Académique Documents
Professionnel Documents
Culture Documents
(cont' d)
13-7
Manual Transmi ssi on
Transmission Removal
(cont'dl
16. Di sconnect the 2P connector
(A)
from the steeri ng
17. Di sconnect the torque sensor 3P connector
(C),
and
remove the wi re harness cl amp
(D).
' 18.
Remove the wi re harness
(A)
and mounti ng bol t,
then remove the i ntake mani fol d stay
(8).
13-8
19.Di sconnect the heated oxygen sensor
(HO25)
{A),
secondary heated oxygen sensor {secondary
HO2S)
(B),
and the back-up l i ght swi tch
(C)
connectors, then remove the wi re harness from the
transmi ssi on.
Remove the three way catal l ti c converter
(TWC)
(A)
and gaskets (B).
a
21. Remove the exhaust mani fol d bracket
(A)
and the
exhaust mani f ol d
( B) .
22.
23.
Remove the propel l er shaft
(see page 16-17).
Remove the four shi ft boot hol der mounti ng bol ts.
24, Remove the rel ease fork boot
(A),
then careful l y
remove the sl ave cyl i nder
(B).
Do not operate the
cl utch
pedal once the sl ave cyl i nder has been
removed.
Pul l out the rel ease fork
(A)
from the rel ease fork
hanger. Wedge a shop towel
(B)
between the
openi ng i n the cl utch housi ng and the rel ease fork
to hol d the rel ease fork i n
pl ace.
(cont' d)
13-9
Manual Transmi ssi on
Transmission Removal
(cont'dl
Remove the fi ve l ower transmi ssi on mounti ng
bol ts.
Pl ace a fl oor
j ack
under the front sub frame and the
engi ne mounti ng sti ffener.
Remove the two center mounti ng bol ts.
Loosen the four mounti ng bol ts 75 mm
(3.0
i n.) as
snown.
21.
28.
29.
1 . 1
\
.
- . . . - t
mm
) i n. )
13- 10
Lower the front subframe i n unti l i t touches the four
l oosened mounti ng bol ts.
Pl ace the fl oor
j ack
under the transmi ssi on, and
remove the three transmi ssi on rear mount bol ts.
Lower the transmi ssi on. Di sconnect the oi ck-uD
sensor connector
(A),
then remove the wi re
har ness
( B)
f r om t he t r ansmi ssi on.
)
33. Remove the three upper tra nsm i ssi on mounti ng
bol ts.
Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the mai nshaft, then l ower the transmi ssi on
on t he
j ack.
Remove the transmi ssi on rear mount from the
t r ansmi ssi on housi ng.
13- 11
Manual Transmi ssi on
Transmission Disassembly
Exploded View-Rear Cover
t--rr-.._
--=-g
11
[l
t\if5
B l
,/--
-"'t-':
6)
@)--"''
x_=----'
7*_-3
X
=--D
\v
----=P=\
-\.1)
8'...
q-
f1 \
l l . '
U
o*--.--
\a'o
o
13-12
(D
27 mm LOCKNUT
Repl ace.
' 162
*
0
-
162 N.m
(16.5 -
0
*
16.5 kgt.m,
119* 0* ' l 19l bf . f t l
O 27 mm SPRING WASHER
O BACK-UP RING
O O.RING
Repl ace.
O COMPANION FLANGE
G) 40 x 60 X 9 mm OIL SEAL
Repl ace.
O BALL BEARING
Repl ace.
@ REAR COVER
O SHIFT ARM B
@ CONICAL SPRING WASHER
Repl ace.
O 8 mm SPECIAL BOLT
31 N. m {3. 1 kgf . m, 22l bf . t t l
@ SHIFT LEVER HOUSING
(}
6 mm FLANGE BOLT
12 N m 11. 2 kgf . m, 8. 7 l bf . f t )
@ 8 mm FLANGE BOLT
27 N.m {2.8 kgf.m,20 lbf.ft)
@ HARNESS BRACKET
@ o-RrNG
Repl ace.
@ SHIFT ROD TUBE
@ SECONDARY SHAFT ASSEMBLY
See page 13-45
@ BEARING OUTER RACE
@ SHIM
O HARNESS CLAMP
(cont' d)
13- 13
Manual Transmi ssi on
Transmission Disassembly
(cont'd)
Exploded View-Transmission Housing
60
@
/
,,--t\
do o
\-:)
t //// rA
d , ( 9 H
,./ G)
@
x\,,
-cr\\-_-
-.o
@---'-r..^
tl
13-14
.]) 29 mm LOCKNUT
{Left-hand threads)
Repl ace.
172
*0 *
172 N. m (17. 5 -
0
*
17. 5 kgf , m,
127-0-127l bf . l t l
(2)
29 mm SPRING WASHER
O 30 x 64x20 mm NEEDLE BEARI NG
O, sEcoNoaRY DRtvE GEAR
O OIL PUMP SHAFT
@ oI L PUMP GEAR
O 6 mm FLANGE BOLT
12 N. m {1. 2 kgt . m, 8. 7 l bf . f t )
@ OIL PUMP PLATE
o SPRI NG L. 19. 1 mm {0. 75 i n. }
(s)
STEEL BALL
O ot l PUMP RoroR
@ BEARING OUTER RACE
@ SHI M
Sel ect i on.
(}
otl GUTDE PLATE s
@ WASHER
Bepl ace.
@ DRATN PLUG
39 N. m
{4. 0 kgf . m, 29l bf . f t }
@ 14 x 20 DowEL Pt N
(D
o-RrNG
Reol ace.
@ PICK-UP sENsoR
@ 6 mm FLANGE BOLT
12 N. m (1. 2
kgf m. 8. 7 l bt f t )
Q]) FILLER PLUG
44 N. m
(4. 5
kgt . m, 33l bf f t )
@ WASHER
Repl ace.
@ SET SCREW
@ SPRI NG L. 27. 4 mm 11. 08 i n. l
@ STEEL BALL
@ 16x 26 x 7 mm ol L SEAL
Repl ace.
@ 12 mm WASHER
Repl ace.
@ 12 mm DRAI N PLUG
39 N.m lil.o kst.m,29 lbf.ft)
@ SPRI NG L. 23 mm (0. 91
i n. ) {BLACK)
@ 8 mm FLANGE BOLT
27 N. m {2. 8 kgt . m. 20l bt . f t )
@ TRANSMISSION HANGER A
@ TRANSMISSION HANGER
@ OIL GUIDE PLATE M
@ 82 mm sHlM
Sel ect i on.
@ SUGTI oN GUI DE
@ crRcLrP
@ OIL PUMP STRAINER
D SPRI NG 1. 23 mm
(0. 91
i n. )
(SI LVERT
@ SPRI NG 1. 32 mm {1. 26 i n. }
(E
WASHER
Repl ace.
O BACK.UP LIGHI SWITCH
@ TRANSMISSION HOUSING
(cont' d)
13- 15
Manual Transmi ssi on
Transmission Disassembly
(cont'd)
Exploded View-Clutch Housing
61
- \
@
I
@
-.'A ^-- -,--@
@--=-ssR-'-,
-.-e
"
e..,
-
@'
FJ-.-
*--"-"*9
\n
1-----.-'
S:.-------t
^Qg- -_@
trE)
13- 16
O coUNTERSHAFTASSEMBLy
O 68 mm SNAP RING
1O
MAINSHAFT ASSEMBLY
O 64 mm SPRING WASHER
O otL GUrDE TUBE
G] REVERSE SHAFT HOLDER
O REvERSE GEAR sHAFT
O THRUST wASHER
9 20 x25 x 26.5 mm NEEDLE BEARING
.O REVERSE IDLER GEAR
O 34 mm SEALING BOLT
69 N.m (7.0
kgf.m,51 l bf.ft)
(n
8 mm WASHER
Repl ace.
d0 8 mm FLANGE BOLT
34N m
(3.5
kgf.m,25l bf.tr)
O 14 x 20 DowEL PtN
(}
SHIFT FORK ASSEMBLY
O SHIFT ARM ROD ASSEMBLY
( l 8x, l 0Pl N
(}
SELECT RETURN SPRING
@ CLUTCH RELEASE HANGER
ED RELEASE HANGER SPRING
(}
8 mm SPECIAL BOLT
27 N. m {2. 8 kgf m. 20 l bf . f t }
@ EREATHER PLATE
@ 6 mm FLANGE BOLT
12 N m
(1. 2
kgf . m, 8. 7 l bf . f t l
] 6 mm FLANGE BOLT
12 N. m
{1. 2 kgf , m, 8. 7 t bf . f t l
q'
RELEASE BEARI NG GUI DE
@ 28 x
il3
x 7 mm OIL SEAL
Repl ace.
' 8 x 6 3 Pl N
0 10 mm FLANGE BOLT
44 N. m 14. 5 kgt . m, 33 l bt . f t )
@ CLUTCH HOUSI NG
@ 1.2 SHIFT FORK
O REVERSE sHIFT FoRK
QA T-2 SHIFT LEVER
@ MAGNET
(cont' d)
13-17
Manual Transmi ssi on
Transmission Disassembly
(cont'd)
Special Tools Required
.
Fl ange hol der 07RAB- TB40108
.
Adj ust abl e bear i ng
pul l er , 20 40 mm 07736- 4010008
.
Mai nshaft hol der 07PAB-0014300
.
Hol der handl e 07JAB- 001020A
Rear Gover Removal
1. Remove the four bol t, and remove the shi ft l ever
housi ng.
2. Lower the shi ft rod
(A),
then remove the 8 mm
speci al bol t
(B),
spri ng washer
(C),
and shi ft arm B
( D) .
B 9
E E
_ l
13- 18
3. Remove the I mm fl ange bol ts i n a cri sscross
pattern i n several stePs,
Remove the rear cover {A) and 14 x 20 dowel pi ns
{ B) .
Remove the shi ft rod tube and O-ri ngs from the
rear cover.
R
t l
l t
l t
l l
g
6. Rai se the 27 mm l ocknut tab from the
qroove
i n the
secondarv shaft.
Instal l the speci al tool onto the compani on fl ange,
and l oosen the 27 mm l ocknut.
7.
a' ::.1-.:,
8. Remove the 27 mm l ocknut
(A),
spri ng washer
(B).
back- up r i ng
( C) ,
and O- r i ng
{ D) ,
Remove the compani on fl ange
(A)
usi ng a
commer ci al l y avai l abl e bear i ng
pul l er ( B)
as shown.
(cont' d)
13- 19
Manual
Transmi ssi on
Transmission
Disassembly {cont'd}
10. Remove t he oi l seal .
1 l . Remove the secondary shaft
(A)
from the rear
cover
(B)
usi ng a press (C)
as shown.
' 12.
Remove t he bal l bear i ng
( D) f r omt he r ear cover '
13-20
13. Remove the beari ng outer race
(A)
and shi m
(B)
from the rear cover
(C).
Remove the beari ng outer race
(A)
from the rear
cover
(B)
usi ng the speci al tool s as shown.
-I6
SLIDE HAMMER
(commerci al l y avai l abl e)
' 14.
Transmission Housing Removal
l . Remove t he oi l pump gear
shaf t and oi l pump gear .
I
- l
l'-"1
t l
H
2. Rai se the 29 mm l ocknut tab from the
qroove
i n the
countershaft.
13-21
3. I nst al l t he speci al l ool ont o t he mai nshaf t spl i ne,
and l oosen the 29 mm l ocknut
(l eft-hand
threads).
07PAB-001A300
4. Remove the 29 mm l ocknut and spri ng washer,
Manual Transmi ssi on
Transmission Disassembly
(cont'd)
Remove the needl e beari ng
(A)
usi ng a
commer ci al l y avai l abl e bear i ng
pul l er ( B)
as shown.
Remove the secondary dri ve
gear (A)
usi ng a
commer ci al l y avai l abl e bear i ng
pul l er ( B)
as shown.
13-22
7. Remove the 6 mm fl ange bol ts, then remove the oi l
pump pl ate (A),
spri ng, steel bal l , and oi l
pump
rotors
(B).
g @
^--.----...:
I
u.
w
8. Remove t he dr ai n
pl ug ( A) ,
f i l l er pl ug ( B) ,
12 mm
drai n pl ug (C),
washers, set screws
(D),
spri ngs,
steel bal l s, and
pi ck-up sensor
(E).
1 1 .
bd
Remove the 8 mm tl ange bol ts i n a cri sscross
oattern i n several steos.
' @
Remove the transmi ssi on
dowel
pi ns (A).
housi ng and 14 x 20
- e e e e ? F
wd"'m
' 12.
Remove the beari ng outer race
(A)
usi ngthe
speci al tool as shown, then remove the shi m
(B)
and oi l gui de pl at e
S.
3/ 8"
. 16
SLI DE HAMMER
(commerci al l v
avai l abl e)
Remove t he 16x26x7 mm oi l seal f r om t he
t r ansmi ssi on housi ng.
(cont' d)
07736-A010008
13-23
Manual Transmi ssi on
Transmission Disassembly
(cont'dl
Remove the ci rcl i p
(A).
then remove the sucti on
gui de ( B)
and oi l
pump
st r ai ner
( C) f r om
t he
t r ansmi ssi on housi ng.
Remove the 82 mm shi m(s)
(A)
and oi l gui de pl ate
M.
@*-^
14.
15.
ti.-
,
lil:l61lt
13-24
L
16. Remove t he oi l gui det ube( A) andmagnet ( B) .
' 17.
Remove the I mm fl ange bol t and washer, then
remove the reverse shaft hol der
(A),
thrust washer
(B),
reverse
gear
shaft
(C),
and needl e beari ng
(D).
19.
18. Remove t he 10 mm f l ange bol t , t hen r emove t he I
x 63 pi n (A)
and l -2 shi ft l evers
(B).
Remove the 5 x 25 spri ng pi n (B)
from shi ft arm A
wi th a 5 mm pi n dri ver, then remove the shi ft rod
(c).
Remove the shi ft arm A from the i nterl ock
(D),
then
remove the sel ect return spri ng
(E)
and the 8 X 40
pi n ( F) .
20.
t -
.J----r--..-
\ , /
22.
21. Remove t he 1- 2 shi f t pi ece.
Remove the 34 mm seal i ng bol t
(A)
from the cl utch
nous I ng.
Expand the 68 mm snap ri ng
(B)
on the
countershaft bal l beari ng, and remove i t from the
gr oove
usi ng a
pai r of snap
r i ng pl i er s.
Remove the mai nshaft, countershaft, and shi ft
forks assembl i es
(C),
and remove the 64 mm spri ng
washer, reverse i dl er gear (D),
thrust washer.
(conl ' d)
23.
24.
13-25
Manual Transmi ssi on
Transmission Disassembly
(cont'dl
Remove the 6 mm fl ange bol ts and rel ease beari ng
gui de ( A) .
Remove the I mm speci al bol ts, cl utch rel ease
hanger
( B)
and r el ease hanger spr i ng
( C) .
Remove the 6 mm fl ange bol ts and breather
pl ate
( D) .
Remove the oi l seal from the cl utch housi ng.
26.
24.
27.
13-26
Mainshaft Assembly Clearance Inspection
NOTE:
.
l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
.
Supportthe beari ng i nner race, and
push down on
the mai nshaft as shown.
1 . Measure the cl earance between 3rd gear (A)
and
t he bal l bear i ng
( B)
wi t h a f eel er
gauge,
.
l f the cl earance i s more than the servi ce l i mi t, go
to steD 2.
.
l f the cl earance i s wi thi n the servi ce l i mi t,
go to
step 4.
Standard: 0.05-0.19 mm
(0.002
0.007 i n.l
Servi ce Li mi t: 0.3 mm
(0.012
i n.)
3.
2. l vl easure the di stance of the di stance col l ar.
.
l f di stance i s notwi thi n the standard, repl ace the
di stance col l ar wi th a new one
.
l f di st ance i swi t hi nt he st andar d,
got o st ep3
Standard: 35.23 35.28 mm
(1.387
1.389 i n.)
Measure the thi ckness of 3rd
gear.
.
l f t het hi cknessof 3r d gear i s l esst hant heser vi ce
l i mi t, repl ace 3rd gear wi th a new one.
.
l f t het hi ckness of 3r d gear i swi t hi nt he ser vi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one,
Standard: 35.09-35.17 mm
(1.381
1.385 i n.l
Servi ce Li mi t: 34.97 mm {1.377 i n.)
(cont' d)
13-27
Manual Transmi ssi on
Mainshaft Assembly Clearance Inspection
{cont'd)
4. Measure the cl earance between 4th gear (A)
and
di st ance col l ar
( B) .
l f t he cl ear ance i s mor e t han t he
servi ce l i mi t, go
to step 5.
Standard: 0.06-0.19 mm {0.002-0.007 i n.}
Servi ce Li mi i : 0.3 mm
10.012 i n.)
B
Measure di stance
O on the di stance col l ar.
.
l f di st anceO i s not wi t hi nt hest andar d, r epl ace
the di stance col l ar wi th a new one.
.
l f di st anceO i swi t hi nt he st andar d, got o st ep6.
Standard; 32.03-32.08 mm
{1.261 1.253 i n.l
13-28
6. fMeasure the thi ckness of 4th gear.
.
l f t het hi ckness of 4t h gear i s l esst han ser vi ce
l i mi t, repl ace 4th gear wi th a new one.
.
l f the thi ckness of 4th gear i swi thi n the servi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one.
Standard: 31.89 31.97 mm
(1.256
1.259 i n.l
Servi ce Li mi t: 31.77 mm
{1.251 i n.)
7. Measure the cl earance between 5th gear (A)
and
the di stance col l ar
(B).
l f the cl earance i s more than
the servi ce l i mi t, go
to step 8.
Standard: 0.06-.0.19 mm
(0.002-0.007
i n.l
Servi ce Li mi t: 0.3 mm {0.012 i n.}
,1.,,,,.'---
....
-'.--.-..,,a.'
8, Measure di stance O on the di stance cotrar.
.
l f di st ance O i s not wi t hi nt hest andar d, r epl ace
the di stance col l ar wi th a new one.
.
l f di st ance@ i swi t hi nt he st andar d,
got ost ep9.
Standard: 32.03 32.08 mm {1.251-
1.263 i n.l
Measure the thi ckness of 5th gear.
.
l f the thi ckness of 5th gear i s l ess than the servi ce
l i mi t, repl ace sth gear wi th a new one.
.
l f the thi ckness of 5th gear i s wi thi n the servi ce
l i mi t, repl ace the 5th/6th synchro hub wi th a new
one.
Standard: 31.89 31.97 mm {1.256- 1.259 i n.)
Servi ce Li mi t: 31.77 mm
(1.251
i n.)
9.
t : - - -
10. Measure the cl earance between 6th
gear (A)
and
the mai nshaft
(B).
l f the cl earance i s more than the
servi ce l i mi t, go to step 11.
Standard: 0.06 0.19 mm
(0.002-0.007
i n.l
Servi ce Li mi t: 0.3 mm
(0.012
i n.)
Measure the thi ckness of 6th
gear.
.
l f thethi ckness of 6th
gear i s l essthan the servi ce
l i mi t, repl ace 6th gear wi th a new one.
.
l f thethi ckness of 6th
gear i s wi thi n the servi ce
l i mi t, repl ace the 5th/6th synchro hub wi th a new
one.
Standard: 28.89 28.97 mm
(1.137-1.141
i n.)
Servi ce Li mi t: 28.77 mm 11.133
i n.
1 1 .
- - - - . - l
13-29
Manual Transmi ssi on
Mainshaft Disassembly
l . Support bal l beari ng
(A)
wi th a commerci al l y
avai l abl e beari ng separator, and remove the bal l
beari ng usi ng a press
as shown.
Remove t he 3r d gear , 35
x 30 x 35 mm needl e
beari ng. di stance col l ar, doubl e cone synchro,
synchro spri ng, and 3rd/4th synchro sl eeve.
Support 4th gear (A)
wi th a commerci al l y avai l abl e
beari ng separator, and remove the 3rd/4th synchro
hub
(B),
doubl e cone synchro, and 4th gear
usi ng a
oress as snown,
PRESS
13-30
4.
1.
Remove the 42 x 47 x 30.5 mm needl e beari ng,
di stance col l ar,sth gear, synchro ri ng, and synchro
spr i ng.
Support 6th gear (A)wi th
a commerci al l y avai l abl e
beari ng separator, and remove the 5th/6th synchro
hub/sl eeve
(B),
synchro ri ng, synchro spri ng. and
6th
gear
usi ng a press
as shown.
Remove the 39 x 44 x 26 mm needl e beari ng.
Support bal l beari ng
(A)wi th
a commerci al l y
avai l abl e beari ng separator, and remove the bal l
beari ng usi ng a press
as shown.
PRESS
Mainshaft Inspection
1. Inspect the
gear surface and the beari ng surface for
wear ano oamage.
2. Measure the mai nshaft at Doi nts
A, B, C, and D. l f
anv Dart of the mai nshaft i s l ess than the servi ce
l i mi t, repl ace i t wi th a new one.
Standard:
A
(Rear
cover end ball bearing contact area):
27. 987 28. 000 mm
( 1. 1018
1. 1024i n. 1
B
{4th/5th
gears contact area}:
34.987-35.000 mm
(1.3774
1.3780 i n.)
C
(6th gear contact area):
38.984-39.000 mm
(1.5348
1.5354 i n.)
D
(Clutch
housing end ballbearing coniact areali
28.002 28.015 mm
(1.102/r
1.1030i n.1
Service Limit:
A: 27. 94 mm
( 1. 100
i n. )
B: 34.94 mm
(1.376
i n.)
C: 38.94 mm
(1.533
i n.)
D: 27. 95 mm
( 1. 100
i n. )
Cl ut ch housi ng
end
Rear cover
eno
3. Inspect for runout by supporti ng both ends of
mai nshaft. Rotate the mai nshaft two compl ete
revol uti ons when measuri ng the runout. l f the
runout i s more than the servi ce l i mi t. repl ace the
mai nshaft wi th a new one.
Standard: 0.02 mm 10.001 i n.l max.
Servi ce Li mi t: 0.05 mm
{0.002
i n.}
13-31
Manual Transmi ssi on
Mainshaft Reassembly
Exploded View
Thin edge of the outer
lacq faces 6th goar
Thin edge of the outer
race faces 3rd
gear
ANGULAR BALL BEARING
Check f or wear and operat i on.
Not e t he di rect i on of
i nst al l at i on.
/,,,sYNcHRo
RING
SYNCHRO
SPRING
5TH/6TH
HUB
SYNCHRO
5TH/6TH
SYNCHRO
SLEEVE
SYNCHRO SPRING
SYNCHRO RING
3 5 x 4 0 x 3 5 mm
NEEOLE BEARING
Check f or wear
ano operat | on.
28 x 35 x 36. 2 mm
DISIANCE COLLAR
\urroro^
3 9 x 4 4 x 2 6 mm
NEEDLE BEARI NG
Check f or wear
ano opet at on.
"4..
,6, i9;*==---28x64x18mm
(a
s}*d5
Rtl*,?:iL'$f."
\ | /
-7\ - of i nsral l at i on.
\ 7
\ oammsPRr Nc
MAI NSHAFT
NEEOLE BEARING
Check for wear
ano operaton.
3 5 x 4 2 x 6 8 mm
DISTANCE COLLAR
sTH GEAR
42 x 47 x 30.5 mm
NEEDLE BEARING
Check for wear and operati on.
'//,,.3RD
GEAR
DOUBLE CONE SYNCHRO
SYNCHRO SPRI NG
3RD/ 4TH SYNCHRO SLEEVE
SYNCHRO HUB
SYNCHRO SPRING
CONE SYNCHRO
4TH GEAR
x 47 x 30.5 mm
13-32
WASHER
Special Tools Required
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment, 30 mm l .D.07746-0030300
NOTE: Refer to the Expl oded Vi ew as needed duri ng
thi s
procedure.
' 1.
Support 2nd
gear (A)
on steel bl ocks, then i nstal l
t he bal l bear i ng { B) usi ng t he speci al t ool s and a
press
as shown.
NOTE: The thi n edge of the outer race faces 6th
gear ,
I nst al l t he 39 x 44 x 26 mm needl e bear i ng, 6t h
gear ,
synchro ri ng, and synchro spri ng.
Instal l the 5th/6th synchro hub
(A)
and sl eeve
(B)
by
al i gni ng t he st ops
( C) .
2.
PRESS
PRESS
4. Press the 5th/6th synchro hub usi ng the speci al tool
as shown. After i nstal l i ng, checkthe operati on of
the 5th/6th svnchro hub and sl eeve.
077,16-0030100
Instal l the synchro spri ng, synchro ri ng, 42 x 47 x
30.5 mm needl e beari ng,5th
gear, di stance col l ar,
and 4th gear.
I nst al l t he doubl e cone synchr o
( A)
and synchr o
spr i ng { B) as shown.
{cont' d)
13-33
Manual Transmi ssi on
' 1.
Mainshaft Reassembly
(cont'd)
Instal l the 3rd/4th synchro hub
(A)
and sl eeve
(B)
by
al i gni ng the stops
(C).
Press the 3rd/4th synchro hub usi ng the speci al tool
as shown. After i nstal l i ng, check the operati on of
the 3rd/4th synchro hub and sl eeve
07746-0030'100
8.
PRESS
13-34
9. Instal l the doubl e cone synchro
(A)and
synchro
sprl ng
(B)
as shown.
I nst al l t he di st ance col l ar
( A) , 35
x 40 x 35 mm
needl e bear i ng
( B) ,
and 3r d gear ( C) .
10.
11. I nst al l t heangul ar bal l bear i ng
( A) wi t ht het hi n
edge of the outer race faci ng 3rd
gear (B).
Use the
speci al tool and a press.
PRESS
Shift Arm Rod Assembly
Disassembly/Reassembly
Refer to reassembl i ng, cl ean al l the
parts i n sol vent, dry
them, and appl y l ubri cant to any contact
parts.
5 x 25 SPRI NG PI N
SHIFT ARM A
13-35
Manual Transmi ssi on
Gountershaft Assembly Glearance Inspection
NOTE: l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
1 . Measure the cl earance between 2nd gear (A)
and
the countershaft
(B)
wi th a feel er gauge.
l f the
cl earance i s more than the servi ce l i mi t, go
to
step 2.
Standard: 0.04 0.17 mm
(0.002
0.007 i n.l
Servi ce Li mi t: 0.3 mm 10.012 i n.)
13-36
2. Measure the thi ckness of 2nd gear.
.
l f t het hi cknessof 2nd gear i s l esst hant he
servi ce l i mi t, repl ace 2nd gear wi th a new one.
.
l f t het hi cknessof 2nd gear
i swi t hi nt he ser vi ce
l i mi t, repl ace the 1sV2nd synchro hub wi th a new
one.
Standard: 32.88-32.96 mm
(1.294
1.298 i n.)
Servi ce Li mi t: 32.76 mm
{1.290 i n.)
Measure the cl earance between
' 1st
gear (A)
and
the di stance col l ar
(B).
l f the cl earance i s more than
the servi ce l i mi t, go to step 4.
Standard: 0.04 0.22 mm
(0.002
0.009 i n.)
Servi ce Li mi t: 0.3 mm
(0.012
i n.)
--:-
-
--=-
=>
4. Measure di stance O on the di stance cottar.
.
l f di stance O i s notwi thi nthe standard, repl ace
the di stance col l ar wi l h a new one.
.
l f di st anceO i swi t hi nt he st andar d,
got ost ep 5.
Standard: 28.03 28.08 mm
(1.104
1.106 i n.l
5. Measure the thi ckness of 1st gear.
.
l f t het hi ckness of 1st gear i s l esst hant heser vi ce
l i mi t, repl ace 1st gear wi th a new one.
.
l f thethi ckness of 1st gear i swi thi n the servi ce
l i mi t, repl ace the 1sV2nd synch ro hub wi th a new
one.
Standard: 31.18
-
31.26 mm {1.22A-
1-231 i n.l
Servi ce Li mi t: 31.06 mm {1.223
i n.)
6. Measure the cl earance between reverse
gear (A)
and the di stance col l ar {B). l f the cl earance i s more
than the servi ce l i mi t, go to step 7.
Standard: 0.04-0.22 mm
(0.002-0.009
i n.)
Servi ce Li mi t: 0.3 mm
(0.012
i n,.
Measure di stance @ on the di stance col l ar.
.
l f di stance @
i s notwi thi n the standard, repl ace
the di stance col l ar wi th a new one.
.
l f di st anceO i swi t hi nt he st andar d,
got o st ep8.
Standard: 25.53 25.58 mm {1.005 1.007 i n.)
7.
(cont' d)
13-37
Manual Transmi ssi on
Countershaft Assembly Clearance
lnspection
(cont'dl
8. fvl easure the thi ckness of reverse gear.
.
l f the thi ckness of reverse gear
i s l ess than the
servi ce l i mi t, repl ace reverse gear
wi th a new one.
.
l f thethi ckness of reverse gear i s wi thi n the
servi ce l i mi t, repl ace the reverse synchro hub
wi th a new one.
Standard: 26.38 26.46 mm
(1.039
1.042 i n.)
Servi ce Li mi t: 26.26 mm
(1.034
i n.)
13-38
Countershaft Disassembly
1. Remove the
Remove the i nner race
(A)
usi ng a commerci al l y
avai l abl e beari ng separator and a
press
as shown.
needl e beari ng.
@
P
ruW
ffi
3. Rai se the 27 mm l ocknut tab from the
groove i n the
countershaft.
4. Securel y cl amp the 4th and 5th gears i n a bench
vi se wi th wood bl ocks
(A).
Remove t he 27 mm l ocknut
( B)
and spr i ng washer
(c).
/--N
| ' . ' l
)'{Y
6. Remove the bal l beari ng usi ng a press as shown.
PRESS
7. Remove the remai ni ng
parts from the countershaft.
13-39
Manual Transmi ssi on
Gountershaft lnspection
1. Inspect the gear
surface and the beari ng surface for
wear and damage.
2. fMeasure the countershaft at
poi nts
A. B, C, and D. l f
any part
of the countershaft i s l ess than the servi ce
l i mi t, repl ace i t wi th a new one.
Standard:
A
(Rear
cover end needle bearing contact areal:
30. 020 30. 029 mm
( 1. 1819- 1. 1822
i n. )
B
(Transmission
housing end needle bearing
contact areal:
3,1.002 34.018 mm
(1.3387
1.3393i n|
C l2nd
gear
contast area):
'tr3.98i[
44.000 mm |'1.7317
1.1323 in.l
D
{Clutch housing end ball beafing contact areal:
28.002
-
28.015 mm
11.1024- 1.1030 i n.l
Service Limit:
A: 29.97 mm
(1.180
i n.)
B: 33.95 mm
(1.337
i n.)
C:
/8.93
mm
(1.730
i n.l
D: 27.95 mm 11.100 i n.l
Rear cover
end
13-40
3. Inspectfor runout by supporti ng both ends of
countershaft. Rotate the countershaft two compl ete
revol uti ons when measuri ng the runout. l f the
runout i s more than the servi ce l i mi t, reDl ace the
countershaft wi th a new one.
Standard; 0.02 mm
(0.001
i n.) max.
Servi ce Li mi t: 0.05 mm
(0.002
i n.)
Countershaft Reassembly
Exploded View
@--
/A
r3r*
28x58x l 8 mm
BALL BEARING
Check f or wear
ano operaoon.
4 4 x 5 0 x 2 8 mm
NEEDLE BEARI NG
Check f or wear and
operat i on.
FRICTION DAMPER
SPRING
1ST/2ND SYNCHRO SLEEVE
(cont' d)
27 mm LOCKNUT
Repl ace.
1 6 2 - 0 - 1 5 2 Nm
116. 5- 0- - 16. 5kgt . m,
1 1 9 * 0 - 1 1 9 | b f . f t )
l ST/2ND SYNCHRO HUS
/R\
i.wj------=..-34 x s7 x 20 mm
X
sYNcHRo SPRTNG
a*'
:|::513;:*|.""0
DOUBLE CONE
SYNCHRO
FRICTION DAMPER
l ST GEAR
5 1 x 5 7 x 2 3 mm
NEEDLE BEARING
Check f or wear and
operat i on.
REVERSE SYNCHRO SLEEVE
38 x, (l x 26 mm
NEEDLE BEARING
Check f or wear and
operat i on.
REVERSE GEAR
SYNCHRO RING
SYNCHRO SPRING
REVERSE SYNCHRO HUB
mm SPRING wASHER
CONE
13-41
Manual Transmi ssi on
Countershaft Reassembly
(cont'd)
Special Tools Required
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment, 30 mm 1.D.07746-0030300
.
Aftachment, 35 mm l .D.07746-0030400
NOTE: Refer to the Expl oded Vi ew as needed duri ng
thi s
procedure.
1. I nst al l t he 44 x 50 x 28 mm needl e bear i ng and 2nd
gear ,
2, Instal l the fri cti on damper
{A), doubl e cone synchro
( B) ,
and synchr o spr i ng
( C)
as shown.
I nst al l t he 1sV2nd synchr o hub
( A)
and sl eeve
( B)
as
snown.
13-42
4. I nst al l t he synchr o spr i ng
( A)
and doubl e cone
synchro {B) as shown.
Instal l the fri cti on damper on the 1st gear,
then
i nstal l the
' 1st
gear
by al i gni ng the grooves
as
snown.
7.
I nst al l t he 5l x 57 x 23 mm needl e bear i ng, di st ance
col l ar , and 38 x 43 x 26 mm needl e bear i ng.
Instal l the reverse gear.
l nst al l t he synchr o r i ng and synchr o spr i ng.
Instal l the reverse synchro hub
(A)
and sl eeve {B).
8.
9.
1 1 .
10. I nst al l t he bal l bear i ng { A) usi ng t he speci al t ool s
ano a oress as snown.
Secur el y cl amp t he 4t h and 5t h
gear s
i n a bench
vi se wi th wood bl ocks
(A).
I nst al l t he spr i ng washer
( B)
and 27 mm l ocknut
( C) .
Ti ghten the 27 mm l ocknut to the speci fi ed-val ue.
Tor que: 162- 0- - t 62Nm
( 16. 5- * 0- - 16. 5kgt . m,
119- t 0- 119| bf . f t )
(cont' d)
' t 2.
13.
PRESS
13-43
Manual Transmi ssi on
Gountershaft Reassembly
(cont'd)
14. Stake the l ocknut tab i nto the
groove.
15. l nst al l t he needl e
speci al t ool s and
beari ng i nner race
(A)
usi ng the
a
press
as shown.
PRESS
07746-0030400
13-44
beaf l ng.
@
16. l nstal l the needl e
1 .
Secondary Shaft Disassembly
Remove the tapered rol l er beari ngs usi ng a
commerci al l y avai l abl e beari ng separator and a
press as shown.
PRESS
Secondary Shaft Inspection
' 1.
Inspect the
gear
surface and the beari ng surface l or
wear and damage.
2. Measure the countershaft at
poi nts A, B, and C. l f
any part of the secondary shaft i s l ess than the
servi ce l i mi t, repl ace i t wi th a new one.
Standard:
A
{Bal l beari ng contact area}:
31.002
-
31.013 mm 11.2205
-
1.2210 in.l
B {Plopeller shaft end tapered roller bearing
contact areal :
41. 002 41. 018 mm
{ 1. 6142
1. 6149i n. )
C
(Transmission
end taper6d roller bearing
contact areal:
35.009 35.025 mm
(r.3783
-
1.3790 i n.)
Service Limit:
A: 30.95 mm {1.219 i n.)
B: 40.95 mm {1.612 i n.)
C: 38.94 mm {1.376 i n.)
(cont' d)
13-45
Manual Transmission
Secondary Shaft Inspection
(cont'd)
l nspect for runout by supporti ng both ends of
secondary shaft. Rotate the secondary shaft two
compl ete revol uti ons when measuri ng the runout.
l f the runout i s more than the servi ce l i mi t, repl ace
the secondary shaft wi th a new one.
Standard: 0.02 mm
(0.001
i n.) max.
Servi ce Li mi t: 0.05 mm {0.002 i n.l
Rotate two compl ete
revol uti ons.
13-46
Secondary Shaft Reassembly
Special Tools Requird
.
Attachment. 45 mm 07947-6890300
.
Beari ng attachment 07LAD-PW50601
' 1.
I nst al l t he t aper ed r ol l er bear i ngs usi ng t he speci al
tool and a Dress as shown,
-6890300
07LAD-PWs0601
Shift Forks Clearance Inspection
NOTE: l f repl acement i s requi red. al ways repl ace the
synchro sl eeve and hub as a set.
1. Measure the cl earance between the each shi ft fork
(A)
and i ts matchi ng synchro sl eeve
(B).
l f the
cl earance exceeds the servi ce l i mi t, go to step 2.
Standard: 0.35 0.65 mm {0.014 0.026 i n.)
Servi ce Li mi t: 1.00 mm
(0.039
i n.)
2. Measure the thi ckness of the shi ft fork fi noers.
.
l f the thi ckness of the shi ft forkfi nger i s l essthan
the standard, repl ace the shi ft fork wi th a new
one.
.
l f t het hi ckness of t he shi f t f or kf i nger i swi t hi n
the standard. repl ace the synchro sl eeve wi th a
new one.
Standard:
1-2 Shi ft Fork: 7.4-7.6 mm
(0.29
0.30 i n.)
3-4. 5-6, Reverse Shift Fork:
6.2 6.i [ mm
10.2i + 0.25 i n.]
3. Measure the cl earance between each shi ft fork,
reverse shi ft pi ece and shi ft arm A. l f the cl earance
exceeds the servi ce l i mi t, go to step 4.
Standard: 0.2 0.6 mm
10.008-0.024 i n.)
Servi ce Li mi t: 0.7 mm {0.028 i n.)
4. Measure the wi dth ofthe shi ft arm A.
.
l f t hewi dt h of t he shi f t ar m Ai s l esst hant he
servi ce l i mi t, reDl ace the shi ft arm A wi th a new
one.
.
l f t hewi dt h of t heshi f t ar m Ai swi t hi nt heser vi ce
l i mi t, reol ace the shi ft fork or the reverse shi ft
pi ece wi th a new one.
Standard: 16.8 17.0 mm
{0.661 0.669 i n.}
Servi ce Li mi t: 16.7 mm
(0.657
i n.)
(cont' d)
13-47
Manual Transmi ssi on
Shift Forks Clearance Inspection
(cont'dl
Measure the cl earance between the 1-2 shi ft l ever
and each shi ft fork and shi ft
pi ece. l f the cl earance
exceeds the servi ce l i mi t, go to step 6.
Standard: 0-0./r mm
(0-0.016
i n.l
Service Limit: 0.5 mm
(0.020
in.)
I . 2 SHI FT FORK
1-2 SHIFT PIECE
13-48
SHIFT PIECE
6. Measur et hewi dt h of t he 1- 2 shi f t l ever .
.
l f t hewi dt h of t he 1- 2 shi f t l ever i s l esst hant he
servi ce l i mi t, repl ace the 1-2 shi ft l ever wi th a
new one.
.
l f t hewi dt h of t he 1- 2 shi f t l ever i swi t hi nt he
servi ce l i mi t, repl ace the shi ft fork or shi ft pi ece
wi th a new one.
Standard: 17.0
-
17.2 mm {0.669-0.677
i n.)
Servi ce Li mi t: 16.9 mm
(0.665
i n.)
REVERSE
Shift Forks Disassembly/Reassembly
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them, and appl y l ubri cant to any contact
parts.
1. 2 SHI FT FORK
3-, 1SHI FT PI ECE
x 22 SPRING PIN
Repl ace.
REVEFSE SHIFT PIECE
s-6 sHtFT 3-4 SHTFT
(
!=n6.+
13-49
Manual Transmi ssi on
Synchro Ri ng and Gear Inspecti on
1. Inspect the i nsi de of the synchro ri ng
(A)
for wear.
Inspect the synchro sl eeve teeth and matchi ng
teeth on the synchro ri ng
(B)
for wear
(rounded
off).
Inspect the synchro sl eeve teeth
(C)
and matchj ng
teeth on the gear for wear
(rounded
off).
@"
I
I
GOOD WORN
t l
WORN
\ /
GOOD
13-50
4. Inspect the
gear hub thrust surface 1A)
for wear.
Inspect the cone surface
(B)
for wear and
rougnness,
Inspect the teeth on al l gears (C)
for uneven wear,
scori ng,
gal l i ng. and cracks.
Coat the cone surface of the gear (B)
wi th oi l , and
pl ace the synchro ri ng on i t. Rotate the synchro ri ng,
maki ng sure that i t does not sl i p.
Measure the cl earance between the synchro ri ng
(A)
and
gear (B)
al l the way around. Hol d the
synchro ri ng agai nst the
gear evenl y whi l e
measuri ng the cl earance. l f the cl earance i s l ess
than the servi ce l i mi t, repl ace the synchro ri ng and
syncnro cone.
Synchro Ring-to-Gear Clearance
Standard:
5th, 6th gear: 0.75
-
1.00 mm
(0.030-
0.039 i n.)
Reverse
gear: 0.85- 1.10 mm
(0.033
0.043 i n.l
Servi ce Li mi t:0.4 mm
(0.016
i n.)
7 .
6.
8.
Double Cone Synchro-to-Gear Clearance
Standard:
O: Outer Synchro Fing to Synchro Cone
1st,2nd, gear:0.70
1.09 mm
(0.028
0.043 i n.)
3rd.4th gear:0.90
1.39 mm
(0.035
0.055 i n.)
@: Synchro Cone to Gear
l st,3rd,4th gear: 0.50 1.04 mm
2nd gear;
(0.020
0.04r i n.)
0.65 1.78 mm
{0.026 0.070 i n.l
O: Outer Synchro Ring to Gear
l st,3rd,4th gear: 0.95 1.68 mm
(0.037
0.066 i n.l
0.70
-
1.82 mm
(0.028
0.072 i n.l
2nd gear:
Service Limit:
O: 0.3 mm
(0.012
i n.)
O: 0. 3 mm { 0. 012 i n. )
O: 0.6 mm
{0.024 i n.)
o
I
Synchro Sleeve and Hub lnspection
and Reassembly
1. l nspect gear teeth on al l synchro hubs and synchro
sl eeves for rounded off corners, whi ch i ndi cate
wear .
2. Instal l each synchro hub
{A} i n i ts mati ng synchro
sl eeve
(B),
and check for freedom of movement. Be
sure to match the three sets of l onger teeth
(C) (120
degrees apart) on the synchro sl eeve wi th the three
sets of deeper grooves (D)
i n the synchro hub. Do
not i nstal l the synchro sl eeve wi th i ts l onger teel h
i n the 1sV2nd synchro hub sl ots {E) because i t wi l l
damage the spri ng ri ng.
NOTE: l f repl acement i s requi red, al ways repl ace
the synchro sl eeve and synchro hub as a set.
B
13-51
Manual Transmission
Oil Pump Glearance Inspection
1 . Measure the radi al cl earance between the i nner
rotor
(A)
and the outer rotor
(B).
l f the cl earance
exceeds the servi ce l i mi t, repl ace the
pump rotor'
lnner Rotor-to-Outer Radial Clearance
Standard: 0.14 mm 10.006 i n.l max
Servi ce Li mi i : 0.20 mm {0.008
i n.}
2. fvl easure the radi al cl earance between the outor
rotor
(B)
and the transmi ssi on housi ng
(C).
l f the
cl earance exceeds the servi ce l i mi t. repl ace the
pump
rotor.
Rotor-to-Transmission Housing Badial Clearance
Standard: 0.1 0.2 mm
(0.004
0.008 i n.l
Servi ce Li mi t: 0.22 mm 10.009 i n.)
13-52
3. Measur e t he axi al cl ear anceont he
pump
r ot or . l f
the cl earance exceeds the standard, sel ect the
appropri ate rotor for the correct cl earance from the
chart bel ow.
Rotor-to-Transmission Housing Axial Clearance
Standard: 0.03 0.07 mm
(0.001
0.003 i n.)
Outer and Inner Botor Set
Part Number Thickness
21168- PCY- 0000 9. 95 9. 97 mm
{ 0. 392 0. 393 i n. )
21169- PCY- o000 9. 93 9. 95 mm
( 0. 391
0. 392 i n. )
c 2' 1 170-PCY-0000 9. 9' l
- 9. 93
mm
( 0. 390
0. 391 i n. )
Secondary Shaft Preload Adjustment
1. I nst al l t he oi l gui de pl at e
S, shi m
( A)
and t he
beari ng outer race
(B)
on the transmi ssi on housi ng
(see
step 16 on page 13-58).
l nstal l the rear cover, then ti ghten the I mm fl ange
bol ts i n a cri sscross panern
i n several steps.
8 x 1. 25 mm
27 N.m
(2.8
kgf.m, 20 lbf.ft)
Rotate the secondary shaft i n both di recti ons to
seat the tapered rol l er beari ng.
Measure the turni ng torque ofthe secondary shaft
by rotati ng i t i n both di recti ons wi th a torque
wrench.
Standard: 1.86-2.84N' m
{19 29 kgf' cm.
16.5
-
25.2 l bf.i n)
5. l f the
prel oad
i s not wi thi n the standard, sel ect a
shi m that wi l l provi de
correct
prel oad.
Shi m
Part Number Thickness
41381-PCY-00000.90 mm
(0.0354
n.
B 41382-PCY-00000.93 mm
(0.0366
n.
c 41383-PCY-o0000.96 mm {0.0378n,
D 41384-PCY-o0000.99 mm
(0.0390
n.
E 41385-PCY-00001. 02 mm
( 0. 0402
n.
F 41386-PCY-00001. 05 mm
( 0. 0413
n.
41387-PCY-0000
' L08
mm
(0.0425
i n.
n 41388-PCY-00001. 1 1 mm
( 0. 0437
i n
41389-PCY-00001. 14 mm
( 0. 0449
i n
J 41390-PCY-00001. 17 mm { 0. 0461 i n
K 41391- PCY- 0000
'1.2O
mm 10.0472
L 41392-PCY-00001. 23 mm
( 0. 0484
n.
M 41393-PCY-00001 .26 mm
(0.0496
n.
N 41394-PCY-00001. 29 mm
( 0. 0508
n.
o 41395-PCY-00001. 32 mm
( 0. 0520
n.
P 41396-PCY-o0001. 35 mm { 0. 0531n,
o 41397-PCY-00001.38 mm
(0.0543
n.
R 41398-PCY-00001. 41 mm
( 0. 0555
i n. l
s 41399-PCY-00001. 44 mm
( 0. 0567
i n.
T 4' ]400-PcY-00001. 47 mm
( 0. 0579
i n. )
13-53
Manual Transmi ssi on
Mainshaft Thrust Clearance Adiustment
Special Tools Required
.
Mai nshaf t hol der 07GAJ' PG20110
.
Mai nshaft base 07GAJ-PG20130
1. I nst al l t he mai nshaf t assembl y i n t he cl ut ch
houst ng.
2. I nst al l t he oi l gui de pl at e M and 82 mm shi m( s)
( A)
i nto the transmi ssi on housi ng.
I nst al l t he t r ansmi ssi on housi ng ont o t he cl ut ch
housi ng, then ti ghten the 8 mm fl ange bol ts i n a
cri sscross
pattern i n several steps.
8 x 1.25 mm
27 N.m
(2.8
kgf m, 20 l bf.ft)
Attach the speci al tool to the mai nshaft as fol l ows:
.
Back-out the mai nshaft hol der bol t
(A)
and l oosen
t he t wo hex bol t s
( B) .
.
Fi t the hol der over the mai nshaft so i ts l i p i s
t owar ds t he t r ansmi ssi on.
.
Al i gn t he mai nshaf t hol der ' s l i p ar ound t he
groove at the i nsi de of the mai nshaft spl i nes,
then ti ghten the hex bol ts.
3.
4.
13-54
5. Seat the mai nshaft ful l y by tappi ng i ts end wi th a
pl ast i c hammer .
6. Thr eadt he mai nshaf t hol der bol t i n unt i l i t j ust
contacts the wi de surface of the mai nshaft base.
7 . Zerc a di al
gauge (A)
on the end of the mai nshaft.
07GAJ-PG20110
07GAJ-PG20130
Turn the mai nshaft hol der bol t cl ockwi se; stop
turni ng when the di al gauge has reached i ts
maxi mum movement. The readi ng on the di al
gauge i s the amount of mai nshaft end pl ay.
NOTE: Do not turn the mai nshaft hol der bol t more
than 60 degrees after the needl e of the di al
gauge
stops movi ng may damage the transmi ssi on.
l f the readi ng i s wi thi n the standard, the cl earance
i s correct. l f the readi ng i s not wi thi n the standard,
r echeck t he shi m t hi ckness.
Standard: 0.14
-
0.21 mm
(0.006
0.008 i n.)
9.
82 mm Shi m
Parts Number Thickness
23931-PR8-F0000. 60 mm
( 0. 0236
i n
B 23932-PR8-F0000.63 mm
(0.0248
n
c 23933-PR8-F0000. 66 mm
( 0. 0260
n
D 23934-PR8-F0000. 69 mm { 0. 0271n
E 23935-PR8-F0000.72 mm
(0.0283
n.
F 23936-PR8-F0000. 75 mm
( 0. 0295
n.
G 23937-PR8-F0000.78 mm
(0.0307
n.
n 23938-PR8-F0000. 81 mm
( 0. 0319
n,
23939-PR8-F0000. 84 mm
( 0. 0331
n,
J 23940-PR8-F0000, 87 mm
( 0. 0343
n.
K 23941-PR8-F000 0.90 mm {0.0354n.
23942-PR8-F000 0.93 mm
(0.0366
i n.
M 23943-PR8-F0000. 96 mm
( 0. 0378
i n
N 23944-PR8-F0000.99 mm
(0.0390
i n
o 23945-PR8-F0001. 02 mm
( 0. 0402
i n
P 23946-PR8-F000
' 1. 05
mm { 0, 0413 i n.
o 23947-PR8-F000 1. 08 mm { 0. 0425 i n.
R 23948-PR8-F0001. 11 mm
( 0. 0437
i n.
S 23949-PR8-F000
' 1. 14
mm
( 0. 0449
i n.
T 23950-PR8-F000 1. 17 mm
( 0. 0461
i n.
23951-PR8-F0001. 20 mm
( 0. 0472
i n.
Transmission Reassembly
Special Tools Required
.
Dri ver 07749-0010000
.
Attachment, 42 x 47 mm 07746-0010300
.
Attachment,62 x 68 mm 07746-0010500
.
Dri ver, 30 mm LD. 07946-M800000
.
Attachment, 35 mm l .D. 07965-5450500
.
Mai nshaft hol der 07PAB-0014300
.
Attachment, T2 x 75 mm 07746-0010600
.
Attachment, 40 x 50 mm LD. 07LAD-PW50601
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Fl ange hol der 07RAB- T84010B
.
Hol der handl e, 07JAB-0010204
Transmission Housing Installation
NOTE: Pri or to reassembl i ng, cl ean al l the parts
i n
sol vent, dry them, and appl y l ubri cate to any contact
surfaces.
1. I nst al l t he oi l seal
( A)
usi ng t he speci al t ool s.
Instal l the rel ease beari ng gui de (A),
the cl utch
r el ease hanger
( B) ,
r el ease hanger spr i ng
( C) ,
and
the breather ol ate
(D).
(cont' d)
2.
,,1<
D
,,
p\
'
)\d.
0
4.0-1t.5 mm
10. 16 0. 18 i n. l
1'3-55
Manual Transmi ssi on
Transmission Reassembly
(cont'd)
Instal l the thrust washer
(A)
and 64 mm spri ng
washer
(B).
69 N.m
(7.0
ksf m, 51 lbf.ft)
l nstal l the reverse i dl er gear (C),
mai nshaft,
countershaft, and shi ft fork assembl i es
(D)
wi th the
snap ri ng
pl i ers,
and set the 68 mm snap ri ng
(E)
i nto the
groove
ofthe countershaft beari ng.
NOTE: Check that the snap ri ng i s securel y seated
i n the groove of the countershaft beari ng.
Standard:0-6.93 mm
(0
-0.273
i n.,
Appl y l i qui d gasket (P/N
08718-0001) to the threads
of the 34 mm seal i ng bol t
(F),
then i nstal l the
34 mm seal i ng bol t.
4.
13-56
6. I nst al l t he 1- 2 shi f t
pi ece.
l nstal l the sel ect return spri ng
(A)
and the 8x40
pi n
(B)
onto the transmi ssi on. then i nstal l the i nterl ock
(c).
7.
Instal l the shi ft arm A by al i gni ng the i nterl ock
fi nger and the shi ft fork grooves.
9. I nst al l t heshi f t r od
( A)
i nt ot he i nt er l ock assembl y
(B)
wi th i t recessed hol e
(C)
toward the top of the
transmi ssi on {D), then i nstal l the 5 x 25 spri ng pi n
( E
) .
10.Instal l the outer si de
i nst al l t he i nner si de
' l -2
shi ft l ever
(A)
fi rst, then
1-2 shi ft l ever
(B).
1 1 .
il4
N m {4.5 kgf m, 33 lbf.ftl
I nst al l t he 8 x 63
pi n ( C) ,
t hen t i ght en t he 10 mm
fl ange bol t
(D),
t -
-
I
-
. l
\ t . t
12. Instal l the needl e beari ng
(A),
reverse gear
shaft
(B),
thrust washer
(C),
and reverse shaft hol der
(D),
then
i nstal l the washer and 8 mm fl ange bol t.
34 N. m {3. 5 kgl . m,
25 rbt.ftt
13. I nst al l t heoi l gui det ube ( A)
and magnet ( B) .
r
14, I nst al l t he oi l gui de pl at e M and 82 mm shi m( s)
( A) .
I
)t-^
{cont' d}
13-57
Manual Transmi ssi on
t 5 .
Transmission Reassembly
(cont'd)
Instal l the oi l
pump
strai ner
(A),
sucti on gui de (B),
and ci r cl i p
( C) .
16. l nst al l t he 16x26x7 mm oi l seal
( A)
as shown.
c
A'
-----_
\
(
--"\1^\
/ l - \
\l-
13-58
18.
17. I nst al l t he oi l gui de pl at e
S and shi m { A) , t hen
i nst al l t he bear i ng out er r ace
( B)
usi ng t he speci al
tool s as shown.
07749-0010000
07746-0010500
Remove the di rty oi l from the transmi ssi on housi ng
seal i ng surface. Appl y l i qui d gasket (P/N
08718-
0001) to the seal i ng surface. Be sure to seal the
enti re ci rcumference of the bol t hol es to prevent oi l
r eaKage.
NOTE:
.
l f 5 mi nutes have passed after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
.
Al l ow i t to cure at l east 20 mi nutes after
assembl y before fi l l i ng the transmi ssi on wi th oi l .
- -
Li qui d gasket
19. I nst al l t he 14 x 20 dowel
pi ns ( A) ,
t r ansmi ssi on
housi ng
( B) .
I mm f l ange bol t s, t r ansmi ssi on
hanger
( C) ,
and t r ansmi ssi on hanger A
( D) .
20.
21. Appl y l i qui d gasket (P/N
08718-0001) to the threads
of the set screws
(A),
then i nstal l the steel bal l s and
spnngs,
A
C 22 N. m
(2. 2
kgt . m, 16 l bf f t l
2 5 N m \ 2 5 Nm \ , - L t 2 7 . 1 mm
i??Ji';,''
\no@t'
l88iri'
----ffi *._1
_
--.
rb
-.,
-
"-----..-l
q-
A
22.
23.
2 2 N m
l2.2 kgt .n,
16 rbf.ft)
39 N. m {4. 0 kgf . m, 29 l bf . f t l
L: 27. 4 mm
( 1. 08 i n. )
F
22 N. m
l2.2 kgl m,
16 tbf.ft)
L: 23 mm
{0. 91 i n. )
(Bl ack)
{2. 2 kgf . m. 15l bt . f t )
Instal l the washer
(B)
and back-up l i ght swi tch
(C).
l nst al l t he washer s 1A) , dr ai n
pl ug ( B) ,
f i l l er pl ug ( C) ,
12 mm dr ai n pl ug
{ D) , and
pi ck- up sensor
( E)
wi t h a
new O-ri ng.
24.
I {l.s t<gt.m,
6 x Lo mm
33 tbf.ftl
12 N. m 11. 2 kgf . m. 8. 7 l bf . f t )
Appl y l i qui d gasket (P/N
08718-0001) to the threads
of the set screws
(F),
then i nstal l the steel bal l s and
spnngs.
{cont' d)
@\
13-59
Manual Transmi ssi on
Transmission Reassembly
{cont'dl
Instal l the oi l
pump
outer rotor S, steel bal l
(A),
spr i ng
{ B) , oi l pump pl at e ( C) .
12 N. m
(1. 2
kgf . m, 8. 7 l bt . f t l
Instal l the secondary dri ve gear (A)
on the
countershaft usi ng the speci al tool as shown.
26.
13-60
27. Instal l the needl e beari ng
(A)
on the countershaft
usi ng the speci al tool as shown.
_
1i l x 1. 5 mm
, y' L. 40 mm { 2. 76 i n. l Ml N.
HEX NUT
07965-SA50500
28. Instal l the spri ng washer and 29 mm l ocknut.
,j,i
j'i-r.
t
t-.
F
-''--
i
!_
,$
29. Instal l the speci al tool on the mai nshaft, then
ti ghten the 29 mm l ocknut
(l eft-hand
threads) to the
speci fi ed val ue.
Torque 172- 0
--
172 N.m
( 17. 5- 0- * 17. 5k 91. m,
127- o
-
127 lbf.ttl
30. Stake the 29 mm l ocknut tab i nto the
groove.
31. Instal l the oi l
pump gear
and oi l
pump gear shaft.
(cont' d)
c
f=l
r.l
Y
fF,h
f t f f i i
i
. --
--:: -:)'--
I
,
l / +. : .
r r '
i - @
u,:l]*?,i'i:
.-.==l
,1
.1-'=1
:.
13-61
Manual Transmi ssi on
Transmission Reassembly
(cont'dl
Rear Cover Installation
NOTE: Pri or to reassembl i ng, cl ean al l the parts i n
sol vent, dry them, and appl y l ubri cate to any contact
su rfaces.
1. I nst al l t he bear i ng out er r ace
( A)
usi ng t he speci al
tool s as shown.
I nst al l t he shi m and t he bear i ng out er r ace i nt o t he
rear cover usi ng the speci al tool s as shown.
I
/A\
v
13-62
3. Instal l the secondary shaft assembl y i nto the rear
cover,
Instal l the new bal l beari ng
(A)
usi ng the speci al
t ool s and ol d bear i ng
( B) .
5. I nst al l t he oi l seal
( Al
usi ng t he speci al t ool s.
49-0010000
il6-0010300
07LAD-PW50601
l nst al l t he compani on f l ange
( A)
usi ng t he speci al
tool as shown.
6.
00
4. 5-5. 0 mm
7. I nst al l t he O- r i ng
( A) ,
back- up r i ng
( B) ,
spr i ng
washer
(C),
and 27 mm l ocknut
{D).
I nst al l t he speci al t ool on t he compani on f l ange,
then ti ghten the 27 mm l ocknut the to the speci fi ed
vat ue.
Torque 162- 0
-*
162 N' m
( 16. 5- * 0- * 16. 5kgf . m.
119-- 0
-*
119| bi .ft)
OTRAB-TB4O1OB
8.
-----...',..
07JAB-001020A
{cont' d)
13-63
Manual Transmi ssi on
Transmission Reassembly
(cont'd)
9. Stake the 27 mm l ocknut tab i nto the oroove.
10. Instal l the shi ft rod pi pe
and O-ri ngs.
I
R
t l
l l
!
t l
l l
v
'.1
- l . .
J
''i
,.
.')
13-64
' 11,
Remove the di rty oi l fromthe rear cover seal i ng
surface. Appl y l i qui d gasket (P/N
08718-0001) to the
seal i ng surface. Be sure to seal the enti re
ci rcumference of the bol t hol es to
prevent
oi l
r eaKage.
NOTE:
.
l f 5 mi nutes have passed
after appl yi ng l i qui d
gasket,
reappl y i t and assembl e the housi ngs.
.
Al l ow i t to cure at l east 20 mi nutes after
assembl y before fi l l i ng the transmi ssi on wi th oi l ,
- -
Liquid gasket
Instal l the 14 x 20 dowel pi ns (A),
rear cover
assembl y
(B),
harness bracket
(C),
harness cl amp
{ D) , and 8 mm f l ange bol t s.
12.
R F
E E
13. Ti ghten the 8 mm fl ange bol ts i n a cri sscross
pattern i n several steps.
8 x 1. 25 mm
27 N.m {2.8 kgf.m,20l bf ft)
14. Lower the shi ft rod
(A),
then i nstal l the shi ft arm B
(B),
spri ng washer
(c),
and 8 mm speci al bol t.
15. I nst al l t he shi f t l ever housi ng.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt , m. 7. 2l bt . f t )
13-65
Manual Transmi ssi on
Transmi ssi on Instal l ati on
1. I nst al l t he t r ansmi ssi on r ear mount l Ai .
10 x 1. 25 mm
38 N.m (3.9
kgf.m.28l bf.ft)
Check the two dowel pi ns
are i nstal l ed i n the cl utch
housi ng.
Appl y super hi gh temp urea grease (P/N
08798-
9002) to the rel ease fork {A), rel ease hanger
(B),
and r el ease bear i ng gui de ( C) .
I nst al l t he r el ease
f or k i nt o t he openi ng i n t he cl ut ch housi ng.
{P/ N 08798-9002}
13-66
4. Pul l t he r el ease f or k
( A)
out unt i l i t st ops. t hen
wedge a shop towel
(B)
between the rel ease fork
and cl utch housi ng to hol d the rel ease fork i n pl ace.
6.
B
Pl ace t he t r ansmi ssi on on a t r ansmi ssi on
j ack,
and
r ai se i t t o t he engi ne l evel .
l nstal l the three upper transmi ssi on mounti ng bol ts.
12 x 1.25 mm
64 N.m
(6.5
kgf m. 47 lbt ftl
7. I nst al l t he wi r e har ness
( A) t o
t he t r ansmi ssi on,
then connect the Di ck-uo sensor connector
(B).
-
r
ar'-] I
8. Rai se the transmi ssi on, then i nstal l the three
transmi ssi on rear mount bol ts.
10 x 1. 25 mm
38 N. m
(3. 9
kgf . m, 28 l bf . f t )
9. Pl ace a fl oor
j ack
under the front subframe and the
engi ne mounti ng sti ffener, and rai se i t to the frame.
SPECIAL BOLTS
Repl ace.
14 x 1. 5 mm
1' t 6 N. m
(11. 8 ksf . m, 85. 3 l bf . f t )
. ' . . . / . j
SPECIAL BOLTS
Repl ace.
12 x 1. 25 mm
59 N.m 16.0 kgf.m, 43 lbf.ft)
10. Ti ghten thefourmounti ng bol ts, and i nstal l the two
center mounti ng bol ts.
11. Instal l the fi ve l ower transmi ssi on mounti ng bol ts.
10 x 1.25 mm
12x 1.25 mtn
64 N. m {6. 5 kgf m. 47 l bt f t )
(cont' d)
13-67
Manual Transmi ssi on
1 t
t J ,
Transmission Installation
(cont'd)
Remove the shop towel , and i nstal l the rel ease fork
onto the rel ease hanger,
Appl y super hi gh urea greese (P/N
08798-9002)to
the end of the sl ave cvl i nder
push
rod
(A).
Instal l
t he sl ave cvl i nder
( B)
and t he r el ease f or k boot
( C) .
{P/N 08798-9002)
ria.
(P/N
08798-90021
14. Instal l the four shi ft boot hol der mounti nq bol ts.
l
6 x 1 . 0 mm
9. 8 N m
(1. 0
kgf . m, 7. 2 l bf . f t l
'..ar.'.-
. :a,a:a,:--.
13-68
15.
t o.
Instal l the
propel l er
shaft
(see page 16-18).
Instal l the
gasket
{A), exhaust mani fol d
(B),
and the
exhaust mani fol d bracket
(C).
SELF.LOCKING NUT
Repl ace.
8 x 1. 25 mm
31 N.m 13.2 kgt.m.
23 rbf.ftl
Instal l the gaskets (A)
and three way catal yti c
converter
(TWC) (B).
17.
SPECIAL BOLT
Repl ace.
8 x 1. 25 mm
22 N. m
(2. 2
ksf m, 16l bl . f t l
SELF.LOCKING NUT
Repl ace.
10 x 1. 25 mrn
33 N. m {3. 4 kgf . m, 25 l bf f t l
18. Instal l the wi re harness
(A)
onto the transmi ssi on,
then connect the heated oxygen sensor
(H02S) (B),
secondary heated oxygen sensor
(secondary
HO2S)
{C),
and the back-up l i ght swi tch
(D)
connectors.
x 1. 25 mm
24 N. m
{2. 4 kgf . m.
17 rbf.ft)
19. l nstal l the i ntake mani fol d bracket
(A)
l ower
mounti ng bol t, then l nstal l the wi re harness
(B)
on
the i ntake mani fol d bracket.
10 x 1. 25 mm
, t l
N. m
14. 5 kgf . m.
33 tbt.ft)
21
20. Reconnect the torque sensor 3P connector
(A),
and
i nst al l t he wi r e har ness cl amp
( B) .
Reconnect the 2P connector
(C)
to the steeri ng
gearbox (D).
I nst al l t he spl ash shi el d.
(cont' d)
13-69
Manual Transmi ssi on
Transmission lnstallation
(cont'd)
23. Connect the TDC1
(A)
and TDC2
(B)
sensor
connectors.
Instal l the upper i ntake mani fol d bracket mounti ng
bol t
(A)
and upper starter motor mounti ng bol t
(B).
Connect the hose
(C)
to the sucti on varve.
24.
A
8 x 1,25 mm
22 N.m
l2.2 kgl n,
16l bl m)
B
10 x 1.25 mm
44 N.m
(,t.5
kgf.m,33 lbt.ftl
13-70
25. Instal l the heat shi el d.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2l bf . f t l
I nst al l t he exhaust mani f ol d cover.
8 x 1. 25 mm
22 N. m {2. 2 kgf . m, 16l bf . f t l
27. Instal l the Ay' C compressor, then connect the 1 P
connecror.
10 x
' 1. 25
mm
29.
Instal l the al ternator and the al ternator-compressor
bel t
(see page 4-25).
Connect the steeri ng
j oi nt (A)
by al i gni ng the
reference marks {B).
4 4 N m
(4. 5 kgt . m,
33 tbf.ft)
8 x 1.25 mm
22N rn
(2.2
kgf.m, 16l bf.ft)
' .
.l
.
..t,'
. .
- . . , r
30. I nst al l t he ai r cl eaner housi ng assembl y.
6 x 1 . 0 mm
12 N.m 11.2
kgf.m,8.7 l bf.ft)
31. Instal l the shi ft l ever spri ng and the shi ft l ever.
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m,
7.2 tbt.ftl
@
{cont' d)
13-71
Manual Transmi ssi on
Transmission Installation
(cont'd)
32. Instal l the shi ft boot and the boot hol der.
Instal l the center consol e
(see page
20-76).
Instal l the shi ft l ever knob, and ti ghten the l ocknut.
10 x 1. 25 mm
9 N. m 10, 9 kgf . m,
7 tbf.ftl
13-72
35.
36.
37.
38.
39.
40.
Instal l the battery. Connect the
posi ti ve (+
) cabl e
fi rst, then the negati ve
(
) cabl e to the battery.
Check the transmi ssi on fl ui d {see
page l 3-3).
Test-dri ve the vehi cl e.
Check the cl utch operati on.
Check the transmi ssi on for noi se and smooth
operatron.
Check the front wheel al i gnment
(camber
angl e.
caster angl e, and front toe)
(see page 18-5).
Transaxle
Rear Differential
Soeci al Tool s . . . . . . . . . . . . . 15-2
Precautio ns for Torsen Type
Li mi t ed Sl i p Di f f erent i al
(LSD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Torsen Type Li mi t ed Sl i p
Di f f erent i al
(LSD)
Operat i on Check . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Syst em Descri pt i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Di f f erent i al Oi l I nspect i on and Repl acement . . . . . . . . . . . . . 15-6
Di f f erent i al Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Di f f erent i al Case Assembl y Removal and
I nst al l at i on . . . . . . . . . . . . . 15-9
Oi l Seal Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
Backl ash l nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
Di f f erent i al Di sassembl y . . . . . . . . . . . . . . . . . . . . 15-12
Di f f erent i al Reassembl v . . . . . . . . . . . . . . . . . . . . . 15-18
Di f f erent i al I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . 15-26
Di f f erent i al Mount Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
Rear Differential
Speci al Tool s
19
lz
I
@
I
,9
tFfl'
15-2
Ret. No. Tool Number Description Qtv
(t
@
@
@
@
@
@
ao
o
07JAD-P190100
07JAB-001020A
07LAD-PW50601
07MAC-S100200
07MAD-PR90100
07NAD,PX40100
OTRAB-TB4O,1OB
07725-0030000
07746-0030100
07746-0030300
07749-0010000
1
1
l
l
i
i
Oi l Seal Dri ver
Hol der Handl e
Attachment, 40 x 50 mm l .D.
Bal l Joi nt Remover. 28 mm
Attachment, 45 x 55 mm l .D.
Attachment, 78 x 80 mm
Compani on Fl ange Hol der
Uni versal Hol der
Dri ver, 40 mm l .D.
Attachment, 30 mm l .D.
Dri ver
Precautions for Torsen Type
Limited Slip Differential
(LSD)
.
The Torsen di fferenti al s are mechani cal l i mi ted sl i p
di fferenti al s whi ch del i ver the avai l abl e Dower to the
wheel s and axl es wi th the most gri p or resi stance as
the engi ne torque output i ncreases.
.
Avoi d repai r procedures that requi re the engi ne
runni ng wi th one rear wheel rai sed; such as an on-
car-wheel bal ancer.
.
Do not tow the vehi cl e wi th the rear wheel s on the
g rou no.
.
Never di smantl e any
part
ofthe di fferenti al other
than ri ght and l eft tapered rol l er beari ngs.
.
To opti mi ze the Torsen di fferenti al s, equi p your
vehi cl e wi th rear ti res of the same brand. the same
si ze, and wi th even wear.
Torsen Type Limited Slip
Differential
(LSDI
Operational Check
The Torsen type l i mi ted sl i p di fferenti al
(LSD)
di stri butes opti mum power between the two dri vi ng
axl es accordi ng to the di fference i n torque demanded
by the dri vi ng wheel s. U nder no ci rcumstances shoul d
the engi ne be started wi th ei ther wheel rai sed off the
ground,
such as usi ng an on-car-wheel bal ancer or
when transporti ng the vehi cl e i n the event of acci dent.
1. Set the parki ng
brake, and bl ock the rear wheel s.
2. Rai se the rear ofthe vehi cl e, and make sure i t i s
securel y supported.
3. Wi th the engi ne off. shi ft the transmi ssi on i nto 1st
gear, and rel ease the
parki ng
brake.
4. Rotate ei ther rear wheel by hand, and check that
the other wheel rotates i n the oDDosi te di recti on.
Check both wheel s.
5. l f the opposi te rear wheel does not rotate, or i f you
cannot spi n t he r ear wheel s at al l , t he l i mi t ed sl i p
di fferenti al i s faul ty and shoul d be repl aced.
15-3
Rear
Differential
System Description
The vehi cl e uses the Torsen type l i mi ted sl i p di fferenti al
(LSD)
whi ch i s rubber mounted to the sub-frame
Construct'ron
.
