Honda 250-4195 User's Manual
Contents
1. 4 Wrecket ti BRAKE SWITCH WIRES gt p h HOT 12V White w Green Stripe SA COLD Green w White Stripe Existing POWER SOURCE Vacant Terminal Fuse Box uum dubii Tower Throttie Hook Up Requires Adaptor Kil 4250 4163 Refer to Supplemental Installation Manual for Proper Installation Pick up Coil amp Magnet Axle Boot EN Pedal Wee 210 Hd Sc i ex Hd Screw Location 2 Bracket 2 Gu Frame Flat j Washer Nut Washer Washer 44 1983 84 HONDA CIVIC 45 N 1 4 Tapping 5 Screw 1 4 Tapping Screw Route servo cable through speeds cable grommet and attach to bracket with 10 32 machine screw Fasten bracket as shown with 2 1 4 tapping screws Attach to accelarator pedal as shown Remove all but 1 8 slack from bead chain but be sure accelerator pedal is allowed to return to idle position No 10 32 Nut Bend chain coupling eyelet type eyelet 1o be free to turn 10 32 Jam nuts 2 10 32 x 1 e Nee 39 Hose 9 32 Diameter Screw oS HN 5154 1 Long Use 3 8 tube clamp to attach to pedal Cut a 1 piece of 9 32 hose to cover the jam nuts and end of screw Place 1 4 tube clamp onto servo cable Use No 10 32 x 1 2 screwand 3 16 Helical s2. The servo mounts forward of the drivers side shock tower Fabricate mounting bracket from servo bracket provided in the basic kit using template STEP 1 back of instructions Attach the mounting bracket to the servo STEP 2 Remove the plastic plug as shown in illustration exposing a 6mm threaded hole STEP 3 Install servo as shown f y y A EL R servo and dump valve mounted Threaded hole for mounting and dump valve ACCORD The servo mounts to the passenger side of the firewall STEP 1 Fabricate mounting bracket from servo bracket provided in the basic kit using templates in back of instructions Attach the mounting bracket to the servo STEP 2 Remove the screw atthe top right corner of the vacuum canister Position mounting brac ket reinstall screw and tighten E Servo and dump valve installed on Accord VACUUM REGULATOR AND VACUUM RESERVOIR INSTALLATION NOTE Vehicles with automatic transmission equipped with a lock up converter require a vacuum regulator and a vacuum reservoir The A um reguiator and vacuum reservoir should be installed away from any sharp hot or moving parts A vacuum schematic is shown below Engine Vacuum t Intake Manifold To Servo Automatic transmission with lock up converter Vehicles with manual transmission do not require the vacuum regulator but the use of a vacuum reser voir may improve the
3. 1988 HONDA CIVIC PRELUDE AND ACCORD SUPPLEMENTAL CRUISE CONTROL INSTALLATION INSTRUCTIONS 250 4195 ADAPTOR PACKAGE Form 2220 PARTS LIST ITEM QTY DESCRIPTION VACUUM REGULATOR REDUCER VACUUM 1 4 3 16 TUBE VACUUM 5 32x48 Lg TUBE VACUUM 7 32x1 3 8 Lg STRAP CABLE WASHER FLAT 3 8 1 0 WASHER FLAT 1 4 1 0 SCREW 1 4 20 3 4 HD NUT amp WASHER ASS Y 1 4 20 NUT No 10 32 HEX SCREW No 10 32x1 RD HD TERMINAL 1 4 FEMALE LEVER THROTTLE LOCKWASHER 3 16 SCREW No 10 16x1 2 TAPPING COVER BEAD CHAIN CONN BRACKET THROTTLE BRACKET ASS Y BOLT M6 1 00x16mm 55A 00754 HOSE CLAMP T nl j 2 Dana Corporation 1987 All Rights Reserved Printed in United States of America PARTS DIAGRAM INDEX Page 1988 HONDA ACCORD AND PRELUDE 1 37 Servo 4 Supercruise Regulator InstallatioNnS 8 Microcruise Regulator Installations 11 Vacuum Regulator and Reservoir Installation 7 Road Speed Pick up Coil Installations 14 Throttle Connections 16 Bracket 21 1985 87 HONDA CIVIC ACCORD PRELUDE WAGOVAN 15006 CRX SUPERCRUISE 38 46 Civic Crx Civic 15005 Installation Instructions 39 Civic Civ
4. O M 1 4 DIA 0 E 0 00 RACKET PICK UP COIL MOUNTING MAKE FROM 199 BRACKET Bracket Assembly Throttle Bracket Assembly made to fit 83 Accord To fit 83 Prelude bracket assembly requires rework Rework Step 1 Flatten bracket and cut off 1 1 4 from end Step 2 Bend bracket to fit template above NOTES NOTE It is not uncommon for vehicle manufacturers to change color of wires or to relocate vehicle components at any time We must depend on the installers good judgement to relocate any component necessary to produce an installation that is free of any interference which might keep the cruise control from functioning properly PRECISION CONTROLS
