBLY SRS MAIN HARNESS DRIVER S AIRBAG PANEL 3 P CONNECTOR SHORT CONNECTOR RED 3 Disconnect the 3 P connector between the driver s airbag and the cable reel then connect the short con nector RED to the airbag side of the connector FRONT PASSENGER S AIRBAG 3 P CONNECTOR SHORT CONNECTOR RE
183. m operation on the steering wheel Turn the ignition ON Il The instrument panel SRS indicator light should go on for about six se conds and then go off CABLE REEL 3 P CONNECTOR Make sure both horn buttons work Take a test drive and make sure the cruise con trol set resume cancel switch works CONNECTOR RED DRIVER S AIRBAG 3 P CONNECTOR ACCESS PANEL 10 Remove the short connectors RED from the seat belt pretensioners then attach them to their holders 11 Reconnect the side wire harness 3 P connector to the driver s seat belt pretensioner and the main wire harness 3 P connector to the front passenger s seat belt pretensioner SHORT CONNECTOR RED SEAT BELT CONNECTOR PRETENSIONER HOLDER 3 P CONNECTOR SIDE WIRE HARNESS 3 P CONNECTOR Driver s side MAIN WIRE HARNESS 3 P CONNECTOR Front passenger s side 23 78 Airbag Seat Belt Pretensioner Disposal Before scrapping any airbags or seat belt pretensioners including those in a whole car to be scrapped the air bags must be deployed and the seat belt pretensioners must be triggered If the car is still within the warranty period before deploying the airbags or triggering the seat belt pretensioners the Honda or Acura District Service Manager must give approval and or special instruction Only after the airbag is already deployed or a seat belt pretensi
184. manufactured piston ring Engine oil Engine Lubrication Section 8 MEASUREMENT Capacity US qt Imp qt Oil pump Inner to outer rotor radial clearance Housing to outer rotor radial clearance Housing to rotor axial clearance Pressure setting at oil temperature 80 C 176 F kPa kg cm psi at idie at 3 000 min rpm Relief valve 0 020 0 044 0 0008 0 0017 0 022 0 046 0 0009 0 0018 Unit of length mm STANDARD NEW SERVICE LIMIT 67 967 68 000 2 6762 2 6772 53 970 53 994 2 1248 2 1257 0 005 0 0002 max 0 004 0 0002 max 0 10 0 29 0 004 0 011 0 020 0 0008 max 0 010 0 0004 0 010 0 0004 0 45 0 018 0 030 0 0012 0 05 0 002 0 05 0 002 STANDARD NEW 70 0 7 10 min 350 3 5 50 min 5 0 5 3 4 4 for engine overhaul 4 7 5 0 4 1 for oil change including filter 4 0 4 2 3 5 for oil change except filter 0 04 0 16 0 002 0 006 0 20 0 008 0 10 0 18 0 004 0 007 0 20 0 008 0 02 0 07 0 001 0 003 0 12 0 005 SERVICE LIMIT Standards and Service Limits Cooling Section 10 STANDARD NEW M T 8 7 9 2 7 7 for overhaul 7 5 7 9 6 6 for coolant change A T 8 7 9 2 7 7 for overhaul 7 5 7 9 6 6 for coolant change 95 125 0 95 1 25 13 5 17 8 76 80 169 176 90 194 10 0 4 min 82 8 85 2 18
185. ment on these circuits CAUTION Be careful not to damage the SRS wire harness es when servicing the retractor Remove the short connector RED from the con nector holder and disconnect the SRS wire har ness connector then connect the short connector RED to the pretensioner connector NOTE To prevent contamination wrap the SRS wire harness connector with a protective cover CONNECTOR HOLDER PRETENSIONER CONNECTOR PROTECTIVE COVER SHORT CONNECTOR SRS WIRE RED HARNESS CONNECTOR SRS WIRE HARNESS CAUTION Check the seat belts for damage and replace them if necessary Be careful not to damage them during removal and installation 1 Remove the front seat and center pillar lower trim 2 Remove all three anchor bolts the retractor bolt and retractor mounting bolt then remove the seat belt and seat belt buckle NOTE When removing the anchor bolts and retractor bolt use a 17 mm socket or box end wrench CAUTION When removing the retractor do not touch the belt pretensioner CLIP SHOULDER ANCHOR ADJUSTER SEAT BELT RETRACTOR GUIDE MOUNTING DOOR TRIM BOLT 6 x 1 0 mm SRS WIRE 10 Nm HARNESS CENTER PILLAR 1 0 kg m 7 2 Ib ft UPPER TRIM 35 RETRACTOR RETRACTOR BOLT 7 16 20 UNF 33 N m 3 3 kg m 24 lb ft 8x 1 25 mm 22 Nem 2 2 kg m 16 Ib ft SEAT BELT UPPER ANCHOR BOLT BUCKLE 7 16 20 UNF 33 N m 3 3 kg m 24 Ib ft OS N d el
186. mm 49 N m 4 9 kg m 35 Ib ft Replace RIGHT ENGINE MOUNT BRACKET RIGHT BRACKET SPECIAL NUT 10 x 1 25 mm 49 N m 4 9 kg m RIGHT LEFT ENGINE 35 Ib ft MOUNT MOUNT BRACKET Replace SPECIAL NUT 10 x 1 25 mm 39 N m 3 9 kg m 28 ib ft Replace CENTER MOUNT BRACKET LEFT MOUNT 10 x 1 25 mm LEFT ERR oa EH BRACKET 39 N m 3 9 kg m 28 Ib ft i Replace 5 16 Additional Mount Bolts Torque Value Specifications REAR ENGINE FRONT ENGINE HANGER HANGER em 12 x 1 25 mm 75 N m 7 5 kg m 54 Ib ft 10 x 1 25 mm 10 x 1 25 mm 45 N m 4 5 kg m 45 N m 4 5 kg m 33 Ib ft 33 Ib ft P S PUMP BRACKET 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft ENGINE STIFFENER ALTERNATOR BRACKET 5 erg G 10 x 1 25 mm V 45 N m 4 5 kg m 12 x 1 25 mm D Install the bolts 33 Ib ft 75 N m 7 5 kg m 8 8 x 1 25 mm 54 Ib ft 22 N m 2 2 kg m 16 Ib ft cont d 5 17 Engine Removal Installation cont d Sub Frame Mount Bolts Torque Value Specifications CAUTION After loosening the special bolts be sure to replace them with new ones ex RIGHT FRONT BEAM BRACKE RACKET REAR BEAM 10 x 1 25 mm 39 N m 3 9 kg m body body LEFT FRONT BEAM BRIDGE RIGHT FRONT BEAM BRIDGE SPECIAL BOLTS 12 x 1 25 mm 60 N m 6 0 kg m 43 lb ft Replace LEFT FRONT BEAM BRACKET
187. mp oil 1 Connect the R 134a gauges as shown 2 Insert a thermometer in the center vent outlet Determine the relative humidity and ambient air temperature by a portable weather station or call ing the local weather station 3 Test conditions Avoid direct sunlight Open hood Open front doors Set the temperature control dial to MAX COOL push the mode control button to VENT and push the recirculation button Push the fan switch to MAX Run the engine at 1 500 rpm min No driver or passengers in vehicle 4 After running the air conditioning for 10 minutes under the above mentioned test conditions read the delivery temperature from the thermometer in the dash vent and the high and low system pressures from the A C gauges 5 To complete the charts Mark the delivery temperature along the vertical line Mark the intake air temperature ambient air temperature along the bottom line Draw a line straight up from the air temperature to the humidity level Mark a point one line above and one line below the humidity level 1096 above and 1096 below the humidity level From each point draw a horizontal line across to the delivery temperature The delivery temperature should fall between the two lines Complete the low side pressure test and high side pressure test in the same way Any measurements outside the line may indicate the need for further inspection THREE VA
188. n Before disconnecting any part of the SRS wire har ness install the short connectors see page 23 54 Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring RADIO REAR REMOTE SWITCH Removal page 23 31 Test page 23 31 Bulb Replacement page 23 32 STEREO RADIO DRIVER S DOOR SPEAKER CASSETTE PLAYER Unit Terminals page 23 30 REAR ARMREST REAR SPEAKER S FRONT PASSENGER S DOOR SPEAKER ANTENNA LEAD POWER ANTENNA MOTOR 23 28 Circuit Diagram UNDER DASH UNDER HOOD FUSE RELAY BOX IGNITION SWITCH FUSE BATTERY No 31 120A No 35 50 ant No 4 10 No 49 15A ANS ono WHT O O j WHT RED OND YEL RED WHT YEL RED BLK WHT YEL ANTENNA WHT YEL BLU GRN FRONT PASSENGER S DOOR RED GRN DRIVER S DOOR BRN BLK SPEAKER STEREO RADIO CASSETTE PLAYER ae LEFT REAR GRY WHT SPEAKER POWER ANTENNA MOTOR With the antenna retracted fully No 49 15A FUSE RED YEL RIGHT REAR BRN WHT SPEAKER sole he uL SECURITY BLK RED BLK CONTROL UNIT C RADIO REAR REMOTE SWITCH GRN GRN WHT U 1 G RED WHT i L L ORN 1 1 RED GRN D RED BLK BLK LT GRN DASH LIGHTS BRIGHTNESS CONTROL pe UNIT G551 G406 G601 G602 23 29 Stereo Sound System model Unit Terminals SH
