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1994 Honda Civic Hatchback Maintenance Manual EDM

1. SE ee EST 52 oe is B an Y S 55559 Ur SS O wc I Bolt Size Torque 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 6 x 1 0 mm 17 1 7 kg m 12 Ib ft 8x 1 25 mm 25 N m 2 5 kg m 18 Ib ft 10 x 1 25 mm OIL GUIDE PLATE M 2 75 mm THRUST SHIM 3 BALL BEARING 5TH SYNCHRO SLEEVE 5 5TH SYNCHRO HUB SYNCHRO SPRING SYNCHRO RING 5TH GEAR 9 35 x 40 x 26 mm NEEDLE BEARING DISTANCE COLLAR 4TH GEAR SYNCHRO RING SYNCHRO SPRING 3RD 4TH SYNCHRO SLEEVE 49 3RD 4TH SYNCHRO HUB 3RD GEAR 42 MAINSHAFT 28 mm WASHER 28 mm SPRING WASHER BALL BEARING 28 41x 7 mm OIL SEAL Replace TRANSFER LEFT SIDE COVER TRANSFER THRUST SHIM 64 O RING Replace 93 TAPERED ROLLER BEARING G TRANSFER DRIVE BEVEL GEAR THRUST SHIM CLUTCH HOUSING LOCK WASHER Replace 5TH REVERSE SHIFT PIECE 8 3RD 4TH SHIFT FORK 63 MAGNET 83 5TH SHIFT FORK 5TH REVERSE SHIFT FORK SHAFT TAPERED ROLLER BEARING 69 TRANSFER SHAFT 54 x 75 x 16 mm NEEDLE BEARING REVERSE IDLER GEAR REVERSE THRUST WASHER REVERSE IDLER GEAR SHAFT 3 x 16 mm SPRING PIN Replace LOCK COLLAR SUPER LOW SHIFT PIECE BAR STEEL BALL SPRING SPRING COLLAR REVERSE SHIFT HOLDER REVERSE SHIFT FORK 8x 14mm DOWEL PIN 14 x 20 mm DOWEL PIN 45 N m 4 5 kg m 33 Ib ft
2. Measure voltage between the NZ connector terminal and body 2 SENSOR O SENSOH m 2 2 ground DIGITAL CIRCUIT TESTER SOCKET 45 N m 4 5 kg m Commercially available or WRENCH 33 Ib ft 07411 002000 07LAA PT50101 Is voltage above 0 6 V at wide open throttle and below 0 4 V NO Repl when the throttle is quickly eprace sensor released YES Stop engine Reconnect the oxygen sensor jooooooooooo Connect the test harness be ooooooooooooo oooooooo tween the ECU connector 014 D22 Restart and warm engine Above 0 6 V normal operating temperature Below 0 4 V then open the throttle wide open then quickly release it Measure voltage between D14 terminal and D22 terminal Is voltage above 0 6 V at wide Repair short or open in WHT wire open throttle and below 0 4 V NO when the throttle is quickly ECU 014 and O sen released YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU 11 19 PGM FI Control System Troubleshooting Flowchart Oxygen Sensor D15B7 Except KO model D15Z1 D16Z6 016277 D16Y1 016279 B16A2 engine Oel EU MEA a SE Self diagnosis Check Engine light indicates code 1 A problem in the Oxygen Oz Sensor ci
3. 6 26 Install a jumper wire on the test L harness between A6 and A26 JUMPER WIRE OOOOOOOOOOOOO OOOOOOOO ooooooooooo Turn the ignition switch ON _ A26 Voltage should start at D14 Measure voltage between D14 0 4 0 5 V when the terminal and A26 terminal as ignition switch is first soon as the ignition switch is turned on and decre turned on ase to below 0 1 V in less than two minutes cont d To page 11 22 11 21 PGM FI Control System Troubleshooting Flowchart Fuel Supply System D15B7 D15Z1 D16Z6 D16Z7 D16Y1 D16Z9 B16A2 engine cont d From page 11 21 ts there 0 1 V or less when the ignition switch is first turned on NO YES OOOOOOOOOOOOQ 0000000000 A26 D14 Voltage should start at 1 Disconnect the connector from the O2 sensor 0 4 0 5 V when the ignition switch is first turned on and decre Measure voltage between D14 terminal and A26 terminal ase to below 0 1 V in less than two minutes YES A Is there more than 0 1 V gt Replace sensor NO Turn the ignition switch OFF Disconnect the 4P connector
4. If codes other than those listed above are indicated verify the code If the code indicated is not listed above replace the ECU The Check Engine light may come on indicating a system problem when in fact there is a poor or intermittent electri cal connection First check the electrical connections clean or repair connections if necessary The Check Engine light and D4 indicator light may light simultaneously when the self diagnosis indicator blinks 6 7 and 17 Check the PGM FI system according to the PGM FI contro system troubleshooting then recheck the 94 indica tor light The Check Engine light does not come on when there is a malfunction in the Electric Load Detector circuits However it will indicate the codes when the SCS Short Connector is connected For reference pages not listed with the respective Self Diagnosis Indicator Blinks refer to base Shop Manuals 11 11 PGM FI Control System Troubleshooting Flowchart ECU Check Engine light stays on or comes on after two seconds Turn the ignition switch ON Connect the SCS short connector to the service check connector see page 11 9 NOTE When there is no code stored the Check Engine light will stay on if the service check connec tor is shorted Does Check Engine light indicate any CODE Go to self diagnostic procedures Remove the SCS short connector from
5. 15 18 Oil Seal Replacement 15 19 Rear Differential itis 15 20 Reassembly J l 15 22 Outline of IModel Change The rear differential assembly has been changed Service Precautions 4WD This 4 wheel drive model is not equipped with the sys tem that mechanically shifts the drive system to the 2 wheel drive Therefore perform the speedometer test by using the free rollers Tip on use of free roller Test cannot be made by using the chassis dy namometer Do not operate the accelerator pedal clutch brake system and steering wheel quickly The car can roll hard or dash out during the test which is very dan gerous Do not raise the speed more than 50 km h Do not use the free rollers continuously for more than 3 minutes at one try Secure the car for safety Attach the ropes to the car not to allow it to roll or dash out during the test Use the free rollers for the rear wheels Set each of the free rollers at the wheelbase and track of the car NOTE Be sure that the free rollers and speedome ter tester rollers are set parallel with each other FREE ROLLER SPEEDOMETER TESTER FRONT WHEEL REAR WHEEL SIDE SIDE SPEEDOMETER TESTERS FREE ROLLERS Move the car to set the front wheels on the speedometer testers and the rear wheels on the free rollers Be sure that the wheels are set at the
6. Mainshaft feed pipe A O D 8 97 8 98 0 353 0 354 8 95 0 352 Mainshaft feed pipe B O D 5 97 5 98 0 2350 0 2354 5 95 0 234 Countershaft feed pipe O D 7 97 7 98 0 3138 0 3142 7 95 0 313 Mainshaft sealing ring thickness 1 980 1 995 0 0780 0 0785 1 80 0 071 Mainshaft bushing I D 6 018 6 030 0 2369 0 2374 6 045 0 2380 Mainshaft bushing I D 9 000 9 015 0 3543 0 3549 9 030 0 355 Countershaft bushing I D 8 000 8 015 0 3150 0 3156 8 030 0 3161 Mainshaft sealing ring groove width 2 025 2 060 0 0797 0 081 2 080 0 082 Regulator valve Sealing ring contact LD 32 000 32 025 1 260 1 261 32 05 1 262 body Shifting device Reverse shift fork finger thickness 5 90 6 00 0 232 0 236 5 40 0 213 and parking brake Parking brake ratchet pawl Wear or other control Parking brake gear defect Throttle cam stopper height 18 5 18 6 0 728 0 732 Servo body Shift fork shaft bore I D A 14 000 14 005 0 5512 0 5514 B 14 006 14 010 0 5514 0 5516 C 14 011 14 015 0 5516 0 5518 Shift fork shaft valve bore I D 37 000 37 039 1 4567 1 4582 37 045 1 4585 Oil pump Oil pump gear side clearance 0 03 0 05 0 001 0 002 0 07 0 003 Oil pump gear to body clearance Drive 0 240 0 266 0 009 0 010 Driven 0 063 0 088 0 002 0 003 Oil pump driven gear 1 0 Oil pump shaft O D 14 016
7. Manufacturer Make Engine Type Type of Vehicle D15B7 1500 SOHC 16 valves Dual point 1HG HONDA OF AMERICA Fuel injected Engine with MFG INC U S A 01629 1600 SOHC 16 valves Sequential HONDA Passenger car Multiport Fuel injected VTEC Line Body and Engine Type Engine with CATA EH4 CIVIC 4 door D15B7 Serial Number EH5 CIVIC 4 door D16Z9 D15B7 3850001 Body Type and Transmission Type D16Z9 1000001 5 4 door Sedan 5 speed Manual 6 4 door Sedan 4 speed Automatic Vehicle Grade Series 4 DX EX 5 EX with ABS Check Digit Model Year R 1994 Factory Code S Ohio Factory in U S A East Liberty Serial Number Manual Transmission Number 520 1000001 Transmission Serial Number Automatic Transmission Number M24A 3000001 Transmission Type Serial Number 1 6 Identification Number Locations EN VIN and Engine Number LHD VIN and Engine Numb D VIN KT umber RHD and BUILT DATE VEHICLE TYPE Certification Plate KQ Certification Plate 4 door Vehicle Identification Number VIN Transmission Number Automatic Transmission Number S22 Manual N SA p A e KP Transmission Number Y21 Manual Engine Number Transmission Number S20 Manual Warning Caution Label Locations SRS AIRBAG SYSTEM Except KB A DRIVER INFORMATION SUNVISOR European m
8. Harsh shift when manually shifting to 1 33 Axle s slips out of transmission on turns Axle s stuck in transmission 43 50 43 Ratcheting noise when shifting into 6 7 38 39 40 Loud popping noise when taking off in Ratcheting noise when shifting from to or from R to N 38 39 40 38 39 40 45 r A r r r m Noise from transmission in all selector lever positions 6 17 Noise from transmission only when wheels are rolling Gear whine rpm related pitch changes with shifts 39 42 8 41 Gear whine speed related pitch changes with speed 38 42 Transmission will not shift into 4th gear in Da Lock up clutch does not lock up smoothly 1 21 28 32 17 36 37 Lock up clutch does not operate properly 2 3 15 18 35 36 37 Transmission has multitude of problems shifting At disassembly large particles of metal are found on magnet 14 4 43 PROBABLE CAUSE Shift cable broken out of adjustment Throttle cable too short Throttle cable too long Wrong type ATF Idle rpm too low high Oil pump worn or binding Rgulator valve stuck 1st clutch defective oo xo ROT 2nd clutch defective 3rd clutch defective 4th clutch defective 1st hold clutch defective Modulator valve stuck Throt
9. Thermo Switch Activation 2WD e When the car is in 4WD the pressured oil passes through check valve and is directed to the thermo switch and the clutch piston e When the differential oil temperature rises excessively the thermo switch pushes open check valve of the relief valve this releases the hydraulic pressure applied on the clutch piston and thereby releases the 4WD RELIEF VALVE RELIEF SPRING Relief Valve Activation 2WD When hydraulic pressure higher than the relief spring load is produced at the thermo switch side and applied on check valve the relief valve regulates the hydraulic pressure applied on the clutch piston to a given pressure this prevents the excessive torque from being transmitted to the rear wheel drive system 15 9 Realtime 4WD Dual Pump System Troubleshooting Forward Drive Quick Starting 4 WD M T 1 Raise the car off the ground and place safety stands under it see section 1 A WARNING e Make sure jacks and safety stands are placed properly e Make sure the car will not roll off stands and fall while you are working under it Start the engine Hold the engine at 3 000 rpm with no load in neutral until the radiator fan comes on then let it idle Shift the lever into low gear and gradually release the clutch Apply the parking brake firmly e If the engine stalls the system is OK e f the engine continues to run check
10. UNDER HOOD FUSE RELAY BOX ill Final Procedure this procedure must be done after any troubleshooting 1 Remove the SCS Short Connector NOTE If the SCS Short Connector is connected and there are no CODE stored in the ECU the Check Engine light will stay on 2 Do the ECU Reset Procedure 3 Set the radio preset stations and the clock setting 11 10 SYSTEM INDICATED Except D15B2 engine ECU 11 12 11 15 OXYGEN SENSOR 11 18 20 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 11 23 11 26 SELF DIAGNOSIS INDICATOR BLINKS PAGE D15B2 engine CRANK ANGLE CRANK SENSOR COOLANT TEMPERATURE TW SENSOR THROTTLE ANGLE TDC POSITION TDC SENSOR 1 CYLINDER POSITION CYL SENSOR INTAKE AIR TEMPERATURE TA SENSOR IMA SENSOR D16A9 engine EXHAUST GAS RECIRCULATION SYSTEM EGR _ ATMOSPHERIC PRESSURE PA SENSOR D15B7 engine D15Z1 D16Z6 engine KS model ELECTRONIC AIR CONTROL EACV IGNITION OUTPUT SIGNAL FUEL INJECTOR D15B2 engine VEHICLE SPEED SENSOR A T LOCK UP CONTROL SOLENOID VALVE A B ELECTRICAL LOAD DETECTOR ELD SPOOL SOLENOID VALVE VALVE TIMING OIL PRESSURE SWITCH OXYGEN SENSOR HEATER D15B7 D16Z6 D16Z7 B16A2 engine LAF SENSOR HEATER D15Z1 engine FUEL SUPPLY SYSTEM D15B2 D15B7 D15Z1 D16Z6 D16Z7 D16Z9 B16A2 D16Y1 engine LAF SENSOR D15Z1 engine olola ojoje o
11. 15 the voltage approx 1 2 V with no vacuum applied and approx 4 3 V with 200 mmHg of vacuum applied to the EGR valve To page 11 40 From page 11 38 YES Repair open in GRN WHT wire lt Is there approx 5 V between EGR valve and ECU D22 NO Turn the ignition switch OFF Connect the test harness D con nector to the ECU only not to the main wire harness Turn the ignition switch ON Measure voltage between D20 terminal and D22 terminal E YES Repair open in YEL WHT wire lt Is there approx 5 V between EGR valve and ECU D20 NO Substitute a known good ECU and recheck If prescribed volt age is now available replace the original ECU Repair open or short in WHT BLK wire between EGR valve and ECU D12 If wire is OK replace the EGR valve cont d 11 39 Emission Control System Exhaust Gas Recirculation System D15Z1 engine cont d From page 11 39 Does the voltage consistently TR NO increase decrease as the vacu um increases decreases Replace the EGR valve YES Reconnect the 16 hose to the EGR valve rac zr Start the engine and allow it to idle minal with a jumper wire Connect A11 terminal to A26 ter NO Repair open in ORN BLU wire be the engine stall rough tween
12. op ueedoun3 uey 19910 104 ueedoung 104 UISIueu2eul 29045 cL 09 5 cL 09 000 L X i 154 19A9U9IUA 1 jo 1 jeu 002 081 091 02 OOL wJ 000 1 x 10 10 OOO X JeA193u 3e 5 ji 10 dn 1sn pe uge uolo dsui ayy 399dsu 5 eoe deu 4 5 Maintenance Schedule suluou 9 20 000 9 WA 000 01 15 5 15 1 z 10 Saju 000721 WA 00002 Aie 3 sped pue sosip sy uow 9 10 seju 00079 WA 000 01 SJedijeo pue sosip 10024 suluouu 9 10 00079 WA 00001 Z 10 sapu 000721 WA 000702 A1343 5162 104 jueuig a 19119AUO02 20AIEIE S462 104 suluoui z 10 000721 00002 i9 3 10 uoissiuuSueJ suluoui 20 00076 000 Mond ueedoJn3 uey s18u10 104 Jeu pue suluou 9 10 00076 000 8 41343 H uone1edo Ajessaoau Ji eoejdei 10 dn ysnipe uonoedsur Jeu 19edsu uoljesjsibas 1611
13. Is there approx 5 V wo Repair open in YEL RED or YEL GRN wire between ECU D19 and MAP sensor Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi ECU To page 11 25 YES YES Measure voltage between YEL RED terminal and GRN WHT terminal lt Is there approx 5 V YES Measure voltage between WHT terminal and GRN WHT terminal Is there approx 5 V Turn the ignition switch OFF Reconnect the 3P connector to the MAP sensor Connect the test harness be tween the ECU and connector Turn the ignition switch ON To page 11 25 OOOOOOOOOOOOO OOOOOOOO OOOOOOOOOOOOO OOOOOOOO D19 D21 OOOOOOOOOOO Repair open GRN WHT or GRN BLU wire between ECU D21 and MAP sensor 11 24 From page 11 24 From page 11 24 Measure voltage between D17 terminal and D21 terminal Turn the ignition switch OFF NO Connect the test harness D lt Is there approx 3 V Replace MAP sensor connector to the ECU only not to the main wire harness YES Turn the ignition switch ON Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU
14. Auessaceu 10 dn 4 Sat 000 1 x 000 L x H 7151 JBABYDIYM Suluou JO 1equinu jeu 1926 10 10 00071 X 15 BdIAIaS 2 5 1 1 199dsu ueeg 229 H 4 6 Engine Engine Lubrication 8 1 Intake Manifold Exhaust System 9 1 Engine Removal Installation 5 1 Outline of Model Changes The 01522 engine has been adopted Compare 01583 engine Main difference is exhaust manifold The D15B7 engine has been adopted Compare to D15B2 engine Main difference is intake manifold The D16Y1 D16Z9 engines have been adopted For the service procedures refer to the procedures for 01626 engine Engine Removal Installation 5 2 Outline of Model Change The mount and bracket bolts nuts torque value specifications have been changed Engine Removal Installation Mount and Bracket Bolts Nuts Torque Value Specifications Except D16Z7 4WD B16A2 engines REAR MOUNT M T TRANSMISSION MOUNT RIGHT FRONT MOUNT 5 2 SIDE ENGINE MOUNT Except D15Z1 D16Z6 D1627 2WD D16Y1 engines 01521 01626 01627 2WD D16Y1 engines Torque Specifications A 10 x 1 25 mm 60 N m 6 0 kg m 43 Ib ft Replace B 12 x 1 25 mm 60 N m
15. D15Z1 engine D16 IP VS HTCNTL AY AS AT AD A15 A17 A19 421423 25 BI 85 67 B 810 B15 D D3 05 07 0 011013 O15 DI 019 021 AZ AB AD 2 22 24 26 B2 84 BE B10 BI2 BIE D2 04 06 OB 010012014 016 DIB 020 022 TERMINAL LOCATION 11 7 System Description Electrical Connections D15B2 engine MAIN RELAY FUEL PUMP MAIN INJECTOR Co D O O AUX INJECTOR 0 O To starter TDC CRANK 7 SENSOR se c ULL PURGE CUT OFF SENSOR E SOLENOID VALVE 4 PA EACV SENSOR TANDEM VALVE CONTROL SOLENOID VALVE THROTTLE 20 Sa Ee ANGLE O 0 SENSOR O 00 O LOCK UP SERVICE CONTROL CLUTCH CHECK bi SOLENOID VALVE REY CONNECTOR gt Q O CHECK ENGINE LIGHT G101 TW SENSOR 9 IGNITER UNIT TA SENSOR OXYGENS SENSOR gt eeN p ALTERNATOR 6 0 SHIFT POSITION CONSOLE A C SWITCH SPEED SWITCH SENSOR AQ AILAISAISAI7 B3 B5 B7 B9 B11B13B15 B17 B19 Ct Co ciiciscis FUSES BATTERY 80 A 6 REAR DEFROST
16. Do not attach the ropes to any section other than the specified section ROPE for prevention of the car from dashing out Attach to the trailing hook ROPE for prevention of the car from rolling the car from rolling Attach to the tie down Attach to the trailing hook hook ROPE for prevention of Start the engine With the gearshift lever in the 3rd range on the manual transmission car or the gear shift lever in the D1 or D2 position on the automatic transmission car start the car and raise the speed gradually CAUTION Take care not to exceed 50 km h of speed and do not test for more than 3 minutes con tinuously After the test slow down the car until it stops by applying the brake gradually Special Tools Tool Number Description Page Reference 07LGC 0010100 07746 0010700 07749 0010000 Snap Ring Pliers Outer Driver 24 x 26 mm Outer Handle A 13 33 37 13 35 13 35 13 23 Transmission Assembly Removal WARNING e Make sure jacks and safety stands are placed proper ly see section 1 e Apply parking brake and block rear wheels so car will not roll off stands and fall on you while working under it CAUTION Use fender covers to avoid damaging paint ed surfaces 1 Disconnect the negative cable first then the pos itive 4 cable from the battery 2 Drain the transmission oil then reinstall the drain plug with a new washer 3 Remov
17. 14 30 Adjustment 14 31 Gearshift Selector KB model Disassembly Reassembly 14 32 Outline of Model Changes Hydraulic circuit has been modified The following parts of the automatic transmission have been changed Parking gear Reverse idler gear shaft and holder guide cap of the sub shaft Secondary valve body Servo body Countershatt Clutch assemblies Supplemental Restraint System SRS Type Ill has been added on KB model Special Tools Tool Number Description Page Reference 07746 0010100 Attachment 32 x 35 mm 14 24 07746 0030100 Driver 40 mm 1 0 14 20 07749 0010000 Driver 14 24 14 2 Description Hydraulic Circuit The hydraulic circuit has been modified due to the secondary valve body modification DESCRIPTION OF PRESSURE LINE DESCRIPTION OF PRESSURE THROTTLE B IDESCRIPTION OF PRESSURE 1ST HOLD CLUTCH LINE LINE THROTTLE B LINE LINE 2ND CLUTCH 2ND CLUTCH GOVERNOR GOVERNOR LINE LINE L LINE 3RD CLUTCH TORQUE CONVERTER TORQUE CONVERTER LINE 3RD CLUTCH TORQUE CONVERTER LINE 4TH CLUTCH OIL COOLER LINE 4TH CLUTCH TORQUE CONVERTER LINE KL THROTTLE A LUBRICATION MODULATOR THROTTLE A TORQUE CONVERTER MODULATOR THROTTLE A TORQUE CONVERTER
18. KG KF KE KW KS KG KF KE KW 3 042 Ibs 3 219 165 3 310 165 3 39 Design Specifications European Model METRIC ENGLISH NOTES 4 door Sedan WEIGHT 3 40 Curb weight ESi with ABS VTi RSTi 1 010 kg 1 015 kg 1 000 kg 1 005 kg 1 030 kg 1 035 kg 1 015 kg 1 020 kg 1 045 kg 1 050 kg 1 050 kg 1 055 kg 1 080 kg 1 085 kg 1 065 kg 1 070 kg 1 095 kg 1 100 kg 1 140 kg 1 145 kg 1 140 kg 1 160 kg 2 227 165 2 238 Ibs 2 205 Ibs 2 216 ibs 2 271 Ibs 2 282 165 2 238 165 2 249 Ibs 2 304 lbs 2 315 Ibs 2 315 Ibs 2 326 lbs 2 381 lbs 2 392 lbs 2 348 lbs 2 359 Ibs 2 414 Ibs 2 425 Ibs 2 513 Ibs 2 524 Ibs 2 513 Ibs 2 557 Ibs Weight distributions Front Rear VEi DXi ESi with ABS VTi RTSi Max Permissible Weight VEi DXi LSi ESi ESi with ABS VTi RTSi 605 405 kg 610 405 kg 595 405 kg 600 405 kg 625 405 kg 630 405 kg 610 405 kg 615 405 kg 640 405 kg 645 405 kg 630 420 kg 635 420 kg 660 420 kg 665 420 kg 640 425 kg 645 425 kg 670 425 kg 675 425 kg 705 435 kg 710 435 kg 675 465 kg 695 465 kg 1 334 893 Ibs 1 345 893 Ibs 1 312 893 Ibs 1 323 893 Ibs 1 378 893 Ibs 1 389 893 Ibs 1 345 893 Ibs 1 356 893 Ibs 1 411 893 Ibs 1 422 893 Ibs 1 389 926 Ibs 1 400 926 Ibs 1 455 926 lbs 1 466 926 Ibs 1 411 937 165 1 422 937 Ibs 1 477 937 165 1 488 937 ibs 1 554 959 Ibs 1 565 959 Ibs 1 488 1 025 Ibs 1 532 1 025 Ibs
19. WASHER REAR MOUNT SPECIAL BOLT BRACKET Replace 23 Pull the transmission away from the engine until it clears the mainshaft then lower it on the transmis sion jack 24 Remove the parts below as shown SPEED SENSOR STARTER MOTOR CHANGE CABLE BRACKET TRANSMISSION MOUNT BRACKET O RING Replace BACK UP LIGHT SWITCH TRANSMISSION HANGER WASHER Replace 13 27 lllustrated Index Refer to the drawing below for the transmission disassembly Clean all the parts thoroughly in solvent and dry with compressed air B Lubricate all the parts with oil before reassembly NOTE This transmission uses no gaskets between the major housings use liquid gasket P N 0 740 99986 inspect all the bearings for wear and operation Z gt O mmm 9 RS d SH 1384 rH Sc OR SX OS d ES 2 ee A lt pets lt W lt Q gt 2 13 28 Bolt Size Torque 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 6 x 1 0 mm 15 N m 1 5 kg m 11 Ib ft 8 x 1 25 mm 25 N m 2 5 kg m 18 Ib ft D TRANSMISSION HOUSING 2 18 mm SEALING BOLT 35 N m 3 5 kg m 25 Ib ft 32 mm SEALING BOLT 70 N m 7 0 kg m 51 Ib ft DRAIN PLUG 40 N m 4 0 kg m 29 Ib ft 5 14 mm WASHER Replace 40 x 76 x 9 mm OIL SEAL Replace OIL FILLER PLUG 45 N m 4 5 kg m 33 Ib ft 14 mm WASHER Replace 9 12mm WASHER Replace SET BALL SCREW 22 N m 2 2 k
20. 1 Turn the ignition switch OFF 2 Check for continuity between the No 1 terminal of the BLU dashboard wire harness 5 P connector and body ground Check the dashboard wire harness 71215 e View from Is there continuity 200 Q or less wire side YES NO Failure in the SRS unit due to short to ground in the BLU wire of the dashboard wire harness Replace the dash board wire harness and the SRS unit C2 Open in the BLU wire of the dashboard wire harness Replace the dashboard wire harness BLU 4 View from wire side 23 53 Troubleshooting DTC 9 2 CAUTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Check the SRS fuse 1 Turn the ignition switch OFF 2 Check for blown No 25 10 A fuse Is the fuse OK YES NO Replace the fuse Turn the ignition switch ON II and check that the fuse doesn t blow Does the fuse blow Check for short to ground between the under dash fuse relay box and the SRS unit 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then discon nect the positive cable and wait for three minutes 3 Connect the short connectors RED to the airbag con nectors see page 23 25 4 Disconnect the SRS main harness 18 P connector from the
21. AOGA REGULATOR VALVE BODY O RING Replace STATOR SHAFT STOPPER SHAFT CHECK BALLS DOWEL PINS MAIN VALVE BODY OIL FEED PIPE OIL FEED PIPE DOWEL PIN MAIN SEPARATOR PLATE OIL PUMP DRIVE GEAR OIL PUMP DRIVEN GEAR SHAFT OIL PUMP DRIVEN GEAR CONTROL SHAFT DETENT ARM SHAFT DETENT SPRING DETENT ARM ATF STRAINER Clean or replace TORQUE CONVERTER HOUSING COUNTERSHAFT NEEDLE BEARING OIL GUIDE PLATE TORQUE CONVERTER HOUSING TORQUE CONVERTER HOUSING MAINSHAFT BALL BEARING OIL SEAL Replace LOCK UP CONTROL SOLENOID VALVE ASSEMBLY LOCK UP CONTROL SOLENOID FILTER GASKET Replace OIL FEED PIPE STOPPER SHAFT STAY Bolt Size Remarks 12 Nem 1 2 kg m 9 Ib ft 6x 1 0 mm 14 13 Secondary Valve Body Disassembly Inspection Reassembly NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages Replace valve body as an assembly if any parts are worn or damaged Check all valves for free movement If any fail to slide freely see Valve Body Repair Coat all parts with ATF before reassembly CAUTION Do not use a magnet to remove the check balls it may magnetize the balls FILTER Replace CHECK BALLS 3 pcs SPRING SEAT GOVERNOR CUT VALVE 2 3 ORIFICE CONTROL VALVE 2ND ON ORIFICE CONTROL VALVE A NC ROLLER 9 2 1 TIMING p P 4 3 KICK DOWN VALVE VALVE REVERSE CONTROL VA
22. D17 D21 Measure voltage between D17 terminal and D21 terminal Repair short WHT or PNK WHT wire between ECU D17 YES Is th gt and MAP sensor approx Repair open in WHT PNK NO WHT wire between ECU D17 and MIAP sensor Substitute a known good ECU and recheck If prescribed volt age is now available replace the original ECU cont d 11 25 PGM FI Control System Troubleshooting Flowchart MAP Sensor cont d word umet Aer 153 Check Engine light has been reported on With the SCS short connector connected page 11 9 CODE 5 is indicated Do the ECU Reset Procedure page 11 10 rpm at 2 000 for one minute L 4 Check Engine light on and does Start the engine and keep engine _ Intermittent failure system is OK at this time test drive may be necessary Make sure all connectors are secure NO it indicate CODE 5 YES Turn the ignition switch OFF Remove the MAP sensor from throttle body Connect a vacuum pump to the MAP sensor and apply vacuum NO Does it hold vacuum S Start the engine Replace MAP sensor YES Put your finger over the MAP port on
23. First Edition 8 93 380 pages HONDA MOTOR CO LTD All Rights Reserved Service Publication Office INTRODUCTION General Info Special Tools How to Use This Manual This supplement contains information for the 94 CIVIC Refer to following shop manuals for service procedures and data not included in this supplement Description Code No CIVIC MAINTENANCE REPAIR and 62SR300A CONSTRUCTION 92 VOL 1 and VOL 2 62SR300B CIVIC SUPPLEMENT 93 62SR320 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 ta ble of contents The symbols printed at the top corner of each page can also be used as a quick reference system Special Information 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 wh
24. 003 For Refrigerant HFC 134a R 134a Condenser Evaporator Line or hose Receiver Lubricant capacity fl oz Imp oz 25 5 6 0 9 60 2 2 1 10 1 3 0 4 10 1 3 0 4 Compressor SANDEN Engine type D15B7 01521 01626 01627 D16Y1 Lubricant type SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Lubricant capacity mt fl oz Imp oz Field coil resistance at 20 C 68 F Q Pulley to pressure plate clearance 120 4 4 2 2 65 2 95 0 5 0 15 0 02 0 006 MATSUSHITA Engine type D12B1 D13B2 D13B3 D15B2 D15B3 D15Y2 Lubricant type GU10 P N 38899 P08 003 For Refrigerant HFC 134a R 134a Lubricant capacity mf fl oz Imp oz Field coil resistance at 20 C 68 F Q Pulley to pressure plate clearance 140 4 2 3 4 9 3 16 3 50 0 5 0 1 0 02 0 004 NIPPONDENSO Engine type B16A2 Lubricant type ND OIL8 P N 38899 PR7 003 For Refrigerant HFC 134a R 134a Lubricant capacity fl oz Imp oz Stator coil resistance at 20 C 68 F 0 Pulley to pressure plate clearance 120 4 4 2 3 4 3 8 0 5 0 15 0 02 0 006 Compressor belt Deflection with 98 N 10 kg 22 Ibs between pulleys 6 5 10 5 0 26 0 41 with used belt 5 0 7 0 0 20 0 28 with new belt Belt tension N kg Ibs Measured with belt tension gauge 350 500 35 50 77 110 with use
25. 14 55 0 5709 0 5728 2 45 2 55 0 096 0 100 24 0 24 1 0 945 0 949 21 0 21 1 0 8268 0 8307 AWD Automatic Transmission M25A cont d Section 14 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Transmission cont d Mainshaft 2nd gear thrust washer thickness Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side Countershaft 3rd gear thrust washer thickness Mainshaft 4th gear thrust washer thickness One way clutch contact area I D Countershaft 1st gear Parking gear Mainshaft feed pipe A O D Mainshaft feed pipe B O D Countershaft feed pipe O D Subshaft feed pipe O D Mainshaft sealing ring thickness Mainshaft bushing I D Mainshaft bushing I D Countershaft bushing I D Subshaft bushing LD Mainshaft sealing ring groove width 3 47 3 50 0 137 0 138 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 145 0 146 3 72 3 75 0 147 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 151 0 152 3 87 3 90 0 153 0 154 Wear or damage Wear or damage 4 45 4 55 0 175 0 179 2 95 3 05 0 1161 0 1201 1 45 1 50 0 057 0 059 2 43 2 50 0 096 0 098 2 87 2 90 0 113 0 114 2 92 2 95 0 115 0 116 2 97 3 0
26. 20 8 Dashboard Replacement KB model SRS wire harnesses are routed near the dashboard and steering column CAUTION All SRS wire harnesses are covered with yellow insu lation Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes SRS Type lll only Whenever the ignition switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could acciden tally deploy and cause damage or injuries Before you disconnect any part of an SRS wire har ness connect the short connectors RED to the air bags Refer to additional precautions beginning on page 23 21 in the SRS sub section FRONT PASSENGER S DRIVER S AIRBAG AIRBAG SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation To remove the dashboard first remove the e Front seats e Center lower cover e Glove box Remove the dashboard lower cover and knee bol ster Remove the access panel Remove the nuts then carefully remove the front passenger s airbag To avoid accidental deployment and possible injury always install the carefully short connector on the airbag connector when the SRS wire harn
27. BEARING 3RD GEAR FK lop ny 177542224 NEEDLE BEARING Lua m THRUST NEEDLE BEARING TM E 4 SPLINED WASHER mi Selective part 3RD CLUTCH ASSEMBLY O RINGS Replace COUNTERSHAFT Check splines for excessive wear or damage Check bearing surface for scoring scratches or excessive wear 14 18 Disassembly Reassembly 1 Using a hydraulic press press out the countershaft while supporting 4th gear NOTE Place an attachment between the press and the countershaft to prevent damage to the shaft CAUTION Do not allow the countershaft to fall and hit the ground PRESS ATTACHMENT 4TH GEAR Assemble the parts below on the countershaft as shown below NOTE Lubricate all parts with ATF during assembling Before installing the O rings wrap the shaft splines with tape to prevent damaging the O rings 4TH GEAR NEEDLE BEARING DISTANCE COLLAR 28 mm Selective 2ND GEAR 3RD GEAR NEEDLE BEARING Selective 3RD CLUTCH ASSEMBLY O RINGS Replace cont d 14 19 Countershaft Disassembly Reassembly cont d 3 Install the reverse selector hub on the countershaft sub assembly and then press the reverse selector hub using the special tool and a press as shown DRIVER 40 mm LD 07746 0030100 REVERSE SELECTOR HUB COUNTERSHAFT SUB ASSEMBY 14 20 Inspection Clearance Measurement NOTE Lubricate all parts with AT
28. Check the SRS unit 1 Reconnect the battery positive cable then connect the negative cable 2 Connect a voltmeter between the No A2 and A5 termi nals of Test Harness B 3 Turn the ignition switch ON and measure voltage There should be 9 4 14 V 4 Turn the ignition switch OFF and measure resistance between the No A8 and A5 terminals of Test Harness B There should be 0 75 1 0 NOTE The resistance will be unstable if you measure immediately after you turn the ignition switch OFF Allow it to settle then take the reading Are voltage and resistance as specified YES NO Faulty SRS unit replace the SRS unit see page 23 66 Check for short to ground in the SRS main harness 1 Check for continuity between the No B2 and B5 termi nals and the No B8 and B5 terminals of Test Harness B CAUTION Do not disconnect short connector from the SRS main harness 3 P connector Is there continuity Short to ground in the SRS main harness replace the harness The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of In termittent Failures on page 23 28 SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS B TEST HARNESS B 07MAZ SP00500 SRS UNIT 07MAZ SP00500 23 49 Troubleshooting DTC 9 1 or
29. 2 DRIVER 8 0 mm CHANGE EXTENSION 17 Remove the front and the rear engine stiffeners FRONT ENGINE d STIFFENER REAR ENGINE STIFFENER 13 14 18 Remove the clutch cover 20 Place a transmission jack under the transmission and a jack stand under the engine 21 Remove the transmission mount TRANSMISSION MOUNT 19 Remove the right front mount bracket 22 Remove the rear mount bracket bolts and the trans mission mounting bolts SPECIAL BOLT Replace WASHER WASHER SPECIAL BOLT Replace RIGHT FRONT MOUNT BRACKET REAR MOUNT BRACKET 23 Pull the transmission away from the engine until it clears the mainshaft then lower it on the transmis sion jack 13 15 Shift Fork Assembly Index 7 B Prior to reassembling clean all the parts in solvent dry them and apply lubricant to any contact parts Q PIN DRIVER 5 0 mm 5TH REVERSE SHIFT FORK 3RD 4TH SHIFT FORK 5 x 22 mm SPRING PIN Replace 1ST 2ND SHIFT FORK 5TH REVERSE SHIFT PIECE 13 16 Transmission Assembly Installation 1 Installthe dowel pins on the clutch housing 2 Apply grease to the parts as shown then install the release fork and release bearing NOTE Use only HONDA Genuine Urea Grease UM264 P N 41211 305 3 install the release fork boot RELEASE FORK BOLT 30 N m 3 0 kg m Bra 22 Ib ft P N 41211 305 RELEASE BEARING RELE
30. EE UNDER HOOD FUSE RELAY BOX d 0 SEIS BEP C REAR WINDOW DEFOGGER RELAY SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors ge SAS REAR WINDOW DEFOGGER SWITCH IN With built in timer ae REAR WINDOW DEFOGGER Description The rear window defogger timer circuit is built into the rear window defogger switch When the defogger switch is turned ON it sends a signal to the rear window defogger timer circuit and the defogger stays on for about 25 minutes or until the ignition switch is turned off The indicator light in the switch comes on when the defogger is ON 23 10 Circuit Diagram UNDER HOOD FUSE RELAY BOX No 41 80A No 39 50A O OD ONO BATTERY REAR WINDOW DEFOGGER RELAY BLK GRN REAR WINDOW DEFOGGER BLK G554 G201 G401 IGNITION SWITCH WHT BLK e WHT O O No 19 10A FUSE UNDER DASH FUSE RELAY BOX BLK YEL RED BLK REAR WINDOW DEFOGGER SWITCH INDICATOR LIGHT 0 84W BLU YEL DASH LIGHTS BRIGHTNESS CONTROLLER BLK G201 G401 23 11 Rear Window Defogger KB model Troubleshooting NOTE The numbers in the table show the troubleshooting sequence Item to be inspected In the rear window defogger switch In the under dash fuse relay box Blown No 34 30 A fuse In the under hood fuse relay box D
31. KG KE KF KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KE KF KW KS KG KG 1 500 kg 1 530 kg 1 545 kg 1 520 kg 1 640 kg 3 307 Ibs 3 373 Ibs 3 406 Ibs 3 351 Ibs 3 616 Ibs Except European Model 2 door Hatchback METRIC ENGLISH WEIGHT 4 door Sedan WEIGHT Curb weight EX M T M T A T M T A T M T A T M T A T 1 000 kg 1 013 kg 1 039 kg 1 051 kg 1 077 kg 993 kg 1 013 kg 1 008 kg 1 028 kg 2 205 Ibs 2 233 Ibs 2 291 Ibs 2 317 165 2 374 165 2 189 165 2 233 Ibs 2 222 165 2 266 Ibs Weight distributions Front Rear CX GLi VTi 1 5EL EX Curb weight VEi GLi VTi 1 5EL 1 5EX Si VEi GLi VTi M T M T A T M T AIT M T A T M T A T 610 390 kg 619 394 kg 647 392 kg 639 412 kg 665 412 kg 611 382 kg 635 378 kg 624 384 kg 648 380 kg M T A T M T A T M T A T M T AIT M T A T Weight distributions Front Rear M T M T A T M T A T M T A T M T A T M T A T 1 043 kg 1 046 kg 1 072 kg 1 088 kg 1 119 kg 1 017 kg 1 037 kg 1 045 kg 1 065 kg 1 090 kg 1 115 kg 1 321 860 Ibs 1 365 869 Ibs 1 426 864 bs 1 409 908 Ibs 1 466 908 Ibs 1 347 842 105 1 340 833 Ibs 1 376 847 Ibs
32. Part Number Thickness 9041 1 PF4 000 3 00 mm 0 118 in 9041 2 PF4 000 3 05 mm 0 120 in 4 9041 3 PF4 000 3 10 mm 0 122 in O IN To 90414 PF4 000 90415 PF4 000 3 15 mm 0 124 in 3 20 mm 0 126 in 904 16 PF4 000 3 25 mm 0 128 in 90417 PF4 000 90418 PF4 000 3 30 mm 0 130 in 3 35 mm 0 132 in 90419 PF4 000 3 40 mm 0 134 in alice d 9041 1 P24 JOO 11 9041 2 P24 JOO 3 45 mm 0 136 in 3 50 mm 0 138 90413 24 00 3 55 mm 0 140 in 90414 P24 JOO 3 60 mm 0 142 in 10 After replacing the splined washer make sure the clearance is within tolerance Sub shaft Disassembly Inspection Reassembly NOTE Lubricate all parts with ATF before reassembly Install 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 damaging the O rings TRANSMISSION HOUSING TRANSMISSION HOUSING BEARING 1ST HOLD CLUTCH ASSEMBLY 6 x 1 0 mm 12 Nem O RINGS 1 2 kg m 9 Ib ft Replace THRUST SHIM THRUST NEEDLE BEARING NEEDLE BEARING SUB SHAFT Check splines for excessive wear or damage Check bearing surface for scoring scratches or excessive wear 4TH GEAR
33. 0 148 0 0035 0 0058 0 200 0 008 Differential carrier Pinion shaft bore diameter Carrier to pinion shaft clearance Driveshaft bore diameter Carrier to driveshaft clearance 18 000 18 016 0 7087 0 7093 0 013 0 045 0 001 0 002 28 000 28 021 1 1024 1 1032 0 025 0 066 0 0010 0 0026 0 10 0 004 0 12 0 005 Differential pinion gear Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance 0 05 0 15 0 002 0 006 18 042 18 066 0 710 0 711 0 055 0 095 0 002 0 004 0 15 0 006 Set ring to bearing outer race Differential 2WD A T M48A Section 15 MEASUREMENT 0 0 10 0 0 004 STANDARD NEW Adjust with shim SERVICE LIMIT Final driven gear Backlash 0 082 0 137 0 0032 0 0054 Differential carrier Pinion shaft bore diameter Carrier to pinion shaft clearance Driveshaft bore diameter Carrier to driveshaft clearance Differential pinion gear Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance Set ring to bearing outer race 15 000 15 018 0 5906 0 5913 0 016 0 052 0 0006 0 0020 26 005 26 025 1 0238 1 0246 0 025 0 063 0 0010 0 0026 0 2 0 0079 0 1 0 004 0 12 0 005 0 05 0 15 0 002 0 006 15 041 15 061 0 5922 0 5930 0 057 0 095 0 0022 0 0037 0 0 15 0 0 006 0 15
34. 1 7 Warning Caution Label Locations 1 8 Lift and Support Points Lift tay aaa eens 1 16 Floor Jack 1 17 Safety Stands 1 18 MOWING tusa usa 1 19 Service Precautions 4WD 1 20 Chassis and Engine Numbers European Model 2 door Hatchback Vehicle Identification Number JHMEG 33200S200001 TTTT Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type EG3 CIVIC 3 door D13B2 EG4 CIVIC 3 door D15B2 D15Z1 EG5 CIVIC 0 1626 EG6 CIVIC 3 door B16A2 Body Type and Transmission Type 3 2 door Hatchback 5 speed Manual 4 2 door Hatchback 4 speed Automatic Vehicle Grade Series DX EG3 KG KF KS KE EX EG3 KG KF DXi EG4 KG KS LSi EG4 KG KF KS KE KW VEi EG4 KG KF KS KE EG5 KG KF KS KE VTi EG6 KG KF KS KE KW Fixed Code Auxiliary Number Factory Code S Suzuka Factory in Japan Model Year 2 1994 Serial Number 1 2 Engine Number B16A2 1200001 Engine Type B16A2 1600 DOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA D13B2 1300 SOHC 16 valves 1 carbureded Engine with CATA D15B2 1500 SOHC 16 valves Dual point Fuel injected Engine with CATA 01521 1500 SOHC 16 valves Sequential Multiport Fuel inje
35. 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 3 22 3 25 0 127 0 128 3 27 3 30 0 129 0 130 3 32 3 35 0 131 0 132 3 37 3 40 0 133 0 134 3 42 3 45 0 135 0 136 3 47 3 50 0 137 0 138 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage A Y Wear or damage Subshaft 4th gear thrust washer thickness One way clutch contact area l D Countershaft 1st gear Parking gear Mainshaft feed pipe A O D Mainshaft feed pipe B O D Countershaft feed pipe O D Subshaft feed pipe O D Mainshaft sealing ring thickness 29 mm and 35 mm Mainshaft bushing LD Mainshaft bushing LD Countershaft bushing I D Subshaft bushing LD Mainshaft sealing ring groove width Sealing ring contact I D Reverse shift fork finger thickness Parking brake ratchet pawl Parking brake gear Throttle cam stopper height 2 93 3 00 0 115 0 118 83 339 83 365 3 2810 3 2821 66 685 66 698 2 6254 2 6259 8 97 8 98 0 353 0 354 5 97 5 98 0 2350 0 2354 7 97 7 98 0 3138 0 3142 7 97 7 98 0 3138 0 3142 1 980 1 995 0 0780 0 0785 6 018 6 030 0 2369 0 2374 9 000 9 015 0 3543 0 3549 8 000 8 015 0 3150 0 3156 8 000
36. CONNECTOR WIRE HARNESS A SS to DASHBOARD WIRE DATA LINK HARNESS CONNECTOR DLC 14 P CONNECTOR 3 P ec ud CHECK SRS MAIN HARNESS to UNDER DASH aN CLG EN FUSE RELAY BOX 2 DRIVER S AIRBAG ASSEMBLY NAMES Replacement page 23 56 Disposal page 23 60 CONNECTOR 2 P WHT BLK SRS UNIT GROUND SRS UNIT SRS MAIN HARNESS Including safing sensor to CABLE REEL and impact sensor 6 P CONNECTOR SRS MAIN Replacement page 23 66 HARNESS SRS MAIN HARNESS to SRS UNIT 18 P CONNECTOR 23 18 a e s Description SRS is safety device which when used conjunction with the seat belt is designed help protect the driver front passenger in a frontal impact exceeding a certain set limit The system consists of the SRS unit including safing sen sor and impact sensor the cable reel and driver s airbag and front passenger s airbag DRIVER S AIRBAG ASSEMBLY FRONT PASSENGER S AIRBAG ASSEMBLY CABLE REEL Operation The main circuit in the SRS unit senses and judges the force of impact and if necessary ignites the inflator charges If bat tery voltage is too low or power is disconnected due to the impact the back up power circuit will keep voltage at a con stant level For the SRS to operate 1 The impact sensor and safing sensor must activate and send electric signals to the micro processor 2 The micro processor must compute the signals and must send si
37. 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 C 104 F 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 LE LOW QUICK JOINT 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 VACUUM PUMP HIGH PRESSURE QUICK JOINT HFC HFC 134a 134a LOW PRESSURE VALVE LOW PRESSURE OUICK JOINT NOTE Run the engine below 1 500 rpm min Open the front door Turn the A C switch ON Set the temperature control lever to MAX COOL Push the mode control button to VENT Slide the heater fan switch to MAX Open the low pressure valve and charge with R 134a refrigerant WARNING Do not open the high pressure valve Do not turn the cans upside down Charge the system with refrigerant capactiy Refrigerant capacity 550 95g 19 41 9 5 02 When fully charg
38. O RING Replace RELIEF VALVE CAP RELIEF VALVE 13 5 N m 1 35 kg m 9 8 Ib ft Sanden RELIEF VALVE 10 N m 1 0 kg m 7 Ib ft 10 N m 1 0 kg m 7 Ib ft HEAT INSULATOR Matsushita O RING Replace RELIEF VALVE 11 1 1 kg m 8 Ib ft 3 Clean the mating surfaces 4 Replace the O ring at the relief valve with a new one and apply a thin coat of refrigerant oil see NOTE be low before installing the relief valve NOTE Each compressor type uses different refrigerant oil Nippondenso ND OIL8 P N 38899 PR7 003 Sanden SP 10 P N 38899 P13 003 Matsushita GU10 P N 38899 PO8 003 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 ab sorption 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 5 Install and tighten the relief valve 6 Charge with R 134a refrigerant to the system and check for leaks 7 Insert the cap into the top of the relief valve 22 3 Service Tips The air conditioning system uses HFC 134a R 134a refrigerant and polyalkyleneglycol PAG refrigerant oil see NOTE below which are not compatible with CFC 12 R 12 refrigerant and mineral oil Do not use R 12 refrigerant
39. PGM FI Control System Troubleshooting Flowchart PA Sensor D15B7 engine D15Z1 D16Z6 engine KS model 52 zt Self diagnosis Check Engine light indicates code 13 A problem in the Atmospheric Pressure Pd 1 Ps 1 Sensor The PA sensor is built into the ECU Check Engine light has been reported on With the SCS short connector connected page 11 9 CODE 13 is indicated Do the ECU Reset Procedures 11 10 Turn the ignition switch Intermittent failure system is OK at this time test drive may be necessary Is Check Engine light on and does it indicate CODE 13 YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU 11 30 Idle Control System Idle Speed Setting Except D15B2 engine Inspection Adjustment NOT E e Before the idle speed setting check the following items The Check Engine light has not been reported on Ignition timing Spark plugs Air cleaner PCV system Connect a tachometer Start the engine Hold the engine at 3 000 rpm with no load A T in N or P position M T in neutral until the radiator fan comes on then let it idle LHD TACHOMETER RHD 2P CONNECTOR 2P V CONNECTOR TACHOMETER P Disconnect the 2P connector from the EACV gt
40. SWITCH only 1 A Il I B3 ATD3 ATLSA A19 gt ATD4 9 ATLSB AV LOCK UP A T LOCK UP 1 CONTROL 3 j jCONTROL Y SOLENOID 5 5 SOLENOID VALVE B VALVEA eege a FUSES x BACK UP 7 5 A BATTERY 80 A SHIFT POSITION SHIFT POSITION IG 50 A CONSOLE INDICATOR STOP HORN 20 SWITCH ECU 15 A I ACG S 15 A G BACK UP LIGHTS 10 P EE vM 2 REAR DEFROSTER RELAY Am HEATER MOTOR RELAY COOLING FAN MOTOR RELAY 7 5 9 STARTER SIGNAL 7 5 A OPTION 50 INTERIOR LIGHT 7 5 A UNDER HOOD FUSE RELAY BOX 11 6 CONTROL UNIT 4WD D19 VCC1 VREF 016 D20 VCC2 MAP SENSOR THROTTLE ANGLE SENSOR IGP1 A21 D16A9 engine Ce g 5 4 IMA SENSOR See See WE EGR VALVE LIFT SENSOR Except D15B7 D16A7 D16A8 D16A9 engine D15Z1 engine D12 EGRL Except D15B7 VALVE D16A7 D16A8 TIMING OIL gt D16A9 engine PRESSURE P S OIL SWITCH gt PRESSURE A SWITCH t EE fe cee VE PGS A20 01521 j D16Z6 D16Z7 D16Y1 D16Z9 B16A2 engine Dear O SENSOR D16A8 D15B7 KO model engine o 79 PURGE CONTROL SOLENOID VALVE Except KO model ALTERNATOR
41. Top 2nd Top 2nd Cil 0 045 0 070 0 0018 0 0028 0 040 0 065 0 0016 0 0026 0 20 0 35 0 008 0 014 0 40 0 55 0 016 0 022 0 20 0 50 0 008 0 020 0 08 0 03 81 070 3 1917 0 05 0 002 0 25 0 01 80 970 3 1878 0 05 0 002 1 060 0 0417 1 260 0 0496 2 840 0 1118 0 13 0 005 0 13 0 005 0 60 0 024 0 70 0 028 0 80 0 031 Unit of length mm in SERVICE LIMIT Diameter Pin to piston clearance Pin to rod interference Small end bore diameter Large end bore diameter End play installed on crankshaft Nominal Main journal diameter No 1 2 4 and 5 journals No 3 journal Rod journal diameter Journal taper Journal out of round End play Total runout No 1 2 4 and 5 journals No 3 journal Rod bearing to journal oil clearance Main bearing to journal oil clearance 20 994 21 000 0 8265 0 8268 0 010 0 022 0 0004 0 0009 0 013 0 032 0 0005 0 0013 20 968 20 981 0 8255 0 8260 48 0 1 89 0 15 0 30 0 006 0 012 0 40 0 016 54 976 55 000 2 1644 2 1654 54 970 54 994 2 1642 2 1651 44 976 45 000 1 7707 1 7717 0 005 0 0002 max 0 004 0 0002 max 0 10 0 35 0 004 0 014 0 020 0 0008 max 0 024 0 042 0 0009 0 0017 0 030 0 048 0 0012 0 0019 0 032 0 050 0 0013 0 0020 0 010 0 0004 0 006 0 0002 0
42. contained in each section LUBRICATION POINTS LUBRICANT Engine API Service Grade SF SG or SH fuel efficient oil SAE Viscosity See chart below Transmission Manual Automatic API Service Grade SF or SG SAE Viscosity 10 W 30 or 10 W 40 Honda Premium Formula or DEXRON II Automatic transmission fluid ATF L Brake Line Brake fluid DOT3 or DOT4 Clutch Line Brake fluid DOT3 or DOT4 Power steering gearbox Steering grease P N 08733 BO70E Shift lever pivots Manual transmission Grease with molybdenum disulfide Release fork Manual transmission Urea Grease UM264 P N 41211 PY5 305 Steering boots Tailgate hinges and latches 2 door Hatchback Steering ball joints Select lever Automatic transmission Pedal linkage Brake master cylinder pushrod Trunk hinges and latch 4 door Sedan Door hinges upper and lower Door opening detents Fuel filler lid Engine hood hinges and engine hood latch Clutch master cylinder pushrod Throttle cable end Rear brake shoe linkages Multi purpose grease Caliper Piston seal Dust seal Caliper pin Piston Silicone grease Power steering system For cars with P S Honda power steering fluid V Rear differential 4WD only Air conditioning compressor Honda Premium Formula or DEXRONS IT Automatic transmission fluid ATF Compressor oil NIPPONDENSO ND OIL8 P N 38899 PR7 0
43. nals of Test Harness B and measure voltage There should be 0 5 V or less Are voltages as specified YES NO Short to power in the SRS main harness replace the harness Faulty SRS unit replace the SRS unit see page 23 66 SRS FRONT PASSENGER S SHORT CONNECTOR RED AIRBAG 3 P CONNECTOR SRS MAIN HARNESS SHORT CONNECTOR A 07MAZ SP0020A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC Gi 07PAZ 001010A SERVICE SCS SHORT MEMORY ERASE CHECK CONNECTOR SIGNAL MES CONNECTOR 2 P CONNECTOR 2 P BRN BLK IBLK WHT SRS MAIN HARNESS SRS UNIT 18 P CONNECTOR TEST HARNESS B 07MAZ SP00500 23 47 Troubleshooting DTC 2 4 cidentally deploy and cause damage or injuries CAUTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could ac Check for short to ground in the passenger s airbag inflator 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the passenger s airbag connector 4 Connect SRS short connector to the SRS main harness 3 P connector CAUTION Do not disconnect the driver s airbag connec tor 5 Connect the SCS short connector to the service check connector 6 Reconnect the batter