5. EAN Regulator installed on Accord 11 PRELUDE The regulator mounts to the passenger side shock tower and brake proportioning valve STEP 1 Fabricate mounting brackets from two cable brackets provided in kit using the templates in back of instructions STEP 2 Remove nut from shock tower Install top regulator mounting bracket as shown Replace nut and retighten STEP 3 Remove bolt from brake proportioning valve bracket Install bracket as shown Replace bolt and retighten STEP 4 Install regulator as shown In Illustration Regulator installed on Prelude 12 MICROCRUISE REGULATOR INSTALLATIONS The regulator mounts to the passenger side firewall STEP 1 Fabricate mounting bracket from one pick up coll bracket and one cable bracket pro vided in kit using the templates in back of instructions Attach brackets to regulator STEP 2 Remove nutfrom solenoid bracket and fuel filter Mount regulator as shown Replace nuts and retighten Firewall Microcruise regulator installed on Civic 13 ACCORD The regulator mounts forward of the drivers side shock tower STEP 1 Fabricate mounting brackets from cable brackets provided in kit using the templates in back of instructions STEP 2 Remove bolts from existing cable bracket Install mounting brackets as shown Replace cable bracket Replace bolts and retighten STEP 3 Install regulator as shown 14 Regulator mounting brack
6. performance of the cruise control vacuum schematic is shown below Engine Vacuum Intake Manifold To Servo Manual Transmission SUPERCRUISE REGULATOR INSTALLATIONS The regulator mounts to the passenger side shock tower and firewall 1 Fabricate mounting brackets from one road speed pick up coil bracket and one serwo cable bracket provided the basic kit using templates back of instructions Attach the brackets to the regulator STEP 2 Loosen screw shown on brake proportioning valve bracket on shock tower Remove screw from fuel filter bracket on firewall STEP 3 Slip slotted regulator mounting bracket between brake lines and shock tower and behind head of screw The remaining bracket attaches to the fuel filter bracket on the firewall Replace and retighten screws KA IL E IA Shock Tower Regulator installed on Civic 10 ACCORD The regulator mounts to the driver side engine mount STEP 1 STEP 2 STEP 3 Fabricate mounting brackets from two road speed pick up coil brackets provided in the basic kit using templates in back of instructions Attach the bracket to the regulator Remove the two screws that secure the existing cable holder to the engine mount Position the cruise control mounting brackets between the engine mount and the cable holder Replace the cable holder and screws and retighten the screws A S 5
7. Hook Up Requires Adaptor Kit 250 4163 en Refer to Supplemental Installation Manual for Proper Installation Mount Bracket TU AT _ Accelerator Pedal UNS Lett Front Axle Doom View of Transaxle 1 Bead Chain HOTE On manual transmission vehicles there is stabilizer bar located below axle flange Remove 10mm bolt and move stabilizer to allow access Re install 42 INSTALLATION INSTRUCTIONS FOR HONDA PRELUDE 3EGULATOR SETTINGS FIN 5 LOW SPEED 1 CENTERING 3 SENSITIVITY MAX SPARK SENSOR WIRE 1 BRAKE SWITCH WIRES HOT TAV White w Green Stripe COLD Green w White Stripe POWER SOURCE Vacant Terminal Fuse Box i E TT Coil Magnet Leit Axte Boot _ Magnet Location 2 Frame 20 Hex v Flat Flat Washer _ Washer ur Throttle Hook Up amp Washer Assy Regulator Mounting I 4 N x In Vy is Nut I X 7 AS t Hn Exist ng iimm Boll Requires Adaptor Kit 8250 4153 Refer t Supplemental Installation Manual for Proper Installation Accelerator Pedal INSTALLATION INSTRUCTIONS Regulator FOR Mounting HONDA ACCORD Regulator REGULATOR SETTINGS PIN 5 E LOW SPEED 1 Bracket 2 CENTERING 2 ff 3 s SENSITIVITY MAX y SPARK SENSOR