The Torsen type LSD assembl y consi sts of the two si de gears, ei ght
pl anetary gears, three si de washers, tvvo center
washers, a gear case cover and a
gear case.
.
The pl anetary gear consi sts of the short and l ong
pl anetary gears, and the l ong
pl anetary gear meshes hori zontal l y
wi th the si de gear. The two
pl anetary gears mesh wi th the si de
gears at both ends.
.
The
pl anetary gears are housed i n the
pockets of the gear case.
.
The l eft and ri ght output shafts are engaged wi th the si de
gears
.
TheTor sent ype LSDassembl y i s a non- ser vi ceabl e
par t except t het aper ed r ol l er bear i ngs. l f t heTor sent ype( LSD)
assembl y i s faul ty, i t must be repl aced as an assembl y.
POCKETS
GEAR
CASE COVER
SIDE WASHEB
tr
15- 4
Operation
.
Strai ght-road dri vi ng
The di fferenti al carri el and gears rotate together as a uni t when both wheel s rotate at the same speed. Turni ng efl ort
from the fi nal dri ven gears
are di rectl v transmi tted to both wheel s.
.
When roundi ng a curve
When the vehi cl e rounds a curve, the di fferenti al al l ows the outer wheel to rotate a l i ttl e faster than the Inner wheel .
When thi s takes pl ace,
the short and l ong pi ni on gears rotate, and wal k around the si de gears i n the di recti ons
shown l f, for exampl e, the ri ght shaft i s rotated i n a countercl ockwi se d i recti on wi th the di fferent
j al
carri erhetd
stati onary, the force i s transmi tted through the ri ght si de gear,
short pi ni on gears
and l ong pi ni on gears
to the l eft
si de gear,
causi ng the l eft shaftto rotate i n a cl ockwi se di recti on. Thi s al l ows the outerwheel to tua ao.".,."a
t han t he i nner wheel when t he vehi cl e goes
ar ound a t ur n.
tt Rotati on of the gear
I
Gear operati on by
thrust torque
t2)
( 1t
SIDE
WASHER
SIDE
WASHER
CENTER
WASHER
SIDE
WASHER
i r Rot at i on of t he gear
When l i mi ti ng di fferenti al acti on
The l i mi ted sl i p di fferenti al acts to l i mi t the di fferenti al acti on when ei ther wheel sl i ps on i ce or snow or on rurns.
Thi s i s done by usi ng the fri cti on created between each gear
and di fferenti al carri er:
(1)
The pi ni ons
are forced agai nst the di fferenti al carri er by the force as they are rotated and repel l ed outward.
(2)
The ends of the pi ni on gears
are hel d fi rml y agai nst the di fferenti al carri er due to the si de thrust from the
hel i cal l y cut gear s.
l2l
t
Gear operati on by
tn rusl torque
Si ower
CENTER
WASHER WASHER
Wi th the pi ni on gears l ocked, the torque appl i ed to the sl i ppi ng wheel i s reduced and the torque del i vered to the
other wheel i s i ncreased.
PI NI OR GEARS
PINIOR GEARS
15-5
Rear Differential
Differential Oil Inspection and Replacement
l . Wi th the vehi cl e on l evel
ground, i nspect the
di fferenti al oi l wi th engi ne OFF.
Remove the oi l fi l l er
pl ug (A)
and seal i ng washer
(B),
then check the condi ti on of the oi l , and make
sure the oi l i s at the
proper l evel
(Cf,
The oi l l evel must be up to the fi l l hol e. l f i t i s bel ow
the hol e, add the recommended oi l unti l i t runs out,
then rei nstal l the oi l fi l l er pl ug wi th a new seal i ng
washer ,
l f the dl fferenti al oi l i s di rty, remove the drai n
pi ug
( D) ,
and dr ai n t he oi l .
3.
4.
15-6
5. Cl ean t he dr ai n
pl ug, t hen r ei nst al l wi t h a new
washer , and r ef i l l t he di f f er ent i al wi t h t he
recommended oi l to the Droper l evel .
Oi l capaci ty
0.74 0
(0.78
US
$),
at oi l change
O.77 A
Q.A1US
qt). at overhaul
Recommended oil
Hypoid gear oil
API Classification GL5 or GL6.
Viscosity: SAE # 90
6. Rei nst al l t he oi l f i l l er
pl ug wi t h a new washer .
Differential Removal
Special Tools Required
Bal l
j oi nt
remover,2S mm 07N4AC-S100200
1. Make a reference marks across the
propel l er
shaft,
the transmi ssi on, and the rear di fferenti al , then
remove the propel l er
shaft
(see page
16-17).
2. Remove the cotter
pi n
from the l ower arm bal l
j oi nt
castl e nut, and remove the nut.
NOTE:
.
To avoi d damagi ng t he bal l j oi nt , i nst al l a hex nut
on to the threads of the bal l
j oi nt.
.
Be careful not to damage the bal l
j oi ntbootwhen
i nstal l i ng the remover,
07MAC-S100200
Separate the bal l
j oi nt
from the l ower arm wi th the
speci al tool
(see page 18- 10).
Remove the ABS sensor harness from the upper
ar m.
F1
'w
4
4.
\ l ' ' i i
5. Make a reference marks
(A)
across the i nboard i oi nt
(B)
and the rear di fferenti al
(C).
Remove the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
(E),
then remove the i nboard
j oi nl
from
the rear di fferenti al .
Remove the rear suspensi on sti ffener
(A).
6.
7.
(cont' d)
,,"f
.3.
15-7
Rear Differential
Diff erential Removal
(cont'd)
8. Remove the cani ster cover.
10.
Pl ace a fl oor
j ack
under the rear di fferenti al
Remove the four di fferenti al mount bracket B
mountang nuts.
t r . \ ' . . - -
,af .--:=
15-8
1 1. Remove the four di fferenti al mount A mounti ng
bol ts,
' 12.
Lower the rear di fferenti al onthefl oorj ack.
Remove the ri ght and l eft di fferenti al mount
bracket A from the di fferenti al
(see page 15-29).
t J .
Differential Case Assembly Removal and Installation
1. Remove the output shafts {A) from the di fferenti al
case assembl y usi ng t he pr y
bar s
( B) .
2. Remove the ten mounti ng bol ts i n a cri sscross
pattern
an several steps, then remove the
di fferenti al case assembl v.
3. Remove the di rt and oi l from the seal i ng surfaces.
Appl y l i qui d gasket (P/N
08718-0001) to the seal i ng
surface. Be sure to seal the enti re ci rcumference of
the bol t hol es to prevent
oi l l eakage.
NOTE:
.
l f 5 mi nutes have passed
after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
.
Al l ow i t to cure at l east 20 mi nutes after assem-
bl y before fi l l i ng the di fferenti al wi th oi l .
Li qui d gasket
Instal l the di fferenti al case assembl y, then torque
the 10 mounti ng bol ts i n a cri sscross
pattern
i n
several steps.
s B H g o
H T I ] US
'o1l*T,.-.',r,0*,
u
ff fiq
B
--------------S
-
15-9
Rear Differential
Oi l Seal Repl acement
Special Tools Required
Oi l seal dri ver 07JAD-P190100
1. Remove the output shafts 1A)
from the di fferenti al
case assembl y usi ng the
pry bars
(B),
2. Remove the oi l seal from the di fferenti al case
assembl y,
{r;j
15- 10
3. l nst al l t he oi l seal usi ng t he speci al t ool s as shown.
07JAO-P190100
4. Repeat steps
' l
through 3 for the other si de.
-='-./
i',
Backlash Inspection
1. Remove the output shafts and di fferenti al case
assembl y
(see page 15-9).
2. Thor oughl y cl ean t he r i ng gear
and dr i ve pi ni on
teeth, and
pai nt
the ri ng gear
teeth wi th Prussi an
Bl ue l i ght l y and evenl y.
3. Rotate the pi ni on three ful l turn i n the forward and
reverse di recti ons to produce
a contact
pattern
on
the ri ng gear.
Good contact pattern
4. Measure the backl ash of the ri ng gear,
.
Set t he di al gauge t i p at a r i ght angl e t o t he r i ng
gear
teeth.
.
Measure four poi nts
on the ri ng gear 90' apart.
.
Backl ash wi l l be wi thi n the standard i f at one
poi nt t he r i ng gear
backl ash i s wi t hi n t he
standard, mi ni mum measurement of 0.05 mm or
above and the di fference between the maxi mum
and mi ni mum measurements do not exceed 0.07
mm.
.
Both adj ustment screws must be adj usted.
For exampl e; i f you turn one adj ustment screw
one notch cl ockwi se, you must turn the other
adj ustment screw one notch countercl ockwi se.
Backl ash:
Standard: 0.09
-
0.11 mm
(0.0035
0.0043 i n. )
Mi ni mum: 0.05 mm {0.0020 i n.
I
Difference range: 0.07 mm
(0.0028
in. )
15- 11
Rear Differential
Y-
nq
,,df#w\,
X \ w \ \ , ,
w^@m
'@
f l t * \
rP,.l
\,
o
6n
I O D
t l ( }
t \ l
t i
@@A
:\g/
Differential Disassembly
Exploded View
@
\ \
;W
BGA.
(fr'a
/ / /
@ @ @ @ )
?q6)
\
(i*?
\ - \
\
\
@
A: 24 N. m 12. 4 kgf m, 17 l bf . f t )
B: 45 N. m (4. 6
kqt . m, 33 l bt . f t )
C: 22 N. m {2. 2 kgf . m,
' 16l bf . f t l
D: 75 N. m
(7. 6
kgt . m, 55l bf . f t )
E: 11 N m
(1. 1
kgf . m. 8l bt . f t )
@ BEARING CAP
@ LOCK PLATE
@ OUTPUT SHAFT
@CLIP
Repl ace.
q!)
OIL SEAL
Repl ace.
q,
FILLER PLUG
45 N. m (' r. 6
kgf . m. 33l bf . f t )
qOSEALI NG
WASHER
Reol ace.
@ DIFFERENTIAL CASE
@SEALI NG WASHER
Repl ace.
O' DRAIN PLUG
45 N m 1,1.6 kgf.m, 33 lbt.ft)
, OIL SEAL
Repl ace.
@ CLIP
Reol ace.
@ OUTPUT SHAFT
@ LOCK PLATE
@ EEARING CAP
13} BREATHER PLATE
O LOCKNUT
Reol ace.
_
127-284 N.m
(r3.0-29.0
kgf.m, 94-210 l bf.ftl
(a)DRIVE
PINION WASHER
OCOMPANION FLANGE
OoIL SEAL
,
Repl ace.
Q)SPACER
Q)TAPERED
ROLLER BEARING
q)BEARING
OUTER RACE
(!)
DIFFERENTIAL CARRIER HOUSING
OBEARING oUTER RACE
(}PINION
SPACER
Reol ace.
OTAI'ERED RoLLER BEARING
@THRUST WASHER
@
DR|VE PtNtON
(]D
ADJUSTMENT SCREW
q'AEARING
OUTER RACE
U'TAPERED ROLLER BEARING
ORING GEAR
@TORSEN LSD ASSEMBLY
@
TAPERED ROLLER BEARING
ED
BEARING OUTER RACE
Q' ADJUSTMENT SCREW
(cont' d)
15- 13
Rear Differential
Differential Disassembly
(cont'dl
Special Tools Bequired
.
Hol der handl e 07JAB- 001020A
.
Compani on Jl ange hol der 07RAB' T840108
1. Careful l y cl amp the rear di fferenti al i n a vi se.
2. Pry out the output shafts
(A)
wi th the pry bars
(B).
ia..
15-14
3. Remove the output shafts.
Remove the 10 mounti ng bol ts i n a cri sscross
Dattern i n several steps, then remove the
di ff erenti al case assembl y.
4.
ar-=i
I
l t r '
I
:.=-
1.. !:.,
7. Remove the adj ustment screws
(A),
beari ng outer
races
(B),
and Torsen LSD assembl y
(C).
8. Instal l the speci al tool s on the compani on fl ange,
then remove the l ocknut
{A) and
pi ni on
washer
(B).
07RAB-TBito10B
(cont' d)
07JAB-001020A
15- 15
5. Make a mark on the beari ng cap. adj ust screw, and
di fferenti al carri er case.
ng caps. Remove the l ock pl ates and beari
a
I
e 9
b E
\ 4 -
Sl
rer $+
-u
E H e H
Y,F-'-;
ll
s
f Py. ;
\ z /
I / -
q
Rear Differential
Differential Disassembly
(cont'dl
Remove the compani on fl ange usi ng a
commerci al l y avai l abl e beari ng
pul l er as shown.
Remove the dri ve
pi ni on (A)
and
pi ni on
spacer
(B)
by tappi ng on the dri ve
pi ni on wi th a pl asti c
hammer .
10.
15- 16
1 1. Remove the beari ng outer race
(A),
tapered rol l er
beari ng
(B),
thrust washer
(C),
and oi l seal
(D)
from
the di fferenti al carri er housi ng.
Remove the beari ng outer race from the di fferenti al
car r i er housi ng.
12
13. Remove the tapered rol l er beari ng
(A)
andthrust
washer
(B)
from the dri ve
pi ni on (C)
usi ng a
commerci al l y avai l abl e beari ng separator and a
Dress as snown.
Remove the tapered rol l er beari ngs from the
Torsen LSD assembl y usi ng a commerci al l y
avai l abl e bear i ng pul l er as shown.
14.
i i I i ]
16.
15. Remove the ten mounti ng bol ts i n a cri sscross
pattern i n several steps, then remove the ri ng gear.
Remove the breather pl ate (A),
fi l l er pl ug (B),
drai n
pl ug ( C) ,
and seal i ng washer s.
#\^
(cont' d)
15-17
Rear Differential
Differential Disassembly
(cont'd)
17. Remove t he oi l seal s.
15- 18
Differential Reassembly
Special Tools Required
.
Attachment, 40 x 50 mm l .D. 07LAD-PW50601
.
Dr i ver , 40 mm 1. D. 07746- 0030100
.
Attachment,30 mm l .D. 07746-0030300
.
At t achment , 45 x 55 mm l . D. 07MAD- PR90100
.
Dri ver 07749-0010000
.
Attachment, TS x 80 mm 07NAD-PX40100
.
Fl ange hol der 07RAB- T840108
.
Hol der handl e 07JAB-001020A
.
Uni versal hol der 07725-0030000
.
Oi l seal dri ver 07JAD-PLgo100
1. Appl y Hondal ock 1
(P/N
08713-0001)to the surface
of t he r i ng
gear and 10 mount i ng bol t s
Hondalock 1
I nst al l t he r i ng gear . t hen t i ght en t he 10 mount i ng
bol ts i n a cri sscross
pattern
i n several steps.
2.
o
C
(a\
:<-4,/
-.--_../
r .
c , / . .
t J . ' - - 1 -
" - 1 ' 1
e - - 9
3. Instal l the tapered rol l er beari ng usi ng the speci al
tool s and a Dress as shown.
l nstal l the standard thrust washer 3.47 mm {0.1366
i n.)
(A)
onto the dri ve
pi ni on (B).
Then i nstal l the
tapered rol l er beari ng {C) usi ng the ol d
pi ni on
sDacer {D) and speci al tool s as shown.
4.
5. Instal l the beari ng outer races {A)
i nto the
di fferenti al carri er housi ng usi ng the speci al tool s
as shown,
(cont' d)
\
15- 19
Rear Differentaal
Differential Reassembly
(cont'd)
6. Appl y l ubri cant to the tapered rol l er beari ng, then
i nstal l the dri ve pi ni on and pi ni on spacer i nto the
di fferenti al carri er housi ng.
7. Appl y l ubri cant to the tapered rol l er beari ng, then
i nstal l the l apered rol l er beari ng and thrust washer
(A)
usi ng the speci al tool s whi l e hol di ng the dri ve
pi ni on ( B) .
46-0030100
07746-0030300
15-20
8. I nst al l t he oi l seal usi ng t he compani on f l ange and
soeci al tool as shown.
46-0030100
9. Appl y mol ybdenum grease to the surface end of
t he compani on f l ange, t hen i nst al l t he compani on
fl ange, dri ve pi ni on washer. and l ocknut.
, t V. ,
10. I nst al l t he speci al t ool t o t he compani on f l ange,
then ti ghten the l ocknut to 20 N.m
(2.0
kgf.m,
14 tbf.ft).
07RAa-TB40t0B
Rotate the dri ve oi ni on several ti mes to assure
proper
tapered rol l er beari ng contact. Measure the
dri ve pi ni on turni ng torque.
1
' I.
'-.'--
-.
/
,..'it .
'. i
ir
Li'
|
.:"1
'
'i-r
12. Ti ght en t he l ocknut t o 127 N. m
( 13. 0
kgf . m.
94 l bf.ft), then remove the sDeci al tool .
07RAB.TB4O1OB
Rotate the dri ve oi ni on several ti mes to assure
proper tapered rol l er beari ng contact. Measure the
dri ve
pi ni on
turni ng torque.
'
l f the dri ve
pi ni on turni ng torque exceedsthe
standard, repl ace the di stance
pi ece.
.
l f t hedr i ve
pi ni ont ur ni ngt or que l esst hant he
standard, adj ust by ti ghteni ng the l ocknut a l i ttl e
at a ti me, but keep the torque wi thi n 127
-
284
N. m
( 13. 0
29. 0 kgf . m, 94 210l bf . f t ) . l f t hi s i s
not possi bl e, repl ace the
pi ni on
spacer.
Turning Torque:
0.88 1.37 N.m
(9.0
14.0 kgf.cm.
7.8 12. t l bf.i n) +Tp(l romstep11)
Tp: Actual measurement of dri ve
pi ni on
turni ng
torq ue
{cont' d)
15-21
Rear Differential
14.
Differential Reassembly
(cont'dl
Instal l the Torsen LSD assembl y
(A),
beari ng outer
races
(B),
adj ustment screws
(C)
onto the
di fferenti al carri er housi ng.
NOTE:
.
Rei nstal l the adj ustment screws i n thei r ori gi nal
posi ti on on the di fferenti al carri er housi ng.
.
Al i gn the threads of the adj ustment screws and
di fferenti al carri er housi ng.
I nst al l t he bear i ng caps { A) whi l e al i gni ng bot h t he
ma rks
(B)
on the threads of the adj ustment screws
and bear i ng caps, t hen i nst al l t he mount i ng bol t s
fi ngerti ght.
t 5 .
15-22
16. Measure the backl ash of the ri ng gear.
Set the di al gauge ti p at a ri ght angl e to the ri ng
gear
teeth.
Measure four poi nts on the ri ng gear 90" apan.
Backl ash wi l l be wi thi n the standard i f at one
poi nt the ri ng
gear
backl ash i s wi thi n the
standard, mi ni mum measurement of 0.05 mm or
above and the di fference between the maxi mum
and mi ni mum measurements do not exceed 0.07
mm.
Both adj ustment screws must be adj usted.
Backl ash:
Standerd: 0.09
' -
0.11 mm 10.0035 0.0043 i n.)
Mi ni mum: 0.05 mm
(0.0020
i n.)
Difference range: 0.07 mm
(0.0028
in.)
17. Ti ghten the beari ng cap mounti ng bol ts.
18. Thoroughl y cl ean the ri ng
gear
and dri ve
pi ni on
teeth, and
pai nt
the ri ng gear teeth wi th Prussi an
Bl ue l i ght l y and evenl y.
19. Rotate the pi ni on three ful l turns i n the forward and
reverse di recti ons to produce a contact
pattern on
the ri ng gear. Duri ng thi s operati on resi stance
shoul d be appl i ed to the ri ng gear.
45 N. m {4. 6 kgt . m, 33l bf . f t l
20. Check the tooth contact, and adj ust i t i f needed.
.
Toe Contact: Use a thi nner thrust washer to
move the dri ve
pi ni on away from the ri ng gear.
.
Heel Contact: Use a thi cker thrust washer to
move the dri ve pi ni on toward from the ri ng gear.
.
Fl ank Contact: To move the ri ng gear away from
the dri ve
pi ni on, ti ghten the adj ustment screw on
the dri ve
pi ni on si de and l oosen the adj ustment
screw on the ri ng gear si de. Recheck backl ash
after adj usti ng the adj ustment screws. l f out of
speci fi cati on, adj ust as descri bed under Toe
Contact.
.
Face Contact: To move the ri ng
gear
toward the
dri ve
pi ni on, ti ghten the adj ustment screw on the
ri ng gear si de and l oosen the adj ustment screw
on the dri ve
pi ni on si de. Recheck backl ash after
adj usti ng the adj ustment screws. l f out of
speci fi cati on, adj ust as descri bed under Heel
Contact.
Correct Tooth Contact
A
Toe Contact
z7-'l\
r
-:
/
\
-'J
(cont' d)
15-23
Rear Differential
Differential Reassembly
(cont'dl
Heel Contact
Flank Cont.cl
Face Contast
Part Number Thi ckness
41361-PCZ-003 3. 08 mm
( 0. 1213
n,
B 41362-PCZ-003 3. 11 mm
( 0. 1224
n.
c 41363-PCZ-003 3. 14 mm
( 0. 1236
n.
D 41364-PCZ-003 3. 17 mm
( 0. 1248
n,
E 41365-PCZ-003 3. 20 mm
( 0. 1260
n.
F 41366-PCZ-003 3. 23 mm
( 0. 1272
n.
G 41367-PCZ-003 3. 26 mm
( 0. 1283
n.
t-l 41368.PC2"003 3. 29 mm { 0. 1295n.
41369-PCZ-003 3. 32 mm
( 0. 1307
n.
41370-PCZ-003 3. 35 mm
( 0. 1319
n.
K 41371. PC2- 0033. 38 mm
( 0. 1331
n.
L 4't31 2-PCZ-003 3. 41 mm { 0. 1343n,
M 41373-PCZ-003 3. 44 mm { 0. 1354n .
41314,PCz.-003 3. 47 mm
( 0. 1366
n.
o 41375-PCZ-003 3. 095 mm
( 0. 1219
n. )
P 41376-PCZ-0033. 125 mm
( 0. 1230
n, )
o 41377
-PCZ-003
3. 155 mm
( 0. 1242
n. l
R 41378-PCZ-0033. 185 mm { 0. 1254n. )
s 4' t379-PCZ-0033. 215 mm
( 0. 1266
n. )
T 41380-PCZ-0033. 245 mm
( 0. 1278
n. )
AA 41381-PCZ-003 3. 275 mm
( 0. 1289
n. )
AO 41382.PCz.-OO33. 305 mm
( 0. 1301
n. )
AP 41383-PCZ-003 3. 335 mm
( 0. 1313
n. )
AO 41384-PCZ-003 3. 365 mm
( 0. 1325
n
AR 41385-PCZ-0033. 395 mm
( 0. 1337
n
AS 41386-PCZ-0033.425 mm
(0.' 1348
n. )
AT 41387-PCZ-0033. 455 mm
( 0. 1360
n. )
N
":
Standard
15-24
21. Rotate the Torsen LSD assembl y several ti mesto
assure
proper
tapered rol l er beari ng contact.
Measure the Torsen LSD assembl y prel oad
usi ng
t he push/ pul l gauge.
.
l f theTorsen LSD assembl y
prel oad
exceeds the
standard. adj ust by l ooseni ng the adj ustment
screws a notch at a ti me.
.
l f t heTor sen LSDassembl y
pr el oad
i s l esst han
the standard, adj ust by ti ghteni ng the adj ustment
screws a notch at a ti me.
Standard: 14
-30
N
( 1. 4- 3. 1
kgt , 3. 1 6. 8 l bf l
22. Instal l the l ock pl ates (A).
2-."1N
G)i-o;
22 N.m (2.2
kgf m, 16 lbl ft)
23. I nst al l t he oi l seal usi ng t he speci al t ool s as shown.
07JAO-P190100
24. I nst al l t he br eat her
pl at e ( A) ,
f i l l er pl ug ( B) ,
dr ai n
pl ug ( C) ,
and seal i ng washer s.
A^\
9-- 9'.
}3\
c
\..-z \.
4 5 N m
(4. 6
kgt . m,
33 rbt.ft)
25. Remove the di rty oi l from the di fferenti al case
seal i ng surface. Appl y l i qui d gasket
(P/N
08718-
0001) to the seal i ng surface.
Be sure to seal the enti re ci rcumference of the bol t
hol es to prevent oi l l eakage.
NOTE:
.
l f 5 mi nutes have passed afterappl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
.
Al l ow i t to cure at l east 20 mi nutes after
assembl y before fi l l i ng the di fferenti al wi th oi l .
- - '
Li qui d gasket
26. l nstal l the di fferenti al case assembl y.
(cont' d)
15-25
Rear Differential
Differential Reassembly
(cont'd)
Ti ghten the 10 mounti ng bol ts i n a cri sscross
pattern i n several steps.
24 N.m {2.4 kgf.m, 17 l bf.ft)
28. I nst al l t he cl i ps
( A)
on t he out put shaf t s, t hen i nst al l
the output shafts
(B).
27.
ili
. l l
- J . '
1 l
I
i:_ -.
15-26
\
1 .
Differential lnstallation
Instal l the ri ght and l eft di fferenti al mount bracket A
to the rear di fferenti al
(see page 15-29).
Pl ace the rear di fferenti al on the fl oor
j ack,
and
rai se i t to the mounti ng l evel .
Instal l the four di fferenti al mount bracket B
mounti ng nul s.
12 x 1. 25 mm
75 N. m (7. 6
kgf m, 55l bf f t l
_ - j
=
4. Instal l the ri ght and l eft di fferenti al mountbracketA
mounti ng bol ts.
10 x 1. 25 mm
45 N. m
(4. 6
kgf . m, 33 l bf . f t )
l nst al l t he cani st er cover.
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m, 7. 2 l bf f t }
6. Instal l the rear suspensi on sti ffener,
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bf . f t )
Instal l the i nboard
j oi nts (A)
onto the rear
di fferenti al by al i gni ng the reference marks
(B).
7.
I
Repl ace.
SPECIAL BOLT
' 10
x 1. 25 mm
A
83 N m {8. 5 kgt . m, 61 l bl . f i )
(cont' d)
10 x 1. 25 mm
45Nm14. 6kgf . m,
33 tbf.ft)
15-27
Rear Differential
.a=:\
\mr{-B
69-78 N.m
6<
{7.0-8.0 kgf.m.
51-58 tbt.ftl
9, Instal l the ABS sensor harness onto the upper arm.
Differential Installation
(cont'dl
Instal l the bal l
j oi nts
onto the l ower arms
(A),
then
i nstal l the castl e nuts
(B)
and new cotter pi ns.
NOTE: Make sure the bal l
j oi nt
boot i s not damage
or cracks.
rbf.ftl
Instal l the
propel l er
shaft to the transmi ssi on and
the rear di fferenti al by al i gni ng the reference marks
( see page
16- 181.
,/__-.-'
6 x 1. 0 mm
9. 8 N. m
(1. 0
kgl . m, 7. 2
10.
15-28
Differential Mount Replacement
NOTE: l f the i nstal l i ng the rear di fferenti al and mount assembl es, ti ghten the di fferenti al mount bracket B mounti ng
nuts fi rst, then the di fferenti al mount bracket A mounti ng bol ts,
12 x 1, 25 mm
64 N.m 16.5 kst.m, 47 lbt.ftl
12 x' 1. 25 mm
75 N. m
(7. 6
kgf . m, 55l bt . f t )
10 x 1. 25 mm
4 5 N m
(4.6
kgf m,
33 tbf.ft)
DIFFERENTIAL MOUNT B
RUBBER ASSEMBLY
12 x 1, 25 mm
64 N. m
(6.5 kgf.m, 47 lbf.ftl
10 x 1 . 25 mm
45 N. m
(4.6 kgl.m,33 lbl.ft)
' 12
x 1.25 mm
64 N.m
(6.5 kgf m,47 l bf.ftl
15-29
Transaxle
Driveline/Axle
Speci al Tool s . . . . . . . . . . . . . 16-2
Dri veshaf t l nsoect i on . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Dri veshaf t s Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Dri veshaf t s Di sassembl y . . . . . . . . . . . . . . . . . . . 16-5
Dri veshaf t s Reassembl y . . . . . . . . . . . . . . . . . . . . 16-8
Dri veshaf t s l nst al l at i on . . . . . . . . . . . . . . . . . . . . . . 16-15
Propel l er Shaf t I nspect i on . . . . . . . . . . . . . . . . . 16-16
Propel l er Shaf t Removal . . . . . . . . . . . . . . . . . . . . 16-17
Propel l er Shaf t I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Driveline/Axle
Speci al Tool s
T
16-2
Ref. No. Tool Number Descriotion Oly
o
n)
0TrvtAc-s100200
07xAc-001020A
Bal l Joi nt Remover , 28 mm
Threaded Adaoter. 24 x 1.5 mm
1
Driveshaft Inspection
1 .
3.
Check the i nboard boot
(A)
and outboard boot
(B)
on the dri veshaft
(C)
for cracks, damage, l eaki ng
grease, and l oose boot bands
(D).
l J any damage i s
found, reDl ace the boot and boot bands.
Turn the dri veshaft by hand, and make sure the
spl i nes
(E)
and
j oi nt
are not excessi vel y l oose.
Make sure the dri veshaft i s not twi sted or cracked;
i f i t i s, repl ace i t.
Driveshafts Removal
Special Tools Required
Bal l j oi nt remover, 28 mm 07MAC-S100200
1. Loosen the wheel nuts sl i ghtl y
2. Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
( see page 1- 13) .
3. Remove the wheel nuts and rear wheel s.
4. Li ft up the l ocki ng tab
(A)
on the spi ndl e nuts
(B),
then remove the nut.
Remove the cotter
pi n (A)
from the l ower arm bal l
j oi nt
castl e nut
(B),
and remove the nut.
NOTE;
.
To avoi d damagi ng t he bal l j oi nt , i nst al l a hex nut
on t o t he t hr eads of t he bal l j oi nt .
.
Be careful not to damage the bal l j oi nt boot when
i nstal l i ng the remover.
07MAC-S100200
,#-......-o
6. Separ at e t he bal l j oi nt f r om t he l ower ar m
( C) wi t h
t he speci al t ool
( see page 18- ' 10: .
(cont' d)
i " I
- 7. .
. . - ' ' . '
" . ( , ' ' :
16-3
Driveline/Axle
Driveshafts Removal
(cont'dl
7. Remove the ABS sensor harness
(A)
from the
upper ar m,
A
Make reference marks
(A)
across the i nboard
j oi nt
(B)
and the rear di fferenti al
(C).
9. Remove the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
(E),
then remove the i nboard
j oi nt
from
the rear di fferenti al .
Pul l the knuckl e outward, and remove the i nboard
j oi nt
from the rear di fferenti al .
' 10.
16-4
11. Pul l t he knuckl e out war d, and r emove t he
dri veshaft outboard
j oi nt
from the wheel hub usi ng
a
pl asti c hammer.
12. Remove the dri veshaft.
Driveshafts Disassembly
Special Tools Required
.
Threaded adaptet,24x 1.5 mm 07XAC-0010204
.
Sl i de hammer , commer ci al l y avai l abl e
lnboard Joint Side:
1. Remove the boot bands. Be careful nottodamage
the boot.
.
l f the boot band i s a doubl e l oop type
(A),
l i ft up
the band bend
(B),
and
push
i t i nto the cl i p
(C).
.
l f the boot band i s a l ow profi l e
type
(D). pi nch
the boot band usi ng a commerci al l y avai l abl e
boot band pi ncers (E).
Double Loop Typ
Low Profile Type
2. Make a mar k
( A)
on each r ol l er
( B)
and i nboar dj oi nt
(C)to
i denti fy the l ocati ons of rol l ers and grooves
i n the i nboard
j oi nt.
Then remove the i nboard
j oi nt
on the shop towel
(D).
Be careful not to drop the
rol l ers when separati ng them from the i nboard
i oi nt .
Make a mar k
( A)
on t he r ol l er s
( B)
and spi der
( C) t o
i denti fy the l ocati ons of rol l ers on the spi der. then
remove the rol l ers.
Remove the ci rcl i p
(D).
Make a mark
(E)
on the spi der and dri veshaft to
i denti fy the
posi ti on
of the spi der on the shaft.
Remove the spi der usi ng a commerci al l y avai l abl e
beari ng remover
(F).
(cont' d)
16-5
Driveline/Axle
7.
Driveshafts Disassembly
(cont'd)
Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the boot.
Remove the i nboard boot. Be careful not to damage
the boot.
9. Remove the vi nyl tape.
16-6
Outboard Joint Side:
1. Pry up the three tabs
(A)wi th
a screwdri ver, then
l i ft up the end of the band. Be careful not to
damage the boot.
2. Sl i de the outboard boot to the i nboard
j oi nt
si de Be
careful not to damage the boot.
3. Wi pe offthe grease
to expose the dri veshaft and
the outboard
j oi nt
i nner race.
4. Make a mark
(A)
on the dri veshaft {B) at the same
posi ti on
of the outboard
j oi nt
end
(C).
5. Careful l y cl amp the dri veshaft i n a vi se.
B
Remove the outboard
j oi nt
{A) usi ng the speci al
t ool and a commer ci al l y avai l abl e 5/ 8" x 18 sl i de
hammer
( B) .
Remove the dri veshaft from the vi se. 7.
8. Remove the stop ri ng from the dri veshaft.
Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the boot.
Remove the outboard boot and boot band
(B).
Be
careful not to damage the boot.
Remove the vi nyl tape.
10.
1 1 .
16-7
Driveline/Axle
INBOARD BOOT
clRcLlP
*/
/ B J
! i
01t /^\
v
/-1
o99 lt
,"
-
Itt
spioen
g
\
Driveshafts Reassembly
Exploded View
Use t he
grease i ncl uded
i n t he i nboard boot set .
Use t he grease i ncl uded
i n t he i nboard boot set .
--------_l
STOP RING
Repl ace.
tu@a
BANDS
-
--.1
a'-
DRIVESHAFT
t----..\
OUTBOARD JOINT
16-8
Special Tools Required
.
Boot band tool , KD-3191 or equi val ent, commerci al l y
avai l abl e
.
Boot band pi ncers, Kent-Moore J-35910 or equi val ent,
commer ci al l y avai l abl e
NOTE: Refer to the Expl oded Vi ew as needed duri ng
thi s orocedure.
Inboard Joint Side:
1. Wrap the spl i nes wi th vi nyl tape
(A)
to
prevent
damage to the i nboard boot.
l nstal l the i nboard boot to the dri veshaft, then
remove the vi nyl tape. Be careful not to damage the
i nboard boot.
Instal l the spi der
(A)
onto the dri veshaft
(B)
by
al i gni ng t he mar ks
( C)
on t he spi der and t he end of
the dri veshaft.
Fi t the ci rcl i p
(D)
i nto the dri veshaft groove. Al ways
rotate the ci rcl i p i n i ts groove
to make sure i t i s ful l y
seated.
5. Fi t the rol l ers
(A)
onto the spi der
(B)
asshown,and
note these i tems;
.
Rei nstal l the rol l ers i n thei r ori gi nal posi ti onson
the spi der by al i gni ng the marks
(C).
.
Hol d the dri veshaft poi nted up to prevent
the
rol l ers from fal l i ng off.
Pack the i nboard
j oi nt
wi th the
j oi nt grease
i ncl uded i n the new dri veshaft set.
Grease quantily
Inboardi oi nt: 150- 160 g (5.3
5.6 oz)
6.
l Jse t he
. . ?-r=.r? l- .-__--
use t ne gr ease I nci uoeo
i
i n t he i nboar d boor sel . I
(cont' d)
16-9
Driveline/Axle
Driveshafts Reassembly
(cont'd)
7. Fi t the i nboard
j oi nt
onto the dri veshaft, and note
these i tems:
.
Rei nstal l the i nboard
i oi nt
onto the dri veshaft by
al i gni ng t he mar ks
( A)
on t he i nboar d
j oi nt
and
the rol l ers.
.
Hol d the dri veshaft so the i nboard
i oi nt
poi nts up
to prevent i t from fal l i ng off.
Adj ust the i nboard
j oi nt
unti l the rol l ers are i n the
mi ddl e of the
j oi nt.
Fi t the boot
(A)
ends onto the dri veshaft
(B)
and the
i nboard
j oi nt (C).
9.
16-10
front of the vehi cl e.
10. l nstal l the boot bands wi th the band end toward to
Pul l up t he sl ack i n t he band by hand.
Mark a
posi ti on (A)
on the band
' 10
14 mm
(0.4
0. 6 i n. ) f r om t he cl i p
( B) .
1 1 .
12.
13. Thread the free end ofthe band through the nose
secti on ofthe commerci al l y avai l abl e boot band
tool KD-3191 or equi val ent
(A),
and i nto the sl ot on
t he wi ndi ng mandr el
( B) .
Pl ace a wrench on the wi ndi ng mandrel of the boot
band tool , and ti ghten the band unti l the marked
spot
(C)
on the band meets the edge ol the cl i p.
Li ft up the boot band tool to bend the free end of
the band 90 degrees to the cl i p. Center-punch the
cl i p, t hen f ol d over t he r emai ni ng t ai l ont o t he cl i p,
1 4 .
t c .
17.
16. Unwi nd the boot band tool , and cut off the excess
free end ofthe band to l eave a 5
..
10 mm
(0.2
0.4
i n.)tai l protrudi ng
from the cl i p.
Bend the band end
(A)
by tappi ng i t down wi th a
nammer .
NOTE:
.
Make sure the band and cl i p do not i nterfere wi th
anythi ng and the band does not move,
.
Remove any grease remai ni ng on the
surroundi ng surfaces.
{cont' d)
's
16- 11
Driveline/Axle
Driveshafts Reassembly
(cont'dl
Outboard Joint Side:
1 . Wrap the spl i nes on the dri veshaft wi th vi nyl tape
(A)
to
prevent
damage to the outboard boot.
2. Instal l the new ear cl amp band
(B)
and outboard
boot. Be careful not to damage the outboard boot.
Remove the vi nyl tape.
Instal l the new stop ri ng i nto the dri veshaft
groove
( A) .
16-12
5. l nse rt the dri veshaft
(A)
i nto the outboard
j oi nt (B)
unti l the stop ri ng
(C)
i s cl ose to the
j oi nt.
To compl etel y seat the outboard
j oi nt, pi ck up the
dri veshaft and
j oi nt,
and drop them from about 10
cm
(4
i n.) onto a hard surface. Do not use a
hammer as excessi ve force may damage the
dri veshaft. Be careful not to damage the threaded
secti on
(A)
of the outboard
j oi nt.
7. Check the al i gnment of the
pai nt
mark
(A)
wi th the
out boar d
j oi nt
end
( B) .
Pack the outboard
j oi nt
wi th the
j oi nt
grease
i ncl uded i n l he new
j oi nt
boot set:
Grease quantity
Outboard
i oi nt:
119 129914.2 4.5o2)
9. Adj ust the l ength of the dri veshafts to the fi gure
bel ow, then adj ust the boots to hal fway between
ful l compressi on and ful l extensi on. Make sure the
ends of the boots seat i n the grooves
of the
dri veshaft and
j oi nt.
Left Driveshaft: 579 584 mm {22.8 23.0 in.l
Right Driveshaft: 624 629 mm(24.6 24.8 in.l
10.Fi t the boot
(A)
ends onto the dri veshaft
(B)
and
outboard
j oi nt (C).
(cont' d)
16- 13
Driveline/Axle
1 1 .
Driveshafts Reassembly
(cont'd)
Set the new ear cl amp band
(A)
by threadi ng the
tab
(B)
i nto hol es
(C)
of the band.
Cl ose the ear
porti on (A)
of the band wi th a
commer ci al l y avai l abl e boot band
pi ncer s
Kent-Moore J-35910 or equi val ent {B).
' t 2.
16-14
Check the cl earance between the cl osed ear
porti on
of the band. l f the cl earance i s not wi thi n the
standard. cl ose the ear Dorti on of the band farther.
14. Repeat steps 12 and 13 Jor the band on the other
end of the boot.
3.0 mm 10.r2 i n.) MAX
Driveshafts Installation
1. Pul l t he knuckl e out war d. and i nst al l t he out boar d
j oi nt
i nto the rear hub.
2. Instal l the i nboard
j oi nt (A)
i ntothe rear di fferenti al
(B)
by al i gni ng the reference marks
(C),
then i nstal l
the si x i nboard
j oi nt
mounti ng bol ts
(D)
and nuts
{E).
, o
-/ 10 x 1. 25 mn
t
83 N. m
{8. 5 kgf . m,
61 tbt.ft)
3. Instal l the knuckl e
(A)
onto the l ower arm
(B).
Be
careful not to damage the bal l
j oi nt
boot
(C).
Wi pe
off the grease
before ti ghteni ng the nut at the bal l
j oi nt.
Torque the castl e nut
(D)
to the l ower torque
speci fi cati on, then ti ghten i t onl y far enough to
al i gn the sl ot wi th the pi n hol e. Do not al i gn the nut
by l ooseni ng i t.
NOTE: Make sure the bal l j oi nt boot i s not damage
or cracks.
E =\
W
\,<
' 12
x 1. 25 mm
69-78 N. m
(7.0-8.0
kg{'m,
4s-51 rbf.ft)
Instal l the new cotter pi n (E)
i nto the
pi n
hol e, and
bend the cotter
pi n.
Instal l the ABS sensor harness
(A)
on the upper
ar m.
6 x 1 . 0 mm
9. 8 N. m,
(1. 0
kgf . m, 7. 2 l bf f t l
(cont' d)
16- 15
Driveline/Axle
Driveshafts Installation
(cont'dl
Instal l a new spi ndl e nut
(A),
then ti ghten the nut.
After ti ghteni ng, use a dri ft to stake the spi ndl e nut
shoul der
(B)
agai nst the dri veshaft.
A 1 2 x 1 . 5 mm
24 x 1.5 mm 108 N.m
245 N.m
(11.0
kgf.m,
(25.0kgt.m, 79.6l bl .ft)
'181
lbf.ftl
1.
9.
8.
Cl ean the mati ng surfaces of the brake di sc and the
rear wheel , then i nstal l the rear wheel wi th the
wheel nuts,
Turn the rear wheel by hand, and make sure the
cl earance between the dri veshaft and
ci rcumference
parts.
Check the rear wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
16- 16
Propeller Shaft Inspection
2.
1 . Shi ft i nto neutrai
posi ti on.
Rai se the vehi cl e off the
ground, and suppon i t wi th
safety stands i n the proper l ocati ons
(see page 1-' 13).
Check the uni versal
j oi nt
boots for damage and
deteri orati on. l f the boots are damaged or
deteri orated, repl ace the propel l er shaft.
Check the
j oi nts
for excessi ve
pl ay
or rattl e. l f the
uni versal
j oi nts
have excessi ve
pl ay
or rattl e,
repl ace the
propel l er shaft.
5. l nstal l a di al i ndi cator
(A)
wi th i ts needl eonthe
center of the
propel l er shaft
(B).
6. Turn the
propel l er shaft sl owl y, and check the
runout. l f the runout exceeds the servi ce l i mi t,
repl ace the
propel l er shaft.
Runout:
Servi ce Li mi t: 1.5 mm {0.06
i n.l
1 .
Propeller Shaft Removal
Rai se the vehi cl e off the ground,
and make sure i t' s
securel y supported.
Remove the propel l er
shaft protector.
Make a reference mark
(A)
across the
propel l er
shaft
(B)
and the transmi ssi on fl ange
(C).
4. Separ at e t he
pr opel l er
shaf t f r om t he t r ansmi ssi on.
5. l Make a reference mark
(A)
across the
propel l er
shaft
(B)
and the rear di fferenti al fl ange
(C).
Separate the
propel l er
shaft from the rear
di fferenti al , then remove the
propel l er
shaft,
't-rt,
\-
16-17
Driveline/Axle
Propeller Shaft Installation
' t .
t
Instal l the
propel l er
shaft
(A)
onto the rear
di fferenti al
(B)
by al i gni ng the reference marks
(C).
NOTE: When the
propel l er shaft i s repl aced, al i gn
the whi te marks
(D)
on the new
propel l er shaft wi th
the whi te mark on the di fferenti al ,
SPECIAL BOLTS
Repl ace.
8 x 1, 25 mm
32 N. m
(3. 3 kgt m. 24l bf . f t l
l nstal l the oropel l er shaft {.A) to the transmi ssi on
(B)
by al i gni ng the reference marks
(Cl .
NOTE: When the
propel l er
shaft i s repl aced, al i gn
the whi te marks
(D)
on the new
propel l er shaft wi th
t he whi t e mar k on t he t r ansmi ssi on,
SPECIAL BOLTS
Repl ace.
8 x 1. 25 mm
32 N. m {3. 3 kgf . m, 24l bf . f t )
16- 18
3. Instal l the
propel l er shaft protector (A).
8 x 1. 25 mm
22 N. m 12. 2 kgf . m,
' 16l bf . f t )
Steering
Steering
Speci af Tool s . . . . . . . . . . . . . 17
-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
St eeri ng Wheel Rot at i onal Pl ay Check . . . . . . . . . . . . . . . . . . . . . . . 17-4
Power Assi st Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
St eeri ng Li nkage and Gearbox I nspect i on . . . . . . . . . . . . . . . . . 17-5
St eeri ng Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 7-6
St eeri ng Wheel Di sassembl y and Reassembl y . . . . . . . . . 17-7
St eeri ng Wheel I nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
St eeri ng Col umn Removal and I nst al l at i on . . . . . . . . . . . . . . . 17-9
St eeri ng Shaf t Removal and I nst al l at i on . . . . . . . . . . . . . . . . . . . . 17-10
St eeri ng Col umn/ Shaf t I nspect i on . . . . 17-12
St eeri ng Lock Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
Rack Gui de Adi ust ment . . . . . . . . . . . . . . . . . . . . . 17-14
Electrical Power Steering
(EPS)
17-15
Steering
Special Tools
Ref.No. Tool Number DescriDtion Oty
o 071\4AA-S10020A Locknut Wrench, 43 mm l
Component Location Index
AIRBAG
ASSEMBLY
STEERING GEARBOX
Rack Gui de Adj ustment, page 17
-14
ELECTRICAL POWER STEERING IEPS)
page 17- 18
STEERI NG WHEEL
Removal , page 17-6
Di sassembl y/ Reassembl y,
page 11- j
I nst al l at i on, page 17-8
STEERING COLUMN
St eeri ng Col umn Removal and I nst al l at i on,
page 17-9
St eeri ng Col umn I nspect i on,
page 17-12
St eeri ng Lock Repl acement ,
page' 11- 13
STEERING SHAFT
St eeri ng Shaf t Removal and I nst al l at i on,
page 17- 10
St eeri ng Shaf t I nspect i on,
page 17
-12
Removal / l nst al l at i on.
page 23-65
17-3
Steering
Steering Wheel Rotational Play
Gheck
1. Turn the front wheel s to the strai ght ahead posi ti on.
2, l vl easure how fa r you can turn the steeri ng wheel
l eft and ri ght wi thout movi ng the front wheel s.
.
l f the
pl ay i s wi thi n the l i mi t, the gearbox and
l i nkage ar e OK.
'
l f the
pl ay
exceedsthe l i mi t, adj ustthe rack gui de
(see page 17-14). l fthe pl ay i s sti l l excessi ve after
rack gui de adj ustment, i nspect the steeri ng
l i nkage and gearbox
{see
page 17-5).
ROTATIONAL PLAY: 0-10 mm l0-0,39 in,)
17-4
' 1.
Power Assist Check
Stan the engi ne, l et i t i dl e.
Attach a commerci al l y avai l abl e spri ng scal e to the
steeri ng wheel . Wi th the engi ne i dl i ng and the
vehi cl e on a cl ean, dr y f l oor ,
pul l
t he scal e as
shown and read i t as soon as the ti res begi n to turn.
l f the scal e reads no more than 34 N
(3.5
kgf, 7.7 Ibf),
the power assi st i s OK. l f i t reads more, check the
steeri ng l i nkage for damage
(see page 17-5), and
check t he r ack gui de adj ust ment
( see page 17- 14) .
Steering Linkage and Gearbox Inspection
STEERING GEARBOX
I nspect l or l oose mount i ng bol t s.
GEARBOX MOUNTING CUSHIONS
I nspect l or det eri orat i on.
STEERING COLUMN
l nspect for l oose col umn
mounti nq bol ts and nuts.
STEERING JOINTS
Check f or l oose
i oi nt
bol t s.
TIE.ROD LOCKNUT
Check for l oose l ocknut.
BALL JOINT BOOT
l nspect for damage and deteri orati on.
\r,.-*oo
a"o,o,-,-,o,",
l nspect I or f aul t y movement
ano oamage.
BOOT
I nspect f or damage and det eri orat i on.
17-5
Steering
Steering Wheel Removal
SRS components are l ocated i n thi s area, Revi ew the
SRS component l ocati ons, precauti ons, and procedures
i n the SRS secti on before performi ng repai rs or servi ce
( see page 23- 10) .
1. Make sure
you
have the anti -theft code for the radi o,
then wri te down the radi o stati on oresets.
2. Al i gn the front wheel s strai ght ahead, then remove
the dri ver' s ai rbag Jrom the steeri ng wheel
{see
page 23-65).
3. Di sconnectthe crui se control swi tch connector
(A)
and horn swi tch connector {B).
4. Loosen the steeri ng wheel bol t {A).
17-6
5. I nst al l a commer ci al l y avai l abl e st eer i ng wheel
pul l er (A)
on the steeri ng wheel
(B).
Free the
steeri ng wheel from the steeri ng col umn shaft by
turni ng the
pressure
bol t
(C)
of the
pul l er,
Note these items when removing the steering
wheel :
.
Do not t ap on t he st eer i ng wheel or t hest eer i ng
col umn shaft when removi ng the steeri ng wheel .
.
l f
Vout hr eadt he
pul l er
bol t s
( D)
i nt ot hewheel
hub more than fi ve threads, the bol ts wi l l hi t the
cabl e reel and damage i t. To prevent
thi s, i nstal l
a pai r of
j am
nuts fi ve threads up on each
pul l er
bol t.
6.
B
Remove the steeri ng wheel pul l er,
then remove the
steeri ng wheel bol t and steeri ng wheel from the
sl eefl ng col umn.
Steering Wheel Disassembly/Reassembly
STEERING WHEEL
\ i ** t
{?'%\-l
Y' - / \
I
.o"{.,,*,.
HORN PLATE
SLIDE SCREWS
Ag>
@ { (
#
*w
I
HORN PLATE COVEB
\h:
Y,
CRUISE CONTROL SWITCH
WHEEL LOWER COVER
I
v
\
CAP
I
ACCESS PANEL
17-7
Steering
Steering Wheel Installation
1. Before i nstal l i ng the steeri ng wheel , make sure the
front wheel s are al i gned strai ght ahead, then center
the cabl e reel
(A).
Do thi s by fi rst rotati ng the cabl e
reel cl ockwi se unl i l i t stoos. Then rotate i t
countercl ockwi se about two and hal f turns. The
ar r ow mar k
( B)
on t he cabl e r eel l abel
poi nt
shoul d
poi nt strai ght up.
Posi ti on the two tabs
(A)
of the turn si gnal
cancel l i ng sl eeve
( B)
as shown, and i nst al l t he
steeri ng wheel on to the steeri ng col umn shaft,
maki ng sure the steeri ng wheel hub
(C)
engages
the
pi ns (D)
of the cabl e reel and tabs of the
cancel i ng sl eeve. Do not tap on the steeri ng wheel
or steeri ng col umn shaft when i nstal l i ng the
steeri ng wheel .
2.
17-8
3. lnstallthe steering wheet bolt and tighten it.
39 N m {4. 0 kgf m, 29l bf . f t }
7.
Connect the horn swi tch connector and crui se
control swi tch connector.
Instal l the dri ver' s ai rbag, and confi rm that the
system i s operati ng properl y (see page 23-66).
Reconnect the battery.
Check the horn, crui se control sevresume swi tch,
and turn si gnal cancel l i ng for proper
operati on.
Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on presets.
For' 01-03 model s; reset the cl ock.
Steeri ng Col umn Removal and Instal l ati on
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and
procedures i n the
SRS secti on before performi ng repai rs or servi ce
(see page 23-10).
Removal
1. Record the radi o stati on presets, and di sconnect the battery.
2. Remove the d ri ver' s a i rbag
(see page 23-65). steeri ng wheel , and cabl e reel
(seepage23-72).
3, Remove the col umn covers
(A)
{' 1. 6 kgl m. 12 l bf . f t l
22 N.m {2.2 kgf.m, 16 lbt ft)
A
4. Remove the combi nati on swi tch assembl y
(B)
from the steeri ng col umn shaft by di sconnecti ng the connectors
and removi ng the screws.
5. Di sconnect the i gni ti on swi tch connectors from the under-dash fuse/rel ay box.
6. Remove t he st eer i ng
j oi nt
bol t
( C) .
7. Remove t he st eer i ng col umn
( D)
by r emovi ng t he at t achi ng nut s{ E} andbol t s( F) .
@G
(cont' d)
17-9
16 N. rn
Steering
Steeri ng Col umn Removal and
Installation
(cont'dl
lnstallation
2.
1 . I nst al l t he st eer i ng col umn, and make sur e t he
wi res are not caught or
pi nched
by any
parts.
Insertthe l ower end ofthe steeri ng
j oi nt (A)
onto
t he st eer i ng shaf t
{ B)
( l i ne
up t he bol t hol e
( C) wi t h
the fl at porti on (D)
on the shaft).
3. Pul l on the steeri ng
j oi nt
to make sure that the
steeri ng
j oi nt
i s ful l y seated, but do not pul l
excessi vel y on the
j oi nt.
Then i nstal l the steeri ng
j oi nt
bol t
(E)
and ti ghten i t to the speci fi ed torque.
US thru VIN JHMAP 114.YT008411
Canada thru VIN JHMAP 114.YT800750
Torque: 22 N'm
(2.2
kgf.m, 16 lbf.ft)
US from VIN JHMAP 114.YT008412
Canada trom VIN JHMAP 114.YT800751
Torque: 29 N.m
13.0
kgf m, 22 l bf.ftl
4, Fi ni sh t he i nst al l at i on, and not e t hese i t ems:
.
Make sure the wi re harness i s routed and
fastened properl y.
.
Make sure the connectors are properl y connected.
.
Rei nstal l the steeri ng wheel
(see page 17-8).
.
Reconnect the battery and reset the radi o presets.
-
Enter the anti -theft code for the radi o. then
enter the customer' s radi o stati on presets.
-
For ' 01- 03 model s; set t he cr ocK.
.
Veri fy crui se control , horn, and turn si gnal swi tch
opera on.
.
Check wheel al i gnment
( see page
18- 5) .
17-10
1 .
Steering Shaft Removal and
Instal l ati on
Removal
Remove the steeri ng col umn
(see page
17-9).
Mar k
( A) t he
st eer i ng
j oi nt ( B)
and pi ni on shaf t
( C)
to i denti fy the posi ti on
of the
j oi nt
on the
pi ni on
shaft.
Remove the steeri ng
j oi nt
bol ts
{D).
Di sconnect the steeri ng
j oi nt
from the
pi ni on
shaft
by pul l i ng the steeri ng shaft
(E).
Remove the steeri ng
j oi nt (B)
from steeri ng shaft.
Remove the steeri ng shaft.
5.
6.
lnstallation
1, Appl y mul ti purpose grease to the i nsi de surface of
t he pi ni on dust seal
( A) .
Insert the steeri ng shaft
(B)
i nto the engi ne
compartment careful l y to avoi d damagi ng the
pi ni on dust seal . Make sure the shaft comes out of
f r ame hol e.
I nst al l t he st eer i ng col umn wi t h t he col umn
mounti ng nuts and col umn hol der
(see page 17-9).
Sl i p the
j oi nt (A)
of the col umn shaft onto the
steeri ng shaft {B), then l oosel y i nstal l the
j oi nt
bol t
(C) (l i ne
up the bol t hol e
(D)
wi th the fl at porti on (E)
of the shaft). Pul l the steeri ng shaft toward the
col umn.
5. Sl i p the upper end
(A)
ot the steeri ng
j oi nt
onto the
17-11
7.
steeri ng shaft
(B) (from
the engi ne companment).
Be sure the steeri ng
j oi nt
and steeri ng shaft are
al i gned wi th the serrati ons; the
j oi nt
shoul d sl i p on
freel v. l f not, reposi ti on the serrati on of the steeri ng
i oi nt.
Li ne up the bol t hol e
(C)
wi th the fl at porti on (D)
of
the shaft
(B),
and l oosel y i nstal l the upper
j oi nt
bol t
(E).
Pul l the steeri ng
j oi nt
to make sure that the
j oi nt
i s ful l y seated.
Sl i p on t he l ower end
( F)
of t he st eer i ng
j oi nt by
al i gni ng t he mar ks
( G)
on t he
pi ni on shaf t
( H)
and
j oi nt.
Li ne up the bol t hol e
(l )
wi th groove around
(J
) the
pi ni on shaft, and i nstal l the l ower
j oi nt
bol t
(K)
and ti ghten i t by band. Don' t torque the bol t
yet.
Pul l the steeri ng
j oi nt
to make sure that the
i oi nt
i s
ful l y seated.
Pul l the steeri ng shaft toward the
pi ni on
shaft. Then
ti ghten the upper
j oi nt
bol t {E}. The l ower
j oi nt
bol t
(K)
{both i n the engi ne companment), and the
i oi nt
bol t on col um shaft
(under
the dashboard) to the
speci fi ed torque.
US thru VIN JHMAP 114.YT008411
Canada thru VIN JHMAP 114.YT800750
Torque: 22 N.m
(2.2
kgf.m, 16 lbf.ftl
US from VIN JHMAP 114.YT008412
Canada from VIN JHMAP 114.YT800751
Torque: 29 N.m
(3.0
kqf.m, 22 lbf.ft)
Steering
Steering Column/Steering Shaft Inspection
Check the steeri ng col umn bal l beari ng
{A) and the steeri ng
j oi nt
beari ngs
(B)
for pl ay
and
proper
movement. l f any
beari ng i s noi sy or has excessi ve pl ay, repl ace the steeri ng col umn as an assembl y.
Check the retai ni ng col l ar
(C)
for damage. l f i t i s damaged, repl ace the steeri ng col umn as an assembl y.
Check the absorbi ng
pl ates
{D) for di storti on or breakage. l f there i s di storti on or breakage repl ace the steeri ng
col umn as an assembl y.
Check the steeri ng shaft
(E)
for bendi ng and damage.
Check the
j oi nt
dust seal
(F)
for deteri orati on and damage.
6401
US thru VIN JHMAP 11i1.YT008411
Canad. t hru VI N JHMAP 114. YT800750
Torque: 22 N. m
(2. 2
kgf . m, 16l bf . f t l
US f rom VI N JHMAP 114. YT008412
Canada f rom VI N JHMAP 114. YT800750
Torque: 29 N. m
(3. 0
kgf . m, 22 l bf . f t l
..@@
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bt . f t )
17-12
Steering Lock Replacement
1. Remove the steeri ng col umn
(see page 17-9),
2. Center DUnch each of the two shear bol ts, and dri l l
thei r heads off wi th a 5 mm {3/16 i n.) dri l l bi t. Be
careful not to damage the swi tch body when
removi ng the shear bol ts.
;-:'
'
5.
6.
7 .
Remove the shear bol ts from the swi tch body.
Instal l the swi tch body wi thout the key i nserted.
Loosel y ti ghten the new shear bol ts.
Insert the i gni ti on key. and check for proper
operati on of the steeri ng wheel l ock and that the
i gni ti on key turns i reel y.
Ti ghten the shear bol ts
(A)
unti l the hex heads
(B)
twist off.
A
17-13
Steering
Rack Guide Adjustment
Special Tools Roquired
Locknut wrench, 43 mm 07MAA-S100204
1. Set the wheel s i n the strai ght ahead posi ti on.
2. Remove the sDl ash shi el d.
3. Remove the l ower radi ator hose bracket
(A).
9. 8 N. m
(1. 0
kgf . m, 7. 2l bt f t l
Loosen the rack gui de screw l ocknut
(A)wi th
the
speci al tooi , then l oosen the rack gui de screw
(B).
07MAA-S100200
Ti ghten the rack gui de screw to 25 N.m
(2.5
kgf.m,
18 l bf.ft), then l oosen i t.
Reti ghten the rack gui de
screw to 3.9 N.m
(0.4
kgf.m, 2.9 l bf.ft) then back i t off to the speci fi ed
a ng r e.
Speci ti ed Return Angl e: 15 + 5"
5.
6.
, - \
17-14
7. Ti ghten the l ocknut to 25 N.m
(2.5
kgf.m, 18l bfft)
whi l e hol di ng the rack gui de screw.
8. Instal l the l ower radi ator cl amp.
9. Check for ti ght or l oose steeri ng from l ock to l ock.
10. Perform fol l owi ng i nspecti ons:
.
Steeri ng wheel rotati onal
pl ay (see page 17-4).
.
Power assi st wi th vehi cl e parked (see page 17
-41.
Electrical Power Steering
(EPSI
EPS Gomponents
Soeci al Tool s
Component Locat i on I ndex . . . . . . . . . . . . . .
General Troubl eshoot i ng I nf ormat i on
DTC Troubl eshoot i ng I ndex
Sympt om Troubl eshoot i ng I ndex . . . . . . . . . . . . . . .
Syst em Descri pt i on . . . . . . . . . . . . . . . . .
Ci rcui t Di agram
DTC Troubl eshoot i ng . . . . . . . . . . . . . . .
EPS I ndi cat or Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . .
Memori zi ng t he Torque Sensor Neut ral Posi t i on . . . . . .
St eeri ng Gearbox Removal and l nst al l at i on
St eeri ng Gearbox Overhaul
Torque Sensor Repl acement
Rack Gui de Rem ova l / l nst a l l at i on . . . . . . . . . . . . . . .
Rack End Removal and I nst al l at i on
Gearbox Bracket Removal/lnstallation
Bal l Joi nt Boot Reol acement . . . . . . . . . . . . . . . . . .
EPS Cont rol Uni t Removal / l nst al l at i on
t / - t o
17-17
17
-18
17- 22
17-23
17-24
17-26
I t - 26
17-42
17
-45
17-46
17-53
17-54
17-54
't7-55
17-58
17-58
17-59
EPS Components
Special Tools
@
ai)
o
Ref.No. Tool Number Description otv
or
a\
11\
G)
07MAC-S100200
07746-0010100
07749-0010000
07974-6790000
Bal l Joi nt Remover , 2S mm
Attachment. 32 x 35 mm
Dri ver
Oi l Seal Dr i ver
,l
1
,l
,l
17-16
Component Location Index
MAI N UNDER-HOOD
FUSE/RELAY BOX
EPS CONTROL UNIT
EPS Control Uni t Bemoval /
Instal l ati on, page 17-59
DATA LINK
CONNECTOR I16PI
UNDER-HOOD FUSE BOX
GAUGE ASSEMBLY
UNDEB.DASH FUSE/RELAY BOX
TOROUE SENSOR
Torque Sensor Bepl acement, page 17-54
STEERING GEARBOX
St eeri ng Gearbox Removal
and l nst al l at i on, page 17-46
St eeri ng Gearbox Ovrhaul , page 17-53
Rack Gui de Bemoval / l nst al l at i on,
page 17-54
Rack End Removal and I nst al l at i on, page 17-55
Gearbox Bracket Removal / l nst al l at i on, page 17-58
Bal l Joi nt Boot Repl acement ,
page' 17-58
17-17
EPS Gomponents
General Troubleshooting Information
EPS Indicator
Under normal condi ti ons. the EPS i ndi cator comes on
when the i gni ti on swi tch i s turned to the ON
(l l ) posi ti on,
then goes off after the engi ne i s started. Thi s i ndi cates
that the bul b and i ts ci rcui t are operati ng correctl y.
l f there i s any troubl e i n the system after the engi ne i s
started, the EPS i ndi cator wi l l stay on, and the power
assi st i s turned off.
When EPS i ndi cator comes on, the control uni t
memori zes the DTC. In thi s case, the control uni t wi l l
not acti vate the EPS system after the engi ne starts
agai n, but i l keeps the EPS i ndi cator on.
When DTC 11, 12, ot 13 i s stored i n the control uni t, the
EPS i ndi cator wi l l stay on unti l the DTC i s erased. Even
though the system i s operati ng normal l y, the EPS
i ndi cator wi l l come on under the fol l owi ng condi ti ons:
.
When the vehi cl e i s barel y movi ng, 0.62 mph
(1
km/h)
or stopped, and the engi ne speed i s 2.000 rpm or
hi gher for about 3 mi nutes.
.
When the engi ne speed i s 500 rpm or l ess, and the
vehi cl e i s travel l i ng at a speed of 6.2 mph
(10
km/h)
or more for about 3 mi nutes.
To determi ne the actual cause of the
probl em. questi on
the customer about the condi ti ons duri ng whi ch the
probl em occured, taki ng the above condi ti ons i nto
consi derati on.
Diagnostic Trouble Code
(DTCI
.
l f the CPU cannot be acti vated. or i tfai l s, the EPS
i ndi cator comes on, but the DTC i s not memori zed.
.
The memory can hol d any number of DTCS. However,
when the same DTC i s detected more than once, the
most recent DTC i s wri tten over the pri or DTC.
therefore onl y one occurance i s memori zed.
.
The l owest DTC i s i ndi cated fi rst. The DTCs are
i ndi cated i n ascendi ng order, not i n the orderthat
they occurred.
.
The DTCS are memori zed i n the EEPROM
(non-
vol ati l e memory) therefore the memori zed DTCs
cannot be erased by di sconnecti ng the battery.
Perform the soeci fi ed Drocedures to ci ear DTCS.
Self-diagnosis
Sel f-di agnosi s can be cl assi fi ed i nto two categori es:
.
Ini ti al di agnosi s: performed ri ght after the engi ne
starts and unti l the EPS i ndi cator
goes
off.
.
Regul ar di agnosi s: performed ri ght afterthe i ni ti al
di agnosi s unti l the i gni ti on swi tch i s turned OFF.
The EPS control uni t
performs
the fol l owi ng functi ons
when a probl em i s detected by sel f-di agnosi s:
' 1.
Turns on the EPS i ndi cator.
2. Memori zes the oTC.
3. Stops power assi st and manual steeri ng operati on
resumes.
NOTE:
.
When DTC 23
(a probl em wi th the ci rcui tfor
engi ne speed si gnal ) i s detected, the
power
assi st wi l l return to normal when the vehi cl e
speed i s 6.2 mph
(10
km/h) or above.
,
Fot OfCs21,22, and 23the EPS i ndi catorwi l l go
off automati cal l V, and the system returns to
nor ma l .
Restriction on Power Assist Operation
Repeated extreme steeri ng force. such as turni ng the
steeri ng wheel conti nuousl y back-and-forth wi th the
vehi cl e stopped. causes an i ncrease of power
consumoti on i n the EPS motor. The i ncrease of el ectri c
current causes the motor to heat uo. Because thi s heat
adversel y affects the system. the control uni t moni tors
the el ectri c current of the motor.
When the control uni t detects heat bui l d-up i n the motor.
i t reduces the el ectri c current to the motor
gradual l y
to
protect the system, and i t restri cts the power assi st
operati on. The EPS i ndi cator does not come on duri ng
thi s functi on.
When steeri ng torque i s not appl i ed to the steeri ng
wheel , or when the i gni ti on i s turned off, the control
uni t wi l l restore the power assi st gradual l y unti l i t' s ful l y
restored
(after
about 8 mi nutes).
EPS Control Unit Noise
A rel ay sound or
"cl i ck"
can be heard from the EPS
control uni t about 30 seconds after the i oni ti on swi tch i s
turned off. Thi s sound i s normal .
Torque Sensor Neutral Position
The EPS control uni t stores the torque sensor neutral
posi ti on i n the EEPROM. Memori ze the torque sensor
neutral posi ti on whenever the gearbox i s removed and
i nstal l ed, or when the l orque sensor or EPS control uni t
i s reDl aced.
NOTE: The toroue sensor neutral oosi ti on i s not
effected when erasi ng the DTCs.
17-18
How to Troubleshoot EPS DTCs
The troubl eshooti ng fl owchart
procedures
assume that
the cause of the probl em
i s sti l l
present
and the EPS
i ndi cator i s sti l l on. Fol l owi ng the fl owchart when the
EPS i ndi cator does not come on can resul t i n i ncorrect
di agnosi s.
The connector i l l ustrati ons show the femal e termi nal
connectors wi th a si ngl e outl i ne and the mal e termi nal
connectors wi th a doubl e outl i ne.
1. Ouesti on the customer about the condi ti ons when
the probl em
occured, and try to reproduce the
same condi ti ons for troubl eshooti ng. Fi nd out
when the EPS i ndi cator came on, such as duri ng
EPS control , after EPS control . when the vehi cl e
was at a certai n speed, etc.
2. When the EPS i ndi cator does not come on duri ng
the test dri ve, but troubl eshooti ng i s done based on
the DTC, check for l oose connectors, poor
termi nal
contact, etc., before you start troubl eshooti ng.
3. Afte r trou bl eshooti ng. cl earthe DTC and test-dri ve
the vehi cl e. Be sure the EPS i ndi cator does not
come on,
How to Retrieve EPS DTCs
Honda PGM Tester Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)to
the 16P data l i nk connector
(DLC)
(B)
l ocated under the dash on the
passenger' s
si de
of the vehi cl e.
\
2. Turn the i gni ti on ON
(l l ),
and fol l ow the
prompts
on
the PGM Tester to di spl ay the DTC(S) on the screen.
After determi ni ng the DTC, refer to the DTC
troubl eshooti ng i ndex.
NOTE: See the Honda PGM Tester user' s manual
for speci fi c i nstructi ons.
Service Check Signal Circuit Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)
to the 16P data l i nk connector
(DLC)
(B)
l ocated under the dash on the
passsenger' s
si de
of the vehi cl e.
B A
Short the SCS ci rcui t to body ground
usi ng the
Honda PGM Tester.
Tur n t he i gni t i on swi t ch ON
( l l ) .
(cont' d)
17-19
, \
EPS Components
General Troubleshooting Information
(cont'dl
4. The bl i nki ng frenquency i ndi cates the DTC. DTCS
are i ndi cated by a seri es of l ong and short bl i nks.
Add the l ong and short bl i nks together to determi ne
the DTC. After determi ni ng the DTC. refer to the
DTC troubl eshooti ng i ndex,
The system wi l l not i ndi cate the DTC unl ess these
condi ti ons are met:
.
Set the front wheel s i n the strai ght ahead dri vi ng
posi ti on.
.
The i gni ti on swi tch i s turned ON
(l l ).
.
The engi ne i s stopped.
'
The SCS ci rcui t i s shorted to body ground before
the i gni ti on swi tch i s turned ON
(l l ).
Example ot DTC 12
Short bl i nks
{two
times)
*l
Examolo ot DTC 23
Turn the i gni ti on swi tch OFF.
Di sconnect the Honda PG M Tester from the DLC.
17-20
How to Clear EPS DTCs
Honda PGM Tester Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)
to the 16P data l i nk connector
(DLC)
{B) l ocated under the dash on the
passenger' s si de
of the vehi cl e.
Turn the i gni ti on swi tch ON
(l l ),
and cl ear the
DTC(S) by fol l owi ng the screen
prompts on the
PGM Tester.
NOTE: See the Honda PGM Tester user' s manual
for speci fi c i nstructi ons.