44. 0 002 Mainshaft 3rd and V D 39 009 39 025 1 5358 1 5364 39 07 1 538 4th gears End play 3rd 0 06 0 21 0 002 0 008 0 33 0 013 4th 0 06 0 19 0 002 0 007 0 31 0 012 Thickness 3rd 30 22 30 27 1 190 1 192 30 15 1 187 4th 30 12 30 17 1 186 1 188 30 05 1 183 Mainshaft 5th LD 37 009 37 025 1 4570 1 4577 37 07 1 459 gear End play 0 06 0 19 0 002 0 007 0 31 0 012 Thickness 28 42 28 47 1 119 1 121 28 35 1 116 Countershaft Diameter of needle bearing contact area A 30 000 30 015 1 1811 1 1817 29 950 1 1791 Diameter of 1st gear contact area B 35 984 36 000 1 4167 1 4173 35 930 1 4146 Diameter of ball bearing contact area C 24 980 24 993 0 9835 0 9840 24 930 0 9815 Runout 0 02 0 0008 max 0 05 0 002 Countershaft 1st LD 41 009 41 025 1 6145 1 6152 41 07 1 617 gear End play When tightened by the specified torque 0 03 0 10 0 001 0 004 0 22 0 009 Thickness 30 41 30 44 1 197 1 198 30 36 1 195 Countershaft 2nd EI LD 44 009 44 025 1 7326 1 7333 44 07 1 735 gear End play When tightened by the specified torque 0 03 0 11 0 001 0 004 0 23 0 009 Thickness 31 92 31 97 1 257 1 259 31 85 1 254 Spacer collar LD 33 000 33 010 1 2992 1 2996 33 05 1 301 Countershaft 2nd O D 38 989 39 000 1 5350 1 5354 38 93 1 533 gear Length 32 03 32 06 1 261 1 262 32 01 1 260
45. 10 x 1 25 mm 44 N m 4 4 kg m 32 Ib ft SELF LOCKING NUT Replace 12 x 1 25 mm CASTLE NUT 65 N m 6 5 kg m 12 x 1 25 mm 47 Ib ft 50 60 N m 5 0 6 0 kg m COTTER PIN 36 43 Ib ft Replace cont d 13 41 Transmission Assembly Installation cont d 21 Install the slave cylinder then install the clutch pipe 18 Install the three transmission mounting bolts and bracket starter motor mounting bolt NOTE Use only HONDA Genuine Urea Grease UM264 P N 41211 PY5 305 6 x 1 0 mm 10 N m 1 0 kg m 71 SLAVE CYLINDER VT S J 0 sd 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft 12 x 1 25 mm 65 N m 6 5 kg m Qm 47 Ib ft CLUTCH PIPE P N 41211 305 BRACKET 8 x 1 25 mm 22 Nem 2 2 kg m 16 Ib ft 19 Install the wire harness clump to the change cable bracket 22 Connect the speed sensor connector the starter motor cables the back up light switch connector 20 Connect the shift and select cables then install the and the transmission ground cable cotter pins LOCKNUT 23 Install the wire harness clamp 30 N m 3 0 kg m 22 Ib ft SHIFT CABLE 6 x 1 0 mm 8 x 1 25 mm COTTER PIN 10 N m 1 0 kg m 22 N m 2 2 kg m 16 Ib ft Replace 7 Ib ft WIRE HARNESS T BACK UP LIGHT CLUMP SPEED ARNESE SWITCH CONNECTOR SENSOR CLAMP CONNECTOR C A UI U 5 d SELECT CABLE Q N Vers I e VES j CHANGE 3 m d CABLE 2
46. 15 and 16 termi nals on rows A SRS unit end and B SRS main harness end of Test Harness B NOTE Do not connect jumper wires to the other termi nals To page 23 44 SRS FRONT PASSENGER S AIRBAG 3 P CONNECTOR SHORT CONNECTOR RED SRS MAIN HARNESS SHORT CONNECTOR A 07MAZ SP0020A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC 07PAZ 001010A SCS SHORT MEMORY ERASE CONNECTOR SIGNAL MES SERVICE CONNECTOR 2 P CHECK BLK WHT CONNECTOR 2 P BRN BLK SRS MAIN HARNESS 18 P CONNECTOR ss UNIT TEST HARNESS B 07MAZ SP00500 07042 SR30100 JUMPER WIRE cont d 23 43 Troubleshooting DTC 2 1 cont d From page 23 43 Check the SRS unit 1 Connect the battery positive cable then connect the neg ative cable 2 Connect a voltmeter between terminals No A2 and 5 of Test Harness B 3 Turn the ignition switch ON Il and measure voltage There should be 9 4 14 V 4 Turn the ignition switch OFF and measure resistance between terminals A8 and 5 There should be 0 75 1 0 kQ NOTE The resistance will be unstable if you measure immediately after you turn the ignition switch OFF Allow it to settle then take the reading Are voltage and resistance as specified YES NO Faulty SRS unit replace the SRS unit see page 23 66 Check for an open in the SRS main harness 1 Turn the ignition switch OFF 2
47. 3 3 3 5 2 9 Engine Oil SAE Viscosity for Outside Temperature Ranges 10 20 30 40 c 0 20 40 60 80 100 Ambient temperature ranges 1 Except D16A7 D16A9 B16A2 engines 2 D16A7 D16A9 B16A2 engines Intake Manifold Exhaust System Intake Manifold Replacement 9 2 Exhaust Manifold Replacement 9 3 Outline of Model Change The D15Z2 D15B7 engines have been adopted Intake Manifold Replacement NOTE Use new gaskets and O rings when reassembling D15B7 engine 5 x 0 8 mm 6 N m 0 6 kg m 4 Ib ft PURGE CUT SOLENOID VALVE INTAKE MANIFOLD Replace if cracked or INTAKE MANIFOLD if mating surfaces are GASKET damaged Replace TA SENSOR O RINGS 5 x 0 8 mm EEN 6 N m 0 6 kg m 4 Ib ft g S9 4 x 0 7 mm GASKETS 2 N m 0 2 kg m e Replace 14 Ib ft 8 x 1 25 mm MAP SENSOR 24 Nam 2 4 kg m 17 Ib ft O RINGS Replace THROTTLE pr di BODY 8 x 1 25 mm EACV 20 N m 2 0 kg m Be careful not 14 Ib ft to damage INTAKE MANIFOLD O RINGS BRACKETS Replace 23 N m 2 3 kg m 8 x 1 25 mm 24 N m 2 4 kg m 17 Ib ft FAST IDLE VALVE Be careful not to damage 6 x 1 0 mm 11 N m 1 1 kg m 8 Ib ft BN Exhaust Manifold Replacement NOTE Use new gaskets and new self locking nuts when reassembling CAUTION In handling a metal gasket care should be taken not to bend
48. 5 BRACKET A 8 x 1 25 mm 9 N m 0 9 kg m 8 x 1 25 mm 6 5 Ib ft B ERO MOTOR 22 N m 2 2 kg m 16 Ib ft TRANSMISSION GROUND CABLE 13 42 24 Install the air cleaner housing assembly intake air duct and intake air pipe 6 x 1 0 mm 10 N m 1 0 kg m 7 lb ft AIR CLEANER HOUSING ASSEMBLY INTAKE AIR DUCT INTAKE AIR PIPE 25 Refill the transmission with oil 26 Connect the positive cable first then the nega tive cable to the battery 27 Check the clutch operation 28 Shift the transmission and check for smooth opera tion 29 Adjust the ignition timing see section 23 Checkthe front wheel alignment see section 18 13 43 SUPPLEMENTAL RESTRAINT SYSTEM SRS If automatic transmission maintenance is required Some model versions of the Civic include a driver s airbag located in the steering wheel hub In addition the KB model has a front passenger s airbag located in the dashboard above the glove box There are two types of SRS Type Il SRS unit is part of the airbag assembly which is used for models without front passenger s airbag all except KB model and Type Ill SRS unit is not part of the airbag assembly and has built in sensors which is used for models with front passenger s airbag KB model information necessary to safely service the SRS is included in this Shop Manual Items marked with an asterisk on the contents page include
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50. 6 O RING Replace 62 SPEED SENSOR 63 35 x 54x 8 mm OIL SEAL Replace 6 12 20 mm DOWEL PIN 65 12 x 16 mm DOWEL TRANSFER HOUSING 62 TRANSFER DRIVEN BEVEL GEAR TAPERED ROLLER BEARING TRANSFER SPACER O RING Replace DRIVEN GEAR THRUST SHIM TRANSFER REAR COVER TRANSFER THRUST WASHER TAPERED ROLLER BEARING 38 x 60 x 11 mm OIL SEAL Replace COMPANION FLANGE 22 mm SPRING WASHER LOCKNUT 120 230 N m 12 0 23 0 kg m 87 166 Ib ft TRANSFER DUST COVER DIFFERENTIAL ASSEMBLY 80 mm SNAP RING OIL GUIDE PLATE C 29 x 55 x 22 mm NEEDLE BEARING COUNTERSHAFT SUPER LOW 3RD GEAR THRUST WASHER 44 x 50 x 24 mm NEEDLE BERING FRICTION DAMPER 1ST GEAR SYNCHRO RING SYNCHRO SPRING 1ST 2ND SYNCHRO HUB REVERSE GEAR SYNCHRO SPRING SYNCHRO RING DISTANCE COLLAR 2ND GEAR 3RD GEAR 4TH GEAR 5TH GEAR BALL BEARING 23 mm SPRING WASHER LOCKNUT 110 0 110 11 0 gt 0 11 0 kg m 80 gt 0 gt 80 lb ft 60 mm SNAP RING 4 x 20 mm SPRING PIN Replace 1ST 2ND SHIFT FORK SHAFT 1ST 2ND SHIFT FORK eeeee OOS SS G9 13 31 Transmission Housing Removal NOTE Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench 1 Remove the shift arm cover assembly 2 Remove the parts below as shown 12 mm WASHER Replace SET BALL SCREW DRAIN PLUG 10 mm WASHER Replace 14 mm WASHER Ki VA S OIL
51. Check for continuity between terminals No B2 and B8 of Test Harness B CAUTION Do not disconnect SRS short connector A from the SRS main harness Is there continuity Jd YES NO Open in the SRS main harness replace the harness The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of Intermittent Failures on page 23 28 23 44 TEST HARNESS B 07MAZ 5 00500 3 12 3 a4 et Jp TEST HARNESS B 07MAZ SP00500 A DTC 2 2 CAUTION Whenever the ignition switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could ac cidentally deploy and cause damage or injuries Check for a short to another wire in the passenger s airbag inflator 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the passenger s airbag connector CAUTION e Do not connect short connector A to the SRS main harness connector e Do not disconnect the driver s airbag connector 4 Connect the SCS short connector to the service check connector 5 Reconnect the battery positive cable then co
52. OIL GUIDE CAP Replace THRUST NEEDLE BEARING 4TH GEAR COLLAR NEEDLE BEARING STOPPER NEEDLE BEARING 14 23 Sub Shaft Disassembly Reassembly Remove the oil guide cap by pushing the sub shaft inside the transmission housing Remove the 1st hold clutch assembly by pulling the sub shaft then remove the sub shaft Install new O rings on the sub shaft NOTE Wrap the shaft splines with tape to prevent damaging the O rings Place the sub shaft in the transmission housing and install the 1st hold clutch assembly Install new oil guide cap using the special tools as shown DRIVER 07749 0010000 ATTACHMENT 32 x 35 mm 07746 0010100 1ST HOLD CLUTCH ASSEMBLY 14 24 Clutch Illustrated Index 3RD CLUTCH CLUTCH DRUM O RINGS Replace CLUTCH PISTON DISC SPRING RETURN SPRING SPRING RETAINER SNAP RING CLUTCH PLATES Standard thickness 2 0 mm 0 079 in CLUTCH END PLATE 1ST CLUTCH CLUTCH DISCS CLUTCH END Standard thickness PLATE CLUTCH DISCS 1 94 mm 0 076 in Standard thickness 1 94 mm 0 076 in SNAP RING SNAP RING SNAP RING SPRING RETAINER RETURN SPRING DISC SPRING O RINGS CLUTCH Replace PISTON CLUTCH DRUM CLUTCH PLATES Standard thickness 2 0 mm 0 079 in CHECK VALVE 14 25 Clutch Illustrated Index cont d 2ND 4TH CLUTCH SNAP RING CLUTCH END PLATE CLUTCH DISCS Standard thickness 1 94 mm 0 076 in
53. Section 12 MEASUREMENT With CATA 0 1 max Without CATA 1 0 1 0 STANDARD NEW SERVICE LIMIT Clutch pedal Pedal height Stroke Total free play Disengagement height to floor to floor to carpet 164 6 46 130 140 5 12 5 51 12 21 0 5 0 8 83 3 27 min 55 2 2 min Reference Flywheel Clutch surface runout 0 05 0 002 max 0 15 0 006 Clutch disc Rivet depth Thickness 1 3 0 051 min 8 4 9 1 0 33 0 36 0 2 0 008 6 0 0 24 Pressure plate 3 10 Warpage Diaphragm spring finger alignment 0 03 0 001 max 0 8 0 03 max 0 15 0 006 1 0 0 04 Unit of length mm 2WD Manual Transmission S20 Section 13 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission oil Capacity US qt Imp qt 1 9 2 0 1 7 for overhaul 1 8 1 9 1 6 for oil change Mainshaft End play 0 11 0 18 0 004 0 007 Adjust Diameter of ball bearing contact area 21 987 22 000 0 8656 0 8661 21 930 0 8634 Transmission housing side Diameter of 4th 5th gear contact area B 26 980 26 993 1 0622 1 0627 26 930 1 0602 Diameter of 3rd gear contact area C 33 984 34 000 1 3380 1 3386 33 930 1 3358 Diameter of ball bearing contact area D 25 977 25 990 1 0227 1 0232 25 920 1 0205 Clutch housing side Runout 0 02 0 001 max 0 05
54. Spacer collar LD 27 002 27 012 1 0631 1 0635 27 06 1 065 Mainshaft 4th O D 4th 33 989 34 000 1 3381 1 3386 33 93 1 336 and 5th gear 5th 31 989 32 000 1 2594 1 2598 31 93 1 257 Length 4th 22 83 22 86 0 899 0 900 22 81 0 898 5th 23 53 23 56 0 926 0 928 23 51 0 926 Reverse idler gear LD 15 016 15 043 0 5912 0 5922 15 08 0 594 Gear to reverse gear shaft clearance 0 032 0 077 0 0013 0 0030 0 14 0 006 Synchro ring Ring to gear clearance Ring pushed against gear 0 73 1 18 0 029 0 046 0 4 0 016 Shift fork Fork finger thickness 6 4 6 5 0 252 0 255 Fork to synchro sleeve clearance 0 25 0 45 0 010 0 018 0 8 0 032 Reverse shift fork Fork pawl groove width 12 7 13 0 0 50 0 51 Fork to reverse idler gear clearance 0 5 1 1 0 020 0 043 1 8 0 071 L groove width 7 05 7 25 0 278 0 285 Fork to 5th reverse shift piece pin clearance 0 05 0 35 0 002 0 014 0 5 0 02 Shift arm A Inner diameter of shift arm C contact point 13 05 13 13 0 514 0 517 Shift arm A to shift arm C clearance 0 05 0 23 0 002 0 009 0 35 0 014 Shift arm B Inner diameter of shift arm B shaft contact point 13 973 14 000 0 5501 0 5512 Shift arm B to shaft clearance 0 013 0 070 0 0005 0 0028 0 16 0 006 Shift arm B to shift piece clearance 0 2 0 5 0 008 0 020 0 62 0 0244 Diameter of shift piece contact point 12 9 13 0
55. Start the engine with the accelerator pedal slightly depressed Stabilize the engine speed at 1000 then slowly release the pedal until the engine idles Check idling in no load conditions headlights blo wer fan rear defogger cooling fan and air condi tioner are not operating NOTE KS Remove No 16 7 5 A fuse in the under dash fuse box then check that the headlights and side marker lights are off Idle speed should be Manual 420 50 rpm Automatic 420 50 min rpm in N or P Adjust the idle speed if necessary by turning the idle adjusting screw NOTE After adjust the idle speed in this step re check the ignition timing If it is out of spec go back to step 4 cont d 11 31 Idle Control System Idle Speed Setting Except D15B2 engine cont d IDLE ADJUSTING SCREW 6 Turn the ignition switch OFF 7 Reconnect the 2P connector on the EACV then remove BACK UP fuse in the under hood fuse relay box for 10 seconds to reset the ECU Restart and idle the engine with no load conditions for one minute then check the idle speed NOTE KS Remove No 16 7 5 A fuse in the under dash fuse box then check that the headlights and side marker lights are off Idle speed should be Manual D15Z1 engine 600 50 min rpm Others 750 50 min rpm 750 50 rpm in N or P Automatic 9 Idle the engine fo
56. WHT BLK 9 WHT O O BLK YEL COMBINATION UNDER DASH FUSE RELAY BOX LIGHT SWITCH No 15 10A wE RED GRN No 40 40 No 14 20 YEL BRAKE SEAT BELT SYSTEM REMINDER LIGHT 1 4W No 18 7 5A FUSE ABS CONTROL UNIT Starter signal 2 a 3 INT OFFANT 2 Si 8 8 s E GRN RED GRN RED BLU WHT AE 5 E c S venu 7 AB INTEGRATED CONTROL UNIT 88 B5 SEAT BELT REMINDER LIGHTS ON BEEPER CIRCUIT INTERMITTENT WIPER RELAY CIRCUIT BULB CHECK CIRCUIT A3 A2 A4 B14 A3 CEILING LIGHT GRN RED Y LT GRN RED GRN BLU RED BLU BLU WHT LT GRN RED d BLK GRN RED GRN RED LT GRN RED RED BLU WINDSHIELD WIPER MOTOR BRAKE PARKING FRONT DRIVER S DRIVER S FLUID BRAKE PASSENGER S DOOR SEAT BELT LEVEL SWITCH DOOR SWITCH SWITCH SWITCH SWITCH G201 G551 G301 G552 G401 23 6 Input Test CAUTION All SRS wire harnesses are covered with yellow insu lation e Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring e Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes SRS Type only Whenever the ignition switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could acciden tally
57. as shown 10 mm 0 39 in 7 mm 0 27 in 12 Pack adhesive into the cartridge without air pockets to ensure continuous delivery Put the cartridge in a caulking gun and run a bead of adhesive around the edge of the rear window as shown NOTE Apply the adhesive within 30 minutes after applying the glass primer 12 mm 0 47 in 14 ADHESIVE 8 mm 0 31 in 2 mm 0 08 in E MOLDING ADHESIVE GLASS REAR WINDOW 1 Make a slightly thicker bead at each corner 13 Use suction cups to hold the rear window over the opening align it with the alignment marks made in step 7 and set it down on the adhesive Lightly push on the rear window until its edges are fully seated on the adhesive all the way around NOTE Do not close or open the doors until adhe sive is dry SUCTION CUPS ALIGNMENT MARKS REAR WINDOW cont d 20 5 Rear Window Installation cont d 14 Scrape or wipe the excess adhesive off with a putty knife or towel NOTE To remove adhesive from a painted surface or the rear window use a soft shop towel damp ened with alcohol 15 Install the lower cover LOWER COVER 16 Let the adhesive dry for at least one hour then spray water over the rear window and check for leaks Mark leaking areas and let the rear window dry then seal with sealant NOTE Let the car stand for at least four hours after rear window installation If the car has to be used
58. be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Refer to additional precautions beginning on page 23 21 in the SRS sub section SRS Type lli SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors 1 Check that the index mark on the indicator aligns with the N mark on the shift indicator panel when the transmission in NEUTRAL 2 If not aligned remove the center console see sec tion 20 3 Remove the shift indicator panel mounting screws and adjust by moving the panel NOTE Whenever the shift indicator panel is re moved reinstall the panel as described above INDEX MARK SHIFT INDICATOR MOUNTING SCREW 3 N m 0 3 kg m 2 2 Ib ft 14 29 Shift Cable KB model Removal Installation CAUTION All SRS wire harnesses are covered with yellow insu lation Before you disconnect any part of an SRS wire harness connect the short connectors Whenever the ignition switch is ON be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Refer to additional precautions beginning on page 23 21 in the SRS sub section SRS y E ed Z AS ET LL N 89 SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors Make sure lifts are placed properly see section 1 1 Remove the center console se
59. or are located near SRS compo nents Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer AWARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS service work must be performed by an authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbags Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON Il SRS Type lll All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of the KB model in the dash board above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type Il Steering wheel Be careful not to bump the steering wheel as the SRS unit sensors inflator etc are located in it Behind the dashboard Under dash fuse relay box SRS Type Ill Steering wheel Behind the dashboard Under dash fuse relay box Front console C
60. remove the key from the ignition so that the steering wheel will not turn 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 the airbag only use genuine Honda replacement parts 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 adjustment of the tie rods not by removing and repositioning the steering wheel Connecting the Short Connectors To avoid accidental deployment and possi ble injury always connect the protective short connec tors on the driver s and passenger s airbag connectors before working near any SRS wiring 1 Disconnect the battery negative cable then discon nect the positive cable and wait at least three min utes 2 Connect the short connectors RED Driver s Side e Remove the access panel from the steering wheel then remove the short connector RED from the panel CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P ACCESS CONNECTOR PANEL SHORT CONNECTOR RED e Disconnect the 3 P connector between the driver s airbag and cable reel then connect the short connec tor RED to the airbag side of the connector SRS Front Passenger s Side Remove the glove box and access panel Disconnect the 3 P connector between the front pas senge
61. rpm and Nominal 1 550 15 5 220 wide open throttle Minimum 950 9 5 135 kPa psi Maximum variation 200 2 0 28 Cylinder head Warpage 0 05 0 002 Height 141 95 142 05 5 589 5 593 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 002 0 004 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe height Primary 33 088 1 3027 Mid 36 267 1 4278 Secondary 34 978 1 3771 Primary 32 785 1 2907 Mid 35 720 1 4063 34 691 1 3658 Valve Valve clearance IN 0 15 0 19 0 006 0 007 EX 0 17 0 21 0 007 0 008 Valve stem O D IN 5 475 5 485 0 2156 0 2159 5 445 0 2144 EX 5 450 5 460 0 2146 0 2150 5 420 0 2134 Stem to guide clearance IN 0 025 0 055 0 0010 0 0022 0 08 0 003 EX 0 050 0 080 0 0020 0 0031 0 11 0 004 Valve seat Width IN 1 25 1 55 0 049 0 061 2 0 0 079 EX 1 25 1 55 0 049 0 061 2 0 0 079 Stem installed height IN 37 465 37 935 1 4750 1 4935 38 185 1 5033 EX 37 165 37 635 1 4632 1 4817 37 885 1 4915 Valve spring Free length OUTER 40 92 1 611 40 91 1 611 INNER 36 71 1 445 41 96 1 652 1 41 94 1 651 Valve guide LD IN 5 51 5 53 0 217 0 218 5 55 0 219 EX 5 51 5 53 0 217 0 218 5 55 0 219 Installed height IN 12 55 13 05 0 494 0 514 EX
62. terminal within 1 second lt ves Turn the ignition switch OFF and reconnect the 2P connector to the EGR control solenoid valve Is there approx 200 mmHg EGR VALVE LIFT SENSOR Disconnect 3P connector from the EGR valve Turn the ignition switch Turn the ignition switch OFF and inspect the 16 and 10 hoses for leaks restrictions or misrouting NO B A 4 B NO Are the hoses OK Correct as necessary YES WHT CVC VALVE EGR CONTROL BLK SOLENOID VALVE YEL Disconnect the lower hose on EGR control solenoid valve and connect a vacuum gauge to the hose Start the engine and allow it to idle Is there 150 250 mmHg of vacuum VACUUM PUMP GAUGE Replace CVC valve Measure voltage between YEL WHT terminal and GRNAWHT terminal Is there approx 5 V lt ES 11 39 11 38 Replace the EGR control solenoid vaive Measure voltage between YEL WHT terminal and body ground page 11 39 From page 11 38 Turn the ignition switch OFF Reconnect the 3P connector to the EGR valve Connect the test harness be tween the ECU and connectors Turn the ignition switch ON Measure voltage between D12 terminal and D22 terminal
63. within the first four hours it must be driven slowly Raise the headliner back up into position then in stall e Rear pillar trim panel e Rear shelf e Rear seat back 20 6 Sunroof Sunroof Panel Glass Height Adjustment The roof panel should be even with the sunroof seal to within 1 0 5 mm 0 04 0 02 all the way around If not slide the sunshade back glass type and Tilt up the sunroof panel or glass Remove the roof liner panel type Loosen the mounting screws and adjust the sunroof panel or glass Repeat on opposite side if necessary Side to side fit of sunroof seal can be adjusted by loosening the sunroof frame mounting bolts and moving the frame right or left and forward or back ward by hand SUNROOF PANEL 1 0 5 mm 0 04 0 02 in A gt ROOF PANEL MOUNTING SCREW SUNROOF SEAL SUNROOF PANEL MOUNTING SCREW 6 x 1 0 mm 10 N m 1 0 kg m 7 2 Ib ft Loosen Seat Rear Edge Closing Adjustment Front Seat Replacement Open the sunroof panel or glass about a foot then close it to check where rear edge begins to rise If it rises too soon and seats too tightly against the roof panel or too late and does not seat tightly enough adjust it NOTE Take care not to scratch the seat covers and body 1 Remove the front seat then take it out from the door opening 1 Remove the sunroof pane
64. 0 508 0 512 12 78 0 5031 3 11 Standards and Service Limits 2WD Manual Transmission Y21 Section 13 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission oil Capacity f US qt Imp qt 2 3 2 4 2 0 for overhaul 2 2 2 3 1 9 for oil change Mainshaft End play Diameter of ball bearing contact area A Clutch housing side Diameter of 3rd gear contact area B Diameter of ball bearing contact area C Transmission housing side 0 11 0 18 0 004 0 007 27 977 27 990 1 1015 1 1020 37 984 38 000 1 4954 1 4960 27 987 28 000 1 1018 1 1024 Adjust 27 930 1 0996 37 930 1 4933 27 940 1 1000 Runout 0 02 0 001 max 0 05 0 002 Mainshaft 3rd and I D 43 009 43 025 1 6933 1 6939 43 08 1 696 4th gears End play 0 06 0 21 0 002 0 008 0 3 0 01 Thickness 3rd 34 92 34 97 1 375 1 377 34 8 1 370 4th 31 42 31 47 1 237 1 239 31 3 1 232 Mainshaft 5th LD 43 009 43 025 1 6933 1 6939 43 08 1 696 End play 0 06 0 21 0 002 0 008 0 3 0 01 Thickness 31 42 31 47 1 237 1 239 31 3 1 232 Countershaft Diameter of ball bearing contact area A 24 980 24 993 0 9835 0 9840 24 940 0 9818 Diameter of 1st gear contact area B 36 984 37 000 1 4561 1 4567 36 930 1 4539 Diameter of needle bearing contact area C 33 000 33 015 1 2992 1 2998 32 950 1 297
65. 03 0 0 02 0 0 001 29 9 30 0 1 177 1 181 13 0 13 5 0 51 0 53 15 0 15 5 0 59 0 61 18 24 1 8 2 4 4 0 5 3 13 20 1 3 2 1 2 9 4 6 0 2 0 008 0 05 0 002 29 0 1 14 8 5 0 33 10 0 0 39 1 D12B1 D13B2 01383 01583 01522 engines 2 01582 D15B7 01521 D16A7 D16A9 D16Z6 01627 D16Y1 B16A2 engines 3 When using a new belt adjust deflection or tension to new belt values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 37 Design Specifications METRIC ENGLISH NOTES DIMENSIONS Overall length 2D H B Overall width Overall height Wheelbase Track Ground clearance Seating capacity Except cars with B16A2 engine Cars with B16A2 engine 4 080 mm 4 090 mm 4 070 mm 4 075 mm 1 695 mm 1 345 mm 1 355 mm 2 570 mm 1 475 mm 1 465 mm 160 mm 150 mm Five 5 Four 4 160 6 in 161 0 in 160 2 in 160 4 in 66 7 in 53 0 in 53 3 in 101 2 in 58 1 in 57 8 in 6 3 in 5 9 in For Finland only KQ KY KY Except VEi model with CATA DIMENSIONS Overall length 4D Overall width Overall height Wheelbase Track Ground clearance Seating capacity Except cars with B16A2 engine Cars with B16A2 engine 3 38 4 405 mm 4 415 mm 4 395 mm 1 695 mm 1 375 mm 1 390 mm 1 395 mm 2 620 mm 1 475 mm 1 465 mm 1 455 mm 160 mm 150 mm F
66. 04 30 3 1 19 2 1 Torque converter check valve spring 1 0 0 04 8 4 0 33 33 8 1 33 8 2 Modulator valve spring 1 2 0 047 7 0 0 276 27 2 1 071 8 0 Australia model and Czecho Slovakia 1 2 0 047 7 0 0 276 26 3 1 035 8 0 01626 engine model Relief valve spring 1 1 0 04 8 6 0 34 37 1 1 46 13 4 Cooler check valve spring 1 0 0 04 8 4 0 33 33 8 1 33 8 2 Governor spring A 1 0 0 04 18 8 0 74 32 9 1 30 4 1 Governor spring B 0 9 0 04 11 8 0 47 27 8 1 09 6 0 0 9 0 04 11 8 0 47 29 1 1 15 6 0 2 3 orifice control valve spring 0 9 0 04 6 6 0 26 33 2 1 31 14 9 1 3 kick down valve spring 1 0 0 04 6 6 0 26 29 9 1 18 14 7 2 3 4 orifice control valve spring 1 0 0 04 8 6 0 34 51 9 2 04 19 8 2nd ON orifice control valve spring 0 9 0 04 8 0 0 31 24 1 0 95 9 6 Throttle valve A spring 1 0 0 04 8 5 0 33 22 2 0 87 6 0 Throttle valve A spring 1 0 0 04 8 5 0 33 22 1 0 87 5 5 Throttle valve A spring 1 1 0 04 8 5 0 33 22 3 0 87 8 1 Throttle valve A spring 1 1 0 04 8 5 0 33 22 3 0 87 7 6 Throttle valve B adjusting spring 0 8 0 03 6 2 0 24 30 1 18 8 Throttle valve A adjusting spring 0 8 0 03 6 2 0 24 27 1 06 8 5 Throttle valve B spring 1 4 0 06 8 5 0 33 41 5 1 63 10 5 Throttle valve B spring 1 4 0 06 8 5 0 33 41 5 1 63 11 2 Throttle valve B spring 1 4 0 06 8 5 0 33 41 6 1 64 12 4 1 2 shift valve spring 0 45 0 018 5 1 0 20 52 8 2 08 29 1 2 shift valv
67. 1 4582 control Parking brake gear Throttle cam stopper height Servo body Shift fork shaft bore I D A B C Shift fork shaft valve bore 1 0 Oil pump Oil pump gear side clearance Oil pump gear to body clearance Drive Driven Oil pump driven gear LD Oil pump shaft O D 0 03 0 05 0 001 0 002 0 240 0 266 0 009 0 010 0 063 0 088 0 002 0 003 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 37 045 1 4585 0 07 0 003 Wear or damage Wear or damage cont d 3 29 Standards and Service Limits MEASUREMENT 4WD Automatic Transmission M25A cont d Section 14 STANDARD NEW SERVICE LIMIT Transfer shaft Diameter of needle bearing contact area Diameter of taper bearing contact area Diameter of drive bevel gear contact area Runout 54 000 54 015 2 126 2 127 16 989 17 000 0 6689 0 6693 24 979 25 000 0 983 0 984 0 02 0 001 max 53 94 2 124 16 93 0 667 24 92 0 98 0 05 0 002 Transfer drive bevel gear LD Diameter of taper bearing contact area 25 000 25 021 0 9843 0 9851 35 002 35 018 1 3780 1 3787 25 06 0 987 34 95 1 376 Transfer driven bevel gear Backlash Diameter of taper bearing contact area Locknut side MEASUREMENT Springs 3 30 Transfer driven gear side Wire Dia 0 10 0 15 0 004 0 006 35 002 35 018 1 3780 1 3787 27 987 28 0
68. 1 4959 Except D15Z1 IN Primary 35 900 1 4134 Mid 38 107 1 5003 Secondary 36 195 1 4250 EX 38 008 1 4964 Valve Valve clearance IN 0 18 0 22 0 007 0 009 EX 0 23 0 27 0 009 0 011 Valve stem O D IN 5 48 5 49 0 2157 0 2161 5 45 0 2183 EX 5 45 5 46 0 2146 0 2150 5 42 0 2134 Stem to guide clearance IN 0 02 0 05 0 001 0 002 0 08 0 003 EX 0 05 0 08 0 002 0 003 0 12 0 005 Valve seat Width IN 0 85 1 15 0 033 0 045 1 6 0 063 EX 1 25 1 55 0 049 0 061 2 0 0 079 Stem installed height IN 53 165 53 635 2 0931 2 1116 53 885 2 1215 EX 53 165 53 635 2 0931 2 1116 53 885 2 1215 Valve spring Free length 01521 IN 54 78 2 157 EX 58 23 2 293 58 26 2 294 2 Except 01521 IN 57 97 2 282 EX 58 41 2 300 Valve guide LD IN 5 51 5 53 0 217 0 218 5 60 0 220 EX 5 51 5 53 0 217 0 218 5 60 0 220 Installed height IN 17 85 18 35 0 703 0 722 EE EX 18 65 19 15 0 734 0 754 1 Rocker arm Arm to shaft clearance IN 0 017 0 050 0 0007 0 0020 0 08 0 003 EX 0 018 0 054 0 0007 0 0021 0 08 0 003 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring 3 3 Standards and Service Limits Cylinder Head Valve Train Section 6 D16A9 Engine MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 250 rpm and Nominal 1 3
69. 12 55 13 05 0 494 0 514 Rocker arm Arm to shaft clearance IN 0 025 0 052 0 0009 0 0020 0 08 0 003 EX 0 025 0 052 0 0009 0 0020 0 08 0 003 Measuring point between camshaft and rocker arm 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring 3 b Standards and Service Limits Engine Block Section 7 Except B16A2 Engine MEASUREMENT STANDARD NEW SERVICE LIMIT Cylinder block Wapage of deck surface 0 07 0 003 max 0 10 0 004 Bore diameter 75 00 75 02 2 953 2 954 75 07 2 956 Bore taper 0 05 0 002 Reboring limit 0 5 0 02 Piston Skirt O D At 16 mm 0 6 in 74 980 74 990 2 9520 2 9524 74 970 2 9516 from bottom of skirt Clearance in cylinder 0 010 0 040 0 0004 0 0016 0 05 0 002 Groove width for ring Top 01521 1 020 1 030 0 0402 0 0406 1 05 0 041 Except 01521 1 220 1 230 0 0480 0 0484 1 25 0 049 Second 01521 1 220 1 230 0 0480 0 0484 1 25 0 049 Except D15Z1 1 520 1 530 0 0598 0 0602 1 55 0 061 Oil D15Z1 01626 01627 D16Y1 2 805 2 820 0 1104 0 1110 2 85 0 112 01522 01582 01587 D16A7 D16A9 2 805 2 825 0 1104 0 1112 2 85 0 112 01281 01382 21383 01583 4 005 4 025 0 1577 0 1585 4 05 0 159 Piston ring Ring to groove Top D15Z1 0 035 0 060 0 0014 0 0024 0 13 0 005 clearance Except D15Z1 0 030 0 055 0
70. 122 F and the breaker 2 OFF above 70 C 158 F open the circuit to pre vent abnormal temperature rise 23 13 Seat Heaters KS model with Headlight Adjuster Circuit Diagram UNDER HOOD FUSE RELAY BOX IGNITION SWITCH BATTERY No 41 80A No 39 50A No 36 50A ONO WHT BLK WHT O O WHT RED YEL UNDER DASH FUSE RELAY BOX DRIVER S ND HR SWITCH 0 84W WHT BLK WHT GRN BLK GRN BLK BLK R SEAT BACK R SEAT CUSHION HEATER HEATER L SEAT HEATER R SEAT HEATER BR1 BREAKER OFF above 50 122 F TH1 THERMOSTAT OFF above 40 C 104 F J 6551 6651 6551 6551 H AKER 9 58 F BR2 BRE OFF above 70 C 1 y G552 G552 G552 G552 23 14 Switch Removal Pry the switch out of the console 2 Disconnect the 6 P connector to remove the switch SN V lt HEADLIGHT ADJUSTER SWITCH 6 P CONNECTOR DRIVER S FRONT PASSENGER S SEAT HEATER SWITCH Switch Test Pry the seat heater switch out of the console Check for continuity between the terminals accord ing to the table DRIVER S FRONT PASSENGER S SEAT HEATER SWITCH INDICATOR LIGHT 0 84W 23 15 Supplemental Restraint System SRS Type Ill KB model Component Wiring Location Index 23 18 Description 23 19 Circuit Diagram 23 20 Precautions Proced
71. 140 1 157 Adjust Reverse idler gear I D 20 016 20 043 0 7880 0 7890 20 08 0 791 Gear to shaft clearance 0 036 0 084 0 0014 0 0033 0 14 0 006 4 Super low Distance of needle bearing contact area 23 984 23 993 0 9443 0 9446 23 93 0 942 1st shaft Super low Diameter of needle bearing contact area 43 984 44 000 1 7318 1 7323 43 93 1 730 31 01 1 221 4WD Manual Transmission S22 Section 13 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Transfer shaft Diameter of needle bearing contact area Diameter of taper bearing contact area Diameter of drive bevel gear contact area Runout 54 000 54 015 2 126 3 127 16 989 17 000 0 6689 0 6693 24 979 25 000 0 983 0 984 0 02 0 001 53 94 2 124 16 93 0 667 24 92 0 98 0 05 0 002 Transfer drive bevel gear Transfer driven bevel gear Synchro ring 1 D Diameter of taper bearing contact area Backlash Diameter of taper bearing contact area Transfer driven gear side Locknut side Ring to gear clearance Ring pushed against gear 25 000 25 021 0 9843 0 9851 35 002 35 018 1 3780 1 3787 0 10 0 15 0 004 0 006 35 002 35 018 1 3780 1 3787 27 987 28 000 1 1018 1 1024 0 85 1 10 0 033 0 043 25 06 0 987 34 95 1 376 Adjust 34 95 1 376 27 93 1 100 0 4 0 02 1st 2nd sh
72. 15 0 002 0 006 gear Pinion gear bore diameter 18 042 18 066 0 7103 0 7112 Pinion gear to pinion shaft clearance 0 059 0 095 0 0023 0 0037 0 15 0 006 Set ring to bearing outer race 0 0 10 0 0 004 Adjust 0 0 15 0 0 006 Rear Differential 4WD Transmission Section 15 MEASUREMENT STANDARD NEW Differential carrier Oil capacity 1 2 1 3 US qt 1 1 Imp qt for overhaul assembly 1 0 1 1 US qt 0 9 Imp qt for oil change 3 32 Steering Section 17 MEASUREMENT Unit of length mm in STANDARD NEW Steering wheel Play at steering wheel circumference Starting load at steering wheel circumference N kg Ib Manual steering Power steering Engine running LHD RHD 0 10 0 0 4 13 18 1 3 1 8 2 87 3 97 Except B16A2 30 3 0 6 6 B16A2 25 2 5 5 5 25 2 5 5 5 Gearbox Angle of rack guide screw loosened M S from locked position P S LHD RHD Preload at pinion gear shaft kg cm Ib in M S P S 50 10 20 25 max 0 5 1 7 5 17 4 3 14 8 0 6 1 1 6 11 5 21 9 55 Pump pressure with valve closed LHD oil temp speed 40 105 F min idle RHD Do not run for more than 5 seconds kPa kg cm psi 8 000 9 000 80 90 1 138 1 280 5 500 6 500 55 65 782 924 Power steering fluid Power steering belt Recommended power steering fluid Fluid capac
73. 17 4 2nd accumulator D12B1 D15B3 20 2 0 795 75 3 2 965 10 8 spring D16A9 20 2 0 795 75 1 2 957 9 8 4th accumulator spring 18 6 0 732 82 7 3 256 12 0 Reverse timing valve spring 5 6 0 220 43 8 1 724 21 7 Servo control valve spring 7 6 0 299 39 4 1 551 18 2 Lock up shift D12B1 D15B3 8 1 0 319 39 0 1 535 15 4 valve spring D16A9 8 1 0 319 51 8 2 039 22 3 Lock up timing valve spring 6 6 0 260 52 3 2 059 30 1 Governor spring A 18 8 0 740 20 4 0 803 4 0 Governor spring B 11 8 0 465 30 9 1 217 6 0 11 8 0 465 26 7 1 051 6 0 Kick down valve spring 10 1 0 398 33 2 1 307 10 3 Orifice control D12B1 D15B3 6 1 0 240 36 2 1 425 14 6 valve spring D16A9 6 1 0 240 36 0 1 417 19 8 Shift timing valve spring 8 6 0 339 42 9 1 689 21 4 4th exhaust valve spring 6 1 0 240 43 7 1 720 20 3 Accumulator control D12B1 D15B3 8 6 0 339 46 9 1 846 15 2 valve spring D16A9 8 6 0 339 45 6 1 795 14 7 Lock up cut valve spring 7 6 0 299 d 29 0 1 142 18 0 Reverse control valve spring 7 6 0 229 37 2 1 465 15 3 CPC Clutch Pressure Control 8 6 0 339 18 2 0 717 valve spring 1st accumulator one way ball spring 4 0 0 157 14 0 0 551 1st accumulator spring 21 5 0 846 58 8 2 315 1st accumulator spring B 7 5 0 295 39 0 1 535 3 21 Standards and Service Limits 2WD Automatic Transmission M24A Section 14 Transmission fluid Hydraulic pressure kPa kg cm2 p
74. 1ST CLUTCH THROTTLE B SUCTION 1ST HOLD CLUTCH THROTTLE B GOVERNOR CUT VALVE BLEED ist cLurcHi amo steen 187 ACCUMULATOR LOCK UP CONTROL SOLENOID VALVI LOCK CONTROL SO ENOIO VAL B acd gt 157 ACCUMULATOR d ACCUMULATOR d s 4 vauvE 1 DN FI e 2 x uia x agi 7 vj ck dh Foo m mero 7 peo ON GRECE SE E H 7 TH EXHAUST VALVE TORQUE CONVERTER at TJ un 4 a e x VN a x THROTTLE VALVE DI m as n X e s ed 4ERULATQR REVERSE SERVO CONTROL TOCK UP TIMING VALVE contra d Ivan l VALVE s T x xor PA MODULATOR YALYE MAOTTLE te BER CONVERTER CHECK VALVE D QIL COOLER GOveRnoe 14 3 Hydraulic System Symptom to Component Chart SYMPTOM Check these items on the PROBABLE CAUSE
75. 25 mm CHANGE ROD 22 N m 2 2 kg m 16 Ib ft SPRING PIN Replace YSPIN DRIVER 8 0 mm 07744 0010600 ed 7 UP SHIFT ROD BOOT CLIP DOWN cont d 13 7 Transmission Assembly Installation cont d 13 Install exhaust pipe A SELF LOCKING NUT Replace 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft GASKETS Replace GASKET Replace EXHAUST PIPE A SELF LOCKING NUT SELF LOCKING NUT Replace Replace 8 x 1 25 mm 10 x 1 25 mm 16 N m 1 6 kg m 55 N m 5 5 kg m 12 Ib ft 40 Ib ft 14 Install the intermediate shaft and driveshafts NOTE Use the set rings with new ones 15 Install the ball joint onto the lower arm 16 Install the damper fork INTERMEDIATE DRIVESHAFT SHAFT 10 x 1 25 mm 40 4 0 kg m 29 Ib ft COTTER PIN 10 x 1 25 mm Replace 44 N m 4 4 kg m 32 Ib ft 12 x 1 25 mm 50 60 N m 5 0 6 0 kg m SELF LOCKING NUT 36 43 Ib ft Replace 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft 17 Install the transmission mounting bolts and lower starter mounting bolt VE Ex 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft TRANSMISSION MOUNTING BOLTS 12 x 1 25 mm 65 N m 6 5 kg m 47 18 Install the slave cylinder then install the clutch pipe bracket NOTE Use only HONDA Genuine Urea Grease UM264 P N 41211 305 CLUTCH PIPE BRACKET 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft
76. 4 0 33 8 6 0 34 8 1 0 32 6 6 0 26 6 4 0 25 88 1 3 488 44 0 1 73 30 3 1 19 36 4 1 43 33 8 1 33 38 5 1 52 35 9 1 41 41 3 1 63 30 0 1 18 40 4 1 59 35 8 1 41 59 7 2 35 71 3 2 81 59 5 2 34 81 0 3 19 88 4 3 48 78 7 3 10 47 9 1 89 43 6 1 72 33 0 1 30 51 0 2 01 42 7 1 68 36 4 1 43 18 2 0 72 42 0 1 65 37 0 1 46 42 7 1 68 Inside diameter No of Coils Differential 2WD M T S20 Section 15 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Final driven gear Backlash 0 07 0 130 0 0028 0 0051 0 180 0 0071 Differential carrier Differential pinion gear Set ring to bearing outer race Pinion shaft bore diameter Carrier to pinion shaft clearance Driveshaft bore diameter Carrier to driveshaft clearance Backlash Pinion gear bore diameter Pinion gear to pinion shaft clearance 18 000 18 018 0 7087 0 7094 0 013 0 047 0 0005 0 0019 26 025 26 045 1 0246 1 0254 28 025 28 045 1 1033 1 1041 0 045 0 086 0 0018 0 0034 0 05 0 15 0 002 0 006 18 042 18 066 0 7103 0 7113 0 055 0 095 0 0021 0 0037 0 095 0 004 0 14 0 006 0 15 0 006 Differential 2WD M T Y21 Section 15 MEASUREMENT 0 0 1 0 0 004 STANDARD NEW Adjust with shim SERVICE LIMIT Final driven gear Backlash 0 090
77. 8 015 0 3150 0 3156 2 025 2 060 0 080 0 081 Wear or damage Wear or damage 8 95 0 352 5 95 0 234 7 95 0 313 7 95 0 313 1 80 0 071 6 045 0 2380 9 030 0 355 8 030 0 3161 8 030 0 3161 2 080 0 082 35 000 35 025 1 3780 1 3782 5 90 6 00 0 232 0 236 27 0 27 1 1 063 1 067 35 050 1 3799 5 40 0 213 Wear or other defect Servo body Shift fork shaft bore LD 14 000 14 010 0 5512 0 5516 Shift fork shaft valve bore I D 37 000 37 039 1 4567 1 4582 37 045 1 4585 Oil pump Oil pump gear side clearance Drive 0 03 0 05 0 001 0 002 0 07 0 003 Driven 0 04 0 06 0 0016 0 0024 0 07 0 003 Oil pump gear to body clearance Drive 0 210 0 265 0 0083 0 0104 Driven 0 070 0 125 0 0028 0 0049 Oil pump driven gear LD Oil pump shaft O D 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 Wear or damage Wear or damage cont d 3 25 Standards and Service Limits 2WD Automatic Transmission 24 cont d Section 14 STANDARD NEW MEASUREMENT Wire Dia O D Free Length No of Coils Springs Regulator valve spring A 1 8 0 07 14 7 0 58 88 1 3 468 16 5 D16Y1 01676 Regulator valve spring A 1 8 0 07 14 7 0 58 86 5 3 406 16 5 D15B2 D15B7 Regulator valve spring B 1 8 0 07 9 6 0 38 44 0 1 73 7 5 Stator reaction spring 5 5 0 22 26 4 1
78. 9 Install the drain plug oil filler plug and breather tube assembly BREATHER TUBE ASSEMBLY j OIL FILLER PLUG 48 N m 4 8 kg m Replace DRAIN PLUG 48 N m 4 8 kg m 35 Ib ft 15 24 Driveshafts Special Tools 4WD 16 2 Rear Driveshafts Disassembly Ui 16 3 Disassembly Inspection 16 4 Reassembly 16 5 Propeller Shafts Inspection 16 8 Removal 16 9 Disassembly 16 10 Reassembly 16 12 Installation 16 13 Outline of Model Changes The rear driveshafts and the propeller shafts for cars with 4WD have been changed Special Tools 4WD Tool Number Description Oty Page Reference 07PAB 0020000 Companion Flange Holder 1 16 10 13 16 2 Rear Driveshafts Disassembly 1 Remove the set ring from the inboard joint 2 To remove the boot band pry up the locking tabs with a screwdriver and raise the end of the band CAUTION Take care not to damage the boot NOTE Carefully clamp the driveshaft in a vise with soft jaws BOOT BAND Replace INBOARD JOINT ncm RING Replace 3 Mark each roller and inboard joint to identify the locations of rollers and g
79. ABS INSPECTION CONNECTOR 19 3 Troubleshooting Symptom to System Chart PROBLEM CODE PROBLEMATIC AFFECTED OTHER COMPONENT PAGE PAGE 4 5 5 MAIN SUB YSTEM FRONT FRONT REAR REAR CODE CODE RIGHT LEFT RIGHT LEFT Solenoid ABS pump motor ABS pump motor over run Pressure switch ABS Motor relay O ABS 19 5 Motor check fuse SE prog emi ABS Motor fuse High pressure u _ D Solenoid I leakage a Pressure D CS _ _ switch Accumulator gas leakage i B Parking brake 1 Brake fluid level 2 O switch related E switch probiem Brake system light D Wheel sensor G 9 Pulser s installation 9 Wheel sensor Modulator 5 4 Wheel Rear brake drag oO SCH F REECH i 5 q Fail safe relay 19 8 Function Test j G eoa 5 19 4 Solenoid related problem ABS B1 fuse Front fail safe relay Rear fail safe relay ABS Flowcharts Problem Code 1 2 ABS Pump Motor Circuit Problem CAUTION Use only the digital multimeter to check the system NOTE f a malfunction is detected this code appears and the fail safe function is activated The ABS indicator light comes ON after restarting the engine until the malfunction code is erased by discon
80. C and check for a short to power in the cable reel 1 Turn the ignition switch OFF 2 Remove the dashboard lower cover and disconnect the cable reel 6 P connector from the SRS main harness 3 Connect Test Harness C to the cable reel 6 P connector 4 Connect a voltmeter between the No 4 terminal of Test Harness C and ground 5 Turn the ignition switch ON Il and measure voltage There should be 0 5 V or less 6 Connect the voltmeter between the No 5 terminal and ground and measure voltage There should be 0 5 V or less Are voltages as specified YES NO Short to power in the cable reel replace the cable reel see page 23 62 Short to power in the SRS main harness replace the harness SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT TEST HARNESS B 07MAZ SP00500 NOTE Do not connect the jumper wires TEST HARNESS B 07MAZ 5 00500 CABLE REEL 6 P CONNECTOR TEST HARNESS C 07LAZ SL40300 TEST HARNESS C 07LAZ SL40300 23 39 Troubleshooting DTC 1 4 accidentally deploy and cause damage or injuries CAUTION Whenever the ignition switch is ON 1 or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could Check for a short to ground in the driver s airbag inflator 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three
81. CABLES 13 12 8 Remove the clutch pipe bracket and the slave cylin 10 Remove the engine splash shield der NOTE Do not operate the clutch pedal once the slave cylinder has been removed CLUTCH ENGINE SPLASH SHIELD PIPE BRACKET 9 Remove the three upper transmission mounting 11 Disconnect the oxygen sensor connector then bolts and lower starter motor mounting bolt remove exhaust pipe A OXYGEN SENSOR CONNECTOR GASKETS Replace STARTER TRANSMISSION MOTOR MOUNTING MOUNTING BOLTS Replace EXHAUST PIPE POET SELF LOCKING NUT SELF LOCKING NUT Replace Replace cont d 13 13 Transmission Assembly Removal cont d 12 Remove the cotter pins and loosen the castle nuts then separate the ball joints from the lower arm see section 18 13 Remove the right damper fork SELF LOCKING NUT Replace COTTER PIN DAMPER CASTLE NUT FORK 14 Remove the driveshafts and the intermediate shaft see section 16 NOTE Coat all the precision finished surfaces with clean engine oil or grease Tie plastic bags over the driveshaft ends SET RING Replace SET RING Replace AS Sex QA CHO DRIVESHAFT H DRIVESHAFT SET RING INTERMEDIATE SHAFT Replace 15 Remove the bolt then disconnect the change exten sion 16 Remove the clip and the spring pin then disconnect the change rod 8x 22mm CHANGE SPRING PIN ROD
82. ECU A11 and control T solenoid valve YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU 11 40 Manual Transmission 2WD Manual Transmission cya mL 13 1 Y21 2WD Manual Transmission S20 Transmission Assembly Removal 13 2 Installation 13 6 Outline of Model Changes The transmission mount right front mount bracket and rear mount bracket have been modified Torque value of transmission mounting bolts have been changed Torque value of transmission mount bolt has been changed installed of transmission breather cap has been changed Transmission Assembly Removal WARNING e Make sure jacks and safety stands are placed proper ly see section 1 e Apply parking brake and block rear wheels so car will not roll off stands and fall on you while working un der it CAUTION Use fender covers to avoid damaging painted surfaces 1 Disconnect the negative cable first then the pos itive cable from the battery 2 Remove the intake air pipe intake air duct and air cleaner housing assembly 3 Drain transmission oil AIR CLEANER INTAKE HOUSING AIR PIPE ASSEMBLY INTAKE AIR DUCT 4 Disconnect the starter motor cables and transmis sion ground wire 5 Remove the engine wire harness clamp 6 Disconnect the b
83. EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR ING OF THE INFLATOR WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDEN TALLY DEPLOYED CAN SERIOUSLY HURT YOU FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY 1 10 S R S a TS UALS Bell dsl ilga Slow sik pag 3021 S R s GLOY aUa S acia Mala al O yall Ae els w ll a Slane postin Bn Al 559 cl Sas S R S 362 SH Al Jad M gas Vao SA alas A otis gi RSUN opal 5 55 ga SRS AIRBAG SYSTEM KB A CABLE REAL CAUTION A REFER TO SERVICE MANUAL FOR DETAILED IN STRUCTION POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS E Z 88070 lt AUSF HRLICHE ANMEISUNGEN SIND DEM ZU ENTINEMEN RAAD PLEEG HET WERKPLAATSHANDBOEK VOOR NA DERE AANWIJZINGEN B STEERING WHEEL NOTICE NOTICE IMPROPER STEERING WHEEL REMOVAL OR INSTALLATION CAN DAMAGE SRS COMPONENTS FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY REMARQUE UN RETRAIT OU UNE REPOSE INCORRECTS DU VOLANT RISQUENT D ENDOMMAGER LES PIECES CNSTITUTIVES DU SRS SUIVRE ATTENTIVMENT LE MANUEL D EN TRETIEN C DRIVER MODULE WARNING WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDEN TALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU DO NOT
84. FR IN YEL BLU FR OUT YEL BLK FL OUT View from ABS control unit terminal side No 8 RED BLU Front Right Inlet No 1 YEL BLU Front Right Outlet No 10 RED BLK Front Left Inlet No 3 YEL BLK Front Left Outlet Is there continuity Remove the rear fail safe relay Check for continuity between the 18 YEL GRN terminal and body ground Is there continuity NO To page 19 10 Repair short in wire between the solenoid and ABS control unit RED BLU Front Right Inlet YEL BLU Front Right Outlet RED BLK Front Left Inlet YEL BLK Front Left Outlet YES 18P CONNECTOR 30 29 28 27 26 25 24 22 21 20 19 1817116 15 14113 Repair short YEL GRN wire between the ABS control unit and front fail safe relay YES YEL GRN FSR View from ABS control unit terminal side cont d 19 9 Troubleshooting Flowcharts cont d From page 19 9 Reinstall the front fail safe relay Turn the ignition switch ON Check for voltage between the ABS control unit connector No 18 YEL GRN terminal and body ground Is there battery voltage YES Check for loose ABS control unit connectors If necessary sub stitute a known good ABS con trol unit and recheck 19 10 NO Repair open in YEL GRN wire between the front fail safe relay and AB
85. Flowchart Fuel Supply System D15B7 01521 01676 01627 D16Y1 01629 B16A2 engine Self diagnosis Check Engine light indicates code 43 Most likely a problem in the Oxygen O2 Sensor circuit or a problem in the Fuel Supply System JC 43 ef Xu au From code 1 troubleshooting page 11 20 Check Engine light has been reported on With the SCS short connector connected page 11 9 CODE 43 is indicated Is the 43 code accompanied by YES the Check Engine light and poor Go to Fuel Supply System driveability NO Do the ECU Reset Procedure page 11 10 Warm up engine to normal oper ating temperature cooling fan comes on Connect the SCS short connector to the service check connector see page 11 9 Hold engine at 3 000 min 1 rpm for two minutes A T Transmission in N or P Intermittent failure system is OK at this time test drive may be Is the Check Engine light on and NO necessary does it indicate CODE 43 Check for poor connections or loose wires at O2 sensor and ECU Turn the ignition switch OFF Connect the test harness be NOTE tween the ECU and connector e Use DIGITAL CIRCUIT TESTER Commercially available or 07411 002000 e Use 2 Volt range ooooooooooooo oooooooo OOOO0000000
86. N m 6 5 kom CASTLE NUT 50 60 N m 5 0 6 0 kg m Replace cont d 36 43 Ib ft 13 19 Transmission Assembly Installation cont d 18 Install the slave cylinder then install the clutch pipe bracket NOTE Use only HONDA Genuine Urea Grease UM264 P N 41211 305 CLUTCH PIPE 6 x 1 0 mm RACKET 8 10 N m 1 0 kg m 7 Ib ft SLAVE CYLINDER 8 x 1 25 mm P N41211 PY5 305 22 2 2 kg m PNA 16 Ib ft 19 Connect the speed sensor connector and the starter motor cables 20 Installthe wire harness clamps 6 x 1 0 mm SPEED 10 N m 1 0 kg m 7 Ib ft SENSOR 8 x 1 25 mm CONNECTOR 8 8 N m 0 9 kg m STARTER HARNESS MOTOR CLAMPS CABLES 13 20 21 Install the lower radiator hose clamp on transmis sion hanger B 22 Connect the transmission ground wire and the back up light switch connector 8 x 1 25 mm LOWER RADIATOR 22 N m 2 2 kg m HOSE CLAMP 16 Ib ft BACK UP LIGHT SWITCH CONNECTOR TRANSMISSION TRANSMISSION GROUND WIRE HANGER B 23 Install the air cleaner housing assembly intake air duct and intake air pipe 6 x 1 0 mm 10 N m 1 0 kg m AIR CLEANER dicas HOUSING INTAKE AIR DUCT ASSEMBLY INTAKE AIR PIPE 24 Refill the transmission with oil 25 Connect the positive cable first then the nega tive cable to the battery 26 Check the clutch operation 27 Shift the transmission and check for smooth opera tion 28 Check t