189. n and grounds are securely attached NOTE All SRS electrical wiring harnesses are covered with yellow outer insulation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring CABLE REEL to DRIVER S SRS MAIN HARNESS to FRONT AIRBAG 3 P Connector PASSENGER S AIRBAG DASHBOARD WIRE HARNESS 3 P Connector to INDICATOR LIGHT in GAUGE ASSEMBLY LEFT DASH SENSOR to EES e Se MAIN WIRE HARNESS to SRS MAIN HARNESS to DASHBOARD WIRE HARNESS MAIN WIRE HARNESS 20 PConnector 3 P Connector RIGHT DASH SENSOR to MAIN WIRE HARNESS SRS MAIN HARNESS 2 P Connector FRONT PASSENGER S SEAT BELT PRETENSIONER to MAIN WIRE HARNESS 3 P Connector SRS MAIN HARNESS to UNDER DASH FUSE BOX 2 P Connector SRS UNIT SRS MAIN HARNESS GROUND to SIDE WIRE HARNESS 3 P Connector MAIN WIRE HARNESS to SRS MAIN HARNESS SIDE WIRE 5 P Connector DRIVER S SEAT BELT HARNESS PRETENSIONER to SIDE WIRE HARNESS 3 P Connector CABLE REEL to SRS MAIN HARNESS 7 P Connector TEST HARNESS SRS MAIN SOCKET HARNESS SOCKET 16 P Connector 18 P Connector 23 43 Supplemental Restraint System SRS General Precautions Carefully inspect any SRS part before you install it Do not install any part that shows signs of being dropped or improperly handled such as dents cracks or deformation Airbag assemblies Dash sensors Cable reel SRS unit Seat belt pretensioners Use
190. n car is slowed by increased grade wind etc 14 6 96 105 162 178 152 168 mph 101 111 984 104 KY KO KT models 04 Position Upshift Throttle angle sensor voltage 0 822 0 878 V 0 5 8 throttle Coasting down hill from a stop Throttle angle sensor voltage 2 175 2 325 V 3 5 8 throttle 1st 2nd 2nd 3rd 3rd 4th Lock up Clutch ON 115 124 Acceleration from a stop Full throttle 105 118 71 5 77 148 166 153 171 Acceleration from a stop 9 Downshift Throttle angle sensor voltage 0 822 0 878 V 0 5 8 throttle Lock up Clutch OFF Coasting or braking to a stop Throttle angle sensor voltage 2 175 2 325 V 3 5 8 throttle When car is slowed by increased grade wind etc Full throttle When car is slowed by increased grade wind etc 4 Accelerate to about 35 mph 57 km h so the transmission is in 4th then shift to 2 position The car should 65 73 5 4th 3rd 3rd 2nd 2 1st 3rd 1st 94 103 58 5 64 145 162 137 154 90 100 5 immediately begin slowing down from engine braking CAUTION Do not shift from or position to 2 1 position at speeds over 62 mph 100 km h you may damage the transmission 5 Check for abnormal noise and clutch s
191. nal Test condition BLU RED Ignition switch ON 11 Check window operation The power windows should work with key OFF Test Desired result Check for voltage to ground There should be battery voltage Faulty power window relay Poor ground G402 G403 An open in the wire Possible cause if result is not obtained Blown No 23 7 5 A fuse Faulty wiper intermittent relay An open in the wire Ignition switch ON 11 position and wiper switch at INT Check for voltage to ground There should be battery voltage Ignition switch ON 11 and washer switch pushed BLK YEL GRN YEL Intermittent dwell time control ring turned GRN WHT ignition switch ON 11 and wiper switch OFF Check for voltage to ground There should be battery voltage Check for resistance between the terminals It should vary from 0 Q to 30 kQ as the ring is turned Check for voltage to ground There should be battery voltage Blown No 23 7 5 A fuse Faulty wiper switch An open in the wire Blown No 23 7 5 A fuse Faulty washer switch An open in the wire Faulty intermittent dwell time controller An open in the wire Blown No 26 30 A fuse Faulty wiper motor automatic stop circuit An open in the wire 23 27 Stereo Sound System model Component Location Index CAUTION SRS wiring harnesses are covered with yellow outer insulatio
192. ndow defogger ground wire R SRS main harness Power antenna motor Left license plate light Right Right taillight assembly Cellular phone system Option Right rear fog light KE and KU models Trunk opener solenoid Trunk latch switch Security trunk latch switch With security system Trunk key cylinder switch With security system Left taillight assembly Trailer lighting connector Left rear fog light KE and KU models Rear fog light switch KE and KU models Front cigarette lighter Glove box light Clock Stereo radio cassette player Climate control unit Stereo radio cassette player With security system Rear window defogger SRS unit 23 15 Interlock System KO model Component Location Index CAUTION All SRS wiring harnesses are covered with yellow CONNECTOR Carries the SRS indicator signal outer insulation Before disconnecting any part of the SRS wire har ness install the short connectors see page 23 54 Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring SRS MAIN HARNESS Covered with yellow outer insulation INTERLOCK CONTROL UNIT Input Test page 23 19 KEY INTERLOCK SOLENOID SHIFT LOCK SOLENOID and KEY INTERLOCK SWITCH Test Replacement page 23 21 Built into the steering lock assembly Test page 23 20 SHIFT LEVER POSITION SWITCH 23 16 Description The car is eq
193. ne or hose 10 1 3 0 35 Reservoir 10 1 3 0 35 Compressor Lubricant capacity fl oz Imp oz 180105 63 6 32 01 Stator coil resistance at 20 C 68 F 2 3 4 3 8 Pulley to pressure plate clearance 0 35 0 65 0 014 0 026 Compressor Deflection with 100 N 10 22 Ibs 8 10 0 31 0 39 with used belt belt between pulleys 5 0 6 5 0 20 0 26 with new belt Belt tension N Kg tbs 400 600 40 60 88 132 with used belt Measured with belt tension gauge 800 1 000 80 100 176 220 with new belt When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values Electrical Section 23 MEASUREMENT Rated voltage V Primary winding resistance at 25 C 77 Q STANDARD NEW 12 1 0 1096 Refer to section 23 15 2 Red 9 5 11 5 0 37 0 45 with used belt 5 5 7 5 0 22 0 30 with new belt 400 600 40 60 88 132 with used belt 800 1 000 80 100 176 220 with new belt STANDARD NEW SERVICE LIMIT Ignition coil Spark Plug Ignition timing At idling Alternator Deflection with 100 N 10 kg 22 lbs between pulleys belt Belt tension kg ibs Measured with belt tension gauge MEASUREMENT Output A at 13 5 V hot and 6 000 alternator min rpm Brush length Type Output kW
194. ng the front and rear elevation mo After installing the front and rear elevation mo tors apply grease to the elevation lead screws tors apply liquid thread lock to the bolts then tighten them gt Bolt locations 2 6 x 1 0 mm 5 N m 0 5 kg m 3 6 lb ft ELEVATION LEAD SCREW REAR ELEVATION FRONT ELEVATION FRONT ELEVATION MOTOR MOTOR MOTOR H Make sure the connectors are connected properly FRONT ELEVTION SENSOR CONNECTOR Blue REAR ELEVATION SENSOR CONNECTOR Gray ELEVATION REAR ELEVATION LEAD SCREW 249 REAR MOTOR SS j ELEVATION REAR ELEVATION MOTOR CONNECTOR Brown FRONT ELEVATION MOTOR CONNECTOR Green Check the elevation lead screw for bend FRONT ELEVATION MOTOR Check the front and rear elevation motor operation 20 14 Slide Joint Cable Replacement CAUTION Wear gloves to remove and install the slide joint cable NOTE Take care not to scratch the seat covers Remove the front seat 1 Remove the slide joint cable NOTE Take care not to bend the slide joint cable SLIDE JOINT CABLE SLIDE MOTOR GEARBOX 0 38 kom Installation is the reverse of the removal procedure NOTE When installing the slide joint cable set the in ner cable securely SLIDE JOINT INNER CABLE Check that the slide motor and slide gearbox operate properly Recline M