2
li - .,/
----==
r
-
-tt"=-=,,-.,-
,,
+rri
Service Check Signal Circuit Method:
NOTE: Use thi s procedure when the PGM Tester
software does not match the yearl model vehi cl e you
are worki ng on.
' 1.
Wi th the i gni ti on swi tch OFF, connect the Honda
PGM tester
(A)
to the 16P data l i nk connector
(DLC)
(B)
l ocated under the dash on the passenger' s
si de
of the vehi cl e.
4.
Whi th the vehi cl e on the
ground,
set the front
wheel s i n the strai ght ahead dri vi ng posi ti on.
Short the SCS ci rcui t to body
ground
usi ng the
Honda PGM Tester.
Turn the steeri ng wheel 45 degrees to the l eft from
the strai ght ahead dri vi ng posi ti on, and hol d the
steeri ng wheel i n that posi ti on.
Turn the i gni ti on swi tch ON
(l l ).
The EPS i ndi cator
comes on, then i t goes off after 4 seconds.
Wi thi n 4 seconds after the EPS i ndi cator goes off,
return the steeri ng wheel to the strai ght ahead
dri vi ng posi ti on
and rel ease the steeri ng wheel .
The EPS i ndi cator comes on agai n 4 seconds after
rel easi ng the steeri ng wheel .
Wi thi n 4 seconds after the EPS i ndi cator comes on,
turn the steeri ng wheel 45 degrees to the l eft agai n
and hol d i t i n that posi ti on.
The EPS i ndi cator
qoes
off after 4 seconds.
5.
7.
8. Wi thi n 4 seconds afterthe EPS i ndi cator goes off,
return the steeri ng wheel to the strai ght ahead
dri vi ng posi ti on agai n and rel ease the steeri ng
wheel . The EPS i ndi cator bl i nks twi ce 4 seconds
after rel easi ng the steeri ng wheel , i ndi cati ng that
the DTC was erased.
NOTE: l f the EPS i ndi cator does not bl i nk twi ce, an
error was made i n the procedure and the DTC was
not erased. Turn the i gni ti on swi tch OFF, and
repeat the operati on from the step 3.
9. Turn the i gni ti on swi tch OFF wi thi n 5 seconds after
the EPS i ndi cator bl i nks twi ce.
NOTE: l f the i gni ti on swi tch i s not turned OFF
wi thi n 5 seconds after the EPS i ndi cator bl i nks, the
system wi l l go
to the memori zi ng mode of the
torque sensor neutral
posi ti on.
To avoi d thi s, turn
the steeri ng wheel 45 degrees to l eft from the
strai ght ahead dri vi ng
posi ti on
and turn the i gni ti on
swi tch OFF. Thi s wi l l return the svstem to the al ert
mooe.
10. Di sconnect the Honda PGM Tester from the DLC.
1 1 , Perform the DTC code output operati on, and be
sure that the code has been erased.
EPS INDICATOB
STEEN {G
17-21
DTC Troubleshooting Index
DTC
Detection ltem
Note
DTC: 1 Power rel ay stuck ON
(see page 17-28)
Drc 2 Fai l -sate rel ay stuck ON
(see page l 7-28)
DTC: 3 LOW FET
(Motor
dri ve transi stor) stuck ON {see
page 17-28)
DTC: 4 UP FET
(Motor
dri ve transi stor) stuck ON
(see page
' 17-29)
DTC: 5 Open to body
ground i n the motor ci rcui t
(see page 17-30)
DTC: 1 1 Di fference of hi gh vol tage and l ower vol tage on the torque sensor
(see page 17' 32)
DTC: 12 A
probl em wi th vol tage for torque sensor VT3
(see page 17-33)
DTC: 13 A
probl em wi th average of vol tage for torque sensor VTl and W2 {see
page 17-32}
DTC: 14 Open or short to body ground i n the torque sensor ci rcui t
(see page 17-34)
DTC: 21 A probl em wi th the vol tage for l G l
(see page 17-35)
DfC:22 Excessi ve change of the vehi cl e speed sensor si gnal
( see page 17' 36)
A probl em wi th average for vehi cl e speed and engi ne speed { see
page 17- 36)
DTC: 23 A
probl em
wi th the ci rcui t for engi ne speed si gnal {see
page l 7-37}
DTC: 30 A
probl em wi th the sub-mi crocomputer
(see page 17-38)
DTC: 31 A probl em wi th the i ni ti al current sensor offset
(see page 17-38)
DTC: 32 A probl em wi th the mai n current sensor offset
( see page' 17- 38)
DTC: 33 A orobl em wi th the current sensor
(see page 17-38)
DTC: 34 A
probl em
wi th the mai n mi crocomputer {see
page l 7-39)
DTC: 35 A probl em wi th the sub-mi crocomputer {see
page 17-39)
DTC: 36 A probl em wi th the change of the motor vol tage
(see page 17-39)
DTC; 37 A
probl em wi th the motor vol tage
( see page 17- 40)
DTC; 50 to 62 A probl em wi th the CPU i n the EPS control uni t
(see page 17-42)
17-22
Symptom Troubleshooting Index
Symptom Diagnostic procedure
Also check for
EPS i ndi cator does not
come on
EPS Indi cator Ci rcui t Troubl eshooti ng
(see page 17' 42)
EPS i ndi cator does not go
off and no DTC is stored
EPS Indi cator Ci rcui t Troubl eshooti ng
(see page 17-42)
EPS i ndi cator does not stay
on, no DTC i s stored, and
there i s no
power
assi st
1. Check the RED wi re between the EPS control uni tandthe
motor for a short to ground. Repai r as needed.
2. l f the RED wi re i s OK, repl ace the steeri ng gearbox (short
i n
the motor).
17-23
EPS Components
System Description
EPS Control Unit lnputs and Outputs for Connector A
(2P)
EPS CONTROL UNITCONNECTOR A {2P}
Wi r e si de of f emal e t er mi nal s.
EPS CONTROL UNIT CONNECTOR A
(14P}
Wi r e si de of f emal e t er mi nal s.
Tormanal
numbet
Wir6 color Terminel sign
{Terminal namel
Description
Trminals Conditions
llonition Switch ON llll)
Vohage
GRN MOTOR
{Mot or mi nus}
Drives the actuator motor 1- Gr ound
2 MOTOR +
{Motor o!us)
Drives the actuator motor 2 Ground
EPS Gontrol Unit Inputs and Outputs for Connector B
(14P)
Terminel
numbl
Wirs color Terminal sign
{Terminal narne)
Description Measuremnt
Te.minals Conditions
on Switch ON {ll)l
Voltage
'l
YEL t G1
(l oni t i on
1
Power source for activating 1-Ground l oni t i on swi t ch ON
( l l )
Batterv voltaqe
l qni t i on swi t ch OFF
2 WHT/BLK VSP
(Vehi cl e
speed
pul se)
Detects vehicle speed signal
fr.jm the soeedometer
2-Ground Turn t he rear wheel
3 PNK vs1
{Voltaoe sensor 1
Detects torque sonsor
4 BLK G ND2
l Ground 2)
Ground f ort he EPS cont rol
unt
5 BLU NEP
l Enqi ne oul se)
Det ect s t achomet er si gnal 5-Ground St a(t he ongi ne About 3 V 6V
6 BLK GNDl
( Gr ound
1
Gr ound l or t he EPS cont r ol
uni t
1 BLU/ RED
l Vol t aoe f ade)
Dri ves t he t orque sensor
8 BRN
(Servi ce
check si onal )
Detects service check
11 WHT/ GRN vs2
(Vol t aqe
sensor 2)
Detects torque sensor
12 YEUBLU Dri ves t he EPS i ndi cat or
l i oht
12- Gr ound St art t he enoi ne Batterv voltaqe
t onr uon swt r cn ui i
BLU/BLK
( Power
st eer i ng si gnal )
Provades i dl e speed' up
si gnal t o t he ECM
l 3- Gr oundSt an t he engi ne and
t ur n t he st eer i ng wheel
1. ' { ul l l ock
Battery voltage
1 4 LT BLU DLC
i Dara l i nk connect or)
Communi cat es wi t h Honda
PGM-Tester
17-24
EPS Control Unit Inputs and Outputs for Connector C
(2P)
EPS CONTROL UNIT CONNECTOR C I2PI
Wi r e si de of f emal e t er mi nal s.
Terminal
numoea
Wire color Terminal sign
l Te. mi nal name)
Description Measurement
Termi nal s Conditions
(lonition
Switch ON {ll)}
Vohege
8LK PG
(Power ground)
Ground f or t he act uat or 1-Ground
2 WHT/BED + B
(Plus
batterv)
Power source fot the 2-Ground At al l t i mes Bat t ery vol t age
17-25
EPS Components
Circuit Diagram
UNDER-OASH
FUSE/RELAY AOX
TOROUE SENSOF 3P CONNECTOR
GAUGE ASSEMBLY CONNECTOR A (1' P)
GAUGE ASSEMELY CONNECTOA A
(T2PI
GAUGE ASSEMBTY CONNECTOF C {2OP)
Term nal si de of femal e tef mi nal s
TOROU
SENSOF
17-26
Wre side oi le male rermina ls
Wi r e si de oi f emal er er m nal s
_+*
h
.L---r-_r
MOTOA CONNECTOR I2P)
/-+'
t 2 t l l
er m nal si de ol f emal e l er mi hal s
EPS CONTROL UNIT
( : connectorl
EPSCONTEO! UNITCONNECTOR C {2P) EPS
l i ; connat or ) l a:
t 2 t 1 l
Ter mi na si de of f ema et er m nal s
CONNECTOR I
(14P)
DATA LTNKCONNECTOR (16p)
ffi
Wr r e si de ot i ema e l e. mi nal s
CONTBOI UNIT CONNECTOR A (2P)
tllu
W r e si de ot i ema et er mi nal s
Ter mr nal si de of f enal e l er f i i na s
17-27
EPS Components
DTC Troubleshooting
DTC 1: Power Rel ay St uck ON
DTG 2: Fail-safe Relay Stuck ON
1. Cl ear t he DTC.
2. Start the engi ne.
3. Wai t at l east 10 seconds.
Does the EPS i ndi catot come on and DTC 1 or
DTC 2 i ndi cated?
YES
-
Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO The system i s OK at thi s ti me.I
17-28
DTC 3: Lower FET Stuck ON
1, Di sconnect EPS control uni t connector A
(2P)
and
the motor 2P connector.
2. Check for conti nui ty between EPS control uni t
connect or A
( 2P)
t er mi nal No. 2 and mot or 2P
connect or t er mi nal No. 1.
FPS
CONTROL UNIT
MOTOR 2P CONNECToR
db-r'rrrriCrOn I tzpt
MOTOR+
(RED}
Termi nal si de of f emal e t ermi nal s
l s thete conti nui ty?
YES
-
Go to step 3.
NO
-
Repai r open i n the wi re between EPS control
uni t and the motor.I
3. Check for conti nui ty between the EPS control uni t
connector A
(2P)
termi nal No. I and motor 2P
connector termi nal No. 2.
MOTOR 2P CONNECTOR
EPS CONTROL UNI T
CONNECTOR A {2PI
MOTOR_
(GRN)
Ter mi nal si de oJ f emal e t er mi nal s
l s thete conti nui ty?
YES Go to step 4.
NO Repai r open i n the wi re between the EPS
control uni t and the motor.l
4. Check for conti nui ty between EPS control uni t
connect or A
( 2P)
t er mi nal s No. 2 and No. 1.
EPS CONTROL UNIT
CONNECTOR A I2P}
MOTOR+
(REDI
MOTOR_
{GRN}
Termi nal si de of l emal e t ermi nal s
ts there conti nui ty?
YES Repai r short between the RED and GRN
wi res for the EPS motor ci rcui t.l
NO Repl ace the steeri ng gearbox. (Short
ci rcui t to
body ground i nsi de the gearbox).I
DTC 4: Upper FET Stuck ON
1. Di sconnect EPS control uni t connector C
(2P).
2. Check for conti nui ty between EPS control uni t
connector C
(2P)
termi nal No. 1 and body ground.
EPS CONTROL UNIT
coNNECTOn C {2P}
Termi nal si de of femal e termi nal s
l s there conti nui ty?
YES-Check for l oose EPS control uni t connectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO- Repai r open i n the wi re between the EPS
control uni t and the body ground (G351).
t
17-29
EPS Gomponents
DTC Troubleshooting
(cont'd)
DTC 5: Open I n The Mot or Wi re Harness
1. Cl ear t he DTC.
2. Sta rt the engi ne.
3. Turn the steeri ng wheel to ri ght or l eft, and wai t 10
seconds or more.
Does the EPS i ndi cator come on?
YES Go to step 4.
NO-Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are
good, the system i s OK at thi s
t i me. l
4. Stop the engi ne, and veri fy the DTC
Is DTC 5 i ndi cated?
YES- Go to step 5.
NO-Perform the appropri ate troubl eshooti ng for
the code i ndi cated.I
5. Check t he EPS
( 70
A) f use i n t he auxi l i ar y under -
hood fuse box, and rei nstal l the Juse i f i t i s OK.
l s the f use OK?
YES Go to step 6.
NO
-
Repl ace the fuse and recheck. !
6. Make sure the i gni ti on swi tch i s OFF, then
di sconnect EPS control uni t connector C
(2P).
17-30
7. Measure the vol tage between termi nal No. 2 and
body
ground.
EPS CONTROL UNIT
CONNECTOR C {2PI
-rD
(WHT/RED)
8.
Termi nal si de of f emal e t ermi nal s
l s there battery vol tage?
YES Go to step 8.
NO
-
Repai r open i n the wi re between the EPS
(70
A) fuse and the EPS control uni t.l
Check for conti nui ty between EPS control uni t
connect or C
( 2P) t er mi nal No. I and body
gr ound
EPS CONTROL UNIT
CONNECTOR C {2P)
Termi nal si de of f emal e t ermi nal s
l s there conti nui ty?
YES Go to step 9.
NO Repai r open i n the wi re between the EPS
control uni t and body
ground
(G35' l ).1
Di sconnect EPS control uni t connector A
(2P)
and
the motor 2P connector.
9.
10. Check for conti nui ty between EPS control uni t
connector A
(2P)
termi nal No. 2 and motor 2P
connect or t er mi nal No. 1.
MOTOR 2P CONNECTOR
EPS CONTROL UNIT
CONNECTOR A {2PI
MOTOR+
(RED)
Termi nal si de of f emal e t ermi nal s
ls there continuity?
YES Go to step 1 1.
NO- Repai r open i n the wi re between EPS control
uni t and the motor.I
1 1. Check for conti nui ty between the EPS control uni t
connector A
(2P)
termi nal No. 1 and motor 2P
connect or t er mi nal No. 2.
FPS
CONTROL UNIT
MoToR 2p coNNEcroR
db-rrrrrrecron n tzpt
MOTOR_
(GRN)
Termi nal si de of f emal e t ermi nal s
Is there continuity?
YES Go to step 12.
NO Repai r open i n the wi re between the EPS
control uni t and the motor.l
12. Check for conti nui ty between EPS control uni t
connect or A
( 2P)
t er mi nal No. 1 and body gr ound.
EPS CONTROL UNIT
CONNECTOR A I2P)
Termi nal si de of f emal e t erm; nal s
ls there continuity?
YES
-
Repai r short to body ground i n the wi re
between the EPS control uni t and the motor.l
NO- Go t o st ep 13.
Check for conti nui ty between EPS control uni t
connector A {2P) termi nal No. 2 and body
ground.
EPS CONTROL UNIT
CONNECTOR A
(2P}
t J .
Moron+
f^T-\
{ R E D }
. - - z l l ,
(.o)
I
L
Termi nal si de of f emal e t ermi nal s
l s there conti nui ty?
YES Repai r short to body ground i n the wi re
between the EPS control uni t and the motor.l |
NO Check for Ioose EPS control uni t connectors. l f
necessary, substi tute a known-good EPS control
uni t and r echeck. I
17-31
EPS Components
DTC Troubleshooting
(cont'd)
DTC 11, 13: Torque Sensor
1. Cl ear the DTC.
2. Sta rt the engi ne.
Does the EPS i ndi cator come on?
YES Go to step 3.
NO-Check for l oose wi res or poor connecti ons. l f
the connecti ons are
good, the system i s OK at thi s
t i me. l
3. Stop the engi ne, and veri fy the DTC.
l s DTC 11 or 13 i ndi cated?
YES
-
Go l o step 4.
NO
-
Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
4. Make sure the i gni ti on swi tch i s OFF, then
di sconnect EPS control uni t connector B
(14P).
5. Check f or cont i nui t y bet ween t er mi nal No. 3and
body ground.
EPS CONTROL UNIT
cONNECTOR B {1i t P)
Termi nal si de of f emal e t ermi nal s
ls there continuity?
YES
-
Go to step 6.
NO- Go to step 9.
Di sconnect the torque sensor 3P connector. 6.
17-32
7. Check for conti nui ty between the appropraate
torque sensor 3P connector termi nal and body
gr ound
( see
t abl e) .
TOROUE SENSOR 3P
CONNECTOR
vs2
{WHT/GRN)
VS1 I PNKI
8.
{8LU/ REDI
Ter mi nal si de of f emal e t er mi nal s
l s there conti nui ty?
YES
-
Repai r short to body ground i n the
appropri ate sensor ci rcui t between the torque
sensor and the EPS control uni t.l
NO Go to step 8.
On the sensor si de, check for conti nui ty between
the torque sensor 3P connector termi nal No. 2 and
body
ground.
TOROUE SENSOR 3P
CONNECTOR
PVF
{ BLU/ BED}
Ter mi nal si de of f emal e t er mi nal s
ls there continuity?
YES The EPS system i s OK at thi s ti me. Check for
l oose EPS control uni t connectors. l f necessary,
substi tute a known-good EPS control uni t and
recheck.l
NO Repl ace the torque sensor.l
Termi nal name Torque Sensor terminal No.
VS1
'l
PVF 2
VS2 3
9. Check for conti nui ty between the appropri ate EPS
control uni t connector B
(14P)
and torque sensor 3P
connector termi nal s {see tabl e).
10.
Termi nal
name
Torque
Sensor
termi nal No.
EPS control
uni t
termi nal No,
VS1 1 3
PVF 2 7
VS2 3 1 1
EPS CONIBOL UN|r
@NNECTOR Bh' P)
'OROIJE SENSOfi 3P
CONNECTOR
Ter mi nal s de ol f emal et er mi nal s
l s there conti nui ty?
YES Go to step 10.
NO Repai r open i n the appropri ate torque sensor
ci rcui t between the EPS control uni t and the torque
sensor . I
On the sensor si de, check for resi stance between
torque sensor 3P connector termi nal s No. 1 and No.
2, and bet ween t er mi nal s No. 2 and No. 3.
Termi .al si de of l enal e termi .al s
l sthe resi stance between 12 14 Q (at 20",
68"F)?
YES-The EPS system i s OK at thi s ti me. Check for
l oose EPS control uni t connectors. l f necessary,
substi tute a known-good EPS control uni t and
r echeck, I
NO Repl ace the l orque sensor.l
TOROUE SENSOq 3P
CONNECIOR
DTC 12: Torque Sensor PVF
1. Cl ear t he DTC.
2. Sta rt the engi ne.
3. Wai t at l east 10 seconds.
Does the EPS indlcator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t t me. l
4. Veri fy the DTC.
l s DTC 12 i ndi cated?
YES Check for l oose EPS control uni t connectors.
l f necessary. substi tute a known-good EPS control
uni t and r echeck. l
NO
-
Perform the appropri ate troubl eshooti ng for
the code i ndi cated.I
17-33
EPS Components
DTG Troubleshooting
(cont'd)
DTC 14: Torque Sensor
(Resi st ance)
1. Cl ear t he DTC.
2. Sta rt the engi ne.
3. Turn the steeri ng wheel ful l y to the l eft, and hol d i t
i n that posi ti on for 10 seconds or more.
Does the EPS indicator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t i me. l
4. Stop the engi ne, and veri fy the DTC.
l s DTC 14 i ndi cated?
YES- Go to step 5.
NO- Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
5. Make sure the i gni ti on swi tch i s OFF, then
di sconnect the torque sensor 3P connector and EPS
control uni t connector B
(14P).
6. Check for conti nui ty between torque sensor 3P
connect or t er mi nal s No, 1 and No. 2.
TOROUE SENSOR 3P
CONNECTOR
Termi nal si de of {emal e t ermi nal s
l s there conti nui ty?
YES Repai r short between the BLU/RED and PNK
wi res i n the torque sensor ci rcui t between the
torque sensor and the EPS control uni t.l
NO Go to step 7.
17-34
7, Check for conti nui ty between torque sensor 3P
connect or t er mi nal s No. 2 and No. 3.
TOROUE SENSOR 3P
CONNECTOR
(BLU/RED}
l ermi nal si de of f emal e t ermi nal s
l s there conti nui ty?
YES Repai r short between the WHT/GRN and
BLU/RED wi res i n the torque sensor ci rcui t between
the torque sensor and the EPS control uni t.l
NO Go to step 8.
Check for conti nui ty between torque sensor 3P
connect or t er mi nal s No. 1 and No. 3.
TOROUE SENSOR 3P
CONNECTOR
vs2
(wHT/GRN)
Termi nal si de ol l emal e termi nal s
l s there conti nui ty?
YES Repai r short between the WHT/GRN and PNK
wi res i n the torque sensor ci rcui t between the
torque sensor and the EPS control uni t.l
NO Go to step L
8.
9. On the sensor si de, check for resi stance between
the torque sensor 3P connector termi nal s No. 1 and
No.2, and between termi nal No. 2 and No. 3.
TOROUE SENSOR 3P
CONNECTOR
Ter mi nal si de oI mal e t er mi nal s
l s the resi stance between 12- 13 Q (at20' ,
68' F)?
YES-The EPS system i s OK at thi s ti me. Check for
l oose EPS control uni t connectors. l f necessary,
substi tute a known-good EPS control uni t and
recheck.l
NO
-
Repl ace the torque sensor,I
2.
3.
DTC 21: Vol t age For l G1
' 1.
check t he I NSTRUMENT LI GHT
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box, and rei nstal l the fuse i f
i t i s OK.
NOTE: Al l i ndi cators except the chargi ng system
i ndi cat or wi l l not come on when t he I NSTRUMENT
LIGHT
(7.5
A) fuse i s bl own.
l s the tuse OK?
YES Go to step 2.
NO Repl ace the fuse and recheck.l
Dl sconnect EPS control uni t connector B
(14P).
Turn the i gni ti on swi tch ON
(l l ).
Measure the vol tage between termi nal No, 1 and
body
ground.
EPS CONTROL UNIT
CONNECTOR B {.l4P}
Termi nal si de of Iemal e termi nal s
ls there battery voltage?
YES Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO Check for an open i n the wi re between the
under-dash fuse/rel ay box and the EPS control uni t,
and repai r i t i f necessary. l f the wi re i s OK, check
for an open ci rcui t i nsi de the under-dash fuse/rel ay
box. l
17-35
EPS Components
DTG Troubleshooting
(cont'dl
DTC 22: Vehi cl e Speed Si gnat
NOTE:
.
l f the l \4l L i ndi cator i s ON, troubl eshootthe PGM-Fl
system iirst.
.
When the engi ne i s runni ng at 2,000 rpm or above
and the vehi cl e speed i s 0.62 mph
(
l km/h) or bel ow
for 3 mi nutes, the EPS i ndi cator comes on.
1. Test-dri ve the vehi cl e.
ls the vehicle speedometer working correctly?
YES Go to step 2.
NO Perform the speedometer system
troubl eshooti ng
(see page 22-53). a
Turn the i gni ti on swi tch OFF.
Bl ock the front wheel s and rel ease the
parki ng
oraKe.
Rai se the vehi cl e, and make sure i t i s securel y
supported.
Di sconnect EPS control uni t connector B
(14P).
17-36
6. Bl ock the ri ght rear wheel , and sl owl y rotate the l eft
rear wheel and measure the vol tage between EPS
control uni t connector B {14P) termi nal No. 2 and
body ground.
EPS CONTROL UNIT
CONNECTOR B I 14P}
{WHT/BLK)
Termi nal si de oJ femal e termi nal s
Does the voltage pulse 0 V and 5 V ?
YES Check for l oose EPS control uni t connectors.
l f necessary. substi tute a known-good EPS control
uni t and recheck.I
NO Repai r open or short to body ground i n the
wi re between the EPS control uni t and body ground,
or faul ty the speedometer.I
DTC 23: Engi ne Speed Si gna
NOTE: l f the MIL i ndi cator i s on, troubl eshootthe PGM-
Fl probl em fi rst,
1. Start the engi ne and check the tachometer.
l s the tachometer worki ng correctl y?
YES Go to step 2.
NO Go to step 5.
2. Connect a commerci al l y avai l abl e spri ng scal e to
the steeri ng wheel .
3. Pul l on the scal e to measure when the front wheel s
start to move. l f the system i s i n good condi ti on,
the scal e shoul d read no more than 34 N {3.5 kgf,
1 .7 tbt).
]t
ls the measurement within the specification?
YES The system i s OK at thi s ti me.I
NO
-
Go to step 4.
Test-dri ve the vehi cl e wi th the vehi cl e above 6.2
mph
( 10
km/ h) .
Does EPS provi de power assi st?
YES Go to step 5.
NO Perform the troubl eshooti ng for DfC 22.a
Turn the i gni ti on swi tch OFF.
Oi sconnect EPS control uni t connector B
(14P).
Start the engi ne.
5.
6.
7.
9.
10.
1 1 .
8. l vl easure the vol tage between the No. 5 termi nal
and body
ground.
,rrn"r"^Oourri))u'"",^;*
YES Check for l oose EPS control uni t connectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO Go to step 9.
Turn the i gni ti on swi tch OFF.
Di sconnect ECM connector A
(32P).
Check for conti nui ty between ECl vl connector
t er mi nal A' 19 and EPS cont r ol uni t
( 14P) connect or
t er mi nal No. 5.
ls there continuity?
YES Go to step 12.
NO
-
Repai r the open i n the wi re between the EPS
control uni t and the ECM.I
12. Di sconnect gauge assembl y connector C
(20P).
13. Check for conti nui ty between EPS control uni t
connector termi nal No. 5 and body ground.
l s thete conti nui ty?
YES
-
Repai r the short i n the wi re between the EPS
cont r ol uni t and t he ECM. I
NO Check for l oose EPS control uni t connectors. l f
necessary, substi tute a known-good EPS control
uni t and r echeck. I
17-37
EPS Gomponents
DTC Troubleshooting
(cont'dl
DTC 30: Su b-Microcomputer
1. Cl ear t he DTC.
2. St an t he engi ne.
3. Wai t at l east 10 seconds.
Does the EPS i ndi cator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t i me. l
4. Veri fy the DTC.
l s DTC 30 i ndi cated?
YES Check for l oose EPS conl rol uni t connectors.
l f necessary, substi tute a known-good EPS control
uni t and r echeck. l
NO Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
17-38
DTC 31, 32, 33: Mot or Current Sensor
1. Cl ear the DTC.
2. Stan the engi ne.
3. Wai t at l east 10 seconds.
Does the EPS i ndi cator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t r me. l
4. Veri fy the DTC.
l s DTC 31, 32, ot 33 i ndi cated?
YES Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
DTC 34, 35: EPS Cont rol Uni t l nt ernal Ci rcui t
1. Cl ear t he DTC.
2. Sta rt the engi ne.
3. Wai t at l east 10 seconds.
Does the EPS i ndi catot come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t i me. l
4. Veri fy the DTC.
l s DTC 34 ot 35 i ndi cated?
YES Check for l oose EPS control uni t connectors.
l f necessary, substi tute a known-good EPS control
uni t and r echeck. l
NO Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
5.
DTC 36: Charge of the Motor Voltage
1. Cl ear t he DTC.
2. Start the engi ne.
3. Turn the steeri ng wheel to ri ght or l eft, and wai t 10
seconds or more.
Doesthe EPS i ndi catot come on?
YES Go to step 4.
NO Check for l oose wi res or
poor connecti ons. l f
the connecti ons are
good, the system i s OK at thi s
t i me. l
4. Stop the engi ne, and veri fy the DTC.
l s DTC 36 i ndi cated?
YES Go to step 5.
NO
-
Perform the appropri ate troubl eshooti ng for
the code i ndi cated. !
Check t he EPS
( 70
A) f use i n t he auxi l i ar y under -
hood fuse box. and rei nstal l the fuse i f i t i s oK.
l s the tuse OK?
YES Go to step 6.
NO- Repl ace the fuse recheck.l
Di sconnect EPS control uni t connector C
(2P).
(cont' d)
17-39
EPS Gomponents
DTC Troubleshooting
(cont'dl
7. Measure the vol tage between termi nal No.2 and
body ground.
EPS CONTROL UNIT
CONNECTOR C
(2P)
+B
{WHT/REDI
Termi nal si de of f emal e t ermi nal s
ls therc battery voltage?
YES Check for l oose EPS control uni t connectors,
l f necessary, substi tute a known-good EPS control
uni t and recheck.l
NO Repai r open i n the wi re between the EPS
(70
A) fuse and the EPS control uni t.I
17-40
DTC 37: Motor Voltage
1. Check t he EPS { 70 A) f use i n t he auxi l i ar y under -
hood fuse box, and rei nstal l the fuse i f i t i s OK.
l s the f use OK?
YES
-
Go to step 2,
NO Repl ace the fuse and recheck. t
2. Check for conti nui ty between EPS control uni t
connector C
(2P)
termi nal No. 1 and body ground.
EPS CONTROL UNI T
CONNECTOR C I2PI
Termi nal si de of t emal e t ermi nal s
l sthere conti nui ty?
YES Go to step 3.
NO-Repai r open i n the wi re be&veen the EPS
cont r ol uni t and body gr ound ( G351) .
t
Di sconnect EPS control uni t connector A
(2P)
and
the motor 2P connector.
4. Check for conti nui ty between EPS control uni t
connector A
(2P)
termi nal No. 2 and motor 2P
connect or t er mi nal No. 1.
FPS CONTROL UNIT
MOTOR 2P CONNECTOR
dbirircron I tzpt
MOTOR+
{RED)
Termi nal si de of f emal e t ermi nal s
l s there conti nui ty?
YES-Go to step 5.
NO Repai r open i n the RED wi re between the EPS
control uni t and the motor.I
5. Check for conti nui ty between EPS control uni t
connector A
{2P)termi nal
No. 1 and motor 2P
connector termi nal No. 2.
MOTOR 2P CONNECTOR
EPS CONTROL UNIT
CONNECTOR A
(2PI
MOTOR_
{GRN)
Termi nal si de of femal e termi nal s
l s there conl i nui ty?
YES Go to step 6.
NO Repai r open i n the GRN wi re between the EPS
control uni t and the motor.l
6. Check for conti nui w between EPS control uni t
connector A {2P) termi nal No. 1 and body
ground.
EPS CONTROL UNIT
CONNECTOR A
(2PI
7.
Termi nal si de of f emal e t ermi nal s
l s there conti nui ty?
YES Repai r short to body ground i n the GRN wi re
between the EPS control uni t and the motor.l
NO Go to step 7.
Check for conti nui ty between EPS control uni t
connector A
(2P)
termi nal No. 2 and body ground.
EPS CONTROL UNIT
CONNECTOR A I2P)
MoroR+
afr)
{ RED)
r - - - - 1
z l r l
6
-L
Termi nal si de ol l emal e t ermi nal s
Is thete conti nui ty?
YES Repai r short to body ground i n the RED wi re
between the EPS control uni t and the motor.l
NO Check for l oose EPS control uni t connectors. l f
necessary, substi tute a known-good EPS control
uni t and r echeck. l
17-41
EPS Components
DTC Troubleshooting
(cont'd)
DTC 50 to 62: Central Processing Unit
(CPU)
1. Cl ear the DTC.
2. Start the engi ne.
3. Wai t at l east 10 seconds.
Does the EPS i ndi cator come on?
YES Go to step 4.
NO Check for l oose wi res or
poor
connecti ons. l f
the connecti ons are good, the system i s OK at thi s
t ame. l
4. Veri fy the DTC.
l s DTC 50 to 62 i ndi cated?
YES Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and r echeck. I
NO- Perform the appropri ate troubl eshooti ng for
the code i ndi cated.l
17-42
EPS Indicator Circuit
Troubl eshooti ng
1. Tur n t he i gni t l on swi t ch ON
( l l ) ,
st ar t t he engi ne,
and watch the EPS i ndi cator.
Does the EPS indicator come on?
YES- l f the EPS i ndi cal or comes on and goes
off, i t' s
OK. l f the EPS i ndi cator stays on or bl i nks, go to
step 13.
NO Go to step 2.
2. Turn the i gni ti on swi tch OFF, then ON
(l l )
agai n,
and watch the brake system i ndi cator.
Does the brake system indicatot come on?
YES Go to step 3.
NO Repai r open i n the i ndi cator power
source
ci r cui t . l
.
Bl own I NSTRUMENT LI GHT
( 7. 5
A) f use.
.
Open i n the wi re between the INSTRUMENT
LI GHT
( 7. 5
A) f use and gauge
assembl y.
.
Open ci rcui t i nsi de the under-dash fuse/rel ay box.
3. Turn the i gni ti on swi tch OFF.
4. Check t he EPS i ndi cat or bul b i n t he gauge
assemor y.
l s the bul b OK?
YES
-
Go to step 5.
NO Repl acet he EPS i ndi cat or bul b. t
5. Tur n t he i gni t i on swi t ch ON
( l l ) .
6, Connect
gauge assembl y connector A
(14P)
termi nal No. 14 to body ground wi th a
j umper
wi re.
GAUGE ASSEMBLY CONNECTOR A {14PI
1 2 3 4
1 8 9 0l) 11 3114
JUMPER
WIRE
WLP
{YEL/BLU}
Wi re si de of f emal e t ermi nal s
Does the EPS i ndi cator come on?
YES Go to step 7.
NO Repl ace the bul b ci rcui t board i n the
gauge
assembl y. I
7. Tur n t he i gni t i on swi t ch OFF.
8. Di sconnect EPS control uni tconnector B
(14P).
9. Turn the i gni ti on swi tch ON
(l l ).
10. Connect EPS cont r ol uni t connect or B( 14P)
t er mi nal No. 12 and body gr ound wi t h a
j umper
wi re.
EPS CONTROL UNIT
CONNECTOR B I14PI
Termi nal si de of femal e termi nal s
Does the EPS i ndi catot come on?
YES Go t o st ep 11.
NO Repai r open i n the wi re between the
gauge
assembl y and the EPS control uni t.l
11. Check for conti nui ty between body
ground and EPS
control uni t connector B {14P} termi nal s No. 4 and
No. 6 i ndi vi dual l y.
EPS CONTROL UNIT
CONNECTOR B I14PI
GNDl IBLKI
Termi nal si de of f emal e t ermi nal s
Is thete continuity?
YES Go to step 12.
NO Repai r open i n the wi res between the EPS
cont r ol uni t and body
gr ound ( G201
and G402) . 1
Measure the vol tage between EPS control uni t
connect or B
( ' l 4P) t er mi nal
No. 1 and body gr ound.
EPS CONTROL UNIT
CONNECTOR B I14PI
Termi nal si de of femal e termi nal s
l s thete battery vol tage?
YES Check for l oose EPS control uni tconnectors.
l f necessary, substi tute a known-good EPS control
uni t and r echeck. l
NO Repai r open i n the wi re between the
I NSTRUMENT LI GHT
( 7. 5
A) f use and t he EPS
cont r ol unr t . l
{cont' d)
17-43
EPS Components
13.
14.
t c .
EPS Indicator Circuit Troubleshooting
(cont'dl
Turn the i gni ti on swi tch OFF.
Di sconnect EPS control uni t connector B
(14P).
Di sconnect the connectors from the fol l owi ng uni ts.
.
ECM {32P)
.
ABS control uni t
.
SRS control uni t
Check for conti nui ty between EPS control uni t
connect or B
( 14P)
t er mi nal No. 8 and body
gr ound.
EPS CONTROL UNIT
CONNECTOR B llilP)
Termi nal si de of f emal e t ermi nal s
ls therc continuity?
YES Repai r short to body ground i n the SCS
ci r cui t . l
NO
-
Go to step 17.
17. Turn the i gni ti on swi tch OFF. then remove the
Honda PGM Tester.
18. ConnectEPS control uni t connector B
(' 14P).
19. Tur n t he i gni t i on swi t ch ON
( l l ) .
t o .
17-44
20. Measure the vol tage between data l i nk connector
( 16P) t er mi nal
No. 1 and body gr ound.
DATA LINK CONNECTOR
(16PI
Wi re si de of f emal e t ermi nal s
Is there about 6 V?
YES Go to step 21.
NO Repai r open i n the wi re between the data l i nk
connect or
( 16P)
and t he EPS cont r ol uni t . l
21. Tur n t he i gni t i on swi t ch OFF.
22. Connect al l di sconnected connectors.
23. Di sconnect EPS control uni t connector B
(14P).
24. Turn the i gni ti on swi tch ON
(l l ),
and startthe engi ne.
Does the EPS i ndi cator go off?
YES Go to step 25.
NO Repai r short to body
ground i n the wi re
between the EPS i ndi cator and the EPS control uni t.
I
25. Inspect the bul b ci rcui t board i n the gauge
assembl y
(see page 22-47).
l s i t normal ?
YES Check for l oose EPS control uni t connectors.
l f necessary substi tute a known-good EPS control
uni t and recheck.l
NO Repl ace t he bul b ci r cui t boar d i n t he gauge
assembl y. l
scs
(BRN)
Memorizing the Torque Sensor Neutral Position
The toroue sensor neutral oosi ti on must be memori zed
whenever the gearbox i s removed or i nstal l ed, or when
the torque sensor or EPS control uni t i s repl aced. Note
that the toroue sensor neutral Dosi ti on i s not affected
when erasi ng the DTC.
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM tester
(A)
to the 16P Data Li nk Connector
(DLC) (B)
l ocated under the dash on the passenger' s
si de of t he vehi cl e.
Wi th the vehi cl e on the ground, set the front wheel s
i n the strai ght ahead dri vi ng
posi ti on.
Shor t t he SCS ci r cui t t o body gr ound usi ng t he
Honda PGM Tester.
Turn the steeri ng wheel 45 degrees to the l eft from
the strai ght ahead dri vi ng
posi ti on, and hol d the
steeri ng wheel i n that
posi ti on.
Tur n t he i gnl t i on swi t ch ON
( l l ) .
The EPS i ndi cat or
comes on, then i t goes off after 4 seconds.
Wi thi n 4 seconds after the EPS i ndi cator goes off,
return the steeri ng wheel to the strai ght ahead
dr i vi ng posi t i on and r el ease t he st eer i ng wheel .
The EPS i ndi cator comes on agai n 4 seconds after
r el easi ng t he st eer i ng wheel .
2.
4.
7. Wi thi n 4 seconds after the EPS i ndi cator comes on,
turn the steeri ng wheel 45 degrees to the l eft agai n
and hol d i t i n that posi ti on.
The EPS i ndi cator
goes
off after 4 seconds.
8. Wi thi n 4 seconds after the EPS i ndi cator
goes
off,
return the steeri ng wheel to the strai ght ahead
dri vi ng
posi ti on and rel ease the steeri ng wheel . Do
not move the steeri ng wheel before turni ng the
i gni ti on swi tch OFF.
NOTE; l f the steeri ng wheel i s moved, the torque
sensor neutral
posi ti on
cannot be wri tten to
memory.
L The EPS i ndi cator bl i nks twi ce 4 seconds after
rel easi ng the steeri ng wheel . then i t bl i nks three
ti mes 5 seconds after. Then, the i ndi cator goes off.
The t or que sensor neut r al
posi t i on i s memor i zed.
NOTE: l f the EPS i ndi cator stays on, there was an
error i n wri ti ng the torque sensor neutral
posi ti on
to memory. Repeat the
procedure
starti ng from
step 3.
10. Turn the i gni ti on swi tch OFF.
11. Di sconnect the Honda PG M Tester from the DLC.
17-45
EPS Components
Steering Gearbox Removal and Installation
Special Tools Required
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
Removal
Note these i tems duri ng removal r
.
Usi ng sol vent and a brush, wash any oi l and di rtoff
the gearbox. Bl ow dry wi th compressed ai r.
.
Be sure to remove the steeri ng wheel before
di sconnecti ng the steeri ng
j oi nt.
Damage to the cabl e
reel can occur.
1. Make sure you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o
preset buttons. Di sconnect the negati ve cabl e from
the battery.
2. Rai se the vehi cl e, and make sure i t i s securel y
supported.
3. Remove the front wheel s-
4. Remove the dri ver' s ai rbag
(see page 23-65).
5. Remove the steeri ng wheel
(see page 17-6).
6. Pl ace a mark
(A)
on the steeri ng
j oi nt (B)
and the
pi ni on
shaft {C) to i denti fy the posi ti on of the
j oi nt
on the
pi ni on
shaft.
@
7.
L
Remove the l ower
j oi nt
bol t {D)
from the steeri ng
j oi nt .
Loosen the upper
j oi nt
bol t
(E)
on the steeri ng
j oi nt,
and pul l the steeri ng
j oi nt
ful l y to the steeri ng shaft
( F)
si de.
\
17-46
9. From the underthe dashboard; l oosen the
j oi nt
bol t
(A)
on the col umn, and pul l the steeri ng shaft
(B)
ful l v to the col umn si de.
From the engi ne companment; di sconnect the
steeri ng
j oi nt (A)
and pi ni on shaft
(8)
by movi ng the
steeri ng
j oi nt
toward the steeri ng shaft
(C).
' 10.
, - 1
' 11.
Remove and di scard the cotter
pi n (A)Jrom
the
12 mm nut
(B).
then remove the nut.
B
12 x 1.25 mm
07MAC-S100200
Separ at e t he t l e- r od bal l j oi nt and knuckl e usi ng t he
speci al t ool
( see page 18- 10) .
Remove the seven cl i ps {A) and the two fl ange
bohs
( B) ,
t hen r emove t he spl ash shi el d
( C) .
' 13.
6 x l . 0 mm
14. Remove the stabi l i zer bar hol der brackets {A) from
the frame, and l ower the stabi l i zer bar
(B).
6 6
Di sconnect the ground cabl e
(A)
and motor 2P
connector
(B).
Loosen the harness band
(C),
and
rel ease the wi re harness
(D)
from the
gearbox.
After di sconnecti ng the connector,
put a pi ece of
tape over the steeri ng
gearbox
connector to protect
i t from dust, di rt, and forei gn materi al s.
(cont' d)
17-47
EPS Components
Steering Gearbox Removal and Installation
(cont'dl
16. Di sconnect the torque sensor 3P connector
(A).
After di sconnecti ng the connector,
put
a
pi ece
of
tape over the steeri ng gearbox connector to protect
i t from dust, di rt, and forei gn materi al s.
' 17.
Remove the four gearbox mounti ng bol ts.
Right side:
Left side:
f,
H
--'\-r:
-=.1' l t'
.'ii,,ir'
)
t---:,tA
17-48
18. Pul l the steeri ng gearbox toward the front. Move
the steeri ng gearbox to the passenger' s si de and
remove i t.
lnstallation
1. Before i nstal l i ng the gearbox, centerthe steeri ng
rack wi thi n i ts stroke.
2. Pass the dri ver' s si de of the steeri ng
gearbox
through the l eft wheel housi ng. Pl ace the steeri ng
gearbox
on the front subframe, and move i t i nto the
or i gi nal
posi t i on.
3. Instal l the four gearbox mounti ng bol ts.
Ri ght si de:
10 x 1.25 mm
(3
N.m
{4. 4 kof m, 32 l bf . f t ) a
\_ll
\ f l H
Left side:
10 x 1. 25 mm
,(l
N.m
14. 4 ksf . m, 32l bf . f t l
{cont' d)
17-49
EPS Components
Steering Gearbox Removal and Installation
(cont'dl
4, Connect the torque sensor 3P connector
(A).
Connect the motor 2P connector
(A)
and
ground
cabl e
(B).
Secure the wi re harness
(C)
wi th the
{1. 0 kgt . m, 7. 2 l bt . f t }
17-50
6. Rai se the stabi l i zer bar
(A)
to the ori gi nal posi ti on,
and i nst al l t he st abi l i zer bar hol der br acket { B) .
7. I nst al l t he spl ash shi el d
( A) wi t h
t he seven cl i ps
( B)
and two fl ange bol ts
(C).
12 x 1. 25 mm
83 N. m
(8.5
kgf.m.
61 tbt.ftl
6 x
' 1.0
mm
9.8 N.m
{1.0 kgf' m,7.2l bf.ft)
ffi
8. Wi pe off any
grease
contami nati on f rom the bal l
j oi nt
tapered secti on and threads. Then reconnect
the ti e-rod ends
(A)to
the steeri ng knuckl es
(B),
and
ti ghten the 12 mm nut
(C)
to the speci fi ed torque.
D C
Instal l the new cotter pi ns (D).
and bend them as
snown.
From the engi ne companment, sl i p the l ower
end {A) of the steeri ng
j oi nt (B)
by al i gni ng the
marks
(C)
on the
pi ni on
shaft
(D)
and
j oi nt.
10.
12.
11. From the under the dashboard,
push
the steeri ng
shaft
(A)
ful l y to engi ne compartment si de, but do
not push excessi vel y on the steeri ng shaft. Then
ti ghten the
j oi nt
bol t
(B)
to the speci fi ed torque.
Li ne up the bol t hol e
(A)
wi th the
groove
around
(B)
the
pi ni on
shaft, and i nstal l the l ower
j oi nt
bol t
(C)
and the upper
j oi nt
bol t
(D)
to the speci fi ed torque.
US rhru VIN JHMAP 114.YT008411
Canada thru VIN JHMAP 114.YT800750
Torque: 22 N m
(2.2
kgf m, 16 lbf.ft)
US from VIN JHMAP 114 YT008412
Canada from VIN JHMAP 114.YT800751
Torque: 29 N.m
(3.O
kgt.m,221b1.11,
{cont' d)
17-51
EPS Gomponents
Steering Gearbox Removal and Installation
(cont'd)
13. i nst al l t he st eer i ng wheel
( see page 17- 8) .
14. I nst al l t he dr i ver ' s ai r bag
( see page 23- 65) .
15. Reconnectthe negati ve cabl e to the battery.
16. Instal l the front wheel s, and adj ust the front wheel
al i gnment
(see page 18-5).
17. After i nstal l ati on, perform the fol l owi ng checks.
.
Make sure the steeri ng gearbox wi res are not
caught or
pi nched by any
parts.
.
Make sure the steeri ng
gearbox connectors are
properl y connected.
.
Tur n t he i gni t i on swi t ch ON { l l ) , and check t hat
the EPS i ndi cator
goes off,
'
l f
you repl acedthe steeri ng
gearbox assembl y,
l et the EPS control uni t memori ze the torque
sensor neutral posi ti on (see page 17-45).
.
Test-dri ve the vehi cl e;
-
Check that the EPS i ndi cator l i ght does not
come on.
-
Check the steeri ng wheel spoke angl e. Recheck
and adl ust the front wheel al i gnment, i f
necessary.
.
Reset the radi o
presets.
.
For ' 01- 03 model s; set t he cl ock.
17-52
Steering Gearbox Overhaul
Exploded View
MOUNTING BUSHING
Inspect for damage and
deteri orati on.
BOX BRACKET
STEERING GEARBOX ASSEMBLY {MOTOR)
l l the gearbox i s faul ty, repl ace
i t as an assembl y.
LOCK WASHER
Repl ace.
/ ,o-RtNG
,/ ,/
^"'"""'
r' ,/ .,
RACK GU|DE
@, / / /
ou,,,
E(/"
P
\-
9'
--,,*,"o
\q- .)
@
\
BOOT BAND
Repl ace.
TOROUE SENSOR ASSEMBLY
l f the torque sensor i s faul ty,
repl ace i t as an assembl v.
TI E. ROD CLI P I nspect f or damage and
det eri orat i on.
BOOT
17-53
EPS Components
Torque Sensor Replacement
Note these i tems duri ng repl acement:
.
Do not al l ow dust, di n, or other forei gn mal eri al s to
enter the
gearbox.
.
Do not try to di sassembl e the torque sensor assembl y.
l f the l orque sensor i s faul ty, repl ace i t as an
assembl y.
.
l f t het or quesensor i s r epl aced, t he EPS cont r ol uni t
must memori ze the torque sensor neutral posi ti on
( see page 17- 45) .
1. Center the steeri ng rack wi thi n i ts stroke.
Remove the torque sensor assembl y
(A),
2.
D
8 x 1. 25 mm
20 N. m
12. 0
kgf . m.
14 tbf.ftl
A
/ : ' /
3.
5.
6.
Coat the new O' ri ng {B) wi th mul ti purpose grease,
and careful l y fi t i t on the torque sensor housi ng.
Appl y mul ti purpose
grease to the needl e beari ng
( C)
i n t he gear box housi ng.
I nst al l t he t or que sensor assembl y
( A)
on t he
gear box housi ng by engagi ng t he
gear .
The al phabet stampi ng
(for
exampl e
"AB")
{D) on
the
pi ni on shaft al i gns wi th the rack gui de screw
(E)
when the rack i s i n the strai ght ahead dri vi ng
posi ti on.
When i nstal l i ng the torque sensor assembl y, make
sure the
"al phabet"
stampi ng
("48")
i s wi thi n the
r ange shown.
Ti ght en t he 8 mm f l ange bol t s
( F) .
17-54
Rack Guide Removal/lnstallation
NOTE: Duri ng removal /i nstal l ati on, do not al l ow dust,
di n, or other forei gn materi al s to enter the
gearbox.
1 .
5.
Appl y mul ti purpose
grease l o the sl i di ng surface of
the rack gui de, and i nstal l i t onto the gearbox
ho usr ng.
Coat the new O-ri ng
(E)
wi th mul ti purpose
grease,
and careful l y fi t i t on the rack gui de screw
groove.
I nst al l t he spr i ng, r ack gui de scr ew, and l ocknut .
Adj ust the rack gui de screw
(see page 17-14).
After adj usti ng, check that the rack moves
smoothl y by sl i di ng the rack ri ght and l eft.
Rack End Removal and Installation
Special Tools Required
.
Attachment, 32 x 35 mm 07746-0010100
.
Dri ver, 07749-0010000
Removal
Note these i tems duri ng removal /i nstal l ati on:
.
Do not al l ow dust, di rt, or other forei gn materi al s to
enter the gearbox.
.
Do not di sassembl e the steeri ng gearbox
assembl y
(motor).
l f the motor i s faul ty, repl ace i t as an
assembl y,
1. Remove t he boot bands { A) anddi scar dt hem.
Remove the ti e-rod cl i ps
(B),
and pul l the boots
away from the ends of the gearbox.
NOTE: After removi ng the boot, check for water,
di rt, or other forei gn matter on the bal l screw
surface
(C)
and i nteri or of the boot. l f contami nated,
cl ean the bal l screw, gearbox housi ng, and boot
compl etel y.
b
2. Unbend the l ock washer.
Hol d the fl at surface secti ons
{A) on the passenger' s
si de steeri ng rack shaft wi th one wrench, and
unscrew both rack ends
(B)
wi th another wrench.
Be careful not to damage the shaft surface wi th the
wrench. Remove the l ock washer
(C)
and di scard i t.
(cont' d)
17-55
EPS Components
Rack End Removal and Installation
(cont'd)
4, Check the rubber stop
(A)
for damage or
deteri orati on. l f the rubber stop i s damaged or
deteri orated, reol ace i t.
Grasp the l eft rack end, and
pul l
the rack shaft al l
the wav to the l eft. Careful l v remove the rubber
stop by pryi ng i t out ofthe
gearbox housi ng
(B)
wi th a fl at ti p screwdri ver {C) on the cut-out
porti on
{D) so as not to damage the housi ng.
l f the rubber stop was removed,
posi ti on
the new
rubber stop
(A)
i n the gearbox housi ng, then dri ve
i t i n usi ng the speci al tool s as shown. Make sure
that the speci al tool
presses agai nst the metal
porti on
{B) of the rubber stop.
07746-0010100
07749-0010000
17-56
lnstallation
1. l nst al l t he new l ock washer { A) ont her ackshaf t .
Al i gn the l ock washer tabs
(B)
wi th sl ots
(C)
i n the
r ack shaf t . I nst al l t he r ack end
( D)
whi l e hol di ng
wi th l ock washer i n pl ace. Repeat thi s step for the
other si de of the rack shaft.
2. Hol d the fl at surface secti ons {E)
on the
passenger' s
si de of the steeri ng rack shaft wi th a wrench, and
ti ghten both rack ends. Be careful not to damage
the shaft surface wi th the wrench.
3. Bend the l ock washer
(A)
back agai nst the fl at spots
on t he r ack end
j oi nt
housi ng.
Appl y mul ti purpose grease
to the ci rcumference
(A)
of the rack end
j oi nt
housi ng.
o-Gr
Appl y a l i ght coat of si l i cone grease
to the boot
grooves
{B) on the rack ends.
Center the steeri ng rack wi thi n i ts stroke. Instal l the
boots
(A)
i n the rack end wi th the ti e-rod cl i ps
(B).
Cl ean off any grease
or contami nati on from the
groove
around {C} on housi ng.
{bN
7.
a'.RE-As!x
(P/ N:
08733-B070El
6.
After i nstal l i ng the boots, wi pe the grease
off the
thread secti on
(D)
of rack end.
9.
8. l nstal l the new boot band
(A)
by al i gni ng the tabs
(B)
wi th hol es
(C)
of the band.
Cl ose the ear porti on (A)
of the band wi th
commer ci al l y avai l abl e pi ncer s,
Oet i ker 1098 or
equi val ent
( B) .
SIi de the rack ri ght and l eft to be certai n that the
boots are not deformed or twi sted.
'1
0.
tf,
, t l
17-57
EPS Components
Gearbox Bracket RemovaU
l nstal l ati on
1. Remove the bracket cl amo bol t
(A)
from the
gearbox bracket
(B),
then pry open the bracket to
remove i t from the gearbox.
Instal l the gearbox bracket on the gearbox wi th the
bracket cl amp bol t toward the rear.
Adj ust the di stance between the bracket mounti ng
bol t hol e {A} and the gearbox mounti ng bol t hol e
(B)
to the di mensi on shown. Make sure the bracket
mounti ng bol t hol es are
paral l el wi th gearbox
mountl ng bol t hol es.
2.
A
8 x 1. 25 mm
25 N. m 12. 5 kgf . m,
18 tbf.ft)
4. Instal l the bracket cl amp bol t, and ti ghten i t to 25 N.
m
(2.5
kgf.m, 18 l bf ft).
17-58
Ball Joint Boot Replacement
Speci al Tool s Requi red
Oi l seal dri ver, 07974-6790000
1. Remove the boot from the ti e-rod end, and wi pe the
ol d grease off the bal l
pi n.
2. Packt he l ower ar ea of t he bal l
pi n ( A) wi t h
f r esh
mul t| purpose grease.
Pack the i nteri or of the new boot
(B)
and l i p {C) wi th
fresh mul ti purpose
grease.
Note these i tems when i nstal l i ng new grease:
.
Keep grease off the boot i nstal l ati on secti on
(D)
and the tapered secti on
(E)
i f the bal l pi n.
.
Do not al l ow dust, di rt, or other forei gn materi al s
to enter the boot.
I nst al l t he new boot { A) usi ng t he speci al t ool . The
boot must not have a gap at the boot i nstal l ati on
secti ons
(B).
After i nstal l i ng the boot, check the bal l
pi n tapered secti on for
grease contami nati on, and
wi pe i t i i necessary.
07974-6790000
-Gl
A
4.
EPS Control Uni t Removal /l nstal l ati on
1 . Make sure you have the anti ,theft code for the radi o,
then wri te down the frequenci es for the radi o
preset
buttons. Remove the battery.
Remove the EPS control uni t.
3. Di sconnect the EPS control uni t connectors.
4. l nstal l the EPS control uni t i n the reverse order of
removal .
NOTE: l f the EPS control uni t i s repl aced. the EPS
control uni t must memori ze the torque sensor
neutral posi ti on (see page 17-45).
17- 59
Suspensi on
Front and Rear Suspension
Speci al Tool s . . . . . . . . . . . . . 18-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
Wheel Al i gnment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18- 5
Wheel Beari ng End Pl ay I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-9
Wheel Runout I nspect i on . . . . . . . . . . . . . . . . . . 18-9
Bal l Joi nt Removal . . . 18-10
Front Suspension
Knuckl e/ Hub Reol acement
Bal l Joi nt Boot Repl acement . . . . . . . . . . . . . . . . . .
St abi l i zer Bar Repl acement . . . . . . . . . . . . . . . . . . . . . .
St abi l i zer Li nk Removal / l nst al l at i on
LowerArm Removal / l nst al l at i on . . . . . . . . . . . . . . .
Upper Arm Repl acement
Damper/ Spri ng Repl acement
Rear Suspension
Knuckl e/ Hub Repl acement
Bal l Joi nt Boot Repl acement . . . . . . . . . . . . . . . . . . . . .
St abi l i zer Bar Repl acement . . . . . . . . . . . . . . . . . . . .
St abi l i zer Li nk Removal / l nst al l at i on
Lower Arm Remova l / l nst a l l at i on . . . . . . . . . . . . . . .
Upper Arm Remova l / l nst a l l at i on . . . . . . . . . . . . . . .
Cont rol Arm Repl acement
Damper/ Spri ng Repl acement
18- 11
18- 16
18-17
18- 18
18- 19
18-20
18-22
18-28
t at -55
18-34
18-34
18-35
18-37
18-38
18-39
Front and Rear Suspension
Speci al Tool s
ar_\
o
i!.l
@
@. o, )
D
Ref.No. Tool Number
Description
OtY
a)
o\
@
lrl
@
a
@
/o
(iE
07GAF-SD40100
07GAF-SD40200
07GAG-SD40700
07JAF-SH20330 or
07933-H83000A
wi thout adj usti ng bol t
07MAC-S100200
07746-0010400
07746-0010500
07746-0010600
07749-0010000
07965-SD90100
Hub Di s/Assembl y Tool , 42 mm
Hub Di s/Assembl y Tool
Bal l Joi nt Boot Cl i p Gui de. 42 x 44 mm
Bushi ng Base
Bal l Joi nt Remover . 28 mm
Attachment. 52 x 55 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Dr i ver , 15 x 1351
SuDoort Base
,]
1
1
1
1
1
1
1
18-2
Component Location Index
Front Suspension:
STABILIZER BAR
Repl acement , page 18 17
Removal , st ep 1 on page 18-23
Di sassembl y/ l nspect i on, st ep 1 on page 18-24
Reassembl y, st ep 1 on page 18-25
I nst al l at i on, st ep 1 on page 18-26
ARM
Repl acement , page 18' 20
STABILIZER LINK
Removal /l nstal l ati on, page 18' 18
KNUCKLE/HUB
Repl acement, page 18-l 1
LOWER ARM
Removal / l nst al l at i on, page 18, 19
18-3
Front and Rear Suspension
Component Location Index
{cont'dl
Rear Suspensi on:
LOWER ARM
Removal /l nstal l ati on, page 18-35
CONTROL ARM
Repl acement,
page 18-38
BAR
Repl acement , page 18-34
REAR DAMPER
Removal , st ep 1 on
page 18-40
Di sassembl v/ l nspect i on, st ep' l on
page 18-41
Reassembl y, st ep 1 on page 18-41
I nst al l at i on, st ep 1 on page 18-42
UPPER ARM
Removal /l nstal l ati on,
page 18-37
KNUCKLE/HUB
Repl acement, page 18-28
STABILIZER LINK
Removal / l nst al l at i on,
page 18-34
18- 4
Wheel Alignment
The suspensi on can be adj usted for caster, camber, and
toe. However, each of these adj ustments are
i nterrel ated to each other, For exampl e, when
you
adj ust toe, l he camber changes. Therefore, you must
adj ust the fronvrear al i gnment whenever you adj ust
caster, camber, or toe.
Pre-Alignment Checks
For proper
l nspecti on and adj ustment of the wheel
al i gnment, do these checks:
1. Rel ease the parki ng
brake to avoi d an i ncorrect
measurement.
2, Make sur e t he suspensi on i s not modi f i ed.
3. Check the ti re si ze and ti re pressure.
Ti re si ze:
Front:205/55R16 89W
Rear: 225l50R15 92W
Tire pressure:
Front/rear:
220 kpa
|2.2 kgt lcm",32
psil
4. Check the runout of the wheel s and ti res.
5. Check t he suspensi on bal l
j oi nt s.
{ Hol d a wheel
wi th your hands, and move i t up and down and
ri ght and l eft to check for wobbl i ng.)
7.
Bounce the suspensi on up and down several ti mes.
Check the hei ght of each suspensi on. Make sure
the vehi cl e i s empty, i s parked
on a l evel surface,
and has properl y i nfl ated ti res
(the
treadwear
i ndi cator must not be showi ng). l fthe hei ght i s out
of speci fi cati on, adj ust the l oad as necessary.
Hei ght:
Front:192 202 mm
FRONT
I
T
The hei ght f rom t he ground t o t he cent er of t he head
of t he l ower arm' s f ront bushi ng bol t .
Rar:220 230 mm
The hei ght f rom t he ground t o t he cent er ol t he head
of t he l ower arm' s rear bushi no bol t .
(cont' d)
FRONT
t
18-5
Front and Rear Suspension
Wheel Alignment
(cont'dl
Front Caster Inspection/Adiustment
Use commerci al l v avai l abl e computeri zed four wheel
al i gnment equi pment l o measure wheel al i gnment
{caster, camber, toe, and turni ng angl e) Fol l owthe
eoui Dment manufacturer' s i nstructi ons.
1. Check the caster angl e. l f adj ustmenti s requi red,
go to step 2.
Front caster angl e: 6' 00' + 15'
2. Hol d t he f l ange bol t
( A)
on t he r ear of t hel ower ar m,
and l oosen t he sel f - l ocki ng nut
( B) .
B
' 12
\1.25 mm
Turn the adj usti ng cam col l ar
(C)
unti l the caster i s
correct.
After adj usti ng, ti ghten the sel f-l ocki ng nut whi l e
hol di ng the fl ange bol t.
18-6
Front Camber Inspection/Adiustment
Use commerci al l y avai l abl e computeri zed four wheel
al i gnment equi pment to measure wheel al i gnment
(caster.
camber, toe, and turni ng angl e) Fol l owthe
equi pment manuJacturer' s i nstructi ons.
1. Check the camber angl e. l f adj ustment i s req ul red,
go to step 2.
Front camber angl e:
-0' 30' t
10'
2. Hol d t he adj ust i ng bol t
( A)
ont hef r ont of t hel ower
arm, and l oosen the sel f-l ocki ng nut
(B).
B
12 x
' 1.25
mm
78 N.m {8.0 kgf m.58 l bf ft)
,
--
-11'',
Turn the adj usti ng bol t unti l the camber i s correct.
After adj usti ng, ti ghten the sel f-l ocki ng nut whi l e
hol di ng the adj usti ng bol t.
Rear Camber Inspection/Adjustment
Use commerci al l v avai l abl e comDuteri zed four wheel
al i gnment equi pment t o measur e wheel al i gnment
(caster,
camber, toe, and turni ng angl e). Fol l ow the
equi pment manufacturer' s i nstructi ons.
1. Check the camber angl e. l f adj ustment i s req u i red.
go to step 2.
Rear camber angl e: 1"30' + 10'
2. Hol d the adj usti ng bol t
(A)
on the control arm, and
l oosen the sel f-l ocki ng nut
(B).
4.
54 N. m
(5. 5
kgf . m,
40 tbf.ft)
Turn the adj usti ng bol t unti l the camber i s correct.
After adj usti ng, ti ghten the sel f-l ocki ng nut whi l e
hol di ng the adj usti ng bol t.
Front Toe Inspection/Adjustment
Use commer ci al l y avai l abl e comput er i zed f our wheel
al i gnment equi pment t o measur e wheel al i gnment
(caster,
camber, toe, and turni ng angl e). Fol l ow the
equi pment manufacturer' s i nstructi ons.
1. Centerthe steeri ng wheel spokes.
2. Check t he t oe. l f adj ust ment i s r equi r ed, got ost ep
Front toe-i n: 0 + 2 mm
(0 + 0.08 i n.l
3, Hol d the ti e-rod end
(A),
and l oosen the ti e-rod
l ocknut
(B).
33 tbt.ftl
Turn the ti e-rod unti l the toe i s correct.
After adj usti ng, ti ghten the l ocknut whi l e hol di ng
the ti e-rod end. Reposi ti on the rack-end boot i f i t i s
twi sted or di sl ocated.
(cont' d)
4,
5,
, . / B
18-7
Front and Rear Suspension
Wheel Al i gnment
(cont' d)
Rear Toe Inspection/Adiustment
Use commerci al l y avai l abl e computeri zed four wheel
al i gnment equi pment to measure wheel al i gnment
(caster,
camber, toe, and turni ng angl e). Fol l ow the
equi oment manufacturer' s i nstructi ons.
' 1.
Rel ease the
parki ng
brake to
prevent
an i ncorrect
measurement.
2. Check the toe. l f adj ustment i s requ i red, go
to step
Rear toe-i n: 6.0 t 2 mm
(0.25
+ 0.08 i n.l
3. Hol d the adj usti ng bol t ofthe control arm
(A),
and
l oosen the sel f-l ocki ng nut
(B).
Hol d the adj usti ng
bol t of the l ower arm {C), and l oosen the sel f-
l ocki ng nut
( D) .
B
12 x1.25 mm
54 N.m (5.5
kgf.m,
i l ol bf.ftl
- ) t , . i
12 x 1. 25 mm
74 N m 17. 5 kgl m. 54l bt . f t )
Turn both adj usti ng bol ts i n opposi te di rectl ons
unti l the toe i s correct.
NOTE: Adj ust the rear toe by adj usti ng the control
arm and the l ower arm by the same amount i n
opposi te di recti ons to each other
(for
exampl e,
when you move the control arm out, move the
l ower arm i n, and vi se versa).
After adj usti ng, ti ghten both sel f-l ocki ng nuts whi l e
hol di ng the respecti ve adj usti ng bol ts.
18-8
Turning Angle Inspection
Use commerci al l v avai l abl e comouteri zed four wheel
al i gnment equi pment to measure wheel al i gnment
{caster, camber, toe. and turni ng angl e). Fol l ow the
eoui Dment manufacturer' s i nstructi ons.
1. Turn the front wheel ri ght and l eft whi l e appl yi ng
the brake. and check the turni ng angl es of both
wneet s.
Turni ng angl e:
lnward wheel; 34"00'
t
2"
Outward wheel: 29'00'
(reference)
l f the turni ng angl es are out of speci fi cati on or the
i nward turni ng angl es di ffer between the ri ght and
l eft, check the toe, and adj ust accordi ngl y.
l f the toe adj ustment i s correct but the turni ng
angl es are out of speci fi cati on, check for bent or
damaged suspensi on component s.
Wheel Bearing End Play lnspection
1 . Rai se the vehi cl e, and suppon i t wi th safety stands
i n the proper l ocati ons
(see page 1-13).
Remove the wheel s, then rei nstal l the wheel nuts.
Attach the di al gauge. Pl ace the di al
gauge agai nst
t he hub f l ange.
Front:
2.
?
Rear:
Measur e t he bear i ng end pl ay movi ng t he br ake
di sc i nward or outwa rd.
Standard:
Front/rear:0 0.05 mm
(0
0.002 i n.l
l f t he bear i ng end pl ay measur ement i s mor e t han
the standard, repl ace the wheel beari ng.
Wheel Runout Inspection
' 1.
4.
Rai se the vehi cl e, and support i t wi th safety stands
i n the
proper
l ocati ons
(see page 1-13).
Check for a bent or deformed wheel .
Set up the di al
gauge as shown, and measure the
axi al r unout by t ur ni ng t he wheel .
Front and rear wheel axial runout:
Standard: 0 0.7 mm {0-0.03
i n.)
Servi ce l i mi t: 2.0 mm 10.08 i n.)
Readj ust the di al
gauge to the posi ti on shown. and
measure the radi al runout.
Fronl and rear wheel radial runout:
Standard: 0-0.7 mm {0 0.03 i n.)
Servi ce l i mi t: 1.5 mm
(0.06
i n.)
l f the wheel runout i s out of speci fi cati on, check the
wheel beari ng end
pl ay.
l f the beari ng end
pl ay i s wi thi n the speci fi cati on
but the wheel runout i s more l han the servi ce l i mi t,
r epl ace t he wheel .
18-9
Front and Rear Suspension
Bal l Joi nt Removal
Special Tools Required
Bal l j oi nt remover, 28 mm 07MAC-S100200
1. Instal l a hex nut onto the threads of the bal l
j oi nt.
Make sur e t he nut i s f l ush wi t h t he bal l j oi nt
pi n
end to
prevent
damage to the threaded end of
the bal l
i oi nt
pi n.
2. Appl y gr ease t o t he speci al t ool ont hear easshown
(A).
Thi s wi l l ease i nstal l ati on of the tool and
prevent damage to the pressure bol t
(B)
threads.
3. Instal l the speci al tool as shown. l nsert the
j aws
careful l y, maki ng sure not to damage the bal l
j oi nt
boot. Adj ust the
j aw
spaci ng by turni ng the
Dressure bol t.
07MAC-S100200
12 mm
HEX NUT
18- 10
4. Once the speci al tool i s i n pl ace, turn the adj usti ng
bol t
(A)
as necessary to make the
j aws paral l el .
Then hand-ti ghten the pressure bol t
(B),
and
recheck the
j aws
to make sure they are sti l l
paral l el .
After maki ng the adj ustment to the adj usti ng bol t,
make sure the head ofthe adj usti ng bol t
(A)
i s i n
the
posi ti on
shown to al l ow the
j aw (C)
to pi vot.
Wi th a wrench, ti ghten the pressure bol t
(B)
unti l
the bal l
j oi nt pi n pops l oose from the steeri ng or
suspensi on arm. l f necessary, appl y
penetrati ng
type l ubri cant to l oosen the bal l
j oi nt pi n.
Remove the tool , then remove the nut from the end
of t he bal l j oi nt pi n, and pul l t he bal l j oi nt out of t he
steeri ng or suspensi on arm. Inspect the bal l
i oi nt
boot, and repl ace i t i f damaged.
1.
Front Suspension
Knuckle/Hub Replacement
Exploded View
SPINDLE NUT
24 x 1.5 mm
329 N.m
(33.5
kgf.m.2,|2 lbf.ft)
Repl ace.
Appy a smal l amount of engi ne oi l
t o t he seat i ng surf ace.
LOWER ARM
BALL JOINT
12 x 1.25 mm
64 N.m
(6.5
kgf.m, 47 lbf.ftl
7
HUB CAP
//
Checktot delormation and damaqe.
d^^/q
,-,----{g /Y /
BEARI NG
Repl ace.
Check l or def ormat i on
ano oamage,
SCREW
5 mm
4. 9 N. m
(0. 5
kgt . m,
3.6 tbf.ft)
BOOT CLIP
BALL JOINT BOOT
Repl ace.
FLAT-HEAD SCREW
6 x 1 . 0 mm
9. 8 N. m {1. 0
kgf . m,
7.2 tbt-ft)
(cont' d)
Check l or def ormat i on,
damage, and cracks,
BRAKE DISC
18- 11
Front Suspension
Knuckle/Hub Replacement
(cont'd)
SpecialTools Required
.
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
.
Beari ng dri ver attachment, T2 x 75 mm 07746-0010600
.
Dri ver, 07749-0010000
.