8. X SPARK SENSOR WIRE 1 BRAKE SWITCH WIRES HOT 12V White w Green Stripe COLD Green w White Stripe POWER SOURCE Vacant Terminal Fuse Box Drill 3 16 and Install Bracket with Tapping Screw Magnet amp Coil m Transaxle Mount Bracket jen Tfi Mr 17 AVE Lett Front Axle Bottom View of Transaxle NOTE On manual transmission vehicles there is a stabilizer bar located below axie flange Remove 10mm bolt and move stabilizer to allow access Re install N Vu Te gt om Bracket 1 Bracket 1 RI d SIT M ES 1 12mmNut DSS lt E wu ON Firewall gt N 22 7 Shock Tower Rack amp Pinion _ Steering Bracket Throttle Hook Up Requires Adaptor Kit 250 4163 Refer to Supplemental Installation Manual for Proper Instructions _ Accelerator Pedal INSTALLATION INSTRUCTIONS Regulator Mounting FOR WAS 2 decr RR nt Brackel 1 E Pf REGULATOR SETTINGS PIN 5 SC ur SPEED 15 CENTERING 3 SENSITIVITY MAX Shock Tower SPARK SENSOR WIRE 1 BRAKE SWITCH WIRES HOT 12V White w Green Stripe Eales Timm Mos COLD Green w White Stripe 2 POWER SOURCE Vacant Terminal Fuse Box ir aL Dy Magnet amp Coil Drill 3 16 and Throtile
9. acket from the servo cable bracket sup plied in this kit Using the template in back of instructions attach the pick up coil to the bracket STEP 2 Remove the bolt behind the drive axle on the passenger side of the transmission STEP 3 Position the road speed pick up coil and mounting bracket behind the drive axle Replace and retighten the bolt Road speed pick up coil installed on Civic 17 THROTTLE CONNECTIONS CIVIC The crulse control cable attaches to the throttle lever provided in adaptor package STEP 1 Remove nut and lock washer from passenger s side of carburetor Install throttle lever Replace lock and nut retighten NOTE Be careful not to cross thread the nut when retightening STEP 2 Fabricate cable anchor bracket from one cable bracket provided in basic kit using the template in back of instructions STEP 3 Install anchor cable bracket to valve cover and attach cruise control cable with clamps as shown STEP 4 Attach bead chain to throttle lever install washer and cotter pin Carburetor Cable anchor bracket installed Throttle with baad chain installed lo carb 18 ACCORD The cruise control cable attaches to the back of the accelerator pedal STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 Modify throttle bracket assembly provided in adaptor package using template in back of instructions Pull carpet on drivers side floor back to gain access t
10. ain connector covers provided in basic kit Be sure bead chain is proper length 22 Bend Discard QS OS 00000000006 N SIS Drill 1 2 CIVIC SERVO BRACKET S Band 55 0000000000 CA Bof S T Discard si Discard CIVIC SUPERCRUISE BRACKET LC CIVIC SUPERCRUISE BRACKET N NS IN lt 00000000000 0000000000 ACCORD SUPERCRUISE BRACKET NS Y SS I Discard Bend Drill 5 16 00000 PRELUDE SUPERCRUISE BRACKET PRELUDE SUPERCRUISE BRACKET le Bend Discard _ An 4686 SS OS 2100 CIVIC MICROCRUISE BRACKET di Bend 4 O Drill 3 8 CIVIC RUI E BRACKET Ps Discard Goooooo N oNN OS Discard 2 55555050011 Drill 5 16 ACCORD MICROCRUISE pe Discard andi 555 N n SS NS bd ME O PRELUDE MICROCRUISE BRACKET ICK UP COIL BRACKET CIVIC ROAD SPEED PICK UP COIL E 00008 SS N NS S SON N N Drill 5 16 SES SES CIVIC CABLE ANCHOR BRACKET ACCORD THROTTLE BRACKET 40 1985 87 HONDA CIVIC ACCORD PRELUDE WAGOVAN CIVIC 1500 CIVIC INSTALLATION INSTRUCTIONS FOR HONDA CRX 15005 REGULATOR SETTINGS PIN 5 LOW SPEED 1 CENTERING 1 SENSITIVITY MA