195. nnect both the negative and positive battery cables Connect the short connectors before working around the dashboard lower panel or the dash sensors After any degree of frontal body damage inspect both dash sensors Replace a sensor if there are any signs of dents cracks or deformation DASH SENSOR Be sure the sensors are installed securely DASH SENSOR MOUNTING BOLTS 23 50 Inspection After Deployment After a collision in which the airbags and seat belt preten sioners were deployed inspect the following 1 Inspect the dash sensors for physical damage If the sensors are damaged replace them inspect all the SRS wire harnesses Replace don t repair any damaged harness Inspect the cable reel for heat damage If there is any damage replace the cable reel After the car is completely repaired turn the igni tion switch on If the SRS indicator light comes on for about six seconds and then goes off the SRS is OK If the indicator light does not function proper ly go to SRS Troubleshooting SRS 23 51 Troubleshooting Self diagnosis Function SRS Indicator Light Troubleshooting The SRS unit includes a self diagnosis function If there Possible conditions is a failure in the sensors SRS unit inflators or their cir 1 SRS indicator light does not come on at all see cuits the SRS indicator light in the gauge assembly page 23 56 comes ON
196. nsion Shaft Installer 07MAF PY40100 07746 0010600 Attachment 72 x 75 mm 07749 0010000 Driver Description Extension Shaft Puller Oty Page Reference 14 24 14 5 14 27 14 24 14 2 Description Hydraulic Flow Hydraulic flow has been changed DESCRIPTION OF PRESSURE pe rt DESCRIPTION OF PRESSURE DESCRIPTION OF PRESSURE LINE 1ST HOLD CLUTCH 1ST CLUTCH 1ST HOLD CLUTCH 1ST CLUTCH TORQUE CONVERTER 1ST CLUTCH TORQUE CONVERTER 2ND CLUTCH TORQUE CONVERTER LINE 3RD CLUTCH OIL COOLER TORQUE CONVERTER MODULATOR MODULATOR MODULATOR 56 MODULATOR 57 4TH CLUTCH LUBRICATION REVERSE CLUTCH THROTTLE B THROTTLE B X THROTTLE B TORQUE CONVERTER SUCTION MODULATOR 1ST HOLD CLUTCH 14 3 A T Speed Sensors Replacement KE KU KG KF KS KX models 1 Remove the 6 mm bolt from the transmission hous ing and remove the A T speed sensors NM and NC speed sensors Replace the O ring with a new one before reassem bling the A T speed sensors 6 x 1 0 mm 12 N m 1 2 kg m 9 ib ft NM SPEED SENSOR WASHER Thickness Replace 0 5 mm 0 02 in O RING Replace NOTE Install the washer to the NM speed sensor before reas
197. nt oil with any other refrigerant oil will result in compressor failure All A C system parts compressor discharge line suction line evaporator condenser receiver dryer expansion valve O rings for joints have to be proper to refrigerant R 134a Do not confuse with R 12 parts Use a halogen gas leak detector designed for refrigerant R 134a Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil Separate the manifold gauge sets pressure gauges hoses joints for refrigerants R 12 and R 134a Do not confuse them 22 2 Compressor Relief Valve Replacement Discharge the refrigerant 4 Remove the splash shield from below the engine 5 Remove the relief valve and the O ring from the compressor NOTE Be sure to use the right O rings for R 134a to avoid leakage CAUTION Be careful not to spill compressor oil and make sure there is no foreign matter in the system RELIEF VALVE 13 5 Nem 1 35 kg m 9 8 Ib ft Clean the mating surfaces Replace the O ring at the relief valve with a new one and apply a thin coat of refrigerant oil ND OIL 8 P N 38899 PR7 003 before installing the relief valve NOTE Do not return the oil to the container once it is dispensed and never mix it with other refrigerant oils to avoid contamination Immediately after using the oil replace the cap on the container and seal it to avoid moisture absorption D
198. nuity at any of the terminals go to step 13 if there is no continuity at any of the terminals go to step 6 Check continuity between body ground and each ter minal of both dash sensors TEST HARNESS B 07MAZ SPO0500 f there is continuity at any of the terminals go to step 17 If there is no continuity at any of the terminals go to step 18 7 Disconnect the cable reel 7 P connector from the SRS main harness then connect Test Harness C only to the cable reel side of the 7 P connector CABLE REEL 7 P CONNECTOR TEST HARNESS C 07MAZ SP00600 8 Check continuity between the No 4 terminal and body ground and between the No 5 terminal and body ground Continuity TEST HARNESS C 07MAZ SPOO600 f there is continuity at either terminal step 9 go to If there is no continuity at either terminal the SRS main harness is faulty Replace it and recheck the voltages according to the chart on page 23 61 cont d 23 63 Supplemental Restraint System SRS Troubleshooting cont d 9 Disconnect the driver s airbag 3 P connector from the cable reel then connect Test Harness C to the driver s airbag 3 P connector CABLE REEL 7P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR TEST HARNESS C 07MAZ SPO0600 10 Check continuity between the No 9 terminal and body ground and between the No 10 terminal and body ground TEST HARNESS C 07MAZ SPO0600
199. o not spill the refrigerant oil on the car it may damage the paint If the refrigerant oil contacts the paint wash it off immediately Install and tighten the relief valve Charge with R 134a refrigerant to the system and check for leaks Insert the cap into the top of the relief valve Install the splash shield 22 3 A C Service Tips The air conditioning system uses R 134a refrigerant and polyalkyleneglycol PAG refrigerant oil ND OIL 8 P N 38899 PR7 003 which are not compatible with R 12 refrigerant and mineral oil Do not use R 12 refrigerant or mineral oil in this system and do not attempt to use R 12 servicing equipment damage to the air conditioning system or your ser vicing equipment will result Separate the manifold gauge sets pressure gauges hoses joints for refrigerants R 12 and R 134a Do not confuse them When handling refrigerant R 134a always wear eye protection do not let refrigerant get on your skin or in your eyes If it does do not rub your eyes or skin splash large quantities of cool water into your eyes or on your skin rush to a physician or hospital for immediate treatment Do not attempt to treat it yourself keep refrigerant containers cans of R 134a stored below 40 1049F keep away from open flame Refrigerant although non flammable will produce poisonous gas if burned work in well ventilated area Refrigerant evaporates quick
200. on SRS wire harness is routed near the gearshift selector CAUTION All SRS electrical wiring harnesses are covered with yellow outer insulation Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring NOTE LHD is shown RHD is symmetrical Make sure lifts jacks and safety stands are placed properly see section 1 Apply parking brake and block rear wheels so the car will not roll off stands and fall while you are working under it 1 Remove the center console 2 Shift to R position then remove the lock pin from the cable adjuster LOCK PIN CABLE SHIFT CABLE LOCKNUT 7 N m 0 7 kg m 5 Ib ft 3 Remove the catalytic converter 4 Remove the exhaust pipe A cover then remove the exhaust pipe A NOTE Nuts in figure below are all self locking replace them when installing 8 x 1 25 mm 22 N m 10 x 1 25 mm 2 2 kg m 16 Ib ft 34 N m 10 x 1 25 mm 3 4 kg m 25 Ib ft 34 N m 3 4 kg m 25 Ib ft A CATALYTIC CONVERTEF GASKET Replace EXHAUST EXHAUST PIPE A PIPE A COVER 8 x 1 25 mm EXHAUST 22 Nem 2 2 kg m 16 lb ft PIPE A COVER 6 x 1 0 mm COVER 10 N m 1 0 kg m 7 Ib ft HOLDER 5 Remove the heat shields 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft HEAT HEAT SHIELD SHIELD 14 30 6 Remove the