Support base, 72 x 78/82.6 mm 07965-SD90100
.
Hub di s/assembl y tool , 07GAF-SD40200
' 1.
Rai se the front ofthe vehi cl e, and suppon i twi th
safety stands i n the
proper l ocati ons
( see page 1- 13) .
2. Remove the wheel nuts
(A)
and the front wheel .
3. Remove the brake hose bracket mounti ng bol t
(A).
9 . 8 Nm
(r.0
kgt.m,
7 .2 tbt.ttl
' ,
108 N m
'
111.0 ksf.m,
79.6 tbf.ft)
Remove the cal i per bracket mounti ng bol ts
(B),
and
r emove t he cal i per assembl v
( C) f r om
t he knuckl e.
To
prevent
damage to the cal i per assembl y or
brake hose, use a shon pi ece of wi re to hang the
cal i per assembl y from the undercarri age. Do not
twi st the brake hose wi th force.
18-12
5. Remove the fl ange bol ts
(A)
and wheel sensor
(B)
from the knuckl e
(C).
Do not di sconnect the wheel
sensor connector.
A
9 . 8 N m
(1. 0
kgf . m,
7.2 tbl.ttl
l r
6. Remove the 6 mm brake di sc retai ni ng screws
(A).
A
9. 8 N. m
{1. 0 kgf . m,
7.2lbt.ttl
1. Screw two 8 x 1.25 mm bol ts
(B)
i nto the di sc to
push i t away from the hub. Turn each bol t two turns
at a ti me to
prevent cocki ng the di sc excessi vel y,
Remove the brake di sc from the knuckl e.
Check the hub for damage and cracks. 9.
i i /
r
t l
10. Remove the cotter
pi n (A)from
the ti e-rod end bal l
j oi nt,
then remove the nut
(B).
B
12 x
' 1. 25
mm
54 N. m
15.5 kgf m.,l0 lbf ft)
1 1 .
07MAC-S100200
Remove the ti e-rod bal l
j oi nt
from the knuckl e usi ng
t he speci al t ool
( see page 18- 10) .
Remove the cotter
pi n (A)
from the l ower arm bal l
j oi nt ,
and r emove t he cast l e nut
( B) .
,--------'tg
14 x 1. 25 mm
56-69 N. m
(6. 0-7. 0
kgt . m. 43-51 l bt . f t l
13. Remove t he l ower ar m bal l
j oi nt
f r om t he knuckl e
usi ng t he speci al t ool
( see page 18- 10) .
14. Remove the l ock pi n (A)
from the upper arm bal l
i oi nt, and remove the castl e nut
(B).
12 x 1.25 mm
49-59 N m
15,0-6.0 kgf
.m,
36-4:t l bf
.ft
)
Remove the upper arm bal l
j oi nt
from the knuckl e
usi ng the speci al tool
(see page 18-10).
Remove the knuckl e.
Remove the hub cap
(A).
16.
11.
' 18.
/a
t ' . -
r )
v
@^--"''-
Rai se the stake
(B)
of the spi ndl e nut
(C),
and
remove the nut and
pul ser (D).
(cont' d)
18- 13
Front Suspensi on
19.
Knuckl e/Hub Repl acement
(cont' dl
Separate the hub
(A)from
the knuckl e
(B)
usi ng a
hydraul i c
press.
Be careful not to deform the spl ash
guard.
Hol d the hub to keep i t from fal l i ng when
presseo
crear.
Remove the screws
(A),
snap ri ng
(B),
and the
spl ash guar d ( C) f r om
t he knuckl e
( D) .
/
Press
I
, ]
' t
18-14
21. Pr ess t he wheel bear i ng
( A)
out of t heknuckl e{ B}
usi ng t he speci al t ool s and a
pr ess.
piess
07746-00'10600
Press the wheel beari ng i nner race
(A)
out of the
hub
( B)
usi ng a commer ci al l y avai l abl e bear i ng
separator {C) and a
press.
49-0010000
23.
24.
Wash t he knuckl e and hub t hor oughl y i n hi gh f l ash
poi nt
sol vent before reassembl y.
Press a new wheel beari ng
(A)
i nto the knuckl e
(B)
usi ng the ol d beari ng
(C).
a steel pl ate (D),
the
speci al tool , and a press, Pl ace the wheel beari ng
on the knuckl e wi th the
pack
seal si de {metal col or)
faci ng i nsi de. Be careful not to damage the sl eeve
of t he Dack seal .
I
B
25. I nst al l t he snap r i ng
( A)
secur el y i n t he knuckl e
( B)
D
4.9 N.m 10.5 ksf.m. 3.6 l bf ft)
I nst al l t he spl ash guar d
{ C) , and t i ght en t he scr ews
( D) .
BLACK COLOR
27.Wash the spi ndl e thoroughl y i n hi gh fl ash poi nt
sol vent before reassembl y,
I nst al l t he hub
( A)
ont o t he knuckl e { B) usi ng t he
speci al tool s and a hydraul i c press. Take care not to
deform the spl ash
guard.
29. I nst al l t he pul ser ( A) .
28.
n-'.X./
\#
./ln*r.u^
e\'/ ?"rlidi.-,
242 tbl.ftl
30. Appl y a smal l amount of engi ne oi l t o t he seat i ng
sur f ace of a new spi ndl e nut
( B) .
I nst al l t he nut , and
ti ghten i t to the speci fi ed torque. Stake the nut
shoul der agai nst the dri veshaft wi th a dri ft.
I nst al l t he hub cap
( C) .
(cont' d)
18- 15
Front Suspension
32.
Knuckle/Hub Replacement
(cont'dl
Instal l the knuckl e i n the reverse order of removal ,
payi ng parti cul ar attenti on to the fol l owi ng i tems:
.
Be careful not to damage the bal l
j oi nt
boot when
i nst al l i ng t he knuckl e.
.
Use a new spi ndl e nut and new sel f-l ocki ng nuts
on reassemoty.
.
Ti ghten al l mounti ng hardware to the speci fi ed
torque val ues,
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn the sl ot wi th the bal l
i oi nt
pi n hol e. Do nol
al i gn by l ooseni ng the castl e nut.
.
Instal l a new cotter pi n or l ock pi n on the castl e
nuts after torqui ng.
.
Before i nstal l i ng the brake di sc, cl ean the mati ng
surface of the hub and the i nsi de of the brake
di sc.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wneet ,
.
Check the wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
18- 16
Bal l Joi nt Boot Repl acement
Special Tools Required
Bal l j oi nt boot cl i p gui de, 07GAG-SD40700
' 1.
Remove the boot cl i p and the boot.
2. Pack the i nteri or and l i p of the new boot {A) wi th
fresh grease. Do not contami nate the l ower col l ar
of the boot
(B)
wi th
grease.
A
Wi pe the
grease
off the tapered secti on of the
pi n
(C),
and
pack the base
(D)
wi th fresh grease.
I nst al l t he boot ont o t he bal l
j oi nt pi n,
t hen squeeze
i t gentl y
to force out any ai r. Do not l et di rt or other
torei gn materi al s get i nto the boot.
Adj ust the speci al tool wi th the adj usti ng bol t
(A)
unti l i ts base i s
j ust
above the
groove
around the
bottom of the boot. Then sl i de the cl i p over the tool
i nto the posi ti on (B)
on the boot.
After i nstal l i ng a boot, wi pe any grease offthe
exposed por t i on of t he bal l j oi nt pi n.
Stabilizer Bar Replacement
1 .
2.
Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons
( see page 1- 13) . Remove t he f r ont wheel .
Remove the cl i ps
(A)
and fl ange bol ts
(B),
then
remove the spl ash
guard (C).
9.8 N.m {1.0 kqf.m,7.2l bt ftl
Remove the sel f-l ocki ng nuts {A) whi l e hol di ng the
j oi nt pi ns (B)
wi th a hex wrench
(C),
and di sconnect
t he st abi l i zer l i nks
( D) f r om
t he st abi l i zer bar
( E)
on
the ri ght and l eft.
A
10 x 1, 25 mm
38 N. m {3. 9 kgf . m.
28 tbf.ftl
4. Remove the bol ts
(A)
and bushi ng hol ders
(B).
then
remove the bushi ngs
(C)
and the stabi l i zer bar
(D).
A
l nstal l the stabi l i zer bar i n the reverse order of
r emoval .
NOTE: Refer to Stabi l i zer Li nk Repl acement to
connect the stabi l i zer bar to the l i nks.
5.
10 x 1. 25 mm
39 N. m
(4. 0
kgf . m.
18-17
Front Suspension
Stabilizer Link Removal/lnstallation
1 . Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons
(see page 1-13). Remove the front wheel .
Remove spl ash guard (see page 18-17).
Remove the sel f-l ocki ng nut
(A)
and fl ange nut
(B)
whi l e hol di ng the respecl i ve
j oi nt pi ns (C)
wi th a
hex wrench
(D).
and di sconnect the stabi l i zer l i nk
( E)
f r om t he st abi l i zer bar
( F)
and t he l ower ar m
( G) .
l nstal l the stabi l i zer l i nk to the stabi l i zer bar and
l ower arm wi th the
j oi nt pi ns set at the center of
thei r range of movement.
18- 18
5. l nstal l the sel f-l ocki ng nut and fl ange nut, and
l i ghtl y ti ghten.
6, Pl ace a
j ack
under the l ower arm, and rai se the
suspensi on to l oad the stabi l i zer.
7. Ti ghten the sel f-l ocki ng nut
(A)
and tl ange nut
(B)
to
the speci fi ed torque val ues whi l e hol di ngthe
respecti ve
j oi nt pi ns (C)
wi th a hex wrench
(D).
A
10 x 1.25 mm
38 N.m
10 x
' 1.25
mm
29 N.m
8. After 5 mi nutes o{ dri vi ng, re-ti ghten the sel f-
l ocki ng nut of the
j oi nt
connected to the stabi l i zer
bar agai n to the speci fi ed torque val ue.
Lower Arm Removal/lnstallation
Speci al Tool s Requi red
.
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
1. Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocai ons {see
page 1-13).
Remove the front wheel .
2. Remove l he fl ange nut
(A)
whi l e hol di ng the
j oi nt
pi n (B)
wi th a hex wrench
(C),
and di sconnect the
st abi l i zer l i nk
( D) f r om
t he l ower ar m
( E) .
A
10 x 1.25 mm
29 N m
(3.0 kgf.m, 22 lbf.ft)
3. Remove the fl ange bol t
(A),
and di sconnect the
damper
( B)
f r om t he l ower ar m
( C)
10 x 1. 25 mm
6 4 N m
(6.5 kgf.m, 47 lbf.ft)
4. Remove the cotter pi n (A)from
the l ower arm bal l
i oi nt, and remove the castl e nut
(B).
Remove the l ower arm bal l
j oi nt from the knuckl e
usi ng the speci al tool
(see page 18-10).
Remove the sel f-l ocki ng nut
(A)
and sel f-l ocki ng
cam nut
(B).
then remove the cam
pl ate
{C).
adj usti ng bol t
(D),
cam col l ar
(E),
fl ange bol t
(F),
and the l ower arm.
5.
6.
12 x 1. 25 f i m
78 N. m
(8. 0 kgf . m, 58l bf . f t )
B
12 x' l . 25 nm
78 N. m
{8.0 kgf rn, 58 lbf.ft}
(cont' d)
18- 19
Front Suspension
Lower Arm Removal/lnstallation
{cont'd)
7. l nst al l t he l ower ar m i n t he r ever se or der of
removal payi ng parti cul ar
attenti on to the fol l owi ng
i tems:
.
Be careful not to damage the bal l
j oi nt
boot when
connecti ng the l ower arm to the knuckl e.
.
Use a new sel f-l ocki ng cam nut and a new sel f-
l ocki ng nut on reassembl y.
.
Ti ghten al l mounti ng hardware to the speci fi ed
toroue val ues.
.
Fi rsti nstal l al l the components and l i ghtl y ti ghten
bol ts and nuts, then pl ace a
j ack
under the l ower
arm, and rai se the suspensi on to l oad the wei ght
before ful l y ti ghteni ng to the speci fi ed torque
val ues,
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn the sl ot wi th the bal l
j oi nt pi n hol e. Do not
al i gn by l ooseni ng the castl e nut.
.Instal l
a new cotter
pi n
on the castl e nut after
torqui ng.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wheel .
.
Check the wheel al i gnment, and adj ust i t i f
necessary {see
page l 8-5).
18-20
Upper Arm Replacement
Special Tools Required
.
Bal l
j oi nt
remover,23 mm 07MAC-S100200
1. Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons
(see page 1-13), Remove the front wheel .
2. Remove the fl ange bol ts
(A)
andthewheel sensor
har ness
( B) f r om
t he upper ar m
( C) .
A
6 x 1 . 0 mm
9. 8 N. m
(1. 0 kgf . m, 7. 2 l bl f t )
Remove t he l ock pi n (A)
f rom t he upper arm bal l
j oi nt ,
and r emove t he cast l e nut { Bl .
07MAC-S100200
12 x 1. 25 mm
49-59 N. m
4.
{5.0-6.0 ksf.m,36-43 l bt ftl
Remove the upper arm bal l
j oi nt
from the knuckl e
usi ng t he speci al t ool
( see page 18- 10) .
3.
5. Remove the fl ange bol ts {A). and the upper arm.
12 x 1. 25 mm
103 N.m
(10,5
kgt.m, 75.9l bt.ftl
I nst al l t he upper ar m i n t he r ever se or der of
removal payi ng parti cul ar
attenti on to the fol l owi ng
i tems:
Be careful not to damage the bal l
j oi nt
boot when
connecti ng the upper arm to the knuckl e.
Ti ghten al l mounti ng hardware to the speci fi ed
t or que val ues,
Fi rst i nstal l al l the susDensi on comoonents and
l i ghtl y ti ghten bol ts and a nut, then pl ace a
j ack
under the l ower arm, and rai se the suspensi on to
l oad the wei ght before ful l y ti ghteni ng to the
sDeci fi ed toroue val ues.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn t he sl ot wi t h t he bal l
j oi nt pi n hol e. Do not
al i gn by l ooseni ng the castl e nut.
l nstal l a new l ock Di n on the castl e nut after
t or qui ng.
Before i nstal l i ng the wheel , cl ean the mati ng
sur f ace of t he br ake di sc and t he i nsi de of t he
wheel .
Check t he wheel al i gnment , and adj ust i t i f
necessary
(see page
18-5).
18-21
Front Suspension
Damper/Spri ng Repl acement
Exploded View
LOWER SPRING MOUNTING CUSHION
Check for deteri orati on and damage.
a9
g
SELF.LOCKING NUT
10 x 1.25 mm
29 N.m
(3.0
kgf.m,22l bf.ftl
Bepl ace.
Check f or det eri orat i on and damage.
COVER PLATE
\auupstop
Check f or weakness and damage.
A
DAMPER MOUNTING coLLAR
n-.'
SPRING MOUNTING CUSHION
_.-ousr
covER SLEEVE
/
Check f or bendi ng and damage.
[:gl '
unecK ror oenorng ano oamage'
V -,or.r aou., ."o
. , r-
Check f or def ormat i on and damage.
f=
5r'-
BUMP sroP PLArE
18-22
Special Tools Required
Strut spri ng compressor, Brani ck MST-580A or Model
7200, or equi val ent. commerci al l y avai l abl e.
Removal
1. Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
(see page 1-13). Remove the front wheel .
2. Remove t he f l ange bol t
( A)
andbr akehose
mounti ng bracket
(B)from
the damper.
Remove the cotter
pi n (A)
from the l ower arm bal l
j oi nt,
and remove the castl e nut
(B)
,--6.
B'
,/-
A
Remove the l ower arm bal l
j oi nt
from the knuckl e
usi ng t he speci al t ool
( see page 18- 10) .
4.
5. Remove the fl ange nuts
(A)trom
the top of the
oamper .
Remove the fl ange bol t
(A)
at the bottom of the
oamper .
{cont' d)
18-23
Front Suspension
Damper/Spring
Replacement
(cont'd)
1 . Lower the l ower arm, and remove the damper
assembl y
(A).
I
t
18-24
Disassembly/lnspection
1. Compress the damper spri ng wi th the
commerci al l y avai l abl e strut spri ng compressor {A)
accordi ng to the manufacturer' s i nstructi ons, then
remove the sel f-l ocki ng nut {B).
Do not compress
the spri ng more than necessary to remove the nut.
4.
Rel ease the
pressure from the strut sprl ng
compressor, then di sassembl e the damper as
shown i n the Expl oded Vi ew.
Reassembl e al l of the
parts, except the spri ng.
Compress the damper assembl y by hand, and
check for smooth operati on through a ful l stroke.
both compressi on and extensi on. The damper
shoul d extend smoothl y and constantl y when
compressi on i s rel eased. l f i t does not, the gas i s
l eaki ng and the damper shoul d be repl aced
5. Check f or oi l l eaks, abnor mal noi ses, or bi ndi ng
duri ng these tests.
2.
3.
Reassembly
1. Assembl e al l of the damper components except the
sel f-l ocki ng nut onto the damper uni t. Al i gn the
spri ng bottom end
(A),
the stepped
pan
of the
l ower spri ng mounti ng cushi on, and the step on the
l ower spri ng seat
(B).
Instal l the damper assembl y on a commerci al l y
avai l abl e strut spri ng compressor
(C).
Posi ti on the damper mounti ng base as shown.
VIEWING FROM TOP
,11
t 3' 4 1 1 3 '
3.
STUD BOLT
Compress the damper spri ng wi th the spri ng
compressor.
Instal l a new sel f-l ocki ng nut
(A)
on the damper
shaft.
{3.0 kst.m,22 l bf.ftl
Hol d the damper shaft wi th a hex wrench {B). and
ti ghten the sel f-l ocki ng nut to the speci fi ed torque.
(cont' d)
f(
1
i . ,
l r ' - -
- r
-
\
- ' r >
\ ^ ' . . \ - \ J t :
\ V
A
10 x' 1, 25 mm
, '
\
18-25
Front Suspension
Damper/Spring Replacement
(cont'dl
lnstallation
1. Lower the l ower arm, and
posi ti on the damper
assembl y {A) i n the body.
Loosel y i nstal l the fl ange nuts
(A)
onto the damper
studs.
A
10 x 1.25 mm
49 N.m
(5.0 kgt.m,36lbt.ft)
2.
18-26
3. Posi ti on the damper bottom on the l ower arm
(A),
and connect the l ower arm and the l ower bal l i oi nt
{ B) .
t ;
-\1,
4.
5.
10 x 1. 25 mm
6 4 N m
(6. 5 kgl . m, 47 l bf . f t l
Instal l the fl ange bol t
(C),
and l i ghtl y ti ghten.
Rai se the suspensi on unti l the vehi cl e
j ust
l i fts off
the safety stand.
Instal l the castl e nut
(A)
onto the l ower bal l
j oi nt pi n,
and ti ghten i t to the speci fi ed torque.
7.
@-o
I nst al l t he cof t er
pi n ( B) .
Ti ght en t he f l ange bol t connect i ng t he damper
bottom to the l ower arm to the speci fi ed torque.
14 x 1. 25 mm
59-69 N. m
(6. 0-7. 0 kgt . m,
il3-51 lbf.ftl
9. Ti ghten the fl ange nuts on the top of the damper to
the soeci fi ed toroue.
10. Instal l the brake hose mounti ng bracket
(A)
and the
fl ange bol t
(B)to
the damper, and ti ghten the bol t
to the speci fi ed torque.
Ex 1. 25 mm
22 N.m
(2.2
kgf.m, 16l bf.ftl
r(
18-27
Rear Suspension
KNUCKLE
r )
iAri
Knuckle/Hub Replacement
Exploded View
LOWER ARM BALL JOINT
12 x 1, 25 mm
64 N. m
(6.5 kgf.m,47 lbf.ft)
WHEEL BEARING
Repl ace.
SNAP RING
I
l
l
I
BOOT CLIP
SPLASH GUARD
Check f or del ormat i on and damage.
SCREW
5 mm
4 . 9 N m
l 0. s kgf . m, 3. 6l bf . f t )
FLAT-HEAD SCREW
6 x
' 1. 0
mm
9. 8 N. m
(1. 0
kgt . m, 7. 2 l bf . f t |
245 N. m
(25. 0
kgt m. 181 l bf . f t l
Repl ace.
Appy a smal l amount o{ engi ne oi l
t o t he seat i ng surf ace.
BALL JOINT BOOT
Repl ace.
BRAKE DISC
Check f or de{ormat i on,
damage, and cracks.
18-28
Special Tools Required
.
Hub di s/assembl y tool attachment, 42 mm
07GAF-SD40100
.
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
.
Beari ng dri ver attachment,62 x 68 mm 07746-0010500
.
Dri ver, 07749-0010000
.
Support base,72 x 78182.6 mm 07965-5D90100
.
Attachment, 52 x 55 mm 07746-0010400
Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
( see page
1- 13) .
Remove the wheel nuts
(A)
and rear wneer. 2.
1 .
A
108 N. m
{11. 0 kgf . m,
79.6 tbf.ftl
3. Remove the cal i per bracket mounti ng bol ts
(A).
and
remove the cal i per assembl y
(B)
from the knuckl e.
To prevent
damage to the cal i per assembl y or
brake hose, use a short
pi ece
of wi re to hang the
cal i per assembl y from the undercarri age. Do not
twi st the brake hose wi th force.
10 x 1. 25 mm
55 N. m
{5.6 kgf.m, il1
lbf ft)
I
o""
4. Remove t he f l ange bol t
( A)
andwheel sensor ( B)
from the knuckl e. Do not di sconnect the wheel
sensor connecl or.
A
6 x 1 . 0 mm
9.8 N m {1.0 kgf m.7.2 l bf.ft)
i
5. Rai se t he st ake
( A)
of t hespi ndl enut ( B) . and
remove the nut.
A
24 x 1.5 mm
245 N.m
(25.0
kgf.m, 181 l bf.ft)
(cont' d)
18-29
Rear Suspension
Knuckle/Hub
RePlacement
(cont'dl
Remove the 6 mm brake di sc retal ni ng fl at-head
screws
(A).
l'1.0
kgf m, 7 2 lbf ft)
7. Scr ew t l vo 8 x 1. 25 mm bol t s
( B)
i nt ot hedi sct o
push l t away from the hub Tu rn each bol t tl vo turns
at a ti me to
prevent cocki ng the di sc excessi vel y
8. Remove the brake di sc from the knuckl e
L Check the hub for damage and cracks.
10. Remove the sel f-l ocki ng
nut
(A),
cam
pl ate (B),
and
adj usti ng bol t
(C),
then di sconnect the control arm
(D)
from the frame
' 12
x 1. 25 mm
54 N. m
(5. 5 kgt . m, 40 l bf f t )
L
18-30
t 5 .
11. Remove t he l ock
pi n ( A) f r om
t he cont r ol ar mbal l
i oi nt, and remove the castl e nut
(B)
B
12 x 1.25 mm
49-59 N.m
' . :
. . y , .
07MAC-S100200
12. Remove t he cont r ol ar mbal l
j oi nt f r om t h e knuckl e
usi ng t he speci al t ool
( see page 18- 10)
NOTE: Turn the control arm
(C)
outward to i nstal l
t he bal l
j oi nt r emover '
13. Remove the control arm.
14. Remove t he cot t er
pi n ( A) f r om
t he l ower ar m bal l
j oi nt,
and remove the castl e nut
(B).
07MAC-S100200
12 x 1. 25 mm
68-78 N. m
(7. 0-8. 0 kgf m,
51-58 l bf . f t l
Remove t he l ower ar m bal l
j oi nt
f r om t he knuckl e
usi ng t he speci al t ool
( see page 18- 101
(5. 0-6. 0 kgf m, 36-43 l bf f t l
,4$:.'
I
.i^\
' -
-
' ( .
. /
' 16.
Remove the l ock pi n (A)
from the upper arm bal l
j oi nt,
and remove the castl e nut
(B).
17.
18.
B
12x' 1, 25 mr n
49-59 N. m
{5. 0-6. 0 kgf . m, 36-i B l bt f t }
Remove the upper arm bal l
j oi nt
from the knuckl e
usi ng t he speci al t ool
( see paSe
' 18- 10) .
Remove the dri veshaft outboard
j oi nt
{A) from the
knuckl e by tappi ng the dri veshaft end wi th a pl asti c
hammer
( B)
whi l e pul l i ng
t he knuckl e
( C)
out war d.
-
-.._..,,:.
r,...'\
.;z +':.
.,.
t-
';l '.-
)
20.
19. Separate the hub
(A)from
the knuckl e
(B)
usi ng the
speci al tool and a hydraul i c press.
Be careful notto
deform the spl ash guard. Hol d the hub to keep i t
from fal l i ng when pressed
cl ear.
Remove the screws
(A),
snap ri ng
(B),
and the
spl ash guar d ( C)
f r om t he knuckl e
( D) .
(cont' d)
18-31
Rear Suspension
21.
Knuckle/Hub Replacement
(cont'dl
Press the wheel beari ng
(A)
out of the knuckl e
(B)
usi ng t he speci al t ool s and a pr ess,
07746-0010,100
Pross
t
)'
--.
Press the wheel beari ng i nner race
(A)
out of the
hub
( B)
usi ng t he speci al t ool , a commer ci al l y
avai l abl e beari ng separator {C), and a
press.
07GAF-SD40100
07749-0010000
I
n
22.
18-32
23. Wash the knuckl e and hub thoroughl y i n hi gh fl ash
poi nt sol vent before reassembl y.
24. Pr ess a new wheel bear i ng
( A)
i nt ot heknuckl e( B)
usi ng t he ol d bear i ng
( C) ,
a st eel pl at e ( D) .
t he
speci al tool , and a
press. Pl ace the wheel beari ng
on the knuckl e wi th the
pack seal si de
(metal
col or)
faci ng i nsi de. Be careful not to damage the sl eeve
of the
pack
seal .
07965-SD90100
25. I nst al l t he snap r i ng
( A)
secur el y i n t he knuckl e
( B) .
D
5 x 1 . 0 m m
4. 9 N. m
(0. 5
kgf . m, 3. 6 l bf f t )
{:""""
O7-,-^
Vr "
===-_9
, B
I nst al l t he spl ash guar d
{ C) , and t i ght en t he scr ews
( D) .
BLACK COLOR
:-.L|-='.u
' F : _
t ' r
' - \
Press
28.
27. I nst al l t he hub { A) ont o t he knuckl e
( B)
usi ngt he
speci al tool s and a hydraul i c press. Be careful not
to deform the spl ash guard.
Press
077,19-0010000
Instal l the knuckl e i n the reverse order of removal
payi ng parti cul ar
attenti on to the fol l owi ng i tems:
.
Be car ef ul not t o damage t he bal l
j oi nt boot when
i nstal l i ng the knuckl e.
.
Use a new spi ndl e nut on reassembl y.
.
Before i nstal l i ng the new spi ndl e nut, appl y a
small amount o{ engine oil to the seating sur{ace
of the nut. After ti ghteni ng, use a dri ft to stake the
spi ndl e nut shoul der agai nst the dri veshaft.
.
Ti ghten al l mountj ng hardware to the speci fi ed
torque val ues.
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn t he sl ot wi t h t he bal l
j oi nt pi n or cl i p hol e.
Do not al i gn by l ooseni ng the castl e nut.
. I nst al l
a new cot t er
pi n
or I ock pi n
on t he cast l e
nut after torqui ng.
.
Before i nstal l i ng the brake di sc, cl ean the mati ng
surface of the hub and the i nsi de of the brake
di sc.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wneet .
.
Check the wheel al i gnment, and adj ust i t i f
necessary (see page
18-5).
Ball Joint Boot Replacement
Special Tools Required
Bal l
j oi nt
boot cl i p
gui de,
07cAG-SD40700
1. Remove the boot cl i p and the boot.
2. Pack the i nteri or and l i p of the new boot
(A)
wi th
fresh grease.
Do not contami nate the l ower col l ar
of the boot
(B)
wi th grease.
4.
Wi pe the grease
off the tapered secti on of the
pi n
(C),
and pack
the base
(D)
wi th fresh grease.
Instal l the boot onto the bal l
j oi nt pi n,
then squeeze
i t gentl y to force out any ai r. Do not l et di rt or other
forei gn materi al s get i nto the boot.
For the upper and l ower arm bal l
j oi nt,
adj ust the
speci al tool wi th the adj usti ng bol t
(A)
unti l i ts base
i s
j ust
above the groove
around the bottom of the
boot. Then sl i de the cl i p over the tool i nto the
posi ti on (B)
on the boot.
For the control arm bal l
j oi nt,
set the boot on the
j oi nt pi n,
and
press
i t wi th the speci al tool unti l
there i s no gap
at the bottom of the boot
(A).
After i nstal l i ng a boot, wi pe any
grease
offthe
exposed porti on
of the bal l
j oi nt pi n.
7.
18-33
Rear Suspension
Stabilizer Bar Replacement
' 1.
Rai se the rear of the vehi cl e, and suppon i t wi th
safety stands i n the proper l ocati ons
{ see
page 1- 13} . Remove t he r ear wheel
Remove the sel f-l ocki ng nuts
(A)
whi l e hol di ng the
j oi nt pi ns (B)
wi th a hex wrench
(C).
and di sconnect
the stabi l i zer l i nks
(D)
from the stabi l i zer bar {E) on
the ri ght and l eft.
A
10 x 1 ,25 mm
43 N.m
(i1.4
kgf.m, 32 lbf.ftl
Remove the bol ts
(A)
and bushi ng hol ders
(B),
then
remove the bushi ngs
(C)
and the stabi l i zer bar
(D)
l nstal l the stabi l i zer bar i n the reverse order of
removal .
NOTE: Refer to Stabi l i zer Li nk Repl acement to
connect the stabi l i zer bar to the l i nks.
18-34
Stabilizer Link Removal/lnstallation
1 . Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons
( see page 1- 13) . Remove t he r ear wheel .
Remove the sel f-l ocki ng nut
(A)
and fl ange nut
(B)
whi l e hol di ng the respecti ve
j oi nt pi ns (C)
wi th a
hex wrench
(D),
and di sconnect the stabi l i zer l i nk
(E)
from the stabi l i zer bar
(F)
and the l ower arm
(G).
l nstal l the stabi l i zer l i nk to the stabi l i zer bar and
Iower arm wi th the
j oi nt pi ns set at the center of
t ner r r ange.
4. Instal l the sel f-l ocki ng nut and fl ange nut. and
l i ghtl y ti ghten.
5. Pl ace a
j ack
under the l ower arm, and rai se the
suspensi on to l oad the stabi l i zer bar.
6. Ti ghten the sel f-l ocki ng nut 1A) and fl ange nut
(B)
to
the speci fi ed torque val ues whi l e hol di ng the
respecti ve
j oi nt pi ns (C)
wi th a hex wrench
(D).
10 x 1. 25 mm
29 N m
(3.0
kgf.m,22 lbf.ft)
7. After 5 mi nutes of dri vi ng. re-ti ghten the sel f-
l ocki ng nut of the
j oi nt
connected to the stabi l i zer
bar agai n l o the speci fi ed torque val ue.
Lower Arm Removal/lnstallation
Special Tools Required
.
Bal l
j oi nt
remover. 28 mm 07MAC-SL00200
1. Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the
proper
l ocati ons
( see page
1- 13) . Removet he r ear wheel .
2. Remove the fl ange nut
(A)
whi l e hol di ng the
j oi nt
pi n (B)wi th
a hex wrench
(C).
and di sconnect the
stabi l i zer l i nk
(D)
from the l ower arm
(E).
A
10 x 1. 25 mm
29 N. m
(3. 0
kgf . m, 22l bf . f t )
Remove t he f l ange bol t
(A),
and di sconnect t he
damper
(B)
from the l ower arm
(C).
(cont' d)
'r-l
18-35
Rear Suspension
Lower Arm Removal/lnstallation
(cont'd)
4. Remove the cotter
pi n (A)
from the l ower arm bal l
j oi nt,
and remove the castl e nut
(B).
/ r-----'------
-
\
07MAC-S100200
|
._
.,,
9-*-----.
12 x 1. 25 mm
69-78 N. m
A
12 x 1. 25 mm
123 N. m
(12.5
kgf.m. 90.4 lbf.ft)
B
12 x 1 .25 mm
1il N.m
{?.5
kgt.m, 54lbt.ft)
{?.0-8.0
kgl .m,
51-58 tbf.ft)
Remove the l ower arm bal l
j oi nt
from the knuckl e
usi ng t he speci al t ool
( see page 18- 10) .
Remove the fl ange bol t
(A),
sel f-l ocki ng nut
(B),
cam
pl ate
{C). adj usti ng bol t
(D).
and the l ower arm
( E
) .
18-36
l nstal l the l ower arm i n the reverse order of
removal
payi ng pani cul ar attenti on to the fol l owi ng
t r ems:
.
Be careful not to damage the bal l
j oi ntbootwhen
connecti ng the l ower arm to the knuckl e.
.
Use a new sel f-l ocki ng nut on reassembl y.
.
Ti ghten al l mounti ng hardware to the speci fi ed
torque val ues,
.
Fi rst i nstal l al l the components and l i ghtl yti ghten
bol ts and nuts, then
pl ace
a
j ack
under the l ower
arm, and rai se the suspensi on to l oad the wei ght
before ful l y ti ghteni ng to the speci fi ed torque
val ues.
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn the sl ot wi th the bal l
j oi nt pi n hol e. Do not
al i gn by l ooseni ng t he cast l e nut .
.
Instal l a new cotter
pi n on the castl e nut after
t or qur ng.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface ofthe brake di sc and the i nsi de ofthe
wneet.
.
Check the wheel al i gnment, and adj ust i t i f
necessary
(see page 18' 5).
Upper Arm Removal/lnstallation
Special Tools Required
.
Bal l
j oi nt
remover. 28 mm 07MAC-S100200
1. Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
( see page 1- 13) . Remove t he r ear wheel .
2. Remove the fl ange bol ts
(A)
and the wheel sensor
har ness
( B) f r om
t he upper ar m
( C) .
A
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf m. 7. 2l bf . f t )
Remove t he l ock pi n
{A)
f rom t he upper arm bal l
j oi nt ,
and remove t he cast l e nut
(Bl .
3.
07MAC-S100200
12 x 1. 25 mm
49-59 N. m
{5. 0-6. 0 kgt m, 36-4: l l bl f t }
4. Remove t he upper ar m bal l
j oi nt
f r om t he knuckl e
usi ng t he speci al t ool
( see page
18- 10) .
6.
5. Remove the fl ange bol ts
(A),
and the upper arm.
12 x 1. 25 mm
132 N. m {13. 5 kgf . m, 97. 6 l bf . f t l
Insl al l the upper arm i n the reverse order of
removal payi ng parti cul ar
attenti on to the fol l owi ng
i tems;
.
Be careful not to damage the bal l
j oi nt
boot when
connect i ng t he upper ar m t o t he knuckl e.
.
Ti ghten al l mounti ng hardware to the speci fi ed
toroue val ues,
.
Fi rst i nstal l al l the suspensi on components and
l i ghtl y ti ghten bol ts and a nut, then
pl ace
a
j ack
under the l ower arm, and rai se the suspensi on to
l oad the wei ght before ful l y ti ghteni ng to the
sDeci fi ed toroue val ues.
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on, then ti ghten onl y far enough to
al i gn the sl ot wi th the bal l
j oi nt pi n
hol e, Do not
al i gn by l ooseni ng the castl e nut.
.l nstal l
a new l ock
pl n
on the castl e nut after
rorqurng.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wneel .
.
Checkthe wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
18-37
Rear Suspensi on
Control Arm Replacement
Special Tools Required
.
Bal l
j oi nt
remover, 28 mm 07MAC-S100200
1. Rai se the rear of the vehi cl e. and support i t wi th
safety stands i n the proper l ocati ons
{ see
page 1- 13) . Remove t he r ear wheel .
2. Remove the sel f-l ocki ng nut
(A),
cam
pl ate (B),
and
adj usti ng bol t
(C),
then di sconnect the conl rol arm
(D)
from the frame.
' 12
x 1.25 mm
54 N.m {5.5 kgf.m, 40l bf.ft)
Remove the l ock pi n (A)
from the conl rol arm bal l
j oi nt.
and remove the castl e nut
(B)
Remove the control arm bal l
j oi nt
from the knuckl e
usl ng t he speci al t ool
( see page 18- 10) .
NOTE:Turn the control arm
(C)
outward to i nstal l
t he bal l j oi nt r emover .
Remove the control arm.
4.
5.
07MAC-S100200
18-38
6. Instal l the control arm i n the reverse order of
removal payi ng parti cul ar attenti on to the fol l owi ng
rrems:
.
Be careful not to damage the bal l
j oi ntbootwhen
connecti ng the control arm to the knuckl e.
.
Use a new sel f-l ocki ng nut on reassembl y.
.
Ti ghten al l mounti ng hardware to the speci fi ed
torque val ues.
.
Fi r st i nst al l al l t he suspensi on component s and
l i ghtl y ti ghten a bol t and nuts, then
pl ace a
j ack
under the l ower arm, and rai se the suspensi on to
l oad the wei ght before ful l y ti ghteni ng to the
speci fi ed torque val ues.
.
Ti ghten the castl e nut to the l ower torque
speci fi cati on. then ti ghten i t onl y far enough to
al i gn the sl ot wi th the bal l
j oi nt pi n hol e. Do not
al i gn by l ooseni ng the castl e nut.
.Instal l
a new l ock pi n on the castl e nut after
t or qui ng.
.
Before i nstal l i ng the wheel , cl ean the mati ng
surface of the brake di sc and the i nsi de of the
wneet.
.
Check the wheel al i gnment, and adj ust i t i f
necessary
(see page 18-5).
Damper/Spring Replacement
Exploded View
RUBBER MOUNTING BUSHING
Check for deteri orati on and damage.
H'*,'
16)
\-,2
---
11--,-----
U
SELF.LOCKING NUI
10 x 1. 25 mm
49 N.m 15.0
kgf m,36 lbf.ftl
Repl ace.
DAMPER MOUNTING COLLAR
/,i-:\
.,,/"DUSf
COVER PLATE
-/DUST
COVER END
)'
Check f or def ormat i on and damaqe.
/DUST COVER SLEEVE
--\-
Check for bendi ng and damage.
t l
g
BUMP STOP PLATE
LOWER SPRING MOUNTING CUSHION
Check f or det eri orat i on and damage.
fZ>-'-'
\gUr' l pSrOp
Check f or weakness and damage.
{cont' d)
18-39
Rear Suspension
2.
Damper/Spring Replacement
(cont'dl
Speci al Tool s Requi red
Strut spri ng compressor, Brani ck MST-580A or Model
7200, or equi val ent. commerci al l y avai l abl e
Removal
1. Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the
proper Iocati ons
(see page 1-13). Remove the rear wheel .
Remove the spare ti re from the trunk.
Remove the fl ange nuts {A) from the top of the
oamper .
4. Remove the fl ange bol t
(A)
at the bottom of the
damper .
18-40
5. Lower the l ower arm, and remove the damper
assembl y
(A).
Disassembly/lnspection
1, Compress the damper spri ng wi th the
commerci al l y avai l abl e strut spri ng compressor {A)
accordi ng to the manufacturer' s i nstructi ons, then
remove the sel f-l ocki ng nut
(B).
Do not compress
the spri ng more than necessary to remove the nut.
Rel ease the
pressure from the strut spri ng
compressor, then di sassembl e the damper as
shown i n the Expl oded Vi ew.
Reassembl e al l of the
parts,
except the spri ng.
Compress the damper assembl y by hand, and
check for smooth operati on through a ful l stroke,
both compressi on and extensi on. The damper
shoul d extend smoothl y and constantl y when
compressi on i s rel eased. l f i t does not, the gas i s
l eaki ng and t he damper shoul d be r epl aced.
Check f or oi l l eaks, abnor mal noi ses, or bi ndi ng
du ri ng these tests.
Reassembly
1. Assembl e al l of the damper components except the
sel f' l ocki ng nut onto the damper uni t. Al i gn the
spri ng bottom end
(A),
the stepped
part
of the
l ower spr i ng mount i ng cushi on, and t he st ep on t he
l ower spri ng seat
(B).
I nst al l t he damper assembl y on a commer ci al l y
avai l abl e strut spri ng compressor
(C).
Posi ti on the damper mounti ng base as shown.
VIEWING FROM TOP
25'30' a 3' 25'30' a 3"
Compress the damper spri ng wi th the spri ng
compressor,
(cont' d)
4.
STUD BOLT
18-41
Rear Suspensiton
Damper/Spring Replacement
(cont'd)
5. l nstal l a new sel f-l ocki ng nut
(A)
on the damper
shaft.
A
10 x 1. 25 mm
29 N. m
(3. 0 kgl . m, 22 l bl . f t l
,'-_\
Hol d the damoer shaft wi th a hex wrench
(B),
and
ti ghten the sel f-l ocki ng nut to the speci fi ed torque.
18-42
lnstallation
1. Lower the l ower arm. and posi ti on the damper
assembl y
(A)
i n the body.
2. Loosel y i nst al l t he f l ange nut s
( A)
ont ot hedamper
studs,
10 x 1. 25 mm
49 N.m
(5. 0
kgf . m,
36 tbf.ftl
3. Posi ti on the bottom ofthe damper on the l ower
ar m
( A) .
Instal l the fl ange bol t
(B),
and l i ghtl y ti ghten.
Rai se the suspensi on unti l the vehi cl e
j ust
l i fts off
the safety stand.
Ti ghten the fl ange bol t
(B)
to the speci fi ed torque.
Ti ghten the fl ange nuts on the top of the damper to
the speci fi ed torque.
1.
18-43
Brakes
Conventional Brake Components
Soeci al Tool s
. . . . . . . . . . . . . 19-2
Comoonent Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19- 3
Brake Syst em I nspect i on and Test s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4
Brake Pedal and Brake Pedal Posi t i on
Swi t ch Adi ust ment . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-6
Parki ng Brake Check and
Adj ust ment . , . . . . . . . . . . . . 19-7
Brake Syst em Bl eedi ng . . . . . . . . . . . . . . . . . . . . . . 19-8
Brake Svstem Indicator Circuit
Di agr am . . . . . . . . . . . . . . . . . . . 19- 10
Parki ng Brake Swi t ch Test . . . . . . . . . . . . . . . . . 19-11
Brake Fl ui d Level Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-11
Front Brake Pads l nspect i on/
ReDl acement . . . . . . . . . . . 19- 12
Front Brake Di sc I nspect i on . . . . . . . . . . . . . . . 19-14
Fr ont Br ake Cal i per Over haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19- 15
Mast er Cyl i nder/ Brake Boost er
Reol acement . . . . . . . . . . . 19-16
Mast er Cyl i nder l nspect i on . . . . . . . . . . . . . . . . 19-17
Mast er Cyl i nder Pushrod Cl earance
Adj ust ment . . . . . . . . . . . . . . 19- 17
Brake Boost erTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19
Rear Brake Pads I nspect i on/
Repl acement . . . . . . . . . . . 19-20
Rear Brake Di sc I nspect i on . . . . . . . . . . . . . . . . 19-22
Rear Brake Cal i per Removal / l nst al l at i on . . . . . . . . . . . . . . . . . . . . 19-23
Rear Brake Cal i oer Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
' 19-24
Brake Hoses and Li nes l nsoect i on . . . . 19-26
Brake Hose Repl acement . . . . . . . . . . . . . . . . . . . 19-27
Parki ng Brake Cabl e Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-28
ABS
(Anti-lock
Brake Systeml
Components
... 19-31
Conventional Brake Components
Speci al Tool s
Rel .No. Tool Number Description Otv
o
07JAG-SD40100 Pushrod Adi ustment Gauqe 1
Component Location Index
FRONT BRAKES
Front Brake Pads, I nspect i on/
Repl acement , page 19-12
Front Brake Di sc
I nspect i on, page 19- 14
Front Brake Cal i per
Over haul , page 19' 15
INDICATOR
Brake Syst em I ndi cat or Ci rcui t
Di agr am,
page l 9- 10
Parki ng Brake Swi t ch
Test , page 19-11
Brake Fl ui d Level Swi t ch
Test , page 19-11
BRAKE PEDAL
Erake Pedal and Brake Pedal Posi t i on
Swi t ch Adj ust ment , page 19-6
REAR BRAKES
Rear Brake Pads I nspect aon/
Repl acement ,
page l 9' 20
Rear Brake Di sc
l nspect i on, page 19-22
Rear Brake Cal i per
Removal / l nst al l at i on,
paqe
19-23
Rear Brake Cal i per
Overhaul ,
page 19-24
MASTER CYLINDER
Brake Syst em Bl eedi ng, page 19-8
Mast er Cyl i nder
Repl acement , page l 9- 16
Mast er Cyl i nder
I nspect i on, page 19-17
Mast er CVl i nder Pushrod
Cl earance Adj ust ment ,
page 19-17
BBAKE HOSES/ LI NES
Brake Hoses and Li nes
l nsoect i on. oaqe 19-26
Brai e Hoses Bdpl acement ,
page' 19-27
PARKING BRAKE CABLE
Parki ng Brake Check and
Adj ust ment ,
page 19-7
Parki ng Brake Cabl e
Repl acement ,
page 19' 28
BRAKE BOOSTER
Brake Boost er
Repl acement ,
page 19' ' 16
Brake Boost er Test , page
' 19' 19
19-3
Gonventional Brake Components
Brake System Inspection and Tests
Brake System Test
Brake pedal sinks/fades when braking
1. Start the engi ne, and l et i t warm up to operati ng temperature.
2. Attach a 2-i nch pi ece of maski ng tape al ong the bottom ofthe steeri ng wheel , and draw a hori zontal reference
marK across tI.
3. Wi th the transmi ssi on i n Neutral , press and hol d the brake pedal l i g htl y
(about
the same
pressu re needed to keep
an A,/T-equi pped car from creepi ng), then rel ease the
parki ng
brake.
Whi l e st i l l hol di ng t he br ake
pedal ,
hook t he end of t he t ape measur e behi nd i t . Then pul l t he t ape up t o t he
steeri ng wheel , noti ng where the tape measure l i nes up wi th the reference mark you made on the maski ng tape.
Appl y steady
pressure
to the brake
pedal for 3 mi nutes.
Watch the tape measure.
.
i f i t moves l ess than 10 mm, the master cvl i nder i s OK.
.
i f i t moves more than 10 mm repl ace the master cyl i nder.
4.
5,
6.
Mast er Cyl i nder Look for damage or si gns of fl ui d l eakage at:
.
Reservoi r or reservoi r grommets
.
Li ne
j oi nt s
Between master cvl i nder and booster
Bul gi ng seal at reservoi r cap, Thi s i s a
si gn of f l ui d cont ami nat i on.
Look f or damage or si gns of f l ui d l eakage at :
.
Li ne
j oi nts
and banj o bol t connecti ons
.
Hoses and l i nes, al so i nspect f or t wi st i ng or
Bul gi ng, twi sted, or bent l i nes.
Look for damage or si gns of fl ui d l eakage at:
.
Pi ston seal
.
Banj o bol t connecti ons
Sei zed or st i cki ng cal i per
pi ns.
Look for damage or si gns of fl ui d l eakage at:
.
Li ne
j oi nts
19-4
Rapid brake pad wear, Vehicle vibration
(after
a long
dri ve), or Hi gh, hard brake pedal
1. Dr i ve t he vehi cl e unt i l t he br akes dr ag or unt i l t he
pedal i s hi gh and har d. Thi s can t ake 20 or mor e
brake pedal appl i cati ons duri ng an extended test
dri ve.
2. Wi t h t he engi ne r unni ng, r ai se t he vehi cl e on a l i f t ,
and spi n al l f our wheel s by hand.
ls there brake drag at any of the wheels?
YES Go to step 3.
NO- Look for other causes of the
pad
wear, hi gh
pedal ,
or vehi cl e vi br at i on. l
3. Turn the i gni ti on swi tch to l ock
(O), pump
the brake
pedal to depl ete the vacuum i n the brake boosl er,
and then spi n the wheel s agai n to check for brake
dr ag.
ls thete brake drag at any of the wheels?
YES Go to step 4.
NO-Repl ace the brake booster.l
4. Wi thout removi ng the brake l i nes, unbol t and
separate the master cyl i nder from the booster, then
spi n the wheel s to check for brake drag.
l s there brake drag at any of the wheel s?
YES- Go t o s t e p S.
NO Check the brake
pedal posi ti on
swi tch
adj ustment and pedal free
pl ay.l
Loosen the hydraul i c l i nes at the master cyl i nder,
then spi n the wheel s to check for brake drag.
ls there brake dtag at any of the wheels?
YES- Go to step 6.
NO
-
Repl ace the master cyl i nder.l
Loosen the bl eeder screws at each cal i per, then
spi n the wheel s to check for brake drag.
ls there brake drag at any of the wheels?
YES Di sassembl e and r epai r t he cal i per on t he
wheel (s) wi th brake drag.l
NO Look for and repl ace any damaged brake l i nes.
l f al l brake l i nes are OK. repl ace the ABS
modul at or . l
19-5
Gonventional Brake Components
Brake Pedal and Brake Pedal Position Switch Adiustment
Pedal Height
' t .
Di sconnect the brake Dedal Dosi ti on swi tch
connector, l oosen the brake
pedal posi ti on
swi tch
l ocknut
(A),
and back off the brake
pedal posi ti on
swi tch {B) unti l i t i s no l onger touchi ng the brake
pedal .
Li ft up the carpet and the i nsul ator cutout
(C).
Measure the pedal hei ght
(D)
from the mi ddl e of
the ri ght si de cener of the
pedal pad
{E).
Standard Pedal Height
(wi th
carpet removed): 179 mm
(7
1/16 i n.l
\
-
-
'-.-,
tt'tll
-
.
" '
' - - - _' ,
p;,' ,'
19-6
5. Check the brake pedal free pl ay.
3. Loosen the
pushrod l ocknut {A), and screwthe
pushrod i n or out wi th pl i ers unti l the standard
pedal hei ght from the fl oor i s reached. After
adj ustment, ti ghten the l ocknut fi rml y. Do not
adj ust the pedal hei ght wi th the
pushrod pushed i n.
{1, 5 kgf . m. 11 l bl f t l
Screw i n the brake Dedal Dosi ti on swi tch unti l i ts
pl unger i s ful l y pushed i n
(threaded
end
(A)
touchi ng the pad (B)
on the pedal arm). Then back
off the swi tch 1/4 turn to make 0.3 mm
(0.01
i n.) of
cl earance between the threaded end and the Dad.
Ti ghten the l ocknut fi rml y.
NOTE: The brakes wi l l drag i f there i s no cl earance.
Connect the brake Dedal oosi ti on swi tch connector.
Make sure that the brake l i ghts go
off when the
oedal i s rel eased.
4.
0. 3 mm
(0. 01
i n. )
i:
\.-
Pedal Free Play
1. Wi th the engi ne stopped, i nspectthe pedal free
pl ay ( A)
on t he
pedal pad ( B)
by
pushi ng t he pedal
by hand.
Fr ee Pl ay: 1 5mm( 1/ 16 3/ 16i n. l
l f the
pedal
free
pl ay
i s out of speci fi cati on, adj ust
the brake pedal posi ti on swi tch
(C).
l f the pedal free
pl ay i s i nsuffi ci ent, i t may resul t i n brake drag.
Parking Brake Check and
Adiustment
Check
1. Pul l t he
par ki ng br ake l ever
( A) wi t h
196 N
( 20
kgf ,
44 l bf) force to ful l y appl y the parki ng brake. The
parki ng brake l ever shoul d be l ocked wi thi n the
speci fi ed cl i cks {B).
Lever Locked Clicks: 9 13
P!lled up with 1gO N {20 kgf,44lbfj
2. Adj ust the
parki ng brake i f the l ever cl i cks are out of
speci fi cati on.
Adjustment
NOTE: After rear brake cal i per servi ci ng, remove the
cent er consol e, l oosen t he
par ki ng br ake adj ust i ng nut ,
startthe engi ne. and press the brake pedal several
ti mes to setthe sel f-adj usti ng brake before adj usti ng
t he par ki ng br ake.
1. Bl ock t he f r ont wheel s. t hen r ai se t he r ear of t he
vehi cl e, and support i t wi th safety stands i n the
pr oper l ocat i ons
( see page 1- 13) .
2. Make sur e t he
par ki ng br ake ar m i A) ont her ear
br ake cal i per cont act s t he br ake cal i per pi n ( B) .
(cont' d
)
19-7
Conventional Brake Components
Parking Brake Gheck and
Adjustment
(cont'd)
5 . Pul l t he par ki ng br ake l ever up one cl i ck.
Remove the center consol e
(see page 20-76).
Ti ghten the adj usti ng nut
(A)
unti l the parki ng
brakes drag sl i ghtl y when the rear wheel s are
t ur ned.
6. Rel ease the
parki ng
brake l ever ful l y, and check
that the parki ng
brakes do not drag when the rear
wheel s are turned. Readj ust i f necessary.
7. Make sur e t he
par ki ng
br akes ar e f ul l y appl i ed
when the
parki ng
brake l ever i s pul l ed up ful l y.
8. Rei nstal l the center consol e.
19-8
Brake System Bleeding
NOTE:
.
Do not r euse t he dr ai ned f l ui d.
.
Al ways use Honda DOT 3 Brake Fl ui d.
.
Make sure no di n or other forei gn matter i s al l owed
to contami nate the brake fl ui d.
.
Do not spi l l brake fl ui d on the vehi cl e; i t may damage
the
pai nt; i f brake fl ui d does contact the pai nt, wash i t
off i mmedi atel y wi th water.
.
The reservoi r on the master cyl i nder must be at the
MAX
(upper)
l evel mark at the start of the bl eedi ng
procedure and checked after bl eedi ng each brake
ca\i Der. Add tl ui d as reoui red.
1. Makesur et he br akef l ui d l evel i n t he r eser voi r i s at
t he MAX
( upper )
l evel l i ne
( A) .
2. Have someone sl owl y
pump
the brake pedal
several ti mes, then appl y steady pressure.
Starti ng at the l eft-front, l oosen the brake bl eed
screw to al l ow ai r to escape from the system. Then
ti ghten the bl eed screw securel y.
Repeat the
procedure
for each wheel i n the
sequence shown bel ow unti l ai r bubbl es no l onger
appear in the fluid.
5. Refi l l the master cyl i nder reservoi r to the MAX
( upper )
l evel l i ne.
BLEEDING SEOUENCE:
, Front Right 0 Rear Ri ght
O Front Left O Rear Lelt
Pressure Bleeding
Instal l the appropri ate
power probe pressure bl eeder
adapter onto the master cyl i nder.
Use the bl eedi ng sequence above, and fol l ow the
bl eedi ng i nstructi ons that come wi th your pressure
bl eeder .
Bleed Screw Locations
FRONT:
REAR:
19-9
Conventional Brake Components
Brake System Indicator Circuit Diagram
.CONVEBTAALE
TOP CONIAOL UNrI
UNDEN.OASH FUSE/
REIAYBOX
PANKING BRAKE SwlTCH
CIOSEO: ldor up
GAUGE
ASSEMALY
.DAYTIME RUNNING IIGHTS
CONTROI UNIT
(Canad.
6odl onlvl
EAAKEFI.UID
LEVEL SWTTCH
ALK
I
-:
G30t
19- 10
Parking Brake Switch Test
1 .
2.
Remove the center consol e, and di sconnect the
connector
(A)from
the swi tch
(B).
Check for conti nui ty between the posi ti ve
termi nal
(C)
and body ground:
.
Wi th the brake l ever up, there shoul d be
conti nui ty.
'
Wi th the brake l ever down. there shoul d be no
conti nui ty.
NOTE
(Canada);
l f the parki ng brake swi tch i s OK,
but the brake system i ndi cator does not work, do
the i nput test for the dayti me runni ng l i ghts control
uni t
{see
page
22-66).
Brake Fluid Level Switch Test
Check for conti nui ty between the termi nal s
(A)
wi th the
fl oat i n the down posi ti on
and the up
posi ti on.
.
Remove the brake fl ui d compl etel y from the reservoi r.
Wi th the fl oat down, there shoul d be conti nui ty.
.
Fi l l t he r eser voi r t o t he MAX
( upper )
l evel
( B) .
Wi t h
the fl oat up, there shoul d be no conti nui ty.
19- 11
Conventional Brake Components
Frequent i nhal ati on of brake pad dust, regardl ess of
materi al composi ti on, coul d be hazardous to your
heal th.
.
Avoi d breathi ng dust
parti cl es.
.
Never use an ai r hose or brush to cl ean brake
assembl i es. Use an OSHA-aooroved vacuum
cr eaner .
Front Brake Pads Inspection/Replacement
' 1.
Loosen the front wheel nuts sl i ghtl y. Rai sethefront
of the vehi cl e, and support i t wi th safety stands i n
the
proper
l ocati ons
(see page 1-13). Remove the
front wheel s.
2. Hol d t he cal i per
pi n ( A) wi t h
a wr ench, bei ng
car ef ul not t o damaget he
pi n boot . Removet he
cal i per bol t
(B)
wi th another wrench, and pi vot the
cal i per
(C)
up out of the way. Check the hoses and
pi n boots for damage and deteri orati on.
Remove the
pad shi ms
(A), pad retai ners
(B),
and
pads ( C) .
19-12
4. Usi ng verni er cal i pers, measure the thi ckness of
each brake pad l i ni ng. The measurement does not
i ncl ude t he
pad backi ng pl at e ( A) t hi ckness.
Brake Pad Thickness:
Stsndard: 9.5 10.5 mm
(0.37
0.41 i n.)
Servi ce Li mi t: 1.6 mm
(0.06
i n.)
l f the brake
pad thi ckness i s l ess than the servi ce
l i mi t, repl ace the front pads as a set.
Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves and cracks.
Check the brake di sc for damage and cracks.
Instal l the pad retai ners
(A).
7 .
9. Appl y Mol ykote M77 grease
or Dai kal ub 528D
grease
to the pad si de of the shi ms
(A)
and back of
the pads (B).
Wi pe excess grease offthe shi m.
Contami nated brake di scs or pads reduce stoppi ng
abi l i ty. Keep grease
off of the di scs and pads.
A
Instal l the brake pads
and
pad
shi ms correctl y.
Instal l the pad wi th the wear i ndi cator
(C)
on the
i nsi de.
l f you
are reusi ng the
pads.
al ways rei nstal l the
brake pads i n thei r ori gi nal
posi ti ons
to prevent
a
momentary l oss of braki ng effi ci ency.
' 10.
1 1 .Push i n the
pi ston (A)
so that the cal i per wi l l fi t over
the pads. N4ake sure the pi ston boot i s i n posi ti on
to
prevent damagi ng i t when pi voti ng the cal i per
down.
D
32 N.m
(3.3
ksf.m,24l bf.ftl
12. Pi votthe cal i per
(B)
down i nto posi ti on,
bei ng
careful not to damage the pi n boot. Hol d the cal i per
pi n (C)
wi th a wrench, bei ng careful not to damage
the
pi n
boot. Instal l the cal i per bol t
(D),
wi th
another wrench, and torque i t to proper
soeci fi cati on,
13. Press the brake pedal several ti mes to make sure
the brakes work, then road-test
NOTE: Engagement of the brake may requi re a
greater pedal stroke i mmedi atel y after the brake
pads
have been repl aced as a set. Several
appl i cati ons of the brake pedal wi l l restore the
normal pedal stroke.
14. After i nstal l ati on. check for Ieaks at hose and l i ne
j o:nts
or connecti ons, and reti ghten i f necessary.
19- 13
Conventional Brake Components
Front Brake Disc Inspection
Runout
1. Loosen the front wheel nuts sl i ghtl y, then rai se the
vehi cl e, and support i t wi th safety stands i n the
proper l ocati ons {see
page 1- 13). Remove the front
wneet s.
2. Removet he br ake
pads ( see page 19- 12) .
3. Inspect the di sc surface for damage and cracks.
Cl ean the di sc thoroughl y, and remove al l rust.
4. Use wheel nuts and sui tabl e fl at washers
(A)
to
hol d t he di sc secur el y agai nst t he hub. t hen mount
a di al i ndi cator as shown, and measure the runout
at 10 mm { 0. 4 i n. ) f r om t he out er edge of t he di sc,
Brake Disc Runout:
Servi ce Li mi t: 0.10 mm
(0.004
i n.)
5.
108 N m
(11 kgf m, 79.6, l bf ft)
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc.
Max. Refi ni sh Li mi t: 23.0 mm
(0.91
i n.l
NOTE;
.
l f t he br akedi sc i s beyondt heser vi ce l i mi t f or
refi ni shi ng, repl ace i t
(see
step 7 on
page 18-12).
.
A new di sc shoul d be refi ni shed i f i ts runout i s
gr eat er t han 0. 10 mm
( 0. 004
i n. ) .
19- 14
Thickness and Parallelism
1. Loosen the front wheel nuts sl i ghtl y, then rai se the
vehi cl e, and support i t wi th safety stands i n the
proper l ocati ons
(see page 1-13). Remove the front
wnee t s.
2. Remove t he br ake pads
{ see
page 19- 12) .
3. Usi ng a mi crometer, measure di sc thi ckness at
ei ght
poi nts, approxi matel y 45" apart and 10 mm
(0.4
l n.) i n from the outer edge of the di sc. Repl ace
the brake di sc i f the smal l est measurement i s l ess
t han t he max. r ef i ni shi ng l i mi t .
Brake Di sc Thi ckness:
Standard: 24.9-25.1mm
(0.98
0.99 i n.)
Max. Refi ni shi ng Li mi t:23.0 mm
{0.91
i n.)
Brake Di sc Paral l el i sm: 0.015 mm {0.0006 i n.} max.
NOTE:Thi s i s the maxi mum al l owabl e di fference
between the thi ckness measurements.
l f t he di sc i s beyond t he ser vi ce l i mi t f or par al l el i sm,
refi ni sh the brake di sc.
NOTE; l f the brake di sc i s beyond the servi ce l i mi t
for refi ni shi ng, repl ace i t
(see
step 1 on page 18-' 12).
4.
Front Brake Caliper Overhaul
Do not spi l l brake fl ui d on the vehi cl e; i t may damage the pai nt; l f brake fl ui d gets on the pai nt, wash i t off
i mmedi atel y wi th water.
To prevent
dri ppi ng, cover di sconnected hose
j oi nts
wi th rags or shop towel s.
Cl ean al l
parts
i n brake fl ui d and ai r dry; bl ow out al l passages wi th compressed ai r.
Before reassembl i ng, check that al l parts are free of di rt and other forei gn parti cl es.
Repl ace parts wi th new ones as speci fi ed i n the i l l ustrati on.
Make sure no di rt or other forei gn matter gets i n the brake fl ui d,
Make sure no grease or oi l gets on the brake di scs or pads.
When reusi ng pads,
al ways rei nstal l them i n thei r ori gi nal posi ti ons to prevent l oss of braki ng effi ci ency.
Do not reuse drai ned brake fl ui d.
Al ways use Honda DOT 3 Brake Fl ui d.
Coatthe pi ston, pi ston
seal groove, and cal i per bore wi th cl ean brake fl ui d.
Repl ace al l rubber parts wi th new ones.
After i nstal l i ng the cal i per, check the brake hose and l i ne for l eaks, i nterference, and twi sti ng.
a
- r cFr asEi J:
Honda
(
al i pcr or ease
( P
N 08C30 80234M)
8 x 1. 25 mm
CALIPEB AOLT
32 N.m {3.3 kgf m,
BRAKE HOSE
SEALI NG WASHERS
I NNER SHI M B
---------*d.
0, l
t /
W
WEAR INDICATON
I nst al l i nner pad w t h
i t s wear i ndi cat or downward.
CALIPER EODY
PISTON BOOT
6-=^"
.:
q!!4s!n
PIN BOOT
' 12
x 1. 25 mm
FLANGE BOLTS
108Nm{ 11. 0k gt . m,
79.5 tbf.ft)
Frequent i nhal ati on of brake pad dust, regardl ess of materi al composi ti on, coul d be hazardous to
your heal th.
.
Avoi d breathi ng dust
parti cl es.
.
Never use an ai r hose or brush to cl ean brake assembl i es. Use an OSHA-aooroved vacuum cl eaner.
Remove, di sassembl e, i nspect, reassembl e, and i nstal l the cal i per, and note these i tems:
CALIPEF
BRACKET
=^.
#.q!A9$
PtN AOOTS
Repl ace.
BANJO BOLT
3 4 N m
{3.5 kg{ m,
25 tbf.ftl
I NNER SHI M A
OUTERPAD SHI M
\
BRAKE PADS
BRACKET
19- 15
Conventional Brake Gomponents
Master Cylinder/Brake Booster Replacement
NOTE:
Do not spi l l brake fl ui d on the vehi cl e; i t may damage the
pai nt; l f brake fl ui d does contact the pai nt, wash i t off
i mmedi atel y wi th water.
1. Di sconnect the brake fl ui d l evel swi tch connectors.
2. Remove the brake fl ui d from the master cyl i nder reservoi r wi th a syri nge
3. Di sconnect the brake l i nes from the master cyl i nder. To
prevent spi l l s, cover the l i ne
j oi nts
wi th rags or shop
towel s.
4. Remove the master cyl i nder mounti ng nuts and washers.
5. Remove the master cyl i nder from the brake booster.
6, Di sconnect the vacuum hose from the brake booster,
7. Remove the l ock pi n and cl evi s
pi n.
8. Remove the four brake booster mounti ng nuts.
9. Pul l the brake booster forward, and removethe brake booster f rom the engi ne compartment. Becareful notto
bend or damage the brake l i nes when removi ng i t.
10. l nstal l l he brake booster and master cyl i nder i n the reverse order of removal , and note these i tems.
.
Repl ace al l rubber
parts and the
gasket wi th new ones whenever removed.
.
Coat t hel i pof t henewr odseal wi t h r ecommended seal
gr ease i n t he mast er cyl i nder set .
. I nst al l
t her odseal ont ot he br ake boost er wi t h i t s gr ooved si det owar dt he mast er cyl i nder .
.
Adj ust the
pushrod l ength before i nstal l i ng the booster
(see
step 5 on page 19-18)
.
Fi l l the master cyl i nder reservoi r, and bl eed the brake system
(see page 19-8).
.
Af t er i nst al l at i on, checkt hebr akepedal hei ght and br ake
pedal f r ee
pl ay ( see page 19- 6) and adj ust i f necessar y.
IODSEAL
t b
LOCXPIN
r 8 ( l
crEvts
19- 16
Master Cyl i nder Inspecti on
NOTE:
.
Before reassembl i ng, checkthat al l parts
are free of
dust and other forei gn parti cl es.
.
Do not try to di sassembl e the master cyl i nder
assembl y. Repl ace the master cyl i nder assembl y wi th
a new Dart i f necessarv.
.
Do not al l ow di rt or forei gn matter to contami nate the
br ake f l ui d.
,z-7--T\ .- RESERVOIR CAP
f - ^l '
Check f or bt ockage
\E+_/ of vent holes.
,/RESERVOIR SEAL
r ?. \ ) - chF. k f or . l ^mane . n. l
\ g
det er i or at r on.
9-----.-
STRAINER
Remove accumul at ed
sedi ment .
MASTER CYLINDER
Check {or l eaks, rust, and damage.
Master Cylinder Pushrod Clearance
Adjustment
Speci al Tool s Requi red
Pushrod adj ustment gauge
07JAG-SD40' 100
NOTE; Master cyl i nder pushrod-to-pi ston
cl earance
must be checked and adj ustments made, i f necessary,
before i nstal l i ng the master cyl i nder.
1. Set t hespeci al t ool
( A)
ont he mast er cyl i nder body
(B), push
i n the center shaft
(C)
unti l rhe top of i t
contacts the end ofthe secondary pi ston (D)
by
t ur ni ng t he adj ust i ng nut
( E) .
Wi thout di sturbi ng the center shaft' s
posi ti on.
i nstal l the speci al tool
(A)
onto the booster.
( 0
760 mmHg. 30 i n. Hg) 07JAG-SDro100
l nst al l t he mast er cyl i nder nut s
( B) ,
and t i ght en t o
the speci fi ed torque.
Connect the booster i n-l i ne wi th a vacuu m gauge
( C)
0 101 kPa
( 0
760 mmHg, 30 i n. Hg) t o t he
boost er ' s engi ne vacuum suppl y, and mai nt ai n an
engi ne speed t hat wi l l del i ver 66 kPa
( 500
mmHg,
20 i n. Hg) vacuum.
(cont' d)
3.
15 N. m {1. 5 kgl m,
11 tbt.ftl
19-17
Conventional Brake Components
Master Cylinder Pushrod Clearance Adiustment
(cont'd)
5, Wi th a feel er
gauge
{A),
measure the cl earance
between the gauge body and the adj usti ng nut
(B)
as shown.
l f the cl earance between the gauge body and the
adj usti ng nut i s 0.4 mm
(0.02
i n.), the pushrod-to-
pi ston cl earance i s 0 mm. However, i f the cl earance
between the
gauge body and the adj usti ng nut i s
0 mm, the
push rod-to-pi ston cl earance i s 0 4 mm
(0.02
i n.) or more. Therefore. i t must be adj usted
and rechecked.
Cl earance: 0 0.4 mm
(0
0.02 i n.l
l f the cl earance i s i ncorrect, l oosen the star l ocknut
(A),
and turn the adj uster
(B)
i n or out to adj ust.
.
Adj ust the cl earance whi l e the speci fi ed vacuum
i s appl i ed to the booster.
.
Hol d the cl evi s
(C)
whi l e adi usti ng.
0-0.4 mm {0-0.02 i n.)
A
22 N.m
{2.2
ksf m, 16l bf.ft}
Ti ghten the star l ocknut securel y.
Remove t he speci al t ool { D) .
6.
7.
07JAG-SD40100
19- 18
9. Check the
pushrod l ength
(A)
as shown i f the
booster i s removed. l f the l ength i s i ncorrect,
l oosen the
pushrod l ocknut
(B),
and turn the cl evi s
(C)
i n or out to adj ust.
116 mm
(i 1. 6 i n. )
15 N. m
(1. 5
kgf , m, 11 l bf f t l
10. I nst al l t he mast er cyl i nder
( see page 19- 16) .
Brake Booster Test
Functional Test
' 1.
Wi th the engi ne stopped, press
the brake pedal
several ti mes to depl ete the vacuum reservoi r, then
press
the
pedal
hard and hol d i t for 15 seconds. l f
the pedal
si nks, ei ther the master cyl i nder i s
bypassi ng i nternal l y, or the brake system
(master
cyl i nder, l i nes, modul ator, proporti oni ng val ve, or
cal i per ) i s l eaki ng.
2. Start the engi ne wi th the brake pedal pressed.
l f the
pedal
si nks sl i ghtl y, the vacuum booster i s
operati ng normal l y. l f the pedal hei ght does not
vary, the booster or check val ve i s faul ty.
3. Wi t h t he engi ne r unni ng, pr ess
t he br ake pedal
l i ght l y. l f t he br ake
pedal
si nks mor e t han 10 mm
(3/8
i n. ) i n 3 mi nutes, the master cyl i nder i s faul ty,
Leak Test
1. Press the brake pedal wi th the engi ne runni ng, then
stop the engi ne. l f the pedal
hei ght does not vary
whi l e pressed for 30 seconds, the vacuum booster
i s OK. l f the pedal
ri ses, the booster i s faul ty.
2. Turn the i gni ti on swi tch to l ock
(0)
and wai t
30 seconds, press
the brake pedal
several ti mes
usi ng normal pressure.