11. amp screw to hold cable PRELUDE THROTTLE HOOK UP Drill a 1 hole in area shown by arrow in picture Servo cable and wiring goes thru this side Use grommet from basic kit to place around servo cable and wiring to fill hole Grommet must be used to protect against sharp edges of metal cutting into servo cable and wiring Remove panels 2 from lower and under dash to get room to see and work Lower arrow there is araised spot measure from there to the left 1 and up 1 center punch that spot and drill 5 32 Dia hole Upper arrow Pullcarpet back so youcan work beneath throttle pedal Using No 10 16 x 1 2 screw from adaptor pac kage affix the reworked throttle bracket assembly to the 5 32 hole you drilled The pulley on bracket will be to the right Do not tighten screw completely yet On lower left corner of the raised metal area on floor just below the throttle pedal Measure 3 8 up and 3 8 over and make a pencil mark This mark is a target to position the lower hole of bracket assembly With bracket lower hole positioned over target or close to it use bracket hole as a template mark hole location center punch and drill 5 32 diameter hole Use 1 4 14 x 3 4 long washer hd screw from basic kit to affix bracket Tighten both upper and lower screws Some of the insulation will have to be cut away to clear bracket assembly Continued 56 PRELUDE THROTTLE HOOK UP Use 3 3 tube cl
12. amp to attach to pedal There clear spot just below the pedal to allow room for 3 8 tube clamp Mark the area and raise pedal upward to place clamp No 10 32 NUT P No 10 32 x 1 SGREW efti No 10 32 A JAM NUT 2 BEAD CHAIN COUPLING EYELET TYPE EYELET TO BE FREE TO TURN Place 1 4 tube clamp onto servo cable Use No 10 32 x 1 2 screw and 3 16 Helical spring lock washer to fasten clamp to bracket SPLIT SLEEVE TO BE UNDER CLAMP TUBE Run bead chain thru pulley and attach to bead chain coupling on pedal Pull cable housing back until it just starts pulling on gas pedal Slide housing cable back 1 8 for slack to let throttle close Tighten 1 4 clamp screw to hold cable NOTE The carpet must be cut to fit around bracket assembly so not to interfere If vehicle has floor mats they may have to be cut as well 57 NOTE Onthe standard automatic and 5 speed automatic with lock up converter avacuum regulator must be used along with the vacuum reservoin VACUUM SCHEMATICS Use 7 32 x 1 3 8 Tube Vacuum 1 4 3 16 Reducer Engine Vacuum Intake Manifold Vacuum Reservoir Vacuum Regulator For Automatic Transmission Vehicle To Servo Engine Vacuum Intake Manifold RT Vacuum Reservoir To Servo For Manual Transmission Vehicle Attach 1 4 female fully insulated terminal Sup plied to brown wire of wiring harness Plug it into fuse panel as shown 58
13. and punch a 1 4 diameter hole thru its center See arrow Route servo cable to this area place above grom met onto cable and pass servo cable thru firewall Put grommet back into hole Remove panels 2 from lower and under dash to get room to see and work Servo cable coming thru to inside of passenger compartment Just above accelerator pedal There is an existing small hole just right on top of steering column From the center of that hole measure over to the right 1 3 6 Make a verti cal ling Remove accelerator pedal stop Use stop to hold servo cable bracket assembly Align hole in top of bracket on line just made Use bracket as tem plate drill a 5 32 diameter hole in firewall Use No 10 16 x 1 2 Hex Hd screw to secure bracket Tighten stop screw Use 3 8 tube clamp to attach to pedal Tilt pedal forward and place clamp just to clear pedal Continued ACCORD THROTTLE HOOK UP No 10 32 NUT No 10 32 x 1 SCREW Mo 10 32 JAM NUT 2 BEAD CHAIN COUPLING EYELET TYPE EYELET BE FREE TO TURN Place 1 4 tube clamp onto servo cable Use No 10 32 x 1 2 screw 3 16 Helical spring washer to fasten clamp to bracket SPLIT SLEEVE TO BE Run bead chain thru pulley and attach to bead chain coupling on pedal Pull cable housing back until it just starts pulling on gas pedal Slide housing cable back 1 8 for slack to let throttle close Tighten 1 4 cl