201. oner is triggered as the result of vehicle collision for example can the normal scrapping procedure be done If the airbags or the seat belt pretensioners appear in tact not deployed or triggered treat them with extreme caution Follow the procedure described below Deploying the Airbags In car NOTE If an SRS car is to be entirely scrapped its air bags should be deployed while still in the car The air bags should not be considered as salvageable parts and should never be installed in another car Confirm that each airbag assembly is se curely mounted otherwise severe personal injury could result from deployment 1 Disconnect both the negative cable and positive ca ble from the battery 2 Confirm that the special tool is functioning properly by following the check procedure on the label of the tool set box or on page 23 83 Driver s Airbag 3 Remove the access panel then disconnect the 3 P connector between the airbag and the cable reel CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR ACCESS PANEL Passenger s Airbag 4 Remove the glove box then disconnect the 3 P con nector between the front passenger s airbag and SRS main harness FRONT PASSENGER S AIRBAG ASSEMBLY SRS MAIN HARNESS FRONT PASSENGER S AIRBAG 3 P CONNECTOR 5 Cut off the airbag connector then strip the wire ends and connect the special tool alligator clips to them Place the special tool approximately 10 m
202. only a digital circuit tester to check the system Using an analog circuit tester may cause an acciden tal deployment and possible injury Do not install used SRS parts from another car When repairing use only new SRS parts Except when performing electrical inspections always disconnect both the negative cable and positive ca ble at the battery before beginning work Replacement of the combination light wiper washer switches and cruise control switch can be done without removing the steering wheel 23 44 Airbag Handling and Storage Do not try to disassemble the airbag assembly It has no serviceable parts Once an airbag has been operated deployed it cannot be repaired or reused For temporary storage of the airbag assembly during serv ice please observe the following precautions Store the removed airbag assembly with the pad sur face up SHORT CONNECTORS RED WARNING If the airbag is improperly stored face down accidental deployment could propel the unit with enough force to cause serious injury Store the removed airbag assembly on a secure flat surface away from any high heat source exceeding 1009 C 212 F and free of any oil grease detergent or water CAUTION Improper handling or storage can internal ly damage the airbag assembly making it inoperative If you suspect the airbag assembly has been damaged install a new unit and refer to the Deployment Disposal Pro
203. orated RIGHT UPPER COVER COVER 6 x 1 0 mm 12 Nem 1 2 kg m RUBBER SEALS 9 ib ft Replace when damaged or deteriorated 6 x 1 0 mm Ka 12 N m 1 2 kg m 99 9 Ib ft 8 x 1 25 mm P S PUMP 22 N m 2 2 kg m 16 Ib ft BELT 6 1 A C COMPRESSOR BLET lee kom PULLEY BOLT 9 ib ft 16 x 1 5 mm O RING 240 N m 24 0 kg m Replace 174 Ib ft 8 x 1 25 mm Apply engine oil to the bolt threads and the surface that contacts the washer 22 N m 2 2 kg m 16 Ib ft ALTERNATOR BELT 10 x 1 25 mm HANDLE 10 x 1 25 mm 07JAB 0010200 SHOE 39 Nm 33 kgm 39 Nm 3 9 kg m PULLEY pod T 28 Ib ft Remove any oil CENTER BRACKET PULLEY HOLDER ATTACHMENT HEX 50 mm 07MAB PY30100 SOCKET WRENCH 19 mm 07JAA 0010200 CENTER 10 x 1 25 mm MOUNT 39 N m 3 9 kg m 28 Ib ft CORROSION RESISTANT BOLT 6 3 Timing Belt 1 2 Inspection Remove the left upper cover Remove the damper from the center bracket DAMPER 8x 1 25 mm 22 N m 2 2 kg m 16 Ib ft CENTER BRACKET Inspect the timing belt for cracks and oil or coolant soaking NOTE e Replace the belt if oil or coolant soaked Remove any oil or solvent that gets on the belt Inspect this area for wear Rotate pulley and inspect belt 6 4 Tension Adjustment CAUTION e Always adjust timing belt tension with the en
204. ot use electrical test equipment on these circuits Outline of Model Change The ECU has been modified P Idle Control System Idle Speed Setting Inspection Adjustment Non contact type Connect a tachometer to loop of igniter unit 1 Start the engine and warm it up to normal operating temperature the cooling fan comes on 2 Connect a tachometer IGNITER Contact type Remove the rubber cap from the tachometer con nector and connect a tachometer LHD TACHOMETER TACHOMETER 3 Set the steering in the straight ahead position and check idling in no load conditions in which the head lights blower fan rear defogger cooling fan and air conditioner are not operating All accessories turned off NOTE KS Remove No 12 RUNNING LIGHT 7 5 NS A fuse in the under dash fuse box then check that et the headlights and side marker lights are off Idle speed should be CONNECTOR RHD M T 650 50 min rpm A T 600 50 min 1 rpm N or P position TACHOMETER RUBBER CAP d A Za fe P 20 0 1 d RSA 8 Leen EK EA O Le SNS der EA NE eg LZ SZ TACHOMETER CONNECTOR 11 2 4 Connect the service check connector terminal with 5 Check the yellow LED display at the ECU under the a jumper wire dash on the passenger side LHD LHD YELLOW LED ECU SERVICE CHECK CONNECTOR 2P
205. ountershaft 2nd gear Countershaft reverse gear Reverse idler gear Secondary gear shaft taper roller bearing preload starting torque N m kg cm Ib in Thrust washer 90 mm thickness torque converter housing side Thrust shim 75 mm thickness 3 10 MMNMNNNNMNNNNNNNNNSOSaaaanauaunauuaoao 59 000 59 016 2 3228 2 3235 40 000 40 016 1 5748 1 5754 39 000 39 016 1 535 1 536 54 000 54 016 2 126 2 127 44 020 44 036 1 733 1 734 44 000 44 016 1 732 1 733 39 000 39 016 1 535 1 536 18 007 18 020 0 7089 0 7094 0 03 0 18 0 001 0 007 0 0 08 0 0 03 0 06 0 16 0 002 0 006 0 10 0 25 0 004 0 010 0 02 0 12 0 001 0 005 0 0 08 0 0 03 0 07 0 15 0 003 0 006 0 05 0 16 0 002 0 006 0 03 0 30 0 001 0 012 3 5 4 5 35 45 30 39 0 99 1 01 0 039 0 040 56 1 58 0 061 0 062 59 1 61 0 0626 0 0634 62 1 64 0 064 0 065 65 1 67 0 065 0 066 68 1 70 0 066 0 067 71 1 73 0 067 0 068 74 1 76 0 0685 0 0693 77 1 79 0 0697 0 0705 80 1 82 0 071 0 072 83 1 85 0 072 0 073 86 1 88 0 073 0 074 89 1 91 0 074 0 075 92 1 94 0 0756 0 0764 95 1 97 0 077 0 078 98 2 00 0 078 0 079 01 2 03 0 079 0 080 04 2 06 0 080 0 081 07 2 09 0 081 0 082 10 2 12 0 0827 0 0835
206. ower steering pump belt Cooling system hoses and connections Radiator coolant Engine coolant Transmission oil Front differential oil Engine Non Emission Related Timing Belt Water pump Catalytic converter heat shield For cars with catalytic converter j Exhaust pipe and muffler e Day to day care engine oil ATF and coolant level should be done practically according to the owner s manual by the customer O Under severe driving conditions service these items more often 1 Replace every 6 years or 100 000 km 60 000 miles whichever comes first 2 Thereafter replace every 2 years or 40 000 km 24 000 miles whichever comes first CAUTION Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil 4 4 R Replace Inspect After inspection clean adjust repair or replace if necessary Service at the interval listed x 1 000 km or miles or after that number of months whichever comes first Brake Non Emission Related Anti lock brake system high pressure hose Anti lock brake system operation Inspect system 10 years after first