When the pedal i s fi rst
pressed, i t shoul d be l ow. On consecuti ve
appl i cat i ons, t he pedal hei ght shoul d gr adual l y
ri se. l f the pedal posi ti on
does not vary, check the
booster check val ve.
3. Di sconnect the brake booster vacuum hose
(check
val ve bui l t-i n)
(A)
at the booster
(B).
Start the engi ne, and l et i t i dl e. There shoul d be
vacuum avai l abl e. l f no vacuum i s avai l abl e, t he
check val ve i s not worki ng properl y.
Repl ace the
brake booster vacuum hose and check val ve, and
retest.
Start the engi ne. and then pi nch the brake booster
vacuum hose between the check val ve and the
DOOSter.
Turn the i gni ti on swi tch to l ock
(0),
and wai t
30 seconds. Press the brake pedal several ti mes
usi ng normal pressure.
When the pedal i s fi rst
pressed, i t shoul d be l ow. On consecuti ve appl i cati ons,
t he pedal hei ght shoul d gr adual l y
r i se.
.
l f t he pedal posi t i on does not var y, r epl acet he
brake booster
(see page 19-16).
.
l fthe pedal posi ti on
vari es, repl ace the brake
booster vacuum hose/check val ve assembl y.
5.
19- 19
Gonventional
Brake Components
Rear Brake Pads Inspection/Replacement
Frequent inhalation of brake pad dust. regardless
of material composition, could be hazardous to
your health.
'
Avoi d breathi ng dust
Parti cl es.
.
Never use an ai r hose or brush to cl ean brake
assembl i es. Use an OSHA-approved vacuum
cl eaner .
Rai se the rear of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons {see
page
1- 13) . Remove t he r ear wheel .
Rel ease the parki ng brake.
Hol d the cal i per
pi n
{A)
wi th a wrench, bei ng
careful not to damage the pi n boot. Remove the
two cal i per bol ts
(B)
wi th another wrench and
cal i per
(C)
from the bracket.
Thoroughl y cl ean the outsi de of the cal i per to
prevent dust and di rt from enteri ng i nsi de.
Support the cal i per wi th a pi ece of wi re so i t does
not hang from the brake hose.
2.
3.
19-20
4. Remove the
pad shi ms
(A)
and brake
pads (B).
Usi ng verni er cal i pers, measure the thi ckness of
each brake
pad l i ni ng. The measurement does not
i ncl ude the
pad backi ng
pl ate (A)
thi ckness.
Brake Pad Thi ckness:
Si andard: 8.9 9.1 mm
(0.35
-
0.36 i n.)
Servi ce Li mi t: 1.6 mm
(0.06
i n.)
5.
I
,l
t
6. Remove the pad retai ners.
. . . . . . . . .
10.
7.
8.
9.
' I
t .
Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves
and cracks.
Check the brake di sc for damage and cracks.
Instal l the pad retai ners.
Appl y Mol ykote M77 grease
or Dai kal ub 528D
grease
to the pad si de of the shi ms
(A).
Wi pe
excess grease
off the shi m.
Contaml nated brake di scs or
pads
reduce stoppi ng
abi l i ty. Keep grease
off of the di scs and pads.
I nst al l t he br ake pads ( B)
and
pad
shi ms on t he
cal i per bracket. Instal l the i nner pad wi th i ts wear
i ndi cator l C) faci ng up ward.
l f you are reusi ng the pads,
al ways rei nstal l the
brake pads i n thei r ori gi nal posi ti ons
to prevent
a
momentary l oss of braki ng effi ci ency.
12. Rotate the cal i per
pi ston (A)
cl ockwi se i nto the
cyl i nder, then al i gn the cutout
(B)
i n the
pi ston
wi th
the tab
(C)
on the i nner pad
by turni ng the pi ston
back. Lubri cate the boot wi th rubber grease
to
avoi d twi sti ng the pi ston
boot. l f the pi ston
boot i s
twi sted, back i t out so i t i s posi ti oned properl y.
23 N.m
{2.3 kgf m,
17 tbf,ftl
I nst al l t he br ake cal i per
( D) .
Hol d t he cal i per pi n ( E) wi t h
a wr ench, bei ng car ef ul
not to damage the pi n
boot. Instal l the cal i per bol ts
(F)
wi th another wrench, and torque the cal i per
bol ts to the proper
speci fi cati on.
After i nstal l ati on, check for l eaks at hose and l i ne
j oi nts
and connecti ons, and reti ghten i f necessary.
Press the brake
pedal
several ti mes to make sure
the brakes work, then road-test.
NOTE: Engagement of the brake may requi re a
greater pedal
stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several
appl i cati ons of the brake
pedal
wi l l restore the
normal pedal stroke.
1 4 .
15.
t o _
19-21
Gonventional Brake Components
Rear Brake Disc Inspection
Runout
1. Rai se the rear of the vehi cl e. and support i t wi th
safety stands i n the
proper l ocati ons
(see page
1- 13
) .
2. Remove the brake
pads (see page 19-20).
3. Inspect the di sc surface for damage and cracks.
Cl ean the di sc thoroughl y. and remove al l rust
4. Use wheel nuts and sui tabl e fl at washers
(A)to
hol d the di sc securel y agai nst the hub, then mount
a di al i ndi cator
(B)
as shown, and measure the
runout at 10 mm
(0.4
i n.) from the outer edge of the
di sc.
Brake Disc Runout:
Service Limit: 0.10 mm {0.004
in.)
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc. Do not use an engi ne-dri ven on-car
brake l athe. Use onl y a motor-dri ven on-car brake
l athe.
Max. Rofi ni shi ng Li mi i : 10.0 mm
(0.39
i n.)
NOTE: A new di sc shoul d be refi ni shed i f i ts runout
i s
gr eat er t han 0. 10 mm
( 0. 004
i n. ) .
108 N. m {11 kgf . m, 80l bf . f t l
19-22
Thickness and Parallelism
1. Loosen the rear wheel nuts sl i ghtl y, then rai sethe
vehi cl e, and support i t wi th safety stands i n the
proper l ocati ons
(see page 1-13). Remove the rear
wneer s.
2. Remove the brake
pads (see page 19-20).
3. Usi ng a mi crometer
(A),
measure di sc thi ckness at
ei ght poi nts, approxi matel y 45' apart and 10 mm
(0.4
i n.) i n from the outer edge of the di sc, Repl ace
the brake di sc i f the smal l est measurement i s l ess
t han t he max. r ef i ni shi ng l i mi t .
Brake Disc Thickness:
Standard: 11.9-12.1 mm
(0.469-0.476
i n.l
Max. Refi ni shi ng Li mi t: 10.0 mm
(0.39
i n.)
Brake Di sc Paral l el i sm: 0.015 mm
(0.0006
i n.) max.
Thi s i s the maxi mum al l owabl e di fference between
the thi ckness measurements.
l f the di sc i s beyond the servi ce l i mi t for
paral l el i sm,
refi ni sh the brake di sc. Do not use an engi ne-dri ven
on-car brake l athe. Use onl y a motor-dri ven on-car
brake l athe.
NOTE: l f the brake di sc i s beyond the servi ce l i mi t
for refi ni shi ng, repl ace i t
(see
step 7 on
page 18-30).
4.
10 mm
(0. 4
i n. )
Frequent inhalalion of brake
pad
dust, regardless
of material composition, could be hazardous to
your health.
.
Avoi d breathi ng dust parti cl es.
.
Never use an ai r hose or brush to cl ean brake
assembl i es. Use an OSHA-approved vacuum
cteaner.
.
Thoroughl y cl ean the outsi de of the cal i per to
prevent dust and di rt from enteri ng i nsi de.
Rear Brake Caliper Removal/lnstallation
Bl ock the front wheel s, l oosen the rear wheel nuts
sl i ghtl y, rai se the rear of the vehi cl e. and support i t
wi th safety stands i n the proper l ocati ons {see
page
1- 13) .
Remove the rear wheel s.
Rel ease the parki ng brake.
Remove the cal i per shi el d {A).
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgl m,
1.2tbf.ft1
5.
3.
Remove the brake hose mounti ng bracket
(A)
from
the rear cal i oer bodv.
6 x 1 . 0 mm
9 . 8 Nm
11.0 kgf.m,7.2 lbt ft)
6. Remove the cabls clip
(A)
from the
parking
brake
cabl e
( B) .
7. Di sconnect the
parki ng
brake cabl e end from the
parki ng
brake arm
(C).
Remove the banj o bol t
(A),
and di sconnect the
brake hose
(B).
Remove the two seal i ng washers
(C),
and repl ace them. Do not spi l l brake fl ui d on
the vehi cl e; i t may damage the pai nt; i t brake fl ui d
gets
on the
pai nt,
wash i t off i mmedi atel y wi th
wal er.
E
23 N.m {2.3 kgt.m, 17 lbf ftl
Hol d the cal i per pi n (D)
wi th a wrench, bei ng
careful not to damage the
pi n
boot. Remove the
two cal i per bol ts
(E)
wi th another wrench, and
remove the cal i per
(F)
from the bracket.
Instal l the rear brake cal i per i n the reverse order of
removal . and note these i tems:
.
When i nstal l i ng the cal i per, al i gn the cutout i n the
pi ston wi th the tab on the i nner pad (see
step 6
on page 19- 21) .
.
Check the brake hose and cal i per fi tti ng for l eaks,
and ti ghten the banj o bol t i f necessary.
.
Check the brake hoses for i nterference and
twi sti ng.
.
Contami nated brake di scs or
pads
reduce
stoppi ng abi l i ty. Keep grease off ofthe di scs and
Daos.
A
34 N. m
{3.5 kgl m.
25 tbf.ft,
10.
19-23
Gonventional Brake Components
Rear Brake Caliper Overhaul
Frequent i nhal ati on of brake
pad dust, regardl ess of materi al composi ti on, coul d be hazardous to
your heal th.
.
Avoi d breathi ng dust
parti cl es.
.
Never use an ai r hose or brush to cl ean brake assembl i es. Use an OsHA-approved vacuum cl eaner.
Di sassembl e. i nspect, and reassembl e the cal i per, and note these i tems:
.
Cl eanal l
par t s i n br ake f l ui d and ai r dr y; bl owout al l
passages wi t h compr essed ai r .
.
Before reassembl i ng, check that al l
parts
are free of di rt and otherforei gn
parti cl es.
.
Repl ace parts wi th new ones as speci fi ed i n the i l l ustrati on.
.
Make sure no di rt or other forei gn matter gets i nto the brake fl ui d.
.
Make sure no grease or oi l
gets on the brake di scs or
pads.
.
Do not reuse drai ned brake fl ui d.
.
Al ways use Honda DOT 3 Brake Fl ui d.
.
Coatthe pi ston, pi stonseal groove, and cal i per bore wi th cl ean brake fl ui d.
.
Reol ace al l rubber oarts wi th new ones.
19-24
#:!@ :Honda cal i per grease (P/N
08c30-Bo234M)
6 x' l 0 mm
9. 8 N m {1. 0 kt q. m, 7. 2 l bf . f t )
\
CALI PER SHI ELD
\
\ e
m
dP
L."-J
*
@
23 N.m
(2.3
kgf.m, 17 lbf.ftl
a^.
CALIPER BODY
8 x 1. 25 mm
23 N. m
(2.3
kts.m, 17 lbl.ft)
PI N A
PIN BOOTS
<-
PAD SPRING
RETAINER
PAD SHIM
BRAKE PADS
/
ourER PAD sHrM
1l / l3il,l"fu.,"
'lffi
/,
(s6ksf
m"rl rbr'ftl
WIJ
/
-
@,-
PIN B
BLEED SCREW
8.8 N.m
10.9 kgt.m,
6.s tbt.frl
8 x 1. 25 mm
=^
-q!4-$n
stLtcoNE
SPRING WASHER
SLEEEVE PISTON
BEARI NG A
ADJUSTING BOLT
CAM BOOT
Bepl ace.
RETURN SPRING
AOJUSTI NG SPRI NG B
SPRI NG COVER
PISTON ASSEMBLY
-PI STON BOOT
19-25
Conventional Brake Components
Brake Hoses and Li nes Inspecti on
1, Inspectthe brake hoses for damage, deteri orati on, l eaks, i nterference, and twi sti ng.
2. Check t he br ake l i nes f or damage, r ust i ng, and l eakage. Al so check f or bent br ake l i nes.
3. Check for l eaks at hose and l i ne
j oi nts
or connecti ons, and reti ghten i f necessary.
4. Check t he mast er cyl i nder and ABS modul at or uni t f or damage and l eakage.
NOTE: Repl ace the brake hose cl i p whenever the brake hose i s servi ced.
MASTER CYLINoEB-to-BRAKE LINE
15 N. m
(1. 5
kqf m. r1 l bf . f t l
BRAKE LINE-to-BRAKE HOSE
15 N.m
(1.5
kgf.m, 11 l bf.ftl
MOOULATOR UNIT-to-
BRAKE LI NES
15 N. m
{1. 5 kgf . m,
11 t bf . f t l
BRAKE HOSE.to.CALIPER
{BANJO BOLTI
34 N m
(3, 5 kgf . m, 25 l bf . f t )
BRAKE LINE-to'BRAKE HOSE
15 N.m 11.5
kgf.m, 11 l bf.ft)
BRAKE HOSE-to-CALIPES
IBANJO BOLTI
3,r N.m {3.5 kgf m,25 l bf.ftl
PROPORTIONING CONTROL VALVE-to-
BRAKE LI NE
15 N m {1. 5
kgf m, 11 l bf . f t }
19-26
Brake Hose Replacement
NOTE;
.
Before reassembl i ng, check that al l
parts are free of
dust and other forei gn
parti cl es.
'
Repl ace parts wi th new ones whenever speci fi ed to
do so.
.
Do not spi l l brake l l ul d on the vehi cl e; i t may damage
the
pai nt; i f brake fl ui d
gets
on the pai nt, wash i t off
i mmedi atel y wi th water.
' 1.
Repl ace the brake hose
(A)
i f the hose i s twi sted,
cr acked, or i f i t l eaks.
3.
Di sconnect the brake hose from the brake l i ne
(B)
usi ng a 10 mm f l ar e- nut wr ench
( C) .
Remove and di scar d t he br ake hose cl i p
( A) f r om
t he br ake hose
( B) .
; - . .
4. Remove t he banj o bol t { C) , and di sconnect t he
brake hose from the cal i per.
Remove the brake hose from the knuckl e and
damper bracket.
6. l nst al l t he br ake hose { A) on t he knuckl e and
damper bracket wi th two 6 mm fl ange bol ts
(B)
and
the 8 mm fl ange bol t
(C)
fi rst, then connect the
brake hose to the cal i per wi th the banj o bol t
(D)
and
new seal i ng washer s
( E) .
f'
,...-1.
: - - -
! ' i .
J.
. ;
; '
. "-.:
6 x 1 . 0 mm
9.8 N.m
{1.0 kgt.m,
1.2 tbt ltl
D
34 N.m
{3.5 kgf.m.
25 tbf.ft)
8 x 1. 25 mm
22 N.m
l 2.2kgl m,
16 tbf.fr)
7. I nst al l t he br ake hose
( A)
on t he upper br ake hose
br ackel
( B) wi t h
a new br ake hose cl i p
( C) .
D
Connect t he br ake l i ne
( D)
t o t he br ake hose.
After i nstal l i ng the brake hose, bl eed the brake
system
(see page 19 8).
Do the fol l owi ng checks:
.
Check t he br ake hose and l i ne
j oi nt
f or l eaks, and
ti ghten i f necessary
(see page 19-26).
.
Check the brake hoses for i nterference and
twi sti ng.
8.
9.
10.
19-27
Conventional Brake Gomponents
PARKING BRAKE CABLE
Check f or f aul t y movement .
BIGHT PARKING BRAKE CABLE
Check for faul ty movement.
Parking Brake Cable Replacement
Exploded View
22 N.m
(2.2
kgf.m, 16 lbt.ftl
PARKING BRAKE SWITCH
22 N.m
\ \
(2.2
kgf.m, 16 l bt.ftl
--------
--------..-
I
CABLE ADJUSTING NUT
CABLE EOUALIZER
PARKING BRAKE LEVER
Check f or smoot h
19-28
NOTE:
.
The
parki ng
brake cabl es must not be bent oI
di storted. Thi s wi l l l ead to sti ff operati on and
premature fai l ure.
.
Refer to the Expl oded Vi ew as needed duri ng thi s
proceoure.
1. Remove t he cal i per shi el d.
2. Rel ease the parki ng brake l everful l y, and remove
the brake hose cl i p
(A)from
the
parki ng brake
cabl e
( B) .
A
Di sconnect the parki ng brake cabl e end from the
parki ng brake arm
(C).
19-29
Brakes
Conventi onal Brake Gomponents ................... 19-1
ABS
(Anti-lock
Brake Systeml Components
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-32
General Troubl eshoot i ng I nf ormat i on . . . . . . . . . . . . . . . . . . . . . . . 19-33
DTC Troubl eshoot i ng I ndex . . . . . . . . . . . . . . 19-37
Sympt om Troubl eshoot i ng I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-38
Syst em Descri pt i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-39
Ci rcui t Di agram . . . . . . . . . 19-46
DTC Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . . 19-48
ABS I ndi cat or Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . 19-56
ABS Modul at or-Cont rol Uni t Removal and
I nst al l at i on . . . . . . . . . . . . . 19-59
Wheel Sensor I nspect i on . . . . . . . . . . . . . . . . . . . 19-60
Wheel Sensor Reol acement . . . . . . . . . . . . . . 19-60
ABS Components
Component Location lndex
DATA LINK CONNECTOR {16P}
MAI N
UNDER. HOOD FUSE/ RELAY BOX
RI GHT-FRONT WHEEL SENSOR
I nspect i on, page' 19-60
Repl acement , page 19-60
LEFT.REAR
WHEEL SENSOR
Inspecti on, page 19-60
Repl acement, page
19-60
RI GHT-REAR WHEEL SENSOR
I nspect i on, page 19-60
Repl acement , page 19-60
ABS MODULATOR.CONTROL UNIT
Removal and Instal l ati on, page 19-59
LEFT.FRONT WHEEL SENSOR
Inspecti on, page l 9-60
Repl acement, page 19-60
I
UNDER-DASH FUSE/RELAY BOX
19-32
General Troubl eshooti ng Informati on
ABS lndicator
.
l f t hesyst em i s OK, t heABS i ndi cat or
goesof f 2
seconds after turni ng the i gni ti on swi tch ON
(l l )
wi t hout st ar t i ng t he engi ne. and t hen comes on agai n
and
goes off 2 seconds l ater after starti ng the engi ne.
Thi s occur s because t he ABS cont r ol uni t i st ur ned
on bv the l G2 oower source.
.
The ABS i ndi cator comes on when the ABS control
uni t detects a
probl em
i n the svsl em. However, even
though the system i s operati ng
properl y, the i ndi cator
wi l l come on under these condi ti ons:
-
Onl y the dri ve wheel s rotate
-
One dri ve wheel i s stuck
-
The vehi cl e goes i nt o a spi n
-
The ABS conti nues to operate for a l ong ti me.
-
The vehi cl e i s subj ected to an el ectri cal si gnal
di sturbance
To determi ne the actual cause ofthe
probl em, questi on
the customer about the
probl em. taki ng the
above-l i sted condi ti ons i nto consi derati on.
.
When a probl em i s detected and the ABS i ndi cator
comes on, there are cases when the i ndi cator stays
on unti l the i gni ti on swi tch i s turned OFF, and cases
when the i ndi cator
goes off automati cal l y when the
system returns to normal .
-
DTC 61 or 62:The ABS i ndi cator goes off
automati cal l v when the system returns to normal .
-
DTC 11, 13, 15, 11, 31, 32, 33, 34, 35, 36, 37, 38, 54,
71. or 8' 1: The ABS i ndi cat or st ays on unt i l t he
i gni ti on swi tch i s turned OFF whether or not the
system returns to normal .
-
Dr c' t2, 1 4, 1 6, 18, 21, 22, 23, 24, 41, 42, 43, 44, 51,
52, or 53: The ABS i ndi cator goes off when the
vehi cl e i s dri ven agai n and the system i s OK after
t he i qni t i on swi t ch i s t ur ned f r om OFF t o ON { l l ) .
Diagnostic Trouble Code
(DTCI
.
The memory can hol d any number oJ DTCS. However,
when the same DTC i s detected more than once. the
more recent DTC i s wri tten over the earl i er one.
Therefore, when the same Drobl em i s detected
repeatedl y, i t i s memori zed as a si ngl e DTC.
.
The DTCS are i ndi cated i n the order they occurred,
begi nni ng wi th the most recent.
.
The DTCS are memori zed i n the EEPROM
(non-
vol ati l e memory). Therefore, the memori zed DTCs
are not cl eared when the battery i s di sconnected. the
i gni ti on swi tch i s turned off, or the system returns to
normal , Do the speci fi ed procedures to cl ear the
DTCs.
Self-diagnosis
.
Sel f-di agnosi s can be cl assi fi ed i nto two categori es:
-
I ni t i al di agnosi s:
Done ri ght after the engi ne starts and unti l the ABS
i ndi cator goes off
-
Regul ar di agnosi s:
Done ri ght after the i ni ti al di agnosi s unti l the
i gni ti on swi tch i s turned OFF
.
When a probl em i s detected by sel f-di agnosi s, the
system does the fol l owi ng:
-
Turns the ABS i ndi cator on
-
Memori zes the DTC
-
Stops ABS control
Kickback
The
pump motor operates when the ABS i s functi oni ng,
and the fl ui d i n the reservoi r i s forced out to the master
cyl i nder , causi ng ki ckback at t he br ake
pedal .
Pump Motor
.
The pump motor operates when the ABS i s
f unct i oni ng.
.
The ABS control uni t checks the pump motor
oDerati on when the vehi cl e i s staned the fi rst ti me
after the i gni ti on swi tch i s turned ON
(l l ),
You may
hear the motor operate at thi s ti me, but i t i s normal .
(cont' d)
19-33
ABS Components
General Troubl eshooti ng Informati on
(cont' dl
How to Troubleshoot ABS DTCs
The troubl eshooti ng fl owchart procedures assume that
the cause of the probl em i s sti l l present and the ABS
i ndi cator i s sti l l on. Fol l owi ng the fl owchart when the
ABS i ndi cator does not come on can resul t i n i ncorrect
di agnosi s.
The connector i l l ustrati ons show the femal e termi nal
connectors wi th a si ngl e outl i ne and the mal e termi nal
connectors wi th a doubl e outl i ne,
1. Ouesti on the customer about the condi ti ons when
the
probl em occured, and try to reproduce the
same condi ti ons for troubl eshooti ng. Fi nd out
when t he ABS i ndi cat or came on, such as dur i ng
ABS control , after ABS control . when the vehi cl e
was at a certarn speed, etc.
2. When the ABS i ndi cator does not come on duri ng
the test-dri ve, but troubl eshooti ng i s done based on
the DTC, check for l oose connectors. poor termi nal
contact, etc., before you start trou bl eshooti ng.
3. After troubl eshooti ng, cl ear the DTC, and test' dri ve
the vehi cl e. Make sure the ABS i ndi cator does not
come on.
How to Retrieve ABS DTCs
Honda PGM Tester Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)to
the 16P data l i nk connector
(DLC)
( B)
under t he passenger ' s si de of t he dashboar d.
19-34
2. Tur n t he i gni t i on swi t ch ON
( l l ) ,
and f ol l ow t he
prompts
on the PGN4 Tester to di spl ay the DTC{S)
on the screen. After determi ni ng the DTC, refer to
t he DTC Tr oubl eshoot i ng I ndex.
NOTE: See the Honda PGM Tester user' s manual
for sDeci f i c i nstructi ons.
Service Check Signal
(SCSI
Circuit Method;
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)
to the 16P data l i nk connector
(DLC)
l B) under the
passenger' s si de oi the dashboard.
2. Shorithe SCS c\rcurtto body ground usingthe
Honda PGM Tester.
3. Turn the i gni ti on swi tch ON
(l l )
wi thout the brake
pedal pressed.
NOTE: l f the brake
pedal
i s pressed when turni ng
the i gni ti on swi tch ON { l l ), the system shi fts to the
DTC cl ea ri ng mode.
4. The bl i nki ng frequency i ndi cates the DTC. DTCs are
i ndi cated by a seri es of l ong and short bl i nks. One
l ong bl i nk equal s 10 shor t bl i nks. Add t he l ong and
shon bl i nks together to determi ne the DTC. After
determi ni ng the DTC, refer to the DTC
Troubl eshooti ng Index.
NOTE:
.
l f the DTC i s not memori zed, the ABS i ndi cator
wi l l go off for 3.6 seconds, and then come back
on.
.
l f the ABS i ndi cator stays on, troubl eshoot for
"ABS
i ndi cator does not
go
off"
(see
step 1 on
page 19- 57) .
The svstem will not indicate the DTC unless these
condi ti ons are met:
.
The brake oedal i s not
pressed,
.
The i gni t i on swi t ch i s t ur ned ON { l l ) ,
.
The SCS ci rcui t i s shorted to body ground before
t he i gni t i on swi t ch i s t ur ned ON
( l l ) .
ExamDl e of OTC 15
Short bl i nks
{five times}
Exsmpl of OTC 22
Turn the i gni ti on swi tch OFF.
Di sconnect the Honda PGM Tester from the DLC.
6.
Long blinks {two times}
How to Clear ABS DTCs
Honda PGM Tester Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGfM Tester {A) to the l 6Pdata l i nk connector
(DLC)
( B)
under t he passenger ' s si de of t he dashboar d.
2. Tur n t he i gni t i on swi r ch oN
( l l ) ,
and cl ear t he
DTC(s) by fol l owi ng the screen
prompts
on the
PGM Tester.
NOTE: See the Honda PGM Tester user' s manual
for speci fi c i nstructi ons.
Service Check Signal
(SCS)
Circuit Method:
1. Wi th the i gni ti on swi tch OFF, connect the Honda
PGM Tester
(A)
to the 16P data l i nk connector
(DLC)
{B) under the
passenger' s si de of the dashboard.
B A
Short the SCS ci rcui t to body
ground usi ng the
Honda PGM Tester.
Press the brake
pedal .
(cont' d)
19-35
ABS Components
General Troubl eshooti ng Informati on
(cont' d)
7.
Turn the i gni ti on swi tch ON
(l l )
whi l e conti nui ng to
press
the brake pedal .
After the ABS i ndi cator goes off, rel ease the brake
peoar.
After the ABS i ndi cator comes on,
press
the brake
pedal
agai n.
After the ABS i ndi cator goes off, rel ease the brake
peoar .
You cannot cl ear the DTC unl ess these condi ti ons
are met;
.
The vehi cl e speed i s 6 mph
(10
km/h) or l ess.
.
The SCS ci rcui t i s shorted to body ground
before
the i gni ti on swi tch i s turned ON
(l l ).
.
The brake pedal i s pressed
before the i gni ti on
swi tch i s turned ON
(l l ).
19-36
10.
After a few seconds, the ABS i ndi cator bl i nks twi ce
and the DTC i s cl eared. l f the i ndi cator does not
bl i nkt wi ce, r epeat st eos l t hr u7. l f t heABS
i ndi cator stays on after i t bl i nks twi ce, check the
DTC, because a
probl em was detected duri ng i ni ti al
di agnosi s before shi fti ng to DTC cl eari ng mode.
Turn the i gni ti on swi tch OFF.
Di sconnect the Honda PGM Tester from the DLC.
DTCTroubl eshooti ng Index
DTC Detection ltem
Note
DTC: 11 Ri oht-front wheel sensor {oDen/short to bodv
qround/short
to
power) (see paqe
19-48
Df Ci ' \2 Ri oht-front wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on)
(see
Daoe 19-49
DTC: 13 Left-front wheel sensor
(open/short
to body
qround/short
to
power) see oaqe 19-48
DTC: 14 Left-f ront wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) {see oaoe 19-49
DTC: 15 Ri oht-rear wheel sensor
(oDen/short
to bodv
qround/short
to
power) see oaoe 19-48
DTC: 16 Ri oht-rear wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) see oaoe l 9-49
DTC: 17 Left-rear wheel sensor
(ooen/short
to bodv
qround/short
to
power)
see Daqe 19-48)
DTC: 18 Left-rear wheel sensor
(el ectri cal
noi se/i ntermi ttent i nterrupti on) see Daqe l 9-49
DTC: 21 Ri qht-front
pul ser see oaoe 19- 51
DfC:22 Left-front Dul ser
( see
Daoe 19- 51
DTC:23 Ri qht - r ear
pul ser see
paqe
19- 51
Drc24 Left-rear DUl ser
( see
Daoe 19- 51
DTC: 31 Sol enoi d
{ see oaoe 19' 51
DTC:32 Sol e noi d
( see paqe
19- 51
DTC:33 Sol e noi d see Daqe 19- 51
DTC:34 Sol e noi d
{ see oaqe 19- 51
DTC:35 Sol enoi d
( see
Daoe 19- 51
DTC:36 Sol enoi d
see Daqe' 19 51
DTC:37 Sol enoi d
l see Daqe 19- 51
DTCr38 Sol enoi d
( see
oaqe 19- 51
DTC:41 Ri oht-front wheel l ock l see
paqe
19-52
DfCt42 Left-front wheel l ock l see
page
19-52
DTC:43 Ri qht - r ear wheel l ock
see Daoe 19-52
DTC:44 Left-rear wheel l ock
see Daoe 19- 52
DTC:51 Motor l ock
see
page 19- 52
DTC:52 fvl otor stuck OFF
see oaoe 19-53
DTC:53 Motor stuck ON
see
paqe
19-53
DTC:54 ABS fai l -safe rel ay see oaoe 19-54
DTC:61 LowFSR +Bvol t aqe see Daoe
' !9-54
DTC:62 Hi oh FSR +B vol t aqe
see Daoe l 9-54
DTC:71 Di fferent di ameter ti re
see Daqe 19-55
DTC: 81 Cenl ral Processi no Uni t
(CPU)
di aqnosi s, and ROl vl /RAM di aqnosi s see Daoe 19- 55
ABS Components
Symptom Troubleshooting Index
symptom Diacnostic
procedure
Also check for
ABS i ndi cator does not come on ABS Indi cator Ci rcui t Troubl eshooti ng
{see
page
19- 56)
ABS i ndi cator does not go off and no
DTC is stored
ABS Indi cator Ci rcui t Troubl eshooti ng
(see
step 1
on oaoe 19-57)
19-38
System Description
ABS Control Unit Inputs and Outputs for 25P Gonnector
Wi re si de of f emal e t ermi nal s
*
1: When measured wi th the ABS control uni t 25P connector termi nal No. 7 connected to body ground wi th a
j umper
(cont' d)
-'-.._.-
-'^
2
c)
FiW
4
STOF
5
RLW
ti
RRW
1
8
FSR
I
N/R
__l
1 0
DLC
F
2
)
1 3
SCS
1 4
RLW
(-)
l l
RF
t
tv
)
1 6
tcz
G|\D1
25
18
FRW
(.)
Terminal
number
Wi re
color
Termi nal si gn
(Termi nal
namel
Description Measurement
(Disconnect
the ABS control unit
_
connector)
Terminals Conditions Voltage
2 BLU FRW{ )
(Front-ri ght
wneel
neqal rve,
Detects ri ght-front
wheel sensor si gnal
2 1 8 Wheel Spi n wheel
at 1 turn/second
AC: 0.053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
above
3 BLU/
ORN
FLW
( +
)
(Front-l eft
wneel
posi t i ve)
Detects left-front
wheel sensor si gnal
4 WHT/
BLK
STOP Detects brake swi tch
sr gnal
4
. GND
Brake pedal Pressed Battery
Vol taqe
Rel eased Bel ow 0. 3 V
5 YEL/
RED
RL W( + )
(Rear-l eft
wneel
posi ti ve)
Detects l eft-rear
wheel sensor si gnal
5 1 4 Wheel Spi n wheel
at l turn/second
AC: 0. 053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
above
6 BLU/ RRWH
YEL
( Rea
r - r i ght
wneel
negat rve)
Detects ri ght rear
wheel sensor si gnal
6 1 5
1 BLU/
RF N ( War ni ng
l amD)
Dri ves ABS i ndi cator 7 GND ABS i ndi cat or
( l gni t i on
swi t ch ON
t ) )
ON
OFF
8 WHT/
GRN
FSR +B
( ABS
I ai l
safe rel ay
batterv)
Power source for the
ABS fai l -safe rel ay
8 GND Every ti me Battery
Vol t age
9 WHT/
.
BLU
MR + B
( Mot or
r el ay
batterv)
Power source for the
motor rel ay
I GND Every ti me Battery
Vol tage
1 0 LT
BLU
DLC Communi cat es wi t h
( Dat a
l i nk t he Honda PGM
connector) Tester
19-39
System Description
(cont'dl
Terminal
numDer
Wire
col or
Termi nal si gn
(Terminal
namel
Description Measurement {Disconnect the ABS control unit
connector,
Terminals Conditions Voltaoe
' t2
BRN/
WHT
FLWH
{Frontl eft
wneel
negat ave)
Detects left-front
wheel sensor si gnal
Wheel Spi n wheel
at 1 turn/second
AC: 0.053 V or
above
Reference
Osci l l oscope
0. 15 Vp- p or
aoove
1 3 BRN
(Servi ce
cnecK
si onal )
Detects service check
connector si gnal
(DTC
i ndi cati on or
DTC cl eari nq)
' t4
G RY/
RED
RLW
( ' )
(Rear-l eft
wheel
neoatave)
Detects Ieft-rear
wheel sensor si gnal
1 4 5 Wheel Spi n wheel
at l turn/second
AC: 0.053 V or
aDove
Reference
Osci l l oscope
0. 15 Vp- p or
above
l 5 GRN/
WHT
RRW
(+
)
(Rear-ri ght
wheel
oosi ti ve)
Detects ri ght-rear
wheel sensor si gnal
1 5 6
l o YEV
BLK
t G2
(l qni ti on
2)
Power source for
acti vati no the svstem
16 GND Battery
Vol taoe
1 8 GRN/
BLK
FRW
( +)
(Front-ri ght
wheel
posi ti ve)
Detects ri ght-front
wheel sensor si gnal
1 4 2 Wheel Spi n wheel
at l turn/second
AC: 0.053 V or
ADOVE
Reference
Osci l l oscope
0. 15 Vp- p or
above
24 BLK GNDl
( G
r ound 1
Gr ound
25 BLK GND2
( Gr ound
2)
Gr ound
19-40
Features
When the brake
pedal i s pressed duri ng dri vi ng, the wheel s can l ock before the vehi cl e comes to a stop. In such an
event, the maneuverabi l i ty of the vehi cl e i s reduced i f the front wheel s are l ocked, and the stabi l i ty of the vehi cl e i s
reduced i f the rear wheel s are l ocked, creati ng an extremel y unstabl e condi ti on. The ABS preci sel y control s the sl i p
rate of the wheel s to ensure maxi mum gri p force from the ti res, thereby ensuri ng the maneuverabi l i ty and stabi l i ty of
t he vehi cl e.
The ABS cal cul ates the sl i p rate of the wheel s based on the vehi cl e speed and the wheel speed, then i t control s the
brake fl ui d pressure to reach the target sl i p rate.
Grip Force of Tire and Road Surlace
TARGET SLIP RATE
COEFFICIENT OF
FRICTION
(cont' d)
19-41
System Description
(cont'dl
COMPONENTS MAIN FUNCTION
Wheel sensor The wheel sensor outputs the speed si gnal to the ABS control uni t
accordi nq to the Dul ser' s rotati on soeed.
Modul ator-
control uni t
ABS control uni t The ABS control uni t processes the si gnal from the wheel sensor,
then outouts the ABS control si onal to the modul ator uni t.
Modul at or uni t The modul ator uni t recei ves the control si gnal , then control s brake
fl ui d oressure for each wheel .
Motor rei ay
(i nsi de
of the ABS
control uni t)
The motor rel ay dri ves the ABS pump motor.
ABS fai l -safe rel ay
(i nsi de
of the
ABS control uni t)
The ABS fai l -safe rel ay cuts the power to the sol enoi d val ve when
the Drobl em i s detected.
MOOUIATOF
UNIT
19-42
ABS Gontrol Unit
Main Control
The ABS control uni t detects the wheel speed based on the wheel sensor si gnal i t recei ved, then i t cal cul ates the
vehi cl e speed based on the detected wheel speed. The control uni t detects the vehi cl e speed duri ng decel erati on
based on the rate of decel erati on.
The ABS control uni t cal cul ates the sl i p rate of each wheel , and transmi ts the control si gnal to the modul ator uni t
sol enoi d val ve when t he sl i p r at e i s hi gh.
The pressure reducti on control has three modes:
pressure
reduci ng, pressure retai ni ng, and pressure i ntensi fyi ng,
Self-diagnosis Function
1. The ABS cont r ol uni t i s equi pped wi t h a mai n CPU and a sub- CPU. Each CPU checks t he ot her f or pr obl ems.
2. The CPUs check the ci rcui l of the system.
3. TheABSc ont r ol uni t t ur ns ont heABSi ndi c at or whent heuni t det ec t s apr obl em, andt heuni t s t ops t hes y s t em.
4. The sel f-di agnosi s can be cl assi fi ed i nto these two categori es:
.
l ni t i al di agnosi s
.
Regul ar di agnosi s
On-board Di agnosi s Functi on
The ABS can be di agnosed wi th the Honda PGM Tester.
The ALB Checker cannot be used wi th thi s system. For ai r bl eedi ng, and checki ng wheel sensor si gnal s. use the Honda
PGM Tester. See the Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
(cont' d)
19-43
ABS Components
System Description
(cont'd)
ABS Modulator
The ABS modul ator consi sts of the i nl et sol enoi d val ve, outl et sol enoi d val ve, reservoi r, pump, pump motor, and the
dampi ng chamber. The modul ator reduces the cal i per fl ui d pressu re di rectl y. l t i s a ci rcul ati ng-type modul ator
becauset he br akef l ui dci r cul at est hr ought hecal i per , r eser voi r , andt hemast er cyl i nder , Thehydr aul i ccont r ol
has
three modes: pressure i ntensi fyi ng,
pressure retai ni ng, and
pressure reduci ng. The hydraul i c ci rcui t i s an i ndependent
four channel tvpe, one channel for each wheel .
MASTEE CYLI NOER
MODULATOR
_.1
FH HL
RR FL
H,,, li"'J.l1,Tiil^illt'iL.::...!..,,
Pressure i ntensi fyi ng mode: In l et va l ve open, outl et val ve cl osed
Mast er cyl i nder f l ui d i s pumped out t o t he cal i per .
Pressure retai ni ng mode: Inl et val ve cl osed, outl et val ve cl osed
Cal i per f l ui d i s r et ai ned by t he i nl et val ve and out l et val ve.
Pressure reduci ng mode: Inl et val ve cl osed, outl et val ve open
Cal i per fl ui d fl ows through the outl et val ve to the reservoi r.
Motor operati on mode: When stani ng the pressure reduci ng mode, the pump motor i s ON.
When stoppi ng ABS operati on, the
pump motor i s OFF.
The r eser voi r f l ui d i s pumped
out by t he pump, t hr ough t he dampi ng chamber , t o t he
mast er cyl i nder .
19-44
GEAR PULSEB
Wheel Sensors
The wheel sensors are the magneti c contactl ess type. As the gear pul ser teeth rotate past the wheel sensor' s magneti c
coi l . AC current i s generated. The AC frequency changes i n accordance wi th the wheel speed. The ABS control uni t
detects the wheel sensor si gnal frequency and thereby detects the wheel speed.
rt LOW SPEED
Wheel Speed and Modulator Control
WHEEL SPEED
INLET
VALVE
ON
OFF
0
o
MoroR
I
r l
^ . F
When the wheel speed drops sharpl y bel ow the vehi cl e speed,the i nl et val ve cl oses and i f necessary, the outl et val ve
opens momentari l y to reduce the cal i per fl ui d pressure.
The
pump
motor starts at thi s ti me. As the wheel speed i s
restored, the outl et val ve cl oses, and the i nl et val ve opens momentari l y to i ncrease the cal i per fl ui d
pressure.
19-45
ABS Gomponents
Circuit Diagram
MAIN UNDER-HOOD FUSE/RELAY BOX
CONNECTOBS
18P CONNECTOR {Onumbe' }
GAUGE ASSEMBLY CONNECTORS BRAKE SWITCH
4P CONNECTOR
16P coNNEcroR {Cnumber)
9 t l 1 1 1 1 4
WHEEL SENSOB
2P CONNECTOR
FRONT
IEIL
( 1 r
l 2 F)
REAR
------_
tfiT;?l
LE=!
Ter mi nal s i de of
mal e t er mi nal s
7P CONNECTOR
I r l 2 l l 3 l
l 4
5 6 7 l
([ number) 12P CONNECTOR {trnumber) OATA LINK CONNECTOR {16P)
Wi r e si de of f emal e t er mi nal s
19-46
-r!rr0'
ABS CONTROL UNIT25P CONNECTOR
Wi r e si de of f emal e t er mi nel s
19-47
2 l 3 i 4 l s l 6 i 7 l a
9
ABS Gomponents
DTC Troubl eshooti ng
DTC 11, 13, 15, 17: Wheel Sensor
(Open/ Short
t o Body Ground/ Short t o Power)
' 1.
Di sconnectthe ABS control uni t 25P connector.
2. St ar t t he engi ne.
3. Measure the vol tage between the appropri ate
wheel sensor { * ) ci r cui t t er mi nal of t he ABS
control uni t 25P connector and body ground (see
t abl e) .
DTC ADpropri ate Termi nal
11
(Rl qht-front)
No. 18: FRW
( +)
13
(Left-front)
15
( Ri qht - r ear )
No. 3: FLW
( +
)
No. 15: RRW
( +
17
(Left-rear)
No. 5: RLWi +)
4.
l s there battery vol tage?
YES Repai r short to power i n the {
+
) ci rcui t wi re
between the ABS modul ator control uni t and the
appropri ate wheel sensor. I
NO Go to step 4.
Turn the i gni ti on swi tch OFF.
ABS CONTROL UNI T 25P CONNECTOR
Wi re si de of f emal e t erml nal s
19-48
5. Check for conti nui ty between the appropri ate
wheel sensor
( +
) ci r cui t t er mi nal and body gr ound
{ see
t abl e) .
DTC Apptopriate Tetminal
11
( Ri qht - f r ont )
No. 18: FRW
( +)
13
(Left-front)
No. 3: FLW
( +)
15
( Ri qht - r ear )
No. 15: RRW
( i
)
17
(Left-rear)
No. 5: RLW
( +
)
l s there conti nui ty?
YES Go to step 6.
NO Go to step 7.
Di sconnect the wi re harness 2P connector from the
appropri ate wheel sensor, then check for conti nui ty
bet ween t he
( +
) and
(
) t er mi nal s of t he wi r e
har ness and body gr ound.
l s there conti nui ty?
YES Repai r shor t t o body gr ound i n t he
( +) or (
)
ci rcui t wi re between the ABS modul ator-control
uni t and t he wheel sensor . l
NO Repl ace t he wheel sensor . l
\
ABS CONTROL UNIT 25P CONNECTOB
7. Check the resi stance between the appropri ate
wheel sensor
( +
) and
(
-
) ci r cui t t er mi nal s
( see
t abl e) .
DTC AoDroDriate Terminal
{+ I Si de ) Si de
11
(Ri qht-front)
No. 18: FRW( - l No. 2: FRW
(
13
(Left-front)
No. 3: FLW
( +i
No. 12: FLW
(
15
( Ri qht - r ear )
N0. 15: RBW
( r )
No, 6: RRW
(
' 17
(Left-rear)
No.5: BLW
(+
) No. 14: RLW
(
FLW
{_}
(BRN/ WHTI
RLW
(_) (GRY/ RED)
Wi re si de of f emal e t ermi nal s
l s the resi stance between 450 2,000 Q ?
YES Check f or a l oose ABS cont r ol uni t 3l P
connector. l f necessary, substi tute a known-good
ABS modul ator-control uni t, and recheck.l
NO Go to step L
8. Di sconnect the wi re harness 2P connector from the
appropri ate wheel sensor, and check the resi stance
between the
(+
) and { ) termi nal s of the wheel
sensor.
Isthe resi stance between 450 2,000A?
YES Repai r open i n t he
( +) or (
) ci r cui t wi r e, or
shor t bet ween t he
( +) ci r cui t
wi r e and t he
(
)
ci rcui t wi re between the ABS modul ator-control
uni t and t he wheel sensor . l
NO Repl ace t he wheel sensor . a
ABS CONTROL UNIT 25P CONNECTOR
FRW I+) {GRN/BLK) RRW (+}
{GRN/WHT)
DTC 12, 14, 16, 18i Wheel Sensor
(Electrical
Noi se/ l nt ermi t t ent I nt errupt i on)
NOTE: l f the ABS i ndi cator comes because of el ectri cal
noi se, the i ndi cator goes off when you test-dri ve the
vehi cl e at 19 mph
( 30
km/ h) .
1. Vi sual l y check for appropri ate wheel sensor and
pul ser i nstal l ati on
(see
tabl e). Measure pul ser-to-
sensor cl earance. Inspect the pul sers for chi pped or
damage teeth
{see
page 19-60).
DTC Aoorooriate Wheel Sensor
t t Ri qht-front
1 4 Left-front
1 6 Ri qht-rear
1 8 Left-rear
Are the wheel sensot and pulser installed
cotrectl y?
YES Go to step 2.
NO Rei nstal l or repl ace the appropri ate wheel
sensor or
pul ser . l
Di sconnect the ABS control uni t 25P connector.
(cont' d)
19-49
ABS Components
DTC Troubleshooting
(cont'd)
Measure the resi stance between the appropri ate
wheel sensor
(
+
) and
( -
) ci r cui t t er mi nal s
( see
t a bl e ) .
l s there l ess than 450 Q ?
YES Go to step 1.
NO Go to step 4.
DTC Appropriate Terminal
l +) Si de
(
) Si de
12
(Ri qht-front)
No. l 8: FFW
(*
) No. 2: FRW{
14
(Left-front)
No. 3: FLW
( +)
No. 12i FLW
(
16
( Ri qht - r ear )
No, 15: BRW{ - No, 6: BBW
(
18
(Left-rear)
No. 5: RLW
( +)
No, l4r RLW
(
19-50
4. Check for conti nui ty between the appropri ate
wheel sensor
(
+ ) ci rcui t termi nal and other wheel
sensor
( +
) ci r cui t t er mi nal s
( see
t abl e) .
DTC Approp ate
Terminal
Other Termi nal
1 2 No. ' 181
FRW { + )
No. 3 No. No. 5
1 4 No. 3:
FLW
( +
)
No. ' 18 No. 15 No . 5
t o No. 15:
RRW
(+
)
No.
' 18
No. 3 No. 5
' 18
No. 5:
RLW
( +)
No. 18 No. 3 No. 15
ABS CONTROL UNIT 25P CONNECTOR
FLW
(+} (BLU/ ORN}
RLW
(+)
-\J
,..1
2 3 4 5 6 7
9
24
t
25
10 12 1 4
RRW {+)
(YEL/RED}
5.
{GBN/WHT)
FRW
(+I
{GRN/BLK)
Wi re si de of femal e termi nal s
l s there conti nui ty?
YES Repai r short i n the wi re between the
appropri ate wheel sensor and the other wheel
sensor . I
NO Cl ear the DTC. and test-dri ve the vehi cl e. l f
the ABS i ndi cator comes on and the same DTC i s
i ndi cared, repl ace the ABS modul ator-control
uni t . I
Di sconnect the harness 2P connector from the
appropri ate wheel sensor, and check the resi stance
between the
(
+
) si de and the
(
) si de of the wheel
sensor.
l s there l ess than 450 S) ?
YES Repl ace the wheel sensor.
NO Repai r short to wi re between the appropri ate
wheel sensor
( +)
and
(
) ci r cui t s. l
DTC 21, 22, 23, 24: Pulser
1. Cl ear t he DTC
( see
st ep 1 on page 19- 35) .
2. Test - dr i ve t he vehi cl e at 19 mph
( 30
km/ h) or mor e.
Does the ABS i ndi cator come on, and are DTCs 21,
22, 23, 24 indicated ?
YES Go to step 3.
NO The system i s OK al thi s ti me. t
3. Check the appropri ate pul ser gears for a chi pped or
damaged tooth
(see
tabl e).
DTC Appropriate Pulser
. , 1
Ri qht-front
22 Left-front
23 Ri oht - r ear
24 Left-rear
Are the pul ser gears OK?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
recheck.l
NO Repl ace the dri veshaft or hub uni t wi th the
chi pped pul ser gear . I
DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid
1. Cl earthe DTC
(see
step 1 on
page
19-35).
2. Tur n t he i gni t i on swi t ch ON { l l } .
3. Veri fy the DTC.
Doesthe ABS i ndi cator come on, and are DTCs 31,
32, 33, 34, 35, 36, 37, 38 indicated?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
r echeck. l
NO
- The
syst em i s OK at t hi s t i me. l
19-51
ABS Components
DTC Troubleshooting
(cont'd)
DTC 41, 42,t|(|, 44: Wheel Lock
1. Li f t up t he vehi cl e so al l f our wheel sar eof f t he
ground, and rel ease the
parki ng brake.
2. Check for brake drag wi th the brakes hot.
Do the brakes drag?
YES Repai r the brake drag.l
NO Go to step 3.
3. Check the i nstal l ati on of the appropri ate wheel
sensor
(see
tabl e).
DTC ADoroDriate Wheel
4'1 Ri qht-front
42 Left-front
43 Ri qht - r ear
44 Left-rear
l s i t cotrect?
YES- Go to step 4.
NO
-
Rei nstal l the wheel sensor correcl l y.I
Connect the PGM Tester to the DLC.
Choose MISC TEST from the ABS menu, then
sel ect functi on test.
Choose the out sol enoi d for the appropri ate DTC
(see
tabl e), and fol l ow the on screen prompts.
Appl y the brakes, and have an assi stant attempt
to rotate the appropri ate wheel for the DTC, then
act uat e t he out sol enoi d. When t he sol enoi d i s
actuated. the wheel shoul d rotate, and then l ock
up.
Di d the wheel rotate?
YES
-
The probabl e cause was that the veh i cl e
spun dur i ng cor ner i ng. l f t he pr obl em r ecur s,
check for l oose connectors, or try a known-good
ABS modul ator-control uni t. I
NO Check for l oose ABS modu l ator-control
uni t connecl ors. l f necessary, repl ace the ABS
modul at or - cont r ol uni t . I
5.
7.
19-52
DTC 51: Motor Lock
1 . Check the ABS MOTOR
(30
A) fuse i n the mai n
under-hood fuse/rel ay box, and rei nstal l the fuse i f
i t i s oK.
l s the f use OK?
YES Go to step 2.
NO Repl ace the fuse, and recheck.l
2. Di sconnect the ABS control uni t 25P connector.
3. Measure the vol tage between the ABS control uni t
25P connector termi nal No. 9 and body
ground.
ABS CONTROL UNIT 25P CONNECTOF
MR +B IWHT
-\;
,rt\
2 3 4 5 6 7
8 I
-
( \ /
I Y
l t I
t0 12 1 4 6
+B
6,
Wi re si de ol femal e termi nal s
l s there battety vol tage?
YES- Go to step 4.
NO Repai r open i n the wi re between the ABS
MOTOR {30 A) fuse and the ABS control uni t.I
connect the ABS control uni t 25P connector.
Cl ear the DTC
(see
step 1 on
page 19-35).
Test-dri ve the vehi cl e at 6 mph
(10
km/h) or more.
Does the ABS i ndi cator come on, and i s DTC 51
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.I
NO The syst em i s OK at t hi s t i me. l
DTC 52: Motor Stuck OFF
' 1.
Check the ABS MOTOR
(30
A)fuse i n the mai n
under-hood fuse/rel ay box, and rei nstal l the fuse i f
i t i s OK.
Is the tuse OK?
YES Go to step 2.
NO
-
Repl ace the fuse, and recheck.l
2. Di sconnect the ABS control uni t 25P connector.
3. Measure the vol tage between the ABS control uni t
25P connector termi nal No. 9 and body ground.
ABS CONTROL UNIT 25P CONNECTOR
Wi re si de of femal e termi nal s
ls there batt.ety voltage?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
recheck.l
NO Repai r open i n the wi re between the ABS
MOTOR
(30
A) fuse and the ABS control uni t.I
DTC 53: Motor Stuck ON
1. Cl ear the DTC
(see
step 1 on page 19-35).
2, Test-dri ve the vehi cl e.
Does the ABS indicatot come on, and is DTC 53
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.l
NO The system i s OK at thi s ti me.l
19-53
ABS Components
DTC Troubleshooting
(cont'dl
DTC 54: ABS Fail-safe Relay
1. Cl ear the DTC
(see
step 1 on
page 19-35).
2. Test-dri ve the vehi cl e.
Does the ABS indicator come on, and is DTC 54
i ndi cated?
YES Repl ace the ABS modul ator-control uni t.l
NO Intermi ttent fai l ure; the vehi cl e i s OK al thi s
t r me. l
19-54
DTC 61, 62: FSR * B Voltage
1. Cl earthe DTC
(see
step 1 on
page 19-35).
2. Test - dr i ve t he vehi cl e at 6 mph { 10 km/ h) or mor e.
Does the ABS indicator come on?
YES
-
Go to step 3.
NO The system i s OK at thi s ti me.l
3. Veri fy the DTC.
l s DTC 61 or 62 i ndi cated?
YES- Check the chargi ng system. I
NO- Do the appropri ate troubl eshooti ng for the
DTC. I
DTC 71: Different Diameter Tire
1. Cl ear the DTC
(see
step 1 on page 19-35).
2. Test-dri ve the vehi cl e.
Does the ABS indicator come on, and is DTC 71
indicated?
YES
-
Make sure al l four ti res are the speci fi ed si ze
and are i nfl ated to
proper
speci fi cati on.l
NO
-
Intermi ttent fai l ure; the vehi cl e i s OK at thi s
t i me. l
DTC 81: Cent ral Processi ng Uni t
(CPU)
Di agnosi s, and ROM/ RAM Di agnosi s
1. Cl ear the DTC
(see
step 1 on
page
19-35).
2. Test-dri ve the vehi cl e.
Does the ABS indicatot come on, and is DTC 81
i ndi cated?
YES
-
Repl ace the ABS modul ator-control uni t.l
NO l ntermi ttent fai l ure; the vehi cl e i s OK at thi s
t i me. l
19-55
ABS Components
ABS lndicator Circuat Troubleshooting
ABS indicator does not come on
1. Turn the i gni ti on swi tch ON
(l l ),
and watch the ABS
i ndi cator.
Does the ABS i ndi cator come on?
YES The system i s OK at thi s ti me.l
?
5.
6.
NO
-
Go to step 2.
Tur n t he i gni t i on swi t ch OFF t hen ON
( l l )
agai n.
Does the fuake system indicator come on?
YES Go to step 3.
NO Repai r open i n the i ndi cator
power
source
ci r cui t . l
.
Bl own I NSTRUMENT LI GHT
( 7. 5
A) f use.
.
Open i n the wi re between the INSTRUMENT
LI GHT
( 7. 5
A) f use and gauge assembl y.
.
Open ci rcui t i nsi de the fuse box.
Turn the i gni ti on swi tch OFF.
Di sconnect the ABS control uni t 25P connector.
Tur n t he i gni t i on swi t ch ON
( l l ) .
Does the ABS indicator come on?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
recheck.l
NO Go to step 6.
Check t he ABS i ndi cat or bul b i n t he gauge
assemor y.
l s the bul b OK?
YES Go to step 7.
NO Repl ace t he ABS i ndi cat or bul b. l
Turn the i gni ti on swi tch OFF.
Remove the gauge assembl y
(see page 22-52).
7.
8.
19-56
9.
10.
Di sconnect the gauge assembl y 16P connector.
Check for conti nui ty between the gauge assembl y
16P connect o r t er m i nal No. 8 and body gr ound.
GAUGE ASSEMBLY 16P CONNECTOR
Wi re si de of {emal e termi nal s
l s there conti nui ty?
YES Repai r short to body ground i n the wi re
between the
gauge assembl y and the ABS control
uni t . l
NO- Go t o st ep 11.
Connect the
gauge assembl y 16P connector, and
di sconnect the
gauge
assembl y 12P connector.
Check for conti nui ty between the gauge assembl y
12P connect or t er mi nal No. I and body
gr ound.
GAUGE ASSEMBLY 12P CONNECTOR
IBLK}
Wi re si de of f emal e t ermi nal s
ls there continuity?
YES Check for l oose termi nal s i n the gauge
assembl y connectors. l f the connector i s OK,
r epl ace t he gauge assembl y. I
NO* Repai r open i n the wi re between the gauge
assembl y and body
gr ound ( G501) . 1
1 1 .
12.
2 3 4 5
6 / 1 d I 10 11 12
GND
'/\'
ABS indicator does not go
off
' 1,
Check t he ABS +B( 20A) f use i n t he mai n under -
hood fuse/rel ay box, and rei nstal l the fuse i f i t i s OK.
l s the f use OK?
YES Go to step 2.
NO Repl ace the fuse, and recheck. l f the fuse i s
bl own, check for a short to body ground i n thi s fuse
ci rcui t. l f the ci rcui t i s OK, repl ace the ABS
modul ator-control uni t. I
Check the R/C MIRROR
(7.5
A) fuse i n the
under-dash fuse/rel ay box, and rei nstal l the fuse i f
i r i s oK.
l s the l use OK?
YES Go to step 3.
NO Repl ace the fuse, and recheck. l f the fuse i s
bl own, check for a short to body ground i n thi s fuse
ci r cui t . I
Di sconnect the ABS control uni t 25P connector,
Measure the vol tage between the ABS control uni t
25P connector termi nal No. 8 and body ground.
ABS CONTROL UNIT 25P CONNECTOR
Wi re si de of femal e termi nal s
ls there battery voltage?
YES Go to step 5.
NO Repai r open i n the wi re between the ABS
( 20
A) f use and t he ABS cont r ol uni t . t
Tur n t he i gni t i on swi t ch ON
( l l ) .
3.
5.
FSR
2 3 4 5 6 1
I
^ t - / \
Y - l
\
__
l t l
rcLj l -
10 12
I
2 3 4 5 6 7
3
24
3
25
t 0 12 1 4
18
tcz
1 .
8.
6. Measure the vol tage between the ABS control uni t
25P connect or t er mi nal No. 16 and body
gr ound.
ABS CONTROL UNIT 25P CONNECTOR
{YEL/BLKI
Wi re si de of t emal e t ermi nal s
ls there battery voltage?
YES Go to step 7.
NO Repai r open i n the wi re between the R/C
MIRROR
(7.5
A) fuse and the ABS control uni t.I
Turn the i gni ti on swi tch OFF.
Check for conti nui ty between the ABS control uni t
25P connector termi nal No. 24 and body ground.
ABS CONTROL UNIT 25P CONNECTOR
IBLK)
Wi re si de of f emal e t ermi nal s
Is there conti nui ty?
YES Go to step 9.
NO Repai r open i n the wi re between the ABS
control uni t and body ground (G303).I
{cont' d)
2 3 4 5 6 7
3
24
I
25
10 12 t o
18
GNDl
+ B
19-57
ABS Components
9.
10.
ABS Indicator Circuit Troubleshooting
(cont'd)
Turn the i gni ti on swi tch ON
(l l ).
Connect the ABS control uni t 25P connector
t er mi nal No. 7 and body
gr ound wi t h a
j umper
wi r e.
ABS CONTROL UNIT 25P CONNECTOR
WALP NEU
2 3 4 5 6 1
I
24
t
25
10 12 1 41 5
] E
JUMPER
WIRE
1 1 .
Wi re si de of femal e termi nal s
Does the ABS i ndi cator go otf?
YES Check for l oose termi nal s i n the ABS control
uni t 25P connector. l f necessary, substi tute a
known-good ABS modul ator-control uni t, and
recheck.l
NO Go t o s t e p l l .
Con nect the
ga
uge assem bl y 16P co nnector
t er mi nal No. 8 and body
gr ound wi t h a
j umper
wi r e.
GAUGE ASSEMBLY 16P CONNECTOR
Wi re si de of femal e termi nal s
Does the ABS i ndi cator go ofl ?
YES Repai r open i n the wi re between the gauge
assembl y and the ABS control uni t.l
NO Check for l oose gauge assembl y connectors.
l f the connector i s OK, repl ace the gauge
assembl y. l
19-58
ABS Modulator-Control Unit Removal and Installation
NOTE:
.
Donotspi l l brake fl ui d on the vehi cl e; i t may damage the
pai nt; i f brake fl ui d gets on the
pai nt, wash i t off
i mmedi atel y wi th water.
.
Take care not to damage or deform the brake l i nes duri ng removal and i nstal l ati on.
.
Topr event t hebr akef l ui df r omf l owi ng, pl ugandcover t hehoseendsandj oi nt swi t hashopt owel
or equi val ent
materi al .
Removal
1. Pul l uot hel ock( B) of t heABScont r ol uni t 25P connect or
( C) ,
t hen di sconnect t he connect or .
FLARE NUT
To righl-tront
To left-rear
To right-rear
To left-front
mm NUT
s. 8 N m 11. 0
kgf . m, 7. 2l bf . f t l
--G
mm EOLT
---' 9. 8 N. m 11. 0 kcI m, 7. 2l bf f t )
2. Di sconnect the si x brake l i nes.
3. Remove the two 6 mm nuts.
4. Remove the ABS modul ator-control uni t
(A).
lnstallation
1. l nstal l the ABS modul ator-control uni t, then ti ghten the two 6 mm nuts.
2, Al i gnthe connecti ng surface of the ABS control uni t 25Pconnector.
3. Pushi nt hel ockof t heABscont r ol uni t 25P connect or unt i l
you hear i t cl i ck i nt o
pl ace, t hen co n nect t he con nect or '
4. Bl eed the brake system, starti ng wi th the front wheel s.
5. Start the engi ne, and check that the ABS i ndi cator
goes off.
6. Test-dri ve the vehi cl e, and check that the ABS i ndi cator does not come on
19-59
ABS Components
Wheel Sensor Inspection
Inspect the front and rear pul sers
for chi pped or
damaged teeth.
Measure the ai r gap between the wheel sensor and
pul ser
al l the way around whi l e rotati ng the pul ser.
Remove the rear brake di sc to measure the gap
on
the rear wheel sensor. l f the gap
exceeds 1.0 mm
( 0, 04
i n) , check f or a bent suspensi on ar m.
Standard:
Front/Rear: 0.4 1.0 mm
(0.02
0.04i n.)
Front/Bear
0, 4- 1. 0 mm
10. 02-0. 0i t i n. l
1 .
19-60
Wheel Sensor Replacement
NOTE; Instal l the sensors careful l y to avoi d twi sti ng the
wi res.
Front:
6 mm BOLT
9, 8 N. m
(1. 0
kgf . m, 7. 2l bf . f t )
Rear: \
mm BOLT
WHEEL SENSOR
9. 8 N. m (1. 0
kgI . m,
1.2 tbt.ftl
6 mm BOLT
9. 8 N. m (1. 0
kgf m,
7. 2l bf . f t l
9. 8 N m {1. 0 kgl . m, 7. 2 l bf f t )
Body
Doors
Comoonent Locat i on l ndex . . . . . . . .
Door Panel Removal /
I nst al l at i on
Door Out er Handl e
Repl acement
Door Lat ch Reol acement . . . . . . . . . . . .
Door Gl ass and Regul at or
Reol acement
Door Gl ass Adj ust ment . . . . . . . . . . . . . . .
Door Sash Hol der
Repl acement
Door Sash Hol der
Adi ust ment
Door Gl ass Out er Weat herst ri o
Repl acement
Door Weatherstrip
Reol acement
Door Wedge and Door Wedge
Hol der Reol acement . . . . . . . . . . . . . . . .
Door Posi t i on and Door St ri ker
Adj ust ment
Mirrors
Component Locat i on I ndex . . . . . . . .
Power Mi rror Repl acement . . , . . . , .
Mi rror Hol der ReDl acement . . . . . . . .
Rearview Mirror
Reol acement
Glass
Component Locat i on l ndex . . . . . . . .
Gl ass Repl acement Process . . . . . . .
Wi ndshi el d Repl acement . . . . . . . . . . . .
Rear Wi ndow Reol acement . . . . . . . .
Convertible Top
Component Locat i on I ndex . . . . . . . .
Convertible Top Assembly
Repl acement
Convert i bl e Too Cl ot h
Reol acement
Rear Wi ndow Repl acement . . . . . . . .
Rear Wi ndow Lower Mol di ng/
Rear Wi ndow Harness Hol der
Repl acement
Convert i bl e Top Cl ot h Repai r . . . . .
Convert i bl e Top Lock Handl e
Repl acement
Convert i bl e Top Lock Handl e
Operat i on Load
Adjustment
20-2
20-4
20-5
20-7
20-8
20-'t'l
20-'15
20- 16
20-16
20-17
20-17
20- 18
20-20
20-21
20-21
20-22
20-23
20-25
20-29
20-32
20-35
20-38
20-40
20-43
20-47
20-48
20-49
20-49
Convert i bl e Top Mot or
Repl acement . . 20- 50
Convert i bl e Too St ri ker
Reol acement . . 20-50
A-Pi l l ar-Header Weat herst ri o
and A- Pi l l ar Mol di ng
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
B-Pi l l ar Out er Weat herst ri p
Repl acement . . 20- 52
Drai n Tank and Lower Drai n
Hose Reol acement . . . . . . . . . . . . . . . . . . . 20-52
Convert i bl e Top Cover Snap
Reol acement . . 20- 53
Removable Hardtop
Comoonent Locat i on l ndex . . . . . . . . 20-54
I nt eri or Tri m Removal /
l nst al l at i on . . . . . . 20-55
Headl i ner Removal /
l nst al l at i on . . . . . . 20-56
Roof Mol di ng Repl acement . . . . . . . . 20-57
Hardtop Lower Weatherstrip
Reol acement . . 20- 60
Roof Front Tri m
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 61
Hardt oo Lock Handl e
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 61
Roof Si de Lock Reol acement . . . . . . 20-62
Hardt op St ri ker Repl acement . . . . . 20-63
Body Si de Cat ch Assembl y
Repl acement . . 20- 63
Body Side Catch
Reol acement . . 20- 64
Roof Posi t i on Adj ust ment . . . . . . . . . . . 20-65
Interior Trim
Component Locat i on I ndex . . . . . . . . 20-67
Tri m Rem ova l / l nst a l l at i on
Front Roof Area . . . . . . . . . . . . . . . . . . . . 20-68
Tri m Removal / l nst al l at i on
Door Area . . . . 20-69
Tri m Remova l / l nst al l at i o n
Seat Si de Area . . . . . . . . . . . . . . . . . . . . . . 20-70
Tri m Remova l / l nst a l l at i on
Rear Tray Area . . . . . . . . . . . . . . . . . . . . . . 2O-71
Tri m Removal / l nst al l at i on
Trunk Area .. 20-73
Carpet Repl acement . . . . . . . . . . . . . . . . . . . . 20-7 4
*
Cent er Carpet Repl acement . . . -. . . . 20-75
Gonsoles
Cent er Consol e Removal /
I nst al l at i on
Wi nd Def ect or Repl acement . . . . . .
Rear Consol e Removal /
l nst al l at i on
Rear Consol e Box
Repl acement
Dashboard
l nst rument Panel Removal /
l nst al l at i on
Radi o Panel Removal /
I nst al l at i on
Front Consol e Cover Removal /
l nst al l at i on
Passenger' s Dashboard Lower
Cover Removal / l nst a l l at i on . . . . .
Passenger' s Si de Vent
Removal / l nst al l at i on . . . . . . . . . . . . . . . .
*
Dashboard Removal /
I nst al l at i on
Seats
Component Locat i on I ndex . . . . . . . .
Seat Remova l / l nst a l l at i on . . . . . . . . . . .
Seat Di sassem bl y/ Reassem bl y
-
Driver' s
Seat Di sassembl y/ Reassembl y
Passenger' s
Seat Cover Repl acement . . . . . . . . . . . .
Bumpers
Front Bumper Removal /
I nst al l at i on
Rear Bumper Removal /
l nst al l at i on
Hood
Adjustment
Hood I nsul at or Repl acement . . . . . .
Fuel Fill Door
Adj ust ment
Exterior Trim
Cowl Cover Repl acement . . . . . . . .
Rear Tray Openi ng Mol di ng
Reol acement
Rear Wi ndow Lower Mol di ng
Reol acement
Embl em Reol acement . . . . . . . . . . . . .
A-Pi l l ar Ext eri or Tri m
Reol acement
20-100
20-101
20-102
20-102
20-103
20-104
Fenderwell
I nner Fender Repl acement . . . . . . 20-105
St rakes Repl acement . . . . . . . . . . . . . . . 20-106
Fenderwel l Tri m
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Rear Ai r Out l et
Reo1acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
Openers
Component Locat i on I ndex . . . . 20-108
Hood Ooener Cabl e
ReDl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Fuel Fi l l Door Opener
Cabl e Reol acement . . . . . . . . . . . . . . 20-1 10
Hood Rel ease Handl e
Reo1acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 111
Hood Lat ch Reol acement . . . . . . . . 20-111
Trunk Li d Lat ch
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 12
Trunk Li d Lock Cyl i nder
Reol acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 13
Frame
Front Subframe
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 14
Rear Subf rame
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . 20- 1 15
*
Fr ame Repai r Char t . . . . . . . . , , . . , . . . . . 20- 116
20-76
20-77
20-78
20-79
20-80
20-80
20-81
20-81
20-82
20-82
20-85
20-86
20-87
20-88
20-89
20-92
20-93
20-94
20-96
Trunk Lid
Adj ust ment . . . . . . . . 20-97
Trunk Li d Torsi on Bar
Repl acement . . 20-98
Trunk Li d Rubber Prot ect or
Repl acement . . 20- 99
Trunk Li d Weat herst ri p
Reol acement . . 20-99
Doors
Component Location Index
WEDGE HOLOER
Repl acement , page 20-17
G
GLASS OUTER
WEATHERSTRIP
Repl acement , page 20-16
r)
@
ts+a
DETENT ROD
/
yo'
#'*e e^/
w>
@(hJ"te
i.%-.
DooRwEDGE b
Repl acement , page 20-17
TWEETER GRILLE
(' 02-03
model s)
DOOR
Posi t i on Adj ust ment ,
page 20' 18
*b{
ft
\,/
I
I
SPEAKER
AY
\J
\
ADAPTER
DOOR GLASS
INNER WEATHERSTRIP
PLASTIC
TWEETER
(' 02-03
model s)
DOOR GRI P
COLLAR
(' 02-03
model s)
Passenger'si
swrrcH PANEL
/9
/ / 8 s
tr
POWER WINDOW
swrTcH
\\..-
qi
20-2
GLASS
Repl acement ,
page 20-8
Adj ust ment , page 20-l ' l
FRONT LOWER
CHANNEL
/ DOOR
SASH HOLDER
/ Repl acement ,
I
page 20-15
/
Adj ust ment ,
f
Page
20' 16
I
GLASS STOP
o
trF
/
)N
DOOR GLASS
REGULATOB
Bepl acement,
page 20-8
REGULATOR
LOWER PATCH
DOOR STRIKER
Adj ustment,
page 20-18
N
LOCK CYLI NDER
CYLINDER SWITCH
LATCH
PROTECTOR
PROTECTOR
RETAINER CLIP
DOOR OUTER HANDLE
Repl acement, page 20-5
ROD CRANK
FRONT LOCK ROD
HANDLE
0
HANDLE
ROD PROTECTOR
DOOR LATCH
Repl acement,
page 20 7
usn
/i'tl:\
/l:, J
w
I NNER
POWER DOOR
LOCK ACTUATOR
\ o Q
o"- An
*Fy'
'r.9
I NNER HANDLE CASE
20-3
Doors
Door Panel RemovaUl nstal l ati on
Speci al Tool s Requi red
Tri m pad remover, Snap-on A 177A, or equi val ent, commerci al l y avai l abl e.