87. No 1 PROPELLER SHAFT 5 lt gt lt D YOKE NUT YOKE NUT FLANGE BOLT 10 x 1 25 mm 40 N m 4 0 kg m 29 Ib ft 12 POINT BOLT 8 x 1 25 mm 33 N m 3 3 kg m 24 Ib ft YOKE NUT No 2 PROPELLER SHAFT 12 POINT BOLT 8 x 1 25 mm 33 N m 3 3 kg m 24 lb ft Align the slots on the hubs 16 12 Reassembly Install the center bearing support onto the No 1 propeller shaft as shown below Install the propeller shaft hub on the No 1 propeller shaft by aligning the marks then loosely install the new hub nut Hold the propeller shaft hub with a special tool and tighten the hub nut HUB NUT 22 x 1 5 mm 60 N m 6 0 kg m 43 Ib ft NOTE After tightening use a drift to stake the hub nut shoulder against the shaft CENTER BEARING SUPPORT No 1 PROPELLER SHAFT PROPELLER SHAFT HUB COMPANION FLANGE HOLDER 07PAB 0020000 Align marks Installation Connect the No 1 propeller shaft to the front differ ential with the four 12 point bolts and yoke nuts by aligning the marks Align marks No 1 PROPELLER SHAFT YOKE NUT Flat portion faces 12 POINT BOLT center of the shaft 33 N m 3 3 kg m 24 Ib ft Install the center bearing support of the No 1 pro peller shaft onto the flame with the two flange bolt as shown below Connect the No 1 and No 2 propeller shaft with the four 12 point bolts and yoke nuts by aligning the slots on the hubs YOK
88. R 24 5 0 96 63 5 2 5 L REAL TIME 4WD EMBLEM 24 5 0 96 58 2 28 20 11 Heater and Air Conditioning Air Conditioning 22 1 Outline of Model Changes Due to the introduction of new refrigerant HFC 134a R 134a part descriptions warnings and handling in formation were rewritten accordingly Air Conditioning Description Outline sii o uuu ai 22 2 Compressor Relief Valve Replacement 22 3 A C Service Tips 22 4 A C System Service Discharge 22 5 Evacuation 22 6 Charging 22 7 Leak Test 22 8 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 m www CONDENSER m Fp RECEIVER DRYER Less liquefied More liquefied low pressure vapor low pressure vapor Absorption of heat EVAPORATOR lt EXPANSION VALVE EVAPORATOR SUCTION LINE COMPRESSOR DISCHARGE LINE RECEIVER DRYER CONDENSER This car uses HFC 134a R 134a refrigerant which does
89. REPAIR Car creeps R1 R2 Car does not move in or Da R4 Transmission locks up in R12 Excessive drag in transmission R6 Sep Excessive vibration rpm related R7 Noise with wheels moving only R5 Main seal pops out R8 NOTES CHART Various shifting problems R9 R10 Harsh upshifts R11 PROBABLE CAUSE DUE TO IMPROPER REPAIR R1 Improper clutch clearance R2 Improper gear clearance R3 Parking brake lever installed upside down R4 One way sprag clutch installed upside down Reverse selector hub installed upside down Oil pump binding Torque converter not fully seated in oil pump Main sea improperly installed Springs improperly installed Valves improperly installed Ball check valves not installed Shift fork bolt not installed 14 6 Set idle rpm in gear to specified idle speed If still no good adjust motor mounts as outlined in engine section of service manual If the large clutch piston O ring is broken inspect the piston groove for rough machining If the clutch pack is seized or is excessively worn inspect the other clutches for wear and check the orifice control valves and throttle valves for free movement If throttle valve B is stuck inspect the clutches for wear If the 1 2 shift valve is stuck closed the transmission
90. SLAVE CYLINDER B ss 22 N m 2 2 kg m 16 Ib ft P N 41211 PY5 305 13 8 19 Connect speed sensor back up light switch con 22 Turn the breather cap so that the F mark points at nectors transmission ground wire and starter ca an angle of 30 towards the front of the car as shown bles NOTE When installing the starter cable make sure Front that the crimped side of the ring terminal is facing out see section 23 20 Install the wire harness clamp BREATHER 8 x 1 25 mm 22 N m 2 2 kg m 16 BACK UP LIGHT SPEED SWITCH CONNECTOR SENSOR CONNECTOR 8 x 1 25 mm 23 Refill the transmission with oil 8 8 N m 0 9 kg m STARTER TRANSMISSION Soh CABLES GROUND WIRE 24 Connect the positive cable first then the negative cable to the battery 21 Install the intake air duct air cleaner housing as sembly and intake air pipe 25 Check the clutch operation 26 Shift the transmission and check for smooth opera tion 6 x 1 0 mm AIR CLEANER e 7 10 1 0 kg m HOUSING 27 Adjust ignition timing see section 23 7 lb ft ASSEMBLY 28 Check the front wheel alignment see section 18 INTAKE INTAKE AIR DUCT AIR PIPE 13 9 2WD Manual Transmission Y21 Transmission Assembly Removal 13 12 Shift Fork Assembly Index luu sua uw PM dies 13 16 Transmiss
91. SRS indicat indicator 4 light OFF 1 i MES connector terminals 23 28 o 4 sec or less Turn the ignition switch ON II The SRS indicator light comes on for about six sec onds and goes off Remove the SCS short connector from the MES connector within four seconds after the SRS indicator light went off The SRS indicator light comes on again Reconnect the SCS short connector to the MES connector with in four seconds after the SRS indicator comes on The SRS indicator light goes off Remove the SCS short connector from the MES connector within four seconds The SRS indicator light indicates that the memory is erased by blinking two times 4 sec or less lt Blinking 1 U 1 1 1 CONNECTED n i 1 I 1 i DISCONNECTED sRs Diagnostic Trouble Code DTC Chart NEC SRS indicator light Possible cause Corrective action See page doesn t come on Faulty SRS indicator light circuit Troubleshooting 23 31 Open in the driver s airbag inflator or 23 34 increased resistance Short to another wire in the driver s airbag 23 36 inflator or decreased resistance Troubleshooting Short to power in the driver s airbag inflator 23 38 Short to ground in the driver s airbag inflator 23 40 Open in the passenger s airbag inflator or 23 43 increased resistance Short to another wire in the passenger s 4 airbag inflator or decrea
92. SRS unit and connect Test Harness B be tween the 18 P connector and the SRS unit 5 Check for continuity between the No B13 and ter minals of Test Harness B Is there continuity YES NO Check for short to ground in the SRS main harness 1 Disconnect the SRS main harness 2 P connector from the fuse relay box 2 Check for continuity between the No B13 and B5 terminals of Test Harness B Is there continuity YES NO Short to ground in the SRS main harness replace the harness Short to ground in the SRS fuse block replace the SRS fuse block Faulty SRS unit replace the SRS unit To page 23 55 UNDER DASH FUSE RELAY BOX To SRS MAIN HARNESS 2 P CONNECTOR SRS FUSE 24 BLOCK U SR FUSE SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT TEST HARNESS B 07MAZ SP00500 A JEBEBHBHBEE BE EE 23 54 From page 23 54 Connect Test Harness B 1 Disconnect the negative battery cable then the positive cable and wait for three minutes 2 Connect the short connectors RED to the airbag connec tors see page 23 25 3 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the 18 P connector and the SRS unit 4 Reconnect the battery positive cable then the negative cable Check for an open in the SRS main harness 1 Connect a voltmeter
93. Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer 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 service work must be performed by an authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbags Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON Il SRS Type lll All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of the KB model in the dash board above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type Il Steering wheel Be careful not to bump the steering wheel as the SRS unit sensors inflator etc are located in it Behind the dashboard Under dash fuse relay box SRS Type Steering wheel Behind the dashboard Under dash fuse relay box Front console Car stereo units and other acce
94. Test Harness B and the No 4 terminal of the SRS main harness 6 P connector Is there continuity YES NO Open in the SRS main harness replace the harness D E To page 23 52 6 CONNECTOR 2 5 6 SRS MAIN HARNESS D 2 C4 DASHBOARD WIRE HARNESS 5 P CONNECTOR CONNECTOR E SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT TEST HARNE S B 07MAZ SP00500 21214 14 12 14 16 16 17 2 4 5 7 yy 12 13 14 16 17 BLU View from wire side cont d 23 51 Troubleshooting DTC 9 1 or No Code cont d From page 23 51 D E Check for continuity between terminals No B11 and No B5 of Test Harness B Is there continuity YES Failure in the SRS unit due to short to ground in the SRS main harness replace the SRS main harness and the SRS unit NO Faulty SRS unit replace the SRS unit Check the SRS indicator light circuit 1 Turn the ignition switch OFF 2 Connect the SRS main harness 6 P connector to the main wire harness 3 Disconnect the main wire harness 14 P connector from the dashboard wire harness 4 Connect a voltmeter between the No 14 terminal of the main wire harness 14 P connector and ground 5 Turn the ignition switch ON Il and measure voltage Is there 8 5 V or more six seconds after the ignition sw
95. at least three min utes 2 Confirm that the special tool is functioning properly by following the check procedure on the tool box label or on page 23 61 Driver s Airbag 3 Remove the access panel then disconnect the 3 P connector between the driver s airbag and the cable reel CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR ACCESS PANEL Front Passenger s Airbag 4 Remove the glove box and access panel then dis connect the 3 P connector between the front pas senger s airbag and SRS main harness FRONT PASSENGER S AIRBAG 3 P CONNECTOR GLOVE BOX 5 Cut off the airbag connector strip the ends of the airbag wires and connect the special too alligator clips to the airbag Place the special tool about 10 meters thirty feet away from the airbag DRIVER S FRONT PASSENGER S AIRBAG AIRBAG ALLIGATOR ALLIGATOR CLIPS CLIPS Yellow Yellow OPERATION SWITCH DEPLOYMENT TOOL 07 2 5600400 12 V BATTERY 23 60 Connect 12 volt battery to the tool e the green light on the tool comes on the air bag igniter circuit is defective and cannot deploy the airbag Go to Damaged Airbag Special Pro cedure e Ifthe red light on the tool comes 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 e f au
96. cable reel 3 P con nector 5 Connect the SCS short connector to the service check connector 6 Reconnect the battery positive cable then reconnect the negative cable 7 Turn the ignition switch ON II and record the most recent DTC Is DTC 1 1 or DTC 1 2 indicated 1 1 1 2 Open in the driver s airbag inflator re place the driver s airbag assembly see page 23 56 Connect Test Harness C 1 Turn the ignition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Remove the glove box and connect the short connector RED to the passenger s airbag assembly see page 23 25 4 Remove the dashboard lower cover and disconnect the cable reel 6 P connector from the SRS main harness Connect Test Harness C to the cable reel 6 P connector NOTE e Do not connect the battery cables e Disconnect only the SCS short connector To page 23 35 DRIVER S AIRBAG ASSEMBLY CABLE REEL 3 P CONNECTOR ___ SRS CONNECTOR SHORT CONNECTOR A RED 07MAZ SP0020A SRS INDICATOR LIGHT IDATA LINK CONNECTOR DLC 07PAZ 001010A MEMORY ERASE SERVICE SCS SHORT SIGNAL MES CHECK CONNECTOR CONNECTOR 2 P CONNECTOR 2 P BLK WHT BLK TEST HARNESS C 07LAZ SL40300 23 34 From page 23 34 Ch
97. center of the speedometer testers and free rollers respec tively CAUTION Be sure that the front and rear wheels are set at the center of the speedometer tester and free rollers securely or the car can roll hard or dash out during the test which is very dangerous Attach the ropes to the trailing hook and tie down hooks to secure the car For prevention of the car from rolling hard or dashing out during the test CAUTION Be sure that the ropes attached to the car for prevention of rolling are not slack Slack ropes do not effectively secure the car and the car can roll during the test Attach the ropes to the car not to interfere with the bumper Do not the ropes to any section other than the specified section ROPE for prevention of the car from dashing out Attach to the trailing hook ROPE for prevention ROPE for prevention of of the car from rolling the car from rolling Attach to the tie down Attach to the trailing hook hook Start the engine With the gearshift lever in the 3rd range on the manual transmission car or the gear shift lever in the D1 or D2 position on the automatic transmission car start the car and raise the speed gradually CAUTION Take care not to exceed 50 km h of speed and do not test for more than 3 minutes con WHEELBASE tinuously Set the positioning After the test slow down the car until it stops by POSITIONING LIN notches on the line app
98. circulates between the oil pumps Therefore the hydraulic pressure is not applied on the clutch piston and the driving force is not directed to the rear wheels that is the car is in 2WD condition FRONT OIL PUMP REAR OIL PUMP E E OIL STRAINER 15 6 Forward Drive Quick Braking 2WD Rear wheel speed is higher than the front wheel speed e When quick braking in forward gear the hydraulic pressure is produced by the rear oil pump as the rear wheel speed is higher than the front wheel speed due to the brake characteristics e The oil is drawn out of the strainer by the rear oil pump passes then through check valve and is pressured by the rear oil pump e Asthe pressured oil is directed to the inlet port of the rear oil pump it is drawn into the rear oil pump again The pressured oil simply circulates through the rear oil pump Therefore no hydraulic pressure is applied on the clutch piston and the driving force is not transmitted to the rear wheels that is the car is in 2WD condition REAR OIL PUMP OIL STRAINER Reverse Drive Quick Starting 4WD Front wheel speed is higher than the rear wheel speed e When quick starting in reverse gear the hydraulic pressure is produced by the front pump as the front wheel speed is higher than the rear wheel speed e The front oil pump rotates in the reverse direction to that of when starting the car in forward gear The oil is drawn out
99. deploy and cause damage or injuries e Before you disconnect any part of an SRS wire har ness connect the short connectors RED to the air bags e Refer to additional precautions beginning on page 23 21 in the SRS sub section Remove the dashboard lower cover then disconnect the 10 P connector from the integrated control unit Next remove the integrated control unit from the under dash fuse relay box Inspect the connector and socket termi nals to be sure they are all making good contact e if any terminals are bent loose or corroded re pair them as necessary and recheck the system e If the terminals look OK make the following in put tests at the connector and socket terminals f any test indicates a problem find and correct the cause then recheck the system f all the input tests prove OK the control unit must be faulty replace it NOTE Do not disconnect any other connectors from the under dash fuse relay box except those for the integrated control unit INTEGRATED CONTROL UNIT 10 P CONNECTOR SRS Type ll nu SRS UNIT With built in sensors SRS MAIN HARNESS Covered with yellow insulation SRS Type SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors mm num H JKLMN UNDER DASH FUSE RELAY BOX View from wire side BLU GRN RED BLU a GRN RED LT GRN RED BLU WHT BLU WHT cont
100. from the sensor Disconnect the connector from the main wire harness Turn the ignition switch ON Measure voltage between D14 terminal and 26 terminal lt Is there more than 0 1 V NO Measure voltage at the engine wire harness side of the O2 sen sor connector between GRN WHT and WHT YES Is there more than 0 1 V Repair open in WHT wire be tween ECU 014 and sensor If wire is OK check for open in GRN WHT wire between ECU D22 and sensor B16A2 engine O2 SENSOR SOCKET WRENCH 07LAA PT50101 11 22 O2 SENSOR 45 N m 4 5 33 Ib ft YES Repair short in WHT wire be tween ECU D14 and O sensor Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU Replace O2 sensor D15B7 01521 01626 01627 D16Z9 D16Y1 engine SENSOR 45 N m GRN WHT WHT SET 4 5 kg m DIGITAL CIRCUIT TESTER Commercially available or 07411 002000 kg m 33 Ib ft Oz SENSOR SOCKET WRENCH 07LAA PT50101 lt Pa Self diagnosis Check Engine light indicates code 3 An electrical problem in the Manifold Absolute 77 r Pressure MAP Sensor system Troubleshooting Flowchart MAP Sensor Except D15B2 engine Breif 5 Self diagnosis Check Engine light indicates code 5
101. from the clutch housing D 6 mm SPECIAL BOLT 2 LOCK WASHER 5TH REVERSE SHIFT PIECE 3RD 4TH SHIFT FORK 5 5TH SHIFT FORK 5TH REVERSE SHIFT FORK SHAFT 4 Remove the reverse shift holder assembly REVERSE SHIFT HOLDER ASSEMBLY DOWEL PIN 13 34 5 Remove the mainshaft and countershaft assem blies then remove the 28 mm spring washer and 28 mm washer NOTE Before removing the mainshaft and counter shaft assemblies tape the mainshaft splines to pro tect them MAINSHAFT COUNTERSHAFT ASSEMBLY ASSEMBLY S S TSA SS ANE 22 9 28 mm WASHER ke 28 mm SPRING WASHER 6 Remove the differential assembly and transfer shaft from the clutch housing DIFFERENTIAL TRANSFER ASSEMBLY SHAFT CLUTCH HOUSING Transfer shaft bearing Replacement NOTE The tapered roller bearing and bearing outer race should be replaced as a set 1 Remove the tapered roller bearing from the transfer shaft using the bearing puller BEARING PULLER lt TRANSFER 2 Install the tapered roller bearing using the special tools and a press as shown OUTER HANDLE 07749 0010000 OUTER DRIVER 24 x 26 mm 07746 0010700 TAPERED ROLLER TRANSFER SHAFT Transmission ore Install the oil gutter plate and 18 mm sealing bolt Reassembly NOTE Apply liquid gasket P N 0Y740 99986 to the threads of the 1
102. ft STIFFENERS 12 x 1 25 mm 58 N m 5 8 kg m 42 Ib ft 11 Install the change rod the spring pin and the clip NOTE Install the clip and the spring pin on the change joint as shown e Turn the shift rod boot so the hole is facing down as shown e Make sure the shift rod boot is installed on the change rod 12 Install the change extension CHANGE ROD assiya PIN Replace PIN DRIVER W mm CHANGE SHIFT ROD BOOT EXTENSION 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft 13 18 13 Install the intermediate shaft and the driveshafts 16 Install exhaust pipe A then connect the oxygen sen see section 16 sor connector NOTE Replace the set rings with new ones OXYGEN SENSOR CONNECTOR DRIVESHAFTS GASKETS Replace GASKETS SET RING Replace Replace SELF LOCKING NUT Replace 8 x 1 25 mm INTE MEDIATE 22 N m 2 2 kg m EXHAUST PIPE A SHAFT 16 Ib ft SELF LOCKING NUT SELF LOCKING NUT Replace Replace 10 x 1 25 mm SET RING 10 x 1 25 mm 8 x 1 25 mm e m 5 5 kg m Replace 40 N m 4 0 kg m 16 N m 1 6 kg m f 29 Ib ft 12 Ib ft 14 Install the ball joints onto the lower arm see sec 17 install the engine splash shield tion 18 15 Install the right damper fork see section 18 10 x 1 25 mm 44 N m 4 4 kg m 32 tb ft RIGHT DAMPER FORK SELF LOCKING NUT ENGINE SPLASH SHIELD Replace L 12 x 1 25 mm 65
103. fuse relay box Is the fuse OK YES Turn the ignition switch ON Disconnect the 3P connector of each sensor one at a time MAP sensor EGR valve lift sensor D15Z1 engine Throttle angle sensor IMA D16A9 engine Does Check Engine light remain ON YES Turn the ignition switch OFF Connect the test harness Disconnect the D connector from the ECU only not the main wire harness Check for continuity between body ground terminals D19 D20 Does continuity exist NO Reconnect all the sensor connec tors Reconnect the D connector to the ECU Turn the ignition switch ON 11 14 NO YES From page 11 12 Turn the ignition switch OFF Replace the fuse Disconnect A connector from Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU the ECU Turn the ignition switch ON Is the Check Engine light ON 22 5 Repair short to body ground GRN ORN wire between the ECU A13 and Check Engine light Replace the sensor that caused the light to go out Repair short to body ground in YEL RED or YEL GRN wire between ECU D19 and MA
104. it or damage the contact surface of the gasket D15Z2 engine 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft EXHAUST MANIFOLD COVER 10 x 1 25 mm 32 N m 3 2 kg m 23 Ib ft 6 x 1 0 mm 10 N m 1 0 kg m 7 lb ft X I Q9 COVER SELF LOCKING NUT 10 x 1 25 mm 55 N m 5 5 kg m 40 Ib ft Replace CATALYTIC CONVERTER OXYGEN SENSOR 45 N m 4 5 kg m 33 Ib ft Be careful not to damage EXHAUST MANIFOLD GASKET METAL Replace SELF LOCKING NUT 8 x 1 25 mm 32 N m 3 2 kg m 23 Ib ft Replace CONVERTER COVER EXHAUST MANIFOLD BRACKET Bg GASKET Replace EXHAUST PIPE A 8 x 1 25 mm 24 2 4 kg m 17 SUPPLEMENTAL RESTRAINT SYSTEM SRS If Fuel and Emissions maintenance is required Some model versions of the Civic include a driver s airbag located in the steering wheel hub In addition the KB model has a front passenger s airbag located in the dashboard above the glove box There are two types of SRS Type Il SRS unit is part of the airbag assembly which is used for models without front passenger s airbag all except KB model and Type lli SRS unit is not part of the airbag assembly and has built in sensors which is used for models with front passenger s airbag KB model 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 compo nents
105. m 2 6 kg m STARTER 19 Ib ft MOTOR Ren RELEASE P N 41211 PY5 305 CHANGE CABLE nt BEARING BRACKET RELEASE 10 x 1 25 mm FORK 39 N m 3 9 kg m BOOT 28 Ib ft TRANSMISSION LN A RELEASE FORK BACK UP LIGHT MOUNT BRACKET N SWITCH P N 41211 PY5 305 9 25 2 5 kg m TRANSMISSION 18 Ib ft HANGER WASHER SM 8 x 1 25 mm Replace 5 Place the transmission on the transmission jack 26 N m 2 6 kg m and raise it to the engine level 19 Ib ft 6 Installthe transmission mounting bolts and the rear mount bracket bolts 2 Installthe dowel pins on the clutch housing SPECIAL BOLT Replace 12 x 1 25 mm 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft 60 N m 6 0 kg m 43 Ib ft CO W SPECIAL BOLT Z SPECIAL BOLT REAR MOUNT Replace Replace BRACKET 14 x 1 5 mm 9 14 x 1 5 mm 80 N m 8 0 kg m 80 N m 8 0 kg m 58 Ib ft DOWEL PIN 58 Ib ft cont d 13 39 Transmission Assembly Installation cont d 7 Raise the transmission then install the transmission mount NOTE Torque the mounting bolt and nuts in se quence shown CAUTION Check that the bushings are not twisted or offset 12 x 1 25 mm 65 N m 6 5 kg m 47 TRANSMISSION 2 12 x 1 25 mm 75 N m 7 5 kg m 54 Ib ft 8 Install the clutch cover mounting bolt 9 Install the front and rear engine stiffereners gt e 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft 8 x 1 25 mm 24 N m 2 4
106. minutes 3 Connect the short connector RED to the driver s airbag connector 4 Connect SRS short connector A to the cable reel 3 P con nector CAUTION Do not disconnect the passenger s airbag connector 5 Connect the SCS short connector to the service check connector 6 Reconnect the battery positive cable then connect the negative cable 7 Turn the ignition switch ON Il and record the most recent DTC Is DTC 1 4 or DTC 1 2 indicated 14 1 2 Short to ground in the driver s airbag inflator replace the driver s airbag assembly see page 23 56 Connect Test Harness B 1 Turn the ignition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Remove the glove box and connect the short connector RED to the passenger s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector To page 23 41 23 40 DRIVER S AIRBAG CABLE REEL 3 P ASSEMBLY CONNECTOR SHORT CONNECTOR RED SRS SHORT CONNECTOR A 107MAZ SP0020A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC SCS SHORT MEMORY ERASE SERVICE CONNECTOR SIGNAL MES CHECK CONNECTOR 2 P CONNECTOR 2 BLK WHT BRN BLK FRONT PASSENGER S SHORT CONNECTOR RED AIRBAG 3 P CON
107. not contain chlorofluorocarbons Pay attention to the following service items Do not mix refrigerants CFC 12 R 12 and HFC 134a R 134a They are not compatible Use only the recommended polyalkyleneglycol PAG refrigerant oil see NOTE below designed for the R 134a com pressor Intermixing the recommended PAG refrigerant oil with any other refrigerant oil will result in compressor failure NOTE Each compressor type uses different refrigerant oil Nippondenso ND OIL8 P N 38899 PR7 003 Sanden SP 10 P N 38899 P13 003 Matsushita GU10 P N 38899 P08 003 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 1 Discharge the refrigerant see page 22 5 2 Remove the relief valve and the O ring from the com pressor NOTE Be sure to use the right O ring for HFC 134a R 134a to avoid leakage CAUTION Be careful not to spill compressor oil and make sure there is no foreign matter in the system Nippondenso
108. of the oil strainer by the front oil pump passes then through check valve and is pressured by the front oil pump e The pressured oil passes through check valve and it is directed to the clutch piston to move the piston Asthe clutch piston moves the clutch plates engage with the clutch discs in the clutch assembly to transmit the driving force from the transfer to the rear wheels that is the car is switched to 4WD e The oil applied on the clutch piston passes through the oil filter orifice and check valve to lubricate and cool the bearings inside the clutch guide and the clutch discs FRONT OIL PUMP pp 64 BEARINGS s dm OIL STRAINER cont d 15 7 Description Realtime 4WD Dual Pump System cont d Normal Reverse Driving 2WD Front wheel speed and rear wheel speed are equal As the front wheel speed is equal to the rear wheel speed during normal reverse driving there is no difference in speed between the front and rear oil pumps and they are producing the equal hydraulic pressure The oil pumps rotate in the reverse direction to that of when driving the car in forward gear The oil is drawn out of the oil strainer by the front and rear oil pumps passes then through check valves and and is pressured by the respective oil pumps The oil pressured by the front oil pump enters the inlet port of the rear oil pump while the oil pressured by th
109. points shown ALIGNMENT MARKS REAR WINDOW 8 With a sponge apply a light coat of glass primer around the edge of the rear window as shown then lightly wipe it off with gauze or cheesecloth NOTE Do not apply body primer to the rear window and do not get body and glass primer sponges mixed up e Never touch the primed surfaces with your hands If you do the adhesive may not bond to the rear window properly causing a leak after the rear window is installed e Keep water dust and abrasive materials away from the primed surface 2 Apply glass primer here UPPER FASTENER GLASS MOLDING x Ts om SIDE ae SPACER LII LOWER SPACER REAR WINDOW 10 Tt With a sponge apply a light coat of body primer to the original adhesive remaining around the rear window opening flange Let the body primer dry for at least 10 minutes NOTE Do not apply glass primer to the body and be careful not to mix up glass and body primer sponges Never touch the primed surfaces with your hands Z Apply body primer here 10 mm 0 39 in 6 mm 0 23 in Or 6 mm 0 22in d 10 mm 0 39 in Thoroughly mix the adhesive and hardener togeth er on a glass or metal plate with a putty knife Follow the instructions that came with the adhesive NOTE Clean the plate with a sponge and alcohol before mixing Before filling a cartridge cut the end of the nozzle as shown Cut nozzle end
110. rattle Check for loose joints or connections e Check the boot for cracking splitting or other faults 16 8 Removal 1 Remove the flange bolts then remove the No 2 propeller shaft protector No 2 PROPELLER SHAFT PROTECTOR FLANGE BOLTS 8 x 1 25 mm 2 Mark the No 2 propeller shaft and rear differential with paint 3 Remove the four 12 point bolts and yoke nuts then remove the No 2 propeller shaft from the rear dif ferential Marks No 2 PROPELLER SHAFT 12 POINT BOLT YOKE NUT REAR DIFFERENTIAL 7 4 Remove the four 12 point bolts and yoke nuts then remove the No 2 propeller shaft from the No 1 pro peller shaft 5 Remove the two flange bolts on the center bearing support No 2 PROPELLER SHAFT N CENTER BEARING SUPPORT FLANGE BOLT 10 x 1 25 mm FLANGE BOLT 10 x 1 25 mm 12 POINT BOLT No 1 PROPELLER SHAFT 6 Remove the flange bolts then remove the No 1 propeller shaft protector No 1 PROPELLER SHAFT PROTECTOR FLANGE BOLTS 8 x 1 25 mm cont d 16 9 Propeller Shafts Removal cont d Mark the No 1 propeller shaft and front differential with paint Remove the four 12 point bolts and yoke nuts then remove the No 1 propeller shaft from the front dif ferential FRONT DIFFERENTIAL 12 POINT BOLT YOKE NUT 16 10 Disassembly Raise the locking tab on the hub nut 2 Remove the hub nut from the No 1 propeller shaft using the sp
111. sponge dampened in alcohol e After cleaning keep oil grease or water from getting on the surface e When applying make sure there are no wrinkles in the emblems Attachment Points Reference 3D os n Civic EMBLEM DOHC EMBLEM 20 10 VERSION EMBLEM Unit mm in Emblem A B DX 94 3 7 105 4 13 Si 67 5 2 66 78 5 3 09 VEi 88 5 3 48 105 5 4 15 DXi 107 4 21 118 4 65 Civic EMBLEM B LSi 94 3 7 105 4 13 ESi 95 3 74 106 4 17 VTi 88 5 3 48 105 5 4 15 27 1 06 GLi 94 3 7 105 4 13 il VERSION EX 90 3 54 101 3 98 EMBLEM EL 84 5 3 33 95 5 3 76 Si KP KT models 6 0 24 EMBLEM VERSION EMBLEM Civic EMBLEM DOHC REAL TIME 4WD EMBLEM Unit mm in Emblem A B DX 92 3 62 103 4 06 EX 88 3 46 99 3 9 DXi 104 5 4 11 115 5 4 55 89 5 3 52 103 4 06 Civic B LSi 92 3 62 103 4 06 EMELEM 93 3 66 104 4 09 VTi 86 3 39 103 4 06 GLi 93 3 39 104 4 09 RSS 30 1 18 Si 65 2 56 76 2 99 EL 81 3 19 92 3 62 VERSION EMBIEM RTSi 116 5 4 59 127 5 5 02 KR model Emblem A B EX 86 3 39 111 5 4 39 Si KP KT models 80 3 15 DOHC EMBLEM RTSi Emblem C D
112. t start it may take 20 seconds of cranking to set the code Intermittent failure system is OK at this time test drive may be Is Check Engine light on and does NO necessary it indicate CODE 15 Check for poor connections or loose wires at igniter unit and YES ECU Turn the ignition switch OFF Disconnect the 2P connector from the distributor Turn the ignition switch ON Measure voltage between YEL terminal and body ground NO Repair open in BLK YEL wire be lt Is there battery voltage tween the 2P connector and igni T tion switch YES To page 11 29 11 28 From page 11 28 Turn the ignition switch OFF Reconnect the 2P connector 10 V OOOOOOOOOOQOqQq OOOOOOOO OOOOOOOOOOO Connect the test harness be tween the ECU and connectors Turn the ignition switch ON Measure voltage between A21 4 terminal and A26 terminal NO Replace the igniter unit e Is there approx 10 V Repair open or short in YEL GRN wire between igniter YES unit and ECU A21 NOTE If the YEL GRN wire was short Substitute a known good ECU ed the igniter may be damaged and recheck If symptom indica tion goes away replace the origi nal ECU 11 29
113. the differen tial oil if the oil is OK replace the rear differen tial assembly 15 10 A T 1 Raise the car off the ground and place safety stands under it see section 1 WARNING e Make sure jacks and safety stands are placed properly e Make sure the car will not roll off stands and fall while you are working under it 2 Mark either the No 1 or No 2 propeller shaft PROPELLER SHAFT 3 Start the engine Hold the engine at 3 000 rpm with no load in N or P position until the radiator fan comes on then let it idle 4 Fix the engine speed at low gear by moving the select lever to the 2 position and pressing the LOW switch 5 Apply the parking brake firmly and measure the time during which the marked propeller shaft ro tates 10 times e ifthe time for 10 turns is 10 seconds more the system is OK e If the time for 10 turns is less than 10 seconds check the differential oil if the oil is OK replace the rear differential assembly Reverse Drive Quick Starting 4WD M T 1 Raise the car off the ground and place safety stands under it see section 1 WARNING e Make sure jacks and safety stands are placed properly e Make sure the car will not roll off stands and fall while you are working under it Start the engine Hold the engine at 3 000 rpm with no load in neutral until the radiator fan comes on then let it idle Shift the le
114. the safety stands as shown on page 1 18 so the car will be approximately level then low er the car onto them A WARNING Always use safety stands when working on or un der any vehicle that is supported by only a jack Never attempt to use a bumper jack for lifting or supporting the car Fronit z Lee x LL e ce LL Lb D 0 Center the jack bracket in the middle of the jack lift platform JACK LIFT PLATFORM Ue ae Ss t Center the jack JACK LIFT PLATFORM bracket in the middle of the jack lift platform 1 17 Lift and Support Points Safety Stands RUBBER ATTACHMENTS FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT 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 towing the car Wheel Lift Equipment The tow truck uses two pivot ing arms which go under the tires front or rear and lifts them off the ground The other two wheels remain on the ground NOTICE On 4WD model Never tow your car with the front or rear wheels off the ground and l
115. throttle body To page 11 27 SEP MAP SENSOR lt 0 VACUUM PUMP GAUGE O RING Replace 11 26 From page 11 26 NO m lt saharae manifold m restriction from throttle YES Stop the engine Connect the test harness be tween the ECU and connector i Turn the ignition switch ON 3V 017 021 OOOOOOOOOOOOO OOOOOOOO OOOOOOOOOOO Measure voltage between D17 terminal and D21 terminal NO Is there approx 3 V Replace MAP sensor YES Install the MAP sensor d Start the engine and allow it to idle L NO Is there approx 1 V sensor YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU 11 27 PGM FI Control System r Troubleshooting Flowchart Ignition Output Signal 173 2115 Self diagnosis Check Engine light indicates code 15 problem the Ignition Output Signal circuit P ad 1 UN Le IHR Check Engine light has been reported on With the SCS short connector connected see page 11 9 CODE 15 is indicated Do the ECU Reset Procedure page 11 10 Start the engine NOTE If the engine won
116. to interfere with the bumper Do not attach the ropes to any section other than the specified section ROPE for prevention of the car from dashing out Attach to the trailing hook ROPE for prevention of the car from rolling the car from rolling Attach to the tie down Attach to the trailing hook hook ROPE for prevention of Start the engine With the gearshift lever in the 3rd range on the manual transmission car or the gear shift lever in the D1 or D2 position on the automatic transmission car start the car and raise the speed gradually CAUTION Take care not to exceed 50 km h of speed and do not test for more than 3 minutes con tinuously After the test slow down the car until it stops by applying the brake gradually 14 35 Transfer Housing lllustrated Index i H 14 36 OIL SEAL Replace SET RING 80 mm Selective part BEARING OUTER RACE BEARING INNER RACE TRANSFER SHAFT DRIVEN GEAR OIL SEAL Replace NEEDLE BEARING DIFFERENTIAL ASSEMBLY TRANSFER REAR COVER BEARING OUTER RACE BEARING INNER RACE OIL SEAL Repiace DUST COVER COMPANION FLANGE DISC SPRING Replace DRIVEN GEAR SHAFT LOCKNUT Replace TRANSFER DRIVEN GEAR SHAFT BEARING INNER RACE BEARING OUTER RACE TRANSFER SPACER O RING Replace DRIVEN GEAR THRUST SHIM Selective part OIL SEAL Replace DOWEL PIN DOWEL PIN SPECIAL SEAL Replace TRANSFER HOUSING TRANSFER DRIV
117. will not upshift If stuck open the transmission has no 1st gear If the 2 3 orifice control valve is stuck inspect the 2nd and 3rd clutch packs for wear If the 2 3 4 orifice control valve is stuck inspect the 3rd and 4th clutch packs for wear If the clutch pressure control valve CPC is stuck closed the transmission will not shift out of 1st gear Improper alignment of main valve body and torque converter housing may cause oil pump seizure The symptoms are mostly an rpm related ticking noise or a high pitched squeek If the ATF strainer is clogged with particles of steel or aluminum inspect the oi pump and differential pinion shaft If both are OK and no cause for the contamination is found replace the torque converter If the 1st clutch feedpipe guide in the R side cover is scored by the mainshaft inspect the ball bearing for excessive movement in the transmission housing If OK replace the R side cover as it is dented The O ring under the guide is probably worn Replace the mainshaft if the bushings for the 1st and 4th feedpipe are loose or damaged If the 1st feedpipe is damaged or out of round replace it If the 4th feedpipe is damaged or out of round replace the right side cover A worn or damaged one way sprag clutch is mostly a result of shifting the transmission in or while the wheels rotate in reverse such as rocking the car in snow Inspect the frame for collision damage ins
118. x 1 25 mm 50 5 0 kg m 36 lb ft 10 Remove the rear differential mount from the rear differential assembly 12 x 1 25 mm 70 N m 7 0 kg m 51 lb ft DIFFERENTIAL MOUNTING REAR DIFFERENTIAL ASSEMBLY 11 Install the rear differential in the reverse order of removal NOTE After installing the rear differential fill in the specified amount of the ATF see page 15 14 lllustrated Index Rear Differential Assembly NOTE Before assembly lubricate all parts with ATF TCD TORQUE CONTROL DIFFERENTIAL CASE DOWEL PIN lt GASKET Replace 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft COMPANION FLANGE 22 mm LOCKNUT Replace 106 N m 10 8 kg m 78 Ib ft K 6 x 1 0 mm PUMP BODY place 12 N m 1 2 kg m ASSEMBLY 9 lb ft SPRING WASHER THRUST WASHER DIFFERENTIAL CLUTCH ASSEMBLY 30 mm WASHER THRUST NEEDLE BEARING OIL PUMP KEYS 2 A DIFFERENTIAL BREATHER TUBE BREATHER TUBE CARRIER JOINT ASSEMBLY OIL SEAL Replace OIL SEAL Replace OIL FILLER PLUG 48 N m 4 8 kg m 35 Ib ft WASHER Replace DRAIN PLUG 48 N m 4 8 kg m 35 Ib ft 15 17 Rear Differential Carrier Oil Leak Repair 1 Remove the bolts in a crisscross pattern in several steps 2 Separate the carrier cover from the rear differential carrier and wipe it clean of the sealant DIFFERENTIAL CARRIER OIL SEAL Replace 3 Apply l
119. 0 Runout 0 02 0 0008 max 0 05 0 002 Countershaft 1st LD 42 009 42 025 1 6539 1 6545 42 08 1 657 gear End play When tightened by the specified torque 0 04 0 12 0 0016 0 0047 0 18 0 0071 Countershaft 2nd LD 47 009 47 025 1 8507 1 8514 47 08 1 854 gear End play When tightened by the specified torque 0 05 0 12 0 0020 0 0047 0 18 0 0071 Thickness 28 92 28 97 1 1386 1 1405 28 8 1 134 Spacer collar LD 36 48 36 49 1 436 1 437 36 50 1 437 Countershaft 2nd O D 41 989 42 000 1 6531 1 6535 41 94 1 651 gear Length A 29 02 29 04 1 1425 1 1433 B 29 07 29 09 1 1444 1 1453 Spacer collar LD 31 002 31 012 1 2205 1 2209 31 06 1 223 Mainshaft 4th O D 37 989 38 000 1 4956 1 4961 37 94 1 494 and 5th gear Length 56 45 56 55 2 2224 2 2264 3 12 4th 5th gear side 26 03 26 08 1 025 1 027 2WD Manual Transmission Y21 Section 13 Reverse idler gear MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT LD 20 016 20 043 0 7880 0 7891 20 09 0 7909 Gear to reverse gear shaft clearance 0 036 0 084 0 0014 0 0033 0 16 0 006 Synchro ring Ring to gear clearance Ring pushed against gear 0 85 1 10 0 033 0 043 0 4 0 016 Double cone Clearance Ring pushed against gear synchro ring Outer synchro ring to
120. 0 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 3 22 3 25 0 127 0 128 3 27 3 30 0 129 0 130 3 32 3 35 0 131 0 132 3 37 3 40 0 133 0 134 2 93 3 00 0 115 0 118 83 339 83 365 3 2810 3 2821 66 685 66 698 2 6254 2 6259 8 97 8 98 0 353 0 354 5 97 5 98 0 2350 0 2354 7 97 7 98 0 3138 0 3142 5 97 5 98 0 2350 0 2354 1 980 1 995 0 0780 0 0785 6 018 6 030 0 2369 0 2374 9 000 9 015 0 3543 0 3549 8 000 8 015 0 3150 0 3156 6 018 6 030 0 2369 0 2374 2 025 2 060 0 080 0 081 Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage 8 95 0 352 5 95 0 234 7 95 9 313 5 95 0 2343 1 80 0 071 6 045 0 2380 9 030 0 355 8 030 0 3161 6 045 0 2380 2 080 0 082 Regulator valve body Sealing ring contact I D Shifting device and parking brake Reverse shift fork finger thickness Parking brake ratchet pawl 35 000 35 025 1 3780 1 3782 35 050 1 3799 5 90 6 00 0 232 0 236 27 0 27 1 1 063 1 067 5 40 0 213 Wear or other defect 14 000 14 005 0 5512 0 5514 14 006 14 010 0 5514 0 5516 14 011 14 015 0 5516 0 5518 37 000 37 039 1 4567
121. 0 006 Adjust with shim 3 31 Standards and Service Limits Differential 2WD A T M24A Section 15 MEASUREMENT STANDARD NEW SERVICE LIMIT EN Final driven gear Backlash 0 071 0 129 0 0028 0 0051 Differential carrier Pinion shaft contact area LD 18 000 18 018 15 8382 15 8540 Carrier to pinion clearance 0 013 0 047 0 0005 0 0019 0 10 0 004 Driveshaft contact area D 26 005 26 025 1 0238 1 0246 Carrier to driveshaft clearance 0 025 0 066 0 0010 0 0026 0 12 0 005 Ball bearing contact area O D 40 002 40 018 1 5749 1 5755 Differential pinion Backlash 0 05 0 15 0 002 0 006 gear LD 18 041 18 061 0 7103 0 7111 Pinion gear to pinion shaft clearance 0 054 0 090 0 0021 0 0035 0 15 0 006 Set ring to bearing outer race 0 0 15 0 0 006 Adjust Front Differential 4WD Transmission Section 15 MEASUREMENT STANDARD NEW SERVICE LIMIT Final driven gear Backlash 0 071 0 129 0 0030 0 0050 Differential carrier Pinion shaft bore diameter 18 000 18 018 0 7087 0 7094 Carrier to pinion shaft clearance 0 016 0 052 0 0006 0 0020 0 1 0 004 Drivershaft bore diameter 28 005 28 021 1 1024 1 1032 Carrier to driveshaft clearance 0 025 0 066 0 0010 0 0026 0 12 0 005 Ball bearing bore diameter 40 002 40 018 1 5749 1 5755 Differential pinion Backlash 0 05 0
122. 0 047 0 8 0 031 7 0 0 276 6 2 0 244 27 2 1 071 27 0 1 063 Throttle valve A spring 1 1 0 043 1 0 0 039 1 1 0 043 1 0 0 039 8 5 0 335 8 5 0 335 8 5 0 335 8 5 0 335 22 3 0 878 22 2 0 874 22 3 0 878 22 1 0 870 Throttle valve B adjusting spring 0 8 0 031 6 2 0 244 30 0 1 181 Throttle valve B spring 1 4 1 653 1 4 1 653 1 4 1 653 8 5 0 335 8 5 0 335 8 5 0 335 Inside diameter 41 5 1 634 41 5 1 634 41 6 1 638 14 17 Countershaft Disassembly Inspection Reassembly NOTE Lubricate all parts with ATF before reassembly install 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 damaging the O rings LOCKNUT 23 x 1 25 mm 140 gt 0 gt 140 Nem 14 0 gt 0 gt 14 0 kom 101 0 gt 101 Ib ft PARKING GEAR REVERSE GEAR 2 4 COLLAR NEEDLE BEARING ONE WAY CLUTCH ASSEMBLY E REVERSE GEAR REVERSE SELECTOR REVERSE 22 NEEDLE BEARING GD SELECTOR HUB y 4TH GEAR 1ST GEAR COLLAR CADAT A NEEDLE BEARING TRANSMISSION DISTANCE COLLAR 28 mm HOUSING BEARING Selective part 2ND GEAR 2 23 THRUST NEEDLE COTTERS d
123. 0 079 Until grooves worn out Clutch plate thickness ist 1 55 1 65 0 061 0 065 Discoloration 2nd 3rd 4th 1 95 2 05 0 077 0 081 Discoloration Clutch end plate thickness MARK 1 2 2 2 3 0 087 0 091 Discoloration D12B1 D15B3 MARK 2 2 5 2 6 0 098 0 102 MARK 3 2 8 2 9 0 110 0 114 MARK 4 3 1 3 2 0 122 0 126 MARK 5 3 4 3 5 0 134 0 138 MARK 11 2 05 2 15 0 081 0 085 MARK 12 2 35 2 45 0 093 0 096 MARK 13 2 65 2 75 0 104 0 108 MARK 14 2 95 3 05 0 116 0 120 MARK 15 3 25 3 35 0 128 0 132 MARK 16 3 55 3 65 0 140 0 144 Discoloration Clutch end plate thickness MARK 1 2 3 2 4 0 091 0 094 Discoloration D16A9 MARK 2 2 4 2 5 0 094 0 098 MARK 3 2 5 2 6 0 098 0 102 MARK 4 2 6 2 7 0 102 0 106 MARK 5 2 7 2 8 0 106 0 110 MARK 6 2 8 2 9 0 110 0 114 MARK 7 2 9 3 0 0 114 0 118 MARK 8 3 0 3 1 0 118 0 122 MARK 9 3 1 3 2 0 122 0 126 MARK 10 3 2 3 3 0 126 0 130 MARK 11 2 0 2 1 0 079 0 083 MARK 12 2 1 2 2 0 083 0 087 MARK 13 2 2 2 3 0 087 0 091 Discoloration cont d 3 17 Standards and Service Limits 2WD Automatic Transmission M48A cont d Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission 3 18 Diameter of needle bearing contact area On mainshaft and stator shaft On mainshaft 2nd gear On mai
124. 00 1 1018 1 1024 STANDARD NEW O D Adjust with shim 34 95 1 376 27 93 1 100 Free Length Regulator valve spring A Regulator valve spring B Stator reaction spring Torque converter check valve spring Relief valve spring 2nd orifice control valve spring Servo orifice control valve spring Throttle control valve B spring Throttle control valve B adjuster spring 1 2 shift valve spring 2 3 shift valve spirng 3 4 shift valve spring 1st accumulator spring 1st hold accumulator spring 4th accumulator spring 2nd accumulator spring 3rd accumulator spring Lock up control valve spring Lock up timing B valve spring CPC valve spring Lock up shift valve spring 4 2 kick down valve spring Cooler relief valve spring Modulator valve spring Servo control valve spring 4th exhaust valve spring 4 3 kick down valve spring E 1 8 0 07 1 8 0 07 5 5 0 22 1 1 0 04 1 0 0 04 0 8 0 03 0 9 0 04 1 6 0 06 0 8 0 03 0 9 0 04 0 8 0 03 0 8 0 03 2 0 0 08 3 2 0 13 3 1 0 12 2 7 0 11 2 8 0 11 0 8 0 03 0 9 0 04 1 4 0 06 1 1 0 04 0 9 0 04 1 1 0 04 0 9 0 04 1 0 0 04 0 9 0 04 0 9 0 04 14 7 0 58 9 6 0 38 26 4 1 039 8 4 0 33 8 4 0 33 6 6 0 26 6 1 0 24 8 5 0 33 6 2 0 24 8 6 0 34 8 6 0 34 7 6 0 30 13 7 0 54 24 3 0 96 18 6 0 73 16 1 0 63 15 5 0 61 6 6 0 26 5 6 0 22 9 4 0 37 8 1 0 32 6 4 0 25 8
125. 00 SOHC 16 valves Dual point Fuel injected Engine with CATA 1500 SOHC 16 valves Sequential Multiport Fuel injected VTEC E Engine with CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected Engine without CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA for Germany and 4WD 1200001 6900001 01626 3700001 5200001 D16Z7 for Germany 1400001 D16Z7 for 4WD 1500001 Transmission Type 20 Except B16A2 engine 4WD model Manual Transmission Number 520 1000001 Y21 For 16 2 engine S22 For 4WD model Serial Number Transmission Type Automatic Transmission Number M24A 3000001 M24A For 2WD model M25A For 4WD model Serial Number 1 3 Chassis Engine Numbers Except European Modei 2 door Hatchback Vehicle Identification Number Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type EG3 CIVIC 3 door D13B3 EG4 CIVIC 3 door D15B3 D15B7 015272 CIVIC 3 door D16A9 D16Y1 Body Type and Transmission Type 3 2 door Hatchback 5 speed Manual 4 2 door Hatchback 4 speed Automatic Vehicle Grade Series 1 EL EG3 KT CX EG4 1 5EL EG4 KY EX EG4 KP KT KY GLi EG4 KQ VTi EG5 KQ Si EG5 KP KT Fixed C
126. 000 80 3000 80 30 30 427 kPa 427 kPa 30 2500 kg cm DELIVERY 3096 2500 kg cm PRESSURE 25 psil PRESSURE 25 356 80 356 2000 1500 C 2000 4500 C 20 5 F 20 5 P 80 12841 1711 Z 80 284 1711 Z 80 1500 14001 30 3096 1500 14004 30 15 4 86 15 4 86 213 57 213 57 1000 3001 25 1000 300 25 10 3 77 10 3 177 30 142 Go 2s INTAKE 2 30 142 200 25 DELIVERY 2 68 PRESSURE DELIVERY 2 68 0 PRESSURE 28 2 PRESSURE 28 230 1001 15 1001 15 Z d 1 59 1 59 P 1141 S 141 Pa INTAKE 9 10 Gg INTAKE 0 10 m PRESSURE 50 PRESSURE 50 P d DELIVERY DELIVERY 5 TEMPERATURE 5 TEMPERATURE DELIVERY 41 lu DELIVERY 41 5 TEMPERATURE 20 25 30 35 40 C TEMPERATURE 20 275 30 35 40 C 68 77 86 95 104 F 68 77 86 95 104 F 22 10 INTAKE AIR TEMPERATURE INTAKE AIR TEMPERATURE SUPPLEMENTAL RESTRAINT SYSTEM SRS Some model versions of the Civic include a driver s airbag located in the steering wheel hub In addition the KB model has a front passenger s airbag located in the dashboard above the glove box There are two types of SRS Type Il SRS unit is part of the airbag assembly which is used for models without front passenger s airbag all except KB model and Type SRS unit is not part of the airbag assembly and has built i
127. 000 min rpm N or P position 2nd clutch pressure at 2 000 min rpm 10 position 3rd clutch pressure at 2 000 min rpm Ds position 4th clutch pressure at 2 000 min rpm 04 position 850 900 8 5 9 0 121 128 420 4 2 60 throttle fully closed 850 900 8 5 9 0 121 128 throttle more than 1 4 opened 800 8 0 114 370 3 7 53 throttle fully closed 800 8 0 114 throttle more than 1 4 opened 850 900 8 5 9 0 121 128 03 position 2nd clutch pressure at 2 000 min rpm 2 position 800 8 0 114 1st clutch pressure at 2 000 min rpm 04 or 850 900 8 5 9 0 121 128 800 8 0 114 Governor pressure at 60 km h 38 mph 151 161 1 51 1 61 21 23 146 1 46 21 Throttle pressure B Throttle fully closed Throttle fully open Throttle pressure A Throttle fully closed 0 800 850 8 0 8 5 114 121 750 7 5 107 0 5 0 0 05 0 1 Throttle fully open 495 510 4 95 5 1 70 73 490 4 9 70 Stall speed min rpm check with car on level ground 2 600 2 300 2 900 Clutch initial clearance 1st 2nd 0 65 0 85 0 026 0 033 3rd 4th 0 40 0 60 0 016 0 024 Clutch return spring free length 1st 31 0 1 22 29 0 1 14 2nd 3rd 4th 30 5 1 20 28 5 1 12 Clutch disc thickness 1 88 2 00 0 074