207. re does not reach more than vacuum pump If the system has been open for 700 mmHg 27 in Hg in 15 minutes there is pro several days the receiver dryer should be bably a leak in the system Check for leaks and replaced repair see Leak Test 2 Connect a R 134a refrigerant gauge pump and 4 If there are no leaks open the valves and continue refrigerant containers cans of R 134a as shown pumping for at least another 15 minutes Then close both valves and stop the pump NOTE Do not open the cans 3 Start the pump then open both pressure valves and the evacuation valve in case of two valve THREE VALVE GAUGE TWO VALVE GAUGE EVACUATION VALVE LOW PRESSURE HIGH PRESSURE LOW PRESSURE VALVE VALVE HIGH PRESSURE EVACUATION STOP VALVE VACUUM PUMP CHECK VALVE CHECK VALVE DI eee HIGH PRESSURE QUICK JOINT LOW PRESSURE LOW PRESSURE QUICK JOINT QUICK JOINT INNER DIAMETER mm 22 6 Charging NOTE Only use a gauge set for refrigerant R 134a Use vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil When handling refrigerant R 134a always wear eye protection do not let refrigerant get on your skin or in your eyes If it does do not rub your eyes or skin splash large quantities of cool water into
208. res have been changed The front seat linkage replacement procedure has been changed The rear power seat with slide adjuster has been added KY KT models Special Tools Tool Number Description Oty Page Reference O7MAZ SP00200 SRS Short Connector 2 20 21 22 20 2 Front Seat Linkage Index Fully power adjustable with memory RECLINE MOTOR Replacement page 20 7 POWER SEAT RECLINE ADJUSTER SWITCH Replacement page 20 4 SLIDE ELEVATION ADJUSTER Replacement page 20 4 IO RECLINE MEMORY SWITCH Replacement page 20 15 SPRINGS SLIDE GEARBOX SC Replacement page 20 8 LOWER CAP FRONT ELEVATION MOTOR Replacement P P ai REAR ELEVATION page 20 11 MOTOR Replacement page 20 11 Replacement page 20 15 Replacement page 20 8 SEAT MEMORY ue CONTROL UNIT HARNESS PROTECTOR 20 3 Front Seat Linkage Recline Adjuster Slide Elevation Adjuster Replacement CAUTION Wear gloves to remove and install the recline adjuster and slide elevation adjuster NOTE Take care not to scratch the seat covers To separate the recline adjuster and slide elevation adjuster elevate the seat cushion at the front and rear Remove the front seat Remove the seat cushion and seat back 1 Remove the power seat switch gt Screw locations 2 M Loosen the mounting POWER SEAT screw SWITCH Disconnect th
209. rroneous operation of the control units The antenna and the body of the radio must be at least 200 mm 7 9 in away from the control units The control unit locations Refer to the Base Shop Manual 62SPOOO section 23 for Relay Control Unit Locations Do not lead the antenna feeder and the coaxial ca ble over a long distance parallel to the car s wiring When crossing the wiring is required execute crossing at a right angle Do not install a radio with a large output max 10 W CAUTION Observe all safety precautions and notes while working Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover Apply liquid gasket to the transmission oil pump rear Work safely and give your work your undivided atten cover and water outlet Use HONDA genuine liquid gasket Part No OY740 99986 tion When either the front or rear wheels are to be raised block the remaining wheels securely Commu nicate as frequently as possible when a work involves two or more workers Do not run the engine unless the shop or working area is well ventilated Check that the mating surfaces are clean and dry before applying liquid gasket Degrease the mat ing surfaces if necessary Apply liquid gasket evenly being careful to cover all the mating surface To prevent leakage of oil apply liquid gasket to the inner threads of the bolt holes Do not apply liquid gas
210. s TRANSMISSION HOUSING DRIVE PLATE ENGINE STIFFENER 26 mm SHIM TORQUE CONVERTER COVERS 28 Pull the transmission away from the engine until it clears the dowel pin then lower it on the transmmis sion jack 14 11 Illustrated Index Rear Cover SE 14 12 EE EE EE EE STEEL BALL ONE WAY BALL SPRING SEALING WASHER Replace O RING Replace REVERSE ACCUMULATOR PISTON O RING Replace REVERSE ACCUMULATOR SPRING O RINGS Replace REVERSE ACCUMULATOR SLEEVE SNAP RING THRUST WASHER 14 x 30 mm NEEDLE BEARINGS REVERSE IDLER GEAR THRUST WASHER 14 x 25 mm REVERSE IDLER GEAR SHAFT DOWEL PIN REVERSE IDLER GEAR SHAFT HOLDER SEALING BOLT 34 x 1 25 mm SNAP RING 1ST HOLD ACCUMULATOR SLEEVE O RING Replace 1ST HOLD ACCUMULATOR SPRING 1ST HOLD ACCUMULATOR PISTON O RING Replace REAR COVER 2ND CLUTCH FEED PIPE O RING Replace FEED PIPE GUIDE SNAP RING REVERSE CLUTCH FEED PIPE O RING Replace FEED PIPE GUIDE O RING Replace OIL FEED GUIDE SNAP RING FEED PIPE FEED PIPE O RING Replace OIL PIPE REAR COVER GASKET Replace DOWEL PIN MAINSHAFT LOCKNUT 24 x 1 25 mm Replace WASHER 24 mm Replace TORQUE SPECIFICATIONS Torque Value 12 Nem 1 2 kg m 9 Ib ft 27 Nem 2 7 kg m 20 Ib ft 18 Nem 1 8 kom 13 Ib ft 130 N m 13 0 kg m 94 Ib ft 130 Nem 13 0 kg m 94 Ib ft 40 N m 4 0 kg m 29 Ib ft 600600868668 606
211. s door wire harness cont d Side wire harness Driver s door wire harness Dashboard wire harness Blower wire harness 23 7 Ground Distribution LHD Circuit Identification cont d s BLK s BLK Power seat control unit a BLK Left rear door lock knob switch Left rear door switch Left rear power seat switch KY model a BLK Left rear ashtray light G521 BLK Power antenna motor Left Right Right taillight assembly Cellular phone system Option Right rear fog light European model license plate light BLK Trunk opener solenoid Trunk latch switch Security trunk latch switch With security system Trunk key cylinder switch G551 With security system Left taillight assembly Trailer lighting connector Left rear fog light European model Shift lever position switch With security system Cigarette lighter Glove box light M Stereo radio cassette player LT GRN as Stereo radio cassette player With security system pe BLK M M Rear window defogger SRS unit R BLK F Side wire harness 0 Left rear door wire harness Shielded wire Dashboard wire harness R SRS main harness Rear wire harness s Driver s power seat wire harness Rear window defogger ground wire 23 8 Ground Distribution RHD Circuit Identification BLK E md Ba
212. sembling the NM speed sensor 14 4 Replacement KY KQ KT models 1 Remove the 6 mm bolt from the transmission hous ing and remove the A T speed sensors NM and NC speed sensors 2 Replace the O ring with a new one before reassem bling the A T speed sensors 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft NM SPEED SENSOR SN 22 YC CT ee sd ve NC SPEED a SE a as SENSOR O RING iu c Thickness ers IS l 2 1 mm 0 08 in O RING Replace WASHER NOTE Install the washer to the NC speed sensor before reassembling the NC speed sensor Road Test NOTE Warm up the engine to operating temperature the radiator fan comes on Apply parking brake and block the wheels Start the engine then move the selector lever to position while depressing the brake pedal Depress the accelerator pedal and release it suddenly Engine should not stall Repeat same test in position Shift the selector lever to position and check that the shift points occur at approximate speeds shown Also check for abnormal noise and clutch slippage NOTE Throttle angle sensor voltage represents the throttle opening 1 Connect the Test Harness between the ECU and connector 2 Set the digital circuit tester to check voltage between D11 terminal and D22 terminal for the throttle angle sensor CAUTION All SRS electrical wiring harnesses are covered with yellow outer insulation Before disconn