NOTE:
.
Take care not to scratch the door panel
anddoor,
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve
tape to prevent
damage.
' 1.
Remove t he door panel i n t he number ed sequence. Remove t he door
panel
wi t h as l i t t l e bendi ng as possi bl e
t o
avoi d cr easi ng or br eaki ng l t .
2. I nst al l t he panel i nt he r ever se or der of r emoval , and not e t hese i r ems:
.
Repl ace any damaged cl i ps.
.
Make sure the connectors are pl ugged
i n properl y.
.
Check the wi ndow and power
door l ock operati ons.
Fastener Locations
A>: Scr ew, 1 B>: Scr ew, 1 C>: Scr ew, ' t D>: Cl i p, I E>: Ct i p, 6
/.\ /\. /^\ .---A A
tlpr
(
F>
(F::["
L----l
J94
-
Er-r
12 mm
-
{ 0. 47 i n. }
(1TwEETER
CONNECTOR
(' 02
03 model s)
Di sconnect ,
,tilPowER
wtNDow
SWITCH CONNECTOR
Di sconnect ,
95 mm {3. 74 i n. )
TRIM PAO REMOVER
t
r
-)?
t
I
O INNER HANDLE cAsE
Turn t he case, and sl i p
t he i nner handl e t hrough
t he hol e i n t he case.
1 m m
{0. 04 i n. l
.5 CAP
20-4
(' OOOR
PANEL
Door Outer Handl e Repl acement
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care not to scratch the door
.
Take care not to bend each rod.
' 1.
2.
3.
Remove these i tems:
.
Door oanel
.
Pl asti c cover, as necessary
(see page 20-2)
Remove the door outer handl e i n numbered sequence
l nstal l the outer handl e i n the reverse order of removal , and note these i tems:
.
Make sure the cyl i nder swi tch harness i s routed properl y.
.
Make sure the cyl i nder swi tch connector i s
pl ugged i n properl y, and each rod i s connected securel y.
.
When i nstal l i ng the l ock cyl i nder, l eave the outer handl e bol ts l oose so the outer handl e
protector does not
i nterfere wi th the l ock cyl i nder i nstal l ati on, then ti ghten the handl e bol ts
. I ns t al l t her et ai ner c l i pont heout er handl e, t heni ns t al l t hel oc k c y l i nder . Bes ur et her et ai ner c l i pi s f ul l y s eat ed
i n the sl ot on the l ock cyl i nder.
.
Make sure the door l ocks and opens
properl y.
.
When rei nstal l i ng the door panel , make sure the pl asti c cover i s i nstal l ed properl y and seal ed around i ts
peri meter.
Fastener Locations
O Rai se t he
gl ass f ul l y.
LOCK CYLINDER
CYLINDER SWITCH
HOLE SEAL
A>: Sc r ew, 1 B>r Sc r ew, 1
C=" O-
i!] RETAINER CLIP
- - ' . : . ' \ J
-
)};i
a\
\
\ , l ?\
. .
ROD PROTECTOR
i9-, HARNESS CLIPS
Det ach.
{cont' d)
:-,
O CYLINDER SWTTCH HARNESS
CONNECTOR
Di sconnect ,
20-5
Doors
Door Outer Handle Replacement
(cont'd)
Fastener Locations
>
: Bolt, 2
I i I \tF,----:\
)
: Bolt, 1
I
i
lllllrr--1
CO : Nut, 1
@
F>: Sc r ew. 1
I" ;r
\i'/--
G) : Sc r e w, 2
f)'-'---,-'-
\}-
@ Tur n t he out er handl e,
and remove i t f rom out er handl e rod.
JOINT
OUTER HANDLE
O Scr i be a l i ne ar ound
t he out er handl e rod on
t he
j oi nt
t o show t he ori gi nal
adl ust ment . OUTER HANOLE ROD
@ Pul l out t he out er handl e.
OUTER HANDLE
PROIECTOR ROD
0 6 x 1 . 0 mm
9.8 N.m
(1.0
kgf m,
7.2 tbl.ftl
JOI NT
n - -
v
@6 x 1 , 0 mm
9. 8 N. m 11. 0 kgt . m.
7. 2l bf . f t l
i1O OUTER HANDLE
PROTECTOR
f' ?5' \
i ' - r . 1
r \ r i 7
c ' 1
,
\.'
l l j l 6x1. omm
9. 8 N. m {1. 0 kgf . m,
7.2tbl.ftl
( ?6x 1. omm
6 N.m {0.6 kgf m.
4 lbf.fr)
LATCH
20-6
Door Latch Replacement
NOTE:
.
Put on
gl oves to
protect your hands.
.
Take care not to scratch the door.
.
Take care notto bend each rod.
1. Remove t he out er handl e
( see page 20- 5) .
2. Remove the door l atch i n numbered sequence.
3. Instal l the l atch i n the reverse order of removal , and note these i tems:
.
Make sure the actuator connectors are
pl ugged i n
properl y, and each rod i s connected securel y
.
l \,4ake sure the door l ocks and opens
properl y.
.
When rei nstal l i ng the door panel , make sure the pl asti c cover i s i nstal l ed
properl y and seal ed around i ts
peri meter.
Fastener Locations
DOOR LATCH
A) : Sc r e w, 3
ClF"
Di sconnect t he i nner
handl e r od.
@ Di sconnect t he rear
l ock rod-
REAR LOCK ROD
/
r
_--,,,,-.
)P
.,
,i .,
6.'
.-, -
..
"
I NNEB HANDLE
A 1 . 1
v. i
\ \
@ FRONT LOCK ROD
O CONNECTORS
Di sconnect.
Det ach t he i nner
handl e rod.
Di sconnect t he f ront
l ock rod.
' ROD CRANK
20-7
Doors
Door Glass and Regulator Replacement
NOTE:
.
Put on gl oves
to protect your hands.
.
Take care notto scratch the door.
.
Take care not to drop the wi ndow gl ass i nsi de the door.
1. Remove these i tems:
.
l nner handl e and r od cr ank
( see page
20- 7)
.
Pl asti c cover
(see page
20-2)
2. Remove the door gl ass
and regul ator i n numbered sequence:
'
Hol d the adj usti ng bol ts wi th a hex wrench when removi ng the l ocknuts.
.
Scri be a l i ne around the stabi l i zer mounti ng bol t, the gl ass mounti ng bol ts, and the regul ator mounti ng nuts to
show the ori gi nal l ocati ons.
Fastener Location
A>: Bol t , 1
{MIED
STABILIZER
Scr i be a l i ne
around t he bol t .
OLoosen t he bol t .
8 x 1. 25 mm
22 N. m
(2.2
kgf.m,
16 tbf.ft)
OCaref ul l y move t he gl ass unt i l you
can remove t ne gl ass st op.
6 x 1 . 0 mm
5 N.m {0.5 kgf.m,
4 tbt.ft)
1
!s
. _)ir'
t . , * L
: - /
-jso_-__.._-.<
./ v^
.a
i r , ,
1
a .
,
".':-
--.:r""'
NUT
20-8
Faslenel Locations
B
>:
Bol t . 3
O Caref ul l y move t he gl ass down Ll nt i l you
can see t he bol t s.
6 x1. 0 mm
I N.m {0.8
kgf m,
6 rbt.ft)
I'
@ Scri be a l i ne around t he bol l s
(Three pl acesi .
I
/ t
'tt'"-'
'"'
' (
:
' ;,"io
""' tt:
'
'
_t . -
l
- a n
(cont' d)
) Remove t he gl ass
f rom t he requl at or.
20-9
Doors
Door Glass and Regulator Replacement
(cont'd)
Fastener Locations
Ca: Nut , 2 o
O
: Nut . 2 F>: Bol t . 2
('
Scri be a l i ne around t he nut s.
@8x 1. 25mm
12Nm( 1, 2k gf . m,
lgf.ft)
@ REGULATOR
E
>
: Bol t,3
td\
l r l @
t
@ coNNEcToR
Di sconnect
and det ach.
6 x 1 . 0 mm
8 N. m
{0.8 k9f.m,
6 tbf.ftl
Loosen.
/
OLOCKNUT
8 x 1.25 mm
12 N.m {1.2 kgf.m,
,&
@ HARNss
CLIP
Det ach.
9 tbf.ftl
ADJUSTING BOLT
Instal l the gl ass
and regul ator i n the reverse order of removal . and note these i tems:
.
Hol d the adj usti ng bol ts wi th a hex wrench when i nstal l i ng the l ocknuts.
.
Before i nstal l i ng the regul ator, Appl y mul ti purpose grease
to al l the sl i di ng surfaces ofthe regul ator.
.
Make sure the connector i s pl ugged i n properl y.
.
Rol l the gl ass
up and down to see i f i t moves freel y wi thout bi ndi ng.
' Makesur et hat t her ei snocl ear ancebet weent hegl assandr oof weat her st r i pswhent hegl assi scl osed.
.
Adj ust the
posi ti on
of the
gl ass
as necessary
(see page
20-1 1).
.
Check for water l eaks
{see step 17 on page 20-14),
.
Test-dri ve and check for wi nd noi se and rattl es.
'
When rei nstal l i ng the door
panel ,
make sure the
pl asti c
cover i s i nstal l ed properl y
and seal ed around i ts
Derrmel er.
=--"--
:--r--r1,,
'\
Y,t;.)'',
,;
b-(
1(.'
20-10
Door Glass Adiustment
NOTE:
.
Check the A-pi l l ar-header weatherstri p, roof
weatherstri ps and B-pi l l ar weatherstri p for damage or
deteri orati on. and repl ace them i f necessary.
.
Wi pe each weatherstri p and the front l ower channel
cl ean wi th a shop towel .
.
Lubri cate the front l ower channel wi thShi n-Etsu
grease P/N08798-9013.
Pl ace the vehi cl e on a fi rm, l evel surface.
Secure the converti bl e top wi th both converti bl e
top l ock handl es.
Make sure they are l ocked securel y.
Lower the gl ass ful l y.
Remove these i tems:
.
Door
panel (see page 20-4)
.
Plastic cover
(see page 20-21
.
A-pi l l a r-heade r weath erstri p, pi l l ar porti on (see
page 20- 51)
.
Roof si de weatherstri p
(see page 20-40)
.
Roof corner weatherstri p
(see page 20-35)
.
B-pi l l ar weatherstri p
(see page 20-40)
Cl ose the door. Check the door fi t to the body
openi ng.
Rai se t he gl ass f ul l y.
At the measuri ng
poi nts (A,
B, C), measure and
record cl earances
"H"
and
"B"
between the gl ass
( D)
and t he mol di ng
( E)
and t he gl ass ( D)
and t he
retai ner
(F).
Adj ust the cl earance as descri bed i n
steps 9 thru
' 10.
4.
1 .
7.
5.
Measuri ng Poi nt A
-\
"8"
Clearance
Measuri ng Poi nt B
"H"
Cl e. rance
Measuri ng Poi nt C
"8"
Cl earance
"H"
Cl earance
Cl earance {Standal d cl earancel
U ni t : mm
( i n. )
l \4easuri ng Poi nt B c
Cl earance
" H"
4
( 0. 16)
?
( 0. 1
1 )
I
( 0. 31)
" 8"
1 1
( 0. 43)
1 4
( 0. 55)
1 8
{ 0. 71)
8. Move the door sash hol der al l the way forward
(see
page 20- 15) .
(cont' d)
\
,v
"8"
Cl earance
20-11
Doors
Door Glass Adjustment
(cont'dl
9. Adj ust cl earance
"H"
as fol l ows:
-1
Loosen the bol ts
(A)
securi ng the stop pl ates (B).
-2
Loosen the bol ts
(Cl securi ng
the gl ass
{D).
-3
Move the gl ass up or down, as wel l as, forward and rearward to al i gn i t wi th the retai ner and mol di ng. Move
the gl ass
unti l cl earcnce
"H"
i s wi thi n the speci fi ed l i mi ts.
-4
Ti ghten the bol ts securi ng the gl ass.
-5
Press the stop pl ates agai nst the gl ass
stops
(E).
-6
Fasten the stop pl ates. Check that the stop pl ates contact the gl ass
stops evenl y.
A
8 x 1. 25 mm
22 N,m
12.2 kbt.rn,
16 rbr.ftl
"H"
Clearance
c
6 x 1 . 0 mm
8 N. m {0. 8 kgf . m,
6 tbf.ft)
.\\
) : .
' -.i...\
.t\.
:
...//.\
t r ' '
20-12
10. Adj ust cl earance
"8"
as fol l ows:
Push the gl ass (A)
outward 10 mm
(0.39
i n.), then l i ghtl y push
the stabi l i zer
(B)
agai nst the
gl ass.
Ti ghten the bol t
(C)
securi ng the stabi l i zer. Check thatthe gl ass
moves smoothl y.
Loosen the l ocknuts
(D).
Turn the adj usti ng bol ts
(E)
unti l the cl earance
"8"
i s wi thi n the speci fi ed l i mi ts. Turn the front and rear
adj usti ng bol ts the same amount to keep the regul ator
(F) paral l el wi th the seati ng su rface of the door.
Ti ghten the l ocknuts. Make sure that the ends of the adj usti ng bol ts sti l l proj ect
out of the l ocknuts.
Move the gl ass up and down to seat i t, then measure cl earance
"8"
at the desi gnated l ocati ons.
Measure cl earance
"H"
agai n to make sure i t i s sti l l wi thi n the speci fi ed l i mi ts at the desi gnated l ocati ons.
Repeat the above steos unti l the correct cl earance are obtai ned.
Adiusting Bolt Top Edge of Glass
Clockwise
-
Moved out
Counter-clockwise
"8"
Cl earance
- 1
-2
-3
-5
-6
-7
ird
c
8 x 1.25 mm
22 N.n 12.2 kgt m,
16 tbf.ft)
D
8 x 1. 25 mm
12 N. m
{1, 2
kgf . m,
9 rbf.ftl
(cont' d)
20-13
Doors
Al i gn t he door sash hol der wi t h t he
gl ass usi ng t he
adj usti ng bol t at the bonom of the door sash hol der
( see page 20- 16) .
After the cl earances have been adj usted
properl y,
rei nstal I each weatherstri p.
13. Check that the gl ass moves smoothl y.
14. Rai se t he gl ass ( A) f ul l y,
and check t hat t he gl ass
contacts each weatherstri p
(B)
evenl y. Measuri ng
poi nts are descri bed at step 7.
Front roof pillar :
Door Glass Adjustment
{cont'd)
' l t .
12.
i
Rool :
Cnt er pi l l ar:
20-14
t c .
t o .
Attach the
pl asti c cover, and i nstal l the door
panel
(see page 20-4).
Make sure that the top i s l ocked securel y, then ral se
the gl ass ful l y, and cl ose the doors.
Check for water l eaks. Run water over the roof and
on the seal i ng area as shown, and note these i tems:
.
Use a 12 mm
( 1/ 2
i n. ) di amet er hose
( A) .
.
Adj ust the rate of water fl ow
(B).
.
Do not use a nozzl e,
.
Hol d the hose about 300 mm
(12
i n.) away from
the door.
17.
12 mm
( 1/ 2
i n. )
7-'
t ,
A
150 mm
(6
i n. )
I
-A
18.
19.
l f there are l eaks, recheck the work
performed,
and
check the door
gl ass, weatherstri p, A-pi l l ar mol di ng.
and retai ner adj ustment.
Test-dri ve and check for wi nd noi se.
Door Sash Holder Replacement
NOTE:
.
Put on gl oves
to
protect your
hands.
.
Take care not to scratch the door.
' 1.
Remove these i tems:
a-.?
.
Door gl ass (see page 20-8)
.
Door weatherstri p, as necessary {see
page 20-171
Remove the door sash hol der i n numbered sequence;
.
Hol d the adj usti ng bol t wi th a hex wrench when removi ng the l ocknut.
.
Scri be a l i ne around the l ocknutto showthe ori gi nal adj ustment.
Instal l the hol der i n the reverse order of removal , and note these i tems:
.
Adj ustthe posi ti on
ofthe door sash hol der
(see page 20-16).
.
Check for water l eaks
(see
step 17 on
page
20-14).
.
Test-dri ve and check for wi nd noi se and rattl es.
'
When rei nstal l i ng the door panel , make sure the pl asti c
cover i s i nstal l ed properl y
and seal ed around i ts
pefl mel er,
Fasrener Localions
A > c
a:
Nur , l
O6 x l . o mm
9. 8 N. m 11. 0 ksf . m,
7. 2l bl . t t l
---1-'-,-=
>
: Bolt, 2
^a:\
l Lrro
: Scr ew, 4 B
n.--
{J*
@ HOIE SEAL
G] LOCKNUT
8 x 1. 25 mm
12 N. m { 1. 2 kgf . m,
I tbf.fi)
o
t
ii-''..-',
j
' ' !a
Di sconnect .
ADJUSTING
AOLT
? SPEAKER
\ ,
20-15
Doors
1 .
2.
Door Sash Holder Adjustment
Rai se t he gl ass f ul l y.
Loosen t he l ocknut
( A)
whi l e hol di ng t he adj ust i ng
bol t
(B)
wi th a hex wrench.
Adjusting Bolt Top Edge of Holder
Clockwis
Counterclockwise
A
8 x 1. 25 mm
12 N. m
(1. 2 kgl . m,
9 rbt.ft)
3. Al i gn t he door sash hol der { C) wi t h t he
gl ass usi ng
the adj usti ng bol t at the bottom of the door sash
hol der, l \4ake sure that there i s no cl earance
between the end of channel
(D)
and gl ass surface.
4. Ti ghten the l ocknut securel y.
5. Rei nstal l al l remai ni ng removed
pans.
6, Check for water l eaks
(see
step 17 on page 20-' 14).
7. Test-dri ve and check for wi nd noi se and rattl es.
t
20-16
Door Glass Outer Weatherstrip
Replacement
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care notto scratch the door and door mol di ng.
1. Remove t he door sash hol der { see
page 20- 15) .
2. Starti ng atthe rear, prythe oute r weatherstri p
(A)
up, and detach the cl i ps
(B,
C).
Fastoner Locations
B>: Cl i p, 1 C) : Cl i p, 6
l nstal l the weatherstri p i n the reverse order of
r emoval , and r epl ace any damaged cl i ps.
Door Weatherstrip Replacement
NOTE:
.
Take care not to scratch the door.
.
Use a cl i p remover, to remove the cl i ps.
1. Remove t he door panel
{ seepage20- 4) .
2. Remove the door weatherstri p as shown.
3. Instal l the weatherstri p i n the reverse order of
removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
l f the ol d weatherstri p i s to be rei nstal l ed, scrape
off al l traces of ol d EPT seal er and butyl tape,
then cl ean the weatherstri p surface wi th al cohol .
.
Gl ue the new weatherstri p i nto pl ace usi ng EPT
seal er and butyl tape.
Fastener Locations
A) : Scr ew, 2 B
EPT SEALER
Thi ckness:5 mm (0.2 i n.)
Wi dth:5 mm {0.2 i n.l
BUTYL TAPE
Thi ckness: 1 mml 0.04 i n.l
Wi deth: 5 mm {0.2 i n.l
WEATHERSTRIP
Door Wedge and Door Wedge
Holder Replacement
NOTE: Take care not to scratch the door and body.
1. Remove l he door wedge and the door wedge
hol der as shown.
2. Instal l the wedge and wedge hol der i n the reverse
order of removal , and when i nstal l i ng the door
wedge hol der, adj ust i t up or down unti l the door
wedge i s centered i n the hol der.
Fastens. Locations
2 B
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf.m,
7.2 tbl.ttl
DOOR WEDGE
)
: Screw,
rN,",,,,-
\).*
)
: Screw
@
, 2
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7 .2 tbf.ftl
DOOR WEDGE
HOLOER
\ ^ .
20-17
Doors
Door Position and Door Striker Adjustment
NOTE:
.
Af t er i nst al l i ngt hedoor , checkf or af l ushf i t wi t ht hebody, t hencheckf or equal
gaps bet ween t he t r ont , r ear , and
bottom door edges and the body. Check l hat the door and body edges are
paral l el .
.
Pl ace the vehi cl e on a fi rm. l evel surface when adj usti ng the door.
.
Pl aceashopt owel on t he
j ack
t o
pr event
damage t o t he door when hol di ng t he door .
' 1.
Removet he door wedge hol der
( A) ( see page 20- 17) .
I x 1.25 mm
29 N.m 13.0
kgf.m,
22 tbt.ttl
4.
Sl i ghtl y l oosen the stri ker mounti ng screws
(B).
Adj ust the door al i gnment i n thi s sequence:
.
Adj ust at l he hi nges
( C) :
-
Loosent he door mount i ng bol t s
( D)
sl i ght l y, andmovet hedoor i nor out unt i l i t ' s f l ush wi t h t he body.
-
Remove the i nner fender
(see page 20-105), then sl i ghtl y l oosen the hi nge mountl ng bol ts
(E).
and move the
door backward or forward, up or down as necessary to equal i ze the gaps.
' Tur nt hedoor c us hi ons ( F) , as nec es s ar y , t omak et her ear of t hedoor f l us hwi t ht hebody .
Make sure the door and body edges are
paral l el , and the door i s fl ush wi th the body. Ti ghten the door and hi nge
mounti ng bol ts, and recheck.
D
8x 1. 25 mm
29 N. m {3. 0 kgf . m,
22lbf.ttl
20-18
5. Adj ust the stri ker
(A);
.
Move the stri ker In or Out to make the l atch fi t ti ghter or l ooser.
.
Move the stri ker Up or Down to al i gn i t wi th the l atch openi ng.
m
\
-i-:-
---
8 x 1. 25 mm
1 8 Nm( 1 . 8 k g f . m,
13 tbf.ft)
. . . . . -
- ;
g i
6 x 1 . 0 mm
9. 8 N' m
{1, 0 kgf . m,
7.2tbl,ftl
6.
7.
Make sure the door l atches properl y. Ti ghten the screws
(B).
and recheck.
Al i gn the door wedge hol der
(C)
up or down unti l the door wedge
(D)
i s centered i n the hol der. Ti ghten the screws
(F),
and recheck.
8. Appl y mul ti purpose grease
to the
pi vot porti ons
ofthe hi nges
(A)
i ndi cated bythe arrows.
Appl y body pai nt
t o t he hi nge and door mount i ng bol t s, and ar ound t he hi nges.
Check f or wat er l eaks
( see
st ep 17 on page 20 14) .
Test-dri ve and check for wi nd noi se.
9.
' 10.
' I
1.
20-19
Mirrors
Component Location Index
LOCK BOLT
POWER MIRROR
Repl acement ,
page 20-21
POWEB MIRROR ACTUATOR
Repl acement,
page 22-106
TOOTHED LOCK WASHER
g
.''
\//
HoLD SPRING
=---'.
HOOK PLATE
/'=,-\2
t-- 1
q . "
/ f
\,/v
.@
BRACKET COVER
REARVIEW MIRROB
Repl acement, page 20-22
, )
, . . , 1 , r
!'.:;r,
20-20
Power Mirror Replacement
NOTE: To avoi d scratchi ng the door, be sure to hol d the
mi r r or whi l e r emovi ng or i nst al l i ng t he nut s.
1. Remove these i tems:
.
Door sash hol der
( see page 20- 15)
.
Pl asti c cover, as necessary
(see page
20-2)
2. Di sconnectthe connector
(A),
and detach i t from
the door.
Fastoner Locations
4.
6x 1. 0mm
9.8 N.m
(1.0
kgf.m.7.2 tbt.ftl
Support the mi rror
(B)
wi th one hand, remove the
nuts
(C).
then remove the mi rror.
Instal l the mi rror i n the reverse order of removal ,
and note these i tems:
.
Make sure the connector i s pl ugged i n properl y.
.
Adj ustthe posi ti on
ofthe door sash hol der
(see
page
20- 16) .
.
Check for water l eaks
(see
step 17 on
page
2O-14).
.
Test-dri ve and check for wi nd noi se and rattl es.
.
When rei nstal l i ng the door panel ,
make sure the
pl asti c
cover i s i nstal l ed properl y
and seal ed
around i ts perl meter.
ca: Nur ,
@
,a
o a
Mirror Holder Replacement
NOTE: Put on
gl oves
to protect your hands-
1. Careful l y pul l
outthe bottom edge ofi he mi rror
hol der
{A} by hand. Take care not to scratch the
mi rror.
Separate the mi rror hol der from the actuator
(B)
by
sl owl y pul l i ng
them apart whi l e detachi ng the cl i ps
(C)
and rel easi ng the hooks
(D).
Reattach the hooks of the mi rror hol der to the
actuator, then
posi ti on
the mi rror hol der on the
actuator. Careful l y push
on the cl i p
porti ons
of the
mi rror hol der unti l the mi rror hol der l ocks i nto
prace.
Check the actuator operati on.
';';''li1'
) . '
\l
20-21
Mirrors
Rearview Mirror RePlacement
NOTE:
.
Take care not to scratch the cover and mi rror stay.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th
protecti ve tape to
prevent damage
1. Remove the rearvi ew mi rror as shown
2. Instal l the mi rror i n the reverse order of removal .
REARVIEW
MIRROR
LOCK BOLT
Turn count ercl ockwi se
t o I oosen enough t o
sl i de t he mi rror cl own.
BRACKET COVER
MOUNTING LUG
20-22
Glass
Component Location Index
WINDSHIELD MOLDING
FASTENER, 2
(Cl i p
t ype, body si de)
:\
i ,
/ i / _.
MoLD|NG
ill/.
stDEsEAL,2
LOWER RUBBER DAM
Fn
V i{rin
20-23
Glass
Component
Location Index
(cont'dl
Removable Hardtop
RUBBER DAM
G
@
e
\
SPACER,
p-...
{ 2 \
-
\
,-o*ri'ro.rr"....
\
(Sel f' adhesi ve{YPe,
\ ol ass si de)
LOWER FASTENER, 2
(Sel f-adhesi ve-type, rooJ si de)
SIDE RUBBER DAM,2
REAR WINDOW
Gl ass Repl acemenl Process,
page 20-25
Repl acement,
page 20-32
MOLDI NG
44
ta'
20-24
Glass Replacement Process
NOTE:
.
Thi s procedure
i s a general
descri pti on ofthe gl ass
repl acement
process.
For detai l s about fastener and
rubber dam l ocati ons, wi ndshi el d {see
page
20-29),
rear window
(see page
20-32l,.
.
Put on gl oves
to protect your hands.
.
Wear eye protecti on
whi l e cutti ng the
gl ass
adhesi ve
wi th pi ano wi re.
.
Use seat covers to avoi d damagi ng any surfaces.
' 1.
To remove the gl ass. fi rst remove the rel ated parts,
wi ndshi el d
(see page
20-29), rear wi ndow
(see
page
20-32).
2. Di sconnect the connectors from the
gl ass
termi nal s.
3. Remove the mol di ng
(A)
from the edge of the gl ass
(B).
l f necessary, cut the mol di ng wi th a uti l i ty kni fe.
4. l f the ol d
gl ass
i s to be rei nstal l ed, make al i gnment
marks across the gl ass
and body wi th a grease
pencl l
at the four poi nts.
Appl y protecti ve
tape al ong the edge of the body
and the rel ated parts.
1 .
Usi ng an awl , make a hol e through the adhesi ve
from i nsi de the vehi cl e at the corner porti on
of the
gl ass, wi ndshi el d
(see page
20-29), rear wi ndow
(see page
20-32).
Push a pi ece of pi ano wi re through the hol e, and
wrap each end around a pi ece
of wood,
Wi th a hel per on the outsi de, pul l the pi ano wi re
{A)
back and forth i n a sawi ng moti on. Hol d the
pi ano
wi re as cl ose to the wi ndshi el d as
possi bl e
to
prevent
damage to the body and dashboard.
Careful l y cut through the rubber dam and adhesi ve
around the enti re wi ndshi el d.
(cont' d)
20-25
Glass
Glass Replacement Process
(cont'd)
9. Careful l y remove the gl ass.
' 10.
Wi th a kni fe, scrape the ol d adhesi ve smooth to a
thi ckness of about 2 mm {0.08 i n.) on the bondi ng
surface around the enti re
gl ass
openi ng fl ange:
.
Do not scrape down to the pai nted surface of the
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng.
.
Remove any remai ni ng parts from the body.
1
' t.
Cl ean the body bondi ng surface wi th a sponge
dampened i n al cohol . After cl eani ng, keep oi l ,
grease and water from
getti ng on the cl ean surface.
12. l f the ol d
gl ass i s to be rei nstal l ed, use a
putty kni fe
to scrape off al l of the ol d adhesi ve and any
remai ni ng parts from the
gl ass. Cl ean the i nsi de
face of the
gl ass wi th al cohol where new adhesi ve
i s to be appl i ed. Make sure the bondi ng surface i s
kept free of water, oi l and
grease.
13, Gl ue the rubber dam
(A),
fastener
(B),
and other
parts to the i nsi de Jace of the gl ass (C).
wi ndshi el d
(see page 20-29), rear wi ndow
(see page 20-32). Be
careful not to touch the gl ass where adhesi ve wi l l
be appl i ed.
-
Insi de
N ^
*
-A..-"
-N
-u-
20-26
14. Gl ue the mol di ng
(A)
wi th adhesi ve tape
(B)
to the
edge ofthe
gl ass (C),
wi ndshi el d
(see p
age 20-291,
rear wi ndow
(see page 20-32). Be careful not to
touch the gl ass where adhesi ve wi l l be appl i ed.
Instal l the fastener
(A)
to the body, wi ndshi el d
(see
page 20-29), rear wi ndow
(see page 20-321.
t 5 .
16. l f the new gl ass i s to be i nstal l ed, set the gl ass (A)
i n the openi ng, and center i t. Make al i gnment
marks
(B)
across the gl ass and body wi th a grease
penci l
at the four ooi nts shown. Be careful not to
touch the gl ass where adhesi ve wi l l be appl i ed.
Remove the gl ass.
Wi th a sponge, appl y a l i ght coat of gl ass pri mer
around the edge of the
gl ass (A)
between the
r ubber dam
( B)
and mol di ng
( C)
as shown, t hen
l i ghtl y wi pe i t off wi th gauze or cheesecl oth,
wi ndshi el d
( see page 2O- 291, r ear wi ndow( see
page
20-32).
.
Appl y gl ass pr i mer t o t he mol di ng.
.
Do not appl y body pri mer
to the gl ass, and do not
get
body and gl ass pri mer
sponges mi xed up.
.
Never touch the pri med surfaces wi th your hands.
l f you
do, the adhesi ve may not bond to the gl ass
properl y,
causi ng a l eak after the gl ass i s
i nst a l l ed.
.
Keep water, dust, and abrasi ve materi al s away
from the pri med
surface.
,./
,ll : Apply glas3 primer here.
' t7
.
18.
l nsi de
19. Wi th a sponge, appl y a l i ght coat of body
pri merto
t he or i gi nal adhesi ve r emai ni ng ar ound t he
wi ndshi el d openi ng fl ange, wi ndshi el d
(see page
20-29), rear wi ndow
(see page 20-32). Let the body
pri mer
dry for at l east 10 mi nutes.
.
Do not appl y gl ass pri mer
to the body, and be
careful not to mi x up gl ass and body pri mer
sponges.
.
Never touch the pri med surfaces wi th your
hands.
.
Mask offthe i nteri or parts
before pai nti ng the
fl ange.
Before fi l l i ng a cartri dge, cut a
"V"
i n the end of the
nozzl e
(A)
as shown.
10 mm {0. 39 i n. l
(cont' d)
: Apply body primr here.
/)7
20-27
Glass
Glass Replacement
Process
(cont'd)
21. Pack adhesi ve i nto the cartri dge wi thout ai r
pockets
to ensure conti nuous del i very. Putthe cartri dge i n a
caul ki ng
gun, and run a bead of adhesi ve
(A)
around the edge oJ the
gl ass (B)
between the
rubber dam
(C)
and mol di ng
(D)
as shown,
wi ndshi el d
(see page 20-29), rear wi ndow
(see
page 20-32). Appl y the adhesi ve wi thi n 30 mi nutes
after appl yi ng the gl ass pri mer. Make a sl i ghtl y
thi cker bead at each corner'
Use sucti on cups to hol d the
gl ass over the openi ng,
al i gn i t wi th the al i gnment marks made i n step 3 or
16. and set i t down on the adhesi ve Li ghtl y
push
on the
gl ass unti l i ts edges are ful l y seated on the
adhesi ve al l the way around. Do not open or cl ose
the doors unti l the adhesi ve i s dry.
Scrape or wi pe the excess adhesi ve off wi th a putty
kni fe or towel . To remove adhesi ve from a
pai nted
surface or the
gl ass, wi pe wi th a soft shop towel
damoened wi th al cohol .
24. Let the adhesi ve dry for at l east t hour,thenspray
water over the
gl ass and check for l eaks. Mark
l eaki ng areas, and l et the gl ass dry, then seal wi th
seal ant:
.
Let the vehi cl e stand for at l east 4 hours after
gl ass i nstal l ati on. l f the vehi cl e has to be used
wi thi n the fi rst 4 hours. i t must be dri ven sl owl y.
.
Keep the gl ass dry for the fi rst hour after
i nstal l ati on.
o\
\ A \
rnsiae
fiJ
.,,\r
^-
fil'..
c
23.
20-28
25. Rei nstal l atl remai ni ng removed
parts. Instal l the
rearvi ew mi rror after the adhesi ve has dri ed
thoroughl y
(wi ndshi el d)
NOTE: Advi se the customer notto do the fol l owi ng
thi ngs for 2 to 3 days:
.
Sl am the doors wi th al l the wi ndows rol l ed up.
.
Twi st the bodv excessi vel v
(such
as when goi ng
i n and out of dri veways at an angl e or dri vi ng
over rough, uneven roads).
Windshield Replacement
NOTE: Fami l i ari ze yoursel f wi th the gl ass repl acement
process (see page 20-25).
Parts Removal
Fi rst remove these i tems:
.
Rearvi ew mi rror {see
page 20-22)
.
Front roof rai l tri m
(see page 20-68)
.
Wi ndshi el d wi per arms
(see page 22-1 14)
.
Cowl cover
(see page 20-101)
Cutting Positions
Sl i p the pi ano wi re through the adhesi ve at each posi ti on as shown, and
pul l
back the
pi ano wi re i n di recti on i ndi cated
by arrow.
FASTENER
FASTENER
PIANO WIRE
PIANO WIRE
WINDSHIELD
(cont' d)
/it
ltli
' ! l !
iil
- . -
, ,
, ' \
\ , \
i i \
\ i
i
T
i
r i \
i i i i - l
-a-'\-"::8.
... .. .>.. i
t ' . .
..
' :;,i /
20-29
Glass
Wi ndshi el d Repl acement
(cont' d)
Rubber Dams and Fastener Installation, and Primer Application
.
Be sure the rubber dams and fasteners l i ne up wi th the al i gnment marks,
' Gl uet her ubber damswi t hadhesi vet ape{ N| TTO501l \ i l , or equi val ent ) , andgl uet hef ast ener wi t hadhesi vet ape
(3M
4215, or equi val ent).
.
To gl ue the mol di ng, appl y
pri mer (3M
N-200, or equi val ent) to the areas between the al i gnment marks of the
wi ndshi el d.
UPPER RUSBER DAM
UPPER CORNER
RUBBER DAM
LOWR RUBBEB
DAM
LOWER RUBBER
DAM
ALI GNMENT
MARKS
Appl y pri mer here.
UPPER SEAL
MOLDING
SIDE SEAL
!r
Molding Installation
.
Be sur e t he al i gnment mar k of t he mol di ng l i ne up wi t h t he al i gnment mar k of t he wi ndshi el d.
.
GI ue t he mol di ng wi t h adhesi ve t ape
( 3M
4212, or equi val ent ) .
.
Gl ue t he mol di ng seal s t o t he mol di ng.
ALIGNMENT
MARKS
ALI GNMENT MARK
MOLDI NG
ALI GNMENT MARK
MOLDING
ADHESIVE
TAPE
WINDSHIELD
MOLDI NG
13.5 mm {0.53 in.) FASTENER
l rt mm
{0. 55 i n. )
WINDSHIELD
20-30
WI NDSHI ELD
Fastener
(body
sidel Installation/Body Primer Application
: Appl y bodv pri mer here.
16 mm
(0. 63
i n. )
6 mm {0. 24 i n, l
Glass Primer and Adhesive Application
.l',,jli
: Apply glass prime. here.
13 mm
(0. 51
i n. )
16 mm
10. 63 i n. l
5 mm
10. 2
i n. )
9 mm 10.35 i n.l
ADHESIVE
WI NDSHI ELD
H
r+)
1,4
f -
"",0"
fl
,/7
LOWER
8xf,tER
ibTf;''.r
UPPER RUBEER
DAM
2mm
{0.08 i n.)
+
E ]
rnsiae
I L..
M.LD'NG
--)&, //
'--*<Y
q\>
8 mm
(0. 31
i n. )
UPPER RUBBER
DAM
WI NOSHI ELO
20-31
Gl ass
Rear Window Replacement
Removable Hardtop
NOTE:
.
To remove and i nstal l the rear wi ndow, remove the roof from the body.
.
Pl ace the roof on padded supports to
prevent
damage.
.
Have an assi stant hel o vou remove and i nstal l the rear wi ndow.
.
Fami l i ari ze
yoursel f wi th the gl ass repl acement process
{see
page 20-25}.
.
Remove the rear wi ndow and mol di ng as an assembl y. l f the mol di ng i s damaged. repl ace i t.
LOCK HANDLE
ROOF SI DE
LOCK
SUPPORT
SUPPORT
REAR WINOOW
Parts Removal
Remove these i tems. and di sconnect the rear wi ndow defogger connectors:
.
Headl i ner
(see page
20-56)
.
Rearwi ndow l owertri m
(see page 20-55)
Cutting Positions
Sl i p the
pi ano wi re through the adhesi ve at each posi ti on as shown, and
pul l back the pi ano wi re i n di recti on i ndi cated
by arrow. For the upper
porti on,
cut the adhesi ve wi th the uti l i ty kni fe from i nsi de whi l e pushi ng the rear wi ndow out.
Cut t hl s area wi t h a ut i l i t y kni f e.
FASTENER
PIANO WIRE
PIANO WIRE
SPACER
PIANO WIRE
MOLOI NG
FASTENERS
20-32
ADHESIVE REAR WINDOW
SPACER
FASTENER
PIANO WIRE
Rubber Dams, Fasteners, and Spacers Installation
.
Be sure the rubber dams, fasteners, and spacers l i ne up wi th the al i gnment marks.
.
Gl uet he upper f ast ener wi t h adhesi vet ape
( 3M
4215, or equi val ent ) a nd t he l owe r f ast ener wi t h ad hesi ve t a De
( 3M
5312, or equi val ent ) .
.
Gl ue t he r ubber dams and spacer s wi t h adhesi ve t ape
( N
I TTO 501M, or equi val ent ) .
UPPER
FASTENER
l Two Pl aces)
srDE RUBBER DAM
ALI GNMENT
MARKS
ALI GNMENT
MARK ./
ALI GNMENT MARK
"u"".i oarrr
RUBBER
DAM
Appl y pri mer and
uret hane adhesi ve,
16 mm REAR WI NDOW
17"?ii?!i"*'
$Ao.'nr".Nr
MARKS
FASTENER
REAR WINOOW
(Two places)
SPACER
ALIGNMENT MARKS
Molding lnstallation
To g\ue
the molding, apply a light coat o{ pr'rmer (3M
N-2O0, or equrvalent) to the bottom area on the ou$-rde of rhe
rear wi ndow
,
and gl ue t he mol di ng wi t h uret hane adhesi ve.
(cont' d)
REAR wlNDOW
20-33
Glass
Rear Window Replacement
{cont'd)
Fastoner {roof side} lnstallation/Body Primer Application
Gl ue the l ower fasteners wi th adhesi ve tape
(3M
4256, or equi val ent).
li/i,i/tt I t ppty bodr
p.imf. h?r'.e.
Uni t mm { i n. )
Glass Primer and Adhesive Application
il/i'///l : Apptr
gl$s ptimet herc.
Uni t i mm { i n. )
( Two pl aces)
1610. 631
31 {1. 21
lAl
portion: AOHESIVE
ALIGNMENT
MANKS
RUBBER
DAM
11
t0.55) t0.o8t
REAN
wtNDow
1210.171
33. 5
11. 32) {1. aol
ALIGNMENT
MARK
[B]
portion:
2 to.oE)
SIDE RUSBER OAM
-TI
***)Lo--=--
+ -\"o.o,"o
[C]
ponion:
ln3ide
20-34
SPACER
MOLDING
Convertible Top
Component Location Index
' 00-01
Model s
LINK STOP RUBBER SPACER
(Wi th
removabl e hardtopi
CONVERTIBLE TOP CLOTH
Repl acement, page 20 40
Repai r, page 20 48
wtNDow
Repl acement ,
page 20-43
CONVERTIBLE TOP
COVER
PLATE B
r\ [
aaoa rora--{q
CONVERTIBLE TOP
COVER SNAP
Repl acement ,
page 20-53
CORNER TRI M
\o*r
\ , / l
SET
PLATE A
i
I
- / nE, t nLvwEn
,----
coll.v.ERTlBLE TOP
REAR LOWER
RETAINER
HANDLE
LINK
STOP
,r/"iili#ie*are
SIDE CONVERTIBLE TOP
RETAINER
(cont' d)
CONVERTIBLE TOP
LOCK HANDLE
Repl acement ,
page 20-49
Operat i on Load Adj ust ment ,
page 20 49
CONVERTIBLE
ASSEMBLY
Repl acement ,
page
20 38
TOP
ROOF CORNEB
WEATHERSTRIP
ROOF RETAINER
ROOF SIDE
WEATHERSTRIP
SEAL TAPES
CONVERTIBLE TOP
TOP TRIM
20-35
Convertible Top
Component Location Index
(cont'd)
'02-03
Models
CONVERTIBLE TOP CLOTH
Repl acement, page 20-40
Repai r, page 20-48
REAR WINOOW
HARNESS HOLDER COVER
CONVERTIBLE TOP
COVER
9o
t/
CONVERTIBLE TOP
COVER SNAP
Repl acement ,
page 20-53
l-*q
\ SET
-.-/SbitiHiiir-le
roe
REAR WI NDOW
LOWER MOLDING
Repl acement ,
page 20-47
REAR WINDOW
PLATE A
CABLE GUIDE
4
REAR WINDOW
HARNESS HOLDER
Repl acement ,
Daae 20 47
. REAR WINDOW
LINK STOP RUBBER SPACER
(Wi th
removabl e hardtop)
DEFOGGER
CONVERTIBLE TOP
TOP TRIM
SEAL TAPE
. +
CONVERTIBLE TOP
HOLDER PLATE
LINK STOP
CONVERTIBLE
CORNER TRIM
REAR LOWER
RETAINER
RAIN RAIL
TOP
HANDLE
LI NK
STOP
SILENCER
SIDE CONVERTIBLE TOP
RETAINER
CONVERTIBLE TOP
LOCK HANOLE
Repl acement,
page 20-49
Operati on Load Adj ustment,
page 20-49
CONVERTIBLE TOP
ASSEMBLY
Repl acement ,
page 20-38
CONVERTIBLE
TOP MOTOR
Repl acement,
page 20-50
ROOF CORNER
WEATHERSTRIP
20-36
ROOF RETAINER
.,
coNvERTIBLE TOP
-STRIKER
///'
Re?lacement'
Page
20'50
-43t
\=,,.,
t!
B-PILLAR
OUTER WEATHERSTRIP
Repl acement,
page 20-52
@
E
PIPE
ase 20-52 page
DRAIN VALVE
A.PILLAR MOLDING
Repl acement,
page 20-51
20-37
Convertible Top
Convertible Top Assembly Replacement
NOTE:
.
Have an assi stant hel p you remove the converti bl e top assembl y.
.
Take care not to scratch the top cl oth and body.
.
Put on
gl oves
to protect your
hands.
' l f t het opdoesnot movewi t ht heconver t i bl et opswi t ch, di sconnect t heemer gencyconnect or near t hepassenger ' s
ki ck panel
l see
page
22-' 147l ., and move the top by hand.
1. Remove both rear tray si de tri ms
(see page 20-71).
2. Bemove the top i n the numbered sequence.
3. Instal l the converti bl e top i n the reverse order of removal , and note these i tems:
.
Make sure the connectors are pl ugged i n properl y.
.
Check operati on ofthe top.
' Checkt hat eacht opl ockhandl ewor kssmoot hl y.
l f necessar y, adj ust t he hook posi t i on ( see page 20- 49) .
'
Check that each door gl ass
contacts the weatherstri ps evenl y.
.
Check for water l eaks {see step 17 on page 20-14).
.
Test-dri ve and check for wi nd noi se and raftl es.
Fastener Locations
A>: Bol t , 2 B>: Bol t , 12 C
a:
Nur , 11
( 8ody
col or ) { Gol d)
D>: Ct i p, 2
)4
tI5
I]
O RIGHT SIDE
CONVERTIELE TOP RETAINER
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgt m,
7 .2 tbt.ttl
BAND
(' 02-03
model s)
"r,/*"*,*
'
,^i
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m, 7. 2l bf . f t )
(0
Pul l back t he carpet .
\ <\-'""'-i*-t\\,,
\
1
*. ' ' \
' \"
"
;'
...t"
t '
. i , . t r - '
I
c : /
d"4 rN.
lrrl r' >' -
'l't"-
..
-,. (' 02
03 model s)
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgt . m, 7. 2 l bf f t )
8,7
Bt7
20-38
A{
!I] LEFT CORNER GUSSET
Fatten6r Locations
E>: Bol t , 10 F>: Ct i p. 2
'00
model
'01-03
models
d\- Flk.. -4E5-
{!i!]!!r
tE,]urPrr'rr
!/4)E\'4
( ,
G>: Cl i p, 2
l o
/Gt\
H
Vt o
OMove t he t op l o t hi s posi t i on
usi ng t he convert i bl e t op swi t ch
l ocat ed i n t he cent er consol e.
@Li f t up t he t op assembl y.
ocLrPs
CONVERTIBLE TOP
ASSEMBLY
DAM SEAL
rai l l rom t he body, and
remove t he t op assembl y.
REAR WINDOW
RAIN RAIL
CONVERTIBLE TOP
RAIN
RAIN RAIL
BANO
{' 02-03model s)
wectoa
/
!'a\
onnecr
/ !
'
detach.//
], ]i
,,(o^^ lliA
29 N. m
13.0 kgf.m,22 lbf.ftl
r*/,' "--=-' *
REAR TRAY
OPENING MOLDING
REAR WINDOW DEFOGGER
SUB.HARNESS CONNECTOR
(' 02
03 model s)
@CONNECTOR
Di sconnecl and
det acn.
FUEL FILL DOOR
OPENER BRACKET
MOLDING
BAND
(Both
si des)
(' 02-03
modet s)
RA| N RAt L
20-39
Convertible Top
Convertible Top Cloth Replacement
NOTE:
.
Take care notto scratch the top frame.
.
Put on gl oves
to protect your hands.
.
Wear eye
protecti on
when removi ng the ri vets wi th a dri l l .
.
When removi ng the ri vets, dri l l hol es i n the ri vets wi th a 4 mm {0.16 i n.) dri l l .
'
Thi si l l ust r at i onshowst hel ef t si deof t he vehi cl e, r epeat t he pr ocedur e
on t he r i ght si de i n t he same manner .
Cloth Replacement
1. Remove the conveni bl e top assembl y
(see page 20-38),
2. Remove the converti bl e top cl oth i n the numbered sequence.
3, Instal l the cl oth i n the reverse order of removal , and note these i tems:
' Topr event wr i nkl eswheni nst al l i ngt hecl ot h, makesur et hemat er i al
i s st r et ched evenl y over t he f r ame bef or e
securi ng the screws and ri vets.
' Af t er i nsl al l i ngt hecl ot h, r ei nst al l t het opassembl y. Checkt heoper at i onof t het op, andi nspect t hecl ot hf or
wr i nkl es.
.
Check that the weatherstri p fi t fl ush.
' Checkt hat eachdoor gl asscont act st heweat her st r i psevenl y,
l f necessar y. adj ust each r et ai ner
( see page 2O- 11) .
'
Check for water l eaks
(see
step 17 on
page
20-14).
.
Test-dri ve and check for wi nd noi se and rattl es.
Fastener Localions
e ) : 7 B ) : c ) , D>: Cl i p. 2
Scrgw.
q,ttr'
Screw, 2
( Bl ack)
@
Screw.
{Si l ver)
@
Bet ore removi ng t he screws,
scri be a l i ne around t he screws.
When rei nst al l i ng t he ret ai ners,
al i gn t hem wi t h t hese marks.
20-40
OROOF BETAI NER
F- : Ri vet , 6
, . . .
Removal I nst al l at i on
. ' ' /
,Q'.t
Y\-..-
'
\ !...-
\,,,
/
Fastener Locations
C>: Scr ew, 4 E
(Si l ver)
)
: Screw
x-/
O Rel ease t he cl ot h
f rom t he f ront edge of t he f rame.
RIVET
Out er di amet e. 4 mm
( 0. 16 i n. )
BIVET TOOL
O Rel ease t he cl ot h
f rom t he f ront and cent er bows.
dX Remove t he ri vet , t hen
remove t he t ensi on wi re.
TENSI ON
WI RE
SPRI NG
(i t
Bemove t he screw, and
sl i p t he t ensi on wi re t hrough
t he hol e i n t he f r ame.
TENSI ON
WI RE
CONVERTIBLE TOP CLOTH
Remove f rom t he f rame.
Remove
t he f l vet ,
illt Remove
t ne f l vet .
O Rel ease t he t ast ener and
cl ot h t rom t he rear bow.
(' 00-01 model s onl y)
F
. F
aL
rQ
,al 11
, i rI
FRONT BOW
Remove t he cl ot h f rom t he
cent er
pi l l ar port i on of t he
f rame.
REAR BOW
Bel ease t he t ensi on cl ot h by
rel easi ng t he f ast ener f rom
(' 02-03
model si
CENTER
BOW
l.
i,
{I SET PLATE B
(cont' d)
Rel ease t he cl ot h
{rom each bow.
.!!] SEAL TAPE
Thi ckness:
3 mm
.9
SET PLATE A
CONVEBTIBLE TOP CLOTH
flETAINER
CONVEBTIBLE TOP FRAME
20-41
Convertible Top
Convertible Top Cloth Replacement
(cont'dl
Reinstalling the Cloth to each Bow
Make sure the al i gnment notch ofthe cl oth i s i n the center porti on
ofthe retai ner. After rei nstal l i ng, press
on the
rel arners securety.
Center Donion:
ALIGNMENT
NOTCH
Cloth and Weatherstrip Check
RETAINER
CONVERTIBLE TOP CLOTH
Make sure t here are no wri nkl es or scrat ches.
B-PILLAR
WEATHERSTRIP
\r,_
\
B-PILLAR
RETAINER
The door gl ass cont act s
t he weat herst ri ps evenl y
on each si de.
l f necessary, adj ust
eacn ret at ner.
ROOF RETAINER
ROOF St OE
WEATHERSTRIP
RETAINERS
The weat herst ri p shoul d f i t f l ush.
20-42
Rear Window Replacement
'00-01
Models
NOTE:
.
Take care not to scratch the top frame.
.
Wear eye protecti on when removi ng the ri vets wi th a
dr i l l .
' 1.
Open the roof, and remove these i tems:
'
Seat, both si des
(see page 20-86)
.
Door si l l tri m, both sl des
(see page 20-69)
.
Rear si de trl m. both si des
(see page
20-70)
.
Rol l bar l ower tri m, both si des
(see page 20-70)
2. Cl ose the roof. Remove the cl i ps that hol d the rear
tray tri m, the rear tray si de tri m, and the rear tray
( see page 20- 71)
Remove the spare ti re cover and the spare ti re,
Remove the rear tray and the rear tray tri m th rough
t he t r unk openi ng.
Li ft the converti bl e top cl oth
(A)
that overl aps the
top of the rear wi ndow
(B),
and remove the patch
(C)
from the roof zi pper.
3.
.l
20-43
6. Open the roof, and l i ft up the center consol e
(see
page 20-761.
7. Remove the rear consol e and the rear consol e box
(see page 20-78).
8. Cl ose the roof. Remove both rol l bars and the rear
tray si de tri m
(see page 20-52).
9. Remove t he 1' 1 nut s, t hen r emovet he r ear l ower
converti bl e top retai ner
(A),
ri ght si de converti bl e
top retai ner
(B),
and l eft si de converti bl e top
r et ai ner
( C) .
Fastenea Locations
f :
(cont' d)
Nut, 1
0
Convertible Top
10.
Rear Window Replacement
(cont'd)
Open the roof hal f-way, and remove the two cl i ps
(A,
B) on each si de of the top between the quarter
panel and the roof.
Fastener Locations
A>: Cl i p, 2 B>: Cl i p, 2
r O
-.r- e
=)=F
Hte
(^lrj
4
11. Pl ace a rear fender cover {A) on the trunk.
12. Li ft up the rai n rai l
(B),
and pl ace i t on top of the
fender cover.
Usi ng a marker or whi te-out, draw a ci rcl e
(C)
ar ound each of t he' 11 al umi ni um r i vet s.
13.
. . . . .
. - ' : ' -
"
-
)'
-' . t ,
20-44
14. Pul l the rai n rai l
{A) up. and turn i t i nsi de-out. Wi th
the rai n rai l resti ng on the roof
(B),
dri l l out the
r i vet s
( C) wi t h
a 4 mm
( 0. 16
i n. ) dr i l l
( D) .
The
washers
(E)
on the rai n rai l are not reused.
Remove the rai n rai l ,
Usi ng a fl at-ti p screwdri ver, pry apart the two brass
ri vets
(A)
hol di ng the l ower roof
(B)
to the l ower
part
of the wi ndow
(C).
-l:-,,.t--
15.
16.
17. Rel ease the fasteners
(A)
to expose the zi pper
(B),
and remove the end stops
(C)
from both ends of the
zi DDer .
Careful l y unzi p the rear wi ndow
(D)
from the roof
(E),
then remove the wi ndow. Hol d the zi pper ti ght
to keep i t from fal l i ng i nto any crevi ces.
18.
19. Zi p the new wi ndow
(A)
onto the roof
(B),
maki ng
sure the al i gnment notches
(C)
are l i ned up.
It may take several attempts to l i ne up the marks.
Turn the converti bl e top cl oth
(A)
i nsi de out, and
appl y a new
patch (B)
on the zi pper
(C).
Make sure the al i gnment notch
(D)
al i gns wi th the
mi ddl e of the rear wi ndow
(E).
\ ' . . :
'l
. 1
a
21. Pl ace the converti bl e toD cl oth on the rear wi ndow.
(cont' d)
20-45
Convertible
Top
Rear Window Replacement
(cont'd)
22. Secure the l ower
part
of the rear wi ndow
(A)
to the
l ower part of the converti bl e top cl oth
(B)
wi th new
two-pi ece brass ri vets
(C).
Attach the converti bl e top cl oth, rear wi ndow, and
rai n rai l together wi th new
pop ri vets and washers.
Make sure the crush end of each ri vet i s faci ng the
rear of the car when the rai n rai l i s si fti ng i n pl ace.
3/ 16' x 3/ 8" 3116 x112' 3/ 16
A>: Ri vet , 3 B>: Ri vet , S C>: Washer , 11
23.
0
20-46
24. Setthe rai n rai l i n posi ti on, and i nstal l the cl i ps
between the
quarter panel and the roof.
Rei nstal l the l eft si de converti bl e top retai ner
(A),
ri ght si de converti bl e top retai ner
(B),
and rear
l ower converti bl e top retai ner
(C).
Fastener Locations
O:
Nut , 11
6 x 1 . 0 mm
9.8 N.m
{1.0 kgl .m, 7.2l bf ft}
26. Rei nst al l al l r emai ni ng i nt er i or component s and
t r i m
pi eces.
27. Check for water l eaks
(see
step 17 on
page 20-14).
Rear Window Lower Molding/Rear Window Harness Holder Replacement
'02-03
Models
NOTE:
.
Put on gl oves to protect your hands.
.
Take care not to scratch the top cl oth.
.
Use seat covers to avoi d damagi ng any surfaces.
1. Lower the converti bl e top cl oth by operati ng the
converti bl e top.
2. From outsi de the rear wi ndow, remove the mol di ng
(A)
from the edge of the rear wi ndow
(B).
From
i nsi de the rear wi ndow, remove the rear wi ndow
harness hol der cover
(C)
from the rear wi ndow
harness hol der
(D),
and di sconnect the rear wi ndow
defogger connectors
(E).
Remove the rear wi ndow
harness hol der from the i nsi de face of the rear
wi ndow. l f necessary, cut the mol di ng wi th a uti l i ty
kni fe.
Cl ean the edge of the rea r wi ndow wi th al cohol
wher e new mol di ng and har ness hol der ar e t o be
i nstal l ed. Make sure the bondi ng surface i s kept
free of the water, oi l ,
grease.
4. Appl y
pri mer (3M
N-200, or equi val ent) to the areas
of the rea r wi ndow
(A)
where the mol di ng and
har ness hol der wi l l be gl ued, and appl y pr i mer ( 3M
C-100, or equ i val ent) to the groove of the mol di ng
(B)
and to the harness hol der
(C).
Be sure the
har ness hol der l i nes up wi t h t he al i gnment mar ks
{ D) .
'ti;',.t,
: Apply primer here.
o-.
\J. \B
Gl ue t he mol di ng and har ness hol der t o t he r ear
wi ndow wi th urethane adhesi ve.
Scrape or wi pe the excess adhesi ve off wi th a
putty
kni fe or towel . To remove adhesi ve from the rear
wi ndow, use a soft shop towel dampened wi th
al cohol .
6.
20-4t
Convertible
Top
Conveftible Top Cloth Repair
1. The fol l owi ng tool s and suppl i es are requi red to
repai r the top cl oth.
.
Repai r cl oth
.
Adhesi ve
(Sunstar
332, or equi val ent)
.
Uti l i ty kni fe
'
Rul er
.
Sandpaper
2. Appl y a
pi ece of t he r epai r cl ot h
( A) t o
t he i nsi de
surface of the top cl oth at the damaged area. Cut
through both the damaged cl oth
(B)
and the repai r
cl ot h usi ng a r ul er
( C)
and a ut i l i t y kni f e
( D) .
A C
Cut a pi ece of repai r cl oth
(A)
so i t overl aps the
r epai r openi ng as shown.
3.
30- 50 mm
{ 1. 2- 2. 0 i n. )
REPAIR CLOTH
20-48
Cl ean the repai r cl oth where adhesi ve wi l l be
appl i ed.
Appl y the adhesi ve
(A)
to the repai r cl oth
(B)
and
top cl oth {C) as i ndi cated by the arrows.
f-
A
6. Push f i r ml y on t he r epai r cl ot h.
Scrape or wi pe the excess adhesi ve off wi th a soft
shop t owel dampened wi t h al cohoL.
Let the adhesi ve dry. Fol l ows the manufacturer' s
r ecommendat i ons f or dr yi ng t i me.
Check f or wat er l eaks
( see
st ep 17 on
page
20- 14) .
1.
9.
Conveftible Top Lock Handle
Repl acement
NOTE: Take care not to scratch the top frame.
' 1.
Remove the converti bl e top l ock handl e as shown.
2. l nstal l the handl e i n the reverse order of removal ,
and appl y mul ti purpose grease to the spri ngs and
the movi ng poni ons,
Fastener Locations
A) : Scr ew. l B>: Scr ew, 1
'00
model
'01-03
models
CONVERTIBLE TOP
LOCK HANOLE
Convertible Top Lock Handle
Operation Load Adiustment
NOTE: Take care not to scratch the i nteri or parts.
1. Remove both reartray si de tri m
(see page 20-7' 1).
2. Cl ose the top, then l ock i t securel y wi th both l ock
handl es { A} .
Loosen the l ocknut
(B)
on the l i nk stop
(C)
on each
sr de.
Adj ust the l i nk stop
(C)
on each si de unti l i t makes
contact wi th the l i nk set bracket
(D).
There shoul d
be no cl earance between the converti bl e top stri ker
( E)
and t he hook
( F) .
Ti ghten the l ocknut, and check that the l ock handl e
works smoothl y on each si de.
Rei nstal l al l removed parts.
3.
4.
t
. .
I
20-49
Convertible Top
Convertible Top Motor
Replacement
NOTE:
.
Take care not to scratch the i nteri or parts.
.
Put on gl oves to
protect your hands.
1. Remove these i tems:
.
Rol l bar upper t r i m
( see page 20- 71)
.
Corner gusset (see page 20-38)
2. Remove the converti bl e top motor as shown.
3. Instal l the motor i n the reverse order of removal .
and note these i tems:
.
Make sure the connector i s pl ugged i n properl y.
.
Appl y mul ti purpose grease to the
gear poni on.
.
Check the motor operati on.
Fastonor Locations
Ai t : Nut , 3
d
6 x 1 . 0 mm
9. 8Nm( 1. 0kgl . m,
7.2 rbf.ft)
20-50
Gonvertible Top Striker
Replacement
NOTE: Take care not to scratch the i nteri or parts.
1. Remove the wi ndshi el d header i nteri or tri m
(see
page
20-68).
2. Remove the converti bl e top stri ker as shown.
3. l nstal l the stri ker i n the reverse order of removal .
Fastonor Locations
A
>
: Screw, 2
f')--
w*
i
, A
\ A
CONVERTIALE TOP
STRIKER
(' 00' 01
model s shape)
6 x l . 0 mm
9. 8Nm11. 0kgf . m,
7.2 tbt.lrl
CONVERTIBLE TOP
STRIKER
('02'03
models shape)
s=
A-Pillar-Header Weatherstrip and A-Pillar Molding Replacement
NOTE:
.
Take care not to scratch the body.
.
Use a cl i p remover, to remove the cl i ps.
1. Remove the A-pi l l ar-header weatherstri p and A-pi l l ar-mol di ng as shown.
2. Instal l the weatherstri p and mol di ng i n the reverse order of removal , and note these i tems:
. l f t heol dmol di ngi st ober ei nst al l ed, scr apeof f t hedoubl e- f acedadhesi vet ape, t hencl eant hemol di ngsur f ace
wi th al cohol . G l ue the new doubl e-faced adhesi ve tape
l 3M
4252, or equi val ent) to the mol di ng.
'
When i nst al l i ng t he mol di ng, f i r st t i ght en t he scr ew at t op of t hemol di ng.
.
Repl ace any damaged cl i ps.
. l f t heol dweal her st r i pi st ober ei nst al l ed, scr apeof f al l t r acesof ol dEPTseal er andbut yl t apes. l hencl eant he
weatherstri p surface wi th al cohol . Gl ue the new EPT seal er and butyl tapes to the weatherstri p.
.
When i nstal l i ng the weatherstri p, al i gn the roof cl i p hol e on the weatherstri p wi th the hol e on the mol di ng.
.
Before i nstal l i ng the weatherstri p, fol d the separator of the butyl tape at the roof porti on.
After i nstal l i ng the
weatherstri p, careful l y pul l the separator away.
.
Press the butyl tape porti ons
to make the adhesi ve sti ck.
'
Checkthateach door gl asscontacts the weatherstri p evenl y.
.
Checkforwater l eaks
(see
step 17 on
page
20-14).
Fastener Locetions
B>: Sc r ew, 5
A.PILLAR
MOLDI NG
A
BUTYL TAPE
Thi ckness: 1mm
( 0. 04
i n. )
Wi dt h: 5 mm
( 0. 2
i n. )
A>: Cl i p, 4
{ 8ot h si des)
B
AB
B
Thi ckness: 3 mm
( 0. 1
an. )
Wi dt hr 5 mm
(0. 2
i n. )
SEALER
TAPE
Thi ckness: 1mm
{0. 04 i n. }
Wi dt h: 5 mm
( 0. 2
i n. )
MOLDING
20-51
Gonvertible Top
B-Pillar Outer Weatherstrip
Replacement
NOTE:
.
Take care notto scratch the body
.
Use a cl i p remover. to remove the cl i ps.
1. Remove the B-pi l l ar outer weatherstri p as shown.
2. Instal l the weatherstri p i n the reverse order of
removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
l f the ol d weatherstri p i sto be rei nstal l ed, scrape
off al l traces of ol d butyl t8pe, then cl ean the
weatherstri p surface wi th al cohol . Gl ue the new
butyl tape i nto posi ti on.
Fastgnsr Locations
A>: Scr ew, 1 BD: Cl i p, 1
B.PILLAR OUTER
WEATHERSTRIP
BUTYLTAPE
Thi ckness: 1. 5 mm
(0. 06
i n. )
Wi dt h: 4 mm {0. 16 i n. )
C> : Cl i p , l
20-52
Drain Tank and Lower Drain Hose
Replacement
NOTE:
.
Take care not to scratch the body
.
Take care not to drop the screw.
1. Remove the conveni bl e top assembl y
(see page 20-
38).
2, Remove the drai n tank and l ower drai n hose as
shown.
3. Instal l i n the reverse order of removal , and note
these i tems:
.
Repl ace the cl i p i f damaged.
.
Make sure the l ower drai n hose i s i nserted to the
drai n val ve properl y.
.
Make sure the drai n tank i s connected to the
l ower drai n hose
properl y.
Fastener Locations
, 1
B>: Cl i p, 1 A
>
: Screw
@
LOWER DRAIN
HOSE
-i
r \ '
,..1 :...-r...
DRAIN VALVE
Convertible Top Cover Snap Replacement
NOTE: Take care not to scratch the converti bl e top
cover.
' 1.
Usi ng a snap ri ng pl i ers (A),
remove the nut
(B)
from the snap
(C).
then remove the snap from the
converti bl e top cover
(D).
Instal l the cover snap i n the reverse order of
removal ,
20-53
Removable Hardtop
Component Location Index
REAR WINDOW
DEFOGGER GROUND
HARNESS
\r?
I -
oqo
ROOF
Posi ti on Adj ustment,
page 20-65
wrNDow
q3
ROOF SIDE
TRIM END CAP
STUD BOLT
Component Locat i on I ndex,
page 20-24
Gl ass Bepl acement Process,
page 20-25
Repl acemenl ,
page 20 32
WEATHERSTRIP
Repl acement ,
page 20' 60
wtNDow
DEFOGGER HARNESS
WINDOW
LOWER TRIM
page 20-55
REAR WINDOW BRACKET
page 20-55
lts\
9r
".r)*, t*,t
\ \ase
20-55 ROOF SIDE LOCK
Repl acement,
page 20-62
%
cusHloN
HARDTOP LOCK
HANDLE
Repl ac_e_ment,
_,,....--.\d
page 20-6'l
,r-rr--\\
{ r " \ \ \
q' v"
\ v
\ &{b
\ -
UPPER DOOR GLASS
WEATHERSTRIP
page 20'57
ROOF MOLDING
Repl acement,
page 20' 57
ROOF RETAINER
page 20 57
BODY SIDE CATCH
ASSEMBLY
Reol acement , oaqe 20-63
Bodv S, de Cal i h
-Repl acement ,
page 20 64
Hardt op Swi t ch Test ,
page 22' 150
ROOF FRONT TRIMS
Repl acement ,
page 20-61
20-54
Interior Trim Removal/lnstallation
NOTE:
.
Put on gl oves to protect your
hands.
.
To remove and i nstal l the i nteri or tri m, remove the roof from the booy.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve
tape to prevent
damage.
.
Use a cl i p remover to remove the rear wi ndow l ower tri m cl i ps.
.
Take care not to bend or scrach the i nteri or tri m.
1. Remove the tri m as shown.
2. Instal l the tri m i n the reverse order of removal , and note these i tems;
.
Repl ace the damaged adhesi ve tape and any damaged cl i ps.
.
Push the cl i p poni ons
i nto pl ace
securel y.
' Bef or epeel i ngawayt headhesi vebacki ngf r omt headhesi vet apeof t heendcap, i nst al l t her oof si det r i mon
the roof tentati vel y to check the posi ti on
of the tri m end.
'
When i nstal l i ng the roof si de tri m, fi rst i nstal l the front end, and i nsert the l ower end i nto the end cap, then
push
l he corner porti on
agai nst the roof securel y, Make sure there i s no cl earance between the tri m and cap.
Fastenor Locations
Clip, I
(bot h
si des)
Clip, 3 C) : Bol t , 4
UPPER DOOR GLASS
,
WEATHERSTRIP
B.PILLAR TRIM
ADHESIVE TAPE
(3M5078,
or equi val ent )
Thi ckness: 1 mm
(0. 04
i n. )
Wi dt h: 5 mm
( 0. 2
i n. )
nb, tu
SNf-
ary
REAR WINDOW
LOWER TRIM
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf m,
7.2 tbf.ftt
View from outside:
l l
C C
r-
\ \ \
u
RooF srDE TR|M
WINDOW
DEFOGGER CONNECTOR
(Lef t
si de onl y)
Sl i p t he connect or t hrough
t he hol e i n t he rear pi l l ar
t ri m.
ROOF SIDE TRIM
END CAP
SIDE TRIM
B.PILLAR TRIM
20-55
Removable Hardtop
Headliner RemovaUlnstallation
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the headl i ner, remove the roof from the body.
.
Have an assi stant hel p you remove and i nstal l the headl i ner.
.
Take care notto bend or scrach the headl i ner.
1. Remove these i tems:
.
B-pi l l ar tri m, both si des
(see page 20-55).
.
Hardtop l ock handl e, both si des {see
page 20-61).
.
Upper door gl ass weathersti rp, front edge
poni ons from both si des as necessary {see
page 20-57)
2. Remove both front edge
porti ons of the u pper door
gl ass weatherstri ps
(A) (seepage20-57).
Fastenea Locations
B>: c l i p. 8
A
Rel ease the cl i ps
(B)
by sl i di ng the headl i ner
(C)
forward, then remove the headl i ner.
Instal l the headl i ner i n the reverse order of removal , and check that the cl i p
porti ons are securel y attached to the
roof.
@
20-56
Roof Molding Replacement
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the roof mol di ng, remove the roof from the body.
.
Take care not to scratch the roof.
.
Use a cl i p remover to remove the cl i p.
. l f t heol dr et ai ner i st obei nst al l ed, scr i beal i near oundt hemount i ngscr ewsbef or er emovi ngt her et ai ner .
Removal
Remove the rear pi l l ar tri m
(see page
20-55), then remove the roof mol di ng as shown.
Fastene. Locations
A> t Cl i p, l B
>:
Screw,
' t
C
)
: Screw, 3
, 1 F
>:
Nur , 2
*: CORROSION RESISTANT SCREW
ROOF MOLDING
E
)
r Screw
o b
\J
D>: Scr ow' 4
( Si l ver )
fi liiIicr"
Be{ore removi ng t he screws, scri be
a l i ne around t he screws
(Si x pl aces).