128. 0012 0 0022 0 13 0 005 0 030 0 060 0 0012 0 0024 2 3 0 13 0 005 Second 01521 0 035 0 060 0 0014 0 0024 0 13 0 005 0 030 0 055 0 0012 0 0022 0 13 0 005 Except D15Z1 0 030 0 055 0 0012 0 0022 0 13 0 005 Ring end gap Top 0 15 0 30 0 006 0 012 0 60 0 024 Second 0 30 0 45 0 012 0 018 0 70 0 028 Oi D15Z1 0 20 0 50 0 008 0 020 0 70 0 028 0 20 0 70 0 008 0 028 0 80 0 031 01626 D16Y1 0 20 0 50 0 008 0 020 1 0 70 0 028 0 20 0 80 0 008 0 031 0 90 0 035 D16Z7 0 20 0 50 0 008 0 020 0 70 0 028 Except D15Z1 D16Z6 D16Z7 D16Y1 0 20 0 80 0 008 0 031 0 90 0 035 Piston Pin O D 18 994 19 000 0 7478 0 7480 Connecting rod Pin to piston clearance Pin to rod interference Small end bore diameter Large end bore diameter Nominal D12B1 D13B2 D13B3 D15B2 01583 D15B7 01521 01522 D16A7 D16A9 016276 D16Z7 D16Y1 End play installed on crankshaft 0 010 0 022 0 0004 0 0009 0 014 0 040 0 0006 0 0016 18 96 18 98 0 746 0 747 43 0 1 69 45 0 1 77 48 0 1 89 0 15 0 30 0 006 0 012 0 40 0 016 Crankshaft Main journal diameter D12B1 D13B2 D13B3 D15B2 D15B3 015 7 01521 01522 D16A7 D16A9 01626 01627 D16Y1 Rod journal diameter D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 D15Z1 D15Z2 D16A7 D16A9 D16Z6 D16Z7 D16Y1 Taper Out of round End play
129. 03 Groove width of select arm contact area 12 05 12 15 0 474 0 478 3 13 Standards and Service Limits 4WD Manual Transmission S22 Section 13 MEASUREMIENT 4 STANDARD NEW SERVICE LIMIT Transmission oil Capacity f US qt Imp qt 2 8 3 0 2 5 for overhaul 2 2 2 3 1 9 for oil change Mainshaft T End play Diameter of 63 28C ball bearing contact area A Diameter of 3rd gear contact area B Diameter of 6306 25 ball bearing contact area C Diameter of 4th 5th spacer collar contact area Runout 0 11 0 18 0 004 0 007 27 977 27 990 1 1015 1 1020 34 984 35 000 1 3773 1 3780 24 987 25 000 0 9837 0 9843 27 987 27 000 1 1018 1 1024 0 02 0 001 max Adjust 27 920 1 0992 34 930 1 3752 24 930 0 9815 27 930 1 0996 0 05 0 002 Mainshaft 3rd gear LD End play Thickness 40 009 40 025 1 5752 1 5758 0 06 0 21 0 002 0 008 32 42 32 47 1 276 1 278 40 07 1 578 0 3 0 012 32 3 1 272 Mainshaft 4th gear Mainshaft 5th gear LD End Thickness LD End Thickness 40 009 40 025 1 5752 1 5758 0 06 0 21 0 002 0 008 30 92 30 97 1 217 1 219 40 009 40 025 1 5752 1 5758 0 06 0 21 0 002 0 008 30 42 30 47 1 198 1 200 40 07 1
130. 03 MATSUSHITA GU10 P N 38899 PO8 003 SANDEN SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Recommended Engine Oil API Service Grade SF SG or SH fuel efficient oil Select the oil for the car according to this chart 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 30 20W 40 20 50 mas sss 15 40 15 50 1 Except B16A2 D16A9 engines 2 B16A2 D16A9 30 20 100 10 20 30 40 engines 20 0 20 40 60 80 100 Ambient temperature ranges 2 door Hatchback D ime as s BEA es Maintenance Schedule sadA 103911910 103 es 15 Buiuonipuoo SIE 104 z uj 1s s Buni881s SIE 104 i4 ay 5 au euop pinoys pue 4 V 710 e ueedoin3 uey 19910 104 c UO eJedo Jauado exouo sjapow ueadoung 104 pue wajsds 9J1101u eseo ueJo Al1ISOd Le 493 1341 and suonoeuuoo pue Seu ant yUeL 19119AuO9 02l1
131. 1 1 4967 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2998 36 000 36 016 1 4173 1 4179 35 000 35 016 1 3780 1 3786 18 007 18 020 0 7089 0 7094 26 000 26 013 1 0236 1 0241 24 000 24 021 0 9449 0 9457 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 07 0 15 0 003 0 006 0 0 08 0 0 003 0 1 0 45 0 004 0 018 0 07 0 15 0 003 0 006 0 07 0 15 0 003 0 006 0 05 0 18 0 002 0 007 0 1 0 45 0 004 0 018 51 87 51 90 2 042 2 043 46 50 46 53 1 8307 1 8319 24 50 24 55 0 9646 0 9665 2 5 2 6 0 098 0 102 SERVICE LIMIT Wear or damage Wear or damage Wear or damage Wear or damage Countershaft distance collar length 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1 542 1 543 39 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90 1 530 1 531 38 92 38 95 1 532 1 533 Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Subshaft 4th gear collar length Subshaft 4th gear collar length of needle bearing con tact area 14 5 14 55 0 5709 0 5728 2 45 2 55 0 096 0 100 14 5
132. 1 31 975 31 991 1 2589 1 2595 31 975 31 991 1 2589 1 2595 25 991 26 000 1 0233 1 0236 27 980 27 993 1 1016 1 1021 13 990 14 000 0 5508 0 5512 35 000 35 016 1 3780 1 3786 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2998 38 000 38 016 1 4961 1 4967 32 000 32 016 1 2598 1 2605 18 007 18 020 0 7089 0 7094 29 000 29 013 1 1417 1 1422 27 000 27 021 1 0630 1 0638 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 05 0 13 0 002 0 0051 0 05 0 135 0 002 0 0053 0 1 0 5 0 004 0 020 0 05 0 13 0 002 0 0051 0 05 0 13 0 002 0 0051 0 05 0 17 0 002 0 007 0 05 0 18 0 002 0 007 0 10 0 25 0 004 0 010 51 87 51 90 2 042 2 043 45 00 45 03 1 772 1 773 27 00 27 15 1 063 1 069 2 5 2 6 2 098 2 102 Wear or damage A Wear or damage Wear or damage Wear or damage Wear damage Wear or damage Countershaft distance collar length 28 mm 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1 542 1 543 39 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90
133. 1 Capacity 85 7 cm rev 5 22 cu in rev Max Speed 10 000 min rpm Lubricant Type SP 10 Lubricant Capacity 120 m 4 fl oz 4 2 Imp oz Compressor Type Make Vane rotary MATSUSHITA D15B2 D15Z1 No of Cylinder 3 Capacity 150 cm rev 9 15 cu in rev Max Speed 8 000 rpm Lubricant GU10 Lubricant Capacity 140 4 2 3 fl oz 4 9 Imp oz Compressor Type Make Swash plate NIPPONDENSO B16A2 No of Cylinder 10 Capacity 155 3 cm rev 9 47 cu in rev Max Speed 7 600 rpm Lubricant Type ND OIL8 Lubricant Capacity 120 4 fl oz 4 2 Imp oz Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Sirocco fan At 12V Motor Input 200 W 12 V max Speed Control 4 speed Max Capacity 430 m h 15 188 cu ft h Temp Control Type Air mix Compressor Type single plate poly V belt drive Clutch Power Consumption 42 W max 12 V SANDEN 3 44 40 W max 12 V Except SANDEN Refrigerant Type Quantity HFC 134a R 134a 550 g 19 43 oz Design Specifications METRIC ENGLISH STEERING SYSTEM SUSPENSION WHEEL ALIGNMENT Type Overall Ratio Turns Lock to lock VTi Steering Wheel Diameter Type Shock Absorber P S M S VTi P S Except VTi P S M S P S P S M S Except VTi and VTi VEi VTi Front and Rear Front and Rear Except VTi Camber Front Rear Caster Front Toe Front Rear VTi 2WD except VTi 4WD VTi 2WD except VTi 4WD
134. 1 0 kW 1 2 kW 5 Unleaded gasoline with 91 R O N or higher may also be used 6 Premium unleaded gasoline with 95 R O N or higher may also be used 3 42 METRIC ENGLISH CLUTCH Type M T Single plate dry diaphragm spring A T Torque converter Clutch Facing Area M T Carbureted engine 160 cm 25 sq in PGM FI engine except B16A2 176 cm 27 sq in B16A2 engine 203 cm 31 sq in TRANSMISSION Synchronized 5 speed forward 1 reverse Except KS A T 2WD 4 speed automatic with lock up clutch 2 KS 1 reverse 3 D13B2 only A T 4WD Electronically controlled 4 speed automatic 1 reverse Primary Reduction Gear Type Ratio Direct 1 1 Manual Transmission Engine Type 2WD D1626 AWD B16A2 Gear Ratio 1st 2nd 3rd 4th 5th Reverse Final Reduction Gear Ratio Type Single helical gear Automatic Transmission Engine Type D15B2 D15B7 01626 2 01626 D16Y1 Gear Ratio 1st 2 600 2nd 1 393 3rd 0 975 4th 0 772 Reverse 1 954 Final Reduction Gear Ratio 4 333 4 333 Type Single helical gear cont d 3 43 Design Specifications cont d METRIC ENGLISH NOTES AIR Cooling Capacity SANDEN 3 351 kcal h 13 290 BTU h RHD CONDITIONING 3 838 kcal h 15 220 BTU h LHD MATSUSHITA 3 851 kcal h 15 270 BTU h NIPPONDENSO 3 851 kcal h 15 270 BTU h Compressor Type Make Scroll SANDEN Except B16A2 No of Cylinder D15B2 0152
135. 1 429 838 Ibs 2 220 165 2 242 Ibs 2 286 Ibs 2 304 Ibs 2 348 Ibs 2 242 165 2 286 Ibs 2 304 Ibs 2 348 Ibs 2 403 Ibs 2 458 Ibs 634 409 kg 626 420 kg 668 420 kg 644 444 kg 677 442 kg 625 392 kg 649 388 kg 633 412 kg 657 408 kg 649 441 kg 680 435 kg 1 398 902 Ibs 1 380 926 Ibs 1 473 926 165 1 420 979 165 1 493 974 165 1 378 864 Ibs 1 431 855 Ibs 1 396 908 Ibs 1 448 899 Ibs 1 431 972 Ibs 1 499 959 Ibs 3 41 Design Specifications ITEM METRIC ENGLISH NOTES ENGINE Type Except B16A2 D16A9 B16A2 D16A9 Cylinder Arrangement Bore and Stroke D1281 D13B2 D13B3 D15B2 D15B3 D15B7 01521 01522 D16A7 D16A9 D16Z6 01677 D16Y1 B16A2 Water cooled 4 stroke SOHC SOHC VTEC gasoline engine Water cooled 4 stroke DOHC or DOHC VTEC gasoline engine 4 cylinders Inline transverse 75 0 x 67 5 mm 75 0 x 76 0 mm 75 0 x 84 5 mm 75 0 x 90 5 mm 81 0 x 77 4 mm 2 95 x 2 66 in 2 95 x 2 99 in 2 95 x 3 33 in 2 95 x 3 54 in 3 19 x 3 05 in Except D15Z1 01676 D16Y1 B16A2 D16A9 01521 01626 D16Y1 D16A9 B16A2 Displacement D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 01521 01522 D16A7 D16A9 01626 01627 D16Y1 B16A2 Compression Ratio Valve Train D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 01572 D15Z1 D16A7 01626 01627 D16Y1 D16A9 B16A2 Except B16A2 D16A9 B16A2 D16A9 Lubrication System Oil Pump Displacement Exce
136. 1 530 1 531 38 92 38 95 1 532 1 533 Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Subshaft 4th gear collar length Subshaft 4th gear collar flange thickness 14 5 14 6 0 571 0 575 2 4 2 6 0 094 0 102 14 5 14 6 0 571 0 575 2 4 2 6 0 094 0 102 24 0 24 1 0 945 0 949 3 00 3 15 0 118 0 124 Wear or damage Wear or damage Wear or damage Wear or damage 2WD Automatic Transmission 24 cont d Section 14 Transmission cont d Regulator valve body Shifting device and parking brake control MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Mainshaft 2nd gear thrust washer thickness 3 47 3 50 0 137 0 138 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 145 0 146 3 72 3 75 0 147 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 151 0 152 3 87 3 90 0 153 0 154 Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side Countershaft 3rd gear thrust washer thickness 35 x 52 mm L 4 45 4 55 0 175 0 179 3 45 3 55 0 136 0 140 1 45 1 50 0 057 0 059 3 43 3 50 0 135 0 138 2 97
137. 11 4 D15B7 engine OXYGEN 02 SENSOR MANIFOLD ABSOLUTE PRESSURE MAP SENSOR COOLANT TEMPERATURE TW SENSOR INTAKE AIR TEMPERATURE TA SENSOR 8 ELECTRONIC AIR CONTROL VALVE EACV FAST IDLE VALVE G FUEL INJECTOR PRESSURE REGULATOR 9 FUEL FILTER FUEL PUMP ENGINE COOLANT JU 49 FUEL TANK 42 AIR CLEANER 3 RESONATOR CATALYTIC CONVERTER PCV VALVE CHARCOAL CANISTER PURGE CONTROL DIAPHRAGM VALVE TWO WAY VALVE FUEL CUT VALVE 09 PURGE CONTROL SOLENOID VALVE Except model 11 5 System Description Electrical Connections Except D15B2 engine MAIN RELAY IGNITION SWITCH c e FUEL PUMP IG2 OO Am A25 IGP1 525 B9 STS e INJECTORS _ 1 EE 5 e B11 CYL P INJ1 A1 as rst B12 CYL M INJ2 A3 ___ 3 roc senson 8 PL II B14 TDC M INJA A2 gt FAVO CRANK sewson g AT To ELD UNIT EACV 0 790 CHECK ENGINE SPEED SENSOR Lol i E SERVICE CHECK CONNECTOR To A C SWITCH B D4 SCS e A C COMPRESSOR CLUTCH RELAY DATA LINK G101 RADIATOR FAN RELAY CONNECTOR 207 TXD RXD FANC A12 oo M TCLUTCH o SWITCH 2 COOLANT D15Z1 engine e E 4 TEMPERATURE QO
138. 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 Wear or damage Wear or damage cont d 3 19 Standards and Service Limits 2WD Automatic Transmission M48A cont d Section 14 STANDARD NEW MEASUREMENT Wire Dia O D Free Length No of Coils Spring 2nd orifice control D12B1 D15B3 0 9 0 035 6 6 0 260 41 2 1 622 22 0 valve spring D16A9 0 9 0 035 6 6 0 260 45 1 1 776 22 0 3 4 shift valve spring 0 7 0 028 9 6 0 378 32 9 1 295 6 4 3 4 shift valve ball spring 0 45 0 018 4 5 0 177 12 0 0 472 6 7 Cooler relief valve spring 1 1 0 043 8 4 0 331 36 4 1 433 12 0 Relief valve spring 1 0 0 039 8 4 0 331 33 8 1 331 12 5 2 3 shift valve spring 0 7 0 028 7 6 0 299 43 0 1 693 12 7 2 3 shift valve ball spring 0 4 0 016 4 5 0 177 14 7 0 579 1 2 shift valve spring 0 5 0 020 4 5 0 177 44 5 1 752 35 1 1 2 shift valve ball spring 0 4 0 016 4 5 0 177 11 3 0 445 8 0 Regulator valve D12B1 D15B3 1 8 0 071 14 7 0 579 86 5 3 406 16 5 spring D16A9 1 8 0 071 14 7 0 579 88 1 3 468 Regulator valve spring 1 8 0 071 9 6 0 378 44 0 1 732 Stator reaction spring 5 5 0 217 26 4 1 039 30 3 1 193 Lock up control D12B1 D15B3 0 7 0 028 6 6 0 260 32 5 1 280 valve spring D16A9 0 6 0 024 6 6 0 260 32 8 1 291 Torque conv
139. 26 25 24 23 16 15 14 413 ground u NO Repair open in YEL GRN wire Is there battery voltage between the rear fail safe relay and ABS control unit YEL GRN YES FSR L Check for loose ABS control unit connectors If necessary sub View from ABS control unit terminal side stitute a known good ABS con trol unit and recheck 19 12 SUPPLEMENTAL RESTRAINT SYSTEM SRS If body maintenance is required Some model versions of the Civic include a driver s airbag located in the steering wheel hub In addition the KB model has a front passenger s airbag located in the dashboard above the glove box There are two types of SRS Type SRS unit is part of the airbag assembly which is used for models without front passenger s airbag all except KB model and Type Ill SRS unit is not part of the airbag assembly and has built in sensors which is used for models with front passenger s airbag KB model 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 compo nents Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe fr
140. 27 Install the 1st 2nd shift fork the countershatt then install 1st 2nd shift fork shaft NOTE Turn the 1st 2nd shift fork shaft so the groove is facing 5th reverse shift fork shaft side Install the super low shift piece bar on the reverse shift holder assembly 1ST 2ND SHIFT FORK GRO VE SHAFT 1ST 2ND SHIFT FORK SUPER LOW SHIFT PIECE BAR 13 36 10 Install the reverse idler gear reverse thrust washer and reverse idler gear shaft NOTE Turn the reverse idler gear shaft so the threads is facing outside REVERSE IDLER GEAR SHAFT THREADS REVERSE THRUST WASHER REVERSE IDLER GEAR 11 Apply liquid gasket to the surface on the transmis sion housing as shown NOTE Use liquid gasket P N 0Y740 99986 e Remove the dirty oil from the sealing surface e 1120 minutes have passed after applying liquid gasket reapply it and assemble the housings Allow it to cure at least 30 minutes after assem bly before filling the transmission with oil 12 13 14 15 Install the 14 x 20 mm dowel pins Lower the transmission housing with the snap ring pliers and set the snap ring into the groove of the countershaft bearing Check that the snap ring is securely seated in the groove of the countershaft bearing Dimension as installed 4 56 9 71 mm 0 180 0 382 in Install the 32 mm sealing bolt NOTE Apply liquid gasket P N 0Y740 99986 to the thr
141. 2WD 4WD 4WD with ABS Power assisted rack and pinion Rack and pinion LHD 17 5 RHD 16 5 LHD 17 5 RHD 17 0 LHD 19 0 RHD 19 0 LHD 3 3 RHD 3 1 LHD 3 6 RHD 3 5 LHD 3 9 RHD 3 9 375 mm 14 8 in 380 mm 15 0 in 377 mm 14 8 in Independent double wishbone coil spring Telescopic hydraulic nitrogen gas filled 0 05 0 00 0215 0 25 0 20 0 25 1 10 1 05 0 in In 0 08 in 0 mm 2 0 mm 0 BRAKE SYSTEM Type Pad and Lining Surface Area Parking Brake Front Rear Front Rear Type Power assisted self adjusting ventilated disc Power assisted self adjusting solid disc or drum 35 8 cm x 2 43 2 cm x 2 51 5 cm2 x 2 21 0 cm2 x 2 5 5 sq in x 2 6 7 sq in x 2 8 0 sq in x 2 3 26 sq in x 2 50 2 cm x 2 7 8 sq in x 2 67 2 cm x 2 10 4 sq in x 2 Mechanical actuating rear two wheel brakes Unit mm in Disc dia 190 7 5 Disc dia 191 7 5 Disc dia 211 8 3 Disc dia 208 8 2 Drum LD 180 7 1 Drum LD 200 7 9 Size and Pressure See tire information label see page 1 15 3 45 Design Specifications ELECTRICAL 3 46 Battery Starter Alternator Fuses In the Under dash Fuse Box In the Under hood Fuse Relay Box In the Under hood ABS Fuse Relay Box Headlights High Low Front Turn Signal Lights Front position Lights Side Turn Signal Lights Rear Turn Signal Lights Brake Taillights High Mount Brake Light Bac
142. 3 28 FRONT PASSENGER S AIRBAG 3 P CONNECTOR SHORT CONNECTOR RED SRS MAIN HARNESS SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT TEST HARNESS B 07MAZ 5 00500 07QAZ SR30100 TEST HARNESS B 07MAZ SP00500 e Del va e v4 5 16 8 9 10 11 gt TEST HARNESS 07MAZ SP00500 7 23 37 Troubleshooting DTC 1 3 CAUTION Whenever the ignition switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Check for a short to power in the driver s airbag inflator 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector 4 Connect SRS short connector to the cable reel 3 P con nector CAUTION Do not disconnect the passenger s airbag connector Connect the SCS short connector to the service check connector 6 Reconnect the battery positive cable then connect the negative cable 7 Turn the ignition switch ON 1 and record the most recent DTC Is DTC 1 3 or DTC 1 2 indicated 1 2 Short to power in the driver s airbag inflator replace the driver s airbag assembly see page 23 56 DRIVER S AIRBAG CABLE REEL 3 P
143. 4 P CONNECTOR C7 DASHBOARD WIRE HARNESS 14 P CONNECTOR 23 30 BLK YEL c2 To GAUGE ASSEMBLY BLK MAIN WIRE HARNESS BER GAUGE T L ata c7 s 4 5 6 DASHBOARD WIRE HARNESS SRS SRS Indicator Light Doesn t Come CAUTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Check the power supply fuse Turn the ignition switch ON 11 and check whether the other indicator lights come on or not charging system etc Do the other indicator lights come on YES NO Check the 24 15 A fuse in the under dash fuse relay box Is the fuse OK YES NO Replace the No 24 15 A fuse and check that the SRS indicator light comes on Does the SRS indicator light come on YES NO END Check for an open in the wire harness between fuse No 24 15 A and the gauge assembly and repair Check that the SRS indicator light comes on Does the SRS indicator light come on YES NO END SRS UNIT Check the SRS unit 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then the positive cable and wait for three minutes 3 Connect the short connectors RED to the airbag connec tors see page 23 25 4 Disconnect the SRS main h
144. 45 0 018 0 030 0 0012 0 05 0 002 0 06 0 002 0 06 0 002 3 7 Standards and Service Limits Engine Lubrication Section 8 Except B16A2 Engine MEASUREMENT STANDARD NEW SERVICE LIMIT Engine oil Capacity f US qt Imp qt Except D16A9 4 0 4 2 3 5 for engine overhaul 3 3 3 5 2 9 for oil change including filter 3 0 3 2 2 6 for oil change without filter D16A9 4 3 4 5 3 8 for engine overhaul 3 5 3 7 3 1 for oil change including filter 3 2 3 4 2 8 for oil change without filter Oil pump Inner to outer rotor radial clearance 0 02 0 14 0 001 0 006 0 20 0 008 Pump body to outer rotor radial clearance 0 10 0 18 0 004 0 007 0 20 0 008 Pump body to rotor axial clearance 0 03 0 08 0 001 0 003 0 15 0 006 Pressure setting 80 C 176 F kPa kg cm psi at idle at 3 000 min rpm Relief valve 70 0 7 10 min 350 3 5 50 min Engine Lubrication Section 8 B16A2 Engine MEASUREMENT SERVICE LIMIT Capacity f US qt Imp qt STANDARD NEW 4 8 5 1 4 2 for engine disassembly 4 0 4 2 3 5 for oil change including oil filter 3 7 3 9 3 3 for oil change without filter 0 04 0 16 0 002 0 006 0 20 0 008 0 10 0 19 0 004 0 007 0 20 0 008 0 02 0 07 0 001 0 003 0 15 0 006 Engine oil Inner to oute
145. 498 1 8683 47 705 1 8781 EX 48 965 49 435 1 9278 1 9463 49 685 1 9561 Valve spring Free length D12B1 D13B2 D13B3 IN 47 97 1 889 49 19 1 937 D15B2 D15B3 D16A7 IN 48 58 1 913 EX 49 19 1 937 D15B7 01522 IN 51 90 2 043 51 88 2 043 2 EX 55 28 2 176 55 31 2 178 2 Valve guide I D IN 5 51 5 53 0 217 0 218 5 55 0 219 EX 5 51 5 53 0 217 0 218 5 55 0 219 Installed height IN 15 95 16 45 0 628 0 648 EX 15 95 16 45 0 628 0 648 Rocker arm 1 NIHON HATSUJO manufactured valve spring 3 2 Arm to shaft clearance 0 017 0 050 0 0007 0 0020 0 018 0 054 0 0007 0 0021 2 CHUO HATSUJO manufactured valve spring 0 08 0 003 0 08 0 003 Cylinder Head Valve Train Section 6 D15Z1 D16Z7 D16Y1 Engines Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 250 min 1 rpm and Nominal 1 300 13 0 184 wide open throttle Minimum 1 150 11 5 166 kPa psi Maximum variation 200 2 0 28 Cylinder head Warpage 0 05 0 002 Height 92 95 93 05 3 659 3 663 Camshaft to holder oil clearance 0 050 0 089 0 002 0 004 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe 01521 IN Primary 38 427 1 5129 height Secondary 32 292 1 2713 37 997
146. 50 13 5 192 wide open throttle Minimum 950 9 5 135 kPa kg cm psi Maximum variation 200 2 0 28 Cylinder head Warpage 0 05 0 002 Height 131 95 132 05 5 195 5 199 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 002 0 004 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe height IN 33 021 1 3000 EX 32 382 1 2749 je Valve Valve clearance IN 0 13 0 17 0 005 0 007 EX 0 15 0 19 0 006 0 008 Valve stem O D IN 6 58 6 59 0 2591 0 2594 6 55 0 2579 EX 6 55 6 56 0 2579 0 2583 6 52 0 2567 Stem to guide clearance IN 0 02 0 05 0 001 0 002 0 08 0 003 EX 0 05 0 08 0 002 0 003 0 11 0 004 Valve seat Width IN 1 25 1 55 0 049 0 061 2 0 0 079 EX 1 25 1 55 0 049 0 061 2 0 0 079 Stem installed height IN 45 545 46 015 1 793 1 812 46 265 1 821 EX 44 735 45 205 1 761 1 780 45 455 1 790 Valve spring Free length IN 47 49 1 870 EX 46 89 1 846 1 0 IN and EX 6 61 6 63 0 260 0 261 6 65 0 262 Valve guide Installed height IN and EX Measuring point between camshaft and rocker arm 19 15 19 65 0 754 0 774 Cylinder Head Valve Train Section 6 Unit of length mm in B16A2 Engine MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 250 min
147. 578 0 3 0 012 30 8 1 212 40 07 1 578 0 3 0 012 30 3 1 193 Countershaft PS Diameter of needle bearing contact area A Diameter of 3rd gear contact area B Diameter of ball bearing contact area C Runout 29 000 29 015 1 1417 1 1423 36 464 36 480 1 4356 1 4362 24 987 25 000 0 9837 0 9843 0 02 0 0008 max 1 28 940 1 1394 36 41 1 433 24 930 0 9815 0 05 0 002 2nd gear End play When tightened by the specified torque Thickness 0 03 0 08 0 001 0 003 32 92 32 97 1 296 1 298 E Countershaft LD 50 009 50 025 1 9689 1 9695 50 07 1 971 151 gear End play When tightened by the specified torque 0 03 0 08 0 001 0 003 0 18 0 0071 Thickness 2 88 33 00 1 297 1 299 32 83 1 293 Countershaft LD 50 009 50 025 1 9689 1 9695 50 07 1 971 0 18 0 0071 32 8 1 29 Mainshaft 4th and 5th gear distance collar 28 002 28 012 1 1024 1 1028 34 989 35 000 1 3775 1 3780 26 03 26 08 1 025 1 027 28 06 1 105 34 93 1 024 26 01 1 024 3rd gear 3 14 Width of needle bearing contact area 31 03 31 08 1 222 2 224 Countershaft 2nd D 36 48 36 49 1 436 1 437 36 54 1 439 gear distance O D 43 989 44 000 1 7318 1 7323 43 93 1 730 collar Length 28 96 29 40 1
148. 6 0 kg m 43 Ib ft Replace C 14 x 1 5 mm 85 N m 8 5 kg m 61 Ib ft Replace D 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft E 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft F 12 x 1 25 mm LEFT FRONT MOUNT 75 Nem 7 5 kg m 54 Ib ft G 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft H 12 x 1 25 mm 6 85 N m 8 5 kg m 61 Ib ft l 12x 1 25 mm 65 6 5 kg m 47 Ib ft Replace d J 10 x 1 25 mm G We NS Replace 53 N m 5 3 kg m 38 Ib ft cont d 5 3 Engine Removal Installation cont d Mount and Bracket Bolts Nuts Torque Value Specifications D16Z7 4WD engine REAR MOUNT TRANSMISSION MOUNT RIGHT FRONT MOUNT M T A T Ie SIDE ENGINE MOUNT Torque Specifications A 10 x 1 25 mm 60 6 0 kg m 43 Ib ft Replace B 12 x 1 25 mm 60 N m 6 0 kg m 43 Ib ft Replace C 14 x 1 5 mm 80 N m 8 0 kg m 58 Ib ft Replace D 12 x 1 25 mm 65 6 5 kg m 47 lb ft E 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft F 12 x 1 25 mm 75 N m 7 5 kg m 54 Ib ft G 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft gt H 12 x 1 25 mm 85 N m 8 5 kg m 61 Ib ft E l 10x 1 25 mm 55 N m 5 5 kg m 40 Ib ft Replace J 12 x 1 25 mm 65 N m 6 5 kg m 47 Replace K 10 x 1 25 mm 53 N m 5 3 kg m 38 Replace K LEFT FRONT MOUNT NS G cont d 5 5 Engine Removal Installation cont d Mount and Bracke
149. 8 mm sealing bolt Install the oil guide plate M and 75 mm thrust shim in the transmission housing 18mm OIL SEALING BOLT GUTTER 35 N m 3 5 kg m PLATE 25 Ib ft 75 mm THRUST SHIM OIL GUIDE e PLATE M TRANSMISSION Lubricate a tapered roller bearing with gear oil then install the transfer shaft in the clutch housing Install the differential assembly in the clutch hous ing DIFFERENTIAL TRANSFER SHAFT CLUTCH HOUSING cont d 13 35 Transmission Reassembly cont d 5 Install the 28 mm spring washer and 28 mm washer with the angle against the clutch housing as shown below then install the mainshaft and countershaft assemblies in the clutch housing NOTE Before installing the mainshaft and counter shaft assemblies tape the mainshaft splines to pro tect them MAINSHAFT COUNTERSHAFT c ASSEMBLY 28 mm WASHER 28 mm SPRING WASHER Install the 8 x 14 mm dowel pins and reverse shift holder assembly 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft REVERSE SHIFT 8 x 14mm HOLDER DOWEL PIN REVERSE SHIFT HOLDER ASSEMBLY Install the parts below as shown NOTE Turn the 5th reverse shift fork shaft so the groove is facing 1st 2nd shift fork shaft side STH REVERSE SHIFT PIECE 3RD 4TH SHIFT FORK 9 5TH SHIFT FORK STH REVERSE SHIFT FORK SHAFT 5 LOCK WASHER 6 MM SPECIAL BOLT GROOVE sa 9 g NS ZZ 22 2 SSS C LI 225 A
150. 8183 SJEO 104 19149AUOO 211 YUM 5122 104 U491S S j01 U09 pue ue doin3 uey 29910 104 15 5 O1 U09 pue 5 104 uoniuB L me Y Y H H H H 19119Au02 OSHR 8183 1nOU1IA SIE 104 000 8p eo2e da J Sy 104 H 8 H 1uejooo H 19119AUu09 2H J6182 YM 5120 104 eds Suonoeuuoo pue s sou ul81s s 5 E z 40Sse1duo2 2 V te Buli9g91s 1 1018u191 V suonipuoo pue uolsu 8 3jeg ueedoun3 uey 18U10 104 ueadoung 104 SaOUEIESI ue doin3 uey 19410 104 H H ueedoun3 104 0 UOISSIUSUEJ e 5 9 JO 000 9 wJ 000 0L Alana ueadoing uey 19910 104 suluoui Z JO 000 9 wJ 000 0 eaejday ue doin3 104 1934 pue e 021 80 96 78 cL 09 8v 96 vc 001 80 96 v8 cL 09 8 96 ve 00071 X 1510 Suluoui jo J8quinu eU Jaye 002 081 091 OZL OOL 08 09 02 000 X 10 s llui 10 00071 BY 1e Sep 4 Ajesse2
151. 998 36 000 36 016 1 4173 1 4179 18 007 18 020 0 7089 0 7094 26 000 26 013 1 0236 1 0241 24 000 24 021 0 9449 0 9457 14 416 14 434 0 5676 0 5683 0 08 0 24 0 003 0 009 0 07 0 15 0 003 0 006 0 10 0 22 0 004 0 009 0 10 0 45 0 004 0 018 0 07 0 15 0 003 0 006 0 07 0 15 0 003 0 006 0 05 0 18 0 002 0 007 0 10 0 45 0 004 0 018 51 87 51 90 2 042 2 043 40 00 40 05 1 5748 1 5768 25 00 25 15 0 9843 0 9902 2 5 2 6 0 098 0 102 Wear or damage 9 a S j 5 3 3 E 3 Countershaft distance collar length 38 97 39 00 1 534 1 535 39 02 39 05 1 536 1 537 39 07 39 10 1 538 1 539 39 12 39 15 1 540 1 541 39 17 39 20 1 542 1 543 39 22 39 25 1 544 1 545 39 27 39 30 1 546 1 547 38 87 38 90 1 530 1 531 38 92 38 95 1 532 1 533 Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness 14 5 14 55 0 571 0 573 2 45 2 55 0 096 0 100 14 50 14 55 0 571 0 573 2 45 2 55 0 096 0 100 2WD Automatic Transmission M48A cont d Section 14 Transmission cont d MEASUREMENT ST
152. A mechanical problem in the Manifold Absolute 4 4 Pressure MAP Sensor system The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECU VACUUM CAVITY N 4 a Si a lar a ar ara ee 20375 a t a 1 Check Engine light has been reported on With the SCS short connector OUTPUT connected page 11 9 CODE VOLTAGE 3 is indicated Do the ECU Reset Procedure page 11 10 in Hg GAUGE Start the engine and allow it to oS 10 5 20 25 39 READING idle 100 200 300 400 500 600 700 mm Hg Intermittent failure system is OK at this time test drive may be Is Check Engine light on and does necessary it indicate CODE 3 Check for poor connection or loose wires at MAP sensor and YES ECU Turn the ignition switch OFF MAP SENSOR Jd Disconnect the 3P connector from the MAP sensor Turn the ignition switch ON To page 11 24 WHT GRN WHT YEL RED cont d 11 23 PGM FI Control System Troubleshooting Flowchart MAP Sensor Except D15B2 engine cont d From page 11 23 Measure voltage between YEL RED terminal and body ground Is there approx 5 V NO Connect the test harness D connector to the ECU only not to the main wire harness Measure voltage between D19 terminal and D21 terminal
153. ANDARD NEW Unit of length mm in SERVICE LIMIT Mainshaft 2nd gear thrust washer thickness 3 47 3 50 0 137 0 138 3 52 3 55 0 139 0 140 3 57 3 60 0 141 0 142 3 62 3 65 0 143 0 144 3 67 3 70 0 145 0 146 3 72 3 75 0 147 0 148 3 77 3 80 0 148 0 150 3 82 3 85 0 151 0 152 3 87 3 90 0 153 0 154 Wear or damage Wear or damage Thrust washer thickness Mainshaft 4th gear Mainshaft ball bearing L side Mainshaft 1st gear L side Mainshaft 1st gear R side 4 45 4 55 0 175 0 179 2 95 3 05 0 116 0 120 1 45 1 50 0 057 0 057 2 43 2 50 0 096 0 098 Wear or damage Wear or damage Countershaft 3rd gear splined washer thickness Mainshaft 4th gear thrust washer thickness One way clutch contact area 1 0 Countershaft 1st gear Parking gear 2 87 2 90 0 113 0 114 2 92 2 95 0 115 0 116 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 3 22 3 25 0 127 0 128 3 27 3 30 0 129 0 130 3 32 3 35 0 131 0 132 3 37 3 40 0 133 0 134 2 93 3 00 0 115 0 118 74 414 74 440 2 930 2 931 57 755 57 768 2 2738 2 2743 5 Wear or damage Wear or damage Wear or damage Wear or damage
154. ARB Changed Wire harness color Fuel feed pipe fuel return pipe and fuel vapor pipe materials for 4WD Except Europe model 5 8 9 Adopted D15Z2 engine for KQ model PGM FI 11 Changed Wire harness color Fuel feed pipe fuel return pipe and fuel vapor pipe materials for 4WD Except Europe model Out of use Fuel sub pump for 4WD model Added Jet pump for 4WD model T Added D15B7 and D16Y1 engines for KO model D15B7 and D16Z9 engines for KB model Modified Electronic Control Unit ECU Throttle body for B16A2 engine Changed Main wire harness Main wire harness for B16A2 engine Fuel pressure for D15B2 engine Throttle body Clutch Changed Torque value of clutch pipe for LHD model Recommended grease Manual Transmis sion Changed e Recommended grease Method of shift fork spring pin installing Modified Transmission mount right front mount bracket and rear mount bracket Changed Torque value of transmission mounting bolts Torque value of transmission mount bolt for 20 and Y21 manual transmissions Transmission breather cap for S20 manual transmission Shift fork for Y21 manual transmission Super low shaft 2 4 select lever and transfer shaft for S22 manual transmission ITEM DESCRIPTION Automatic Transmission Modified Hydrau
155. ASE RELEASE FORK Sams P N 41211 305 4 Place the transmission on the transmission jack and raise it to the engine level 5 Install the transmission mounting bolts and the rear mount bracket bolts SPECIAL BOLT Replace 12 x 1 25 mm 14 x 1 5 mm 65 N m 6 5 kg m 47 Ib ft 85 N m 8 5 kg m 61 Ib ft REAR MOUNT BRACKET 6 Raise the transmission then install the transmission mount NOTE Torque the mounting bolt and nuts in the sequence shown CAUTION Check that the bushings are not twisted or offset 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft TRANSMISSION MOUNT 12 x 1 25 mm 75 N m 7 5 kg m 54 Ib ft 7 Install the three upper transmission mounting bolts and lower starter motor mounting bolt 12 x 1 25 mm 65 6 5 kg m 47 Ib ft 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft cont d 13 17 Transmission Assembly Installation cont d 8 Installthe right front mount bracket SPECIAL BOLT Replace 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft RIGHT FRONT MOUNT BRACKET 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft 9 Install the clutch cover 6 x 1 0 mm 12 N m 1 2 kg m 9 lb ft CLUTCH COVER 8 x 1 25 mm 24 N m 2 4 kg m 17 Ib ft 10 Install the front and rear engine stiffeners REAR ENGINE 12 x 1 25 mm STIFFENERS 58 N m 5 8 kg m 24 N m 2 4 kg m 17 Ib ft 8 x 1 25 mm 24 N m 2 4 kg m FRONT ENGINE 17 Ib
156. ASSEMBLY CONNECTOR SHORT CONNECTOR RED SRS SHORT CONNECTOR A 07MAZ SP0020A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC 3 P 07PAZ 001010A SCS SHORT MEMORY ERASE SERVICE CONNECTOR SIGNAL MES CHECK CONNECTOR 2 P CONNECTOR 2 P BLK WHT BLK FRONT PASSENGER S SHORT CONNECTOR RED Connect Test Harness B AIRBAG 1 Turn the ignition switch OFF and remove the SCS short 3 P CONNECTOR connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Remove the glove box and connect the short connector RED to the passenger s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector To page 23 39 SRS MAIN HARNESS 23 38 From page 23 38 eu Check the SRS Unit 1 Connect the battery positive cable then connect the neg ative cable 2 Connect a voltmeter between the No B1 and B5 termi nals NOTE Do not connect any jumper wires to Test Harness B 3 Turn the ignition switch ON 1 and measure voltage There should be 0 5 V or less 4 Connect the voltmeter between the terminals No B5 and B7 and measure voltage There should be 0 5 V or less Fay Are the voltages as specified YES NO Faulty SRS unit replace the unit see page 23 66 Connect Test Harness
157. CS short connector to the service check connector see page 11 9 Does Check Engine light indi cate any CODE NO Remove the SCS short connector from the service check connector the engine Try to start Did the engine start NO Remove and inspect the ECU 15 A fuse in the under hood fuse relay box Is the fuse OK YES To page 11 16 YES YES NOTE When there is no code stored the Check Engine light will stay on if the service check connector is shorted Go to self diagnostic procedures 000000000 fJ 0000000000 f 00000000 000000000 OOOOOOOOOO j R v V Turn the ignition switch OFF B20 C12 5v Connect the te st harness be tween the ECU and connectors Turn the igniti on switch ON terminal and C12 Measure voltage between B20 terminal Is there approx 5 V NO Repair short to BRN wire between the ECU B20 and service check connector body ground in YES to the service check connector Measure voltage between B20 terminal and body ground Connect the SCS short connector Repair open Repair open tween service check connec tor and G101 tween ECU B20 and service check connector in BRN wire be in BLK wire be YES Is there app
158. Coil resistance rotor Q 3 4 3 8 Slip ring O D 22 7 0 89 22 2 0 87 Brush length 20 0 0 79 5 0 0 20 Brush spring tension g oz 300 450 10 6 15 9 Alternator NIPPONDENSO Output 13 5 Vathot A Coil resistance rotor 0 Slip ring O D Brush length Brush spring tension g oz 80 2 9 14 4 0 567 10 5 0 41 300 360 10 6 12 7 14 0 0 551 1 5 0 06 Starter motor HITACHI 0 8 kW Type Mica depth Commutator runout Commutator Brush length Brush spring tension new kg Ibs Direct drive 0 5 0 8 0 02 0 03 0 0 1 0 0 004 40 0 1 574 14 5 15 5 0 57 0 61 13 1 3 2 9 0 2 0 008 0 4 0 016 39 0 1 535 11 0 0 43 Starter motor MITSUBA 1 0 kW 1 2 kW 1 4 kW Type Mica depth Commutator runout Commutator O D Brush length 1 0 kW 1 2 kW 1 4 kW 1 0 kW 1 2 kW 1 4 kW Brush spring tension new N kg 165 Gear reduction 0 4 0 5 0 016 0 020 0 0 02 0 0 001 28 0 28 1 1 102 1 106 14 3 14 7 0 56 0 58 15 8 16 2 0 62 0 64 18 5 23 5 1 85 2 35 4 1 5 2 16 18 1 6 1 8 3 5 4 0 0 15 0 006 0 05 0 002 27 5 1 083 9 5 0 37 11 0 0 43 Starter motor NIPPONDENSO 1 0 kW 1 2 kW Type Mica depth Commutator runout Commutator O D Brush length Brush spring tension new N kg Ibs Gear reduction 0 5 0 8 0 02 0
159. D TO SUPPLEMENT THE SEAT BELT IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER B MAINTENANCE LID CAUTION BEFORE MAINTENANCE SWITCH OFF THE IGNITION ATTENTION AVANT TOUT ENTRETIEN COUPER LE CONTACT ACHTUNG VOR WARTUNG Z NDUNG AUSSCHALTEN LET OP ZET HET KONTAKTSLOT AF ALVORENS MET HET ON DERHOUD TE BEGINNEN MONITOR NOTICE NOTICE SRS REFER TO SERVICE MANUAL FOR DETAILED 1 STRUCTIONS REMARQUE POUR LES INSTRUCTIONS DETAILL EES SE REPORT ER AU MANUEL DE REPARATIONS LET UP RAADPLEEG HET WERKPLAATSHANDBOEK VOOR DERE AANWIJZINGEN ACHTUNG AUSF HRLICHE ANWEISUNGEN SIND DEM WERK STATTHANDBUCH ZU ENTNEHMEN D BODY COVER CAUTION CAUTION ACHTUNG 585 OSRSAVFFVARUITH Va Phe BRT ZKE REFER TO THE SHOP MANUAL SE REPORTER AU MANUEL D ATELIER WERKSTATTHANDBUCH LESEN LEES HET WEKPIAATSHANDBOEK E SRS WARNING HOOD LHD model WARNING THIS VEHICLE IS EQUIPPED WITH A DRIVER AS A SUP PLEMENTAL RESTRAINT SYSTEM SRS ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE SRS WIRING COULD RESULT IN AC CIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYS TEM 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
160. DISC SPRING CLUTCH PISTON CLUTCH PLATES C Standard thickness 0 079 i SNAP RING 2 0 mm 0 079 in 2ND CLUTCH SPRING RETAINER RETURN SPRING lt gt Replace RETURN SPRING CHECK VALVE SPRING RETAINER SNAP RING Standard thickness O RINGS CLUTCH PISTON DISC SPRING 4TH CLUTCH DRUM CLUTCH PLATES 2 0 mm 0 079 in Replace UL 2 3 at 2 DISCS Standard thickness 1 94 mm 0 076 in CLUTCH END PLATE SNAP RING 14 26 1ST HOLD CLUTCH CLUTCH END PLATE SNAP RING CLUTCH PLATES Standard thickness 2 0 mm 0 079 in SNAP RING SPRING RETAINER g RETURN SPRING b DISC SPRING CLUTCH PISTON CLUTCH DISCS 2 Standard thickness 1 94 mm 0 076 in O RINGS Replace CLUTCH DRUM 14 27 Reverse Idler Gear Installation 1 Install the reverse idler gear IDLER GEAR lt e CF OY 2 Install the reverse idler gear shaft holder and needle bearing into the transmission housing then tighten the bolts 6 x 1 0 mm 12 N m 1 2 kg m 8 7 Ib ft REVERSE IDLER GEAR SHAFT ASSEMBLY NEEDLE BEARING REVERSE IDLER GEAR 14 28 Shift Indicator Panel KB model Adjustment CAUTION All SRS wire harnesses are covered with yellow insu lation Before you disconnect any part of an SRS wire harness connect the short connectors Whenever the ignition switch is ON
161. E GEAR BEARING INNER RACE BEARING OUTER RACE O RING Replace TRANSFER THRUST SHIM Selective part TRANSFER L SIDE COVER L SIDE COVER PROTECTOR POOOOODOOOHHOHHOOGOOOOOSHGOOOKGGOOOOO TORQUE SPECIFICATIONS Torque value Bolt Size Remarks 12 1 2 kg m 9 Ib ft 6x1 0 mm 26 Nem 2 6 kg m 19 Ib ft 8 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft 10 x 1 25 mm 120 230 N m Driven Gear Shaft Locknut 12 0 23 0 kg m 87 166 Ib ft 14 37 Rear Differential Service Precautions 15 2 Special Tools ccs uuu u 15 3 Description Realtime 4WD Dual Pump System 15 4 Realtime 4WD Dual Pump System Troubleshooting Forward Drive Quick Starting 4WD 15 10 Reverse Drive Quick Starting 4WD 15 11 Forward Drive Quick Braking 2WD 15 12 Reverse Drive Quick Braking 4WD 15 12 Rear Differential Troubleshooting 15 13 Maintenance Differential Oil 15 14 Rear Differential Assembly Removal Installation 15 15 Illustrated Index 15 17 Rear Differential Carrier Oil Leak Repair
162. E NUT Flat portion faces 2 POINT BOLT center of the shaft 33 3 3 kg m 24 lb ft No 1 PROPELLER SHAFT LONG HOLE PROPELLER SHAFT FLANGE BOLT 10 x 1 25 mm 40 N m 4 0 kg m 29 Ib ft Align marks CENTER BEARING SUPPORT 16 13 Propeller Shaft Installation cont d 4 Connect the No 2 propeller shaft and rear differen 6 tial with the four 12 point bolts and yoke nuts by aligning the marks Align marks No 2 PROPELLER SHAFT REAR DIFFERENTIAL 12 POINT BOLT 33 N m 3 3 kg m 24 Ib ft YOKE NUT Flat portion faces center of the shaft 5 Install the No 1 propeller shaft onto the flame No 1 PROPELLER SHAFT PROTECTOR FLANGE BOLTS 8 x 1 25 mm 22 N m 2 2 kg m 15 Ib ft 16 14 Install the No 2 propeller shaft onto the flame No 2 PROPELLER SHAFT PROTECTOR FLANGE BOLTS 8 x 1 25 mm 22 N m 2 2 kg m 15 lb ft Anti lock Brake System ABS 4WD Circuit Diagram 19 2 Troubleshooting Symptom to System Chart 19 4 Flowcharts 19 5 Outline of Model Changes As the ABS of the cars with 4WD has been modified the changes were described in this section NOTE Refer to the 92 CIVIC shop manual No 62SR300 for service procedures and data not included in this supplement Circuit Diagram FUSE LABEL NAME ACG 5 BACK UP LIGHT RR DEF RLY HEATER MOTOR RLY
163. E SLEEVE THROTTLE CAM 1ST ACCUMULATOR PISTON 6 x 1 0 mm 12 Nem 1 2 kg m 9 lb ft Do not remove or adjust these nuts THROTTLE VALVE B THROTTLE LONG VALVES 25 ACCUMULATOR A PISTON SPRING SEAT SERVO VALVE SHIFT FORK SHAFT MODULATOR VALVE MODULATOR VALVE BODY MODULATOR SEPARATOR PLATE DOWEL PINS 2 pcs 2ND ACCUMULATOR PISTON O RINGS Replace 14 16 SPRING SPECIFICATIONS z Spring Unit of length mm in Standard New Wire Dia O D Free Length No of Coils 3rd accumulator spring 2 6 0 102 17 5 0 689 91 8 3 614 15 8 2nd accumulator spring 3 5 0 138 22 O 0 866 77 O 3 031 9 5 1st accumulator spring 2 6 0 102 24 3 0 957 101 9 4 012 11 6 151 accumulator spring 2 3 0 091 9 9 0 390 49 0 1 929 4 6 4th accumulator spring 2 6 0 102 16 0 0 630 90 1 3 547 15 6 G 2 3 4 orifice control valve spring 1 0 0 039 8 6 0 339 51 9 2 043 19 8 Australia model and Czecho Slovakia D16Z6 Modulator engine model valve spring Czecho Slovakia D15B2 engine model Other models Throttie valve A adjusting spring 1 2 0 047 1 2 0 047 1 2 0 047 1 2 0 047 7 O 0 276 7 0 0 276 7 0 0 276 7 0 0 276 27 2 1 071 26 3 1 035 27 2 1 071 27 6 1 087 1 2
164. EARING 10 Remove the pump body assembly and oil pump pin OIL PUMP PIN 15 22 Reassembly Install the oi pump pin and pump body assembly NOTE Align the oil pump pin and groove of the rear oil pump 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft GROOVE BODY ASSEMBLY OIL PUMP PIN 2 Install the thrust needle bearing and thrust washer on the pump body assembly 3 Install the oil pump keys on the differential clutch assembly and install it NOTE Align the oil pump keys and groove of the front oil pump 4 Install the 30 mm shim 30 mm SHIM DIFFERENTIAL CLUTCH ASSEMBLY C gt E gt THRUST NEEDLE BEARING PUMP BODY ASSEMBLY GROOVE 5 Install the 6 x 10 mm dowel pins and gasket and install the TCD Torque Control Differential case TCD CASE 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft GASKET Replace 6 x 1 0 mm DOWEL PIN 6 Install the companion flange 22 mm spring washer and 22 mm locknut NOTE Lubricate the ATF on the threads of the shaft 22 mm LOCKNUT e Replace 22 mm e SPRING WASHER COMPANION FLANGE 7 COMPANION FLANGE HOLDER 07PAB 0020000 8 Tighten the locknut using the special tool as shown Torque 108 N m 10 8 kg m 79 Ib ft 8 x 1 25 mm 33 N m 3 3 kg m 24 Ib ft Stake the locknut tab into the groove 22 mm LOCKNUT cont d 15 23 Rear Differential Assembly Reassembly
165. ER RELAY OOOOOOOOO OOOOOOOOOO OOOOOCOOO 16 50 HEATER MOTER RELAY li 00000000 ECU 15 A COOLING FAN MOTOR RELAY 7 5 A S 15 A 2 BACK UP LIGHTS 10 A 2 AS AB AIUATZ ATA ATE 82 B4 B6 B8 810812814 816818820 C2 C4 CF CR CIRCHOH STARTER SIGNAL 7 5 BACK UP 7 5 UNDER HOOD FUSEJRELAY BOK TERMINAL LOCATION 11 8 gt b Troubleshooting Self diagnostic Procedures L When the Check Engine light has been reported on do the following 1 Connect the SCS short connector to Service Check Connector as shown The 2P Service Check Connector is locat ed under the dash on the passenger side of the car Turn the ignition switch on LHD RHD DATA LINK CONNECTOR 3P CONNECTOR 3P NOTE NOTE I Do not attach Do not attach a jumper wire jumper wire SCS SHORT CONNECTOR 07PAZ 0010100 SERVICE CHECK SERVICE CHECK CONNECTOR 2P CONNECTOR 2P 2 Note the CODE the Check Engine light indicates a failure code by the length and number of blinks The Check Engine light can indicate simultaneous component problems by blinking separate codes one after another Problem codes 1 through 9 are indicated by individual short blinks Problem codes 10 through 48 are indicated by a series of long and short blinks The number of long blinks equals the first digit the number of short blinks equals the second digit Sometimes
166. F during assembly 1 Remove the countershaft bearing from the transmission housing 2 Install the parts below on the countershaft using the special tool and a press as described on this page NOTE Do not assemble the O rings while in specting 627 8 GEAR NEEDLE BEARING lt DISTANCE COLLAR 28 mm Selective COTTERS D THRUST NEEDLE BEARING 4 SPLINED WASHER lt Selective CLUTCH ASSEMBLY COUNTERSHAFT 2 3 Install the parts below on the countershaft sub 4 Measure the clearance between 4th gear and the assembly then torque the locknut to Nem reverse selector hub with a feeler gauge 3 0 kg m 22 Ib ft NOTE Take measurements in at least three places and take the average as the actual clearance STANDARD 0 05 0 13 mm 0 002 0 005 in REVERSE SELECTOR HUB 4TH GEAR LOCKNUT 30 N m 3 0 kg m 22 Ib ft PARKING GEAR 1ST GEAR ONE WAY CLUTCH ASSEMBLY NEEDLE BEARING B Na NS NE SE Ne 1ST GEAR COLLAR any TRANSMISSION HOUSING DISTANCE COLLAR 25722 BEARING 28 mm REVERSE GEAR COLLAR FEELER GAUGE lt COUNTERSHAFT DISTANCE COLLAR SUB ASSEMBLY 28 mm 4TH GEAR REVERSE SELECTOR P i HUB FEELER GAUGE cont d 14 21 Countershaft Inspection cont d Measure the clearance between 3rd gear and 2nd gear using a feeler gauge while leaving the fee
167. FILLER PLUG 14 mm WASHER Replace REVERSE IDLER GEAR SHAFT BOLT SUPER LOW LEVER CENTER BOLT 13 32 3 MOUNTING BOLTS 4 Remove the transmission under guard TRANSMISSION UNDER GUARD Remove the clutch housing mounting bolts in a crisscross pattern in several steps Mainshaft Countershaft Assemblies Removal Remove the 32 mm sealing bolt 1 Remove the reverse idler gear shaft reverse thrust washer and reverse idler gear 6 Expand the snap ring on the countershaft ball bear ing and remove it from the groove using a pair of snap ring pliers REVERSE IDLER GEAR SHAFT SNAP RING PLIERS 07LGC 0010100 32 mm SEALING BOLT REVERSE THRUST WASHER SNAP RING TRANSMISSION HOUSING REVERSE IDLER GEAR 7 Separate the transmission housing from the clutch housing and wipe it clean of the sealant 2 Remove the 1st 2nd shift fork shaft super low shift piece bar and 1st 2nd shift fork 8 Remove the 75 mm thrust shim and oil guide plate M then remove the 18 mm sealing bolt and oil gut ter plate OIL GUTTER PLATE 1ST 2ND SHIFT FORK SHAFT 18 mm SEALING BOLT 5 mm THRUST SHIM OIL GUIDE PLATE M 1ST 2ND SHIFT FORK TRANSMISSION HOUSING SUPER LOW SHIFT PIECE BAR cont d 13 33 Mainshaft Countershaft Assemblies Removal cont d 3 Remove the following parts in the order shown
168. FUSE No 12 15 BATTERY 13 UNDER HOOD COOLING FAN MOTOR RLY LTER ALTERNATOR FUSE RELAY UNDER DASH FUSE RELAY IGNITION BLKNEL WHT BLU 80 A CHARGING SYSTEM LIGHT SWITCH O BLK YEL WHT O O YEL BLK YEL BRAKE SWITCH GRN WHT IG 50 A STOP HORN 15 A BRAKE SYSTEM LIGHT UNDER HOOD ABS FUSE RELAY BOX ABS B1 20 A O 17 12 ABS B2 15 O O 17 14 ABS INDICATOR LIGHT ABS MOTOR 50 A BLK YEL WHT GRN WHT YEL RED BRN YEL YEL GRN YEL RED BRN YEL BLK YEL BRN BLK YEL GRN BRN BLK BRN BLK _ BRN BLK ABS PUMP MOTOR BLU BLK BLU BLK BLK SUR Ke 6202 6202 19 2 ABS CONTROL UNIT GRN RED GRN RED PARKING FLUID BRAKE LEVEL SWITCH SWITCH en JI FUE GRN RED et S 019 WARN 2 P NOOy nr FRW YEL RED BRN YEL FRW SOLENOIDS YEUGRN FLW RIGHT FRONT BRN BLK e BRN BLU RED BLU FLW 4 YELBLU RRW LEFT FRONT BRN BLK e BRN BLK RED BLK RRW RLW 2 REAR BLU BLK e BRN WHT RED WHT RLW 156 YELAWHT 18P CONNECTOR 12P CONNECTOR pap o ABS CONTROL CONNECTORS View from terminal side ECM SCS ear SERVICE CHECK CONNECTOR PRESSURE SWITCH
169. G AND CONNECTORS ARE COLORED YELLOW TAMPERING WITH DISCONNECTING OR USING ELECTRI CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR ING OF THE INFLATOR WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDEN TALLY DEPLOYED CAN SERIOUSLY HURT YOU FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY G LABEL AIRBAG FRONT SEAT PASSENGER INFLATOR WARNING WARNING ACCIDENTAL AIRBAG DEPLOYMENT CAN SERIOUSLY HURT OR KILL YOU INSTALL THE RED SERVICE CONNECTOR WHEN THE IN FLATOR HARNESS IS DISCONNECTED ATTENTION TOUT DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE TUER OUAND LE FAISCEAU DE FILS DU GONFLEUR EST DECON NECTE INSTALLER LE CONNECTURE D ENTRETIEN ROUGE I GLOVE BOX INFORMATION AIRBAG INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM SRS THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED THE DATE OF INSTALLATION IS SHOWN ON THE CERTIFICATION PLATE LOCATED ON THE DRIVER S DOOR JAMB DIAGNOSTIC CHECKS AND REPLACEMENT OF SRS COMPONENTS MUST BE DONE BY AN AUTHORIZED DEALER SEE YOUR OWNER S MANUAL FOR ADDITIONAL SRS INFORMATION cont d 1 13 Warning Caution Label Locations cont d J FRONT SEAT PASSENGER AIRBAG MODULE DANGER K MONITOR NOTICE A DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH A
170. HT BLU terminal and body ground L Is there battery voltage NO YES Check for voltage between the No 1 WHT BLU terminal and No 2 BLK terminali lt Is there battery voltage YES Faulty pump motor Replace the ABS pump assem bly ABS UNDER HOOD ABS FUSE RELAY BOX Replace the under hood ABS fuse relay box HARNESS SIDE CONNECTOR BLK GROUND WHT BLU MOTOR RELAY EZ View from terminal side Repair open in WHT BLU wire between the motor relay and pump motor HARNESS SIDE CONNECTOR BLK GROUND WHT BLU MOTOR RELAY EE 2 1 View from terminal side Repair open in BLK wire between the pump motor and ground or poor ground G202 cont d 19 7 Troubleshooting Flowcharts cont d Problem Code 6 1 Front Fail Safe Relay Circuit CAUTION Use only the digital multimeter to check the system Pre test steps Check ABS B1 20 A fuse in the under hood ABS fuse relay box Check for loose under hood ABS fuse relay box connectors Remove the front fail safe relay from the under hood ABS fuse relay box Check relay function NO c Does it work properly gt Replace the front fail safe relay YES Turn the ignition switch ON Check for voltage between the fail safe relay No 1 BL