213. skin cancer if repeated ly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil lt LJ sell 4 3 Maintenance Schedule R Replace I Inspect After inspection clean adjust repair or replace if necessary Service at the interval listed x 1 000 km or miles or x 1 000 km after that number of months whichever comes first x 1 000 miles months Emission Related 48 54 60 54 60 For European type KO and KU B Air cleaner element Except for European type KO and KU Except for KX KS For KX KS E Idle speed and idle CO HE D For cars with catalytic converter EN E G R system For cars without catalytic converter E G R filter Secondary air supply system For cars with catalytic converter Evaporative emission control system Ignition timing Except for KX KS For KX KS Positive crankcase Except for KX KS SERES ventilation valve For KX KS Fuel filter Tank fuel line and connections Spark plugs For cars with catalytic converter For cars without catalytic converter I Engine oil and oil filter Alternator drive belt P
214. t could HONDA investigate all such ways Anyone using service procedures or tools whether or not recommended by HONDA must satisfy him self thoroughly that neither personal safety nor vehicle safety will be jeopardized All information containes in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publica tion may be reproduced stored in retrieval System or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables ere marked sections are not included in this manual First Edition 12 92 280 pages Rights Reserved HONDA MOTOR CO LTD Service Publication Office Suspension Brakes Including ABS Heater and Air Conditioning Electrical Including SRS As sections with include SRS components special precautions are required when servicing Outline of Model Changes DESCRIPTION MODELS REFERENCE SECTION Automatic Transmission Changed Engine mounts brackets and Transmission mounts brackets 5 6 14 ECU modified 11 Changed Gearshift points and Torque value of locknuts Modified Gearshift selector KO Hydraulic flow circuit A T speed sensor Valve bodies and Rear cover
215. teer ing gearbox mounting bolts on the RHD are sym metrical Corrosion resistant bolt Reinstall these bolts LOWER PLATE 17 Remove the shift cable guide CAUTION Take care not to bend the shift cable 18 Remove the transmission beam rear transmission mount bracket mount and exhaust pipe stay REAR TRANSMISSION MOUNT BRACKET MOUNT SHIFT CABLE GUIDE TRANSMISSION PIPE STAY BEAM EXHAUST 19 Shift to P position rotating the control shaft 20 Remove the secondary cover and 36 mm sealing bolts 14 10 21 Remove the extension shaft from the differential us ing the special tool as shown EXTENSION SHAFT PULLER S 07LAC PW50101 or 3 07LAC PW50100 36 mm SEALING BOLT SECONDARY COVER SECONDARY GEAR SHAFT EXTENSION SHAFT PULLER 07LAC PW50101 or O7LAC PW50100 EXTENSION SHAFT 22 Place a jack under the transmission and raise the transmmission just enough to take weight off of the mounts then remove the mid mounts 23 Remove the transmission housing mounting bolts TRANSMISSION HOUSING MOUNTING BOLTS 4 TRANSMISSION HOUSING MOUNTING Remove the engine stiffener 25 Remove the torque converter covers 26 Remove the drive plate bolts one at a time while rotating the crankshaft pulley NOTE If necessary remove the spark plugs when rotating the crankshaft pulley 27 Remove the transmission housing mounting bolt
216. the mount ed position The seat belt should lock when the retractor is leaned over 40 CAUTION Do not attempt to disassemble the retractor Mounted Position RETRACTOR Forward Inside s 20 20 Dashboard Replacement SRS wire harnesses are routed near the dashboard and steering column CAUTION SRS wiring harnesses are covered with yel low outer insulation Before disconnecting any part of the SRS wire harness connect the short connectors see page 23 54 Replace the entire affected SRS harness assem bly if it has an open circuit or damaged wiring FRONT PASSENGER S AIRBAG RIGHT DASH SENSOR T RETRACTOR SEAT BELT PRETENSIONER SRS UNIT LEFT DASH SENSOR SRS MAIN HARNESS 1 To remove the dashboard first remove the Front seats Center console panel Center armrest Stereo radio cassette Glove box lower panel Glove box Left glove box cover Dashboard lower cover Kick panel 2 Lower the steering column see section 17 To avoid accidental deployment and possible injury always install the short connector on the airbag connector when the SRS wire harness is disconnected NOTE Remove the access panel then remove the short connector RED Disconnect the connector be tween the airbag and cable reel then connect the short connector RED to the airbag connector CABLE REEL CONNECTOR
217. the switch plate take care SWITCH not to damage the memory switch Make sure the connector is connected properly Check the recline adjuster operation 20 7 Front Seat Linkage Slide Motor Slide Gearbox Replacement CAUTION Wear gloves to remove and install the slide if necessary slide the lower rails on both side motor and slide gearbox backward fully as follows NOTE Take care not to scratch the seat covers remove the slide motor and slide gearbox slide the SCREWDRIVER ockwise front seat forward fully Remove the front seat Remove the seat cushion 1 Remove the slide joint cable NOTE Take care not to bend the slide joint cable SLIDE LEAD SCREW Disconnect the connectors GEARBOX 3 8 N m 0 38 kg m 2 7 tb ft 20 8 2 Remove the bolts and nuts gt Bolt locations 8 NUT 8 x 1 25 mm 2 Nem 0 2 kg m 1 4 Ib ft SLIDE GEARBOX SLIDE MOTOR 3 Remove the slide motor and slide gearbox as shown NOTE Take care not to damage the slide lead Screws SLIDE LEAD SCREW SLIDE GEARBOX SLIDE MOTOR SLIDE LEAD SCREW cont d 20 9 Front Seat Linkage Slide Motor Slide Gearbox Replacement cont d 4 Installation is the reverse of the removal procedure When installing the slide motor and slide gearbox make sure the end of the slide lead screw is set NOTE properly
218. ther sensor go to step 19 19 Connect Test Harness D between the dash sensor and SRS main harness 2 P connector Check the resistance between the No 1 terminal and No 2 terminal SRS MAIN HARNESS DASH SENSOR DASH SENSOR 2 P CONNECTOR TEST HARNESS D 07LAZ SL40400 TEST HARNESS D O7LAZ SL40400 3 8 4 2 kQ If resistance is 3 8 4 2 the SRS main harness is faulty Replace it and recheck the voltages according to the chart on page 23 61 If resistance is less than 3 8 the dash sensor F is faulty Replace it and recheck the voltages ac L cording to the chart on page 23 61 SRS Mode C Short in one cowl sensor contact or open in 3 Connect Test Harness D between the dash sensor both dash sensors and SRS main harness 2 P connector Check the Mode D Open in one dash sensor resistance between the No 1 terminal and No 2 terminal 1 Before disconnecting any part of the SRS wire har ness connect the short connectors see page 23 54 2 Connect the Test Harness B between the SRS unit SRS MAIN HARNESS and the SRS main harness 18 P connector Check the resistance between the left dash sensor termi nals B12 and B16 and between the right dash sen sor terminals B4 and B6 DASH SENSOR SRS UNIT DASH SENSOR 2 P CONNECTOR TEST HARNESS B A TEST HARNESS D 07MAZ SPO0500 07LAZ SL40400 TEST HARNESS D 07LAZ SL40400 SRS MAIN HARNESS TEST HARNESS B