ROOF RETAINER
UPPER OOOR GLASS
WEATHERSTRIP
(cont' d)
20-57
Removable Hardtop
Roof Molding Replacement
(cont'd)
lnstallation
Instal l the roof mol di ng i n the numbered sequence, and note these i tems:
Before rei nstal l i ng the roof mol di ng, cl ean the roof surface where the seal ant wi l l be appl i ed.
When r ei nst al l i ngt he r et ai ner . al i gn i t wi t ht hemar ksf or t heor i gi nal
posi t i ons.
Check that the weatherstri p i s securel y i nstal l ed to the retai ner.
Check that the door gl ass contacts the weatherstri p evenl y. l f necessary, adj ust the retai ner,
Check for water l eaks
(see
step 1 1 on
page 20-66).
Fa3tener Locations
C) : Scr ew, 3 D
>:
Scr ew, 4 E
>:
Sc. ew, I F
>:
Nut , 2
*
(Si l ved
@F
) : Cl i p, 1
B>: Sc r ew. 1
hlll
lrr#ffia lrr- tfi#r+'A
I'.r]]]]]]]]]]]]]u ti ,Dir*rlrg
Yil
l1.l;;,.;',11
: Sealant
(Cemedine 336, or equivalontl
5 x 0 . 8 mm
4 N' m
(0. 4 kgf m, 3 l bf . f t )
@UPPER DOOR GLASS
WEATHERSTRIP
r\
{ l ' } r l D
\-./ @. ,
ROOF MOLDING
*: CORROSION RESISTANT SCREW
seal ant t o t he back
of t he roof mol di ng
t he roof as shown.
@BOOF MOLOING
OAppl y seal ant to the
edge of the roof
as shown.
OAppl y seal ant t o t he edge of
t he roof mol di ng, t o t he roof ,
i nt o t he hol der of t he roof ret ai ner,
and i nt o t he gap under t he mol di ng
I
A
!DROOF RETAINER
3 N. m
(0. 3
kgf . m, 2l bf . f t l
20-58
Weatherstrip Check
NOTE:
.
Make sure the hardtop i s l ocked securel y wi th both l ock handl es and both roof si de l ocks.
.
Check that the weatherstri p i s securel y i nstal l ed to the retai ner.
.
Rai se t he gl ass f ul l y.
.
Check that the door gl ass
contacts the weatherstri p evenl v.
.
Check for water l eaks
(see
step 11 on
page
20-66).
ROOF SIDE DOOR
WEATHERSTRIP
- - - t _t _. . - - .
_
- _- - -
' . . t . .
'
.\.
ROOF RETAINER
ROOF RETAINER
ooor gl ass cont act s
t he weat herst ri p evenl y
on each si de.
l f necessary, adj ust
t he ret ai ner,
UPPER DOOR GLASS
WEATHERSTRIP
20-59
Removable Hardtop
Hardtop Lower Weatherstrip Replacement
NOTE:
.
To remove and i nstal l the hardtop l ower weatherstri p, remove the roof from the body
.
Take care not to scratch the roof,
.
Use a cl i p remover to remove the cl l ps.
1. Remove the rear wi ndow l ower tri m
(see page 20-55).
2, Remove the hardtop l ower weatherstri p as shown.
3. Instal l the weatherstri p i n the reverse order of removal , and note these i tems:
.
Before i nstal l i ng the weatherstri p, cl ean the roof bondi ng surface wi th al cohol .
. l f t heol dweat her st r i pi st obei nst al l ed, scr apeof f t hedoubl e- f acedadhesi vet ape, t hencl eant heweat her st r i p
surface wi th al cohol . Gl ue the new doubl e-faced adhesi ve tape
(3M
5304, or equi val ent) to the weatherstri p.
.
Repl ace any damaged cl i ps.
.
Before i nstal l i ng the weatherstri p, fol d the edge of the adhesi ve backl ng from the doubl e-faced adhesi ve tape.
After i nstal l i ng the weatherstri p, careful l y
pul l the adhesi ve backi ng away.
.
Press the doubl e-faced adhesi ve tape
porti on
to make the adhesi ve sti ck.
Fastener Locations
A) : Sc r e w, 2 B> : c l i p , 2 C
p
: Cl i p, 19
ff
. : l t I -
\e:>
DOUBLE. FACED
ADHESIVE TAPE
Thi ckness:0.8 mm
(0.03 i n.)
Wi dth: 6 mm
(0.24
i n.)
EPT SEALER
Thi ckness: 3 mm
(0. 1
i n. )
Wi dt h: 5 mm
( 0. 2 i n. )
UPPER DOOR GLASS
WEATHERSTRIP
\
lAl
portions:
HARDTOP LOWER
WEATHERSTRIP
A
A
Adhesi ve t ape area.
A
20-60
1 .
Roof Front Trim Replacement
NOTE:
.
To remove and i nstal l the rooffronttri m. remove the
roof from the body.
'
Take care not to scratch the roof.
Scrap off al l traces of the ol d tri m, then cl ean the
roof bondi ng surface wi th a sponge dampened i n
al cohol . After cl eani ng. keep oi l , grease, and water
from getti ng
on the surface.
Appl y pri mer (3N4
N-200, or equi val ent)to the areas
where the roof front tri m wi l l be appl i ed.
Appl y the roof front tri m
(A
and B):
-1
Peel the adhesi ve backi ng
(C)from
the front
edge of the tri m.
-2
Center and fi t the tri m agai nst the roof.
-3
Appl y the tri m to the roof whi l e peel i ng the
remai ni ng adhesi ve backi ng
(D)
from i t a l i ttl e
at a ti me. Check that the tri m i s
parai l el
and
free of wri nkl es.
-4
Remove the appl i cati on tape.
Hardtop Lock Handle Replacement
NOTE:
.
To remove and i nstal l the hardtop l ock handl e,
remove the roof from the body.
.
Take care not to scratch the headl i ner.
1 . Remove the hardtop l ock handl e as shown.
Instal l the handl e i n the reverse order of removal ,
and note these i tems:
.
Appl y mul ti purpose grease to the spri ngs and the
movi ng porti ons.
.
Appl y l i qui d thread l ock to the thread of the
(A)
screw before rei nstal l ati on.
Fastener Locations
A>: Scr ew, l B) : Scr ew, 1
LIOUID THREAD
LOCK
6 mm 2 mm
10. 24i n. ) 10. 08 i n. l
/D:n:-)
6 x 1 . 0 mm
12 N. m
(1. 2 kgt . m,
8.7 rbf.ft)
B
20-61
Removable Hardtop
Roof Side Lock Replacement
NOTE:
.
Put on
gl oves
to
protect your hands.
.
To remove and i nstal l the roof si de l ock, remove the
roof from the body.
.
Take care not to scratch the roof.
.
l f t he ol d l ocki st o be i nst al l ed, scr i bea l i ne ar ound
the mounti ng bol ts before removi ng the l ock.
1. Remove the B-pi l l ar tri m {see
page
20-55).
2. Remove the roof si de l ock as shown.
l nstal l the l ock i n the reverse order of removal , and
note these rtems:
.
l f t heol d l ock i st o be i nst al l ed, al i gnt he l ockwi t h
the marks for the ori gi nal
posi ti on.
.
Appl y mul ti purpose grease to the spri ngs and the
movi ng porti ons.
.
l f necessary. adj ustthe l ock al i gnment; referto
the roof
posi ti on
adj ustment
(see page
20-65).
Fastener Locations
A
>:
Bol t, 3
{1. 0 kgf . m, 7. 2 l bf . f t l
20-62
Application
-6{
Grease
Hardtop Striker Replacement
NOTE:
'
To remove and i nstal l the hardtop stri ker, removethe
roof from the body.
.
Take care not to scratch the i nteri or parts.
1. Remove the wi ndshi el d header i nteri or tri m
(see
page 20-68).
2. Remove the hardtop stri ker as shown.
3. Insl al l the stri ker i n the reverse order of removal .
Fastener Locations
A>: Sc. w, 2
f!,\:r.-r
\a*
6 x 1 . 0 mm
' 16
N. m
{1. 7 ksf . m, 12l bf . f t l
Body Side Catch Assembly
Replacement
NOTE: Put on
gl oves
to
protect your hands.
1. Remove the roof from the body. Take care not to
bend or scratch the tri m and
panel s.
2. Remove the rear si de ti rm
(see page 20-70).
3. On l eft si de, detach and di sconnect the connector
(A),
then detach the harness cl i p
(B).
Fastener Locations
C
>:
Bol r , 2 D
>:
Bol t . 2
4. Remove the bol ts
(C,
D), then remove the body si de
catch assembl v {E).
(cont' d)
20-63
Removable Hardtop
Body Side Catch Assembly
Replacement
(cont'dl
oi i"
|
. ' 1'
, <
|
' e
t . /
6 x 1 . 0 mm
9 . 8 N m
(1. 0 kgf . m,
7.2tbl.ftl
29 N.m
(3.0
kgf.m.
22 tbt.ttl
Grease the catch.
Rei nstal l the catch assembl y
(E)
on the corner
gusset (F)
and the converti bl e top frame; ti ghten
the bol ts
(G.
H). On l eft si de, reconnect the
connector
(l ).
Rei nstal l al l of the removed parts.
Remove the l ower cl i p
(A)
fasteni ng the B-pi l l ar
outer weatherstri o
(B)
from outsi de of the front
door openi ng. Make sure the center ofthe cl i p hol e
al i gns wi th the center of the hol e i n the converti bl e
top frame
(C),
l f necessary, l oosen the mounti ng
bol t
(D),
and move the converti bl e top frame
sl i ghtl y unti l the hol es al i gn. Then ti ghten the bol t,
and i nstal l the cl i p.
Fastener Locations
G>: Bol t , 2 H
>:
Bol t , 2
u] l @
( Ll ] i - n
8 x 1. 25 mm
29 N. m
(3. 0
kgf m,
22 tbt.ttl
8x 1. 25mm
,
7.
20-64
Body Side Catch Replacement
1 . Remove the body si de catch assembl y from the
body
(see page 20-63).
Remove the body si de catch as shown.
Instal l the catch i n the reverse order of removal ,
and note these i tems:
.
Appl y mul ti purpose grease to each l ocati on as
i ndi cated by the arrows.
.
Appl y l i qui d thread l ock to the screw before
rei nstal l ati on.
Fastener Location
5 x 0 . 8 mm
4 N. m
{0.4 kst m.3 l bf.ft)
BODY SIDE
CATCH BASE
BODY SIDE CATCH
Grease Application
>
: Screw, 1
f\t",,,'-
\,,"
Roof Position Adjustment
NOTE: Have an assi stant hel p you adj ust the roof posi ti on.
1. Remove the B-pi l l ar tri m from both si des
(see page 20-55), and make sure both l ock handl es
(A)
androofsi de
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf m,7.2l bt ftl
K
8 x 1.25 mm
22 N.m
(2.2
kgf.m, 16l bf.ft)
Measui ng Poi nt I A]
Measuri ng Poi nt [ B]
ROOF MOLDI NG
LOCK
8 a l m m
(0.31
0.04 i n.)
UNLOCK
1 4 1 l mm
{0.55 + 0.04 i n.}
t
.r)
6 . 6 a 1 mm
(0.26
A 0.04 i n.)
2. Set the roof
(C)
onto the body
(D):
.
l \/l ake sure the l ock pi ns
{E) of both roof si de l ocks are securel y i nserted i nto the body si de catches
(F).
.
l Make sure the rear wi ndow defogger harnesses are not pi nched.
Adj ust the roof al i gnment:
- 1
Checkt hat t her e i s no cl ear ance bet ween t he st r i ker
( G)
and t he boss
( H)
of t he l ock handl e at t he measur i ng
poi nts (A),
and check that the cl ea ra nce i s wi l h i n speci fi cati on at the measu ri ng poi nts
IBJ
onthebottomof
both rear pi l l ars.
-2
To fi t the boss i nto the stri ker, and to adj ust the verti cal cl earance to the speci fi cati on, l oosen the roof si de
l ock mounti ng bol ts
(l ),
then move the roof up or down, as wel l as. forward and rearward.
- 3
Toadj ust t he hor i zont al cl ear ance bet ween bot h si deedgesof t he r oof andt he r ear t r ayopeni ng mol di ng
( J)
to the speci fi cati on, l oosen the hol der pl ate mounti ng bol ts
(K),
then move the roof to the ri ght or l eft.
-4
Fasten both roof si de l ocks.
-5
Lock the roof securel y wi th both l ock handl es and roof si de l ocks.
-6
Recheck the roof al i gnment.
(cont' d)
184 mm
17.24 in.l
:/'
20-65
Removable Hardtop
Roof Position Adjustment
(cont'dl
4. l f the roof al i gnment i s sti l l not wi thi n speci fi cati on, unl ock the roof, and repeat the
precedi ng
steps.
5. l f the roof al i gnment i s not wi thi n speci fi cati on, check the body si de catches, and check for body de{ormati on.
6. Lockthe roof
(A)
securel y wi th both l ockhandl es(B) and roof si de l ocks
(C).
Checkthe l evel di fference between
the roof and body
(D)
at the measuri ng poi nt
LAl .l f the di fference i s notwi thi n speci fi cati on, removethe roof
from the body, and adj ust the di fference wi th the spacers
(E)
that are i nstal l ed between the l ock handl e and the
roof,
SPACER: Thickness= 1 mm 10.04 in.) Measurlng Point [AJ :
7. Set the roof onto the body, and l ock i t securel y. Check that the weatherstri p fi ts fl ush, and check that each door
gl ass contacts the weatherstri p evenl y. l f necessary. adj ust the retai ner; refer to the roof mol di ng repl acement
(see page 20-57).
8. Removethe roof fromthe body, and rei nstal l the B-pi l l artri m onthe roof.
9. Set the roof onto the body. and l ock i t securel y. Reconnect the rear wi ndow defogger connectors securel y.
10. Make sure that the roof i s l ocked securel y, then rai se the door
gl ass ful l y, and cl ose the doors.
11. Check for water l eaks. Run water over the roof and on the seal i ng area as shown, and note these i tems:
.
Use a 12 mm
( 1/ 2
i n. ) di amet er hose
( A) .
.
Adj ust the rate of water fl ow
(B).
.
Do not use a nozzl e.
.
Hol d the hose about 200 mm
(7.9
i n.) away from the door.
12 mm
( 1/ 2
i n. )
*_r*
CI
itY
A
70 mm 12. 8 i n. l
200 mm
(7. 9
i n. l
20-66
Interior Trim
Component Location Index
A-PILLAR INTERIOR
TRIM
page 20-68
WINDSHIELD HEADER
INTERIOR TRIM
page 20' 68
CARPETS
Bepl acement,
page 20-1 4
CONVERTIBLE TOP COVER PIN
page20- 70
REAR TRAY
page 20-71
ROLL BAR
UPPER TRIM
page 20-71
REAR TRAY
REAR TRIM
page 20-71
REAR TRAY
SIDE TRIM
page 20-71
CONVERTIBLE TOP COVER
'aa.
l .
MALE HOOK
page 20-71
REAR SIDE TRIM
page 20 70
ROLL BAR LOWER TRIM
page 20-70
CENTER CARPET
Repl acement , page 20-75
KICK PANEL
page 20-69
DOOR SI LLTRI M
page 20-69
SPARE TIBE COVER
page 20' 13
t -
TRUNK FLOOR TRIM PANEL
page 20 73
TOOL BOX LID
page 20-73
TOOL BOX
page 20 73
REAR TRI M PANEL
page 20-73
TRUNK SIDE TRIM PANEL
page 20-13
20-67
lnterior Trim
Trim Removal/lnstallation
-
Front Roof Area
NOTE:
.
Put on
gl oves
to
protect your
hands.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve
tape to
prevent
damage.
.
Take care not to bend or scratch the tri m and oanel s.
1. Remove the tri m i n numbered seouence.
2. Instal l the tri m i n the reverse order of removal . and note these i tems:
.
Repl ace any damaged cl i ps.
.
Make sure the connector i s pl ugged
i n properl y.
.
Push the cl i p
porti ons i nto pl ace
securel y.
. l f t het hr eadsont hevi sor scr ewsar ewor nout , useanover si zedscr ew( P/ N90132- 523- 0030)
made speci f i cal l y
for thi s appl i cati on.
F stener Locations
A
>:
Screw,2 B
):
Screw,
d-\ ,K\
(1r)l P
i l l D
-\.-r'
Y-/
2 C) : Cl i p, 4 D
>:
Cl i p, 2
\
OsuNVtsoR
5 x 0 , 8 mm
, l Nm{ 0. 4kgt . m,
3 tbf.ftt
osulvrson
,/ lire
/ q
@sPorLrGHr
/
20-68
' 1.
Trim Removal/lnstallation
-
Door Area
NOTE:
.
Put on
gl oves
to
protect your hands.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to bend or scratch the tri m and Danel s.
Remove the tri m as shown.
Instal l the tri m i n the reverse order of removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p porti ons i nto pl ace securel y.
Clip, 1
l,g
SII[gsqI
,,711
t q
F 3tenel Locations
A>t Cl i p, 3 B>: c| i p. l
w 2im
er Tle
c D,
D
: Cl i p, 1
M
tffi\
I
I:TTrFF
Y)
A.PILLAR.HEAOER
WEATHERSTRIP
Pul l back as necessary.
i_
i
I
,.. ;
-'
t/
\ai
KICK PANEL
_-z-(
l c ' r
SIDE TRIM REAR
/
SILL TRIM
TAB
20-69
Interior Trim
Trim Removal/lnstallation
-
Seat Side Area
NOTE:
.
Put on gl oves
to
protect your hands.
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve
tape to prevent
damage.
.
Take care not to bend or scratch the tri m and
panel s.
1. Remove the door si l l tri m
(see page
20-69).
2. Remove the tri m as shown.
3. Instal l the tri m i n the reverse order of removal . and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p
porti ons
securel y i nto pl ace.
.
Wi th removabl e hardtop: Makesurethe rear wi ndow defogger connector i s pl ugged
i n properl y eftsi de onl y).
Fastener Locations
A
>:
Screw,l B
):
Screw,2
ftP:ao [D]trn.]I1r]:]r"
<-,/
ROLL BAR
UPPER TRIM
ROLL BAR
LOWER TNIM
F
C>: oi p, ? D>: Cl i p, 1
CAP
REAR SIDE TRIM
(Left
si de wi th
convert i bl e t op onl y)
GROMMET
(Left
si de wi th removabl e
hardtop onl y)
CONVERTIBLE TOP
COVER PIN
6 x 1 . 0 mm
REAR WINDOW
DEFOGGER CONNECTOR
(Left
si de wi th removabl e
hardtoD onl v)
REAR
::$
L r [
-
.,f
iii-;
l.f\
' "
- \
COAT
HANGER
20-70
COAT HANGER
4 N m 10. ' l kgt . m, 3 l bf . f t l
SI OE TRI M
Trim Removal/lnstallation
-
Rear Tray Area
NOTE:
.
Put on
gl oves to
protect your hands.
'
When
pryi ng wi th a fl at-ti p screwdri ver. wrap i t wi th protecti ve tape to
prevent damage.
.
Take care not to bend or scratch the top cl oth, rear wi ndow, tri m and
panel s.
1, Remove t he t r i m i n number ed sequence.
2. l nstal l the tri m i n the reverse order of removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
Appl y l i qui d thread l ock to the anchor bol ts before rei nstal l ati on.
.
Before i nstal l i ng the anchor bol ts, make sure there are no twi sts or ki nks i n the seat bel t.
.
Push the cl i p
porti ons i nto
pl ace
securel y.
Fast6ner Locations
B>: Cl i p, 7
l Cl
/@l
H
Vf o
r\e
1 ,
i '>-----
i -'
\ . . -
I - ' L -
A>: Cl i p, a
a _
'#!
l-f
REAR TRAY STOPPER
(' 02-03
model s)
@ REAR TRAY
REAR TRAY
STOPPER
(' 02-03
model s)
x 1. 0 mm
9. 8 N. m {1. 0 kgf . m, 7. 2l bf . f t }
(' 02-03
model s)
(cont' d)
O REAR TRAY REAR TRIM
20-71
lnterior Trim
Trim Removal/lnstallation
-
Rear Tray Area
(cont'dl
Fastener Locations
C>: Bol t , 8 D
>:
Scr ew, 4
CONVERTIBLE TOP
COVER PIN
' 00-0l model s:
Outsi de and mi ddl e.
' 02-03
model s: Outsi de onl y.
Fastener Locations
O ROLL BAR AND UPPER TRIM ASSEMBLY
Fi rst remove the these i tems:
. Rear
consol e
. Rear
si de t ri m
6] SEAT BELT UPPER ANCHOR BOLT
@ @ r 6 x
7/16-20UNF
t \ "-, {: 3*' . m. 24' bf . f t )
r \6\"\
4
uPPER ANcHoR cAP
a/
D
V
Sl i p t he seat bel t
t hrough t he hol e i n
t he r ol l bar upper t r i m.
'02-03
models shape
8 x 1. 25 mm
22 N.m 12.2 kgl m,
16 rbf.ft)
G
>:
Cl i p, 1
'00-01
models shaoe
O HARNESS cLIP
Detach
(l eft
si de onl y).
(' 02-03
model s)
OSEAT BELT
LOWER ANCHOR BOLT
7/16-20UNF
32 N.m, {3.2 ksf.m,
24 tbt,ft)
Fi rst remove the seat.
E>: Cl i p, 1 F>: oi p. 1
@4 .^-ts!-^\
-4.
S 7:7n ! fl+-
\ r/
-/E\
\-/ u4)
r(D
P
Vf o
@ REAR TRAY
SI DE TRI M
-
- : ' : : : " : : -
-
"-::"
'
"l
'
. . :
' '
O HARNESS GROMMET
Rel ease i t f rom t he t ri m
(l ef t
si de onl y).
(' 02-03
model s)
20-72
Tri m Removal /l nstal l ati on
-
Trunk Area
NOTE:
.
Put on
gl oves to
protect your hands.
.
When
pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to bend or scratch the tri m and panel s.
1. Remove t he t r i m as shown.
2. l nstal l the tri m i n the reverse order of removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push t he cl i ps i nt o pl ace secur el y.
Fastener Locations
A>: Cl i p, 18 B> r Cl i p, a c
>:
Cl i p, 3
, ^ t t ; . : i
T
-Fl
,.{tr]
TOOL BOX
RI GHTTBUNKSI DE
TRIM PANEL
SPARE TIRE COVER
V.
LEFT TRUNK SIDE
TRIM PANEL
TRUNK FLOOR
TBIM PANEL
REAR TRI M PANEL
TOOL AOX LID
V
V
20-73
lnterior Trim
Carpet Replacement
NOTE:
.
Put on
gl oves
to
protect your
hands,
.
Take care not to damage. wri nkl e, or twi st the carpets.
.
Becar ef ul not t odamaget he dashboar d or ot her i nt er i or t r i m
pi eces.
1. Remove these i tems, then remove the carpet as shown:
.
Seat
(see page 20-86)
.
Ki ck panel
{see
page
20-69)
.
Front consol e cover
(see page 20-81)
.
Rear si de tri m
(see page 20-70)
2. Instal l the carpet i n the reverse order of removal . and note these i tems:
.
Make sure the seat harness i s routed correctl y.
.
Repl ace any damaged cl i ps.
.
Appl y l i qui d thread l ock to the anchor bol t and seat mounti ng bol ts before rei nstal l ati on.
.
Before i nstal l i ng the l ower anchor bol ts, make sure there are no twi sts or ki nks i n the seat bel ts.
.
Push the cl i ps i nto pl ace
securel y.
Fastener Locations
A> : Bo l t , 2 B> : Sc r e w, 4 Car Nut . 2 D>: Cl i p, 1/ r E>: Cl i p, 10 F
>:
Cl i p, 2
ACCELERATON
PEDAL STOP
SEAT HARNESS
DRI VER' S CARPET
RETAINERS
FASTENER
FASTENER
CENTER CARPET
Pul l back as
necessary.
FASTENERS
To center carpet.
'i*"')y
TUNNEL
SIDE CLIP
DOUBLE.FACED
ADHESIVE TAPE
(3M
85603, or equi ral ent)
FLOOB MAT HOLDEB
1' 02-03 model s)
lf necessary, remove it.
TUNNEL SIDE
NET
PASSENGER'S
CARPET
SEAT BELT LOWER
ANCHOR BOLT
7/ 16-20UNF
32 N. m
(3.3
kgt.m,2il lbt ft)
3>j
g'",
20-74
Center Carpet Replacement
SRS components are l ocated i n thi s area. Revi ewthe SRS component l ocati ons {see
page
23-9) and the
precauti ons
and
procedures (see page 23-10) i n the SRS secti on before
performi ng repai rs or servi ce,
NOTE:
.
Put on gl oves to
protect your hands.
.
Take care not to damage, wri nkl e, or twi st the carpet.
.
Becar ef ul not t o damage t he dashboar d or ot her i nt er i or t r i m pi eces.
.
Before di sconnecti ng the negati ve cabl e from the battery, make sure you have the anti -theft code for the radi o, then
wri tedown the frequeci es for the radi o' s preset buttons.
.
Di sconnect the negati ve cabl e from the battery, and wai t at l east 3 mi nutes before begi nni ng work.
1. Remove these i tems, then remove the center carpet as shown:
.
Dashboard {see
page 20-82)
.
Rear consol e
(see page 20-78)
.
The har ness cl i ps secur i ng t he SRS wi r e har ness and st eer i ng hanger beam wi r e har ness.
.
Cut the carpet i n the areas shown.
2. Instal l the center carpet i n the reverse order of removal , and note these i tems:
.
Make sure the SRS wi re harness and steeri ng hanger beam wi re harness are routed correctl y, and cl i pped i nto
pt ace.
.
Repl ace any damaged cl i ps.
.
Push the cl i ps i nto pl ace securel y.
'
Refasten the cut areas wi th wi re ti es.
.
Reconnect the negati ve cabl e to the battery.
.
Enter the anti -theft code for the radi o, then enter the customer' s radi o stati on
presents.
.
Reset the cl ock.
.
Do t he PCM i dl e l ear n
pr ocedur e ( see page 11- 100) .
Fastener Locations
A>: Aok . 2 B>: Cl i p, 14 C>: Cl i p, 2
ftr ,,Th /If
/ \ / \ , / \ ,
,/
\J
CENTER
CARPET
CARPET
6 x 1 , 0 mm
9. 8 N. m
(' 1. 0
kgf . m, 7. 2l bf . f t )
STEERING HANGER
BEAM WIRE HARNESS
SRS WI RE
HARNESS
cV
B
FASTENERS
, - B !
B r . .
Bv-
,
D,B
FASTENERS
Cut here.
CENTER CARPET
20-75
Consoles
Center Console RemovaUlnstallation
NOTE:
.
When
pryi ng
wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care not to scratch the front seat, dashboard and rel ated parts.
.
Remove the shi ft knob by turni ng i t countercl ockwi se.
1. Remove the center consol e as shown.
2. Instal l the center consol e i n the reverse order of removal . and note these i tems:
.
Repl ace any damaged cl i ps.
.
Make sure the connectors are
pl ugged
i n properl y.
.
Push the cl i p
poni ons i nto pl ace
securel y.
.
Instal l the shi ft knob i n numbered seouence.
Fastener Locations
A
>:
Cl i p, 5 B>: Cl i p. 2 C> : Cl i p.
+
SHIFT KNOB
@SHI FT KNOB
By hand, t hread
t he shi f t knob
on t he shaf t .
@ l Vove to proper
posrtron.
By hand, t hread sei urel y.
) o
k
*,-*.q
. ) } '
' o \ , " n , n " , o " * " , ,
\O
CONSOLE
HAZARD WARNING
SWITCH CONNECTOR
Forward
t he l ocknut down.
t A
. \
v t \ c
,l
^N,,-
-1r
:;/8o
':'
j.,.
B
20-76
Wind Deflector Replacement
' 01-03
Models
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to prevent damage.
.
Take care notto scratch the rear consol e upper l i d and rel ated
parts.
1. Remove the wi nd defl ector as shown.
2. Instal l the wi nd defl ector i n the reverse order of removal .
.
Appl y l i qui d thread l ock to the th read of the A screws before rei nstal l ati on.
.
Make sure the caps are i nstal l ed securel y onto the screws.
Fastener Locations
A) : Sc r e w. 2
LI OUI D THREAD LOCK
REAR CONSOLE
UPPER LI D
WIND DEFLECTOB
20-77
Consoles
Rear Consol e Removal /l nstal l ati on
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th protecti ve tape to
prevent damage.
.
Take care not to scratch the front seat and rel ated
parts.
1. Remove these i tems:
'
Center consol e
(see page 20-76)
.
Rear t r ay
( see page 20- 71)
.
Rol l bar l ower tri m, both si des
(see page 20-70)
Remove the rear consol e as shown.
Instal l the rear consol e i n the reverse order of removal , and note these i tems;
.
Repl ace any damaged cl i ps.
.
Make sure the connectors are pl ugged i n
properl y.
.
Push the cl i p porti ons i nto pl ace securel y.
Fastoner Locations
A>: Scr . w, 4 B>: Scr ew, l o
CONSOLE
c
>
: Cl i p.5 D>: Cl i p, 4
+
d
-+
REAR CONSOLE
BACK BOARD
TRUNK LI D
OPENER SWITCH
CONNECTOR
Di sconnect .
REAR CONSOLE
BOX
ft::E:7l::.--'1
'f-
=i
, - - 9
I
1
.::j tt: ..
t:
I
/1
20-78
Rear Console Box Replacement
NOTE: Take care not to scratch the front seat and rel ated parts.
' 1.
Remove these i tems, then remove the rear consol e box as shown;
.
Rol l bar upper tri m, both si des
(see page 20-71]
' Spar et i r e
2. Remove the rear consol e box as shown,
3. Instal l the rear consol e box i n the reverse order of removal .
Fastsne. Locations
A>: Sc r ew, 4
5 x 0 . 8 mm
4 N. m
{0. 4
kg{. m,
3 rbf.ftl
HARNESS CLI P
Det ach.
REAR CONSOLE BOX
20-79
Dashboard
Instrument Panel Removal /
Installation
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th
protecti ve tape, and appl y protecti ve tape around the
rel ated pans, to prevent damage.
.
Take care not to scratch the dashboard and rel ated
parts,
1. Remove t he i nst r ument
panel asshown.
2. Instal l the panel i n the reverse order of removal ,
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Make sure the connectors are
pl ugged i n
properl y.
.
Push the cl i p poni ons i nto pl ace securel y.
Fastener Locrtions
A> : Sc r e w, 2 B> : Cl i p . 2 CF:
I NSTRUMENT PANEL
Cl i p, 4
,/:i
.I,
)
: Cl i p. 2
(-
'--
)
: Cl i p. 2
CRUISE CONTROL
MAIN SWITCH
CONNECTOR
ENGI NE
START
swtTcH
CONNECTOR
20-80
Radio Panel RemovaUlnstallation
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap l t wi th
protecti ve tape, and appl y
protecti ve tape around the
rel ated
parts, to prevent damage.
.
Take care not to scratch the dashboard and rel ated
pans.
1. Remove t he r adi o panel as shown.
2. I nst al l t he
panel i n t he r ever se or der of r emoval .
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p
porti ons i nto pl ace securel y.
Fastener Locations
5 B) : Cl i p , 2
)
: Cl i p,
.raa
=-
TABS
RADIO PANEL
Front Console Cover Removal/
Instal l ati on
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver. wrap i t wi th
protecti ve
tape, and appl y protecti ve tape around the
rel ated parts, to prevent damage.
.
Take care not to scratch the dashboard and rel ated
parts.
1. Remove the front consol e cover as shown.
2. Instal l the cover i n the reverse order of removal ,
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p porti ons i nto pl ace securel y.
Fastener Locations
, 1
B> r Cl i p . 2
)
: Screw
0."
Passenger's Dashboard Lower
Gover Removal /l nstal l ati on
NOTE:
.
When pryi ng wi th a fl at-ti p screwdri ver, wrap i t wi th
protecti ve tape, and appl y protecti ve tape around the
rel ated parts,
to
prevent
damage.
.
Take care not to scratch the dashboard and rel ated
parts.
1. Remove the passenger' s
dashboard l ower cover as
shown,
2. Instal l the cover i n the reverse order of removal ,
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p porti ons i nto pl ace
securel y.
Fastener Locations
A) : Cl i p, 6
l5=,.'
i;';-
20-81
Dashboard
Passenger's Side Vent Removal and
lnstallation
1. Wrap a fl at-ti p screwdri ver wi th protecti ve tape,
and appl y
protecti ve tape around the rel ated
parts
to prevent damage. Careful l y i nsert a fl at-ti p
screwdri ver next to the cl i p
(A),
and detach the cl i ps
by
pryi ng on the
passenger' s si de vent
(B).
Take
care not to scratch the dashboard and rel ated
parts.
Fastener Locations
A>: Cl i p, 2
Remove the vent by rel easi ng the hooks
(C).
Rei nstal l the hook portl ons ot the vent fi rst. then
push the cl i p porti ons i nto pl ace securel y.
2.
3.
/
.-.
---.2- - a
.
'...
.\___t
20-82
Dashboard RemovaUlnstallation
SRS comoonents are l ocated i n thi s area. Revi ew the
SRS component l ocati ons
(see page 23-9) and the
precauti ons and procedures
(see page 23-10) i n the SRS
secti on bel ore
performi ng repai rs or servi ce.
NOTE:
.
When
pryi ng wi th a fl st-ti p screwdri ver, wrap i t wi th
protecti ve tape, and appl y
protecti ve tape around the
rel ated
parts to
prevent damage.
.
Have an assi sl ant hel p
you
when remove and i nstal l
the dashboard.
.
Take care not to scratch the dashboard, body and
other rel ated parts.
.
Put on gl oves to protect your hands.
1. Make sure you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o' s
Preset
buttons.
2. Di sconnect the negati ve cabl e from the battery, and
wai t at l east 3 mi nutes before begi nni ng work.
3. Remove these i tems:
.
Radi o
panel (see page 20-80)
.
Audi o uni t {see
page 20-89}
.
Steeri ng col umn
(see page 17-9)
.
Passenger' s dashboard l ower cover {see
page
20- 81)
.
Front consol e cover, both si des
(see page 20-81)
.
Passenger' s ai rbag assembl y
(see page 23-65)
.
Ki ck panel , both si des
(see page 20-69)
.
Front
pi l l artri m, both si des
(see page 20-68)
4. Di sconnect the engi ne wi re harness connector
(A),
engi ne compartment wi re harness connectors
(B),
door wi re
harness connectors
(C),
rear wi re harness connector
(D),
steeri ng hanger beam wi re harness connectors
(E),
SRS
mai n harness connector {F), radi o antenna harness connector
(G),
ECM connector
(H}.
keyl ess entry control uni t
connector
(
l ), and converti bl e toD control uni t connector
(J).
K
6 x 1 . 0 mm
9. 8 N. m
(' 1. 0
kg' t . m,
7. 2 t bt . f t l
1. 0 mm
N. m {1. 0 kgf . m,
rbf.ft)
Remove the ground bol ts
(K).
Detach al l of the harness and connector cl i ps.
(cont' d)
\-.--..-
K
6 x
9.8
7.2
- = - .
20-83
Dashboard
Dashboard Removal/lnstallation
(cont'd)
7. From outsi de the doors. remove the caps
(A),
then remove the bol ts
(8,
C, D) and screws {E), and l i ft up on the
dashboard
(F)
to rel ease i t from the
gui de pi ns (G
).
Take care not to scratch the center consol e and shi ft knob.
Fasten6r Locations
A>: Bol t , 2 B>: Bol t , 2 C 2 D>: Scr ow, 2
{1\
>
: Bolt,
(t t rm (ii
DtE
6 x 1 . 0 mm
9. 8 N. m 11, 0 kgt . m,
7.2 tbt.ttl
'
\*
6 x 1 . 0 mm
9. 8 N. m {1. 0 kqf . m,
7.2 tbt.ftl
Careful l y remove the dashboard through the front door openi ng.
l nstal l the dashboard i n the reverse order of removal , and note these i tems:
.
Make sure the dashboard fi ts onto the gui de pi ns
correctl y.
.
Before ti ghteni ng the bol ts, make sure the dashboard wi re harness and steeri ng hanger beam wi
not pi nched.
.
Make sure the connectors are
pl ugged i n properl y.
.
Reconnect the negati ve cabl e to the battery.
.
Enter the anti -theft code for the radi o, then enter the customer' s radi o stati on
presets.
.
Reset the cl ock
.
Do t he PCM i dl e l ear n pr ocedur e ( see page 11- 100) .
re narness are
20-84
\
Component Location Index
Removal / l nst al l at i on, paqe
20-86
Di sassembl y/ Reasseni bl t Dri ver' s, page 2O-87
Di sassembl y/ Reassembl y Passenger' s, page2O-88
Seat Cover Replacement; page
2O-8r-9
Seats
Seat Removal/lnstallation
NOTE: Take care not to scratch the body or tear l he seat covers.
2.
1 . Remove the seat as shown.
Instal l the seat l n the reverse order of removal , and note these i tems:
.
Sl i p the seat bel t through the sl i ts i n the seat bel t
gui de properl y
.
Make sure the seat bel t swi tch connector i s pl ugged i n properl y,
.
Appl y l i qui d thread l ock to the seat mounti ng bel ts before rei nstal l ati on
Fastener Locations
A>: Bol t , 2 B
10 x 1. 25 mm
29 N.m {3.0
kgl .m,
22tbl.ftl
I x 1. 25 mm
22 N.m {2.2 kgt.m,
16 rbr.ftt
)
: Bolt. 2
I DI D
SEAT BELT GUIDE
SEAT BELT
Remove {rom the
seat bel t gui de.
SEAT BELT
SWITCH HARNESS
(Dri ver' s)
SEAT BELT
SWITCH CONNECTOR
Di sconnect
(dri ver' s).
20-86
Seat Disassembly/Reassembly
-
Driver's
NOTE:
.
Make sure the bushi ng and pi vot
washer are i nstal l ed correctl y.
.
Appl y mul ti purpose grease
to the movi ng porti on
of th seat track.
.
To prevent wri nkl es i n the seat-back cover, stretch the mal eri al evenl y over the
pad,
.
Rei nstal l the connecti ng wi re through the hol es i n the hooks.
PIVOT NUT
8 x 1.25 mm
22Nml 2.2ksl .m,
16 tbf.ftt
PIVOT
WASHER
BUSHI NG
INNER SEAT TRACK
, , ' i / t \ ' '
\ t['b^1
>\ u\
-?
xdox i
/
sEAr BELr I
swfTcH
| ,
HARNESS
,//
/
cLrP
I /
t ,
:LfPS
I A
r.
lol" a- -
Pul l back.
SEAT.BACK
RECLINE ADJUSTER
Rel ease the cl i ps as
necessary, then pul l
back the seat-back
cover.
HOO|(
10 x 1.25 mm
,07
N.m 14.8 kgt.m,
35 rbr.ft)
10 x 1. 25 mm
,17
N.m
(4.8
kgf.m,
3s rbt.ftl
8 x 1.25 mm
22 N.n
12.2ksi.m,
r6l bt.ftl
CONNECTING
WIRE
10 x 1.25 mm
47 N.m
(4.8
kgf.m,35l bt.ftl
HOOK
RECLINE KNOB
20-87
Seats
Seat Disassembly/Reassembly
-
Passenger's
NOTE:
.
l Make sure the bushi ng and
pi votwasher are i nstal l ed correctl y.
.
Appl y mul ti purpose
grease to the movi ng
porti on of the seat track.
' Topr event wr i nkl esi nt heseat - backcover , st r et cht hemat er i al evenl y over t he
pad'
.
Adj ustthe connecti ng cabl e as necessary.
.
Make sure the connecti ng cabl e i s connected
properl y
Rel ease t he cl i ps as
necessary, t hen pul l
back t he seat -back
d
10 x 1. 25 mm
4 7 N m
(4. 8 kql . m.
35 tbf.ftl
I x 1.25 mm
22N.n
l2.2 kgl m,
16 rbf.ftl
SEAT.
PIVOT NUT
8 x 1.25 mm
22N m 12.2 kgt.m,
16 tbf.ft)
PI VOT WASHER
SEAT CUSHION
BUSHI NG
10 x 1. 25 mm
4 7 N m
14. 8
kgf . m,
3s rbf.ft)
INNER SEAT TRACK
CONNECTI NG
CABLE
10 x 1. 25 mm
4 7 N m
{4.8
ksf.m,35 l bf.ft)
HOOK
l :
'
20-88
RECLINE KNOB
Seat Cover Replacement
NOTE:
.
Take care not to tear the seams or damage the seat covers.
.
Put on
gl oves
to
protect your hands,
Seat-back Cover
1. Remove the seat-back cover i n numbered sequence.
2. Instal l the cover i n the reverse order of removal , and note these i tems:
' Topr event wr i nkl eswheni nst al l i ngaseat - backcover , makesur et hemat er i al
i s st r et ched evenl y over t he pad
before securi ng the cl i ps, fasteners and hooks.
.
Repl ace the rel eased cl i ps wi th new ones usi ng commerci al l y avai l abl e uphol stery pl i ers.
.
Repl ace any damaged headrest cover cl i ps.
Fastenor Locations
A>: Scr ew4 B>: Scr ew' 2
HEAOREST
COVER
/ d
. )
l i ,,-:r
@ sE,
GU
1r, /
@
O HOOKS
CLIPS
Rel ease.
(cont' d)
C>; Cl i p, 4
20-89
Seats
Seat Cover Replacement
(cont'dl
FASTENER
O CLIP
Pul l back t he edge of t he cover
on t he cent er
pad al l t he way
around, and rel ease t he cl i ps.
i.{.
i . r \ \
. . . . - \
--/ ""11
back t he cent er
Pad
CLIP
Rel ease f rom undert hepent er
pad.
@SEAT.BACK
COVER
Pul l backt he edge o{t he cover
al l t he way around, and rel ease
t he f ast ener, t hen remove t he cover.
20-90
I
Seat Cushion Cover
1. Remove the seat
(see page 20-86).
2, Remove the seat cushi on, dri ver' s {see
page 20-87), passenger' s (see page 20-88).
3. Remove the seat cushi on cover i n numbered sequence.
4. Instal l the cover i n the reverse order of removal , and note these i tems;
' Topr event wr i nkl eswheni nst al l i ngaseat cushi oncover , makesur et hemat er i al
i s st r et ched evenl y over t he
pad
bef or e secur i ng t he cl i ps.
.
Repl ace the rel eased cl i ps wi th new ones usi ng commerci al l y avai l abl e uphol sl ery ri ng pl i ers.
ID CLIP
Rel ease f rom under t he seat cushi on
OPul l back t he edge
of t he cover al l t he
-
TRIM CORDS
l Cover si de)
Clip installation:
UPHOLSTERY BING
PLI ERS
OSEAT CUSHI ON COVER
Remove t he cover f rom
t he pad/ f rame.
SEAT CUSHI ON
WIRE
(Pad
si de)
OcLtP
Rel ease.
NEW CLI P
20-91
Bumpers
Front Bumper Removaulnstallation
NOTE:
.
Have an assi stant hel p
you remove and i nstal l the front bumper.
.
Take care notto scratch the front bumper and body.
.
Put on gl oves to
protect your hands.
1. Remove the front bumoer as shown.
2. Instal l the bumDer i n the reverse order of removal , and make sure the front bumper engages the hooks of the
corner upper beams and front fenders securel y
Fastonor Locations
A>: Bol t , 5 B>: Bol t , 9 C>: Bol t , 2 C) : Sc r ew, 2
tr
@@ 0r='
\FENDER
ABSORBER
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbf.ftl
FRONT BUMPER
A
B
l
+
t-"..--.-
l
6 x 1 . 0 mm
9. 8 N. m
{1. 0
kgf . m,
7.2 tbt.kl
FRONT BUMPER
UPPER STI FFENER
FRONT BUMPER BEAM
\ gF.
=_l:-.----J
L
---
i r l
' ' -
\
20-92
Rear Bumper Removal /l nstal l ati on
NOTE:
.
Have an assi stant hel p you remove and i nstal l the rear bumper.
.
Take care notto scratch the rear bumoer and bodv.
.
Put on gl oves
to
protect your hands.
1. Remove t he r ear bumDer as shown.
2. Instal l the bumper i n the reverse order of removal , and note these i tems:
.
Make sure the rear bumper engages the hooks
(bumper
spacers and under the tai l l i ght) on each si de securel y.
.
Make sure the l i cense pl ate
l i ght connector i s pl ugged i n properl y.
.
Repl ace any damaged cl i ps.
Fastener Locations
B>: Cl i p, 2 C A
>
: Screw,2
[E EP
..---l
"; ' . -. : l
-1
L---/-\f-'-'-'-'-
.
t ,
>
: Cl i p, 5
I
E*>.
m*
HOOKS
REAR BUMPER AEAM
r'l
"
,-:,-.,-
REAR BUMPER
20-93
Hood
1 .
)
Adjustment
Sl i ghtl y l oosen each hood hi nge bol t.
Adj ust the hood al i gnment:
.
Adj ust t he hood r i ght and l ef t , as wel l asf or war dandr ear war d, byusi ngt heel ongat edhol esont hehoodhi nge
(A).
.
Turn the hood edge cushi ons
(B),
as necessary. to make the hood fi t fl ush wi th the body at front and si de edges.
6 x 1 . 0 mm
9.8 N.m 11.0 kgt m,
7.2l bf.ft)
. 1. 1 i
. , . i '
. i : . . .
,.
6x 1. 0 mm
9.8 N.m {1.0 kgt.m,
7.2 tbf.ft)
Adj ust the hood l atch
(C)
to obtai n the proper hei ght at the forward edge, and move the hood l atch ri ght on l eft
unti l the stri ker
(D)
i s centered i n the hood l atch.
Ti ghten each bol t securel y.
20-94
7.
Check that the hood opens
properl y
and l ocks
securel y.
Appl y body
pai nt
to the hi nge mounti ng bol ts and
around the hi nges.
Remove the ai r gui de pl ate cover
(see page 20-1 1 1),
then remove the l atch cover
(A).
Appl y
mul ti purpose grease to each l ocati on of the hood
l atch
(B)
and hood hi nge
(C)
as i ndi cated by the
arrows.
20-95
Hood
Hood Insulator Replacement
NOTE:
.
Take care notto scratch the hood.
.
Use a cl i p remover to remove the cl i ps.
1. Remove the hood i nsul ator i n numbered sequence.
2. l nstal l the i nsul ator i n the reverse order of removal . and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i ps i nto pl ace securel y.
.
Make sure the wi ndshi el d washer tubes are connected
properl y.
Fastengr Locations
A>: Cl i p, 10 B
>
: Cl i p. 2
o cLrPs
O HooK
O HooD
INSULATOR
OWINOSHIELD WASHER TUBES
Bel ease from the I cl i ps,
and di sconnect.
20-96
Trunk Li d
a
1 .
2.
Adjustment
Sl i ghtl y l oosen each bol t.
Adj ust t he t r unk l i d al i gnment :
.
Adj ust the trunk l i d ri ght and l eft, as wel l as forward and rearward, by usi ng the el ongated hol es on the trunk l i d
hi nges( A) .
.
Turn the trunk l i d edge cushi ons
(B)
i n or out as necessary. to make the trunk l i d fi t fl ush wi th the body at the
rear and si de edges.
.
Adj ust the fi t between the trunk l i d and the trunk l i d openi ng by movi ng the stri ker
(C).
6 x
' 1. 0
mm
9. 8 N. m (1. 0
kgf . m,
7.2 tbf.ftt
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
1.2 tbt.ttl
*'.*:':-''''
i -
3. Ti ghten each bol t securel y.
4. Make sure the trunk l i d opens properl y and l ocks securel y.
5. Appl y body
pai nt
to the trunk l i d mounti ng bol ts and around the hi nges.
/.1 /
/,/;,/.,/i
20-97
Trunk Lid
Trunk Lid Torsion Bar Replacement
NOTE:
.
Take care not to scratch the bodv.
.
Put on gl oves to protect your hands.
.
Useat or si on bar t ool t o r emove and i nst al l t het or si on bar s.
.
Fi rst remove ri ght torsi on bar, and remove the l eft torsi on bar.
1. Remove the trunk l i d torsi on bar as shown,
2. Instal l the torsi on bar i n the reverse order of removal , and note these i tems:
.
Ther i ght t or si onbar hasapi eceof r ubber oni t asshown. I nst al l t her i ght andl ef t t or si onbar si nt hei r pr oper
l ocati ons.
.
Make sure the trunk l i d opens
properl y and l ocks securel y.
20-98
a
Trunk Lid Rubber Protector
Replacement
NOTE;
.
Take care not to scratch the trunk l i d.
.
Use a cl i p removerto remove the cl i ps.
' t .
Remove the trunk l i d rubber protector as shown.
Instal l the protector i n the reverse order of removal ,
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p
porti ons
i nto
pl ace
securel y.
Fastonel Locations
A >
: Cl i p, 8
RUBBER
PROTECTORS
RUBBER
PROTECTORS
Trunk Lid Weatherstrip
Replacement
1. Remove the trunk l i d weatherstri p by pul l i ng i t off.
2. Locat e t he
pai nt ed
al i gnment mar k
( A)
ont het r unk
l i d weatherstri p
(B).
Al i gn the pai nted mark wi th the
al i gnment tab i n the center of the trunk, and i nstal l
the weatherstri p al l the way around faci ng i n the
di recti on shown. Make sure there are no wri nkl es i n
the weatherstri p.
20-99
Fuel Fill Door
Adjustment
1. Sl i ghtl y l oosen the hi nge mounti ng bol ts
(A).
6 x 1 , 0 mm
9.81{.m 11.0 kgf.m,
7.2 tbt.frl
Adj ust the fuel fi l l door
(B)
i n or out unti l i t' s fl ush
wi th the body, and up or down as necessary to
equal i ze the gaps.
Ti ghten the hi nge mounti ng bol ts.
Check that the fuel fi l l door opens
properl y
and
l ocks securel y.
20-100
5. Appl y mul ti purpose grease to each l ocati on
i ndi cated by the arrows.
Appl y body pai nt to the hi nge mounti ng bol ts and
around the hi nges.
o.
_
_1---.
I
l , t
1- l
Exterior Trim
Cowl Cover Replacement
NOTE;
.
Take care not to scratch the body.
.
Use a cl i p remover to remove the cl i ps.
1. Remove the wi ndshi el d wi per arms l see
page 22-112).
2. Remove t he cowl cover asshown.
Instal l the cover i n the reverse order of removal , and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p
porti ons i nto pl ace
securel y.
Fastener Locations
A
>: Cl i p, 7 B
>:
Cl i p, 9
n
\ /
= Fr I - l
\ Y U
REAR HOOD SEAL
20-101
Exterior Trim
Rear Tray Openi ng Mol di ng
Replacement
NOTE:
.
Take care not to scratch the body.
.
Be careful not to
pry
too far or
you may bend the
mol di ng.
.
Put on gl oves to protect your hands.
1. Remove these i tems:l hen remove the rear tray
openi ng mol di ng as shown:
.
Converti bl e top assembl y
(see page 20-38)
'
B-pi l l ar outer weatherstri ps, both si des
(see page 20' 52)
.
Drai n tank, both si des
(see page 20-52)
2. Remove the rear tray openi ng mol di ng as shown.
Fastenel Locations
A> : Bo l t , 1 0
MOLDING
@
REAR TRAY
OPENI NG MOLDI NG
6 )( 1. 0 mm
9. 8 N. m
(1. 0
kgl . m,
7.2 tbl.ltl
3. I nst al l t he mol di ng i n t he reverse order of removal .
20-102
\
Rear Window Lower Molding
Replacement
NOTE: Take care not to scratch the body.
1. Remove the rear wi ndow l ower mol di ng as shown.
2. Instal l the mol di ng i n the reverse order of removal ,
and repl ace the cl i p i f i t' s damaged.
Fastener Locations
A>: Sc r eul I
>:
Cl i p. 1
s'
?
$ r o
a
Emblem Replacement
NOTE: When removi ng the embl ems. take care not to scratch the body.
Appl y the embl ems where shown, and note these i tems:
.
Cl ean the body surface wi th a sponge dampened i n al cohol .
.
After cl eani ng. keep oi l , grease and water from getti ng
on the surface.
Adhesive tape: 3M
,12'13E,
or equivalent
Thi ckness 0.8 mm 10.03 i n.)
Uni t mm {i n.)
'00-01
modelsi
FRONT BUMPER
ADHESIVE
EMBLEM
T
ADHESIVE
EMBLEM
REAR
"H"
EMBLEM
APPLICATION FRONT SIDE
20-103
Exterior Trim
A-pillar Exterior Trim Replacement
NOTE:
.
Keep dust away from the worki ng area.
.
When worki ng at l ower temperatures, heat the body and tri m wi th a hai r dryer.
Body: about 59' F
(
15"C)
Tri m: about 86"F
(30' C)
.
When heati ng the tri m, heat i t evenl y and gradual l y to prevent deformati on,
.
Cl ean the body bondi ng surface wi th a sponge dampened i n al cohol .
.
After cl eani ng. keep oi l ,
grease and water from getti ng on the surface.
1. Remove these i tems, then
peel up the ol d tri m whi l e heati ng i t wi th a hai r dryer.
.
A-pi l l ar-header weatherstri p
(see page
20-51)
.
A-pi l l ar mol di ng, both si des
(see page 20-51)
2. Appl y the tri m i n the numbered sequence, and note these i tems:
.
Al i gn the appl i cati on tape wi th the A-pi l l ar as shown.
.
When pressi ng the tri m, sl owl y
press i t from the corner to
prevent ai r bubbl es and wri nkl es.
. l f t her ear eai r bubbl esi nt het r i m, peel
up t he t r i m, t hen r eappl y i t .
.
After rei nstal l i ng al l removed
parts, checkthatthe body col or i s covered bythetri m.
ALI GNMENTMARK OWI NDSHI ELDHEADER
ALI GNMENTMARKS
EXTERIOR TRIM Al i gn t hem wi t h t he end of t he
wi ndshi el d header ext er i or t r i m.
A.PILLAR TRIM
ALIGNMENT NOTCH
{Body f l ange)
WI NDSHI ELD
MOLDI NG
WINDSHIELO HEADER
EXTERIOR TRIM
Al i gn t he appl i cat i on t ape
wi t h t he A- pi l l ar .
@) A.PILLAR TRIM
20-104
Fenderwell
a
Inner Fender Repl acement
NOTE: Take care not to scratch the body.
1. Remove the front wheel .
2. Remove t he i nner f ender as shown.
3. I nst al l t he i nner f ender i n t he r ever se or der of r emoval , and r epl ace any damaged cl i ps.
D
r Clip,
x
"#
Fastener Locations
A>: Bol t , 5 B) : Sc r ew. 2 C
{rl}rF
(
} ltr>
'-t-/
\-/
FRONT BUMPER
FRONT UNDEB
COVER
FRONT SPLASH
SHI ELD
INNER FENDER
6 x 1 . 0 mm
9 . 8 Nm( 1 . 0 k g l . m,
7.2 tbl.ttl
I
nc .
u :
c
/"f
i;'t{
I , i
49 A
. i :
C l
a
20-105
Fenderwell
Strakes Replacement
NOTE: Take care not to scratch the body.
1. Remove the strakes as shown.
2. l nstal l the strakes i n the reverse order of removal
Fastener Locations
A>: Bol t , 2 B>: Bol t , 4 C>: Sc r ew. 3
F
A
I
6 x 1 . 0 mm
9. 8 N. m
(1. 0
7.2 rbf.ftl
FRONT BUMPER
INNER
FENDER
REAR
STRAKE A
...6.
,
I
FRONT STRAKE
20-106
I
Fenderwell Trim Replacement
NOTE:The steel core i n the fenderwel l tri m cannot be
restored to i t ori gi nal shape once i t i s bent. Repl ace the
fenderwel l tri m when the steel core i s bent.
1. Remove the fenderwel l tri m by pul l i ng i t out.
2. Instal l the fenderwel l tri m, and note these i tems:
.
Cl ean the body bondi ng surl ace wi th a sponge
dampened i n al cohol .
.
After cl eani ng, keep ei l , grease
and waterfrom
getti ng
on the cl ean surface.
.
Appl y cl ear seal ant i n the groove of the tri m at
the area i ndi cated by the arrow.
.
Scrape or wi pe the excess seal ant off wi th a soft
shop towel dampened i n al cohol .
Seal ant: Cemedi ne P/N 08712-0004, or equi val ent
a
Rear Air Outlet Replacement
NOTE: Take care not to scratch the body.
1. Remove these i tems:
.
Rear tri m panel (see page 20-73)
.
Rear bumper {see
page 20-93)
Remove the rear ai r outl et as shown.
I nst al l t he ai r out l et i n t he r ever se or der of r emoval ,
and note these i tems:
.
Repl ace any damaged cl i ps.
.
Push the cl i p porti ons i nto pl ace securel y.
Fastener Locations
A>: Cl i p. 2
(1.r4
-
x
REAR AIR OUTLET
2.
?
20-107
Openers
Component Location Index
.::._':
HOOD LATCH
Repl acement , page 20 111
TRUNK LI D
LOCK CYLINOER
Repl acement ,
page 20-1 13
TRUNK LID LATCH
Repl acement , page 20-112
FUEL FILL OOOR OPENER CABLE
Repl acement , page 20 1' 10
FUEL FILL DOOB OPENER
page 20-110
HOOD RELEASE HANOLE
Repl acement ,
page 20' 1 1 1
HOOD OPENER CABLE
Repl acement , page 20-109
20-108
Hood Opener Cable Replacement
NOTE:
.
Put on
gl oves
to protect your hands.
.
Take care not to scratch the body and rel ated parts.
.
Take care notto bend the cabl e.
1. Remove these i tems:
.
Inner fender
(see page 20-105)
.
Ki ck panel (see page 20-69)
.
Front bumper
(see page 20-92)
.
Ai r gui de pl ate
2. Di sconnect t he hood opener cabl e
( A) f r omt he
hood l at ch
( 8)
andhoodr el easehandl e( C) ( seepage20- 111) .
Fastenor Locations
D>: Cl i p, 1 E
>:
Cl i p, 6
##)
'rl)
_ '
I
3.
4.
Usi ng a cl i p remover, detach the cl i ps
(D.
E) and remove the grommet
{F)
from the body, then remove the hood
opener cabl e. Take care not to bend the cabl e,
Instal l the cabl e i n the reverse order of removal . and note these i tems;
.
Repl ace any damaged cl i ps.
.
Route the cabl e through the hol e
(G)
i n the body.
20-109
Openers
Fuel Fill Door Opener Cable Replacement
NOTE:
.
Put on
gl oves to
protect your hands
.
Take care not to scratch the body and rel ated
parts
.
Take care not to bend the cabl e.
' 1.
Remove these i tems:
.
Rear si de tri m
(see page 20-70)
.
Rear tray
(see page 20' 71)
.
Trunk si de tri m
panel , l eft si de
(see page 20-73)
2. Removethefuel fi l l door opener knob
(A)
from the fuel fi l l door opener bracket
(B)
byturni ng l t90' , and remove
the fuel fi l l door l atch
(C)from
the body i n the same way.
Fastener Location
E
>:
Cabl e cushi on,l
Remove the fuel fi l l door opener cabl e {D).
l nstal l the cabl e i n the reverse order of removal wi th a new cabl e cushi on
(E).
3.
4.
.\
' f l
-l vl
. ;-t
/
_
-::....
20-110
a
Hood Release Handle Replacement
NOTE: Take care not to bend the caore.
1. Remove the ki ck panel (see page 20-69).
2, Remove the hood rel ease handl e as shown,
3. Instal l the handl e i n the reverse order of removal ,
and note these i tems:
.
l Make surethe hood openercabl e i s connected
propefl y.
'
Make sure the hood opens properl y.
Fa3tenor Locations
A) : Bol t , 2
(JJ
@
HOOD OPENER CABLE
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 tbt.ttl
HOOD RELEASE HANDLE
Hood Latch Replacement
NOTE: Take care not to bend the cabl e.
Replacement
1. Remove the ai r gui de pl ate
cover, then remove the
hood l atch as shown.
2. l nstal l the l atch i n the reverse order of removal , and
note these ttems:
.
Appl y grease to the hood l atch.
.
Make sure the hood opener cabl e i s connected
propefl y.
.
Adj ustthe hood l atch al i gnment {see step 3 on
page 20-94).
.
Make sure the hood l ocks securel y.
Fastener Locations
A>: Bol t , 3 B>: Oi p, 3
@
5 x 1 . 0 mm
9. 8 N. m
{1. 0 kgt . m,
7.2 tbf.ttl
(cont' d)
20-111
Openers
Hood Latch Replacement
(cont'd)
Grease Application
1. Remove the l atch cover, and Appl y mul ti purpose
grease to each l ocati on of the hood l atch i ndi cated
by the arrows.
20-112
Trunk Lid Latch Replacement
NOTE:
'
Put on gl ovest o pr ot ect your hands.
.
Take care not to scratch the body
.
Take care not to bend the cyl i nder rod
' 1.
Remove t he t r unk l i d l at ch as shown.
' i ^
l nstal l the l atch i n the reverse order of removal , and
note these rtems:
.
N4ake sure the connector i s
pl ugged i n
properl y
and the opener cabl e i s connected
properl y.
.
Make sure the trunk l i d opens
properl y and l ocks
securel y.
Fastener Locations
)
: Bolt. 2
lnl f-:l
rnurux LtD LArcH
-l
--'
6 x 1 . 0 mm
9. 8 N. m
{ 1. 0 kgf m, 7. 2l bf f t }
t
A
' 01-03
model s shape
{Wi t h
handl e}
Trunk Lid Lock Cylinder Replacement
NOTE:
.
Take care notto scratch the body.
.
Take care notto bend the cyl i nder rod.
1. Remove t he t r unk l i d l ock cyl i nder as shown.
2. Instal l the cyl i nder i n the reverse order of removal ,
and note these i tems:
.
Make sure the cyl i nder rod i s connected properl y.
.
l \4ake sure the trunk l i d opens properl y.
Fastener Locations
A
>
: Bol t,2
,Sc.r{\
{UI ] E
] CYLINDER ROD
TRUNK LIO
LOCK CYLINDER
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 rbf.ft)
20-113
Frame
Front Subframe Replacement
After l ooseni ng the subframe mounti ng bol ts, be sure to repl ace them wi th new ones'
Reference holes alignment:
SUBFRAME
INSTALLATION
REFERENCE HOLE
{Subframe si de)
E t -
V A
/ 9 9
I /./
t//
x 1.25 mm
N.m {3.9
kgf.m,
tbt.ftl
10
38
2a
INSTALLATION
REFERENCE HOLE
I x 1.25 mm
22N.m l2.2kgl..n,
16 rbf.ftl
LEFT GUSSET
8 x 1.25 mm
22N.m 12.2kgl.m,
16 rbf.ftl
To body.
- To bodv.
t o oooy.
RIGHT GUSSET
12 x 1,25 m.n
59 N.m
(6.0 ksf.m,
43 tbf.ftl
Repl ace.
10 x 1. 25 mm
38 N. m
(3. 9
kgf m,
28 tbt.ftl
10 x L25 mm
38 N. m 13. 9 kgf . m,
28 tbf.ftt
1i l x 1. 5 mm
116 N. m
{11. 8 kgf . m,
85.3 tbt.ftt
Repl ace.
- Y
.:1
'..
ia..
1+.lr
-,'
__
-:
\.\
20-114
Rear Subframe Replacement
After l ooseni ng the subframe mounti ng bol ts, be sure to repl ace them wi th new ones.
Reference holes alignment:
SUBFRAME
(Body
si de)
SCREWORIVER or
TAPERED PUNCH
INSTALLATION
REFERENCE HOLE
REAR SUBFRAME
INSTALLATION
REFERENCE HOLE
To body.
- / , _\ \ , t t ,
L , t - - 7 - - J
) i A
t \ of i ) a
} V f l
?
o
S
I t
e ) l
- $ * \
/
\ i
B tr) ,.ru ,,'.
]1
59 N.m
(6.0
ksf.m,,|:} tbf.ftt
I
Rept ace.
14 x 1. 5 mm
lg?rT;T
{10 5 ksr'm' 76 rbr'ft1
REAR SUSPENSION
STI FFENER
10 x 1. 25 mm
45 N. m (, 1. 6
k91. m, 33l bt . f t )
To body.
20-115
Frame
Frame Repair Chart
Top View
Uni t rmm
(i n. )
d: lnner diameter
CE IER
ut{E
POI NT
a
b
o
t
s
For bumper beam 010 {0. 4)
For tie down s23 x 30
(0.9
x 1 21
For stabilizer d24 {0.91
For stabilizer d24 {0.9}
For upper arm al3
(0.5)
Damper center
For subt rame o17
(0. 7)
POINT
h For upper arm 613 {0. 5)
i For subf rame s17 10. 7)
j For subframe 617 {0.7)
k Locate hole o25
(1.01
I Fort ransmi ssi on mount bracket d13 l 0 5l
m For transmission mount bracket o13
(0.5)
n For transmission mount brackst 613 {0.5)
VEFTNAL
LINE
12.11
20-116
POINT
o Locate hole o15 10.59)
p For rear subframe 11610.63l
q For rear subtrame 616 {0.631
r Rear dampe. cnter 650 12.01
s For rear subfr.rne 616 10.6i|l
t Locate hol6 r20 {0.81
(cont' d)
20-117
Frame
Frame Repair Chart {cont'd)
SideView
Uni t mm
(i n. )
o: l nner di amet er
POI NT
a For bumper beam o10 {0.41
b For tie down o23 x 30 {0.9
x 1 2)
c For stabilizer s24 10.9)
d For stabilizer s24 {0.91
e For upper ar m ol 3
( 0. 51
f Dampel centet
g For subt r ame 617
( 0. 71
POINT
h For upper ar m s13 { 0 51
i For subf r ame o17 { 0. 7)
i
For subframe s17 {0.7)
k Locat e hol e 625l l . 0)
I Fortransmission mount bracket 613
(0
5)
m For transmission mount btacket 613 {0 5)
n For transmission mount bracket t13 {0.5)
SECTION AA
SECTION BB
BASE
UltE
20-118
POINT
o Locate hole s15 10.59)
$
Cs\ rsar s\bhaNsd$\$S3\
q
For rear subframe 016 {0.631
r Rer damper centor ,50
(2.0)
s For rear Bublramo 116 lo.fill
t Locale hole s20 {0.8}
SECT|O
OO
20-119
a
HVAC
(Heating,
Ventilation,
and Ai r Condi ti oni ngl
Heati ng and Ai r Condi ti oni ng
Speci af Tool s . . . . . . . . . . . . . 21-2
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 3
A, / C Servi ce Ti ps and Precaut i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6
A"/ C Ref ri gerant Oi l Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2' l -6
General Troubl eshoot i ng I nf ormat i on . . . . . . . . . . . . . . . . . . . . . . . 21-8
DTC Troubl eshoot i ng I ndex . . . . . . . . . . . . . . 21-9
Sympt om Troubl eshoot i ng I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-10
Syst em Descri pt i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-11
Ci rcui t Di agram . . . . . . . . . 21-14
DTC Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . . 21-16
Reci rcul at i on Cont rol Mot or Ci rcui t
Tr oubl eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 24
Heat er Cont rol Power and Ground Ci rcui t s
Tr oubl eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 25
Condenser Fan Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . 21-27
Radi at or and Condenser Fans Common Ci rcui t
Troubf eshoot i nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-28
Compressor Cl ut ch Ci rcui t Troubl eshoot i ng . . . . . . . . . . . . . 21-29
Ay' C Pressure Swi t ch Ci rcui t Troubl eshoot i ng . . . . . . . . . . . 21-31
Ai r Mi x Cont rol Mot or Test and Repl acement . . . . . . . . . . . 21-33
Mode Cont rol Mot or Test and Reol acement . . . . . . . . . . . . . . 21-34
Reci rcul at i on Cont rol Mot or Test and
Repl acement . . . . . . . . . 21- 35
Evaporat orTemperat ure SensorTest . . . . . . . . . . . . . . . . . . . . . . . . 21-36
Power Transi st or Test . . . . . . . . . . . . . . . . . . . . . . . . 21-36
Heat er Cont rol Panel Removal and I nst al l at i on . . . . . . . . . 2' l -37
Bl ower/ Evaporat or Uni t Removal and I nst al l at i on . . . . 21-38
Bl ower/ Evaporat or Uni t Component s
Repl acement . . . . . . . . . 21- 39
*
Heat er Uni VCore Reol acement . . . . . . . . . 21-40
Dust and Pol l en Fi l t er Repl acement . . 21-42
Heat er Val ve Cabl e Adj ust ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43
Compressor Repl acement . . . . . . . . , . . . , . , , , 21-44
Compressor Cl ut ch Check . . . . . . . . . . . . . . . . . 21-46
Compressor Cl ut ch Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-47
CompressorThermal Prot ect orRepl acement . . . . . . . . . . . 21-49
Compressor Rel i ef Val ve Repl acement . . . . . . . . . . . . . . . . . . . . . . 21-49
Condenser Reol acement . . . . . . . . . . . . . . . . . . . 21- 50
Ref ri gerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . 21-51
Syst em Evacuat i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-52
Syst em Chargi nS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-53
Ref ri gerant Leak Test s . . . . . . . . . . . . . . . . . . . . . . . 21-54
f uc syst em Test s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-55
Blower/Evaporator Unit Components Replacement
Note these i tems when overhaul i ng the bl ower/evaporator uni t:
.
The reci rcul ati on control motor
(A),
the powertransi stor (B),
and the bl ower motor
(C)can
be repl aced wi thout
removi ng the bl ower/evaporator uni t.
. l f you' r ei nst al l i nganewevapor at or cor e( D) , addr ef r i ger ant oi l ( KEI HI N
SP- 10)
( seepage2l - 6) .
.
l f necessarV, removethe expansi on val ve
(E).
.
Repl ace t he O- r i ngs wi t h newones at eachf i t t i ng and appl yat hi n coat of r ef r i ger ant oi l bef or e i nst al l i ng t hem.
Be sure to use the correct O-ri ngs for HFC-134a {R-134a) to avoi d l eakage.
.
l mmedi atel y after usi ng the oi l . rei nstal l the cap on the contai ner, and seal i t to avoi d moi stu re absorpti on.
.
Rei nstal l the eva
porator
tem
peratu re senso r
(F)
i n i ts ori gi nal l ocati on.
.
Before reassembl y, make surethatthe reci rcul ati on control l i nkage and doors move smoothl y.
.
After reassembl y, makesurethe reci rcul ati on control motor runs smoothl y
(see page
21-35).
.
Make sure no ai r i s l eaki ng from the upper housi ng {G) and the l ower housi ng
(H)
fi tti ng.
21-39
Heati ng and Ai r Condi ti oni ng
Heater Unit/Core Replacement
SRS comoonents are l ocated i n thi s area. Revi ew the
SRS component l ocati ons, precauti ons, and procedures
i n the SRS secti on before performi ng repai rs or servi ce
(see page 23-10).
1. Make sure
you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o' s
Dreset buttons.
2. Di sconnectthe negati ve cabl e from the battery.
3. Remove the heat shi el d of the exhaust mani fol d
(see
step 16 on page 6-27l,.
4. From under the hood, open the cabl e cl amp
(A),
then di sconnect the heater val ve cabl e
(B)
from the
heater val ve arm
(C).