14. ets Regulator mounted on Accord attached to cable bracket PRELUDE The regulator mounts forward of the drivers side shock tower STEP 1 STEP 2 STEP 3 STEP 4 STEPS Fabricate mounting bracket from one cable bracket provided in kit using the template in back of instructions Remove top right bolt on engine mounting bracket Install regulator mounting bracket Replace bolt and retighten Install regulator as shown Using the regulator as a template mark the flat surface and drill a 3 16 hole Install 1 4 self tapping bolt through existing hole in regulator and through 3 16 hole in flat surface Regulator installed on Prelude 15 ROAD SPEED PICK UP COIL INSTALLATIONS ACCORD and PRELUDE The road speed pick up coil mounts to the passenger side of the transmission above the drive axle STEP 1 Fabricate road speed pick up coil mounting bracket from road speed pick up coil bracket provided in the basic kit using template in back of instructions Attach the pick up coil to the bracket STEP 2 Remove the bolt above the drive axle on the passenger side of the transmission STEP 3 Position the road speed pick up coil and mounting bracket over the drive axle Replace and retighten the bolt Road speed pick up coil installed on Accord and Prelude 16 CIVIC The road speed pick up coil mounts to the passenger side of the transmission behind the drive axle STEP 1 Fabricate road speed pick up coll mounting br
15. ic Wagovan Installation Instructions 41 Prelude Installation Instructions 43 Accord Installation 5 45 1983 84 HONDA CIVIC 47 54 Servo Mounting and Throttle Attachment 48 Bracket Templates 51 Magnet Installation 54 1983 HONDA ACCORD AND PRELUDE 55 66 Rework Instructions 96 Pick up Coil Mounting 57 Servo 58 Accord Throttle 59 Prelude Throttle 60 Vacuum Schematics and Power Source 63 Bracket 5 64 te rs 7 1 1988 HONDA CIVIC ACCORD PRELUDE MODEL R SERVO INSTALLATIONS o CIVIC The servo mounts to the passenger side shock tower STEP 1 Fabricate bracket from servo bracket provided in basic kit using template in back of instructions Attach mounting bracket to servo STEP 2 Remove nut and lock washer from shock tower Install mounting bracket over stud Replace lockwasher and nut and retighten NOTE Be sure that servo bracket does not touch brake lines Firewall Passenger Side T Shock Tower Servo and dump valve installed on Civic PRELUDE
16. o area below accelerator pedal Place lower left corner of throttle bracket into the corner produced by the raised pads on the floorboard cover as shown in illustration Using the bracket as a template drill a hole into the cover with a No 8 drill for No 10 self tapping screw Drill 3 16 hole through existing hole in the top of the throttle bracket for a 1 4 self tap ping screw NOTE Do not drill more than 1 2 through the floorboard otherwise you may damage brakelines Insert No 10 self tapping screw into lower hole on throttle bracket and tighten Insert 1 4 self tapping screw into top hole on throttle bracket and tighten Attach cruise control cable to throttle bracket using cable sleeve and P clamp Attach clamp to throttle bracket at existing threaded hole with a No 10 screw as shown Pull bead chain through pulley assembly and attach to cruise control cable using bead chain connector Slide connector cover over connector Reposition carpet Cut to allow only bead chain and pulley assembly to come through Attach clamp to pedal assembly and tighten with No 10 screw and nuts Slide eyelet coupling over No 10 screw on P clamp Cut bead chain to proper length Attach bead chain to eyelet coupling and secure with one nut and one jam nut 19 20 Floorboard Cover Throttle bracket Installed on Accord Bead chain o to cruise control cable w sleeve and clamp P Clamp w Mo 10 sc