219. tion key to O LOCK position or remove the key from the ignition so that the steering wheel will not turn Rotate the cable reel clockwise until it stops Then rotate it counterclockwise approximately two turns until The yellow gear tooth lines up with the alignment mark on the cover CABLE REEL The arrow mark on the cable reel label points HARNESS straight up CONNECTOR HOLDER SRS MAIN HARNESS Do not replace the original steering wheel with any other design since it will make it impossible to properly install CABLE REEL the airbag only use genuine Honda replacement parts LABEL ALIGNMENT MARK After reassembly confirm that the wheels are still turned straight ahead and that the steering wheel spoke angle is correct If minor spoke angle adjustment is necessary do so only by adjusting of the tie rods not by removing and repositioning the steering wheel YELLOW GEAR TOOTH 23 46 Wiring Precautions Never attempt to modify splice or repair SRS wiring NOTE SRS wiring can be identified by special yel low outer protective covering Be sure to install the harness wires so that they are not pinched or interfering with other car parts Make sure all SRS ground locations are clean and all ground terminals are tightly fastened for optimum metal to metal contact Poor grounding can cause in termittent problems that are difficult to dia
220. ts on Reminder System No Terminal Test condition Driver s door open Check for voltage to ground Faulty ignition key switch There should be 1 V or less Poor ground G402 G403 An open in the wire Test Desired result Possible cause if result is not obtained Check for continuity to ground Faulty driver s door switch There should be continuity An open in the wire NOTE Before testing remove No 57 15 A fuse Combination light switch ON Connect the A14 terminal to the BLU terminal Check for voltage to ground Blown No 49 15 A fuse There should be battery voltage Faulty combination light switch Faulty taillight relay An open in the wire Check chime operation Chime Faulty chime should sound each time the An open in the wire battery is connected cont d 23 25 Integrated Control Unit KY model Input Test cont d GRN WHT GRN WHT BLK A1 A2 A3 A4 A5 A6 A7 WS Se GRN WHT WHT BLK Ri du View from ea el e eie c wire side GRN YEL BLU RED BLU BLU WHT A8 A9 A10 A11 A12 A13 A14 BLU YEL GRN WHT Seat Belt Reminder System No Terminal Test condition Test Desired result Possible cause if result is not obtained BLU YEL Ignition switch ON 11 Check for voltage to ground Faulty driver s seat belt switch and driver s seat belt There should be 1 V or less Poor ground G402 G403 not buckled An open in the wire Entry Li
221. ttery Engine cylinder block Q G1 BLK Right valve cover Q G2 ECU BRN BLK HF38 BRN BLK BRN BLK BLK ngine oil temperature sensor Neutral position switch M T BLK BLK ECU main relay BRN BLK BRN BLK ECU BLK BLK G101 Right heated oxygen SC RED BLU dE EE RED BLU 9 RED BLU S E RED BLU Leftheated oxygen WHT E z sensor roms nM H ET Tee i BLU YEL i E BLU YEL BLU GRN E BLU GRN CYL sensor 1 WHT BLU E WHT BLU ECU ORN BLU E ORN BLU he atarax E a mm mm pn mm mm d em em zm mm mm vm sl ce 4 Sage e m a i WHT BLU r E WHT BLU Crank angle ORN BLU E ORN BLU SE eent C wHT E WHT 1 ORN BRN BLK NM speed E ORN sensor E WHT eS r See Se ECU NC speed BLU GRN E BLU GRN sensor BLU YEL E BLU YEL bee e rs meee Le jJ Battery ground cables D Engine compartment wire harness Shielded wire Engine ground wire E Main wire harness x Execpt KT Engine wire harness A T sub harness cont d 23 9 Ground Distribution RHD Circuit Identification cont d H D BLK ns D BLK D BLK D BLK 8 D BLK 0 e D BLK l e D B
222. tween ECU A20 and the 2P connector If wire is OK substitute a known good ECU and recheck If symp tom goes away replace the origi nal ECU Inspect vacuum hose routing OK replace purge control solenoid valve cont d 11 9 Emission Control System Evaporative Emission Controls cont d From page 11 9 LHD RHD VACUUM PRESSURE GAUGE 0 4 in Hg 0 100 mm Hg Connect a vacuum pressure gauge to purge air hose PURGE HOSE Start the engine and raise speed to 3 500 rpm Connect a vacuum pressure gauge to the purge hose and raise the engine speed to 3 500 min rpm Does vacuum appear on gauge within 1 minute plete Evaporative emission controls are OK YES Replace the charcoal canister d 11 10 VACUUM PRESSURE GAUGE 0 4 in Hg 0 100 mm Hg PURGE AIR HOSE NO Inspect the purge hose appear the and throttle body port See two way valve test to com gaugs for pinch or blockage SUPPLEMENTAL RESTRAINT SYSTEM SRS If automatic transmission maintenance is re quired The Legend Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service t
223. ty of Automotive Engineers B or BAT Battery SW Switch BTDC Before Top Dead Center SOHC Single Overhead Camshaft CATA Catalytic Converter SOL V Solenoid Valve CPC Clutch Compressor Control SRS Supplemental Restraint System EACV Electronic Air Control Valve 4 g O Top Dead Center lt z ECU Electronic Control Unit for Fuel Injection Vehicle Identification Number System and or Automatic Transmission Control System P Parking EGR Exhaust Gas Recirculation R Reverse EX Exhaust N Neutral GND Ground Drive Position 1st 4th LD Inside Diameter Drive Position 1st 3rd IG Ignition Fixed 2nd speed IN Intake Fixed 1st speed INT Intermittent o 4 Low gear L Left 2ND Second gear LHD Left Hand Drive 3RD Third gear M T Manual Transmission 4TH Fourth gear O D Outside Diameter 5TH Fifth gear Positive Crankcase Ventilation 1 28 Special Tools Individual tool lists are located at the front of each section Specifications Standards and Service Limits Design Specifications Body Specifications Standards and Service Limits Cylinder Head Valve Train Sections 6 MEASUREMENT Compression 200 min 1 rpm and wide open throttle Nominal Minimum Maximum variation Cylinder head Warpage Height Camshaft End play Total runout Cam lobe height Valve Valve clearance Valve stem O D Stem to guide clearance Valve seat Width Stem installed height
224. udes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in this shop manual Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda or Acura dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda or Acura dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits Outline of Model Changes The front passenger s airbag and seat belt pretensioners have been added The dashboard replacement procedure has been changed The front seat belt replacement inspection procedu
225. uipped with the following devices to pre vent inadvertent shifting Shift lever with shift lock Key cylinder with interlocked ignition key Shift Lock System The shift lock system prevents the shift lever from mov ing to R or D from position P unless you step on the brake pedal NOTE In case of system malfunction the shift lever can be released by pushing a key into the release slot near the shift lever SHIFT LEVER SHIFT LOCK LOCK PIN SOLENOID OFF LOCK rS SHIFT LOCK SD S LEVER LOCK PIN SHIFT LOCK SOLENOID ON UNLOCK RELEASE LEVER SHIFT LOCK LEVER KEY LOCK PIN RELEASE LEVER SHIFT LOCK LEVER Key Interlock System The ignition key cannot be removed from the ignition switch unless the shift lever is in P When the shift lever is in any position other than P a solenoid is activated making it impossible to remove the key until the lever is moved to P The shift lever is in the P position KEY CYLINDER SOLENOID OFF The shift lever is in any position except P KEY CYLINDER SOLENOID ON 23 17 Interlock System KO model Circuit Diagram IGNITION UNDER DASH WITCH FUSE BOX SWIT BAT WHT BLK YEL 161 BACK UP WHT GRN LIGHTS BRAKE WHT GRN WHT GRN BRAKE GRN WHT YEL UNDER HOOD FUSE RELAY BOX No 31 120A No 35 50A e ses ON Q BATTERY WHT GRN HORNS