171. INT 16 mm cont d INNER DIAMETER mm 22 9 System Service Performance Test cont d 5 To complete the charts Sanden Mark the delivery temperature along the vertical line psi Mark the intake air temperature ambient air tem 3000 80 perature along the bottom line 30 Draw a line straight up from the air temperature 427 kPa DELIVERY 3096 to the humidity level 2500 kg cm PRESSURE 3 25 psil Mark a point one line above and one line below 356 the humidity level 1096 above and 1096 below 2000 1500 C humidity level 20 5 en 8096 From each point draw a horizontal line across to 284 71 80 i 1500 400 30 2 the delivery temperature 15 4 The delivery temperature should fall between the 21 2 157 du two lines 1000 3901 25 299 Complete the low side pressure test and high side 10 3 77 INTAKE pressure test in the same way 142 20 PRESSURE Any measurements outside the line indicate pELIVERY 2 68 Z 30 the need for further inspection PRESSURE 28 4 199 15 Es 1 59 Lo 14 y 10 gt VA INTAKE 50 SC PRESSURE 5 DELIVERY 41 1 TEMPERATURE DELIVERY e LEITET a aes TEMPERATURE 20 25 30 35 40 c 68 77 86 95 104 P INTAKE AIR TEMPERATURE Nippondenso Matsushita kPa kPa kg cm kg cm psi psi 3
172. IRCUIT PGM FI main relay In the gauge assembly Charging system light SRS INDICATOR LIGHT 1 4W FRONT PASSENGER S DRIVER S AIRBAG INFLATOR 11 SRS UNIT 16 DATA LINK ECM SERVICE CONNECTOR CHECK MEMORY ERASE DLC CONNECTOR SIGNAL MES CONNECTOR SRS UNIT TERMINAL 23 20 Precautions Procedures General Precautions Carefully inspect any SRS part before you install it Do not install any part that shows signs of being drop ped or improperly handled such as dents cracks or deformation Airbag assemblies Cable reel SRS unit Use only a digital multimeter to check the system If it s not a Honda multimeter make sure its output is 10 mA 0 01 A or less when switched to the smallest value in the ohmmeter range A tester with a higher output could damage the airbag circuit or cause acci dental deployment and possible injury Do not install used SRS parts from another car When making SRS repairs use only new parts Except when performing electrical inspections al ways disconnect both the negative cable and positive cable from the battery and wait at least three min utes before beginning work Replacement of the combination light and wiper washer switches and cruise control switch can be done without removing the steering wheel Combination light and wiper washer switch replace ment Cruise control set resume switch replacement Whenever the ignition switch is ON
173. Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Whenever the airbag has been activated replace the SRS unit 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 ser vice please observe the following precautions Store the removed airbag assembly with the pad sur face up If the airbag is improperly stored face down accidental deployment could propel the unit with enough force to cause serious injury e Store the removed airbag assembly a secure flat surface away from any high heat source exceeding 100 C 212 F and free of any oil grease detergent or water CAUTION Improper handling or storage can internally damage the airbag assembly making it inoperative If you suspect the airbag assembly has been damaged in stall a new unit and refer to the Deployment Disposal Procedures for disposing of the damaged airbag 23 21 Precautions Procedures SRS Unit Precautions Inspection After Deployment After a collision in which the airbags were deployed re place the SRS unit and inspect the following e Take extra care when painting or doing body work in the area below the dashboard Avoid direct exposure of
174. K YEL terminal and body ground UNDER HOOD ABS FUSE RELAY BOX Repair open in BLK YEL wire be tween the No 13 RR DEF RLY HEATER MOTOR RLY NO Is there battery voltage COOLING FAN MOTOR RLY 7 5 A fuse in the under dash YES fuse relay box and front fail safe relay Turn the ignition switch OFF REAR FRONT ABS FAIL SAFE FAIL SAFE MOTOR CHECK PUMP RELAY 7 5 A Disconnect the connector from the solenoid Check for continuity between the fail safe relay No 9 10 BRN BLK terminal and body ground To page 19 9 16 13 8 9 104 1 3 5 2 14 12 UNDER HOOD ABS FUSE RELAY BOX CIRCUIT DIAGRAM 19 8 From page 19 8 lt Is there continuity NO gt Check each wire for continuity between the solenoid terminals and body ground No 6 BRN BLU Front Right No 4 BRN BLK Front Left Is there continuity NO Disconnect the connectors from the ABS control unit Check each wire for continuity between the ABS control unit and body ground Repair short in BRN BLK wire between the solenoid and front fail safe relay YES YES Faulty solenoid short Replace the modulator unit ABS SOLENOID SIDE CONNECTOR BRN BLU BRN BLK View from terminal side 12P CONNECTOR RED BLK FL IN RED BLU
175. LDREN DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU OU DES METAUX LOURDS COMME LE CUIVRE LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS OU DES COMPOSES EXPLOSIFS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLE MENT SRS DU MANUEL D ENTRETIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS SI LE CONTENU EST ABSORBE INDUIRE UN VOMISSE MENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LES CAS OBETENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS Label D and E locations Refer to page 1 11 1 12 E DRIVER INFLATOR WARNING TAG WARNING ACCIDENTAL AIRBAG DEPLOYMENT CAN SERIOUSLY HURT OR KILL YOU INSTALL THE RED SERVICE CONNECTOR WHEN THE IN FLATOR HARNESS IS DISCONNECTED ATTENTION TOUT DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR RISQUE DE PROVOQUER DES BLESSURES GRAVES DE TUER QUAND LE FAISCEAU DE FILS DU GONFLEUR EST DECON NECTE INSTALLER LE CONNECTURE D ENTRETIEN ROUGE F SRS WARNING HOOD SUPPLEMENTAL RESTRAINT SYSTEM SRS THIS VEHICLE IS EQUIPPED WITH A DRIVER AND FRONT SEAT PASSENGER AIRBAG ALL SRS ELECTRICAL WIRIN
176. LIST Check these items on the NOTES CHART Engine runs but car does not move in any gear 1 6 7 16 Car moves in R and 2 but not in Ds or 1 8 29 44 48 Car moves in Ds Da 1 R but not in 2 9 30 49 Car moves in Ds D4 2 1 but not 1 11 22 34 38 38 40 Car moves in N 1 8 9 10 11 46 47 Excessive idle vibration 5 17 Slips in all gears 6 7 16 No engine braking in 1 position 12 Slips in 1st gear 8 29 44 48 Slips in 2nd gear 9 20 23 30 49 Slips in 3rd gear 10 21 23 31 44 Slips in 4th gear 11 23 32 Slips in reverse gear Flares on 1 2 upshift 11 32 34 3 15 Flares 2 3 upshift 3 15 24 44 m Flares on 3 4 upshift No upshift transmission stays in low gear 3 15 25 44 14 19 23 m No downshift to low gear 12 19 Late upshift Erratic shifting 14 2 14 Tolo Harsh shift up and down shifting 2 4 15 23 24 27 47 gt lt Harsh shift 1 2 Harsh shift 2 3 2 9 2 10 23 24 Harsh shift 3 4 2 11 23 25 Harsh kick down shifts 2 23 27 28 Harsh kick down shift 2 1 48 Harsh downshift at closed throttle 15
177. LVE SECONDARY VALVE BODY CAP DOWEL PINS 2 pcs qu STOPPER SEAT CPC VALVE SERVO CONTROL VALVE 14 14 CHECK BALLS ET ann SECONDARY VALVE CHECK BALL BODY Sectional View Unit of length mm in Standard New z 2 Spring Wire Dia OD Free Length No of Coils D 2nd ON orifice control valve spring 0 9 0 035 8 0 0 315 24 1 0 949 9 6 4 3 kick down valve spring 1 0 0 039 6 6 0 260 29 9 1 177 14 7 3 Governor cut valve spring 0 8 0 031 7 6 0 299 44 5 1 752 17 0 2 3 orifice control valve spring 0 9 0 035 6 6 0 260 33 2 1 307 14 9 2 1 timing valve spring 0 6 0 024 5 6 0 220 33 0 1 299 11 0 6 Reverse control valve spring 0 6 0 024 7 1 0 280 40 0 1 575 10 0 Servo control valve spring 0 9 0 035 6 4 0 252 34 1 1 343 17 5 CPC Clutch Pressure Control valve 0 9 0 035 8 4 0 331 24 9 0 980 9 8 spring 14 15 Servo 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 Coat all parts with ATF before reassembly Replace the O rings and filters 4TH ACCUMULATOR PISTON 2 3 4 ORIFICE CONTROL VALVE THROTTLE VALVE A VALV
178. NECTOR et SRS MAIN HARNESS From page 23 40 Check the SRS Unit 1 Connect jumper wires to the No 13 14 15 and 16 termi nals on rows A SRS unit end and B SRS main harness end of Test Harness B NOTE Do not connect jumper wires to the other termi nals 2 Connect the battery positive cable then connect the neg ative cable 3 Connect a voltmeter between the No A1 and A5 terminals of Test Harness B 4 Turn the ignition switch ON 11 and measure voltage There should be 9 4 14 V 5 Turn the ignition switch OFF and measure resistance be tween the No 7 and terminals There should be 0 75 1 0 kQ NOTE The resistance will be unstable if you measure immediately after you turn the ignition switch OFF Allow it to settle then take the reading Are voltage and resistance as specified YES NO Faulty SRS unit replace the unit see page 23 66 Connect Test Harness C and check for a short to ground in the cable reel 1 Turn the ignition switch OFF 2 Remove the dashboard lower cover and disconnect the cable reel 6 P connector from the SRS main harness 3 Connect Test Harness C to the cable reel 6 P connector 4 Check for continuity between the No 4 terminal of Test Harness C and ground and between the No 5 terminal of Test Harness C and ground Is there continuity YES NO Short to ground in the cable reel replace
179. NING e Make sure jacks and safety stands are placed proper ly see section 1 e Make sure the car will not roll off stands and fall while you are working under it 1 Disconnect the exhaust pipe and three way cat alytic converter TWC GASKET Replace EXHAUST PIPE A 2 Remove the mounting rubbers then remove the three way catalytic converter TWC exhaust pipe B and muffler assemblies RUBBER MOUNTING RUBBER 3 Disconnect the No 2 propeller shaft and rear differ ential NOTE Mark the shaft and companion flange before disconnecting them No 2 PROPELLER SHAFT 12 POINT BOLT 8 x 1 25 mm 33 N m 3 3 kg m 24 Ib ft 4 Remove the rear differential dynamic damper 12 x 1 25 mm 55 N m 5 5 kg m 40 Ib ft REAR DIFFERENTIAL DYNAMIC DAMPER cont d 15 15 Rear Differential Assembly Removal Installation cont d 5 Place a transmission jack under the rear differential 6 Remove the right and left rear differential mounting bracket B 12 x 1 25 mm 40 Ib ft REAR DIFFERENTIAL MOUNTING BRACKET B 7 Remove the breather tube joint BREATHER TUBE JOINT 15 16 55 N m 5 5 kg m 8 Remove the mounting bolts and plates 9 Lower the rear differential on the transmission jack by pulling the inboard joint and remove the drive shaft from the rear differential case as an assembly see section 16 REAR DIFFERENTIAL MOUNTING DRIVESHAFT 10
180. NT STANDARD NEW SERVICE LIMIT Transmission Capacity US qt Imp qt 6 4 6 8 5 6 for overhaul fluid 3 2 3 4 2 8 or fluid change Hydraulic Line pressure at 2 000 mier rpm N or P position 850 900 8 5 9 0 121 128 800 8 0 114 Pressure Ds 500 5 0 71 450 4 5 61 position throttle fully closed throttle fully closed kPa kg cm psi 2nd clutch pressure at 2 000 min rpm 3rd clutch pressure at 2 000 min rpm 04 position 850 900 8 5 9 0 121 128 800 8 0 114 sl throttle more than 3 8 opened throttle more than 3 8 4th clutch pressure at 2 000 min rpm D4 position opened 2nd clutch pressure at 2 000 min rpm 2 position 850 900 8 5 9 0 121 128 800 8 0 114 Ist clutch pressure at 2 000 min rpm Da 1 850 900 8 5 9 0 121 128 800 8 0 114 position 1st hold clutch pressure at 2 000 min rpm 1 850 900 8 5 9 0 121 128 800 8 0 114 position Throttle B pressure Throttle fully closed 0 Throttle fully open 850 900 8 5 9 0 121 128 800 8 0 114 Stall speed min rpm check with car on level ground 2 600 2 300 2 900 Clutch Clutch initial clearance 1st 2nd 0 65 0 85 0 026 0 033 3rd 4th 0 40 0 60 0 016 0 024 1st hold 0 5 0 8 0 02 0 03 Clutch return spring free length 1st 31 0 1 22 29 0 1 14 2nd 3
181. No Code CAUTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Check the SRS indicator circuit input voltage 1 Turn the ignition switch OFF and disconnect Test Harness B c 2 Connect the SRS main harness 18 P connector to the SRS unit 3 Disconnect the SRS main harness 6 P connector from the main wire harness 4 Connect a voltmeter between the No 4 terminal 4 of the SRS main harness 6 P connector and ground 5 Turn the ignition switch ON Il and measure voltage Is there 8 5 V or more six seconds after the ignition switch has been turned ON II YES NO MAIN WIRE HARNESS 6 P CONNECTOR SRS MAIN HARNESS 6 P CONNECTOR Check for short to ground in the SRS indicator light cir cuit 1 1 Turn the ignition switch OFF 2 Check for continuity between the No 4 terminal MAIN WIRE HARNESS 4 of the main wire harness 6 P connector and 6 P CONNECTOR ground BLU D C5 Is there continuity 200 Q or less View from wire side YES NO View from terminal side Check for short to ground in the SRS indicator light circuit 2 1 Remove the dashboard wire harness 14 P con nector from the main wire harness 2 Check for continuity between the No 14 termi nal of the dashboard wire harness 14 P co
182. OUTBOARD JOINT Inspect for faulty movement and wear Inspect ball bearings while rotating OUTBOARD JOINT BOOT Inspect for cracking splitting and wear OUTBOARD RINGS Check for damage Pack cavity with grease 16 4 0 0 Reassembly 1 Wrap the splines with vinyl tape to prevent damage 4 Fitthecirclip into the driveshaft groove to the boots NOTE Always rotate the circlip in its groove to be 2 Install the boots and new boot bands to the drive sure it is fully seated shaft then remove the vinyl tape CAUTION Take care not to damage the boots INBOARD BOOT BOOT BANDS CIRCLIP VINYL T STE GROOVE OUTBOARD BOOT DRIVESHAFT 3 Install the spider rollers on the driveshaft by align 5 Pack the outboard joint with the joint grease includ ing the marks on the spider rollers and end of the ed in the new driveshaft set driveshaft Grease quantity 40 60 g 1 4 2 1 oz CAUTION Be careful not to damage the rollers DRIVESHAFT Marks ROLLER SPIDER ROLLERS cont d 16 5 Rear Driveshafts Reassembly cont d 6 Pack the inboard joint with the joint grease included 8 Adjust the length of the driveshafts to the figure in the new driveshaft set below then adjust the boots to halfway between full compression and full extension Grease quantity 85 105 g 3 0 3 7 oz NOTE The ends of boots seat in the groove of the driveshaft and joint Left 635 640 mm 25 0 25 2
183. P sensor Repair short to body ground in YEL WHT wire between ECU D20 and throttle angle sensor or EGR valve lift sen sor D15Z1 engine or IMA D16A9 engine D19 OOOOOOOOOOO OOOOOOOOOQO Continuity cont d 11 13 PGM FI Control System Troubleshooting Flowchart ECU cont d From page 11 13 Measure voltage between body ground and the following termi nal individually A26 B2 2000000000000 J 00000000 Less than 1 V Is there less than 1 V BRN BLK B2 and G101 NO Repair open in BLK RED A26 or YES l Measure voltage between A26 and the following B1 and A25 1 Measure voltage between 26 B1 and the following B1 and A25 OOooooooooooool ooooooo A25 A26 BATTERY VOLTAGE Repair open in YEL BLK wire between ECU A25 B1 and main relay Check main relay and wiring connectors at main relay Is there battery voltage YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nai ECU 11 14 Troubleshooting Flowchart ECU D15B2 engine Check Engine light stays on or comes on after two seconds Turn the ignition switch ON Connect the S
184. PPER OIL GUIDE CAP Replace REVERSE IDLER GEAR SHAFT HOLDER NEEDLE BEARING OIL SEAL Replace SET RING 80 mm Selective part TRANSMISSION HANGER TRANSMISSION MOUNT BRACKET REVERSE IDLER GEAR TRANSMISSION HOUSING GASKET Replace DOWEL PIN SNAP RINGS TRANSMISSION HOUSING SUB SHAFT BEARING TRANSMISSION HOUSING MAINSHAFT BEARING TRANSMISSION HOUSING COUNTERSHAFT BEARING TRANSMISSION HOUSING DIFFERENTIAL ASSEMBLY OIL SEAL Replace Bolt Size Remarks 12 Nem 1 2 kg m 9 lb ft 14 Nem 1 4 kom 10 lb ft 34 N m 3 4 kg m 25 Ib ft 50 Nem 5 0 kg m 36 Ib ft 6 x 1 0 mm 6 x 1 0 mm 8 x 1 25 mm Special bolt 12 x 1 25 mm 14 11 lllustrated Index Torque Converter Housing Valve Body 14 12 eo099999699 e9eeoee 9e 9999999999 ATF MAGNET Clean ACCUMULATOR COVER O RING Replace OIL FEED PIPE ATF MAGNET Clean DETENT BASE LOCK WASHERS Replace OIL FEED PIPE BAFFLE PLATE SERVO BODY SERVO SEPARATOR PLATE THROTTLE CONTROL SHAFT E RING CHECK BALLS SECONDARY VALVE BODY DOWEL PINS SECONDARY SEPARATOR PLATE LOCK WASHERS Replace GOVERNOR BODY DOWEL PIN OIL FEED PIPE MODULATOR VALVE BODY DOWEL PINS MODULATOR SEPARATOR PLATE LOCK UP VALVE BODY DOWEL PINS LOCK UP SEPARATOR PLATE COOLER CHECK VALVE SPRING COOLER CHECK VALVE TORQUE CONVERTER CHECK VALVE SPRING TORQUE CONVERTER CHECK VALVE TORQUE SPECIFICATIONS Torque Value
185. RETENUE COMPLEMENTAIRE SRS TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYS TEME DE RETENUE COMPLEMENTAIRE SRS SONT DE COULEUR JAUNE N UTILISEZ PAS UN EQUIPEMENT D ES SAIS ELECTRIQUES SUR CES CIRCUITS NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME SRS CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU RENDRE LE SYSTEME IN OPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES WARNUNG DIESES FAHRZEUG IST MIT EINEM FAHRER AIRBAG SRS ALS ZUS TZLICHEM R CKHALTESYSTEM AUS GER STET ALLE ELEKTRISCHEN KABEL SOWIE DIE ZUGEH RIGEN STECKVERBINDER DES SRS SYSTEMS SIND IN GELBER FARBE AUSGEF HRT KEINE ELEKTRISCHEN PR FGER TE AN DIE SRS VERKABELUNG ANSCHLIBN VER NDERN ODER UN TEBRECHEN DER SRS VERKABELUNG KANN NUKONTROL LIERTES 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 BESCHERMING SRS ALLE ELEKTRISCHE LEIDINGEN EN AANSLUTINGEN VAN DE SRS ZIJN GEEL GEKLEURD GEBRUIK GEEN ELEK TRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS KNOEIEN MET OF LOSKOPPELEN VAN DE SRS LEIDINGEN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKELEN VAN HET SYSTEEM DIT KAN TOT ERN STIGE ONGELUKKEN LEIDEN cont d 1 9 Warning Caution Label Locations cont d E
186. Replace DRAIN PLUG SEALING WASHER Replace ee9e 9e 999999999999999999999999e9e99 9o TORQUE SPECIFICATIONS Torque Value Geeoeeeeeeeeecse 1ST CLUTCH FEED PIPE O RINGS Replace FEED PIPE GUIDE CIRCLIP MAINSHAFT LOCKNUT FLANGE NUT Replace 1ST CLUTCH ASSEMBLY O RINGS Replace THRUST WASHER THRUST NEEDLE BEARING NEEDLE BEARING MAINSHAFT 1ST GEAR THRUST WASHER MAINSHAFT 1ST GEAR COLLAR 1ST HOLD CLUTCH FEED PIPE O RING Replace FEED PIPE GUIDE O RING Replace CIRCLIP SUB SHAFT LOCKNUT FLANGE NUT Replace SUB SHAFT DISC SPRING Replace SUB SHAFT 1ST GEAR LOCK WASHER Replace THROTTLE CONTROL LEVER THROTTLE CONTROL LEVER SPRING OIL SEAL Replace THROTTLE CONTROL CABLE HOLDER SEALING WASHERS Replace ATF COOLER PIPE JOINT BOLT ATF COOLER PIPES ATF LEVEL GAUGE VEHICLE SPEED SENSOR O RING Replace ATF COOLER PIPE JOINT BOLT SEALING WASHERS Replace Bolt Size Remarks 12 Nem 1 2 kg m 9 lb ft 14 1 4 kg m 10 Ib ft 11 Nem 1 1 kg m 8 Ib ft 22 N m 2 2 kg m 16 Ib ft 8 Nem 0 8 kg m 6 b ft 29 Nem 2 9 kg m 21 lb ft 50 5 0 kg m 36 lb ft 95 9 5 kg m 69 Ib ft A B C D F G 140 0140 N m 14 0 0 14 0 kg m 1010 101 Ib ft 95 N m 9 5 kg m 69 Ib ft 6x1 0 6x1 0 mm 6x1 0 mm 8 1 25 5 0 8 mm 12 x 1 25 18 x1 5 mm 19 x 1 25 mm Special bolt ATF cooler pipe
187. S BATTERY CAUTION AIR CLEANER RECOMMENDED OIL and ir FILTER SERVICE 02222222 CRE P S SPARK PLUG INFORMATION RADIATOR CAP CAUTION TIRE INFORMATION LHD 4 door and KY 3 door 4 Except KY 3 door 1 15 Lift and Support Points Lift When heavy rear components such as suspension fuel tank spare tire and hatch are to be removed place additional weight in the luggage area before hoisting When substantial weight is removed from the rear of the car the center of gravity may change and can cause the car to tip forward on the hoist NOTE Since each tire wheel assembly weighs approximately 14 kg Ibs placing the front wheels in the trunk can assist with the weight distribution 1 Place the lift blocks as shown 2 Raise the hoist until the tyres are slightly off the ground and rock the car to be sure it is firmly supported 3 Raise the hoist to full height and inspect lift points for solid support ey cse FRONT SUPPORT POINT LIFT BLOCKS REAR SUPPORT POINT 1 16 Floor Jack 1 Setthe parking brake and block the wheels that are not being lifted 2 When lifting the rear of the car put the gearshift lever in reverse Automatic in P position 3 Raise the car high enough to insert the safety stands 4 Adjust and place
188. S COPPER LEAD OR MERCURY MAY PRODUCE HARM FUL AND IRRITATING GASES OR EXPLOSIVE COM POUNDS STORAGE TEMPERATURE MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE 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 KEEP OUT OF REACH OF CHILDREN WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDEN TALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB ING DEVICES THEY CAN CAUSE ACCIDENTAL DEPLOYMENT NO SERVICEABLE PARTS INSIDE DO NOT DISAS SEMBLE PLACE AIRBAG UPRIGHT WHEN REMOVED Label J and K locations Refer to page 1 13 FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY NOTICE NO SERVICEABLE PARTS INSIDE REFER TO SERVICE MANUAL FOR DETAILED IN STRUCTIONS SHEL ESZ t Z 7 Bv REMARQUE AUCUNE PIECE REPARABLE A L INTERIEUR POUR LES INSTRUCTIONS DETAILL EES SE REPOR TER AU MANUEL DE REPARATIONS LET UP GEEN ONDERDELEN BINNEN DEZE UNIT WAARAAN WERKZAAMHEDEN KUNNEN WORDEN VERRICHT RAADPLEEG HET WERKPLAATSHANDBOEX VOOR NA DERE AANWIJZINGEN ACHTUNG DIE INNENTILE BED RFEN KEINER WART
189. S control unit 18P CONNECTOR 30 29 28 27 26 25 24 23 22 21 20 19118 17116 15 14 13 YEL GRN FSR View from ABS control unit terminal side 5 Problem Code 6 4 Rear Fail Safe Relay Circuit CAUTION Use only digital multimeter to check the system Pre test step Check for loose under hood ABS fuse relay box connectors Remove the rear fail safe relay from the under hood ABS fuse relay box Check relay function el N Does it work properly 8 Replace the rear fail safe relay 5 Turn the ignition switch ON T 1 Check for voltage between the fail safe relay No 1 BLK YEL terminal and body ground UNDER HOOD ABS FUSE RELAY BOX Repair open in BLK YEL wire be tween the No 13 RR DEF RLY NO HEATER MOTOR RLY COOLING Is there battery voltage FAN MOTOR RLY 7 5 A fuse in the under dash fuse relay box and YES front fail safe relay ABS Turn the ignition switch OFF REAR FRONT FAIL SAFE i MOTOR CHECK PUMP RELAY RELAV FE 7 5 MOTOR Disconnect the 10P connector from the solenoid Check for continuity between the fail safe relay No 8 BLU BLK terminal and body ground 4 6 6 S 16 13 8 9 10 4 1 3 5 2 14 12 UNDER HOOD ABS FUSE RELAY BOX CIRCUIT DIAGRAM YES Repair short in BLU BLK wire b
190. S unit sensors inflator etc are located in it Behind the dashboard Under dash fuse relay box SRS Type Steering wheel Behind the dashboard Under dash fuse relay box Front console Carstereo units and other accessories A C heater 1 Special Tools 23 2 Ignition System Spark Plug Inspection 23 3 Ignition Timing Inspection and Setting 23 4 Integrated Control Unit KO model Input Test 23 6 Rear Window Defogger KB model Component Location Index 23 10 Troubleshooting 23 12 Seat Heaters KS model with Headlight Adjuster Component Location Index 23 13 Switch Removal dee 23 15 Switch Test 23 15 Supplemental Restraint System SRS E 23 17 Read SRS precautions on page 23 21 then install the short connector s on the airbag s before working in these areas Outline of Model Changes Ignition System As the engine types of KO model have been changed related items have been rewritten Integrated Control Unit As the integrated control unit of KO model has been changed related items have been rewritten Items related to the newly added KB model have been included Seat Heaters As th
191. S unit terminals or connec tors Do not disassemble the SRS unit it has no service able parts 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 discon nect the positive cable and wait at least three min utes 2 Connect the short connectors to the airbags see page 23 25 3 Remove the right side cover from the SRS unit SRS UNIT TORX BOLTS Use a Torx RIGHT SIDE COVER 23 66 4 Remove the left side cover from the SRS unit then disconnect the SRS main harness 18 P connector from the SRS unit SRS UNIT SRS MAIN HARNESS TORX BOLTS 18 P CONNECTOR M Use a Torx T30 bit LEFT SIDE COVER 5 Remove the four Torx bolts from the SRS unit then pull out the SRS unit from the driver s side CAUTION 9 Remove and properly store the short connectors sure to install the SRS wiring so that it is not RED then reconnect the airbag connectors and pinched or interfering with other car parts reinstall the access panel and glove box e When tightening the Torx bolts to the specified torque after replacement be careful to turn 10 Reconnect the battery positive cable then the nega them in so that their heads rest squarely on the tive cable brackets 11 After installing t
192. SRS WARNING HOOD RHD model SUPPLEMENTAL RESTRAINT SYSTEMI SRS THIS VEHICLE IS EQUIPPED WITH A DRIVER SIDE AIRBAG ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW E SRS WARNING HOOD KS WARNING SRS THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE SRS 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 FOR FORARSATET SOM ETT KOMPLETTERANDE SKYDDSSYSTEM SRS SAMTLIGA ELLEDNINGAR OCH KONTAKTER SRS SYSTEMET AR GULFARGADE ANVAND INTE ELEKTRISK PROVUTRUSTNING FOR DESSA KRETSAR OM DU AN DRAR ELLER LOSSAR EN SRS LEDNING KAN DET RESULTERA I EN OAVSIKTLIG UTLOSNING AV TRYCKPUM PEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA DA KAN EN ALLVARLIG OLYCKA UPPSTA VAROITUS TASSA AUTOSSA ON YLIMAARAISENA TUKIJARJESTEL AJAJAN ILMATYYNY SRS KAIKKI SRS S HK JOHDOT JA LITTIMET OVAT KELTAISET L K YT SAHKOKOELAITTEITA N ISS VIRTAPI IREISA SRS JOHTOJEN TUKKEAMINEN TAI IRROTAAMI NEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TAI TEHD JARJESTELMAN KAYTTOKELVOTTOMAKSI TASTA TAAS SAATTAA AIHEUTUA VAKAVIA VAURIOITA TAMPERING WITH DISCONNECTING OR USING ELECTRI CAL TEST
193. T30 bit DRIVER S AIRBAG ASSEMBLY TORX BOLT 10 N m 1 0 kg m 7 2 Ib ft Replace Use a Torx T30 bit Front Passenger s Side e Place the front passenger s airbag assembly into the dashboard Loosely install all six mounting nuts Tighten the upper four nuts first then tighten the lower two nuts The lower mounting brackets can be adjusted if necessary NOTE If there is some space between the airbag as sembly lid and the dashboard after tightening the nuts loosen the lower mounting nuts and lightly press down the airbag assembly Then retighten the lower mounting nuts FRONT PASSENGER S AIRBAG ASSEMBLY LID FRONT PASSENGER S AIRBAG ASSEMBLY UPPER MOUNTING NUTS ACCESS MOUNTING NUTS LOWER MOUNTING NUTS 10 N m 1 0 kg m 7 2 Ib ft Replace 23 58 5 Remove and properly store the short connectors then reconnect the airbag connectors Front Passenger s Side Attach the short connector RED to the connector holder Then reinstall the access panel and glove box on the dashboard FRONT PASSENGER S FRONT PASSENGER S AIRBAG AIRBAG 3 P CONNECTOR ASSEMBLY SHORT RED GLOVE BOX Driver s Side e Remove the short connector RED from the driver s 6 Connect the battery positive cable then the nega 7 After installing the airbag assembly confirm proper airbag connector then connect the airbag 3 P con nector to the cabl
194. Total runout 44 976 45 000 1 7707 1 7717 54 976 55 000 2 1644 2 1654 39 976 40 000 1 5739 1 5748 41 976 42 000 1 6256 1 6535 44 976 45 000 1 7707 1 7717 0 0025 0 00010 max 0 0025 0 00010 max 0 10 0 35 0 004 0 014 0 03 0 001 max 0 005 0 0002 0 005 0 0002 0 45 0 018 0 04 0 002 Bearings Main bearing to journal oil clearance No 1 and 5 journals No 2 3 and 4 journals Rod bearing to journal oil clearance 0 018 0 036 0 0007 0 0014 0 024 0 042 0 0009 0 0017 0 020 0 038 0 0008 0 0014 0 05 0 002 0 05 0 002 0 05 0 002 1 TEIKOKU PISTON RING manufactured piston ring 2 RIKEN manufactured piston ring 3 ALLIED RING CORP manufactured piston ring 3 6 Engine Block Section 7 B16A2 Engine MEASUREMENT STANDARD NEW Cylinder block Piston T Warpage of deck surface Bore diameter Bore taper Reboring limit Skirt O D At 15 mm 0 59 in from bottom of skirt Clearance in cylinder Ring groove width Top 2nd Oil 0 05 0 002 81 000 81 020 3 1890 3 1898 80 980 80 990 3 1882 3 1886 0 010 0 035 0 0004 0 0014 1 030 1 040 0 0406 0 0409 1 230 1 240 0 0484 0 0488 2 805 2 820 0 1104 0 1110 Piston ring Piston pin Connecting rod Crankshaft Bearing Piston to ring clearance Ring end gap
195. Transmission M24A cont d Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission 3 24 T gt Diameter of needle bearing contact area On mainshaft and stator shaft On mainshaft 2nd gear On mainshaft 4th gear collar On mainshaft 1st gear collar On countershaft L side On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On subshaft L side On subshaft 4th gear collar On reverse idler gear shaft On mainshaft 1st gear On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear Inside diameter of needle bearing contact area On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On subshaft 4th gear On reverse idler gear On stator shaft R side On stator shaft stator side On reverse idler gear shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Subshaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness 22 980 22 993 0 9047 0 9052 35 975 35 991 1 4163 1 4169 31 975 31 991 1 2589 1 2595 30 975 30 991 1 2195 1 2201 36 004 36 017 1 4175 1 4180 31 980 31 996 1 2590 1 2600 27 980 27 993 1 1016 1 102
196. UNG AUSF HRLICHE ANWEISUNGEN SIND DEM WERK STATTHANBUCH ZU ENTNEHMEN DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU QU DES METAUX LOURDS COMME LE CUIVRE LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS OU DES COMPOSES EXPLOSIFS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLE MENT SRS DU MANUEL D ENTRETIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS SI LE CONTENU EST ABSORBE INDUIRE UN VOMISSE MENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LES CAS OBETENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS ATTENTION LE GONFLEUR DE COUSSIN D AIR EST EXPLOSIBLE ET S LL SE DEPLOIE ACCIDENTELLEMENT IL RISQUE DE PROVO QUER DES BLESSURES GRAVES QU DE TUER NE PAS UTILISER DE MATERIEL D ASSAI ELECTRIQUE NI DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR IL N Y A PAS DE PIECES REPARABLES L INTERIEUR NE PAS DEMONTER QUAND ON RETIRE LE COUSSIN D AIR LE TENIR A LA VERTICALE SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN 1 14 ABS CAUTION SERVICE INFORMATION COOLANT INFORMATION K
197. URE EVACUATION VALVE VALVE HIGH PRESSURE VALVE HFC CG 134 134 LOW PRESSURE QUICK JOINT HIGH PRESSURE QUICK JOINT INNER DIAMETER mm 13 mm 22 8 Close the evacuation valve in case of two valve gauge close the evacuation stop valve Open the cans Open the high pressure valve to charge the system to about 100 kPa 1 0 kg cm 14 psi then close it NOTE Close the low pressure valve 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 If you find any leaks tighten the joint nuts and bolts to the specified torque Recheck the system for leaks using a leak detector 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 After checking and repairing leaks the system must be evacuated see System Evacuation TWO VALVE GAUGE LOW PRESSURE VALVE VACUUM PUMP S ae HIGH PRESSURE QUICK JOINT HFC 134a 134a LOW PRESSURE QUICK JOINT Performance Test The performance test will help determine if the air con THREE VALVE GAUGE ditioner system is operating within s
198. USE ELECTRICAL TEST EQUIPMENT OR PROB ING DEVICES THEY CAN CAUSE ACCIDENTAL DEPLOYMENT NO SERVICEABLE PARTS INSIDE DO NOT DISAS SEMBLE PLACE AIRBAG UPRIGHT WHEN REMOVED FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY ATTENTION LE GONFLEUR DE COUSSIN D AIR EST EXPLOSIBLE ET S LL SE DEPLOIE ACCIDENTELLEMENT IL RISQUE DE PROVO QUER DES BLESSURES GRAVES OU DE TUER NE PAS UTILISER DE MATERIEL D ASSAI ELECTRIQUE NI DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIMENT ACCIDENTEL DU COUSSIN D AIR IL A PAS DE PIECES REPARABLES L INTERIEUR NE PAS DEMONTER OUAND ON RETIRE LE COUSSIN D AIR LE TENIR A LA VERTICALE SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN 1 11 Warning Caution Label Locations D DRIVER MODULE DANGER DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARM FUL AND IRRITATING GASES OR EXPLOSIVE COM POUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO THE SERVICE MANU AL 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 KEEP OUT OF REACH OF CHI
199. UTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could ac cidentally deploy and cause damage or injuries Check for an open in the passenger s airbag inflator 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the passenger s airbag connector 4 Connect the SRS short connector A to the SRS main har ness 3 P connector CAUTION Do not disconnect the driver s airbag connec tor 5 Connect the SCS short connector to the service check connector 6 Reconnect the battery positive cable then connect the negative cable 7 Turn the ignition switch ON 11 and record the sel recent DTC Is DTC 2 1 or DTC 2 2 indicated 2 1 2 2 Open in the passenger s airbag inflator replace T passenger s airbag assembly see page 23 56 Connect Test Harness B 1 Turn the ignition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector 5 Connect jumper wires to the No 13 14
200. ack up light switch connector and speed sensor connector BACK UP LIGHT SPEED SWITCH CONNECTOR SENSOR CLAMP CONNECTOR STARTER TRANSMISSION CABLES GROUND WIRE 7 Remove the clutch pipe bracket and slave cylinder NOTE Do not operate the clutch pedal once the slave cylinder has been removed CLUTCH SLAVE PIPE CYLINDER BRACKET 13 2 8 Remove the three transmission mounting bolts and lower starter mounting bolt STARTER MOUNTING BOLT TRANSMISSION MOUNTING BOLTS Remove the driveshafts intermediate shaft and right damper fork see section 16 NOTE Coat all precision finished surfaces with clean engine oil or grease Tie plastic bags over the driveshaft ends SET RING Replace DRIVESHAFTS RIGHT DAMPER FORK INTERMEDIATE SHAFT SELF LOCKING NUT Replace COTTER PIN Replace 10 Remove exhaust pipe A SELF LOCKING NUT Replace GASKETS Replace 3 J 45 Le e SR 2 GASKET e Replace EXHAUST PIPE A SELF LOCKING NUT Replace SELF LOCKING NUT Replace 11 Remove the change rod and change extension CHANGE ROD 8 x 20 mm SPRING PIN Replace CHANGE EXTENSION PIN DRIVER 8 0 mm 07744 0010600 cont d 13 3 Transmission Assembly Removal cont d 12 Install the bolts in the cylinder head and attach a chain hoist to the bolts then lift the engine slightly to unload the mounts D16A9 e
201. al ON temperature 3 9 Standards and Service Limits Fuel and Emissions Carbureted Engine Section 11 MEASUREMENT STANDARD NEW Fuel pump Displacement 60 seconds cm fl oz Imp oz Relief valve opening pressure kPa kg cm psi 833 3 28 2 29 4 min 6 8 22 6 0 07 0 23 1 0 3 2 min Fuel tank Engine Fuel pump Capacity f US gal Imp gal Idie speed with headlight and cooling fan off ro minis AEn D12B1 D15B3 D13B2 D13B3 D15Z2 45 11 9 9 9 Neutral A T N or P position 800 50 800 50 1 000 50 Fuel and Emissions PGM FI Engine Section 11 Idle CO MEASUREMENT With CATA 0 5 max Without CATA 1 0 max STANDARD NEW Displacement 10 seconds cm fl oz Imp oz Relief valve opening pressure kPa kg cm psi 120 4 0 4 2 min 450 600 4 5 6 0 64 85 min Pressure regulator D15B2 Except D15B2 Pressure with regulator vacuum hose disconnected kPa kg cm psi 245 285 2 45 2 85 35 41 280 330 2 8 3 3 40 47 Fuel tank Engine Capacity US gal Imp gal Idle speed with headlight and cooling fan off in min rpm D15B2 D15B7 01649 01625 01627 D16Y1 01521 D16A7 B16A2 45 11 9 9 9 M T Neutral A T N or P position 810 50 750 50 750 50 700 50 710 50 750 50 810 50 750 50 750 50 Clutch
202. and wiper blades in BLU GRN rest position Blown No 14 20 A fuse in the under dash fuse relay box Faulty windshield washer switch An open in the wire Blown No 14 20 A fuse in the under dash fuse relay box Faulty windshield wiper switch An open in the wire Check for continuity between the BLU WHT and BLU GRN termi nals There should be continuity Faulty windshield wiper switch Faulty windshield wiper motor An open in the wire 23 9 Rear Window Defogger KB model Component Location Index CAUTION SRS Il e All SRS wire harnesses are covered with yellow insu SRS UNIT 5 lation With built in sensors e Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Before disconnecting the SRS wire harness turn the ignition switch OFF disconnect the battery negative cable then disconnect the positive cable and wait at least three minutes SRS Type Ill only e Whenever the ignition switch is ON or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could acciden tally deploy and cause damage or injuries Before you disconnect any part of an SRS wire har ness connect the short connectors RED to the air bags SRS MAIN HARNESS e Refer to additional precautions beginning on page Covered with yellow insulation 23 21 in the SRS sub section SRS Type
203. arness 18 P connector from the SRS unit 5 Reconnect the battery positive cable then the negative cable 6 Turn the ignition switch ON 11 and check that the SRS indicator light comes on Does the SRS indicator light come on Tm 5 SRS MAIN Faulty SRS unit replace the unit HARNESS 18 P CONNECTOR To page 23 32 cont d 23 31 Troubleshooting The SRS Indicator Light Doesn t Come On cont d From page 23 31 SRS MAIN HARNESS SRS UNIT 18 P CONNECTOR Check the SRS indicator circuit input voltage 1 Turn the ignition switch OFF 2 Connect Test Harness B between the SRS unit and the SRS main harness 18 P connector 3 Connect jumper wires as shown to the No 13 14 15 and 16 terminals on rows A SRS unit end and B SRS main harness end of Test Harness NOTE Be careful not to connect the jumper wires to other terminals 4 Connect a voltmeter between terminals A11 and A5 5 Turn the ignition switch ON I and measure voltage Is there 8 5 V or less for six seconds after the ignition switch TEST HARNESS p M has been turned ON 11 07MAZ SP00500 e ves NO Faulty SRS unit replace the SRS unit 07042 SR30100 JUMPER WIRE TEST HARNESS B 07MAZ SP00500 A B mm efspe 7jolo v val 1 Check the SRS indicator light bulb 1 Turn the ignition switch OFF and disconnect Test Har ness B 2 Conne
204. arstereo units and other accessories A C heater Automatic Transmission 2WD Automatic Transmission S 14 1 Outline of Model Changes M24A automatic transmission has been changed 4WD automatic transmission has been modified 2WD Automatic Transmission 24 Special Tools 14 2 Description Hydraulic Circuit 14 3 Hydraulic System Symptom to Component Chart 14 4 illustrated Index Right Side Cover 14 8 Transmission Housing 14 10 Torque Converter Housing Valve Body 14 12 Secondary Valve Body Disassembly Inspection Reassembly 14 14 Servo Body J Disassembly Inspection Reassembly 14 16 Countershaft Disassembly Inspection Reassembly 14 18 Disassembly Reassembly 14 19 INSPOCHON MERE 14 20 Sub shaft Disassembly Inspection Reassembly 14 23 Disassembly Reassembly 14 24 Clutch Illustrated Index 14 25 Reverse Idler Gear Installation 14 28 Shift Indicator Panel KB model Adjustment 14 29 Shift Cable KB model Removal Installation
205. ay have been pushed out by hydraulic pressure causing a leak internal affecting all forward gears Throttle cable adjustment is essential for proper operation of the transmission Not only does it affect the shift points if misadjusted but also the shift quality and lock up clutch operation A cable adjusted too long will result in throttle pressure being too low for the amount of engine torque input into the transmission and may cause clutch slippage A cable adjusted too short will result in too high throttle pressures which may cause harsh shifts erratic shifts and torque converter hunting 14 7 lllustrated Index Right Side Cover 5552 14 8 ROLLER COLLAR O RING Replace FEED PIPE FLANGE O RING Replace CIRCLIP 3RD CLUTCH FEED PIPE COUNTERSHAFT LOCKNUT FLANGE NUT Replace PARKING GEAR ONE WAY CLUTCH ASSEMBLY COUNTERSHAFT 1ST GEAR NEEDLE BEARING COUNTERSHAFT 1ST GEAR COLLAR RIGHT SIDE COVER BREATHER COVER BREATHER CHAMBER GASKET Replace BREATHER CHAMBER O RINGS Replace RIGHT SIDE COVER GASKET Replace DOWEL PINS O RING Replace 1ST HOLD ACCUMULATOR PISTON 1ST HOLD ACCUMULATOR SPRING O RING Replace 1ST HOLD ACCUMULATOR COVER CIRCLIP PARKING BRAKE PAWL PARKING BRAKE PAWL SPRING PARKING BRAKE PAWL SHAFT PARKING BRAKE PAWL STOPPER PARKING BRAKE LEVER SPRING PARKING BRAKE LEVER PARKING BRAKE STOPPER LOCK WASHER
206. between the No B13 and B5 termi nals of Test Harness B 2 Turn the ignition switch ON 11 and measure voltage Is there battery voltage YES Faulty SRS unit replace the SRS unit Open in the SRS main harness replace the harness SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS B 07MAZ SP00500 SRS UNIT 23 55 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 e Do not install used SRS parts from another car When repairing use only new SRS parts e Carefully inspect the airbag 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 Always keep the short connectors RED on the air bags when the harness is disconnected Do not disassemble or tamper with the airbag as sembly 1 Disconnect the battery negative cable then discon nect the positive cable and wait at least three min utes 2 Connect the short connectors RED to the airbag side of the connectors Driver s Side Remove the access panel from the steering wheel then remove the short connector RED from the panel e Disconnect the 3 P connector between the driver s airbag and cable reel then connect the shor
207. ck for voltage to ground There should be battery voltage Blown No 19 10 A fuse in the under dash fuse relay box An open in the wire Ignition switch ON II Check for voltage to ground There should be battery voltage Blown No 15 10 A fuse in the under dash fuse relay box An open in the wire GRN BLU Driver s door open Front passenger s door open LT GRN RED Check for voltage to ground There should be 1 V or less Check for voltage to ground There should be 1 V or less Faulty driver s door switch An open in the wire Faulty front passenger s door switch An open in the wire Driver s seat belt is not RED BLU buckled Intermittent Wiper Relay Circuit No Terminal Test condition Under all conditions Check for voltage to ground There should be battery voltage Test Desired result Check for continuity to ground There should be continuity Poor ground G551 G552 Faulty Driver s seat belt switch An open in the wire Possible cause if result is not obtained Poor ground G301 G401 An open in the wire Ignition switch ON 1 Check for voltage to ground There should be battery voltage Ignition switch ON 11 and windshield wiper switch to INT 3 YEL BLU Check for voltage to ground There should be battery voltage Windshield wiper a BUT switch to OFF or INT and
208. ct the SRS main harness 18 P connector to the SRS unit DASHBOARD WIRE 3 Remove the gauge assembly HARNESS 5 P CONNECTOR 4 Check for blown SRS indicator light bulb Is the SRS indicator light bulb OK YES NO Replace the bulb and reconnect the gauge assembly connectors Then turn the ignition switch ON I Does the SRS indicator light come on YES NO END Check the SRS indicator light circuit 1 Disconnect the dashboard wire harness 5 P connector from the gauge assembly 2 Connect a voltmeter between the No 1 terminal of the 5 P connector and ground 3 Turn the ignition switch ON 1 and measure voltage Is there 8 5 V or less for six seconds after the ignition switch has been turned ON 11 YES NO C2 Faulty SRS indicator light circuit in the gauge assembly replace the gauge assembly BLU View from wire side To page 23 33 23 32 From page 23 32 Check the wire harness of the SRS indicator light circuit 1 1 Turn the ignition switch OFF 2 Disconnect the main wire harness 14 P connector from the dashboard wire harness 3 Connect a voltmeter between the No 14 terminal of the main wire harness 14 P connector and ground 4 Turn the ignition switch ON 1 and measure voltage Is there 8 5 V or less for six seconds after the ignition switch has been turned ON YES NO Short to power in the BLU wire of the da
209. cted VTEC E Engine with CATA D16Z6 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA Serial Number B16A2 1200001 D13B2 2200001 D15B2 6900001 D15Z1 D16Z6 3700001 Manual Transmission Number 520 1000001 Transmission 520 Except B16A2 engine Y21 For B16A2 engine Serial Number Automatic Transmission Number M24A 3000001 EE Transmission Type Serial Number European Model 4 door Sedan Vehicle Identification Number JHMEG85400S200001 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type 8 CIVIC 4 door D15B2 01571 9 CIVIC 4 door B16A2 EH1 CIVIC 4 door 4WD D1627 CIVIC 4 door D16A7 D16Z6 D1627 Body Type and Transmission Type 5 4 door Sedan 5 speed Manual 6 4 door Sedan 4 speed Automatic Vehicle Grade Series DXi EG8 KG KS EX KR LSi EG8 KG KF KS KE KW VEi EG8 KG KF KS KE ESi EH9 KG KF KS KE KU RTSi EH1 KG VTi EG9 KG KF KS KE KW Fixed Code Auxiliary Number Factory Code S Suzuka Factory in Japan Model Year 2 1994 Serial Number B16A2 D15B2 01571 D16A7 01626 Serial Number B16A2 D15B2 D15Z1 D16A7 Engine Number B16A2 1200001 1600 DOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA 15
210. d 23 7 Integrated Control Unit Input Test cont d Kat idi Im NOTE Different wires with the same color have been given a number suffix to distinguish them for example BLU WHT and BLU WHT not the same Bulb Check Circuit brake system light No Terminal Test condition Under all conditions Test Desired result Check for continuity to ground There should be continuity LT GRN RED BLU WHT GRN RED BLU WHT BLU GRN YEL BLU RED BLU GRN BLU View from wire side Possible cause if result is not obtained Poor ground G301 G401 An open in the wire Turn the ignition BLU WHT switch to START Check for voltage to ground There Blown No 18 15 A fuse in the should be battery voltage under dash fuse relay box Faulty neutral position switch A T An open in the wire Ignition switch ON 11 brake fluid reservoir full and parking brake lever down GRN RED 23 8 Connect to ground The brake sys tem light should come on Blown No 15 10 A fuse in the under dash fuse relay box Blown brake system light An open in the wire Seat Belt Reminder Lights on Beeper Circuit Terminal Test condition Under all conditions Test Desired result Check for continuity to ground There should be continuity Possible cause if result is not obtained Poor ground G301 G401 An open in the wire Headlight switch ON Che
211. d belt 600 800 60 80 132 176 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 3 36 Electrical Section 23 Unit of length mm in STANDARD NEW MEASUREMENT Ignition coil Rated voltage V Primary winding resistance Q at 20 C 68 F Secondary winding resistance kQ at 20 C 68 F Spark plug Type Gap Ignition timing Atidling BTDC Alternator bett 12 0 5 0 7 14 4 21 6 0 6 0 8 13 2 19 8 See Section 23 1 1 04 0 043 8004 D15B3 A T 12 2 Red BTDC D13B2 B13B3 01522 D15B3 M T D15B4 20 2 Red BTDC Others 16 2 Red BTDC Deflection with 100 N 10 kg 22 Ibs between pulleys Except B16A2 B16A2 7 0 10 5 0 28 0 41 with used belt 5 5 8 0 0 22 0 31 with new belt 5 0 7 0 0 20 0 28 with new belt Tension measured with belt tension gauge N kg Ibs Except B16A2 350 550 35 50 77 110 with used belt 550 750 55 75 121 165 with new belt B16A2 700 900 79 90 154 198 with new belt Alternator Output 13 5 Vathot A 70 NIPPONDENSO Coil resistance rotor 0 2 3 Slip ring O D 14 4 0 567 14 0 0 551 Brush length 10 5 0 41 1 5 0 06 Brush spring tension g oz 330 11 6 Alternator Output 13 5 Vathot A 70 MITSUBISHI
212. d still be consid ered a potentially explosive device that can cause seri ous injury 1 If installed in a car follow the removal procedure on page 23 56 2 Inall cases make sure a short connector is properly installed on the airbag connector 3 Package the airbag in exactly the same packaging that the new replacement part came in 4 Mark the outside of the box DAMAGED AIRBAG NOT DEPLOYED so it does not get confused with your parts stock 5 Contact your Honda District Service Manager for how and where to return it for disposal Deployment Tool Check Procedure 1 Connect the yellow clips to both switch protector handles on the tool connect the tool to a battery 2 Push the operation switch green means the tool is OK red means the tool is faulty 3 Disconnect the battery and the yellow clips 23 61 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 e 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 e Always keep the short connectors on the airbags connector when the harness is disconnected Do not disassemble or tamper with the airbag 5 sembly 1 Discon
213. der the side sill reinforcement sec tion see section 1 REAR LEFT WHEEL REAR LEFT WHEEL 2 Turn the wheel by hand anticlockwise several times 2 Turn the wheel by hand clockwise several times e If the wheel increasingly gets hand to turn the system is OK If the wheel turn easily the system is faulty Check the differential oil if it is OK replace the differential assembly If the wheel turns easily the system is OK If the wheel increasingly gets hard to turn the system is faulty Check the differential oil if it is OK replace the differential assembly 15 12 Rear Differential Troubleshooting CAUTION Most problems in the unit are to be diagnosed by identifying noises from the gears or bearings Care should be taken during diagnosis not to confuse the differential noises with those from other drive train components Symptom Probable Cause Do not 4WD Lack of oil Use of other oil than specified Replenish oil Replace Do not 2WD ABS mal function Lack of oil Use of other oil than specified Replenish oil Replace Consistent noise or abnormal noise Lack of oil Use of other oil than specified Overheating Lack of oil Use of other oil than specified Oil Leak Replenish oil Replace Replenish oil Replace Oil level too high Clogged breather hole Worn or damaged oil seal Inadequate sealing Da