17. pring washer to fasten clamp to bracket SPLIT SLEEVE TO BE __ UNDER CLAMP TUBE Run bead chain thru pulley and attach to bead chain coupling on pedal Pull cable housing back until it just starts pulling on gas pedal Slide hous ing cable back 1 8 for slack to let throttle close Tighten 1 4 clamp screw to hold cable 47 Flatten BRACKET ASS BRACKET PICK UP COIL MOUNTING FOR CIVIC CRX 165 Bend Line This hole Used to Mount Pick up Coil Drill 1 4 Use 1 4 Tapping Screw to Secure 4 3 8 DRILL 3 16 AN INSTALL BRACKET N 1 4 TAPPING SCREW E zen TRANSAXLE MOU XN BRACKET Seo ee D Qs cease eee Lo me 2 UL 2 FRONT AXLE BOTTOM VIEW OF TRANSAXLI HONDA VIC CRX MAGNET NS 1983 HONDA ACCORD AND PRELUDE 51 STEP 1 To begin remove servo bracket and servo cable bracket from your Basic Kit Using sketches provided make your pick up coil mounting bracket and servo mounting bracket STEP 2 The throttle bracket assembly from adaptor kit has been made tofit the Accord If you are installing on a Prelude rework is required Using sketch provided rework as explained on sketch STEP 3 Remove metal sleeve from servocableand cutto 5 8 Remove any excess metal or burrs from sleeve Re attach sleeve to servo cable STEP 4 Assemble servo cable assembly to se
18. rew and bead chain coupling w jam nut PRELUDE The cruise control cable attaches to the back of the accelerator pedal STEP 1 Modify throttle bracket assembly provided adaptor package using template in back of instructions STEP 2 Pull carpet on driver side floor back to gain access to area below accelerator pedal Cut insulation away to expose accelerator pedal step and a path for throttle bracket assembly STEP 3 Attach eyelet bead chain coupling provided in basic kit to back of accelerator pedal with cable strap thru the eyelet bead and coupling thenthru the base of the accelerator pedal back thru the eyelet bead chain coupling then thru the cable strap lock 21 STEP 4 Route cruise control cable behind engine to firewall There is arubber plug directly above the accelerator pedal in the firewall Remove this plug and pass cable thru STEP 5 Attach cruise control cable to the throttle bracket assembly with a 1 4 tub clamp pro vided in the basic kit Be sure that the cable sleeve is on the cruise control cable STEP 6 Secure the throttle bracket assembly to the accelerator pedal stop with a 1 4 self tap ping screw provided in the basic kit Cruise control cable and throttle bracket assembly installed Reposition and cut carpet to allow only the pulley and bead chain to be exposed STEP 7 Connect the cruise control cable to the eyelet bead chain coupling with bead chain a bead chain connector and two bead ch
19. rvo see Owners Manual from basic kit section servo amp dump valve mounting Cut a length of bead chain 19 beads long and attach to end of servo cable 5 8 19 Beads TT 66007000 pM 3 8 Long Y Connector Plastic Sleeve 4200 2 Sleeve in Place 52 Pick up Coil Mounting Road Speed for Accord amp Prelude Pick up mounting bracket is formed to fit 172 hole existing in frame M E NA s WA T U gt AXLE BOOT 7 MAGNET LOCATION 2 Looking Fonward 1 4 20 x 3 4 HEX HD SCREW Secure magnets in position with 24 1 4 20 NUT A long tie strap Strap must have ribbed WASHER ASSEMBLY side against magnets and must pass between two ribs on magnet casings 4 FLAT WASHER Feed strap end through strap lock and cinch it Place blade of screwdriver 3 8 FLAT WASHER against strap lock and pull on end of strap with pliers Use about as much force as would be required to lift 15 Ibs Cut excess strap flush to 1 16 from Place 2 magnets 180 apart against boot left side The lock axle is not round make sure plastic strap locking joint is in a recessed area of axle You need all the clearance to clear existing vehicle bracket Route coil leads up and over to lower right corner of engine compartment Tie leads neatly to clear hot or moving parts ET com ACCORD THROTTLE HOOK UP Remove existing grommet
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