226. ulator 21 Disconnect the brake booster vacuum hose VACUUM HOSE Ch gt SN FUEL FEED HOSE SEALING BOLT WASHER 2 s M 22Nm 2 2kg m Replace E uS 16 Ib ft BR a Q BL 7 FUEL PRESSURE SCH REGULATOR el Ne 2 EEE Ne PURGE HOSE FUEL RETURN BRAKE BOOSTER HOSE VACUUM HOSE 22 Disconnect the automatic transmission sub harness connector then remove the harness clamp 6x 1 0 mm 10 N m 1 0 kg m 7 Ib ft CONNECTOR RHD 24 Relieve fuel pressure by slowly loosening the ser vice bolt on the fuel filter about one turn Do not smoke while working on the fuel system Keep open flame away from work area Drain fuel only into an approved container CAUTION Before disconnecting any fuel line the fuel pres sure should be relieved as described above Place a shop towel over the fuel filter to prevent pressurized fuel from spraying over the engine 25 Disconnect three connectors then remove the con trol box e Do not disconnect the vacuum hoses 26 Remove the fuel return hose 6x 1 0 mm 10 N m 1 0 kg m 7 Ib ft AQ S CONTROL BOX FUEL RETURN HOSE CONNECTORS 27 Remove the fuel feed hose 28 Disconnect the brake booster vacuum hose 29 Disconnect the automatic transmission sub harness connector then remove the harness clamp SEALING BOLT 22 N m 2 2 kg m 16 Ib ft WASHER Replace BRAKE BOOSTER VACUUM HO
227. urther increase the effectiveness of the seat belt In a front end collision the pretensioner instantly retracts the belt firmly to secure the occupants in their seats LHD RHD FRONT PASSENGER S FRONT PASSENGER S D DRIVER S SEAT BELT AIRBAG ASSEMBLY PRETENSIONER AIRBAG ASSEMBLY SEAT BELT PRETENSIONER RIGHT DASH SENSOR SRS UNIT RIGHT DASH SENSOR SRS UNIT LEFT DASH SENSOR DRIVER S SEAT BELT LEFT DASH SENSOR DRIVER S PRETENSIONER FRONT PASSENGER S FRONT PASSENGER S AIRBAG ASSEMBLY AIRBAG ASSEMBLY SEAT BELT PRETENSIONER Operation As shown in the diagram below the left and right dash sensors are connected in parallel The parallel set of sensors is connected in series to each airbag inflator circuit and the car battery In addition a back up power circuit is connected in parallel with the car battery The back up power circuit and the cowl sensor are located inside the SRS unit For the SRS to operate 1 One or both cowl sensor contacts and one or both dash sensors must activate 2 Electrical energy must be supplied to the airbag inflators by the battery or the back up power circuit if the bat tery voltage is too low 3 Airbag and seat belt pretensioner charges must be released Then the airbags will deploy and the pretensioners will activate It takes about O 1 second from the beginning of the airbags deployment until they are completely deflated SRS INDICATOR CIRCUIT 4 onvers SEAT BELT PRETENSIONER
228. voltages 4 First check for voltage between Test Harness Ter minal No 12 and ground If voltage is indicated there is a poor ground see page 23 75 If no voltage is indicated continue with check ing all the other terminals Record your voltage readings for each terminal in the row of blank boxes near the top of the chart Compare each reading with the voltage ranges list ed in the column below it If the reading is within a range circle that range If you circled all the Failure Mode ranges across any row check the car for the Probable Failure Mode listed at the end of the row Refer to the letter for that mode on the following pages If you did not circle all the ranges across any row replace the SRS unit with a known good unit and retest If all your voltage readings are now Normal replace the original SRS unit If your voltage readings are still not Normal but they don t match a complete row of Failure Mode ranges check the condition of the SRS connectors shown in the system diagram on page 23 42 23 60 NOTE Do not disconnect the airbags when checking SRS unit voltages Test Harness Terminal Normal Voltage Your Voltage Reading 10 5 14 5 4 5 5 5 12 0 14 0 10 5 10 5 14 5 14 5 12 0 10 5 14 0 14 5 7 1 7 1 9 5 9 5 12 0 10 5 Failure Mode 14 0 14 5 Probable Failur
229. wn No 39 20 fuse to ACC 1 and the key There should be battery voltage Faulty steering lock assembly key interlock solenoid An open in the wire 23 19 Interlock System KO model Key Interlock Solenoid Test 1 Remove the dashboard lower cover 4 Check that the key cannot be removed with power and ground connected to the A and C terminals 2 Disconnect the 8 P connector from the main wire harness f the key cannot be removed the key interlock solenoid is OK f the key can be removed replace the steering lock assembly key interlock solenoid is not avail able separately 8 P CONNECTOR 3 Check for continuity between the terminals in each switch position according to the table Ignition switch 23 20 Shift Lock Solenoid Test Replacement Test 1 Remove the console then disconnect the 2 P con nector of the shift lock solenoid from the side wire harness NOTE This solenoid has a diode in it To get an ac curate reading either test it with a volt ohmmeter that compensates for diodes or make sure you con nect your test leads to match the polarity shown SOLENOID Connect battery power to the A terminal ground the B terminal momentarily and check to see if the sole noid works If the solenoid does not work replace it NOTE When the shift lock solenoid is ON check th
230. y a jack 2 When lifting the rear of the car put the gearshift Never attempt to use a bumper jack for lifting or sup lever in reverse Automatic in P position porting the car 3 Raise the car high enough to insert the safety stands 4 Adjust and place the safety stands as shown on page 1 21 so the car will be approximately level then lower the car onto them Front Center the jack bracket in the middle of the jack lift platform JACK LIFT PLATFORM Rear Center the jack bracket in the middle of the jack lift platform JACK LIFT PLATFORM 1 20 Safety Stands e d A nt D gt Of pepe ez PAY ee SS Lem GH 1 21 Towing If the car needs to be towed call a professional towing service Never tow the car behind another car with just a rope or chain It is very dangerous Emergency Towing There are three popular methods of towing a car Flat bed Equipment The operator loads the car on the back of a truck This is the best way of transporting the LEGEND Wheel Lift Equipment The tow truck uses two pivot ing arms which go under the tyres front or rear and lifts them off the ground The other two wheels remain on the ground Sling type Equipment The tow truck uses metal ca bles with hooks on the ends These hooks go around parts of the frame or suspension and the cable lift that end of the car off the ground The car s suspension and
231. ystem SRS Airbag Seat Belt Pretensioner Disposal cont d Triggering the Seat Belt Pretensioners NOTE If an SRS car containing one or both intact seat belt pretensioner s is to be entirely scrapped the seat belt pretensioner s should be triggered while still in the car A pretensioner is not a salvageable part and should never be installed in another car 1 Disconnect both the negative cable and positive ca ble from the battery 2 Confirm that the special tool is functioning properly by following the check procedure on the label of the tool box or on page 23 83 3 Remove the B side trim panel 4 Cut off the seat belt pretensioner connector then strip the wire ends and connect the special tool alli gator clips to them as shown Place the special tool approximately 10 meters 30 ft away from the car 5 Buckle the seat belt then pull out about five cen timeters two inches of slack make a loop with it and hold the loop in place with a clip as shown CLIP 5 cm 2 in of slack SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER 3 P CONNECTOR ALLIGATOR CLIPS Connect a 12 volt battery to the tool If the green light on the tool goes on the preten sioner igniter circuit is defective Go to Damaged Airbag or Pretensioner Special Procedure If the red light on the tool goes on the preten sioner is ready to trigger Push the tool s deployment switch to trigger the pretension

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