214. dible visible deployment happens and the green light on the tool comes on continue with this procedure e if the airbags don t deploy yet the green light comes on the igniters are defective Go to Damaged Airbag Special Procedure During deployment the airbag assem bly can become hot enough to burn you Wait thirty minutes after deployment before touch ing 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 e Wear a face shield and gloves when handling a deployed airbag e Wash your hands and rinse them well with water after handling a deployed airbag AIRBAG ASSEMBLY STURDY PLASTIC BAG Deploying the Airbag Out of car NOTE If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit storage or service it should be deployed as follows Position the airbag assembly face up out doors on flat ground at least 10 meters thirty feet from any obstacles or people 4 N 1 Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool box label 2 Remove the short connector from the airbag con nector 3 Follow steps 5 6 7 and 8 of the in car deployment procedure Damaged Airbag Special Procedure If an airbag cannot be deployed it should not be treated as normal scrap it shoul
215. does the EGR valve hold vacuum Disconnect the 2P connector from the control box Measure voltage between BLK YEL terminal on the main wire harness and body ground is there battery voltage YES Reconnect the vacuum pump gauge to the 16 hose Start the engine and allow it to idle To page 11 38 From page 11 36 YES A Is there any vacuum RR NO Check vacuum hose routing of the entire EGR system If hose routing is OK replace EGR con trol solenoid valve Turn the ignition switch OFF and disconnect the A connector from the ECU Check for continuity to ground on ORN BLU wire of 2P connector lt Does continuity exist NO Substitute known good ECU and retest symptom indica tion goes away replace the origi nal ECU Replace EGR valve Repair open in BLK YEL wire be tween the solenoid valve and S 15 A fuse Repair short in ORN BLU wire be tween EGR control solenoid valve and ECU A11 BLK YEL cont d 11 37 Emission Control System Exhaust Gas Recirculation System D15Z1 engine cont d From page 11 37 Connect the battery positive ter minal to the terminal of the 2P connector While watching the vacuum gauge connect the bat tery negative terminal to the B
216. e 15 there continuity tween the solenoid and rear safe relay NO To page 19 12 cont d 19 11 Troubleshooting Flowcharts cont d Fro 19 11 erom ia SOLENOID SIDE CONNECTOR Check for continuity between the solenoid No 5 BRN WHT terminal and body ground ls there continuity YES Faulty solenoid short Replace the modulator unit NO Disconnect the connectors from the ABS control unit View from terminal side Check each wire for continuity between the ABS control unit and body ground 12P CONNECTOR No 11 RED WHT Rear Inlet RED WHT R IN No 6 YEL WHT Rear Outlet Repair short in wire between the YES solenoid and ABS control unit s lt Is there continuity 2 RED WHT Rear Inlet NO YEL WHT Rear Outlet Remove the front fail safe relay View from ABS control unit terminal side YEL WHT R OUT Check for continuity between the No 18 YEL GRN terminal and body ground 18P CONNECTOR 29 28 27 Repair short in YEL GRN wire YES lt Is there continuity gt between the ABS control unit 22 21 20 19118117 and rear fail safe relay NO YEL Reinstall the rear fail safe relay are View from ABS control unit terminal side Turn the ignition switch ON N zi Check for voltage between the 18P CONNECTOR ABS control unit connector No 18 YEL GRN terminal and body
217. e ball spring 0 45 0 018 4 5 0 18 10 7 0 42 12 7 2 3 shift valve spring 0 9 0 04 7 1 0 28 65 3 2 57 32 1 2 3 shift valve ball spring 0 45 0 018 4 5 0 18 13 3 0 52 8 0 3 4 shift valve spring 0 9 0 04 9 6 0 38 32 5 1 28 10 3 3 4 shift valve ball spring 0 5 0 02 4 5 0 18 11 3 0 44 7 4 1st hold accumulator spring 4 0 0 16 21 5 0 85 71 7 2 82 8 3 1st accumulator spring 2 6 0 10 24 3 0 96 101 9 4 01 11 6 1st accumulator spring B 2 3 0 09 9 9 0 39 49 0 1 93 4 6 2nd accumulator spring 3 5 0 14 22 0 87 77 0 3 03 9 5 3rd accumulator spring 2 6 0 10 17 5 0 69 91 8 3 61 15 8 4th accumulator spring 2 6 0 10 16 0 63 90 1 3 55 15 6 Lock up shift valve spring 0 9 0 04 7 6 0 30 73 7 2 90 32 Lock up timing valve spring 0 8 0 03 6 6 0 26 61 5 2 42 27 6 Lock up control valve spring 0 9 0 04 6 6 0 26 38 4 1 51 23 3 Governor cut valve spring 0 8 0 03 7 6 0 30 44 5 1 75 17 CPC valve spring 0 9 0 04 8 4 0 33 24 9 0 98 9 8 Reverse control valve spring 0 6 0 02 7 1 0 28 40 1 57 10 0 3 2 timing valve spring 1 2 0 05 8 6 0 34 45 6 1 80 143 Servo control valve spring 0 9 0 04 6 4 0 25 34 1 1 34 17 5 2 1 timing valve spring 0 6 0 02 5 6 0 22 33 1 30 11 0 4th exhaust valve spring 0 9 0 04 6 6 0 26 43 3 1 70 22 3 26 Inside Diameter Unit of length mm 4WD Automatic Transmission M25A Section 14 MEASUREME
218. e car can roll hard or dash out during the test which is very dangerous Attach the ropes to the trailing hook and tie down hooks to secure the car For prevention of the car from rolling hard or dashing out during the test CAUTION Be sure that the ropes attached to the car for prevention of rolling are not slack Slack ropes do not effectively secure the car and the car can roll during the test Attach the ropes to the car not to interfere with the bumper Do not attach the ropes to any section other than the specified section ROPE for prevention of the car from dashing out Attach to the trailing hook ROPE for prevention ROPE for prevention of of the car from rolling the car from rolling Attach to the tie down Attach to the trailing hook hook Start the engine With the gearshift lever in the 3rd range on the manual transmission car or the gear shift lever in the D1 or D2 position on the automatic transmission car start the car and raise the speed gradually CAUTION Take care not to exceed 50 km h of speed and do not test for more than 3 minutes con WHEELBASE tinuously Set the positioning After the test slow down the car until it stops by POSITIONING LIN notches on the line applying the brake gradually 1 20 Special Tools Individual tool lists are located at the front of each section Specifications Standards and Service Limits Design Specification
219. e rear oil pump enters the inlet port of the front oil pump The oil pressured by the front oil pump and rear oil pump circulates between the oil pumps Therefore the hydraulic pressure is not applied on the clutch piston and the driving force is not directed to the rear wheels that is the car is in 2WD condition FRONT OIL PUMP REAR OIL PUMP TS OIL STRAINER Reverse Drive Quick Braking 4WD Rear wheel speed is higher than the front wheel speed When quick braking during reverse driving the hydraulic pressure is produced by the rear oil pump as the rear wheel speed is higher than the front wheel speed due to the brake characteristics The oil pump rotates in the reverse direction to that of when the car is running in forward gear The oil is drawn out of the strainer by the rear oil pump passes then through check valves and and is pressured by the rear oil pump The pressured oil passes through check valve and it is directed to the clutch piston to move the piston As the clutch piston moves the clutch plates engage with the clutch discs in the clutch assembly to transmit the driving force from the transfer to the rear wheels that is the car is switched to 4WD The oil applied on the clutch piston passes through the oil filter orifice and check valve to lubricate and cool the bearings inside the clutch guide and the clutch discs REAR OIL PUMP NE OIL STRAINER 15 8
220. e reel 3 P connector CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR ACCESS PANEL Attach the short connector RED to the access panel then reinstall the panel on the steering wheel tive cable system operation e Turn the ignition ON Il The instrument panel SRS indicator light should come on for about six seconds and then go off e Make sure both horn buttons work Take a test drive and make sure the cruise con trol switches work 23 b9 Airbag Assembly Disposal Before scrapping any airbags including those in a whole car to be scrapped the airbags must be de ployed If the car is still within the warranty period before you deploy the airbags the Honda District Service Manager must give approval and or special instructions Only after the airbags have been deployed as the result of vehicle collision for example can they be scrapped If the airbags appear intact not deployed treat them with extreme caution Follow this procedure 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 the airbag assemblies are se curely mounted otherwise severe personal injury could result from deployment 1 Disconnect the battery negative cable then discon nect the positive cable and wait
221. e seat heater system of some KS model has been changed related items have been rewritten Supplemental Restraint System SRS The SRS type lll has been added Special Tools Tool Number Description Page Reference 07PAZ 001010A 07HAZ SG00400 07MAZ SP0020A 07MAZ SP00500 07LAZ SL40300 070 2 SR30100 SCS Short Connector Deployment Tool Short Connector A Set Test Harness B Test Harness C Jumper Wire Included in SRS Tool Set 07 2 SM5000A Included in SRS Tool Set 07MAZ SL0010A 23 2 23 4 27 23 60 23 34 23 32 23 34 23 32 Ignition System Spark Plug Inspection 1 Inspect the electrodes and ceramic insulator for Worn or deformed electrodes Improper gap Oil fouling Carbon deposits Cracked center Damaged electrode insulator gasket Cracked insulator Anti seize compound applied to threads Burned or worn electrodes may be caused by Advanced ignition timing Loose spark plug Plug heat range too low e insufficient cooling Fouled plug may be caused by Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too high Excessive idling low speed running Clogged air cleaner element Deteriorated ignition coil or ignition wires 2 Adjustthe gap with a suitable gapping tool Electrode Gap 1 1 9 mm 0 043 ene in 1 1 mm 0 043 in ee 3 Replace the plug i
222. e section 20 2 Shift to N position then remove the lock pin from the cable adjuster LOCK NUT 7 N m 0 7 kg m 5 1 Ib ft SHIFT 14 30 ADJUSTER CONTROL SHAFT 3 Remove the shift cable bracket SHIFT CABLE BRACKET 6 x 1 0 mm 12 1 2 kg m 9 Ib ft 4 Remove the shift cable holder 5 Remove the shift cable cover 6 Remove the control lever from the control shaft then remove the shift cable Take care not to bend the cable when removing installing it SHIFT CABLE HOLDER 8 x 1 25 mm SHIFT CABLE 22 Nem 2 2 kg m 16 Ib ft LOCK WASHER CONTROL LEVER Replace 6 x 1 0 mm 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft 14 N m 1 4 kg m 10 Ib ft 7 Install the shift cable in the reverse order of removal 8 Check the cable adjustment on reassembly on page 14 31 Adjustment CAUTION All SRS wire harnesses are covered with yellow insu lation Before you disconnect any part of an SRS wire harness connect the short connectors Whenever the ignition switch is ON be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Refer to additional precautions beginning on page 23 21 in the SRS sub section SRS Type Ill SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors Make sure lifts are placed properly see section 1 1 Start the engine Shift to P position to see if t
223. e the intake air pipe intake air duct and the air cleaner housing assembly AIR CLEANER INTAKE HOUSING AIR PIPE ASSEMBLY INTAKE AIR DUCT 4 Disconnect the starter motor cables and the trans mission ground wire 5 Remove the wire harness clamp 6 Disconnect the back up light switch and the speed sensor connectors WIRE BACK UP LIGHT SPEED HARNESS SWITCH CONNECTOR SENSOR CLAMP CONNECTOR 5 2 STARTER TRANSMISSION MOTOR GROUND WIRE CABLES 7 Remove the clutch pipe bracket and the slave cylin der NOTE Do not operate the clutch pedal once the slave cylinder has been removed CLUTCH PIPE SLAVE BRACKET CYLINDER 13 24 8 Remove the cotter pins then loosen the locknuts and remove the select and shift cables NOTE Take care not to bend the cables when re moveing from them and hang them by cable up to the body 9 Remove the wire harness clump from the change cable bracket WIRE COTTER PIN HARNESS Replace LOCKNUT CLUMP SHIFT CABLE SELECT CABLE CHANGE CABLE BRACKET 10 Remove the three transmission mounting bolts and starter motor mounting bolt STARTER MOTOR MOUNTING BOLT TRANSMISSION MOUNTING BOLT 11 Remove the cotter pins and the loosen castle nuts then separate the ball joints from the lower arm see section 18 12 Remove the right damper fork SELF LOCKING NUT A Replace RIGHT CASTLE NUT Y DAMPER COTTER PIN FORK Replace 13 R
224. e you disconnect any part of an SRS wire harness connect the short connectors Whenever the ignition switch is ON be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Refer to additional precautions beginning on page 23 21 in the SRS sub section SRS MAIN HARNESS Covered with yellow insulation SRS UNIT With built in sensors SELECT LEVER KNOB PUSH KNOB Apply non hardening thread lock sealant SHIFT INDICATOR PANEL LEVER COVER SILICONE GREASE P conl SILICONE GREASE LOCK PIN ROD C Ga sn 5 Nem 0 5 kg m 3 6 lb ft AUTOMATIC TRANSAXLE GEAR POSITION SWITCH 111117109 12 1 2 kg m 9 Ib ft 10 N m 1 0 kg m 7 Ib ft 14 32 4WD Automatic Transmission Service Precautions 14 34 Transfer Housing Illustrated Index 14 36 Outline of Model Change 4WD disengagement mechanism has been abolished Service Precautions 4WD This 4 wheel drive model is not equipped with the sys tem that mechanically shifts the drive system to the 2 wheel drive Therefore perform the speedometer test by using the free rollers Tip on use of free roller Test cannot be made by using the chassis dy namometer Do not operate the accelerator pedal clutch brake system and steering wheel quickly The car can roll hard or dash out during the test whic
225. eads 32 mm SEARING BOLT 70 N m 7 0 kg m 4 56 9 71 mm 0 180 0 382 in SNAP RING cont d 13 37 Transmission Reassembly cont d 16 Torque the bolts in a crisscross pattern in several steps as shown 8 x 1 25 mm 26 N m 2 6 kg m 19 Ib ft 17 Install the transmission under guard and mounting bolts 8x 1 25 mm 26 N m 2 6 kg m 19 Ib ft TRANSMISSION UNDER GUARD 8 x 1 25 mm 26 N m 2 6 kg m 19 Ib ft 13 38 18 Install the parts below as shown NOTE Apply liquid gasket P N 0Y740 99986 to the threads of the super low lever center bolt TRANSMISSION SET BALL SCREW HOUSING 22 N m 2 2 kg m 16 Ib ft 12 mm WASHER Replace 10 mm WASHER Replace EN QA DRAIN PLUG S XG 40 Nm 4 0 kg m ANS 29 Ib ft SUPER LOW LEVER CENTER BOLT 14 mm OIL FILLER 40 N m 4 0 kg m WASHER PLUG 29 Ib ft Replace 45 N m 4 5 kg m REVERSE IDLE GEAR 33 Ib ft SHAFT BOLT 10 x 1 25 mm 55 N m 5 5 kg m 40 Ib ft 19 Install the shift arm cover assembly Transmission Assembly Installation 1 Install the parts below as shown 3 Apply grease to the parts as shown then install the release fork and release bearing 6 x 1 0 mm NOTE Use only HONDA Genuine Urea Grease 12 N m 1 2 kg m 9 Ib ft UM264 P N 41211 PY5 305 SPEED SENSOR 10 x 1 25 mm 4 Install the release fork boot 45 4 5 kg m 33 Ib ft 8 x 1 25 mm 26 N
226. ecial tool to prevent the shaft form turn ing HUB NUT 22 x 1 5 mm Replace PROPELLER SHAFT HUB COMPANION FLANGE HOLDER 07PAB 0020000 3 Mark the No 1 propeller shaft and propeller shaft hub with paint 4 Remove the propeller shaft hub from the No 1 pro peller shaft using a commercially available bearing puller No 1 PROPELLER SHAFT BEARING PULLER PROPELLER SHAFT HUB Check for damage Marks 5 Holding the center bearing support with one hand lightly tap on the shaft end with a soft hammer until the shaft is clear of the bearing support SHAFT END CENTER BEARING SUPPORT If difficulty is encountered in removing the shaft use a commercially available bearing puller Re place the bearing support with a new one when a puller is used to remove it BEARING PULLER CENTER BEARING SUPPORT 16 11 Propeller shafts Reassembly NOTE e When replace the marked parts replace the propeller shaft as assembly If replace the marked parts only the shaft may vibrate e When installing the yoke nut the flat portion faces center of the shaft When installing the parts align the marks HUB NUT 22 x 1 5mm 60 N m 6 0 kg m 43 Ib ft Replace NOTE After tightening use a drift to PROPELLER SHAFT HUB stake the hub nut shoulder against 12 POINT BOLT Align the slots on the hubs the shaft 8 x 1 25 mm 4 93 Bm CENTER BEARING SUPPORT j Boc
227. eck for an open in the cable reel Check for continuity between the No 4 and No 5 terminals of Test Harness C Is there continuity YES NO Open in the cable reel replace the cable reel see page 23 62 Check the SRS Unit 1 1 Disconnect the SRS main harness 6 P connector from the cable reel 2 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B 3 Connect jumper wires as shown to the No 13 14 15 and 16 terminals on rows A SRS unit end and B SRS main harness end of Test Harness B NOTE Be careful not to connect jumper wires to the other terminals 4 Connect the battery positive cable then connect the neg ative cable 5 Connect a voltmeter between terminals No A1 and No A5 of Test Harness B 6 Turn the ignition switch ON Il and measure voltage There should be 9 4 14 V 7 Turn the ignition switch OFF and measure resistance between terminals No A7 and 5 There should be 0 75 1 0 kQ NOTE The resistance will be unstable if you measure immediately after you turn the ignition switch OFF Allow it to settle then take the reading Are voltage and resistance as specified YES NO Faulty SRS unit replace the unit see page 23 66 Check for an open in the SRS main harness 1 Turn the ignition switch OFF 2 Check for continuity between terminals No B1 and No B7 of Test Har
228. ed close the low pressure valve and the refrigerant cans Check the system Stop the engine and disconnect the charge hose quickly 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 HIGH PRESSURE QUICK JOINT INNER DIAMETER mm 22 7 System Service Leak Test NOTE Only use a gauge set for refrigerant HFC 134a 134 Use vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil When handling refrigerant 134 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 C 104 F 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 THREE VALVE GAUGE LOW PRESS
229. efogger timer circuit input SE gt 7 2 2 EX S 2 9 87 o c z z 99 m Open circuit loose or disconnected terminals Function test Defogger switch Poor ground Symptom Defogger Defogger works but indicator light does not go on Defogger does not work and YEL BLU YEL or BLK YEL indicator light does not go on Defogger does not work but BLU YEL BLK YEL or indicator light goes on BLK GRN Defogger on time is too long or too short normal operation time is 25 minutes 23 12 Seat Heaters KS model with Headlight Adjuster Component Location Index SEAT HEATER MAIN RELAY Wire colors WHT GRN WHT BLK BLK GRN and BLK DRIVER S FRONT PASSENGER S SEAT HEATER SWITCH R SEAT BACK HEATER Removal 23 15 EC Vas Test page 23 15 LJLJLJLJLILJLJLIC C MI L SEAT BACK HEATER lt gt Sei SEAT CUSHION HEATER 54 SEAT HEATER RELAY L SEAT CUSHION HEA L SEAT HEATER ei e T Description Two heaters are provided in each front seat one in the seat cushion and one in the seat back During normal use temper ature is automatically controlled by the thermostat OFF above 40 104 F built into each seat cushion heater In case of an emergency the breaker 1 OFF above 50 C
230. emove the driveshafts and the intermediate shaft see section 16 NOTE Coat all precision finished surfaces with clean engine oil or grease Tie plastic bags over the driveshaft ends SET RING Replace SET RING Replace DRIVESHAFT DRIVESHAFT INTERMEDIATE SHAFT cont d 13 25 Transmission Assembly Removal cont d 14 Remove exhaust pipe A 16 Install the bolts the cylinder head and attach chain hoist to the bolts then lift the engine slightly SELF LOCKING NUT to unload the mounts Replace GASKETS Replace CHAIN HOIST Ka Lie GASKET EN E SELF LOCKING SELF LOCKING NUT Replace Replace EXHAUST PIPE A 15 Disconnect the No 1 propeller shaft from the com panion flange NOTE Mark the shaft and companion flange before 17 Remove the engine splash shield disconnecting them 18 Remove the right front mount bracket COMPANION FLANGE RIGHT FRONT No 1 PROPELLER MOUNT BRACKET SHAFT SPECIAL BOLT Replace 13 26 19 Remove the front and the rear engine stiffeners 20 Remove the clutch cover mounting bolt CLUTCH COVER MOUNTING BOLT ENGINE STIFFENERS 21 Place a jack under the transmission then remove the transmission mount TRANSMISSION MOUNT LY E d m A Dm 72 IS N 22 Remove the rear mount bracket bolts and the trans mission mounting bolts SPECIAL BOLT Replace
231. en added for KB model refer 01626 engine The Electronic Control Unit ECU Except D15B2 engine has been modified and changed following trou bleshooting flowcharts Oxygen Sensor Fuel Supply System Atmospheric Pressure PA Sensor Exhaust Gas Recirculation System D15Z1 engine Idle Speed Setting The main wire harness SCS Ignition Output Signal Main Relay circuit has been changed The main wire harness MAP sensor circuit has been changed for B16A2 engine The fuel pressure has been changed for D15B2 engine The throttle body disassembly has been changed The throttle body has been modified for B16A2 engine Special Tools Tool Number Description Remarks 07PAZ 0010100 SCS Short Connector Component Locations Index D15B7 engine MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PURGE CONTROL Troubleshooting SOLENOID VALVE page 11 23 Except model THROTTLE ANGLE SENSOR TEMPERATURE TA SENSOR FAST IDLE VALVE TDC CRANK CYL SENSOR Built into the DISTRIBUTOR IGNITER UNIT Built into the DISTRIBUTOR COOLANT LOCK UP CONTROL TEMPERATURE 02 am SENSOR Troubleshooting page 11 18 11 3 System Description Vacuum Connections D15B7 engine MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PURGE CONTROL SOLENOID VALVE Except model CHARCOAL CANISTER ub FRONT OF VEHICLE PRESSURE REGULATOR
232. eplace 15 20 Rear Differential Disassembly 1 Remove the breather tube assembly drain plug and oil filler plug BREATHER TUBE ASSEMBLY Replace DRAIN PLUG 2 Raise the 22 mm locknut tab from the groove of the shaft 22 mm LOCKNUT Replace 3 Installthe special tool as shown COMPANION FLANGE HOLDER 07PAB 0020000 8 x 1 25 mm 33 N m 3 3 kg m 24 4 Loosen the 22 mm locknut slightly about 35 so that the tab moves away from the groove 22 mm LOCKNUT 5 Retighten the 22 mm locknut so that the tab returns into the groove 6 Remove the fragments of the broken locknut from the groove and loosen the locknut NOTE If no fragments appear in the groove repeat steps 4 and 5 LOCKNUT 7 Remove the 22 mm locknut 22 mm spring washer and companion flange 22 mm LOCKNUT Replace 22 mm SPRING WASHER COMPANION FLANGE 8 Remove the bolts in a crisscross pattern in several steps then remove the TCD Torque Control Differ ential case gasket and 6 x 10 mm dowel pins TCD CASE GASKET Replace u P DOWEL PIN cont d 15 21 Rear Differential Disassembly cont d 9 Remove the 30 mm shim differential clutch assem bly oil pump keys thrust washer and thrust needle bearing amp gt 30 mm SHIM DIFFERENTIAL CLUTCH ASSEMBLY OIL PUMP Lass CS THRUST WASHER KEYS lt THRUST NEEDLE Ss B
233. eported on With the SCS short connector connected page 11 9 CODE 12 is indicated the ECU Reset Procedure page 11 10 Connect the SCS short connector to the service check connector see page 11 9 Road test necessary Warm up the engine to normal operating temperature cooling fan comes on Drive the car on the road for ap prox 10 minutes With the trans mission in low gear keep the engine speed in the 1 700 2 500 range 4 Is Check Engine light on and does it indicate CODE 12 YES With the engine at idle discon nect the 16 hose from the EGR valve and connect a vacuum pump gauge to the hose NO Intermittent failure system is OK at this time Check for poor connections or loose wires at EGR valve control box and ECU Is there any vacuum NO Move the vacuum pump gauge to the EGR valve 16 HOSE To page 11 37 11 36 YES Disconnect 2P connector from the control box and check the 16 hose for vacuum again To page 11 37 Self diagnosis Check Engine light indicates code 12 A problem in the Exhaust Gas Recirculation r system VACUUM PUMP GAUGE CONTROL BOX From page 11 36 With the engine at idle apply 200 mmHg of vacuum to the EGR valve Does the engine stall or run rough and
234. erter check valve spring 1 1 0 043 8 4 0 331 36 4 1 433 12 0 Modulator valve D12B1 D15B3 1 2 0 047 7 0 0 276 26 3 1 035 8 0 spring 1 2 0 047 7 0 0 276 27 2 1 071 8 0 D16A9 1 2 0 047 7 0 0 276 26 3 1 035 8 0 1 2 0 047 7 0 0 276 26 4 1 039 8 0 Throttle valve D12B1 D15B3 1 1 0 043 8 5 0 335 22 3 0 878 8 1 spring 1 1 0 043 8 5 0 335 22 3 0 878 7 6 1 0 0 039 8 5 0 335 22 2 0 874 6 0 1 0 0 039 8 5 0 335 22 1 0 870 5 5 D16A9 1 0 0 039 8 5 0 335 22 2 0 874 6 0 1 0 0 039 8 5 0 335 22 1 0 870 5 5 1 0 0 039 8 5 0 335 22 5 0 886 7 3 1 0 0 039 8 5 0 335 22 3 0 878 6 6 Throttle valve A adjusting spring 0 8 0 031 6 2 0 244 27 0 1 063 8 5 Throttle valve B D12B1 D15B3 1 4 0 055 8 5 0 335 41 5 1 634 10 5 spring 1 4 0 055 8 5 0 335 41 5 1 634 11 2 1 4 0 055 8 5 0 335 41 6 1 638 12 4 D16A9 1 6 0 063 8 5 0 335 41 3 1 626 13 9 1 6 0 063 8 5 0 335 41 4 1 630 11 7 1 6 0 063 8 5 0 335 41 3 1 626 13 0 3 20 Inside D ameter 2WD Automatic Transmission M48A cont d Section 14 Unit of length mm in STANDARD NEW MEASUREMENT O D Free Length No of Coils Throttle valve B adjusting spring 6 2 0 244 3000380 3rd accumulator spring 15 5 0 610 82 5 3 248
235. ess is disconnected NOTE Disconnect the connector between the front passenger s airbag and SRS wire harness Connect the short connector RED to the airbag connector see section 23 FRONT PASSENGER S AIRBAG AIRBAG CONNECTOR BOLSTER 2 DASHBOARD LOWER COVER 6 1 0 mm 10 N m 1 0 kg m 7 2 lb ft SRS WIRE HARNESS HOOK 3 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 har 6 x 1 0 mm ness is disconnected 10 N m 1 0 kg m SHORT 7 2 Ib ft CONNECTOR NOTE Before lowering the steering column re RED ACCESS PANEL move the access panel then disconnect the connec tor between the cable reel and driver s airbag Con 5 Remove the access panels on both side and the nect the short connector RED to the driver s airbag upper air vent connector see section 23 6 Remove the power mirror control switch then dis connect the connector DRIVER S AIRBAG CONNECTOR CABLE REEL CONNECTOR 7 Disconnect the connectors and air mix control ca E ble 8 Remove the dashboard mounting bolts then lift and remove the dashboard 9 Installation is the reverse of the removal procedure SHORT CONNECTOR RED ACCESS PANEL 20 9 Rear Emblems Installation Apply the emblems where shown NOTE e Before applying clean the body surface with a
236. ether or not recommended by HONDA might be done or of the possible hazardous consequences of every conceivable way nor 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 erg Eeer All information contained in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publica tion may be reproduced stored in retrieval System 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 Body Heater and Air Conditioning marked sections not included in this manual As sections with include SRS components x special precautions are required when servicing Electrical Including Outline of Model Changes ITEM DESCRIPTION 93 MODEL MODEL REFERENCE SECTION Modified Rocker shaft collar for D15Z1 engine O Adopted e 01522 01587 and D16Y1 engines for KO model D15B7 01679 engines for KB model Changed Torque value of mount and bracket bolts and nuts Recommended engine oil PGM C
237. eu Ji eoe doeJ 10 dn 3sn pe uge 1099dsu 2 eoej deu H 1 5 20 Hue YPM 5129 103 26 p nb si Sy 10 3deoxe Aq sjepoul SY 104 iex adA 1018JnqJ82 104 z uu 1s s 18 5182 104 11 5 Z JO Saju 000 9 000 01 Alana 12 5 SI A8 T pue uonoun Buuaa1g J9MOg s100q pue spua pol al sjueuoduioo uoisuedsng 9H JE162 Sued 104 Dias uonipuoo pue ui 1s s 1sneux3 on 9500 ainsseid uBiu 16 6 ayesg xoo nuy s uie1s s xoo Huv Saul pue sesou exejg s Sgv Buipnioul uoneiedo Burned sBuiui pue suapuljAd suinip sped pue suadijeo sosip seay 1 SJedi eo pue sosip 11044 um 00001 12edsuj sped exeiq 30024 sjapow ueedo4n3 uey 19910 104 sjapow ueedoun3 ueui 19910 104 10101 pue deo 101nquisiq ueedoun3 uey 19410 104 UJ81S S 013u09 88 aAneJodeA3 O2 pue peeds 419 Aq Aolg 15 5 041u09
238. f the center electrode is rounded as shown below ROUNDED ELECTRODE NOTE Do not use spark plugs other than those list ed below because these plugs are a new type ISO standard These marks are sealed on the timing belt cover Spark Plug D12B1 D13B3 engine BKR5E 11 K16PR 011 Nippondenso BKR6E 11 NGK K20PR U11 Nippondenso For all normal driving For hot climates or continuous high speed driving D13B2 D15B2 D15B3 D15Z2 D16A7 D16Z6 D16Z7 D16Y1 engine BKR6E 11 K20PR U11 Nippondenso BKR7E 11 NGK K22PR U11 Nippondenso For all normal driving For hot climates or continuous high speed driving D15B7 D15Z1 engine ZFR5F 11 KJ16CR 111 Nippondenso ZFR6F 11 NGK KJ20CR L11 Nippondenso For all normal driving For hot climates or continuous high speed driving D16A9 B16A2 engine BKR6E N11 NGK K20PR L11 Nippondenso BKR7E N11 NGK K22PR L11 Nippondenso For all normal driving For hot climates or continuous high speed driving 4 Screw the plugs into the cylinder head finger tight then torque them to 18 N m 1 8 kg m 13 Ib ft NOTE Apply a small quantity of anti seize com pound to the plug threads before installing 23 3 Ignition System Ignition Timing Inspection and Setting Fuel injected Engine 1 Start the engine and a
239. g m 16 Ib ft d SUPER LOW LEVER CENTER BOLT 40 N m 4 0 kg m 29 Ib ft 43 8 x 14 mm DOWEL d3 10 mm WASHER Replace REVERSE IDLER GEAR SHAFT BOLT 10 x 1 25 mm 55 N m 5 5 kg m 40 Ib ft TRANSMISSION HANGER CLUTCH PIPE BRACKET 4 OIL GUTTER PLATE INTERLOCK SHIFT ARM A SELECT RETURN PIN 12 1 2 kg m 9 Ib ft SELECT RETURN SPRING 5 x 22 mm SPRING PIN Replace SELECT ARM 0 SHIFT ARM COVER 16 x23 x 5 mm OIL SEAL Replace 00 SELECT LEVER SHIFT LEVER BREATHER CAP 09 6 mm WASHER Replace SPRING L 20 7 mm 0 815 in 6 12 mm WASHER Replace 62 SET BALL SCREW 22 N m 2 2 kg m 16 Ib ft 63 INTERLOCK BOLT 40 N m 4 0 kg m 29 Ib ft STEEL BALL SPRING L 23 5 mm 0 925 in 12 mm WASHER Replace 0 BACK UP LIGHT SWITCH 25 N m 2 5 kg m 19 Ib ft 14 mm WASHER Replace SET BALL SCREW 22 N m 2 2 kg m 16 Ib ft SHIFT ARM SHAFT 18 mm PLUG BOLT 40 N m 4 0 kg m 29 Ib ft REVERSE LOCK CAM SHIFT ARM 13 29 Illustrated Index Refer to the drawing below for the transmission disassembly Clean all the parts thoroughly in solvent and dry with compressed air 7 B Lubricate all the parts with oil before reassembly NOTE e This transmission uses no gaskets between the major housings use liquid gasket P N 0Y740 99986 e inspect all the bearings for wear and operation e Always clean the magnet 62 whenever the transmission housing is disassembled
240. gear 0 95 1 68 0 037 0 066 0 6 0 024 Inner synchro ring to gear 0 5 1 0 0 02 0 04 0 3 0 01 Outer synchro ring to synchro cone 0 5 1 0 0 02 0 04 0 3 0 01 Shift fork Fork finger thickness 7 4 7 6 0 291 0 299 Fork to synchro sleeve clearance 0 35 0 65 0 015 0 026 1 0 0 04 Reverse shift fork Fork pawl groove width 13 0 13 3 0 512 0 524 Fork to reverse idler gear clearance 0 5 1 1 0 02 0 04 1 8 0 07 L groove width At 5th gear side 7 4 7 7 0 29 0 30 At reverse side 7 05 7 25 0 278 0 285 Fork to 5th reverse shift piece pin clearance At 5th gear side 0 4 0 9 0 02 0 04 mE Ed At reverse side 0 05 0 45 0 002 0 018 Shift piece Shift piece to shift arm clearance 0 1 0 3 0 004 0 012 0 6 0 02 Groove width of shift arm contact area 8 1 8 2 0 319 0 329 Shift piece to shift fork shaft clearance 0 2 0 5 0 008 0 020 0 6 0 02 Width of shift fork contact area 11 9 12 0 0 469 0 472 Select arm Select arm to interlock clearance 0 05 0 25 0 002 0 014 0 5 0 02 Select arm to shim clearance 0 01 0 2 0 0004 0 008 Interlock Width of select arm contact area 9 9 10 0 0 390 0 394 Change piece Change piece to shift arm holder clearance 0 05 0 35 0 002 0 014 0 8 0 03 Groove width of shift arm holder contact area 12 05 12 15 0 474 0 478 Change piece to select arm clearance 0 05 0 35 0 002 0 014 0 8 0
241. gnals to the airbag inflators 3 The inflators must ignite and deploy the airbags SRS INDICATOR SRS INDICATOR CIRCUIT LIGHT SRS UNIT POWER SEPARATION CIRCUIT BACK UP POWER CIRCUIT 4bit MICRO PROCESSOR BACK UP CONDENSER MEMORY CIRCUIT VOLTAGE MONITOR WATCHDOG INITIAL SETTING IMPACT SENSOR CURRENT LIMITER DRIVER S AIRBAG INFLATOR CURRENT LIMITER FRONT PASSENGER S AIRBAG INFLATOR MICRO PROCESSOR BACK UP CONDENSER DATA LINK CURRENT CIRCUIT LIMITER BATTERY Self diagnosis System A self diagnosis circuit is built into the SRS unit when the ignition switch is turned ON II 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 For better serviceability the memory will store the cause of the malfunction and the data link circuit passes on the infor mation from the memory to the data link connector 23 19 Circuit Diagram IGNITION UNDER H00D FUSE RELAY BOX SWITCH BATTERY 41 80 No 39 50A NO O O WHT BLK WHT O BLK YEL UNDER DASH FUSE RELAY BOX EE gt BLK YEL A BLK YEL SRS INDICATOR C
242. gnition Timing Inspection see page 23 102 to 23 105 of Shop Manual 62SR300 If it is necessary adjust ignition timing to the following specifications 01572 engine Initial Timing 2 BTDC WHT at 800 min rpm Ignition Timing 20 2 BTDC RED at 800 min rpm D12B1 engine Initial Timing 0 WHT at 800 min rpm A T 0 WHT at 1 000 min rpm Ignition Timing 16 2 RED at 800 min rpm A T 16 2 RED at 1 000 min rpm D13B2 D13B3 engine Initial Timing 2 BTDC WHT at 800 min rpm Ignition Timing 20 2 BTDC RED at 800 min rpm D15B3 engine Initial Timing 2 BTDC WHT at 800 min rpm A T 2 BTDC WHT at 1 000 min rpm Ignition Timing 20 2 BTDC RED at 800 min rpm A T 12 2 BTDC RED at 1 000 min rpm NOTE e Shift lever in neutral position All electrical systems are turned OFF 23 b Integrated Control Unit KO model Circuit Diagram Description integrated control unit located behind the dashboard lower cover integrates the functions of the bulb check circuit seat belt reminder light on beeper circuit and the intermittent wiper relay circuit onto one circuit board sharing common circuit functions UNDER HOOD FUSE RELAY BOX IGNITION SWITCH No 41 80A No 39 50A ONO ONO BATTERY
243. h is very dan gerous Do not raise the speed more than 50 km h Do not use the free rollers continuously for more than 3 minutes at one try Secure the car for safety Attach the ropes to the car not to allow it to roll or dash out during the test Use the free rollers for the rear wheels Set each of the free rollers at the wheelbase and track of the car NOTE Be sure that the free rollers and speedome ter tester rollers are set parallel with each other FREE ROLLER SPEEDOMETER TESTER FRONT WHEEL REAR WHEEL SIDE SIDE SPEEDOMETER TESTERS FREE ROLLERS WHEELBASE Set the positioning POSITIONING LINE 14 34 notches on the line Move the car to set the front wheels on the speedometer testers and the rear wheels on the free rollers Be sure that the wheels are set at the center of the speedometer testers and free rollers respec tively CAUTION Be sure that the front and rear wheels are set at the center of the speedometer tester and free rollers securely or the car can roll hard or dash out during the test which is very dangerous Attach the ropes to the trailing hook and tie down hooks to secure the car For prevention of the car from rolling hard or dashing out during the test CAUTION Be sure that the ropes attached to the car for prevention of rolling are not slack Slack ropes do not effectively secure the car and the car can roll during the test Attach the ropes to the car not
244. he reverse gear engages If so refer to troubleshooting 2 With the engine off remove the center console see section 20 3 Shift to N position then remove the lock pin from the cable adjuster LOCK NUT 7 N m SHIFT CABLE ADJUSTER Mann co mg 0 7 kg m 5 1 Ib ft 4 Check that the hole in the adjuster is perfectly aligned with the hole in the shift cable There are two holes in the end of the shift cable They are posi tioned 90 apart to allow cable adjustment in 1 4 turn increments ADJUSTER SHIFT CABLE Cable Cable Exact Too Short Too Long Alignment 5 If not perfectly aligned loosen the locknut on the shift cable and adjust as required 6 Tighten the locknut to 7 Nem 0 7 kg m 5 Ib ft 7 Install the lock pin on the adjuster If you feel the lock pin binding as you reinstall it the cable is still out of adjustment and must be read usted 8 Move the selector to each gear and verify that the automatic transaxle gear position indicator follows the automatic transaxle gear position switch 9 Start the engine and check the shift lever in all gears If any gear does not work properly refer to troubleshooting 10 Insert the ignition key into the key cylinder on the shift indicator panel verify that the shift lock lever is released 14 31 Gearshift Selector KB model Disassembly Reassembly CAUTION SRS Type Ill All SRS wire harnesses are covered with yellow insu lation Befor
245. he SRS unit confirm proper system operation Turn the ignition to ON 1 the instru ment panel SRS indicator light should come on for about six seconds and then go off 6 Install the new SRS unit 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 SRS MAIN SP CONNECTOR TORX BOLTS 6 mm 10 N m 1 0 kg m 7 2 Ib ft Replace Use a Torx T30 bit 7 Connect the SRS main harness 18 P connector to the SRS unit push it into position until it clicks 8 Install the SRS unit covers right and left NOTE Make sure the covers snap together in the middle 23 67
246. he front wheel alignment see section 18 4WD Mlanual Transmission S22 Service Precautions 13 22 Special Tools 13 23 Transmission Assembly Removal 13 24 Illustrated Index 13 28 Transmission Housing Removal e 13 32 Mainshaft Countershaft Assemblies Removal 13 33 Transfer Shaft Bearing Replacement 13 35 Transmission Reassembly 13 35 Transmission Assembly Installation 13 39 Outline of Model Changes The transmission mount right front mount bracket and rear mount bracket have been modified Torque value of transmission mounting bolts have been changed The super low shaft 2 4 select lever and transfer shaft have been changed Service Precautions 4WD This 4 wheel drive model is not equipped with the sys tem that mechanically shifts the drive system to the 2 wheel drive Therefore perform the speedometer test by using the free rollers Tip on use of free roller Test cannot be made by using the chassis dy namometer Do not operate the accelerator pedal clutch brake system and steering wheel quickly The car can roll hard or dash out during the test which is very dan gerous D
247. he new compressor A Volume of removed compressor Draining volume NOTE Even if no oil is drained from the removed compressor don t drain more than 50 m 1 2 3 fl oz 1 8 Imp oz from the new compressor REMOVED NEW COMPRESSOR COMPRESSOR A Nippondenso 120 m 4 fl oz 4 2 Imp oz Sanden 120 4 fl oz 4 2 Imp oz Matsushita 140 4 2 3 fl oz 4 9 Imp oz DRAINING VOLUME SAME LEVEL 22 4 System Service Discharge 4 Slowly open the high pressure valve slightly to let Keep away from open flames The refrigerant although nonflammable will produce a poisonous gas if burned Work in a well ventilated area Refrigerant evaporates quickly and can force all the air out of a small enclosed area refrigerant flow from the center hose only Do not open the valve too wide Check the shop towel to make sure no oil is being discharged with the refrigerant 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 HFC 134a system R 134a 5 After the high pressure gauge reading has dropped below 1 000 kPa 10 kg cm 142 psi open the low side valve to discharge both high and low sides of the system 1 Connect the R 134a gauges as shown 2 Disconnect the center hose of the gauge set and place the free end in a shop towel 6 Note the gauge reading and as system pressu
248. ift fork and 3rd 4th shift fork Synchro sleeve groove width Shift fork to synchro sleeve clearance Thrust Radial Shift fork finger thickness 7 95 8 05 0 313 0 317 0 45 0 65 0 018 0 026 0 05 0 45 0 002 0 018 7 4 7 5 0 29 0 30 1 0 0 04 0 8 0 03 bth shift fork Synchro sleeve groove width Shift fork to synchro sleeve clearance Thrust Radial 5 95 6 05 0 234 0 238 0 25 0 45 0 010 0 018 0 05 0 45 0 002 0 018 0 8 0 03 Reverse shift fork Fork pawl thickness Fork to reverse idler gear clearance L groove width Fork to 5th reverse shift piece pin clearance 13 0 13 3 0 51 0 52 0 25 0 84 0 010 0 033 7 05 7 25 0 278 0 285 0 05 0 35 0 002 0 014 Shift arm A Diameter of shift piece contact area Shift arm to shift piece clearance LD Shift arm to shaft clearance 12 9 13 0 0 508 0 512 0 2 0 5 0 01 0 02 16 000 16 068 0 6299 0 6326 0 011 0 092 0 0004 0 036 Shift arm Diameter of shift arm A contact area Select arm to shift arm A clearance 11 9 12 0 0 469 0 472 0 05 0 25 0 002 0 010 0 5 0 02 Select arm Diameter of shift arm A contact area Select arm to shift arm A clearance 7 95 8 00 0 313 0 315 0 10 0 25 0 004 0 010 0 5 0 02 Super low shift fork Synchro sleeve groove width Fork to synchro sleeve clearance Thr
249. il see above NOTE 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 see above NOTE after replacing the following parts NOTE Do not return the oil to the container once it is dispensed and never mix with other refrigerant oils to avoid con tamination 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 Nippondenso Sanden Matsushita Condenser 25 5 6 fl oz 0 9 Imp oz 20 2 3 fl oz 0 7 Imp oz 15 1 2 fl oz 0 5 Imp oz Evaporator 60 mt 2 fl oz 2 1 Imp oz 45 1 1 2 fl oz 1 6 Imp oz 35m 1 1 6 fl oz 1 2 Imp oz Line or hose 10 m 1 3 fl oz 0 4 Imp oz 10 m 1 3 fl oz 0 4 Imp oz 10 m 1 3 fl oz 0 4 Imp oz Receiver Dryer 10 m 1 3 fl oz O 4 Imp oz 10 1 3 fl oz 0 4 Imp 10 1 3 fl oz 0 4 Imp oz Leakage repair 25 5 6 fl oz 0 9 Imp oz 25 5 6 fl oz 0 9 Imp oz 25 5 6 fl oz O 9 Imp oz Compressor On compressor replacement subtract the volume of oil drained from the removed compressor from A and drain the calculated volume of oil from t
250. imer 2 Clean the body bonding surface with a sponge dampened in alcohol ALIGNMENT NOTE After cleaning keep oil grease and water from getting on the surface 3 f the old rear window is to be reinstalled use a putty knife to scrape off all traces of old adhesive then clean the rear window surface with alcohol where new adhesive is to be applied NOTE Make sure the bonding surface is kept free 5 Install the upper fasteners and glue the lower fas of water oil and grease tener to the body as shown CAUTION Avoid setting the rear window on its NOTE The numbers after the part names show the edges small chips may later develop into cracks quantities of the parts used UPPER FASTENER 2 NOTE Clean the shadowed area CLEANING WIDTH 20 mm 0 78 in REAR WINDOW LOWER FASTENER 1 REAR WINDOW OPENING CONVEX BEAD cont d 20 3 Rear Window Installation cont d 6 Glue the side and lower spacers and fasteners to the inside face of the rear window and molding as shown NOTE The numbers after the part names show the quantities of the parts used gt Spacer fastener locations A SIDE SPACER 4 MOLDING 1 GLASS ALIGNMENT MARKS On the glass B LOWER SPACER 3 MOLDING 20 4 7 Set the rear window then center it in the opening Make alignment marks across the rear window and body with a grease pencil at the four
251. in Right 582 587 mm 22 9 23 1 in 7 Fit the inboard joint onto the driveshaft by aligning 9 Install new boot bands on the boots and bend both the marks on the inboard joint and rollers sets of locking tabs 10 Lightly tap on the doubled over portions to reduce INBOARD JOINT their height BOOT BAND LOCKING TABS 16 6 11 Installthe new set ring onto the driveshaft groove CAUTION Always use a new set ring whenever the driveshaft is being installed INBOARD JOINT SET RING 16 7 Propeller Shafts Inspection Shaft Runout Splines Center Bearing Support 1 Putthe transmission in neutral for manual transmis 1 Raise the car off the ground and support it with sion models and in P for automatic transmission safety stands in the proper locations models 2 Inspect the shaft splines for excessive play or rattle 2 Raise the car off the ground and support it with safety stands in the proper locations 3 Inspect the center bearing support for play 3 Install a dial indicator with the indicator contacting the center of the No 1 or No 2 propeller shaft SPLINES 4 With someone holding either rear wheel rotate the other wheel and check the runout Propeller Shaft Runout Service Limit 1 0 mm 0 04 in No 1 Propeller shaft CENTER BEARING SUPPORT No 2 Propeller shaft UNIVERSAL JOINT Universal Joint Joint Boot e Check each universal joint for excessive play or
252. ion Assembly Installation 13 17 Outline of Model Changes The transmission mount right front mount bracket and rear mount bracket have been modified Torque value of transmission mounting bolts have been changed Torque value of transmission mount bolt has been changed The shift forks have been changed Transmission Assembly Removal WARNING e Make sure jacks and safety stands are placed proper ly see section 1 Apply parking brake and block rear wheels so car will not roll off stands and fall on you while working under it CAUTION Use fender covers to avoid damaging paint ed surfaces 1 Disconnect the negative cable first then the pos itive cable from the battery 2 Drain the transmission oil then reinstall the drain plug with a new washer 3 Remove the intake air pipe intake air duct and the air cleaner housing assembly AIR CLEANER INTAKE HOUSING AIR PIPE ASSEMBLY INTAKE AIR DUCT 4 Disconnect the back up light switch connector and the transmission ground wire 5 Remove the lower radiator hose clamp from trans mission hanger B LOWER RADIATOR BACK UP LIGHT HOSE CLAMP SWITCH CONNECTOR TRANSMISSION TRANSMISSION GROUND WIRE HANGER B 6 Remove the wire harness clamps 7 Disconnect the starter motor cables and the speed sensor connector SPEED SENSOR WIRE HARNESS CONNECTOR CLAMPS STARTER MOTOR
253. iquid gasket to the carrier cover mating sur face as shown NOTE e Use liquid gasket P N 0Y740 99986 e Remove the dirty oil from the sealing surface e If 20 minutes have passed after applying liquid gasket reapply it and assemble the carrier Allow it to cure at least 30 minutes after assembly before filling the differential with oil 15 18 4 Install the carrier cover and tighten the bolts in a crisscross pattern in several steps 8 x 1 25 mm 22 N m 2 2 kg m 16 Ib ft DIFFERENTIAL OIL SEAL Replace 5 Install the oil seals see page 15 19 Oil Seal Replacement 1 Remove the oil seal from the rear differential carri er OIL SEAL Replace OIL SEAL Replace 0 0 2 Install the oil seal using the special tools as shown NOTE The oil seal must sit squarely against the case Right side Make sure that distance is correct OUTER HANDLE A 07749 0010000 OUTER DRIVER 78 x 80 mm 07NAD PX40100 Replace Left side Drive the oil seal in until it is flush with differential case end OIL SEAL DRIVER 07GAD PH70201 OIL SEAL Replace cont d 15 19 Oil Replacement cont d 3 Remove the oil seal from the TCD Torque Control Differential case OIL SEAL 4 Installthe oil seal using the special tools as shown NOTE The oil seal must sit squarely against the case OIL SEAL DRIVER 07JAD PL90100 pd OIL SEAL R
254. istics at 200 N 20 kg 44 Ibs pedal force Vacuum mmHg inHg Line pressure kPa kg cm psi 01627 4WD 0 0 1 310 13 1 186 without ABS 300 11 8 5 460 54 6 776 500 19 7 8 300 83 0 1 180 B16A2 0 0 1 310 13 1 186 without ABS 300 11 8 5 460 54 6 776 500 19 7 7 650 76 5 1 088 D16Z7 4WD and 0 0 920 9 2 131 B16A2 with ABS 300 11 8 5 570 55 7 792 500 19 7 8 740 87 4 1 243 D13B2 D13B3 3D 0 0 1 520 15 2 216 300 11 8 5 310 53 1 755 500 19 7 7 880 78 8 1 120 Others 0 0 1 520 15 2 216 300 11 8 6 380 63 8 907 500 19 7 8 870 88 7 1 261 3 35 Standards and Service Limits Air conditioning system SANDEN Engine type D15B7 D15Z1 D16Z6 D16Z7 D16Y1 Air Conditioning Section 22 MEASUREMENT STANDARD NEW Lubricant type SP 10 P N 38899 P13 003 For Refrigerant HFC 134a R 134a Condenser Evaporator Line or hose Receiver Lubricant capacity fl oz Imp oz 20 2 3 0 7 45 1 1 2 1 6 10 1 3 0 4 10 1 3 0 4 MATSUSHITA Engine type D12B1 D13B2 D13B3 D15B2 D1583 D15Y2 Lubricant type GU10 P N 38899 003 For Refrigerant HFC 134a R 134a Condenser Evaporator Line or hose Receiver Lubricant capacity fl oz Imp oz 15 1 2 0 5 35 1 1 6 1 2 10 1 3 0 4 10 1 3 0 4 NIPPONDENSO Engine type B16A2 Lubricant type ND OIL8 P N 38899 PR7
255. itch has been turned ON YES NO Check the main wire harness 1 Turn the ignition switch OFF 2 Check for continuity between the No 14 terminal of the main wire harness 14 P connector and body ground Is there continuity YES NO Failure in the SRS unit due to short to ground in the BLU wire of the SRS main harness replace the SRS main harness and the SRS unit Open in the BLU wire of the SRS main harness replace the SRS main harness To page 23 53 SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT TEST HARNESS B 07MAZ SP00500 MAIN WIRE HARNESS 14 P CONNECTOR BLU View from terminal side View from terminal side 23 52 From page 23 52 DASHBOARD WIRE Check the SRS indicator light circuit HARNESS 5 P CONNECTOR 1 Turn the ignition switch OFF 2 Connect the main wire harness 14 P connector to the dashboard wire harness 3 Remove the gauge assembly 4 Disconnect the dashboard wire harness 5 P connector from the gauge assembly 5 Connect a voltmeter between the No 1 terminal of the dashboard wire harness 5 P connector and ground 6 Turn the ignition switch ON il and measure voltage Is there 8 5 V or more six seconds after the ignition switch has been turned ON II YES NO Faulty SRS indicator light circuit in the gauge assembly replace the gauge assembly
256. ity System LHD US qt Imp qt RHD Reservoir HONDA Power Steering Fluid V 1 1 1 16 0 97 1 0 1 06 0 88 0 4 0 42 0 35 Deflection with 100 N 10 kg 22 Ibs between pulleys Except D16A9 D16A9 8 0 12 0 0 31 0 47 with used belt 6 0 9 5 0 24 0 37 with new belt 5 5 9 0 0 22 0 35 with new belt Tension measured with belt tension gauge N kg Ibs Except D16A9 D16A9 M S Manual steering P S Power steering When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust the deflection or tension to used belt values 350 500 35 50 77 110 with used belt 500 700 50 70 110 154 with new belt 550 750 55 75 121 165 with new belt 3 33 Standards and Service Limits Suspension Section 18 MEASUREMENT STANDARD NEW SERVICE LIMIT Wheel alignment B16A2 Camber Front 0 05 1 Rear 0 25 1 Caster Front 1 10 1 Total toe Front 0 2 0 0 0 08 Rear 2 0 733 0 08 19 Front wheel Inward wheel 36 2 turning angle Outward wheel 30 30 2WD except B16A2 Camber Front 0 00 1 Rear 0 20 1 Caster Front 1 10 1 Total toe Front 0 2 0 0 0 08 Rear 2 0 2 0 08 998 Front wheel Inward wheel 41 2 TI VIII ELT turning angle Outward wheel 33 30 4WD Camber Front 0 15 1 0 25 1 Caste
257. ive 5 Four 4 Except KO KY For Finland only 2WD KY 4WD Except VEi model with CATA European Model 2 door Hatchback METRIC ENGLISH NOTES WEIGHT Curb weight VTi 955 kg 960 kg 970 kg 975 kg 980 kg 965 kg 970 kg 995 kg 1 000 kg 980 kg 985 kg 1 010 kg 1 015 kg 1 015 kg 1 030 kg 1 020 kg 1 045 kg 1 060 kg 1 050 kg 1 100 kg 1 105 kg 2 105 Ibs 2 116 Ibs 2 138 Ibs 2 149 165 2 161 Ibs 2 127 165 2 138 Ibs 2 194 Ibs 2 205 Ibs 2 161 Ibs 2 172 165 2 227 Ibs 2 238 Ibs 2 238 Ibs 2 271 Ibs 2 246 Ibs 2 303 165 2 337 Ibs 2 315 Ibs 2 425 Ibs 2 436 Ibs KG KF KE KS KG Austria KG KF KE KG KF KE KW KS KG KF KE KW KS Weight distributions Front Rear DX EX DXi VTi Max permissible weight EC DX EX VEi DXi LSi VTi ESi 580 375 kg 585 375 kg 595 375 kg 600 375 kg 605 375 kg 590 375 kg 595 375 kg 620 375 kg 625 375 kg 605 375 kg 610 375 kg 635 375 kg 640 375 kg 625 390 kg 635 395 kg 630 390 kg 655 390 kg 665 395 kg 660 390 kg 695 405 kg 700 405 kg 1 279 827 165 1 290 827 Ibs 1 312 827 Ibs 1 323 827 165 1 334 827 Ibs 1 301 827 Ibs 1 312 827 165 1 367 827 Ibs 1 378 827 Ibs 1 331 827 Ibs 1 345 827 165 1 400 827 165 1 411 827 Ibs 1 378 860 lbs 1 400 871 Ibs 1 389 860 Ibs 1 444 860 Ibs 1 460 871 165 1 455 860 Ibs 1 532 893 Ibs 1 543 893 tbs 1 380 kg 1 460 kg 1 500 kg
258. joint bolt Drain plug Mainshaft locknut flange nut Left hand threads Countershaft locknut flange nut Sub shaft locknut flange nut 23 x 1 25 mm 19 x 1 25 mm 14 9 lllustrated Index Transmission Housing 14 10 COUNTERSHAFT REVERSE GEAR COLLAR NEEDLE BEARING COUNTERSHAFT REVERSE GEAR LOCK WASHER Replace REVERSE SHIFT FORK REVERSE SELECTOR REVERSE SELECTOR HUB COUNTERSHAFT 4TH GEAR NEEDLE BEARING DISTANCE COLLAR 28 mm COUNTERSHAFT 2ND GEAR COTTERS THRUST NEEDLE BEARING COUNTERSHAFT 3RD GEAR NEEDLE BEARING THRUST NEEDLE BEARING SPLINED WASHER Selective part 3RD CLUTCH ASSEMBLY O RINGS Replace COUNTERSHAFT CIRCLIP THRUST SHIM THRUST NEEDLE BEARING MAINSHAFT 4TH REVERSE GEAR NEEDLE BEARINGS 4TH REVERSE GEAR COLLAR THRUST NEEDLE BEARING THRUST SHIM 2ND 4TH CLUTCH ASSEMBLY O RINGS Replace THRUST WASHER 36 5 x 51 mm Selective part THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR NEEDLE BEARING THRUST NEEDLE BEARING TORQUE SPECIFICATIONS Torque Value ee6e999poeeeoeeeocee9999999e9 599eeeeee MAINSHAFT SEALING RINGS 35 mm SEALING RING 29 mm NEEDLE BEARING SET RING 1ST HOLD CLUTCH ASSEMBLY O RINGS Replace THRUST SHIM THRUST NEEDLE BEARING NEEDLE BEARING SUB SHAFT 4TH GEAR THRUST NEEDLE BEARING SUB SHAFT 4TH GEAR COLLAR SUB SHAFT NEEDLE BEARING NEEDLE BEARING STO
259. k up Lights License Plate Lights Ceiling Lights Trunk Luggage Area Lights Gauge Lights Indicator Lights Illumination and Pilot Lights Heater lllumination Lights Rear Fog Light METRIC ENGLISH 12 V 47 AH 36 AH 38 AH 5 HR 12 V 0 8 kW 12 V 1 0 kW 12 V 1 2 kW 12V 1 4 kW 12V 70A 80A 7 5 A 10 A 15 A 20 A 30A 7 5 A 10 A 15 A 20 A 30 A 40 A 50A 80A 7 5 A 15 A 20 A 50 A 12 V 60 55 W 12V 21W 12 V 43 3CP 12V 5W 12V 5W 12V 21W 12V 21 5 W 12 21 12V 32 CP 12V 21W 12V 21W 12V 5W 12V 8W 12V 5W 12V 3 4W 12V 3 0W 12 V 1 2 W 1 4 W 0 84 W 12V 1 4 W 1 12 W 0 84 W 12 V 0 81 W 0 56 W LED 12V 1 4W 12V 21W KY model KO and KY models KB model KO and KY models KB model European KB and KP models Body Specifications 1719 S9v L 8 SGE L 0 29 Sv L 2 99 96971 86 S v L 091 90 20911 0 0 wel LU 060 9091 080 1d92X3 ps AN cx OM 0 62 Ajuo 3 47 Body Specifications 3 48 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
260. kg m Ki CLUTCH 17 ib ft COVER ENGINE A STIFFENERS 27 d 8 1 25 mm O 24 N m 2 4 kg m 2 17 Ib ft 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft 13 40 10 Install the right front mount bracket 11 Install the engine splash shield 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft RIGHT FRONT MOUNT BRACKET SPECIAL BOLT Replace 10 x 1 25 mm 55 5 5 kg m 40 lb ft 12 Remove the chain hoist then install the distributor mounting bolt 8 1 25 24 N m 2 4 kg m CHAIN HOIST 17 Ib ft 13 Align the marks then connect the No 1 propeller shaft and companion flange see section 16 COMPANION FLANGE No 1 PROPELLER SHAFT 12 POINT BOLT 8 x 1 25 mm 33 3 3 kg m 24 Ib ft 14 Install exhaust pipe A SELF LOCKING NUT Replace 8 x 1 25 mm 22 N m 2 2 kg m 16 lb ft GASKETS Replace EXHAUST PIPE A SELF LOCKING NUT GASKET Replace SELF LOCKING NUT Replace Replace 8 x 1 25 mm 10 x 1 25 mm 16 N m 1 6 kg m 55 N m 5 5 kg m 12 lb ft 40 lb ft 15 Install the intermediate shaft and the driveshafts see section 16 NOTE Replace the set rings with new ones DRIVESHAFTS Replace CY INTERMEDIATE SHAFT SET RIN 10 x 1 25 mm 39 N m 3 9 kg m 28 Ib ft 16 Install the ball joints onto the lower arm see sec tion 18 17 Install the right damper fork see section 18
261. l or glass Remove the recline cover and center cover 2 Remove the motor Remove the clips from the seat back then fold the 3 Align the tilt up position of the lifter on each side seat cover back Remove the headrest PANEL GLASS d BRACKET Fixed type 4D KB model Clip locations 5 8 x 1 25 mm 22 N m 2 2 kg m HEADREST 16 Ib ft Check that the alignment left right then install the motor NOTE If necessary check the tilt up position of motor idler cam as shown HEADREST PILLAR TRIM PANEL NOTE Take care not to scratch the headrest pillar trim panel SET PLATE Remove the heater relay and detach the wire har ness heated seat for KS model MOTOR IDLER CAM LIMIT SWITCH cont d 20 7 Seat Front Seat Replacement cont d 6 If so equipped disconnect the rear seat access cable 3D passenger s P Clip location 1 RECLINE ADJUSTER REAR SEAT ACCESS CABLE CUSHION 7 Remove the pivot nut PIVOT WASHER _ 8 x 1 25 22 N m 2 2 kg m 16 Ib ft BUSHING Remove the seat back and seat cushion from the seat tracks and recline adjuster Installation is the reverse of the removal procedure NOTE e To prevent wrinkles when installing a seat back cover make sure the material is stretched evenly over the frame before securing all the clips Apply grease to the moving surfaces
262. lacement 20 7 Sunroof Sunroof Panel Glass Height Adjustment 20 6 Rear Edge Closing Adjustment 20 7 Outline of IModel Changes The dashboard replacement procedure has been changed KB model Some version emblems have been added The quantities of the fastener and spacers for the rear window have been changed The rear seat access cable has been added 3D passenger s The sunroof panel glass height adjustment procedure has been changed The sunroof rear edge closing adjustment procedure has been changed Rear Window Index NOTE The numbers after the part names show the quantities of the parts used UPPER FASTENER 2 Clip type UPPER FASTENER 2 Eie Self adhesive type Gi Di REAR WINDOW Installation page 20 3 SIDE SPACER ag MOLDING LOWER FASTENER 1 Self adhesive type LOWER SPACER 3 LOWER FASTENER 1 Self adhesive type body side 20 2 Installation Scrape the old adhesive smooth with a knife to a 4 Glue the molding around the edge of the rear win thickness of about 2 mm 0 08 in on the bonding dow as shown surface around the entire rear window opening flange REAR WINDOW NOTE Do not scrape down to the painted surface of the body damaged paint will interfere with proper bonding e Remove the upper and lower fasteners from the body e Mask off surrounding surfaces before applying pr
263. lay Replace main relay Turn the ignition switch OFF Measure the voltage between A7 4 terminal and A23 terminal when the ignition switch is first turned ON for two seconds Battery voltage 7 A23 OOOOOOOOOOOOO OOOOOOOO Is there 1 0 V or less NO Substitute a known good ECM and recheck If Prescribed volt age is now available replace the original ECM YES d Check the main 11 34 00ooooooooo 4 1 0 Air Intake System Throttle Body Except D15B2 engine Disassembly All models CAUTION The throttle stop screw is non adjustable After reassembly adjust the throttle cable and A T throttle control cable for cars with A T ae RECS ross gt NS AU n ON e 2 e 77 THROTTLE CABLE e P A T THROTTLE CONTROL CABLE B16A2 engine O RING MANIFOLD ABSOLUTE e PRESSURE 5 5 SENSOR Troubleshooting page 11 23 THROTTLE ANGLE SENSOR FA IDLE VALVE 10 1 0 kg m 7 lb ft 11 35 Emission Control System Exhaust Gas Recirculation System D15Z1 engine Troubleshooting Flowchart 122 Check Engine light has been r
264. ler gauge from step 4 between 4th gear and reverse selector hub 1 Measure the clearance with 3rd gear push ed towards the 3rd clutch 2 Measure the clearance with 3rd gear push ed towards the 2nd gear NOTE Take measurements in at least three places and take the average as the actual clearance 3 Subtract the measurements of step 2 from step 3 and you have the clearance between 3rd gear and 2nd gear STANDARD 0 05 0 13 mm 0 002 0 005 in 4TH GEAR REVERSE SELECTOR HUB 3RD GEAR 2ND GEAR 3RD CLUTCH ASSEMBLY FEELER GAUGE SPLINED WASHER COTTER DISTANCE COLLAR 28 mm 3RD GEAR eg GEAR FEELER GAUGE 14 22 6 If the clearance is out of tolerance remove the splined washer and or distance collar and measure the thickness and or the width 7 Select and install a new distance collar then recheck DISTANCE COLLAR 28 mm Part Number Thickness 90503 PC9 000 39 00 mm 1 535 in 90504 9 39 10 mm 1 539 90505 PC9 000 39 20 mm 1 543 in 90507 PC9 000 39 30 mm 1 547 in 90508 PC9 000 39 05 mm 1 537 in 90509 PC9 000 39 15 mm 1 541 in 90510 PC9 000 39 25 mm 1 545 in 9051 1 PC9 000 38 90 mm 1 531 in 90512 PC9 000 38 95 mm 1 533 in 8 After replacing the distance collar make sure the clearance is within tolerance 9 Select and install a new splined washer then recheck SPLINED WASHER 35 x 52 mm z o
265. lic circuit Secondary valve body Reverse idler gear Changed Drain plug Throttle pressure and governor pressure Reverse selector hub on the countershaft REFERENCE SECTION Modified Hydraulic circuit Changed Parking gear Reverse idler gear shaft and holder Oil guide cap of the sub shaft Secondary valve body Servo body Countershaft Clutch assemblies Abolished 4WD disengagement mechanism Rear Differential Changed Rear differential assembly Driveshafts Changed Rear driveshaft and propeller shaft for AWD model Modified Wire colors between solenoids and ABS control unit Modified ABS for 4WD model Changed Fastener and spacer for rear window Limit switch position of sunroof motor unit Added Some version emblems Rear seat access cable Abolished Shim for sunroof panel glass height adjustment Air Conditioning Adopted New refrigerant HFC 134a R 134a Electrical 4 Changed Wire color of ignition switch Data link connector Alternator brushes Mitsuba type Terminal number of shift lock solenoid Modified Power supply circuit Changed Ignition system for KO model Integrated Control Unit for KO and KB models Seat heater for some KS model Added Supplemental Restraint System SRS type lll General Information Chassis and Engine Numbers 1 2 Identification Number Locations
266. ling the steering wheel the front wheels should be aligned straight ahead e Be sure to install the harness wires so that they are not pinched or interfering with other car parts e After reassembly confirm that the wheels are stili turned straight ahead and that steering wheel spoke angle is correct road test If minor spoke angle adjustment is necessary do so only by adjustment of the tie rods not by removing and repositioning the steering wheel 11 Align the cancel sleeve grooves with the cable reel projections CABLE REEL CANCEL SLEEVE GROOVES PROJECTIONS 12 Carefully install the cable reel on the steering col umn shaft Then attach the connector holder to the steering column CANCEL SLEEVE CABLE REEL CABLE REEL 6 P CONNECTOR CONNECTOR HOLDER 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 align ment mark on the cover e The arrow mark on the cable reel label points straight up ARROW MARK CABLE REEL LABEL ALIGNMENT MARK YELLOW GEAR TOOTH 15 Install the steering wheel and attach the cable reel 3 P connector to the clip HORN CONNECTOR CRUISE CONTROL SWITCH CONNECTOR CABLE REEL 3 P CONNECTOR 16 Connect the horn connector and cruise control s
267. llow it to warm up cooling 4 Adjust ignition timing if necessary to the following fan comes on specifications 2 Pull out the service check connector located behind Ignition Timing the front passenger s side kick panel Connect the 01521 engine BRN and BLK terminals with a jumper wire or SCS 16 2 BTDC RED at 600 min rpm short connector D15B2 engine NOTE The illustration shows LHD type RHD type 16 2 BTDC RED at 810 rpm is symmetrical D15B7 D16A7 D16A9 D16Y1 D16Z6 D16Z7 B16A2 engine 16 2 BTDC RED at 750 min rpm E CHECK CONNECTOR 2 P PGM FI ECU SERVIC NOTE e Shift lever in neutral position Ail electrical systems are turned OFF POINTER DATA LINK CONNECTOR 3 P NOTE Do not attach the jumper wire JUMPER WIRE CRANKSHAFT RED MARK PULLEY 3 Connect a timing light to the No 1 ignition wire and point it toward the pointer on the timing belt cover TIMING LIGHT 23 4 If it is necessary to adjust the ignition timing loosen the distributor mounting bolts and turn the distrib utor housing counterclockwise to advance the tim ing or clockwise to retard the timing To ADVANCE b Le MOUNTING BOLTS 24 N m 2 4 kg m 17 Ib ft P 6 Tighten the adjusting bolts and recheck the timing 7 Remove the jumper wire from the service check connector Ignition Timing Inspection and Setting Cabureted Engine NOTE For I
268. loyment and possible injury Whenever the ignition switch is ON Il be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Before you remove the SRS main harness connect the short connectors RED to the airbag connectors Do not touch a tester probe to the terminals in the SRS unit or harness connectors and do not connect the terminals with a jumper wire Use only the test harness and the SCS short connectors Make sure the battery is sufficiently charged If the battery is dead or low or the back up power circuit in the SRS unit is faulty measuring values won t be correct 23 26 Diagnostic Trouble Code DTC The SRS indicator light indicates the DTC by the number of blinks when the short connector is connected to the ser vice check connector 1 With the ignition switch OFF connect the SCS short connector to the service check connector DATA LINK CONNECTOR 3 P Do not connect G the terminals 07PAZ 001010A SCS SHORT MEMORY ERASE CONNECTOR SRS INDICATOR LIGHT SIGNAL SERVICE MES CHECK CONNECTOR CONNECTOR 2 P 2 P BLK WHT BRN BLK 2 Turn the ignition switch ON Il The SRS indicator light comes on for about six seconds and goes off Then it will indi cate the DTC The DTC consists of a main code and a sub code Including the most recent problem up to three different malfunctions can be indicated In case of a conti
269. lying the brake gradually 15 2 Special Tools Number Description Page Reference 07GAD PH70201 07JAD PL90100 07NAD PX40100 07PAB 0020000 07749 0010000 Oil Seal Driver Oil Seal Driver Outer Driver 78 x 80 mm Companion Flange Holder Outer Handle A 15 19 15 20 15 19 15 21 23 15 19 15 3 Description Realtime 4WD Dual Pump System Cars equipped with the Realtime 4WD Dual Pump System have in addition to the differential system a hydraulic clutch in the rear differential assembly Under normal conditions the car is driven by the front wheels but in response to changes in the front wheel driving force or road conditions the system momentarily provides the optimal driving force to the rear wheels without the driver having to change from front wheel drive to 4WD The system has been integrated into the rear differential to make it compact and light weight When braking during forward driving the dual pump system will cut power to the rear wheels to allow the anti lock brake system ABS to operate Components and their Function e The Differential assembly consists of the differential hypoid gear set hypoid drive pinion gear and hypoid ring gear oil pump body and differential clutch assembly built into the torque control differential case differential carrier and dif ferential carrier cover e The oil pump body contains the front oil pump rear oil pump hydraulic c
270. maged sealing washer Loose differential carrier mounting bolts Lower to proper level Clean Replace Replace Replace Recheck torque 15 13 Maintenance Differential Oil NOTE Check the oil with the engine OFF and the car on level ground Oil Level Check 1 Remove the oil filler plug then check the oil level 2 The oil level must be up to the filler hole If it is below the hole add oil until it runs out then rein stall the new washer and oil filler plug WASHER Replace OIL FILLER PLUG 48 N m 4 8 kg m 35 Ib ft 15 14 Oil Change 1 Remove the oil filler plug 2 Remove the drain plug and drain the dirty oil 3 Reinstall the drain plug with a new washer and refill the differential oil to the proper level NOTE Drain plug and oil filler plug washers should be replaced at every oil change 4 Reinstall the oil filler plug with a new washer Oil Capacity 1 0 1 1 US qt 0 9 Imp qt at oil change 1 2 1 3 US qt 1 1 Imp qt at overhaul Use only HONDA Premium Formula Automatic Transmission Fluid or an equivalent DEXRON II Automatic Transmission Fluid ATF OIL FILLER PLUG 48 N m 4 8 kg m 35 Ib ft WASHER i Replace DRAIN PLUG 48 N m 4 8 kg m 35 Ib ft NOTE Check the 4WD system function see page 15 14 and recheck the differential oil level after the differential has been disassembled Rear Differential Assembly Removal Installation WAR
271. mes on After checking the DTC troubleshoot as follows Record the DTC Erase the DTC memory see Erasing the DTC Memory OPWN blinks ON OFF Remove the SCS short connector from the service check connector With the shift lever in neutral turn the ignition switch ON 11 and let the engine idle Connect the SCS short connector to the service check connector The SRS indicator light will blink continuous short __ 6 Shake the wire harness and the connector and or take test drive quick acceleration quick braking cornering to find the cause of the intermittent failure If the problem recurs the SRS indicator light will stop blinking and stay on ON OFF es recurs light stays on 7 Ifyou can t duplicate the intermittent failure the system is OK at this time Disconnect the SCS short connector Erasing the DTC Memory NOTE Use only the SCS short connector Otherwise you may not erase the memory because it is akward to connect and disconnect a jumper wire quickly enough 1 Turn the ignition switch OFF and disconnect the SCS short connector from the service check connec tor 2 Connect the SCS short connector to the MES con nector 4 Kaes DATA LINK Do not connect Ee the terminals SERVICE MEMORY ERASE ne M SIGNAL 07PAZ 001010A ONNEC R 2 P MES SCS SHORT BRN BLK CONNECTOR CONNECTOR 2 P BLK WHT 4 sec or less
272. mmHg 27 in Hg in 15 minutes there is pro bably a leak in the system Check for leaks and repair see Leak Test replaced 4 If there are no leaks open the valves and continue 2 Connect a R 134a refrigerant gauge pump and pumping for at least another 15 minutes Then refrigerant containers cans of R 134a as shown 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 Sena a re 4 VACUUM PUMP CHECK VALVE ell _ gt lt Eet EE HIGH PRESSURE QUICK JOINT 22 6 CHECK VALVE HIGH PRESSURE EVACUATION STOP VALVE 4 77 1 i 1 See EEN ER Z 34a HIGH PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT INNER DIAMETER mm VACUUM PUMP Charging NOTE Only use a gauge set for refrigerant HFC 134a R 134a Use a 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
273. n nector and ground Is there continuity 200 Q or less YES NO Failure in the SRS unit due to short to ground in the BLU wire of the main wire harness replace the main wire harness and the SRS unit DASHBOARD WIRE HARNESS 14 P CONNECTOR A B C To page 23 51 To page 23 51 View from wire side 23 50 From page 23 50 From page 23 50 A B C Check for short to ground in the SRS indicator light circuit 3 1 Remove the gauge assembly 2 Check for continuity between the E3 and E5 termi nals of the gauge assembly 5 P connector Is there continuity 200 or less Failure in the SRS unit due to short to ground in the SRS indicator light circuit in the gauge assem bly replace the gauge assembly and the SRS unit Failure in the SRS unit due to short to ground in the BLU wire of the dashboard wire harness replace the dashboard wire harness and the SRS unit Check for an open in the SRS main harness 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then discon nect the positive cable and wait for three minutes 3 Connect the short connectors RED to the airbag con nectors see page 23 25 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B be tween the SRS unit and the 18 P connector 5 Check for continuity between the No B11 terminal of
274. n sensors which is used for models with front passenger s airbag KB model 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 compo nents Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done by an authorized Honda dealer 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 service work must be performed by an authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbags Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON II SRS Type All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of the KB model in the dash board above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type Il Steering wheel Be careful not to bump the steering wheel as the SR
275. nd read the fuel pressure If the fuel pressure is not as specified first check the fuel pump If the pump is OK check the following lf the pressure is higher than specified inspect for Pinched or clogged fuel return hose or piping Faulty pressure regulator If the pressure is lower than specified inspect for Clogged fuel filter Faulty pressure regulator Leakage in the fule line Main Relay Except D15B2 engine Troubleshooting Flowchart Engine will not start Inspection of main relay and relay harness Disconnect the main con nectors Check for continuity between BLK terminal and body ground 4 NO Repai in BLK wire b e er open in wire between Does continuity exist main relay and G101 YES Measure the voltage between YEL WHT terminal D and body ground Replace ECU 15 A fuse NO Repair open or short in the 2 Is there battery voltage YEL WHT wire between the main relay and the ECU 15 A YES fuse Turn the ignition switch ON Measure the voltage between BLK YEL terminal and body ground Replace ACG S 15 A fuse NO Repair open in the BLK YEL wire between the main relay GRN VES and the S 15 A fuse BLU YEL WHT Turn the ignition switch to the T START III position BLK 2 YEL WHT 4 S Measure the vol
276. nect the battery negative cable then discon nect the positive cable and wait at least three min utes 2 Make sure the wheels are aligned straight ahead 3 Remove the dashboard lower cover and knee bol ster KNEE BOLSTER DASHBOARD LOWER COVER 23 62 4 Connect the short connectors to the airbags see page 23 25 CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR ACCESS PANEL SHORT CONNECTOR RED SHORT CONNECTOR RED FRONT PASSENGER S SRS MAIN HARNESS AIRBAG 3 P CONNECTOR 5 Remove the driver s airbag assembly from the ste ering wheel two T30 Torx bolts then remove the steering wheel nut DRIVER S AIRBAG ASSEMBLY TORX BOLTS Use a Torx T30 bit STEERING WHEEL NUT 6 Disconnect the connectors from the horn and cruise control switches then remove the cable reel 3 P connector from it s clip CRUISE CONTROL SWITCH CONNECTOR HORN 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 6 P connector between the cable reel and SRS main harness then remove the con nector holder from the steering column CABLE REEL CANCEL SLEEVE CONNECTOR CONNECTOR HOLDER 10 Remove the cable reel from the column cont d 23 63 Cable Reel Replacement cont d CAUTION Before instal
277. necting the ABS B2 15 A fuse in the under hood ABS fuse relay box for three seconds Pre test steps Check ABS MOTOR 50 fuse in the under hood ABS fuse relay box Check MOTOR CHECK 7 5 A fuse in the under hood ABS fuse relay box Check for loose under hood ABS fuse relay box connectors Remove and check the ABS pump motor relay Does it work properly NO Replace the ABS pump motor YES Connect the No 16 and No 18 JUMPER WIRE terminals using a jumper wire UNDER HOOD ABS FUSE RELAY BOX L e Does the ABS pump motor run NO To page 19 7 YES REAR FRONT ABS FAIL SAFE FAIL SAFE MOTOR CHECK N MOTOR Disconnect the jumper wire BELAY RELAY LSA 18 50 A j Remove the MOTOR CHECK fuse 7 5 A from under hood ABS fuse relay box T Turn the ignition switch ON 16 13 8 6 3 To page 19 6 UNDER HOOD ABS FUSE RELAY BOX CIRCUIT DIAGRAM cont d 19 5 Troubleshooting Flowcharts cont d From page 19 5 Check for voltage between the under hood ABS fuse relay box MOTOR CHECK fuse No 3 ter minal and body ground Is there battery voltage Reinstall the fuse in the under hood ABS fuse relay box from the ABS pump motor Check for voltage between the ABS pump motor relay No 16 terminal and body ground NO Is there batte
278. ness B _ Is there continuity Open in the SRS main harness replace the harness The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of Intermittent Failures on page 23 28 TEST HARNESS C 07LAZ SL40300 SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS B 07MAZ SP00500 07QAZ SR30100 JUMPER WIRE TEST HARNESS B 07MAZ 5 00500 at e e e ve 11 12 e 14 181160 17 18 12 1 1 ole 2 3 vel TEST HARNESS 07MAZ SP00500 A Ku gt s e ro v 2e e De 0 gt 91 16 DD EDID 23 35 Troubleshooting DTC 1 2 CAUTION Whenever the ignition switch is ON Il or DRIVER S AIRBAG has been turned OFF for less than three minutes be ASSEMBLY careful not to bump the SRS unit the airbags could ac cidentally deploy and cause damage or injuries Check for a short to another wire in the driver s a rbag infla tor 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector CAUTION Do not connect short connector to the cable reel 3 P connector Do not disconnect the passenger s airbag connector 4 Connect the SCS
279. ng DTC 2 2 cont d From page 23 45 Check the SRS unit 1 Connect the battery positive cable then connect the neg ative cable 67 TEST HARNESS 2 Connect a voltmeter between the No A2 and A5 termi 07MAZ SPO0500 nals of Test Harness B 3 Turn the ignition switch ON Il and measure voltage There should be 9 4 14 V 4 Connect the voltmeter between the No A8 and A5 termi B nals of Test Harness B and measure voltage There should be 0 5 V or less Are voltages as specified NO Faulty SRS unit replace the SRS unit see page 23 66 YES TEST HARNESS B 07MAZ SP00500 Check for short to another wire in the SRS main harness 1 Turn the ignition switch OFF 2 Check for continuity between the No B2 and B8 termi nals of Test Harness B A B Is there continuity 1 1 l l Jel l i 1 d d du YES NO Short in the SRS main harness replace the harness The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of Intermittent Failures on page 23 28 23 46 DTC 2 3 CAUTION Whenever the ignition switch is ON Il or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could ac cidentally deploy and cause damage or injuries Check for short to power in the passenger s airbag infla
280. ngine CHAIN HOIST 13 Remove the engine splash shield and right front mount bracket SPECIAL BOLT Replace WASHER RIGHT FRONT MOUNT BRACKET ENGINE SPLASH SHIELD 14 Remove the front and rear engine stiffeners and the clutch cover CLUTCH COVER FRONT ENGINE REAR ENGINE STIFFENER STIFFENER 15 Place a transmission jack under transmission and a jack stand under the engine 16 Remove the transmission mount TRANSMISSION MOUNT 13 4 17 Remove the rear mount bracket bolts transmis sion mounting bolts SPECIAL BOLT Replace MOUNT BRACKET SPECIAL BOLT Replace 18 Pull the transmission away from the engine until it clears the mainshaft then lower it on the transmis sion jack 13 5 Transmission Assembly Installation 1 Install the dowel pins 4 Place the transmission on the transmission jack and raise it to the engine level 5 Install the transmission mounting bolts and rear mount bracket bolts SPECIAL BOLTS Replace 12 x 1 25 mm 14 x 1 5 mm 65 N m 6 5 kg m 47 ib ft 85 N m 8 5 kg m 61 Ib ft DOWEL PINS WASHER REAR MOUNT 2 Apply grease to the parts as shown BRACKET SPECIAL BOLT NOTE Use only HONDA Genuine Urea Grease Replace UM264 P N 41211 PY5 305 14 x 1 5 mm 85 N m 8 5 kg m 61 Ib ft 3 Install the release bearing release fork and release fork boot 6 Raise the transmission then install
281. ngth Clutch disc thickness Clutch plate thickness 1st 2nd 3rd 4th 1st hold 1st 2nd 3rd 4th 1st hold 1st Except 1st Clutch end plate thickness except 1st hold MARK 1 MARK 2 MARK 3 MARK 4 MARK 5 MARK 6 MARK 7 MARK 8 MARK 9 MARK 10 MARK 11 MARK 12 MARK 13 0 65 0 85 0 026 0 033 0 40 0 60 0 016 0 024 0 5 0 8 0 02 0 03 31 0 1 22 30 5 1 20 34 6 1 36 1 88 2 00 0 074 0 079 1 55 1 65 0 061 0 065 1 95 2 05 0 077 0 081 29 0 1 14 28 5 1 12 32 6 1 28 Until grooves worn out Discoloration Discoloration 2 3 2 4 0 091 0 094 2 4 2 5 0 094 0 098 2 5 2 6 0 098 0 102 2 6 2 7 0 102 0 106 2 7 2 8 0 106 0 110 2 8 2 9 0 110 0 114 2 9 3 0 0 114 0 118 3 0 3 1 0 118 0 122 3 1 3 2 0 122 0 126 3 2 3 3 0 126 0 130 2 0 2 1 0 079 0 083 2 1 2 2 0 083 0 087 2 2 2 3 0 087 0 091 Clutch end plate thickness 1st hold MARK 1 MARK 2 MARK 3 MARK 4 NO MARK MARK 6 MARK 7 2 05 2 10 0 081 0 083 2 15 2 20 0 085 0 087 2 25 2 30 0 089 0 091 2 35 2 40 0 093 0 094 2 45 2 50 0 096 0 098 2 55 2 60 0 100 0 102 2 65 2 70 0 104 0 106 Discoloration A Y Discoloration Discoloration Discoloration cont d 3 23 Standards and Service Limits 2WD Automatic
282. nnect the negative cable 6 Turn the ignition switch ON 11 and record the most recent DTC Is DTC 2 2 or DTC 2 1 indicated 2 2 2 1 Short to another wire in the passenger s airbag infla tor replace the passenger s airbag assembly see page 23 56 Connect Test 1 Turn the ignition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit 5 Connect Test Harness B between the SRS unit and the 18 P connector 6 Connect the No 13 14 15 and 16 terminals on rows A SRS unit end and B SRS main harness end of Test Harness B with jumper wires NOTE Do not connect jumper wires to the other termi nals 23 46 NOTE Do not connect SRS FRONT PASSENGER S SHORT CONNECTOR RED AIRBAG 3 P CONNECTOR m s MAIN HARNESS short connector A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC Af Dag 3 AV 7 p 8222 22 07PAZ 001010A k SCS SHORT SERVICE CONNECTOR MEMORY ERASE CHECK SIGNAL MES CONNECTOR 2 P CONNECTOR 2 P BRN BLK BLK WHT SRS UNIT SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS B 07MAZ SP00500 07QAZ SR30100 JUMPER WIRE cont d 23 45 Troubleshooti
283. nnector RED to the passenger s airbag 3 P connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector Check the SRS Unit 1 Connect jumper wires as shown to the No 13 14 15 and 16 terminals on rows A SRS unit end and B SRS main harness end of Test Harness B NOTE Do not connect jumper wires to the other termi nals 2 Connect the battery positive cable then connect the neg ative cable 3 Connect a voltmeter between the No A1 and A5 terminals of Test Harness B 4 Turn the ignition switch ON Il and measure voltage There should be 9 4 14 V 5 Connect the voltmeter between the No A7 and A5 termi nals of Test Harness B and measure voltage There should be 0 5 V or less Are the voltages as specified YES NO Faulty SRS unit replace the unit see page 23 66 Check for a short in the SRS main harness 1 Turn the ignition switch OFF 2 Check for continuity between the No B1 and B7 termi nals of Test Harness B NOTE Do not connect the cable reel 6 P connector Is there continuity Short in the SRS main harness replace the SRS main harness The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of Intermittent Failures on page 2
284. nshaft 4th gear collar On mainshaft 1st gear collar On countershaft L side On countershaft 3rd gear distance collar On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On reverse idler gear shaft On mainshaft 1st gear inside diameter of needle bearing contact area On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On reverse idler gear On stator shaft R side On stator shaft stator side On reverse idler shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1th gear collar length Mainshaft 1th gear collar flange thickness 19 980 19 993 0 7866 0 7871 35 975 35 991 1 4163 1 4169 31 975 31 991 1 2589 1 2595 27 975 27 995 1 1014 1 1022 36 004 36 017 1 4175 1 4180 31 975 31 991 1 2589 1 2595 27 980 27 993 1 1016 1 1021 29 980 29 993 1 1803 1 1808 29 980 29 993 1 1803 1 1808 13 990 14 000 0 5508 0 5512 33 000 33 016 1 2992 1 2998 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 35 000 35 016 1 3780 1 3786 38 000 38 016 1 4961 1 4967 33 000 33 016 1 2992 1 2
285. nt spoiler remove it before towing so it is damaged TOWING HOOK 1 19 Service Precautions 4WD This 4 wheel drive model is not equipped with the sys tem that mechanically shifts the drive system to the 2 wheei drive Therefore perform the speedometer test by using the free rollers Tip on use of free roller Test cannot be made by using the chassis dy namometer Do not operate the accelerator pedal clutch brake system and steering wheel quickly The car can roll hard or dash out during the test which is very dan gerous Do not raise the speed more than km h Do not use the free rollers continuously for more than 3 minutes at one try Secure the car for safety Attach the ropes to the car not to allow it to roll or dash out during the test Use the free rollers for the rear wheels Set each of the free rollers at the wheelbase and track of the car NOTE Be sure that the free rollers and speedome ter tester rollers are set parallel with each other FREE ROLLER SPEEDOMETER TESTER FRONT WHEEL REAR WHEEL SIDE SIDE SPEEDOMETER TESTERS FREE ROLLERS Move the car to set the front wheels on the speedometer testers and the rear wheels on the free rollers Be sure that the wheels are set at the center of the speedometer testers and free rollers respec tively CAUTION Be sure that the front and rear wheels are set at the center of the speedometer tester and free rollers securely or th
286. nuous failure the DTC will be indicated repeatedly see example 1 below In case of an intermittent failure the SRS indicator light will indicate the DTC one time then it will stay on see example 2 below If both a continuous and an intermittent failure occur both DTCs will be indicated as continuous failures In case the system is normal is no DTC the SRS indicator light will start blinking continuous short blinks see example 3 below Example of DTC Indications 1 Continuous failure SRS Indicator Light is 128 128 438 25 jeas P2 ON OFF Bulb check gt Maincode dH be be M Indications are period 2 Sub code 1 Main code 1 Sub code 2 Main code 1 Sub code 1 repeated in case e of continuous failure DTC 2 1 DTC 1 2 OTC 1 1 Most recent problem Second most recent Third most recent 2 8 bl 2 Intermittent failure SRS Indicator Light is oe problem ON OFF al Bulb check h Light stays on in case of 1 period t Kam EC intermittent failure DTC 5 1 3 Normal no failure SRS Indicator Light is No DTC system is normal the OFF light blinks Bulb check period 23 27 Troubleshooting Troubleshooting of Intermittent Failures If there was a malfunction but it doesn t recur it will be stored in the memory as an intermittent failure and the SRS indi cator light co
287. o not raise the speed more than 50 km h Do notuse the free rollers continuously for more than 3 minutes at one try Secure the car for safety Attach the ropes to the car not to allow it to roll or dash out during the test Use the free rollers for the rear wheels Set each of the free rollers at the wheelbase and track of the car NOTE Be sure that the free rollers and speedome ter tester rollers are set parallel with each other FREE ROLLER SPEEDOMETER TESTER FRONT WHEEL REAR WHEEL SIDE SIDE SPEEDOMETER TESTERS FREE ROLLERS WHEELBASE Set the positioning POSITIONING LINE 13 22 notches on the line Move the car to set the front wheels on the speedometer testers and the rear wheels on the free rollers Be sure that the wheels are set at the center of the speedometer testers and free rollers respec tively CAUTION Be sure that the front and rear wheels are set at the center of the speedometer tester and free rollers securely or the car can roll hard or dash out during the test which is very dangerous Attach the ropes to the trailing hook and tie down hooks to secure the car For prevention of the car from rolling hard or dashing out during the test CAUTION Be sure that the ropes attached to the car for prevention of rolling are not slack Slack ropes do not effectively secure the car and the car can roll during the test Attach the ropes to the car not to interfere with the bumper
288. ocked on the towing dolly as shown in the illustration This method of towing may damage your car s transmis sion and the vehicle may jump off the dolly 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 cables lift that end of the car off the ground The car s suspension and body can be seriously damaged if this method of towing is attempted If the car cannot be transported by flat bed it should 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 Manual Transmission Release the parking brake e Shift to transmission in neutral Automatic Transmission Release the parking brake Start the engine e Shift to transmission in 04 position then in N po sition Turn off the engine NOTICE Improper towing preparation will damage the transmission Follow the above procedure exactly If you cannot shift the transmission or start the engine auto matic transmission the car must be transported on a flat bed It is best to tow the car farther than 80 km 50 miles and keep the speed below 55 km h 35 mph NOTICE Trying to lift or tow the car by the bumpers will cause serious damage The bumpers are not designed to support the car s weight Front CAUTION If the car is equipped with a fro
289. ode Auxiliary Number Factory Code S Suzuka Factory in Japan EM JHMEG33100S200001 Model Year 2 1994 Serial Number 1 4 Engine Number D1383 2200001 Engine Type D13B3 1300 SOHC 16 valves 1 carbureded Engine without CATA D15B3 1500 SOHC 16 valves 1 carbureded Engine without CATA D15B7 1500 SOHC 16 valves Dual point Fuel injected Engine with CATA 01522 1500 SOHC 16 valves 1 carbureded Engine with CATA D16A9 1600 DOHC 16 valves Sequential Multiport Fuel injected Engine without CATA D16Y1 1600 SOHC 16 valves Sequential Fuel injected VTEC Engine with CATA Serial Number D13B3 D15B3 D16A9 2200001 D15B7 3700001 01522 D16Y1 1000001 Manual Transmission Number 20 1000001 Transmission Type Serial Number Automatic Transmission Number M24A 3000001 Transmission Type M24A Di6Y1 engine M48A Except D16Y1 engine Serial Number European Model 4 door Sedan Vehicle Identification Number JHMEH85100S200001 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD JAPAN HONDA Passenger car Line Body and Engine Type 7 CIVIC 4 door D13B3 EG8 CIVIC 4 door D15B3 D15B7 01521 EH8 CIVIC 4 door D12B1 EH9 CIVIC 4 door D16A9 D16Y1 Body Type and Transmission Type 5 4 door Sedan 5 speed Manual 6 4 doo
290. odels ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER ATTACHEZ TOUJOURS VOTRE CEINTURE CE VEHICULE EST EQUIPE D UN COUSSIN D AIR POUR LE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S CE COUSSIN D AIR COMPLETE LA FONCTION DE LA CEINTURE DE SECURITE SILE TEMOIN SRS S ALLUME PENDANT LA CONDUITE ADRESSEZ VOUS A VOTRE CONCESSIONNAIRE HONDA OFFICIEL SRS SICHERHEITSGURTE BEI JEDER FAHRT ANLEGEN DIESES FAHRZEUG BESITZT EINEN FAHRER AIRBAG ALS ZUSATZLICHES R CKHALTESYSTEM S R S ES IST EINE ERGANZUNG ZUM SICHERHEITSGURT WENN DIE SRS KONTROLLEUCHTE WAHREND DER FAHRT AUFLEUCHTET UMGEHEND FINEN HONDA HANDLER AUFSUCHEN DRAAG ALTIJD UW VEILIGHEIDSGORDEL DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN AAN DE BESTUURDERSKANT ALTS EXTRA BESCHERM ING S R S DIT IS ONTWORPEN ALS EXTRA BESCHERMING BIJ DE VEILIGHEIDSGORDEL ALS HEL SRS WAARSCHUWINGSLAMPJE BRAN DEN ONDER HET RIJDEN NEEM DAN KONTAKT OP MET EEN HONDA DEALER A DRIVER INFORMATION SUNVISOR Except European models ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS IT IS DESIGNE
291. on the ECU receives the signals from the sensor and varies the duration during which fuel is injected The oxygen sensor is installed on the exhaust manifold EXHAUST GAS ZIRCONIA VOLTAGE V STOICHI ATMOSPHERE AIR FUEL RATIO PLATINUM RICH AIR 9 LEAN FUEL RATIO 452 5072 1 SC 1 Check Engine light has been reported on With the SCS short connector connected page 11 9 CODE 1 is indicated Do the ECU Reset Procedure page 11 10 Inspect fuel pressure NO Is it normal gt H Go to Fuel Supply System YES Warm up engine to normal oper ating temperature cooling fan comes on Connect the SCS short connector to the service check connector see page 11 9 Starting at 1600 min rpm ac celerate using wide open throttle for at least 5 seconds Then de celerate for at least 5 seconds with the throttle completely clos ed p Intermittent failure system is OK e Check Engine warning light on NO at this time Check for poor con and does LED indicate CODE 1 nections or loose wires at O2 sensor and ECU ES 11 19 11 18 From page 11 18 Disconnect engine wire harness ur d 2 from the O2 sensor Warm up engine to normal oper ating temperature again then open the throttle wide open then quickly release it
292. ontal collision all SRS service work must be performed by an authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the airbags Do not bump the SRS unit Otherwise the system may fail in case of a collision or the airbags may deploy when the ignition switch is ON II SRS Type All SRS electrical wiring harnesses are covered with yellow insulation Related components are located in the steering column front console dashboard dashboard lower panel and in case of the KB model in the dash board above the glove box Do not use electrical test equipment on these circuits Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda dealer SRS Type 11 Steering wheel Be careful not to bump the steering wheel as the SRS unit sensors inflator etc are located in it Behind the dashboard Under dash fuse relay box SRS Type 111 Steering wheel Behind the dashboard Under dash fuse relay box Front console Car stereo units and other accessories heater Body Dashboard Replacement 20 8 Rear Emblems Installation 20 10 Rear Window Indek uu ER 20 2 Installation 20 3 Seat Front Seat Rep
293. ontrol system and clutch piston e The piston spring a disc spring is installed inside the clutch piston and provides a preset torque continuously to the differential clutch assembly to prevent abnormal sounds e The driving force from the transfer is transmitted to the differential clutch assembly s clutch guide which is connected to the propeller shaft via the companion flange e Theclutch guide rotates the clutch plates and the front oil pump in the oil pump body e The clutch discs of the differential clutch assembly are fixed to the clutch hub which engages with the splined section of the hypoid drive pinion gear shaft e The hypoid drive pinion gear drives the rear oil pump e The front oil pump and the rear oil pump are trochoid type pumps which reverse the inlet port and discharge oil port when rotating in the reverse direction e ATF is used for the differential oil Operation When there is a difference in speed between the front wheels clutch guide and the rear wheels hypoid drive pinion gear the hydraulic clutch is engaged by the hydraulic pressure produced by the front and rear oil pumps transmitting the driving force from the transfer to the rear wheels The hydraulic control system in the oil pump body provides the driving force to all four wheels when the car starts in for ward or reverse gear that is when there is a difference in speed between the front and rear wheels or when the brake is applied during driving in re
294. or mineral oil in this system and do not attempt to use R 12 servicing equipment damage to the air conditioning system or your servicing equipment will result NOTE Each compressor type uses different refrigerant oil Nippondenso ND OIL8 P N 38899 PR7 003 Sanden SP 10 P N 38899 P13 003 Matsushita GU10 P N 38899 P08 003 Separate the manifold gauge sets pressure gauges hoses joints for refrigerants R 12 and R 134a Do not confuse them A WARNING 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 C 104 F 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 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 Before connecting any hose or line apply a few drops of refrigerant o
295. pecifications LOW PRESSURE VALVE EVACUATION VALVE NOTE Only use a gauge set for refrigerant HFC 134a R 134a Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil HIGH PRESSURE VALVE 1 Connect the R 134a gauges as shown gt DN Le 2 Insert thermometer in the center vent outlet pm Determine the relative humidity and ambient air temperature by a portable weather station or call ing the local weather station HFC HFC 3 Test conditions 134a 134a HIGH Avoid direct sunlight DUCUNT Open hood Open front doors LOW PRESSURE Set the temperature control lever to MAX COOL QUICK JOINT push the mode control button to VENT and push the recirculation button Slide the heater fan switch to MAX Run the engine at 1 500 rpm min 1 No driver or passengers in vehicle 4 After running the air conditioning for 10 minutes under the above mentioned test conditions read TWO VALVE GAUGE the delivery temperature from the thermometer in LOW PRESSURE the dash vent and the high and low system pressures from the gauges HIGH PRESSURE VALVE EVACUATION STOP VALVE 5 VACUUM PUMP 1 D I I i f 1 1 H 134 134 LOW PRESSURE HIGH PRESSURE QUICK JOINT QUICK JO
296. pect for damage or wear 1 Reverse selector gear teeth chamfers 2 Engagement teeth chamfers of countershaft 4th and reverse gear 3 Shift fork for scuff marks in center 4 Differential pinion shaft for wear under pinion gears 5 Bottom of 3rd clutch for swirl marks Replace items 1 2 and 4 if worn or damaged If transmission makes clicking grinding or whirring noise also replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1 2 3 or 4 If differential pinion shaft is worn overhaul differential assembly and replace ATF strainer and thoroughly clean transmission flush torque converter cooler and lines If bottom of 3rd clutch is swirled and transmission makes gear noise replace the countershaft and ring gear Be very careful not to damage the torque converter housing when replacing the main ball bearing You may also damage the oil pump when you torque down the main valve body This will result in oil pump seizure if not detected Use proper tools Install the main seal flush with the torque converter housing If you push it into the torque converter housing until it bottoms out it will block the oil return passage and result in damage Harsh downshifts when coasting to a stop with zero throttle may be caused by a bent in throttle valve retainer cam stopper Throttle cable adjustment may clear this problem Check if separator plate is installed If it was not installed the servo valve m
297. pt B16A2 D16A9 D16A9 B16A2 Water Pump Displacement at 6 000 min rpm Except B16A2 D16A9 D16A9 B16A2 Fuel Required D12B1 D13B3 D15B3 D13B2 D15B2 01522 D15B7 01521 D16Y1 01626 01627 16 2 D16A9 D16A7 1 193 cm 1 343 cm 1 493 cm 1 590 cm 1 595 cm 73 0 cu in 82 0 cu in 91 0 cu in 97 0 cu in 97 3 cu in Belt driven 4 valves per cylinder SOHC or SOHC VTEC Belt driven 4 valves per cylinder DOHC or DOHC VTEC 4 Forced and wet sump trochoid pump 45 f 48 US qt 40 Imp qt minute 63 67 US qt 55 Imp qt minute 73 77 US qt 64 Imp qt minute 125 132 US qt 110 Imp qt minute 112 118 US qt 99 Imp qt minute 140 148 US qt 123 Imp qt minute Leaded gasoline with 85 R O N or higher Leaded gasoline with 91 R O N or higher Unleaded gasoline with 91 R O N or higher Premium unleaded gasoline with 95 R O N or higher Premium leaded gasoline with 95 R O N or higher Leaded gasoline with 91 R O N or higher At 6 300 min rpm At 6 800 min rpm At 7 800 rpm STARTER Make Type Output HITACHI Direct drive 0 8 kW MITSUBA Gear reduction 1 0 kW 1 2 kW and 1 4 kW NIPPONDENSO Gear reduction 1 0 kW Normal Output 1 2 kW 0 8 kW 1 0 kW 1 2 kW 1 4 kW Normal Voltage 12V Hour Rating 30 seconds Direction of Rotation Clockwise as viewed from gear end Weight HITACHI 0 8 kW MITSUBA 1 0 kW 1 2 kW 1 4 kw NIPPONDENSO
298. r Front 1 05 1 Total toe Front 0 2 0 0 0 08 Rear without ABS 2 0 33 0 08 93 38 with ABS O 29 0 9 98 Front wheel Inward wheel 41 2 turning angle Outward wheel 33930 Wheel Rim runout Aluminum wheel Axial 0 0 7 0 0 03 2 0 0 08 Radial 0 0 7 0 0 03 1 5 0 06 Steel wheel Axial 0 1 0 0 0 04 2 0 0 08 Radial 0 1 0 0 0 04 1 5 0 06 0 0 05 0 0 002 0 0 05 0 0 002 Wheel bearing End play Front Rear 3 34 Brakes Section 19 Unit of length mm in MEASUREMENT STANDARD NEW SERVICE LIMIT Parking brake Play in stroke at 200 N 20 kg 44 Ibs lever force To be locked when pulled lever 6 10 notches Foot brake pedal Pedal height with floor mat removed M T 160 6 30 A T 165 6 50 E Free play 1 5 1 16 13 64 Master cylinder Piston to pushrod clearance 0 0 4 0 0 016 Disc brake Disc thickness Front 21 0 827 19 0 748 D13B2 D13B3 3D 17 0 67 15 0 59 Rear 9 0 35 8 0 31 Disc runout Front 0 1 0 004 Rear 0 1 0 004 Disc parallelism Front and rear 0 015 0 0006 Front D13B2 D13B3 3D 9 5 0 37 1 6 0 006 B16A2 01627 4WD 10 0 0 39 1 6 0 006 Others 9 0 0 35 1 6 0 006 Rear 7 5 0 03 1 6 0 006 Rear brake drum I D 2WD 180 7 09 181 7 13 4WD 200 7 87 201 7 91 Lining thickness 2WD 4 5 0 18 2 0 0 08 4WD 4 0 0 16 2 0 0 08 Brake booster Character
299. r Sedan 4 speed Automatic Vehicle Grade Series 1 2EL EH8 KT EL EG7 KP 1 5EL EG8 KP KT KY 1 2 EH8 KU EX EG8 KP KT KY GLi EG8 KO VEi EG8 Si EH9 KP KT KY VTi KO Fixed Code Auxiliary Number Factory Code S Suzuka Factory in Japan Model Year 2 1994 Serial Number Engine Number D12B1 2200001 Engine Type D12B1 1200 SOHC 16 valves 1 carbureded Engine without CATA D13B3 1300 SOHC 16 valves 1 carbureded Engine without CATA D15B3 1500 SOHC 16 valves 1 carbureded Engine without CATA D15B7 1500 SOHC 16 valves Dual point Fuel injected Engine with CATA 01521 1500 SOHC 16 valves Sequential Multiport Fuel injected VTEC E Engine with CATA 1600 DOHC 16 valves Sequential Multiport Fuel injected Engine without CATA D16Y1 1600 SOHC 16 valves Sequential Multiport Fuel injected VTEC Engine with CATA Serial Number D12B1 D13B3 D15B3 D16A9 2200001 D15B7 D15Z1 3700001 D16Y1 1000001 Manual Transmission Number 520 1000001 Transmission Serial Number Automatic Transmission Number M24A 3000001 Transmission Type M24A Except D12B1 D15B3 D16A9 engine M48A D12B1 D15B3 D16A9 engine Serial Number 1 5 Chassis and Engine Numbers Except European Mlodel 4 door Sedan KB Vehicle identification Number Engine Number 1HGEH454 RL700001 D15B7 3850001
300. r one minute with headlights Low ON and check the idle speed Idle speed should be D15Z1 engine 700 50 min rpm Others 750 50 min rpm 750 50 min rpm in or P Automatic 10 Turn the headlights off Idle the engine for one minute with heater fan switch at HI and air condi tioner on then check the idle speed Idle speed should be Manual 01521 engine 810 50 min rpm Others 810 50 min rpm 810 50 min rpm in IN or Automatic NOTE If the idle speed is not within specification see Idle Control System Troubleshooting Guide 11 32 Fuel Supply System Fuel Pressure D15B2 engine Inspection 1 Relieve fuel pressure 2 Remove the service bolt on the fuel filter while hold ing the banjo bolt with another wrench Attach the special tool Start the engine Measure the fuel pressure with the engine idling and vacuum hose of the pressure regulator disconnected from the pressure regulator Pressure should be 275 324 kPa 2 8 3 3 kg cnv 40 47 psi Reconnect vacuum hose to the pressure regulator Pressure should be 211 260 kPa 2 15 2 65 kg cm2 31 38 psi FUEL PRESSURE GAUGE 07406 0040001 PRESSURE REGULATOR FUEL FILTER If the engine will not start turn the ignition switch on wait for two seconds turn it off then back on again a
301. r rotor radial clearance Pump body to rotor radial clearance Pump body to rotor axial clearance Pressure setting 80 176 F kPa kg cm at idle at 3 000 mir rpm Oil pump Relief valve 70 0 7 10 min 350 3 5 50 min Cooling Section 10 MEASUREMENT STANDARD NEW Unit of length mm in Radiator Radiator cap Coolant capacity f US qt Imp qt including engine heater cooling line and reservoir Reservoir capacity 0 4 0 42 US qt 0 35 Imp qt M T B16A2 4 8 5 1 4 2 for overhaul 3 9 4 1 3 4 for coolant change Except B16A2 01521 4 5 4 8 4 0 for overhaul 3 6 3 8 3 2 for coolant change 01541 4 4 4 6 3 9 for overhaul 3 5 3 7 3 1 for coolant change D12B1 D15B2 D15B3 D15B7 4 4 4 6 3 9 for overhaul 3 5 3 7 3 1 for coolant change D16A9 01626 D16Z7 D16Y1 4 7 5 0 4 1 for overhaul 3 8 4 0 3 3 for coolant change Opening pressure kPa kg cmv psi 95 125 0 95 1 25 14 18 Thermostat Cooling fan Start to opening C F Fully open C F Valve lift at fully open D15Z1 Except D15Z1 D15Z1 Except D15Z1 Thermoswitch ON temperature Thermoswitch OFF temperature C F C F 80 84 176 183 76 80 169 176 95 203 90 194 8 0 0 31 min 91 0 95 0 196 203 Subtract 3 8 5 15 from actu
302. r s airbag and SRS main harness then connect the short connector RED to the airbag side of the connector SHORT CONNECTOR RED SRS MAIN HARNESS FRONT PASSENGER S AIRBAG 3 P CONNECTOR 23 25 Troubleshooting Self diagnostic Procedures The self diagnostic function of the SRS system allows it to locate the causes of system problems and to store this informa tion in memory For easier troubleshooting this data can be retrieved via the data link circuit When you turn the ignition switch ON II the SRS indicator will come on If it goes off after six seconds the system 15 normal If there is an abnormality the system locates and defines the problem and stores this information in memory while the SRS indicator light turns on NOTE The data will remain in the memory even when the ignition switch is turned off or if the battery is disconnected When you connect the SCS short connector to the service check connector 2 and turn the ignition switch ON II the SRS indicator light will indicate the diagnostic trouble code DTC by the number of blinks After reading and recording the DTC proceed with the troubleshooting for this code Precautions Use only a digital multimeter to check the system If it s not a Honda multimeter make sure its output is 10 mA 0 01 A or less when switched to the smallest value in the ohmmeter range A tester with a higher output could damage the airbag circuit or cause accidental airbag dep
303. rcuit The Oxygen sensor detects the oxygen content in the exhaust gas and signals the ECU In operation the ECU receives the signals from the sensor and varies the duration during which fuel is injected The oxygen sensor has an internal heater The heater stabilizes the sensor s output The oxygen sensor is installed in the exhaust manifold ZIRCONIA ELEMENT Check Engine light has been reported on With the SCS short connector connected page 11 9 CODE 1 is indicated Do the ECU Reset Procedure page 11 10 Warm up engine to normal oper ating temperature cooling fan comes on Run engine for 60 seconds LJ Connect the SCS short connector to the service check connector see page 11 9 Road test with the transmission in 2nd gear M T 4th gear Starting at 1600 min 1 rpm ac celerate using wide open throttle for at least 5 seconds Then de celerate for at least 5 seconds with the throttle completely closed Is Check Engine light on and NO does it indicate CODE 1 SENSOR TERMINAL VOLTAGE V HEATER TERMINAL Intermittent failure system is OK at this time Check for poor con nections or loose wires at sen sor and ECU YES Go to page and perform test for CODE 43 page 11 21 11 20 STOICHIOMETRIC AIR FUEL RATIO RICH AIR gt LEAN FUEL RATIO e Troubleshooting
304. rd 4th 30 5 1 20 28 5 1 12 1st hold 34 6 1 36 32 6 1 28 Clutch disc thickness 1 88 2 00 0 074 0 079 Until grooves worn out Clutch plate thickness 1st 1 55 1 65 0 061 0 065 Discoloration Except 1st 1 95 2 05 0 077 0 081 Discoloration Clutch end plate thickness MARK 1 2 3 2 4 0 091 0 094 Discoloration except 1st hold MARK 2 2 4 2 5 0 094 0 098 MARK 3 2 5 2 6 0 098 0 102 MARK 4 2 6 2 7 0 102 0 106 MARK 5 2 7 2 8 0 106 0 110 MARK 6 2 8 2 9 0 110 0 114 MARK 7 2 9 3 0 0 114 0 118 MARK 8 3 0 3 1 0 118 0 122 MARK 9 3 1 3 2 0 122 0 126 MARK 10 3 2 3 3 0 126 0 130 MARK 11 2 0 2 1 0 079 0 083 MARK 12 2 1 2 2 0 083 0 087 Y MARK 13 2 2 2 3 0 087 0 091 Discoloration Clutch end plate thickness MARK 1 2 05 2 10 0 081 0 083 Discoloration 1st hold 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 NO MARK 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 Discoloration cont d 3 27 Standards and Service Limits 4WD Automatic Transmission M25A cont d Section 14 MEASUREMENT STANDARD NEW Transmission 3 28 Diameter of needle bearing contact area On mainshaft and stator shaft On mainshaft 2nd gear On mainshaft 4th gear collar On mainshaft 1st gear collar On countershaf
305. re D i 400 4 0 57 350 3 5 50 1 kPa kg cm psi 2nd clutch pressure at 2 000 min rpm 04 position throttle fully closed throttle fully closed D15B2 D15B7 TES m 3rd clutch pressure at 2 000 min rpm 94 position 800 850 8 0 8 5 114 121 750 7 5 107 D throttle more than 1 8 opened throttle more than 1 8 4th clutch pressure at 2 000 min rpm D4 position opened 2nd clutch pressure at 2 000 min rpm 2 position 800 850 8 0 8 5 114 121 750 7 5 107 1st clutch pressure at 2 000 min rpm 04 1 800 850 8 0 8 5 114 121 750 7 5 107 position Governor pressure at 60 km h 38 mph 182 192 1 82 1 92 26 27 177 1 77 25 Throttle B pressure Trottle fully closed 0 15 0 0 15 0 2 Trottle fully open 800 850 8 0 8 5 114 121 750 7 5 107 Throttle A pressure Trottle fully closed 0 5 0 0 05 0 1 D15B2 Trottle fully open 515 530 5 15 5 30 73 75 510 5 1 73 Throttle pressure Trottle fully closed 0 5 0 0 05 0 1 D15B7 Trottle fully open 485 500 4 85 5 00 69 71 480 4 8 68 Stall speed min rpm check with car on level ground 2 600 2 400 2 800 3 22 2WD Automatic Transmission M24A cont d Section 14 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Clutch Clutch initial clearance Clutch return spring free le
306. re drops gradually open both high and low side valves fuily until both gauges indicate O kPa O kg cm 3 Open the evacuation valve in case of two valve gauge open the evacuation stop valve O psi THREE VALVE GAUGE TWO VALVE GAUGE EVACUATION VALVE LOW PRESSURE HIGH PRESSURE LOW PRESSURE HIGH PRESSURE VALVE VALVE VALVE I I D LOW PRESSURE QUICK JOINT LOW PRESSURE QUICK JOINT SS a HIGH PRESSURE m QUICK JOINT HIGH PRESSURE QUICK JOINT INNER DIAMETER mm 22 5 System Service Evacuation NOTE Only use a gauge set for refrigerant HFC 134a R 134a Use a vacuum pump adapter which is equipped with a check valve to prevent the backflow of the vacuum pump oil 1 When an A C System has been opened to the at mosphere such as during installation or repair it must be evacuated using a R 134a refrigerant vacuum pump If the system has been open for several days the receiver dryer should be gauge open the evacuation stop valve Run the pump for about 15 minutes Close both pressure valves and the evacaution valve in case of two valve gauge close the evacuation stop valve and stop the pump The low pressure gauge should in dicate above 700 mmHg 27 in Hg and remain steady with the valves closed NOTE If low pressure does not reach more than 700
307. rooves in the inboard joint Then remove the inboard joint on the shop towel INBOARD JOINT SHOP TOWEL ROLLER 4 Mark the spider rollers and driveshaft to identify the position of the spider rollers on the shaft 5 Remove the circlip 6 Remove the spider rollers using a commercially available bearing remover NOTE Do not disassemble the spider rollers BEARING REMOVER SPIDER ROLLERS DRIVESHAFT CIRCLIP Marks 7 Wrap the splines on the driveshaft with vinyl tape to prevent damage to the boots 8 Remove the boot bands and boots CAUTION Take care not to damage the boots INBOARD BOOT BOOT BANDS Replace VINYL T PE OUTBOARD BOOT Rear Driveshafts Disassembly Inspection NOTE e Clean the disassembled parts with solvent and dry them throughly with compressed air Do not wash the rubber parts with solvent R nn Thoroughly pack the inboard joint and both joint boots with the joint grease included in the new driveshaft set Grease quantity Inboard Joint 85 105 g 3 0 3 7 oz Outboard Joint 40 60g 1 4 2 1 oz INBOARD JOINT SET RING Check splines for wear or damage Replace K Check inside bore for wear Q wi spect for cracks CIRCLIP BEE Pack cavity with grease LI INBOARD JOINT BOOT Inspect for cracking splitting and wear Pack cavity with grease BOOT BANDS Replace BOOT BANDS DRIVESHAFT
308. rox 5 V Remove the SCS short connector from the service check connector NO 22 74 Replace the fuse Engine light for a code To page 11 16 NOTE After repair disconnect the SCS short con nector test drive the car and recheck the Check E cont d 11 15 Control System Troubleshooting Flowchart ECU D15B2 engine cont d From page 11 15 From page 11 15 Inspect the ACG S 15 A fuse in Turn the ignition switch OFF the under dash fuse relay box NO Disconnect A connector from lt Is the fuse OK Replace the fuse R the ECU YES Turn the ignition switch ON Turn the ignition switch ON Is the Check Engine light ON gt Substitute a known good ECU and recheck If symptom indica Disconnect the 3P connector of tion goes away replace the origi each sensor one at a time nal ECU MAP sensor Throttle angle sensor Does Check Engine light NO Replace the sensor that caused remain ON the light to go out YES Turn the ignition switch OFF YES Repair short to body ground in GRN ORN wire between the ECU B6 and Check Engine light C13 C15 OOOOOOOOO M F OOOOOOOOO M E Connect the test harness Disconnect the C connector from
309. ry voltage YES Check for voltage between the No 2 terminal and body ground NO Is there battery voltage YES Reinstall the ABS pump motor relay Disconnect the 18P connector from the ABS control unit Check for voltage between the ABS control unit connector No 17 YEL RED terminal and body ground NO Is there battery voltage TES YES Check for loose ABS control unit connectors If necessary substi tute a known good ABS control unit and recheck Disconnect the 2P connector I Repair open in BRN YEL wire be tween the MOTOR CHECK 7 5A fuse in the under hood ABS fuse relay box and ABS control unit Replace the under hood ABS fuse relay box Repair open in BLK YEL wire be tween the No 13 RR DEF RLY HEATER MOTOR RLY COOLING FAN MOTOR RLY 7 5 A fuse in the under dash fuse relay box and ABS pump motor relay UNDER HOOD ABS FUSE RELAY BOX 18P CONNECTOR YEL RED PMR View from ABS control unit terminal side Repair open in YEL RED wire be tween the ABS pump motor relay and ABS control unit 19 6 From page 19 5 Check for voltage between the and body No 18 ground terminal NO Is there battery voltage Disconnect the 2P connector from the pump motor Check for voltage between the No 1 W
310. s Body Specifications Standards and Service Limits Cylinder Head Valve Train Section 6 D12B1 D13B2 D13B3 D15B2 D15B3 D15B7 D15Z2 D16A7 Engines MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 250 min rpm and Nominal 1 300 13 0 184 wide open throttle Minimum 950 9 5 135 kPa kg cm2 psi Maximum variation 200 2 0 28 Cylinder head Warpage 0 05 0 002 Height 94 95 95 05 3 738 3 742 Camshaft End play 0 05 0 15 0 002 0 006 0 5 0 02 Camshaft to holder oil clearance 0 050 0 089 0 002 0 004 0 15 0 006 Total runout 0 03 0 001 max 0 04 0 002 Cam lobe height D12B1 D13B2 D13B3 IN 35 472 1 3965 EX 35 693 1 4052 D15B3 IN 36 603 1 4411 EX 36 747 1 4467 D15B2 IN 36 603 1 4411 EX 36 750 1 4468 D16A7 IN 36 782 1 4481 EX 36 947 1 4546 D15B7 D15Z2 IN 36 057 1 4196 EX 36 198 1 4251 Valve Valve clearance IN 0 18 0 22 0 007 0 009 EX 0 23 0 27 0 009 0 011 Valve stem O D IN 5 48 5 49 0 2157 0 2161 5 45 0 2183 EX 5 45 5 46 0 2146 0 2150 5 42 0 2134 Stem to guide clearance IN 0 02 0 05 0 001 0 002 0 08 0 003 EX 0 05 0 08 0 002 0 003 0 11 0 004 Valve seat Width IN 0 85 1 15 0 033 0 045 1 6 0 063 EX 1 25 1 55 0 049 0 061 2 0 0 079 Stem installed height IN 46 985 47 455 1 8
311. sed resistance 23 45 HEURE Troubleshooting comes on Short to power in the passenger s airbag inflator CS Short to ground in the passenger s airbag inflator 23 48 Internal failure of the SRS unit Troubleshooting or SRS unit replace ment SRS unit replacement code SRS unit must not SRS unit replace be used any longer ment Faulty SRS indicator light circuit Troubleshooting Faulty SRS power supply system NOTE e if muitiple DTCs including DTC 5 1 are indicated first troubleshoot all DTCs except DTC 5 1 then erase the memory and recheck the DTC indication If DTC 5 1 doesn t reappear it is not necessary to replace the SRS unit When you return the SRS unit in case of a warranty claim do not erase the memory The data will remain in the memo ry even when the ignition switch is turned off e If an intermittent failure occurs DTC 9 1 will be indicated In case of a continuous problem there will be no DTC 23 29 Troubleshooting SRS Indicator Light Wire Connections SRS Indicator Light Power Circuit DASHBOARD WIRE HARNESS To UNDER DASH FUSE RELAY BOX 20 P CONNECTOR eo Je va 13 vs J 19 20 SRS MAIN HARNESS C1 DASHBOARD WIRE HARNESS 20 P CONNECTOR C2 DASHBOARD WIRE HARNESS 5 P CONNECTOR C3 SRS MAIN HARNESS 18 P CONNECTOR C4 SRS MAIN HARNESS 6 P CONNECTOR C5 MAIN WIRE HARNESS 6 P CONNECTOR C6 MAIN WIRE HARNESS 1
312. shboard wire harness replace the harness MAIN WIRE HARNESS 14 P CONNECTOR View from terminal side Check the wire harness of the SRS indicator light circuit 2 1 Turn the ignition switch OFF 2 Disconnect the SRS main harness 6 P connector from the main wire harness 3 Connect a voltmeter between the No 4 terminal of the SRS main harness 6 P connector and ground 4 Turn the ignition switch ON II and measure voltage Is there 8 5 V or less for six seconds after the ignition switch has been turned ON 11 YES NO Short to power in the BLU wire of the main wire har ness replace the harness SRS MAIN HARNESS 6 P CONNECTOR Short to power in the BLU wire of the SRS main har D 222 D C4 ness replace the harness 5 BLU View from wire side 23 33 Troubleshooting DTC 1 1 CAUTION Whenever the ignition switch is ON II or has been turned OFF for less than three minutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injuries Check for an open in the driver s airbag inflator E Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag assembly CAUTION Do not disconnect the passenger s airbag connector 4 Connect SRS short connector to the
313. short connector to the service check connector 2 P RED 5 Reconnect the battery positive cable then connect the negative cable 6 Turn the ignition switch ON 1 and record the most recent DTC Is DTC 1 2 or DTC 1 1 indicated G 9 1 2 1 1 Short in the driver s airbag inflator re place the driver s airbag assembly see page 23 56 SHORT CABLE REEL 3 P CONNECTOR CONNECTOR NOTE Do not connect the oO short connector A SRS INDICATOR LIGHT DATA LINK CONNECTOR DLC 07PAZ 001010A SCS SHORT Check for a short in the cable reel CONNECTOR 1 Turn the ignition switch OFF MEMORY ERASE SERVICE NOTE Do not disconnect the SCS short connector SIGNAL MES CHECK 2 Remove the dashboard lower cover and disconnect the CONNECTOR 2 P CONNECTOR 2 P SRS main harness 6 P connector from the cable reel BLK WHT BRN BLK 3 Turn the ignition switch ON li and record the most recent DTC Is DTC 1 2 or DTC 1 1 indicated 12 1 1 Short in the cable reel replace the cable reel see page 23 62 To page 23 37 SRS MAIN HARNESS CABLE REEL 6 P CONNECTOR 23 36 From page 23 36 Connect Test Harness B 1 Turn the ignition switch OFF and disconnect the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Remove the glove box and connect the short co
314. si 01676 D16Y1 opened 2nd clutch pressure at 2 000 min rpm 2 position 850 900 8 5 9 0 121 128 MEASUREMENT STANDARD NEW SERVICE LIMIT Capacity f US qt Imp qt 5 9 6 2 5 2 for overhaul 2 7 2 8 2 4 for fluid change Line pressure at 2 000 min rpm N or P position 850 900 8 5 9 0 121 128 800 8 0 114 LA S 400 4 0 57 350 3 5 50 1 2nd clutch pressure at 2 000 min rpm D4 position throttle fully closed throttle fully closed 3rd clutch pressure at 2 000 rpm Dal position 850 900 8 5 9 0 121 128 800 8 0 114 H W throttle more than 1 8 opened throttle more than 1 8 4th clutch pressure at 2 000 mier rpm 04 position 8 0 114 1st clutch pressure at 2 000 min rpm 04 or 1 850 900 8 5 9 0 121 128 800 8 0 114 position Governor pressure at 60 km h 38 mph 182 192 1 82 1 92 26 27 177 1 77 25 Throttle B pressure Trottie fully closed 0 15 0 0 15 0 2 Trottle fully open 850 900 8 5 9 0 121 128 800 8 0 114 Throttle A pressure Trottle fully closed 0 5 0 0 05 0 1 Trottle fully open 485 500 4 85 5 00 69 71 480 4 8 68 Hydraulic Line pressure at 2 000 min rpm or P position 800 850 8 0 8 5 114 121 750 7 5 107 pressu
315. ssories A C heater Fuel and Emissions Carbureted Engine Outline of Model Changes The D15Z2 engine has been added for model refer to D13B2 engine in the base Shop Manuals Fuel Injected Engine Special Tools 11 2 Ignition Output Signal 11 28 Component Locations Atmospheric Pressure PA Sensor 11 30 Index UN WD vau BERENS NNN NEEN SEN SEN e SEN EN 11 3 Idle Control System System Description Idle Speed Setting 11 31 Vacuum Connections eegen 11 4 Fuel Supply System Electrical Connections 11 6 Fuel Pressure D15B2 engine 11 32 Troubleshooting Main Relay cde tiri eie redd 11 33 Self diagnostic Procedures 11 9 Air Intake System PGM FI Control System Throttle Body 11 35 Troubleshooting Flowcharts Emission Control System Electronic Control Unit ECU 11 12 Exhaust Gas Recirculation System Oxygen Sensor 01521 engine Fuel Supply System Manifold Absolute Pressure MAP Sensor 11 23 Outline of Model Changes The special tool SCS short connector has been added The D15B7 engine has been added for KO KB model The D16Y1 engine has been added for KO model refer to D16Z6 engine The 01629 engine has be
316. t L side On countershaft 3rd gear distance collar On countershaft 4th gear On countershaft reverse gear collar On countershaft 1st gear collar On subshaft L side On subshaft 4th gear collar On reverse idler gear shaft Inside diameter of needle bearing contact area On mainshaft 1st gear On mainshaft 2nd gear On mainshaft 4th gear On countershaft 1st gear On countershaft 3rd gear On countershaft 4th gear On countershaft reverse gear On subshaft 4th gear On reverse idler gear On stator shaft R side On stator shaft stator side On reverse idler gear shaft holder End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Reverse idler gear Countershaft reverse gear Selector hub O D Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness 19 980 19 993 0 7866 0 7871 35 975 35 991 1 4163 1 4169 31 975 31 991 1 2589 1 2595 30 975 30 991 1 2195 1 2201 36 004 36 017 1 4175 1 4180 31 975 31 991 1 2589 1 2595 27 980 27 993 1 1016 1 1021 29 980 29 993 1 1803 1 1808 31 975 31 991 1 2589 1 2595 27 991 28 000 1 1020 1 1024 29 980 29 993 1 1803 1 1808 13 990 14 000 0 5508 0 5512 36 000 36 016 1 4173 1 4179 41 000 41 016 1 6142 1 6148 38 000 38 016 1 4961 1 4967 38 000 38 016 1 496
317. t Bolts Nuts Torque Value Specifications B16A2 engine TRANSMISSION MOUNT RIGHT FRONT MOUNT 5 6 Torque Specifications SIDE ENGINE MOUNT A 10 x 1 25 mm 60 N m 6 0 kg m 43 Ib ft Replace B 12 x 1 25 mm 60 N m 6 0 kg m 43 Ib ft Replace C 14 x 1 5 mm 85 N m 8 5 kg m 61 Ib ft Replace D 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft E 12 x 1 25 mm 75 N m 7 5 kg m 54 F 10 x 1 25 mm 45 4 5 kg m 33 G 12 x 1 25 mm 85 N m 8 5 kg m 61 Ib ft H 12 x 1 25 mm 65 N m 6 5 kg m 47 Replace cont d 5 7 Engine Removal Installation cont d lt gt gt 167 7 5 Y Engine Lubrication Engine Oil Replacement 8 2 Outline of Model Change The recommended oil has been changed Engine Oil Replacement 1 Warm up the engine 2 Drain the engine oil OIL PAN DRAIN PLUG 45 N m 4 5 kg m 33 Ib ft Replace Do not overtighten 3 Reinstall the drain plug with a new washer and refill with the recommended oil Requirement API Service Grade SF SG or SH Change Every 10 000 km 6 000 miles or 6 12 3 months 3 European models Capacity US qt Imp qt After engine At change 9 overhaul including filter D16A9 engine 4 3 4 5 3 8 3 6 3 8 3 2 B16A2 engine 4 8 5 1 4 2 4 0 4 2 3 5 Except D16A9 B16A2 engines 4 0 4 2 3 5
318. t connec tor RED to the airbag side of the connector CABLE REEL 3 P CONNECTOR DRIVER S AIRBAG 3 P CONNECTOR ACCESS PA CONNECTOR RED Se Front Passenger s Airbag e Remove the glove box and access panel then re move the short connector RED from its holder FRONT PASSENGER S FRONT PASSENGER S AIRBAG AIRBAG ASSEMBLY 3 P CONNECTOR SHORT CONNECTOR RED GLOVE BOX e Disconnect the front passenger s airbag 3 connec tor from the SRS main harness and connect the short connector RED to the front passenger s airbag 3 P connector 23 b6 3 Remove the airbags Driver s Side e Remove the two Torx bolts using a Torx T30 bit then remove the driver s airbag assembly DRIVER S AIRBAG ASSEMBLY CRUISE lt gt CONTROL SET RESUME SWITCH TORX BOLT Use a Torx T30 bit Front Passenger s Side e Remove the six mounting nuts then carefully lift the front passenger s airbag out of the dashboard FRONT PASSENGER S AIRBAG ASSEMBLY UPPER MOUNTING NUTS UPPER MOUNTING NUTS LOWER MOUNTING NUTS cont d 23 57 Airbag Assembly Replacement cont d CAUTION Be sure to install the SRS wiring so that it is not pinched or interfering with other car parts 4 Install the new airbags Driver s Side Place the driver s airbag assembly in the 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
319. t of the oil strainer by the front oil pump Then the oil passes through check valve and is pres sured by the front oil pump e The pressured oil passes through the rear oil pump and check valve B and it is directed to the clutch piston to move the piston Asthe clutch piston moves the clutch plates engage with the clutch discs in the differential clutch assembly to transmit the driving force from the transfer to the rear wheels that is the car is switched to the 4WD condition e The oil applied on the clutch piston passes through the oil filter orifice and check valve O to lubricate and cool the bearings inside the clutch guide and the clutch discs CLUTCH PISTON FRONT OIL PUMP REAR OIL PUMP kis THERMO SWITCH ___ Normal Forward Driving 2WD Front wheel speed and rear wheel speed are equal OIL STRAINER As during normal forward driving the front wheel speed is equal with the rear wheel speed there is no difference in speed between the front rear oil pumps and they produce equal hydraulic pressure e The oil is drawn out of the oil strainer by the front and rear oil pumps passes then through check valves and 8 and is pressured by the respective oil pumps e The oil pressured by the front oil pump enters the inlet port of the rear oil pump while the oil pressured by the rear oil pump enters the inlet port of the front oil pump e The oil pressured by the front oil pump and rear oil pump
320. tage between YEL ZU BLU WHT terminal and body BLK 3 BLK ground 6 Replace STARTER SIGNAL YEL MAIN NO 7 5 A fuse GRN RELAY Is there battery voltage Repair open or short in the BLU WHT wire between YES the main relay and the STAR TER SIGNAL 7 5 A fuse Is there battery voltage To page 11 34 cont d 11 33 Fuel Supply System Main Relay Except D15B2 engine cont d From page 11 33 d Turn the ignition switch off Connect the test harness be tween the ECU and connector Disconnect A connector from the ECU only not the main wire harness Check for continuity between GRN YEL terminal and A7 ter minal se NO Repai i i uri Ger pair open in GRN YEL wire be lt ee tween ECU 7 and main relay YES Reconnect A connector to the ECU Connect the main relay connec L tor Turn the ignition switch ON Measure the voltage between A23 terminal and the follow ing terminals A25 B1 4 Battery voltage A23 A25 B1 A7 OOOOOOOOOOOOO OOOOOOOO OOOOOOOOOOOOO Is there battery voltage Repair open in the YEL BLK wire between the ECU A25 B1 and main re
321. the ECU only not the main wire harness Continuity body ground terminals C13 C15 Check for continuity between Repair short to body ground in YEL GRN wire between TEENS US YES ECU C15 and MAP sensor P Does continuity exist gt Repair short to body ground in YEL WHT wire between NO ECU C13 and throttle angle sensor Reconnect all the sensor connec tors Reconnect the C connector to the ECU Turn the ignition switch ON 11 17 11 16 From page 11 16 Measure voltage between A18 and the following A13 and A15 A13 A15 BATTERY OOOOOOOOO B OOOOOOOOOO 00000000 VOLTAGE f 0000000000 A18 Repair open in YEL BLK wire NO between ECU A13 A15 and Is there battery voltage main relay Check main relay and wiring YES connectors at main relay Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU 11 17 PGM FI Control System Troubleshooting Flowchart Oxygen Sensor D16A7 D16A8 D15B7 KO model engine H at i z 1 self diagnosis Check Engine light indicates code 1 A problem the Oxygen Sensor circuit SS mS The Oxygen sensor detects the oxygen content in the exhaust gas and inputs the ECU In operati
322. the SRS unit or wiring to heat guns welding or spraying equipment 1 Inspect all the SRS wire harnesses Replace don t repair any damaged harnesses Connect the short connectors before working below the dashboard near the SRS unit Inspect the cable reel for heat damage If there is any damage replace the cable reel After any degree of frontal body damage or after a collision without airbag deployment inspect the SRS unit for physical damage If it is dented cracked or deformed replace it After the car is completely repaired turn the ignition switch on If the SRS indicator light comes on for about six seconds and then goes off the SRS sys tem is OK If the indicator light does not function properly go to SRS Troubleshooting Be sure the SRS unit is installed securely Do not disassemble the SRS unit Store the SRS unit in a cool and dry place Do not spill water or oil on the SRS unit and keep it from dust During installation or replacement be careful not to bump impact wrench hammer etc the area around the SRS unit The airbags could accidentally deploy and cause damage or injuries 23 22 SRS Wiring Precautions e Never attempt to modify splice or repair SRS wiring Disconnecting the SRS Connector at the Under dash Fuse Relay Box NOTE SRS wiring can be identified by special yellow outer protective covering CAUTION Avoid breaking the connector it s double locked 1 First lift the connec
323. the cable reel see page 23 62 To page 23 42 SRS MAIN HARNESS SRS UNIT 18 P CONNECTOR TEST HARNESS B 07MAZ 5 00500 07QAZ SR30100 JUMPER WIRE TEST HARNESS B 07MAZ SP00500 S e 9 e a5 el 17 19 UHHBHBHBHBHEEE HEB EE CABLE REEL 6 P CONNECTOR 07LAZ SL40300 TEST HARNESS C 07LAZ SL40300 cont d 23 41 Troubleshooting DTC 1 4 cont d From page 23 41 SRS MAIN HARNESS 18 P CONNECTOR SRS UNIT Check for a short to ground in the SRS main harness 1 Disconnect Test Harness C from the cable reel 6 P con nector and reconnect the cable reel 6 P connector to the SRS main harness 2 Check for continuity between the No B1 and B5 termi nals and the No B5 and B7 terminals of Test Harness B CAUTION e Make sure the ignition switch is turned OFF Do not disconnect the SRS short connector A from the cable reel 3 P connector Is there continuity YES NO Short to ground in the SRS main harness replace the harness TEST HARNESS B 07MAZ SP00500 A 2 s s o v o o sof el 16 21 EE The problem has disappeared due to disconnecting and connecting the connectors Be sure all terminals make good contact and recheck the system see Troubleshooting of Intermittent Failures on page 23 28 23 42 DTC 2 1 CA
324. the first blink is difficult to see always count the blinks at least twice to verify the code NOTE Two Trip Detection Method To prevent false indications the Two Trip Detection Method is used for the O sensor fuel metering related EGR system self diagnostic functions When an abnormality occurs the ECU stores it in its memory When the same abnormality recurs after the ignition switch is turned OFF and ON again the ECU informs the driver by lighting the Check Engine light However to ease troubleshooting this function is cancelled when you short the service check connector The Check Engine light will then blink immediately when an abnormality occurs Separate Problems Short L n n n Problem CODE 1 See Problem CODE 3 L See Problem CODE 14 Long short Simultaneous Problems ni nme qn z See Problem CODE 1 and 3 mmm uL vu See Problem CODE and 4 CHECK z See Problem CODE 1 and 14 ENGINE LIGHT cont d 11 9 Troubleshooting Self diagnostic Procedures cont d I ECU Reset Procedure 1 Turn the ignition switch off 2 Remove the BACK UP fuse 7 5 A from the under hood fuse relay box for 10 seconds to reset the ECU NOTE Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting Make note of the radio presets before removing the fuse so you reset them BACK UP FUSE
325. the service check connector OOOOOOOOOOOOO OOOOOOOO OOOOOOOOOOO 1300000000009 D4 D22 L 5 v 4 Turn the ignition switch OFF Try to start the engine Did the engine start Connect the test harness be tween the ECU and connectors l Turn the ignition switch ON Measure voltage between D4 terminal and D22 terminal Remove and inspect the ECU 15A fuse in the under hood fuse relay box 1 NO Is the fuse OK YES To page 11 13 Is there approx 5 V YES Connect the SCS short connector 4 WD model 12 V to the service check connector No Repair short to body ground in BRN wire between the ECU D4 Measure voltage between D4 and service check connector terminal and body ground Repair open in BRN wire be tween ECU D4 and service check connector YES Is there approx 5 V Repair open in BLK wire be 4WD model 12 V tween service check connec tor and G101 NO Remove the SCS short connector from the service check connector Replace the fuse NOTE After repair disconnect the SCS short con nector test drive the car and recheck the Check Engine light for a code To page 11 13 11 12 From page 11 12 Inspect the ACG S 15 A fuse in the under dash
326. the transmission mount Baren P N 41211 PY5 305 RELEASE NOTE Torque the mounting bolt and nuts in the sequence shown BEARING CAUTION Check that the bushings are not twisted or offset Kee D 12 x 1 25 mm ET 65 N m 6 5 kg m 47 Ib ft TRANSMISSION MOUNT RELEASE FORK P N 41211 PY5 305 12 x 1 25 mm 75 N m 7 5 kg m 54 Ib ft 13 6 7 Install the clutch cover then install the front and rear engine stiffeners 6 x 1 0 mm 12 N m 1 2 kg m 9 lb ft FRONT ENGINE STIFFENER CLUTCH COVER REAR ENGINE STIFFENER 10 x 1 25 mm 45 4 5 kg m 33 Ib ft 8 Install the right front mount bracket 9 Install the engine splash shield SPECIAL BOLT Replace 12 x 1 25 mm 65 N m 6 5 kg m 47 Ib ft RIGHT FRONT MOUNT BRACKET WASHER 10 x 1 25 mm 45 N m 4 5 kg m 33 Ib ft ENGINE SPLASH SHIELD d 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft 10 Remove the chain hoist then reinstall the distribu tor mounting bolt D16A9 engine CHAIN HOIST DISTRIBUTOR MOUNTING BOLT 8 x 1 25 mm 24 N m 2 4 kg m 17 Ib ft 11 Install the change rod the spring pin and the clip NOTE Install the clip and the spring pin on the change joint as shown Turn the shift rod boot so the hole is facing down as shown e Make sure the shift rod boot is installed on the change rod 12 Install the change extension 8 x 1
327. tle valve B stuck ATF strainer clogged Torque converter defective Torque converter check valve stuck 1 2 shift valve stuck 2 3 shift valve stuck 3 4 shift valve stuck Servo control valve stuck Clutch pressure control CPC valve stuck 2 3 orifice control valve stuck 2 3 4 orifice control valve stuck 2nd ON orifice control valve stuck 4 3 kick down valve stuck 4th exhaust valve stuck 1st accumulator defective 2nd accumulator defective 3rd accumulator defective 4th reverse accumulator defective 1st hold accumulator defective Servo valve stuck Lock up timing valve stuck Lock up shift valve stuck Lock up control valve stuck Shift fork bent Reverse gears worn damaged 3 gears Reverse selector worn 3rd gears worn damaged 2 gears Final gears worn damaged 2 gears Differential pinion shaft worn Feedpipe O ring broken 4th gears worn damaged 2 gears Gear clearance incorrect Clutch clearance incorrect One way sprag clutch defective Sealing rings guide worn Axle inboard joint clip missing cont d 14 5 Hydraulic System Symptom to Component Chart cont d Check these items on the The following symptoms can be caused seite 9 Items the by improper repair or assembly PROBABLE CAUSE DUE TO IMPROPER
328. tor 1 Turn the ignition switch OFF 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the passenger s airbag connector 4 Connect SRS short connector A to the SRS main harness 3 P connector CAUTION Do not disconnect the driver s airbag connec tor 5 Connect the SCS short connector to the service check connector 6 Reconnect the battery positive cable then connect the negative cable 7 Turn the ignition switch ON Il and record the most recent DTC Is DTC 2 3 or DTC 2 2 indicated 2 3 2 2 Short to power in the passenger s airbag inflator replace the passenger s airbag assembly see page 23 56 Connect Test Harness B 1 Turn the ignition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector 5 Reconnect the battery positive cable then connect the negative cable 6 Connect a voltmeter between the No B2 and B5 termi nals of Test Harness B 7 Turn the ignition switch ON Il and measure voltage There should be 0 5 V or less 8 Connect the voltmeter between the No B8 and B5 termi
329. tor lid with a thin screwdriver then press the connector tab down and pull the connector out CONNECTOR LID UNDER DASH FUSE RELAY BOX e Be sure to install the harness wires so that they are not pinched or interfering with other car parts SRS MAIN HARNESS 2 Toreinstall the connector push it into position until it clicks then close its lid e Make sure all SRS ground locations are clean and grounds are securely fastened for optimum metal to metal contact Poor grounding can cause intermittent problems that are difficult to diagnose 23 23 Precautions Procedures Steering related Precautions Steering Wheel and Cable Reel Alignment NOTE To avoid misalignment of the steering wheel or airbag on reassembly make sure the wheels are turned straight ahead before removing the steering wheel Rotate the cable reel clockwise unit 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 CABLE REEL LABEL YELLOW GEAR TOOTH 23 24 Steering Column Removal CAUTION Before removing the steering column first discon nect the connector between the cable reel and the SRS main harness e If the steering column is going to be removed with out dismounting the steering wheel lock the steer ing by turning the ignition key to 0 LOCK position or
330. ully open 515 530 5 15 5 3 73 75 510 5 1 73 Hydraulic Line pressure at 2 000 min rpm N or P position 850 900 8 5 9 0 121 128 800 8 0 114 pressure kPa kg cm psi D15B3 420 4 2 60 370 3 7 53 fully closed PUE fully closed 2nd clutch pressure at 2 000 min rpm 94 position 04 position 3rd clutch pressure at 2 000 min rpm 850 900 8 5 9 0 121 128 800 8 0 114 throttle more than 1 4 opened throttle more than 1 4 opened 850 900 8 5 9 0 121 128 800 8 0 114 850 900 8 5 9 0 121 128 800 8 0 114 4th clutch pressure at 2 000 min rpm 04 position 2 1st clutch pressure at 2 000 min rpm 94 or position Governor pressure at 60 km h 38 mph 2nd clutch pressure at 2 000 min rpm 2 position 151 161 1 51 1 61 21 23 0 800 850 8 0 8 5 114 121 750 7 5 107 0 5 0 0 05 0 1 515 530 5 15 5 3 73 75 146 1 46 21 Throttle pressure B Throttle fully closed Throttle fully open Throttle pressure Throttle fully closed Throttle fully open 510 5 1 73 3 16 2WD Automatic Transmission M48A cont d Section 14 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Hydraulic pressure kPa psi D16A9 Clutch Line pressure at 2
331. ures General Precautions 23 21 Airbag Handling and Storage 23 21 SRS Unit Precautions 23 22 Inspection After Deployment 23 22 Wiring Precautions 23 23 Steering related Precautions 23 24 Connecting the Short Connectors 23 25 Troubleshooting Self diagnostic Procedures 23 26 Diagnostic Trouble Code DTC Chart kuu ice ae 23 29 SRS Indicator Light Wire Connections 23 30 Flowcharts 23 31 Airbag Assembly Replacement 23 56 Disposal TTE 23 60 Cable Reel Replacement 23 62 SRS Unit Replacement 23 66 Component Wiring Location Index SRS INDICATOR LIGHT In the gauge assembly Troubleshooting page 23 27 To HORN SWITCH To CRUISE CONTROL CABLE REEL SET RESUME SWITCH Replacement page 23 62 Q 7 AN SOS s C ww d To DRIVER S AIRBAG L SE ASSEMBLY SRS MAIN HARNESS DASHBOARD WIRE HARNESS FRONT PASSENGER S to MAIN WIRE HARNESS to SRS INDICATOR LIGHT AIRBAG ASSEMBLY 6 P CONNECTOR in GAUGE ASSEMBLY Replacement page 23 56 5 P CONNECTOR Disposal page 23 60 DASHBOARD WIRE HARNESS SRS MAIN HARNESS Be to FRONT PASSENGER S AIRBAG 3
332. ust Radial 5 75 5 85 0 226 0 230 0 25 0 45 0 010 0 018 0 05 0 45 0 002 0 018 0 8 0 031 0 8 0 031 3 15 Standards and Service Limits 2WD Automatic Transmission M48A Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission Capacity US at Imp qt 5 4 5 7 4 8 for overhaul fluid 2 4 2 5 2 1 for fluid change Hydraulic Line pressure at 2 000 min rpm N or P position 800 850 8 0 8 5 114 121 750 7 5 107 pressure 420 4 2 60 370 3 7 53 kPa kg cm psi 2nd clutch pressure at 2 000 min rpm De position throttle fully closed fully closed D12B1 3rd clutch pressure at 2 000 min rpm Da position 800 EN 8 0 8 5 114 121 750 107 MES 2 throttle more than 1 4 opened throttle more than 1 4 4th clutch pressure at 2 000 rpm D4 position opened 2nd clutch pressure at 2 000 min rpm 2 position 800 850 8 0 8 5 114 121 750 7 5 107 1st clutch pressure at 2 000 min rpm Da or Ds 800 850 8 0 8 5 114 121 750 7 5 107 position i cre cues Governor pressure at 60 km h 38 mph 151 161 1 51 1 61 21 23 146 1 46 21 Throttle pressure B Throttle fully closed O Throttle fully open 800 850 8 0 8 5 114 121 750 7 5 107 Throttle pressure A Throttle fully closed 0 5 0 0 05 0 1 Throttle f
333. ver into reverse gear and gradually re lease the clutch Apply the parking brake firmly e engine stalls the system is OK e If the engine continues to run check the differen tial oil if the oil is OK replace the rear differen tial assembly A T 1 Raise the car off the ground and place safety stands under it see section 1 AWARNING e Make sure jacks and safety stands are placed properly Make sure the car will not roll off stands and fall while you are working under it 2 Mark either the No 1 or No 2 propeller shaft PROPELLER 3 Start the engine Hold the engine at 3 000 rpm with no load in N or P position until the radiator fan comes on then let it idle 4 Fix the engine speed at low gear by moving the select lever to the R position 5 Apply the parking brake firmly and measure the time during which the marked propeller shaft rotates 10 times e Ifthe time for 10 turns is 10 seconds or more the system is OK e f the time for 10 turns is less than 10 seconds check the differential oil if the oil is OK replace the rear differential assembly 15 11 Realtime 4WD Dual Pump System Troubleshooting Forward Drive Quick Braking 2WD Reverse Drive Quick Braking 4WD 1 Raise the rear left wheel off the ground and place safety stands under the side sill reinforcement sec tion see section 1 1 Raise the rear left wheel off the ground and place safety stands un
334. verse gear When the car is running normally in forward or reverse gear that is when there is no difference in speed between the front and rear wheels or when the brake is applied during forward driving the hydraulic control system transmits the driving force to the front wheels To protect the 4WD system when the differential oil temperature rises excessively the thermo switch releases the system by releasing the hydraulic pressure applied on the clutch piston 15 4 Rear Differential Assembly OIL PUMP BODY DIFFERENTIAL CLUTCH ASSEMBLY CLUTCH GUIDE DIFFERENTIAL CARRIER TORQUE CONTROL DIFFERENTIAL CASE HYPOID DRIVE PINION GEAR DIFFERENTIAL zi HYPOID RING COMPANION FLANGE CLUTCH HUB CLUTCH PLATE CLUTCH DISC Hydraulic Control System CLUTCH PISTON DIFFERENTIAL CLUTCH ASSEMBLY THERMO SWITCH FRONT OIL PUMP DIFFERENTIAL CARRIER COVER REAR OIL PUMP PISTON SPRING FRONT OIL PUMP REAR OIL PUMP OIL STRAINER RELIEF VALVE cont d 15 5 Description Realtime 4WD Dual Pump System cont d Forward Drive Quick Starting 4WD Front wheel speed is higher than the rear wheel speed As at forward quick starting the front wheel speed is higher than the rear wheel speed the rotation speed of the front oil pump is higher than the rear oil pump speed producing hydraulic pressure The oil is drawn ou
335. witches connector 23 64 17 Installthe steering wheel nut 20 Remove and properly store the short connectors RED then reconnect the airbag connectors and STEERING WHEEL NUT reinstall the glove box 50 N m 5 0 kg m 36 Ib ft Replace 21 Reconnect the battery positive cable then the nega tive cable 22 After installing the cable reel confirm proper sys tem operation e Turn the ignition ON II the instrument panel SRS indicator light should come on for about six seconds and then go off e Make sure both horn buttons work e Make sure the headlight and wiper switches DRIVER S work AIRBAG ASSEMBLY e Go for a test drive and make sure the cruise con trol switches work TORX BOLTS e Rotate the steering wheel counterclockwise to make sure the yellow gear tooth lines up with the slot on the cover 10 N m 1 0 kg m 7 2 Ib ft Replace Use a Torx T30 bit 18 Install the driver s airbag assembly 19 Connect the cable reel 6 P connector to the SRS main harness then install the knee bolster and dashboard lower cover ALIGNMENT MARK YELLOW GEAR TOOTH KNEE BOLSTER DASHBOARD LOWER COVER 23 65 SRS Unit Replacement CAUTION Before disconnecting any part of the SRS wire har ness install the short connectors RED on the air bags During installation or replacement do not bump impact wrench hammer etc the area near the SRS unit Do not damage the SR
336. y positive cable then connect the negative cable 7 Turn the ignition switch Il record the most recent DTC Is DTC 2 4 or DTC 2 2 indicated 2 4 2 2 Short to ground in the passenger s airbag inflator replace the passenger s airbag assembly see page 23 56 Connect Test Harness B 1 Turn the gnition switch OFF and remove the SCS short connector 2 Disconnect the battery negative cable then disconnect the positive cable and wait for three minutes 3 Connect the short connector RED to the driver s airbag connector 4 Disconnect the SRS main harness 18 P connector from the SRS unit and connect Test Harness B between the SRS unit and the 18 P connector 5 Connect the No 13 14 15 and 16 terminals on rows A SRS unit end and B SRS main harness end of Test Harness B with jumper wires NOTE Do not connect jumper wires to the other terminals To page 23 49 23 48 FRONT PASSENGER S AIRBAG 3 P CONNECTOR SHORT CONNECTOR RED SHORT CONNECTOR A 07 2 SP0020A SRS MAIN HARNESS SRS INDICATOR LIGHT 07PAZ 001010A SCS SHORT CONNECTOR MEMORY ERASE CHECK SIGNAL MES CONNECTOR 2 2 BLK WHT SRS UNIT SRS MAIN HARNESS 18 P CONNECTOR TEST HARNESS B 07MAZ SP00500 07QAZ SR30100 JUMPER WIRE 23 48

1994 Honda Civic Hatchback Maintenance Manual EDM

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