Turn the heater val ve arm to
the ful l y opened posi ti on as shown.
5. When the engi ne i s cool , drai n the engi ne cool ant
from the radi ator
(see page 10-8).
21-40
7.
Remove the mounti ng bol t from the heater val ve.
Sl i de the hose cl amps
(A)
back, then di sconnect the
i nl et heater hose
(B)
and the outl et heater hose {C)
from the heater uni t. Engi ne cool ant wi l l run out
when the hoses are di sconnected; drai n i t i nto a
cl ean dri p
pan. Be sure not to l et cool ant spi l l on
the el ectri cal
pans or the pai nted surfaces. l f any
cool ant spi l l s, ri nse i t off i mmedi atel y.
Remove the mounti ng nut from the heater uni t.
Take care not to damage or bend the fuel l i nes, the
brake l i nes, etc.
8 x
' 1. 25
mm
13 N. m
( 1. 3
ksf . m, 9. 4l bl f t )
j.'
..:,
' ...aa' :'
6 x 1 . 0 mm
9.8 N.m
{1.0 kgt.m,
7 .2 tbt.ttl
8. Remove the dashboard {see
page 20-82).
9. Remove the bl ower/evaporator uni t
( see page 21- 38) .
10. Remove the mounti ng bol ts, the center brackets
(A),
and the audi o brackets
(B).
8 x 1,25 mm
22 N.m 12.2 kgf.m, 16l bt ft)
l -
6 x 1 , 0 mm
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bf . f t l
8 x 1.25 mm
2 2 Nm
{2.2 kgf.m, 16 l bf.ft}
Remove the SRS uni t {see
page 23' 75),
Remove the sel f-tappi ng screws and the defroster
outl et
(A),
then remove the wi re harness cl i ps
(Bi .
1 1 .
12.
Di sconnect the connectors
(A)
from the mode
control motor and the ai r mi x control motor, then
remove the wi re harness cl i p {B).
Remove the
mounti ng nuts, the mounti ng bol t, and the heater
uni t
( C) .
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m,
7.2 tbf.lrl
6 x 1 . 0 mm
9 . 8 N m
11. 0 ksf . m, 7. 2l bf . f t l
/
\
4. Remove the sel f-tappi ng screw and the passenger' s
heater outl et
(A),
then remove the sel f-tappi ng
screw and the cl amp
(B).
Be careful not to bend the
i nl et and outl et pi pes duri ng the heater core
(C)
removal , and oul l out the heater core.
B---_
t
___|.+
(cont' d)
rK
M-
21-41
Heating and Air Conditioning
Heater Unit/Core Replacement
(cont'dl
15. Instal l the heater core i n the reverse order of
removal .
' 16.
l nstal l the heater uni t i n the reverse order of
removal , and note these i tems:
.
Do not i nterchange the i nl et and outl et heater
hoses, and i nstal l the hose cl amps securel y.
.
Refi l l the cool i ng system wi th engi ne cool ant
(see
page
10-8).
.
Adj ust the heater val ve cabl e
(see page 21-43).
.
Make sure that there i s no cool ant l eakage.
.
Make sure that there i s no ai r l eakage.
.
For evaporator and Ay' C-rel ated i nformati on, refer
to bl ower /evaporator uni t removal and
i nstal l ati on
(see page 21-38).
.
Do the ECM i dl e l earn procedure
{ see
page 11- 100) .
.
Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on presets.
.
For' 01-03 model s, reset the cl ock.
21-42
4. l nstal l the fi l ter i n the reverse order of removal
Dust and Pollen Filter Replacement
The dust and
pol l en fi l ter shoul d be repl aced every
30,000 mi l es under normal condi ti ons, or every 15,000
mi l es under extremel y dusty or sooty condi ti ons.
Reol ace the fi l ter more often i f the ai r fl ow i s l ess than
usua L
1. Open t he hood.
2. Remove the cl i ps
(Al and
the hood seal
(B).
Li ftthe
ri ght si de of the cowl cover
(C)
up, and remove the
dust and
pol l en
fi l ter
(D)
as shown. Be careful not to
damage the hood seal when removi ng the cl i ps.
C B
Remove the fi l ter
(A)from
the housi ng
(B).
Repl ace
the fi l ter.
Heater Valve Cable Adjustment
1 . From under the hood, open the cabl e cl amp
(A),
then di sconnect the heater val ve cabl e
(B)
from the
heater val ve arm
(C).
From under the dash, di sconnect the heater val ve
cabl e housi ng f r om t he cabl e cl amp
( A) ,
and
di sconnect the heater val ve cabl e
(B)
from the ai r
mi x cont r ol l i nkage { C) .
4.
Set the temperature control di al on Max Cool wi th
t he i gni t i on swi t ch ON
( l l ) .
Attach the heater val ve cabl e {B) to the ai r mi x
control l i nkage
(C)
as shown above. Hol d rhe end
of the heater val ve cabl e housi ng agai nst the stop
( D) ,
t hen snap t he heat er val ve cabl e housi ng i nt o
t he cabl e cl amp
( A) .
From under the hood, turn the heater val ve arm
(C)
to the ful l y cl osed
posi ti on
as shown, and hol d i t.
Attach the heater val ve cabl e
(B)
to the heater val ve
arm. and gentl y pul l on the heater val ve cabl e
housi ng to take up any sl ack, then i nstal l the heater
val ve cabl e housi ng i nto the cabl e cl amp {A).
21-43
Heati ng and Ai r Condi ti oni ng
Compressor Replacement
1. l f the compressor i s margi nal l y operabl e. run the
engi ne at i dl e speed, and l et the ai r condi ti oni ng
work for a l ew mi nutes, then shut the engi ne off.
2. Make sure
you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o' s
preset buttons.
3. Di sconnect the negati ve cabl e from the battery.
4. Recover the refri gerant wi th a recovery/recycl i ng/
chargi ng stati on
(see page 21-511.
5. Remove the ai r cl eaner housi ng
(see
step 5 on
page
6-25).
6. Remove the alternator
(see page 4-26).
7. Remove the nuts, then di sconnect the sucti on l i ne
(A)
and the di scharge l i ne
(B)from
the compressor.
PIug or cap the l i nes i mmedi atel y after
di sconnecti ng them to avoi d moi sture and dust
contami nati on.
x 1. 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ltl
21-44
8, Di sconnect the compressor cl utch connector, then
remove the mounti ng bol ts and the compressor.
10 x 1.25 mm
il4
N.m
(4.5
kgt m,
33 rbf.ftt
9. l f necessary. remove the mounti ng bol ts and the
compressor bracket,
8 x 1. 25 mm
22 N. m
12.2 kgl.m,
16 tbf.ft)
\
10. l nst al l t he comDr essor i n t he r ever se or der of
removal , and note these i tems:
.
l f you' re i nstal l i ng a newcompressor, you must
cal cul ate the amount of refri gerant oi l to be
removed from i t
(see page 21-6).
.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them. Be sure to use the correct O-ri ngs
f or HFC 134a
( R- 134a) t o
avoi d l eakage.
.
Use r ef r i ger ant oi l
( KEl Hl N
SP- 10) f or HFC- 134a
KEIHIN spi ral type compressor onl y.
.
To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed, and never mi x i t
wi th other refri gerant oi l s.
.
l mmedi at el y af t er usi ng t he oi l , r ei nst al l t he cap
on the contai ner, and seal i t to avoi d moi sture
aosorpl ron.
.
Do not spi l l t he r ef r i ger ant oi l ont hevehi cl e; i t
may damage the pai nt. l f the refri gerant oi l
contacts the
pai nt,
wash i t off i mmedi atel y.
.
Charge the system {see
page 21-53).
.
Do the ECM i dl e l earn procedure
( see page 11- 100) .
.
Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on
presets.
.
For
' 01-03
model s. reset the crocK.
21-45
Heati ng and Ai r Condi ti oni ng
Compressor Clutch Check
1 . Check the armature pl ate for di scol orati on,
peel i ng,
or other damage. l f there i s damage, repl ace the
cl utch set
(see page 21-47).
Check the rotor pul l ey beari ng pl ay and drag by
rotati ng the rotor pul l ey
by hand. Repl ace the
cl utch set wi th a new one i f i t i s noi sy or has
excessi ve
pl ay/drag
{see
page
21-47).
Measure the cl earance between the rotor
pul l eV (A)
and the armature pl ate
{B)
al l the way around. l f the
cl earance i s not wi thi n speci fi ed l i mi ts, remove the
armature
pl ate (see page 21-47) and add or remove
shi ms as needed to i ncrease or decrease cl earance.
Cl earance: 0.5+0.15 mm {0.02040.006 i n.)
NOTE: The shi ms are avai l abl e i n four thi cknesses:
0. 1 mm, 0. 2 mm. 0. 4 mm, and 0. 5 mm.
21-46
4. Rel ease the fi el d coi l con nector f rom the ho l der,
then di sconnect i t. Check the thermal
protector
for
conti nui ty. l f there i s no conti nui ty, repl ace the
thermal
protector (see page 21-49).
NOTE: The thermal protector wi l l have no
conti nui ty above 252to262F 1122 to 128"C). When
the temperature drops bel ow 241 to 219' F
(' 116
to
104' C), the thermal
protector wi l l have conti nui ty.
Check resi stance of the fi el d coi l . l f resi stance i s not
wi thi n speci fi cati ons, repl ace the coi l
(see page 21-47).
Field Coil Resistance: 3.05 3.35 ohms at
68"F {20' C)
'it
t
Compressor Clutch Overhaul
Special Tool Required
A,/C cl utch hol der, Robi nai r
' 10204,
Kent-Moore J37872,
or Honda Tool and Equi pment KMT-J33939,
commer ci al l y avai l abl e
1. Remove the center nut
(A)
whi l e hol di ng the
armature pl ate wi th a commerci al l y avai l abl e A,/C
cl utch hol der
(B).
' 17. 5
N. m 11. 8 kgf . m,
13 rbf.ftl
Remove the armature pl ate (A)
and shi m(s) {B),
taki ng care not to l ose the shi m(s). l f the cl utch
needs adj ustment, i ncrease or decrease the
number and thi ckness of shi ms as nesessary, then
rei nstal l the armature pl ate, and recheck i ts
cl earance
(see page
21-46).
NOTE: The shi ms are avai l abl e i n four thi ckness:
0. 1 mm, 0. 2 mm, 0. 4 mm, and 0. 5 mm.
3, l f you are repl aci ng the fi el d coi l , remove the snap
ri ng {A) wi th snap ri ng pl i ers,
then remove the rotor
pul l ey (B).
Be careful not to damage the
pul l ey
and
compressor.
Remove the bol t and hol der
(A),
then di sconnect
the fi el d coi l connector
(B).
Loosen the cl amp screw
(C)
to free the fi el d coi l wi re. Remove the snap ri ng
( D)
wi t h snap r i ng pl i er s, t hen r emove t he f i el d coi l
(E).
Be careful not to damage the fi el d coi l and
comDressor.
.-__-.\-)
-g
@
ffi
e--.--=-o
{0. 75 kgf . m, 5 l bf . f t )
(cont' d)
7. 4 N. m
21-47
Heati ng and Ai r Condi ti oni ng
(
Compressor Clutch Overhaul
(cont'd)
5. Reassembl e the cl utch i n the reverse order of
di sassembl y, and note these i tems:
' l nst al l
t he f i el d coi l wi t h t he wi r e si de f aci ng
down, and al i gn the boss on the fi el d coi l wi th the
hol e i n the compressor.
.
Cl ean t he r ot or pul l ey
and compr essor sl i di ng
surfaces wi th contact cl eaner or other
non-petrol eum sol vent.
. I nst al l
new snap r i ngs, not e t he i nst al l at i on
di recti on, and make sure they are ful l y seated i n
the
groove.
.
Make sure that the rotor
pul l ey
tu rns smoothl y
after i t' s reassembl ed.
.
Rout e and cl amp t he wi r es pr oper l y
or t hey can
be damaged by the rotor pul l ey.
21-48
Compressor Thermal Protector
Replacement
1. Remove t he bol t , t he gr ound t er mi nal { A) , andt he
hol der
(B).
Di sconnect the fi el d coi l connector
(C),
then remove the thermal protector (D).
7. 4 N. m
(0. 75
kgf . m, 5 l bf . f t l
2.
3.
A
Instal l the thermal protector i n the reverse order of
r emoval .
Compressor Relief Valve
Repl acement
' 1.
3.
Recover the refri gerant wi th a recove ryl recycl i ng/
char gi ng st at i on
( see page 21 51) .
Remove t he r el i ef val ve i A) , and t he O- r i ng
( B) .
Pl ug
the openi ng to keep forei gn matter from enteri ng
t he syst em and t he compr essor oi l f r om r unni ng
out .
Cl ean the mati ng surfaces.
Repl ace the O-ri ng wi th a new one at the rel i ef
val ve, and appl y a thi n coat of refri gerant oi l before
i nst al l i ng i t .
Remove the
pl ug,
and i nstal l and ti ghten the rel i ef
val ve.
Char ge t he syst em
( see page 21- 53) .
9. 8 N. m
(1. 0 kgf . m,
21-49
Heati ng and Ai r Condi ti oni ng
Condenser Replacement
1 .
3.
Recover the refri gerant wi th a recovery/recycl i ng/
char gi ng st at i on
( see page 21- 51) .
Remove t he ai r cl eaner housi ng
( see
st ep 5 on
page
6-25).
Remove the bol ts, then remove the upper mount
brackets from the radi ator.
6 x 1 . 0 mm
9, 8 N. m {1. 0
kgf . m. 7. 2 l bt . f t )
Remove the bol ts. then di sconnect the di scharge
l i ne
( A)
and t he condenser l i ne
( B)
f r om t he
condenser. Pl ug or cap the l i nes i mmedi atel y after
di sconnecti ng them to avoi d moi sture and dust
conr amt naI | on.
, - a.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ttl
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m, 7. 2 l bt . f t )
4.
21-50
5. Remove the bol ts and the upper mount brackets
(A),
then remove the condense.
(B)
by l i fti ng i t up. Be
careful not to damage the radi ator or the condenser
fi ns when removi ng the condenser.
s-------\
i B \
6 x 1 . 0 mm
9.8 N.m {1.0 kgt.m, 7.2l bf.ftl
Instal l the condensor i n the reverse order of
removal . and note these i tems:
.
l f you' re i nstal l i ng a new condenser, add
r ef r i ger ant oi l
( KEl Hl N
SP- 10)
( see page 2' 1- 6) .
.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them. Be sure to use the correct O-ri ngs
f or HFC- 134a
( R- 134a) t o
avoi d l eakage.
.
l mmedi atel y after usi ng the oi l , rei nstal l the cap
on the contai ner, and seal i t to avoi d moi sl ure
absorDti on,
.
Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the
pai nt. l f the refri gerant oi l
contacts the
pai nt, wash i t off i mmedi atel y.
.
Be careful not to damage the radi ator or the
condenser fi ns when i nstal l i ng the condenser.
.
Charge the system {see
page 21-53).
Refrigerant Recovery
Ai r condi ti oni ng refri gerant or l ubri cant vapor
can i rri tate your eyes, nose, or throat.
Be careful when connecti ng servi ce equi pment.
Do not breathe refri gerant or vapot.
Use onl y servi ce equi pment that i s U.L.-l i sted and i s
certi fi ed to meet the requi rements of SAE J2210 to
r emove HFC- 134a
( R- 134a) f r om
t he ai r condi t i oni ng
sysrem.
l f acci dental system di scharge occurs, venti l ate the
work area before resumi ng servi ce
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufacturers.
r.1i.,.',,,-':ir-- =,,'-
I
"l
i-.-':l::
.
1. Connect a R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh' pressure servi ce
port (B)
and the Iow-pressure servi ce port (C) (see
page 2' 1- 3) , as shown. f ol l owi ng t he equi pment
manufacturer' s i nstructi ons.
Measure the amount of refri gerant oi l removed
from the A,/C system after the recovery process i s
compl eted. Be sure to put the same amount of new
refri gerant oi l back i nto the A,/C system before
cnar gr ng.
21-51
Heati ng and Ai r Condi ti oni ng
(
(
System Evacuation
Use onl y ser vi ce equi pment t hat i s U. L. - l i st ed and i s
certi fi ed to meet the requi rements of SAE J2210 to
r emove HFC- 134a
( R- 134a)
f r om t he ai r condi t i oni ng
system.
l f acci dental system di scharge occurs. venti l ate the
work area before resumi ng servi ce
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufacturers.
1. When an 4!/C system has been opened to the
atmosphere, such as duri ng i nstal l ati on or repai r, i t
must be evacuated usi ng a R-]34a refri gerant
recovery/recycl i ng/chargi ng stati on
(l f
the system
has been open for several days, the recei ver/dryer
shoul d be repl aced, and the system shoul d be
evacuated for severai hours.
)
.
Ai r condi ti oni ng refri gerant or l ubri cant vapor
can i rri tate
your
eyes, nose, or throat.
'
Be careful when connecti ng servi ce equi pment.
'
Do not breathe refri gerant or vapor.
21-52
2. Connect a R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh-pressure servi ce
port (B)
and the l ow-pressure servi ce
port
{C)
(see
page 2l -3), as shown, fol l owi ng the equi pment
manufacturer' s i nstructi ons. Evacuate the svstem.
l f the l ow-Dressure does not reach more than 93.3
kPa
(700
mm Hg, 27.6 i n.Hg) i n 15 mi nutes, there i s
probabl y
a l eak i n the system. Parti al l y charge the
system, and check for l eaks
(see
step 3 on
page
21-
541.
,t:itt
.t,
l = = -
==;
i
i|]ll
Y
System Charging
Use onl y servi ce equi pment that i s U.L.-l i sted and i s
ceni fi ed to meet the requi rements of S AE J2210l o
remove HFC-134a
(R-134a)
from the ai r condi ti oni ng
system.
l f acci dental system di scharge occurs, venti l ate the
work area bel ore resumi ng servi ce.
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufactu rers.
1. Connect a R-' 134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh-pressure servi ce
port (B)
and the l ow-pressure servi ce port (C)
{see
page 21-3), as shown, fol l owi ng the equi pment
manuf acturer' s i nstructi ons.
at
.
Ai r condi ti oni ng refri gerant or l ubri cant vapor
can i rri tate your eyes, nose. or throat.
'
Be careful when connecti ng servi ce equi pment.
.
Do not breathe refri gerant or vapor.
I
1,7 ,,_,,
.,, -
,..
I
i =--' -' ==' -'
l
i ' r ; ; l
l ,
i l
lt ,.
itLillt
il
t
21-53
2. Evacuate the system
(see page
21-52).
3. Add the same amount of new refri gerant oi l to the
system that was removed duri ng recovery. Use
onl y KEIHIN SP-10 refri gerant oi l .
4. Charge the system wi th the speci fi ed amount of
R-134a refri gerant. Do not overcharge the system;
the compressor wi l l be damaged.
Sel ect the appropri ate uni ts of measure for you r
ref ri gerant chargi ng stati on.
Refrigerant capacity:
550 to 600
g
0.55 to 0.60 kg
1.2 to 1.3 l bs
19.4 to 21.2 oz
5. Check for refri gerant l eaks
(see page 21-54).
6. Check for system performance (see page 21-56).
Heati ng and Ai r Condi ti oni ng
Refrigerant Leak Test
Special Tool Required
Leak detector. Honda Tool and Equi pment YGK-H-10PM
commer ci al l y avai l abl e
Use onl y servi ce equi pment that i s U.L.-l i sted and i s
certi i fi ed to meet the requi rements of SAE J2210 to
r emove HFC- 134a
( R- 134a)
f r om t he ai r condi t i oni ng
system.
l f acci dental system di scharge occurs, venti l ate the
wor k ar ea bef or e r esumi ng ser vi ce.
R- 134a ser vi ce equi pment or vehi cl e ai r condi t i oni ng
systems shoul d not be pressure tested or l eak tested
wi th compressed ai r.
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufacturers.
.
Compressed ai r mi xed wi th R-134a forms a
combusti bl e vapor.
.
The vapor can bur n or expl ode causi ng ser i ous
i nj ur y.
.
Never use compressed ai r to pressure test
R- 134a ser vi ce equi pment or vehi cl e ai r
condi t i oni ng syst em.
.
Ai r condi t i oni ng r ef r i ger ant or l ubr i cant vapor
can i rri tate your eyes, nose, or throat.
'
Be careful when connecti ng servi ce equi pment.
.
Do not breathe refri gerant or vapor.
21-54
1. Connecta R-134a refri gerant recovery/recycl i ng/
chargi ng stati on
(A)
to the hi gh-pressure servi ce
port (B)
and the l ow-pressure servi ce
port (C) (see
page 21-3), as shown, fol l owi ng the equi pment
manufacturer' s i nstructi ons.
4.
5.
Open the hi gh pressure val ve to charge the system
to the speci fi ed capaci ty, then cl ose the suppl y
val ve, and remove the chargi ng system coupl ers.
Sel ect the appropri ate uni ts of measure for your
ref ri gerant chargi ng stati on.
Befrigerant capacity:
550 to 600
g
0.55 to 0.60 kg
1. 2 t o 1. 3 l bs
19.4 to 21.2 oz
Check the system for l eaks usi ng a R-134a
refri gerant l eak detector wi th an accu racy of 14 g
(0.5
oz)
per year or better.
l f you fi nd l eaks that requi re the system to be
opened
(to
repai r or repl ace hoses, fi tti ngs, etc.),
recover the system.
After checki ng and repai ri ng l eaks, evacuate the
system.
A/C System Tests
Pressure Test
Test results Related svmDtoms Probabls causo Remedv
Di scharge (hi gh)
pressure
abnormal l y hi gh
At t er st opprng compressor,
pressure
drops t o about 196 kPa
(2. 0
kgt / cm' , 28 psi l qui ckl y, and t hen
f al l s oradual l v.
Ai r i n syst em Hecover, evacuat e
(see page 2l -51),
and recharge wi t h speci f i ed amount
(see page 21-53).
Reduced or no ai r f l ow t hrough
conoenser
Cl ogged condenser or
radi at or f i ns
Condenser or radi at or f an not
worki no orooerl v
Cl ean
Check vol t age and f an rpm.
Check f an di rect i on.
Li ne t o condenser i s excessi vel y hot . Hest ri ct ed t l ow of rel ri gerant i n Rest ri ct ed l i nes
l Jrscharge
pressure
abnormal l y l ow
Hi gh and l ow pressures
are
bal anced soon af t er st oppi ng
compressor. Low si de i s hi gher t han
normal .
Faul t y compressor di scharge
Faul t y compressor seal
Repl ace t he compressor.
Out l et of expansi on val ve i s not
f rost ed, l ow-pressure gauge
i ndi cat es vacuum.
Faul t y expansron val ve
Moi st ure i n syst em
.
Repl ace
.
Recover, evacuate, and rechatge
wi t h soeci f i ed amount .
Suctron {l ow)
pressure
abnormal l y l ow
Expansi on val ve i s not f rost ed, and
l ow-oressure l i ne i s not col d. Low,
oressure oauoe i ndi cat es vacuum.
Frozen expansron val ve
(Moi sture
i n system)
Faul t v exoansi on val ve
.
Recover, evacuat e, and recharge
wi t h speci f ; ed amount .
.
Reol ace
Di scharge t emperat ure i s l ow, and
t he ai r f l ow f rom vent s i s rest ri ct ed.
l _rozen evaporat or Run t he f an wi t h compressor of f ,
t hen check evaporat or t emperat ure
sensor.
Expansi on val ve i s f rost ed Cl oqqed expansi on val ve Cl ean or repl ace.
Recei ver/ dryer out l et i s cool , and
i nl et i s warm
(shoul d
be warm
du. i nq oDerat i on)-
Cl ogged recei vet dryer Fl epl ace
Suctron pressure
abnormal l y hi gh
Low-pressure hose and check
I oi nt
are cool er t han t he t emperat ure
around evaoorat or.
t xpansron val ve open t oo l ong Repai r or repl ace.
Sucti on pressure i s l owered when
condenser i s cool ed bv water.
Excessi ve ret ri gerant i n syst em Recover, evacuat e, and recharge
wi t h soeci f i ed amount .
Hi gh and l ow-pressure are
equal i zed as soon as t he
compressor i s st opped, and bot h
oauoes f l uct uat e whi l e runni no.
Faul t y gasket
Faul t y hi gh-pressure val ve
Forei gn pani cl e
st uck i n hi gh-
HePl ace t he compressor.
Suct i on and
di scharge
pressures
abnormal l v hi oh
Reduced ai r f l ow t hrough
condenser,
Cl ogged condenser or
radi at or f i ns
Condenser or radi at or f an not
worki no orooerl v
ul ean
Check vol t age and f an rpm.
Check f an di rect i on.
Suct i on ancl
di scharge
pressure
abnormal l y l ow
Low-pressure hose and met al end
areas are cool er t han evaporat of .
Cl ogged or ki nked l ow-pressure
nose oans
Bepai r or repl ace.
Temperat ure around expansi on
val ve i s t oo l ow compared wi t h t hat
around recei ver/ rl rver
Cl ogged hi gh-pressure l i ne Heparr or repl ace.
Ref ri gerant l eaks ComDressor ci ut ch i s d i rt v. Compressor shaf t seal l eaki nq ReDl ace t he comDressor.
Compressor bol t (s) are di rt y. Leaki ng around bol t (s) I rght en bol t (s) or repl ace
comoressor.
ComDressor oasket i s wet wi t h oi l - Gasket l eaki nq Repl ace t he compressor.
Heati ng and Ai r Condi ti oni ng
{
{
a
A/C System Tests
(cont'dl
Performance Test
Ai r condi ti oni ng refri gerant or l ubri cant vapor
can i rri tate vour
eyes, nose, or throat.
Be car ef ul when connect i ng ser vi ce equi pment .
Do not breathe refri gerant or vapor.
The performance test wi l l hel p determi ne i f the ai r
condi ti oner system i s operati ng wi thi n speci fi cati ons.
Use onl y ser vi ce equi pment t hat i s U. L. - l i st ed and i s
certi fi ed to meet the requi rements of SAE J2210 to
r emove HFC 134a
( R- 134a) f r om
t he ai r condi t i oni ng
system.
l f acci dental system di scharge occurs, venti l ate the
work area before resumi ng servi ce.
R- ' 134a ser vi ce equi pment or vehi cl e ai r condi t i oni ng
systems shoul d not be pressure tested or l eak tested
wi th compressed ai r.
Addi ti onal heal th and safety i nformati on may be
obtai ned from the refri gerant and l ubri cant
manufacturers.
1. Connect a R 134a refri gerant recovery/recycl i ng/
chargi ng stati on to the hi gh-pressure servi ce port
and the l ow-pressure servi ce
port, fol l owi ng the
equi pment manuf act ur er ' s i nst r uct i ons.
2. Det er mi ne t he r el at i ve humi di t y and ai r
l em
peral Ure.
Compressed ai r mi xed wi th R-134a forms a
combusti bl e vapor.
The vapor can bur n or expl ode causi ng ser i ous
i nj ur y.
Never use compressed aar to pressure test
R- 134a ser vi ce equi pment or vehi cl e ai r
condi ti oni ng systems.
21-56
3.
4.
Remove the
passenger' s dashboard l ower cover
(see page 20-81).
l nsert a thermometer
(A)
i n the center vent, and
pl ace another thermometer {B)
near the bl ower uni t.
Test condi ti ons:
.
Avoi d di rect sunl i ght,
putthe top up.
.
Open the hood.
.
Open the front doors.
.
Set the temperature control di al on Max Cool , the
mode control di al on Vent, and the reci rcul ati on
control swi tch on Reci rcul ate.
.
Turn the A,/C swi tch on and the fan swi tch on Max.
.
Run t he engi ne at 1, 500 r pm.
.
No dri ver or passengers i n vehi cl e.
Af t er r unni ng t he ai r condi t i oni ng f or 10 mi nut es
under the above test condi ti ons, read the del i very
temperature from the thermometer i n the center
vent, the i ntake temperature near the bl ower uni t,
and the hi gh and l ow system
pressure from the A,/C
gauges.
5.
7. To compl ete the charts:
.
Markthe del i ve ry tem peratu re al ong the verti cal l i ne.
.
Mark the i ntake temperature
(ambi ent
ai r temperal ure) al ong the bottom l i ne.
.
Draw a l i ne strai ght up from the ai r temperature to the humi di ty.
.
Mar k a poi nt 10 % above and 10 % bel owt he humi di t y l evel .
.
From each poi nt,
draw a hori zontal l i ne across the del i very temperature.
.
The del i very temperature shoul d fal l between the two l i nes.
.
Compl ete the l ow-si de pressure
test and hi gh-si de pressure test i n the same way.
.
Any measurements outsi de the l i ne may i ndi cate the need for further i nspecti on.
(!rrl!m')
2900
-l
(301
|
ta3ol I
2500
{25)
t3601
980
n0l
{ t r ol
'190
ls) -
1 1 1
HUMIDITY
LEVEL
HUMIDITY
LEVEL
2000
t20l
I 2Bol
1500
(rs)
12101
(lpl/!m' )
t?,r
DELI VERY
fc)
86
t30)
400
Irl ,
l 57l
HUMIOIIY
IEVEL
OELIVERY
PRESSURE
300
( 31
l13l
200
\ 21
l2al
INTAKE
PRESSURE
95
{ 351
t0o
fii
INTAKE
PRESSURE
86
(30)
11
( 251
68
t20)
(40)
fc)
21-57
I
Body Electrical
Body El ectri cal
Gener al Tr oubi eshoot i ng
I nf or mat i on
Rel av and Control
Uri i t Locati ons ........
Connectors and
Harnesses
Fuse/Rel av Boxes .......
Power Di si ri buti on .....
Ground Di stri buti on ..
8at t er v . . . . . . . . . . . . . . . . . . . . . . . . .
Rel avs' . . . . . . . . . . . . . . . . . . . . . . . . . .
*l gni ti on
Swi tch
Test . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . - . . . - . .
*Gauges
Comoonent Locat i on I ndex . . . . . . . .
Gauge Bul b Repl acement . . . .
Ci rcui t Di agram
Gauge Assembl y
*Audi o
System
Component Locat i on I ndex . . . . . . . . 22-A7
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22' 88
Audi o Uni t Removal . . . . . . . . . . . . . 22 89
Audi o Uni t Connect or
Rep1acement . . . . . . . . . . . . . . . . . . . . . . 22-eg
Radi o Remot e Swi t chTest . . . 22-90
SpeakerRepl acement . . . . . . . . . . 22-91
Mast Ant enna
Rep1acement . . . . . . . . . . . . . . . . . . . . . . 22. 92
Accessory Power Socket
Componen! Location Index ........ 22-93
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22-94
Accessory Power Socket
TesVHepl acement . . . . . . . . . . . . . 22 95
Horn
Component Locat i on I ndex . . . . . . . .
Ci rcui t Di agram
HornTest . . . . . . . . . . -. . . . . . . . -. . . . . . . . . . .
Switch Test
Trunk Opener
Component Locat i on I ndex . . -. -. , .
Ci rcui t Di agram
Trunk Opener Switch Test ...
Trunk Opener Sol enoi d
Test . . . . . . -. -. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Mirrors
Component Locat i on I ndex . . . -. . . .
Ci rcui t Di agram
Function Test
Power Mi rror Swi t ch Test . . . .
Power Mi rror Act uat or
Test -. . . . . . . . -. . . . . . . -. , . . . , . , . . , , , . , . , . ,
Power Mirror Actuator
Repl acement
Wiper/Washer
Component Locat i on I ndex . . . . . . . .
Ci rcui t Di agram
Intermittent Wiper Control
Ci rcui t 1nput Test . . . . . . . . . . . . . . .
Wiper,A/Vasher Switch
TesVRepl acement . . . . . . . . . . . . .
Wi perMot orTest -. . . . . . -. . . . . . . . -.
Washer Mot or Test . . . . . . . . . . . . . . .
Washer Reservoi r
Bepl acement
Wi ndshi el d Wi per Mot or
Repl acement
Keyless/Power Door Locks
Component Locat i on I ndex . . . . . . . . 22 130
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-131
Keyless Door Lock Control
Uni t f nput Test . . . . . . . . . . . . . . . . . . . . . . 22-132
l gni t i on Key Swi t ch Test . . . . . . . 22-135
Driver's Door Lock Knob
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-136
Driver's Door Lock
Act uat orTest . . . . . . . . . . . . . . . . . . . . . 22-136
Passenger's Door Locl
Act uat or Test . . . . . . . . . . . . . . . . . . . . . 22-137
Dri ver' s Door Key Cyl i nder
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-131
Transmi t t er Test . . . . . . . . . . . . . . . . . . . . 22-138
Transmitter Proqrammina ... 22-138
onvertible Top
Component Location Index ........ 22-139
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-140
Syst em Desci pt i on . . . . . . . . . . . . . . . . 22-142
Convenible Top Switch
Te s t , . . . ,
22-52
22-52
22-53
. . 22-54
Troubl eshoot i ng . . . . . . . . . . . . . . . . 22-55
Cool ant Temperat ure Gauge
Ci rcui t Troubl eshoot i na . . . . 22-55
Li qhts-on, Kev-i n, Seat Bel t
Remi nder System
Ci rcui t Di a9ram . . . . . . . . . . . . . . . . . . . . . 22-56
Svst em l nput Test . . . . . . . . . . . . . . . . . 22-57
Exterior Lights
22-2
22-5
22-9
22-32
22-35
22-38
22-39
22-40
22-43
22-44
22 46
22 41
Bepl acement
VSS Repl acement . . . . . . . . . . -. . . . . .
VSS Ci rcui t
Troubl eshoot i ng . . . . . . . . . . . . . . -.
Mai nt enance Requi red
I ndacat or Beset Procedure
Tachomet er Ci rcui t
22-96
22-91
22 91
22-9a
22 99
22-100
22 101
22. 101
22. 102
22-103
22 104
22-105
22 105
22-106
22 101
22-108
22-110
22111
22-1t2
22- 112
22-114
22-115
22-1t 6
22- 117
22-119
22-120
22 121
22-122
22-123
22 124
22-125
22 124
22-129
22 129
22-143
Convrtible Top Control
Uni t l nput Test . . . . . . . . . . . . . . . . . . . 22-144
Convertible Top Motor
J
Test 22-141
Removabl e Hardtop
Component Locat i on I ndex . . . . . . . . 22' 1 49
Convert i bl e Top Di sabl e
Swi t chTest . . . . . . . . . . . . . . . . . . . . . . . . 22-150
Rear Window Defogger
Component Location Index ........ 22'151
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . 22-153
Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-155
Funct aonTest . . . . . . . . . . . . . . . . . . . . . . . . . 22-156
Def ogger Wi re Repai r . . . . . . . . . . . 22-157
Component Locat i on I ndex . - . . . . . .
Ci r cui t Di agr am
Br ake Li ght s
Ci r cui t Di a9r am . . . . . . . . . . . . . . . . .
Back- up Li ght s Ci r cui t
Di a9r am . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combi nat i on Li ght Swi t ch
TesVRepl acement . . . . . . - . . . . . .
DRL Cont r ol Uni t
I nput Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . .
HI D Lamp Syst em
Tf oubl eshoot i ng . . . . . . . . . . . . . . . .
HI D Bul b Remov al . . . . . . . . . . . . . . . .
Headl i ght Repl acement . . . . . . . .
Headl i ght Adj ust ment . . . . . . . . . .
Si de Tur n Si gnal Li ght
Repl acement
Tai l l i ght Repl acement . . . . . . . . . . .
Hi gh Mount Br ake L, ght
Repl acement
Li cense Pl at e Li ght
Repl acement
Turn Si qnal /Hazard
Fl ash6r System
Component Local i on I ndex . . . . . . . .
Ci rcui t Di agram
Turn Si gnal / Hazard Rel ay
I nput Test . . . . . . . . . . . . . . . . . . . _. _. _. . .
Hazard Warni ng Swi t ch
Test . . . . . , . . . , . , , , - , . . . _. . . . . . . . . . . . . . . ,
Interior Lights
Component Locat i on I ndex , , , , , . . .
Ci rcui t Di agram
Cei l i n9/ Spot l i ght s Test . . . . -. . . .
Trunk Li ght Test
Trunk Lid Latch Switch Test .
Dash Li qhts Bri qhtness
Contr-oller
Ci rcui t Di agram
Cont rol l er I nput Test . . . . . . . . . . . . .
Repl acement
mmobi l i zer System
Component Locat i on I ndex . , . , . . -.
Syst em Descri pt i on . . . . . . . . . . . . . .
Ci rcui t Di agram
Troubl eshoot i ng
l mmobi l i zer Recei ver Uni t
PowiiiWinilb-i
Component Locat i on I ndex . . . . . . . .
Ci rcui t Di agram
l Mast er Swi t ch Test . . . . . . . . -. . . . . .
Mast er Swi t ch
I nput Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger's Window Switch
T6 d / e a ^ l 2 . a mo n r
Dri ver' s Wi ndow
Mot or Test . . . . . . . . . . . . . . . -. . . . . . -. . .
Passenger's Window Motor
22-59
22-61
22 64
22-64
22 65
22-66
22-64
22 69
22 t 1
22 t 2
22 14
22-7 4
2 2 1 5
22-16
2 2 1 1
2 2 1 4
2 2 1 9
22 80
22-81
22 82
22 A3
22-83
22-84
22-45
J
Test
Body Electrical
(
{
{
General Troubleshooting Information
Tips and Precautions
Betore Troubleshootin g
1. Check appl i cabl e fuses i n the appropri ate fuse/rel ay
box.
2. Check the bal tery for damage, state of charge, and
cl ean and ti ght connecti ons.
.
Do not qui ck-charge
a battery unl ess the battery
ground
cabl e has been di sconnected, otherwi se
you wi l l damage the al ternator di odes.
.
Do not attempt to crank the engi ne wi th the
battery ground cabl e l oosel y connected or you
wi l l sever el y damage t he wi r i ng.
3. Check the al ternator-comDressor bel t tensi on.
Handling Connectors
.
Make sure the connectors are cl ean and have no
l oose wi re termi nal s,
.
Make sure mul ti pl e cavi ty connectors are packed wi th
di el ectri c
grease (except
waterti ght connectors).
.
Al l connectors have push-down rel ease type l ocks
(A).
22-2
.
Some connectors have a cl i p on thei r si de used to
attach l hem to a mount bracket dn the body or on
another component. Thi s cl i p has a
pul l type l ock.
.
Some mounted connectors cannot be di sconnected
unl ess you fi rst rel ease the l ock and remove the
connector from i ts mount bracket
(A).
Never try to di sconnect connectors by
pul l i ng on thei r
wi res; pul l on the connecl or hal ves i nstead.
Al ways rei nstal l
pl asti c
covers.
Before connecti ng connectors, make sure the
termi nal s
(A)
are i n
pl ace
and not bent.
J
Check for l oose retai ner
(A)
and rubber seal s
(B).
The backs of some connectors are
packed
wi l h
di el ectri c grease.
Add grease i f necessary. l f the
grease
i s contami nated, repl ace i t.
(P/N
08798-90011
Insert the connector al l the way and make sure i t i s
securel y l ocked.
Posi ti on wi res so thal the open end of the cover faces
down.
Handling Wires and Harnesses
.
Secure wi res and wi re harnesses to the frame wi th
thei r respecti ve wi re ti es at the desi gnated l ocati ons.
.
Remove cl i ps careful l y; don' t damage thei r l ocks
(A).
Sl i p pl i er s ( A)
under t he cl i p base and t hr ough t he
hol e at an angl e, then squeeze the expansi on tabs to
rel ease the cl i o.
After i nstal l i ng harness cl i ps, make sure the harness
doesn' t i nterfere wi th any movi ng parts,
Keep wi re harnesses away from exhaust pi pes
and
other hot parts.
from sharp edges of brackets and
hol es, and from exposed screws and bol ts.
Seat grommets
i n thei r grooves properl y (A).
Do not
l eave grommets
di storted
(B).
-W
R
I t
(cont' d)
l / o
) t /
r1J \ t/
5E;j=-
't
t,
I
22-3
Body Electrical
(
{
General Troubleshooting
lnformation
(cont'dl
Testing and Repairs
.
Do not use wi res or harnesses wi th broken i nsul ati on.
Repl ace them or repai r them by wrappi ng the break
wi th el ectri cal tape.
.
After i nstal l i ng
parts, make sure that no wi res are
pi nched under them.
.
When usi ng el ectri cal test equi pment, fol l ow the
manufacturer' s i nstructi ons and those descri bed i n
t hi s manual .
.
l f
possi bl e,
i nsertthe
probe
of the testerfrom thewi re
si de
(except
waterproo{ connector).
22-4
Use back
probe adaptor 07TAz-0010204
Refer to the i nstructi ons i n the Honda Termi nal Ki t for
i denti fi cati on and repl acement of connector termi nal s.
Five-step Troubleshooting
1. Veri fy The Compl ai nt
Turn on al l the components i n the probl em
ci rcui t
to veri fy the customer compl ai nt. Note the
symptoms. Do not begi n di sassembl y or testi ng
unti l you have narrowed down the
probl em
area.
2. Anal yze The Schemati c
Look up the schemati c for the
probl em
ci rcui t.
Determi ne how the ci rcui t i s supposed to work by
traci ng the current paths
from the
power
feed
through the ci rcui t components to ground.
l f
several ci rcui ts fai l at the same ti me, the fuse or
ground i s a l i kel y cause,
Based on the symptoms and your
understandi ng of
the ci rcui t operati on, i denti fy one or more possi bl e
causes of the probl em.
3. l sol ate The Probl em By Testi ng The Ci rcui t
Make ci rcui t tests to check the di agnosi s you made
i n step 2. Keep i n mi nd that a l ogi cal , si mp,e
procedure
i s the key to effi ci ent troubl eshooti ng.
Test for the most l i kel y cause oI Iai l ure fi rst. Try to
make tests at poi nts
l hat are easi l y accessi bl e.
4. Fi x The Probl em
Once the speci fi c probl em
i s i denti fi ed, make the
repai r. Be sure to use
proper
tool s and safe
procedures.
5. Make Sure The Ci rcui t Works
Turn on al l components i n the repai red ci rcui t i n al l
modes to make sure you' ve
fi xed the enti re
probl em.
l fthe probl em
was a bl own fuse, be sure
to test al l of the ci rcui ts on the fuse. Make sure no
new probl ems
turn up and the ori gi nal probl em
does not recur,
Wire Color Codes
The fol l owi ng abbrevi ati ons are used to i denti fy wi re
col ors i n the ci rcui t schemati cs:
WHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wnr r e
YE1. . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . Yel l ow
B1K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ack
B1U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ue
GRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr een
RED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
ORN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Or ange
PNK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pi nk
BRN. . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br own
GRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ay
PUR. . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . Pur pl e
1T81U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Li ght Bt ue
1TGRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ll ght Gr een
The wi re i nsul ati on has one col or or one col or wi th
another col or stri pe. The second col or i s the stri pe.
WHT IBLK
22-5
Relay and Control Unit Locations
{
a
ABS MODULATON UNIT
Engine Gompartment
EPS CONTROL UNIT
MAIN UNDER.HOOD
FUSE/RELAY BOX
INTERMITTENT WIPER RELAY
{'02-03 models)
AUXILIARY
UNDER-HOOD FUSE BOX
AIR PUMP RELAY
BLOWER MOTOR RELAY
CONDENSER FAN RELAY
RADIATOR
FAN RELAY
A/C COMPRESSOR
CLUTCH RELAY
22-6
HORN RELAY
ELD UNIT
a
Dashboard
l{lGH BEAM CUT RELAY lcanadal
f
Wi re col ors: RED/ BLU, ORN, I
LBLU
and BLU/ RED
I
INTERMITTENT WIPER RELAY
{'00-01 modelsl
I Wi re
col ors: GRN/ REO, CAru, I
L
GRN/ BLK, BLK and BLUAr' YHT
. l
REAR wlNDOW DEFOGGER RELAY
{'02-03 modelsl
f
Wi re col ors: WHT/GBN, ELIVRED,
L
YEVBLU, and YEUBLK
DOOR LOCK CONTROL UNIT
CRUI SE CONTROL UNI T
/
ECM
UNDER.DASH FUSE/RELAY BOX
TURN SIGNAL/HAZARD RELAY
f
Wi re col ors: BLK,/RED, cBN/WHLI
I and BLK I
TAILLIGHT RELAY
l Wi re
col ors: RED/BLK, WHT/GRNI
LWHT/GRN
and BLU
J
REAR WINDOW DEFOGGER RELAY
lwith hardtopl
{'00-01 modelsl
ZTN
7=<
\ l
3 q
)_)
7t
'
-
--
: :
---
L-l
L_l
tr-
S
L I
-:l
L I
-
I
-
- -
f
Wi re col orsr BLVBED, WHT/GRN,
I
LYEUBLK
and BLK,/YEL
J
22-7
Relay and Control Unit Locations
Dashboard and Door
IG2 RELAY
fwi re
col ors: BLK/RED,
I
LLT
BLU, BLUAVHT and YEL
I
POWER SOCKET RELAY
Wi re col orsr WHT/RED,
LT BLU, YEURED and BLU,lwHT
POWER WINDOW
MASTER SWITCH
(Has
bui l t -i n cont rol uni t )
OAYTIME RUNNING LIGHTS
CONTROL UNIT
(Canadal
CONVERTIBLE TOP
CONTROL UNIT
REAR WINDOW DEFOGGER
CHANGE RELAY f02-03 models)
IWi re col ors: BLVRED, BRN,
1
L
LT GRNAVHT, BLK/^/EL and BLK
I
22-8
Connectors and Harnesses
Connector Index
Tl , T6 end
(+
)
( see pag6 22 14)
C204, C303 and C402
t hrough C404, C451
C501 t hrough C504
.
2: ' 02-03 model s
22-9
Gonnectors and Harnesses
Connestor to Harness Index
EPS Subharness
22-10
Connector or Terminal Cavities Location Connects to Notes
EPS cont rol uni t connect or C 2
I
2
2
Ri ght si de oI engi ne companment
Left side of engine compartment Lef t engi ne compart ment wi re
harness
(see
oaoe 22-16)
T1
T6
l
7
Ri ght si de of engi ne companment
Lef t si de o{ engi ne compart ment
Mai n under hood f use/ r el ay
Auxi l i ar y undeFhood f use
G351
3 Ri ght si de of engi ne compart ment Body ground vi a EPS
suDnarness
8afterv Batterv oositive terminal
Battery Ground Cable
Connector or Terminal Cavities Location Connects lo Notes
4 Ri ght si de o{ engi ne compar t ment Body ground via battery
Batterv Batterv neqative terminal
Starter Cable
Connector or Trminal Ret Cavities Location Connects to Nols
r2
T3
n
I
1 l
6
Lef t si de of engi ne compart ment
Lef t si de of engi ne compart ment
Left side ot engine compartment
St aner mot or
Engi ne bl ock
Auxi l i ary under-hood f use
Left side ot enqine compartment Bodv
qr ound
vi a st ar t er cabl e
Engi ne Ground Cabl e
Connector orTorminal Cavities Location ;onnecls to Notes
'10
Let t si de of enqi ne compart ment Enqi ne block
12 Rear beam Rear beam
ground vi a engi ne
oround cabl e
EPS Gearbox Ground Cabl e
Conncto. or Terminal Cavities Location ;onnects to Notes
14
Lef t si de of enqi ne compart ment EPS
qear
G4
1 4 Front beam Front beam vi a EPS gearbox
oround cabl e
BATTERY GROUND CABLE
a
EPS SUBHARNESS
STARTER CABLE
(+t
EPS GEARBOX
GROUND CABLE
ENGI NE GROUND CABLE
22-11
Gonnectors and Harnesses
(
Connector to Harness Index
(cont'dl
Engine Wire Harness
Connector or Terminal C.vitie3 Location Connecis to Notes
IVC compressor clutch
Al t ernat or
Back-up l i ght swi t ch
CKP sensor
CMP {TDC) sensor A
CMP {TDC) sensor B
ECM connector B
ECM connect or C
Engi ne cool ant t emperat ure
(ECT)
sensor
l dl e ai r cont rol {l AC) val ve
Intake airtemperature
(lAl
sensor
Knock sensor
Map sensor
No. 1 i gni t i on coi l
No. 2 i gni t i on coi l
No. 3 i gni t i on coi l
No. 4 i gni t i on coi l
No. 1 injector
No. 2 i nj ect or
No. 3 i nj ect or
No. 4 i nj ect or
Primary heated oxygen sensor
t PHO2S)
Seconda.y heated oxygen sensor
(sHo2s)
Staner solenoid
Throftle position
1TP) sensor
Vehi cl e speed sensor
(VSS)
VTEC oil pressure switch
VTEC sol enoi d val ve
cr 01
C102 {Junction connector)
C103
(Connect
t o C104)
c104 {connect t o c103}
1 1
6
34
20
28
24
3
5
7
32
30
33
22
I
1 0
29
1 2
2
36
1 4
1 8
19
17
1
2
3
2
2
2
3
2
1
3
3
3
3
2
2
2
2
4
4
1
3
3
2
1
1 6
20
2
2
Left side ofengine compartment
Lef t si de of engi ne compart ment
Mi ddl e of t ransmi ssi on
N, l i ddl e of engi ne
Mi ddl e oI engi ne
Ri ght si de of engi ne compart ment
Behi nd l ef t ki ck panel
Behind left kick panel
Mi ddl e oI engi ne
Left side ofengine compartment
Lef t si de of engi ne compart ment
Mi ddl eof engi ne
Lef t si de of engi ne compart ment
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
N4i ddl e of engi ne
Mi ddl e of t ransmi ssi on
Mi ddl e ot t ransmi ssi on
Left side ol engine companment
Left side ofengine compartment
Mi ddl e ot t ransmi ssi on
Ri ght si de of engi ne compart ment
Ri ght si de of engi ne companment
Behi nd l ef t ki ck panel
Eehi nd l ef t ki ck panel
Behi nd l ef t ki ck panel
Behi nd l ef t ki ct oanel
Dashboard wi re harness A
lsee
page 22-22)
T10t
r102
T103
1 Main under-hood fuse/relay box
Alternator
Fndi ne ni l nr c. cr r r p
qwi t
h
G 10'1 8 Maddl e of engi ne Engi ne ground vi a engi ne
22-12
a
mff
\ -1. . . --
' 16
1 7
1 8
ENGINE WIRE HARNESS
22-13
Gonnectors and Harnesses
4
(
{
Connector to Harness Index
(cont'dl
Bight Engine Compartment Wire Harness
Connector or Terminal Ret Cavitie3 Location
Connects to Notes
ABS ri ght f ront wheel sensor
Ay'C pressure switch
Condenser f an mot or
ELD uni t l see
page 22-321
EPS cont rol uni t connect or A
EPS cont rol uni t connect or I
EPS t orque sensor
EPS mot or
Horn
(l ow)
Horn
(hi gh)
Mai n underhood f use/ rel ay box
connector A
(see page 22-32)
Mai n under' hood {use/ rel ay box
connector B
(see page 22-32)
Mai n unde. hood f use/ rel ay box
connect or C
(see page 22-32)
Mai n unde. hood f use/ rel ay box
connect or D
(see page 22-32)
Radi at or f an mot or
Ri ght f ront parki ng l i ght
Ri ght f ront t urn si gnal l i ght
Ri ght headl i ght
(hi gh
beam)
Bi ght headl i ght
(l ow
beam)
Ri ght si de t urn si gnal l i ght
Wi ndshi el d washer mot or
c201
c202
c203
c204
1 0
1
1 4
2
5
23
22
6
' l l
1 2
8
I
1 7
20
21
24
1 9
1 8
2
2
2
3
2
1 4
3
2
1
1
1 8
7
3
1 6
2
2
2
3
2
2
2
6
7
' 18
Ri ght si de of engi ne compart ment
Mi ddl e of engi ne companment
Left side of engine compartment
Underhood f use/ rel ay box
Ri ght si de of engi ne companment
Ri ght si de of engi ne companment
Left side of engine compartment
Lef t si de of engi ne companment
Mi ddl e of engi ne compart ment
Bi ght si de of engi ne compart ment
Ri ght si de of engi ne compart ment
Ri ght si de of engi ne compart ment
Ri ght si de of engi ne compart ment
Ri ght si de of engi ne compart ment
Bi ght si de of engi ne compart ment
Behi nd ri ght headl i ght
Behi nd ri ght headl i ght
Behi nd ri ght headl i ght
Behi nd ri ght headl i ght
Ri ght si de of engi ne compart ment
Ri ght si de ol engi ne compart ment
Behi nd ri ght si de ot dash
Behi nd ri ght si de of dash
Behi nd ri ght si de of dash
Behi nd ri ght si de of dash
Dashboard wi re harness B
(see page 22-18)
Dashboard wi re harness B
(see page 22' 18)
Dashboard wi re harness B
(see page 22-18)
Dashboard wi re harness A
tsee naoe 22-22)
'02-03
mooers
G201
7 Ri ght si de of engi ne compar t ment Body ground vi a ri ght
engi ne companment wi re
22-14
ENGINE COMPARTMENT
WIRE HARNESS
22-15
Connectors and Harnesses
Connector to Harness Index
(cont'd)
Left Engine Compartment Wire Haness
Connec-tor or Terminal Cavities Location Connects to Notes
ABS left front wheel sensor
ABS modul at or uni t
Ai r
pump
el ect ri c current sensor
Ai r pump el ect ri c current sensor
connector B
Ai r pump
Ai r pump rel ay connect orA
Ai r pump rel ay connect or B
Auxi l i ary under' hood f use box
connect or A
(see page 22-34)
Auxi l i ary underhood f use box
connect or B {see
page 22-34)
Brake f l ui d l evel swi t ch
cruise control actuator
EVAP cani st er purge val ve
I nt ermi t t ent wi per rel ay
Left tront parking light
Lef t f ront t urn si gnal l i ght
Lef t headl i ght
(hi gh
beam)
Lef t headl i ght l l ow beam)
Lef t si de t urn si gnal l i ght
Radiator fan switch
Secondary air control valve vacuum
cont rol sol enoi d val ve
Test t achomet er connect or
Wi ndshi el d wi per mot or
c30'!
c302
c303
c35r
1 0
26
' 14
1 5
5
7
4
24
1 2
' 19
2A
2 7
1 7
9
1 1
6
8
1
29
1 8
23
20
22
2 1
2
25
2
3
2
2
2
2
3
2
4
2
6
2
2
3
2
2
2
2
2
5
1 4
1 4
2
Left side ol engine compaftment
Left side ofengine compartment
Left side of engine compartment
Let t si de of engi ne companment
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Auxi l i ary under-hood f use box
Auxiliary under-hood fuse box
Left side of engine compartment
LeIt side oI engine compartment
Left side oI engine compartment
Left side of engine compartment
Behi nd l ef t headl i ght
Eehi nd l ef t headl i ght
Eehi nd l ef t headl i ght
Behi nd l ef t headl i ght
Lef t si de of engi ne companment
Lef t si de of engi ne companment
Left side of engine compartment
Left side of engine compartment
Left side ol engine compartment
Under left side ol dash
Under left side of dash
tJnder left side of dash
Left side of engine compartment
Dashboard wire harness B
(see page 22-18)
Dashboard wi re harness B
{see
page 22-18)
Dashboard wi re harness A
\see
page 22 221
EPS subharness {see
page
,2-1.)\
'02-03
G301
G302
G303
2 Left side ofengine compartment
Left side ofengine compartment
Left side of engine compartment
Eody ground vi a l ef t engi ne
compart ment wrre harness
Eody ground vi a l ef t engi ne
compart ment wi re harness
Body ground vi a l ef t engi ne
. ^mn. r t mpnt wi r p hr r ness
22-16
LEFT ENGINE COMPARTMENT
WIRE HARNESS
26 25
24
'17
' 1 6
t 5
'ftt|--'-'
r'1;i$
/i';
"t;
-r.,ffi-...'
22-17
Gonnectors and Harnesses
Connector to Harness Index
(cont'd)
Dashboard Wire Harness B
(Left
branch)
Connector or Terminal Ret Cavities Location Connec't3 to Notes
Brake pedal position
switch
Cabl e reel
Clutch
pedal position switch
Clutch interlock switch
Combi nat i on l i ght swi t ch
Cruise control unit
Hi gh beam cut rel ay
lgnition key switch
Intermittenl wiper relay
l mmobi l i zer recei ver uni t
Rear wi ndow del ogger rel ay
Wi ndshi el d wi per/ washer swi t ch
c301
c302
c401
c402
c402
c403
c404
t 8
8
1 0
' t 1
I
6
3
1
2
7
l
1 1
4
1 4
5
5
1 4
't4
2
2
' 14
1
4
6
1 6
24
Under left side of dash
Under left side of dash
L, nder l et t si de of dash
Under l ef t si de of dash
Under left side of dash
Under left side ol dash
Under left side of dash
Under l ef t si de of dash
Under l ef t si de ot dash
Under left side of dash
Under l ef t si de oI dash
Under left side of dash
Under left side of dash
Under left side of dash
Behind left kick panel
Under left side ol dash
Under left side of dash
Under l ef t si de of dash
Under left side oI dash
Left engine compa.tment wire
harness
(see page 22-16)
Left engine compartment wire
harness
(see page 22-16)
Rearwi re harness
(see page
22-24')
Dashboard wire harness A
lsee
page 22-22)
Dashboard wi re harness A
lsee
page 22-221
Dashboard wi re harness A
\see
page 22-221
Dashboard wi re harness A
lsee oeoe 22-22\
Canada
'00-0'1
model s
'02-03
mooet s
'00,01
mooers
'02-03
G401 5 Under left side oI dash Body ground vi a dashboard
wire harness B
22-18
't',
1?
13 14 15
( Cont i nues
t o r i ght br anch)
UNDER. DASH
FUSE/ RELAY
DASHBOARO WI RE
HARNESS B
BOX
4
( cont ' d
)
22-19
Connectors and Harnesses
{
a
a
Connector to Harness Index
{cont'dl
Dashboard Wire Harness B
(Right
branch)
Connector orTorminal Cavitios Location Connects to Notes
Accessory power socket relay
Ai r mi x cont rol mot or
Blower motor
Convert i bl e t op mot or emergency
Convert i bl e t op mot or emergency
connector B
Convertible top control unit connector
Convertible top switch
Daytime running lights control unit
Dat a l i nk connect or l DLC)
Dat a l i nk connect or
(DLC)
Di ode l DFL)
Evaporat or t emperat ure sensor
Hazard warni ng swi t ch
l G 2 rel ay
Mode control motor
Parking brake switch
PGM-Fl mai n rel ay
Rear window de{ogger switch
Recirculation control motor
c201
c202
c203
c451
c4s2
2
8
1 2
20
1 1
5
7
26
I
23
I
6
22
3
1 0
24
2 1
1 4
1 6
1a
5
7
2
2
2
1 4
6
1 4
2
2
1 0
5
7
1
7
5
5
7
6
'7
2
Under mi ddl e of dash
Under mi ddl e of dash
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Middle of floor between seats
Under mi ddl e of dash
Under mi ddl e of dash
Under mi ddl e of dash
Under mi ddl e of dash
Under ri ght si de ot dash
Mi ddl e of f l oor bet l veen seat s
Under mi ddl e of dash
Under mi ddl e of dash
Middle of floor between seats
Under mi ddl e of dash
Under ri ght si de of dash
lvliddle ot floor betlveen seats
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Under ri ght si de of dash
Ri ght engi ne compart ment
wi re harness
(see page 22' 14)
Ri ght engi ne companment
wi re harness
(see page 22 14)
Fi ght engi ne compart ment
wi re harness l see
page 22-14)
Dashboard wi re harness A
lsee
page 22-221
Roof wi re harness
(see page
22-26)
Canada
'00-01
model s
'02-03
Canada
Har dt oP
i
G402 1 7 Body gr ound vi a dashboar d
\
22-20
3
(Cont i nues
t o l ef t branch) 10
11 12
13
1 4
1 5
DASHBOARD WIRE HARNESS B
22-21
Connectors and Harnesses
a
a
Connector to Harness Index
(cont'd)
Dashboard Wire Harness A
Conn6ctor or Teraninal Cavitie3 Location Connectsto Notes
Antenna ampl i fi er
Audi o uni t
Convertible top control unit connector
Cruise control main switch
ECM connector A
Engine start switch
Gauge assembl y connector A
Gauge assembl y connector B
Gauge assembl y connector C
Gauge assembl y connector o
Heater control
panel
Keyless door lock control unit
Radio remote switch
Rear wi ndow defogger swi tch
c 101
c204
c303
c402
c402
c403
c404
c451
c501
c501
c502
c503
c504
1 1
1 8
I
1
1 4
1 2
1 1
5
6
22
3
20
24
24
1 0
1 9
I
1
2
2 1
2
20
1 0
6
5
1 4
1 2
20
30
1 8
6
6
1 8
1 4
6
24
1 4
1 8
3
1 4
Behi nd audi o uni t
Behi nd audi o uni t
Under ri ght si de of dash
Under l ef t si de of dash
Behi nd l ef t ki ck panel
Under l ef t si de of dash
Behi nd gauge assembl y
Behi nd gauge assembl y
Behi nd gauge assembl y
Behi nd gauge assembl y
Under mi ddl e of dash
Under l ef t si de of dash
Under l ef t si de of dash
Under mi ddl e of dash
Behi nd l ef t ki ck panel
Under l ef t si de of dash
Under l ef t si de of dash
Under left side of dash
Under l ef t si de of dash
Under left side of dash
Under left side of dash
Under ri ght si de of dash
Behi nd l ef t ki ck panel
Behi nd l ef t ki ck panel
Behi nd l ef t ki ck panel
Under l ef t si de of dash
Behi nd ri ght ki ck panel
Engi ne wi re harness
(see
page 22 12]'
Ri ght engi ne companment
wi re harness {see
page 22 14)
Left engine compartment wire
harness
(see page 22-' 16)
Dashboard wi re harness I
l see
page 22-18)
Dashboard wi re harness B
l see
page 22-18)
Dashboard wi re harness I
{see
page
22-18)
Dashboard wi re harness B
l see
page 22-18)
Dashboard wi re harness B
{see
page 22-18)
Rearwi re harness
(see page
22-24')
Rear wi re harness
(see page
22-24)
Dri ver' s door wi re harness
{see
page 22-28)
SRS mai n harness {see
page
22-27)
Passenger' s door wi re
harness i see oaoe 22-29)
'02-03
' 00
01
mooet s
'02-03
'00-01
model s
'02
03
G50l 26 Body gr ound vi a dashboar d
Body gr ound vi a dashboar d
22-22
a
o
1 o
8 i \
1 1 1 2 1 3
1 4
OASHBOARD WI RE HABNESS A
22-23
Gonnectors and Harnesses
Connector to Harness Index
(cont'd)
Rear Wire Harness {Left blanch)
Connector orTrminal Cevitios Locetion Connocts to Notes
ABS left rearwheel sensor
Condenser
Di ode
Driver's door switch
Driver's seat belt switch
EVAP bypass solenoid valve
EVAP control canister vent shut valve
Fuel
pump/ f uel gauge
sendi ng uni t
Fuel t ank pressure sensor
Hi gh mount brake l i ght
Left convertible top motor
Left back-up light
Left brake/taillight
Left rear side marker light
Lef t reart urn si gnal l i ght
Rear wi ndow def ogger
change relay
Trunk l i ght
Trunk opener swi t ch
Trunk opener sol enoi d/ l at ch swi t ch
c40l
cs01
c501
c601
c602
1
1 1
3
9
1 0
23
8
20
5
'17
1 6
1 8
24
1 9
1
2
2
1 4
2
2
2
I
2
2
2
5
3
2
2
2
3
2
2
2
2
3
22
1 2
2
1 4
Left side oltrunk
Left side oltrunk
Behind left corner gusset
Under driver's seat
Left side of underfloor
Lef t si de of underl l oor
Mi ddl e of t uel t ank
Left side ot undertloor
Mi ddl e of t runk l i d
Behind left corner gusset
Behi nd i ef t t ai l l i ght assembl y
Behi nd l ef t l ai l l i ght assembl y
Eehi nd l ef t t ai l l i ght assembl y
Behi nd l ef t t ai l l i ght assembl y
Lef t si de of t runk
Mi ddl e of t runk
Behind rear console between seat-
back
Mi ddl e of t runk l i d
Behind left kick panel
Behi nd l ef t ki ck panel
Eehind left kick panel
Left side oftrunk
Left side oftrunk
Dashboard wi re harness B
(see page 22-18)
Dashboard wi re harness A
lsee
page 22-22)
Dashboard wi re harness A
Hardtop subharness
(see
page 22-30l,
Rearwi ndow def ogger
sr bhar ness l sce nadc 22- 31)
'02,03
mooels
'02-03
model s
' 02-03
mooet s
'00-01
mooet s
'02-03
mooels
Hardtop
'02-03
G601 Body g. ound vi a rear wi re
22-24
(Cont i nues
t o ri ght branch)
( Cont i nues
t o r i ght br anch )
(cont' d)
22-25
Gonnectors and Harnesses
Connector to Harness Index
(cont'd)
Rear Wire Harness
(Right
branch)
Connector or Terminal Cavities Location Connects to Notes
ABS right rear whee, sensor
Accessory power socket
Li cense
pl at e l i ght
Passenger' s door swi t ch
Ri ght conveni bl e t op mot or
Ri ght back up l i ght
Ri ght brake/ t ai l l i ght
Ri ght rear si de marker l i ght
Ri oht rear t urn si onal l i oht
4
3
I
1
2
7
6
5
a
2
2
2
1
2
2
3
2
,
Bj ght si de of t runk
Behi nd rear consol e bet l veen seat -
Behi nd rear bumper
Behi nd ri ght corner
gusset
Eehind right corner gusset
Behi nd ri ght t ai l l i ghr
Behi nd ri ght t ai l l i ght
Behi nd ri ght t ai l l i ght
achi nrl ri oh ai l l i ohr
G602 10 Body ground vi a rear wi re
Roof Wire Harness
Connector or TeIminal Cavities Location Connects to Notes
Cei l i ng/ sopt l i ght s
c452
1
2
4
2
Roof area
L, nder ri ght si de of dash Dashboard wi re harness B
i see oaoe 22-18)
(Cont i nues
t o l ef t branch)
REAR WIRE HARNESS
(Cont i nues t o l ef t branch)
WIRE HARNESS
22-26
REAR WIRE HARNESS
SRS Main Hamess
Connector or Terminal C.vitie3 Location Connects to Notes
Cable reel
Driver's seat belt tensioner
Memory erase si gnal
(MES)
connect or
Passenger's airbag inflator
Passenger's seat belt tensioner
Under-dash fuse/relay box connector
A
(see page 22-33)
c503
5
9
'l
7
8
6
2
4
2
2
2
2
2
1 8
2
3
Under l ef t si de ot dash
Behi nd dri ver' s seat -back
Under-dash f use/ rel ay box
Undr ri ght si de of dash
Behind passenger's
seat-back
Mi ddl e of f l oor
Under-dash l use/ rel ay box
Under l ef t si de ot dash Dashboard wi re harness A
G801 10 Middle of floor Body ground vi a SRS mai n
lgnition Switch Lead
Connctor or Terminel Cavitie3 Location
Conn6cts to
Under dash fuse/relay box connector
B l see oaoe 22-33)
3 7 L.Jnder left side of dash
SRS MAI N HARNESS
UNDER.DASH
FUSE/RELAY BOX
N\
it
'
"-
IGNITION SWITCH LEAD
22-27
Gonnectors and Harnesses
Connector to Harness Index
(cont'd)
Driver's Door Wire Harness
Connector or Terminal Cavities Locltion Connocts to Notos
Dri ver' s door key cyl i nder swi t ch
Dri ver' s door l ock act uat or
Dri ver' s door l ock knob swi t ch
Dri ver' s door speaker
Dri ver' s wi ndow mot or
Left power mirror actuator
Lett tweeter
Power mi rror swi t ch
Power window master switch
c502
1
I
9
3
6
1
1 0
5
4
2
2
2
3
2
3
2
' 10
1 4
' 18
Dri ver' s door
Dri ver' s door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Dri ver' s door
Driver's door
Behind left kick panel Dashboard wire harness A
Isea oa(,e 22-221
'02-03
moo6rs
DRIVER'S DOOR WIRE HARNESS
22-28
Connoctor or Torminal Cavitios Localion Connects to Notes
Passenger's door lock actuator
Passenger's door speaker
Passenger's window motor
Pass6nger's window switch
Ri ght power
mi rror act uat or
Ri ght t weet er
c504
6
3
5
4
2
1
2
2
2
3
2
1 4
Passenger's door
Passenger's door
Passenger's door
Passenger's door
Passnger's door
Passenger's door
Behi nd ri ght ki ck panel
Dashboard wi re harness A
(see
oeoe 22-221
' 02,03
Passenger's Door Wire Harness
PASSENGER'S DOOR WIRE HARNESS
22-29
Connectors and Harnesses
{
{
Connector to Harness Index
(cont' d)
HARDTOP:
2
4 Rearwi re harness {see
page
22 241
Rear wi ndow def ogger connect or
( +)
REAR WINDOW DEFOGGER
GROUND WIRE
HARDTOP SUBHARNESS
22-30
J
CONVERTIBLE TOP:
Left side ot rear wandow
Lef t si deof t runk
\
,/.
/
::-2'/
=a/
REAR WINDOW DEFOGGEN
SUBHARNESS
22-31
Fuse/Relay Boxes
{
{
Connector to Fuse/Relay Box Index
Mai n Under-hood Fuse/Rel ay Box
5
Socket Ref Terminal Connects to
Ay' C compressor cl utch rel ay
B
Bl ower motor rel ay
c
Condenser fan rel ay
D
Di ode
ELD U ni t
Hor n r el ay
Headl i ght rel ay
' l
Headl i ght r el ay 2
Radi ator fan rel av
I t
3
1 4
1 1
I J
1
9
4
1 0
7
8
2
' 18
'l
4
3
4
1 6
2
3
4
Ri ght engi ne compartment wi re harness
(see page 22-14)
Ri ght engi ne compartment wl re harness
(see page 22-14)
Ri ght engi ne compar t ment wi r e har ness
( see page 22- 14)
Ri ght engi ne compartment wi re harness
(see page 22-14)
Ri ght engi ne compartment wi re harness
(see page 22-14)
T1 Batterv Dosi ti ve cabl e
(see
Daoe 22-10)
T101 5 Enqi ne wi r e har ness
( see paqe
22- 12)
22-32
-
Socket Bef Terminal Connects to
B
c
D
E
Memory erase si gnal
(MES)
connector
Rear wi ndow defogger rel ay
(' 00-01
model s)
Staner cut rel ay
Tai l l i ght rel ay
Turn si onal /hazard rel av
5
1
7
8
9
5
6
1 0
2
7
,|
1
1
4
3
SRS mai n harness
(see page
22-27)
l gni ti on swi tch harness
(see page 22-27)
Opti onal connector
Opti onal connector
Opti onal connector
SRS mai n harness
(see page
22-27)
Under-dash Fuse/Relay Box
ttftftft
o a a o
Lt L_l L_lL_l
t l
t l
t l
f r3l f 27l
ltzl lza_)
L
rr
l f zsl
f rol f zrl
f sl f zgl
f
ef
f zzf
I zl-1
f z . l - I
- - t 2 0
1
! " 1 f r sl
=
-
: L18-l
l i ! i - -
= = L
17_l
t ? l
1 6
l z ) , . . .
L r _ t
f 1 1 I
22-33
Fuse/Relay Boxes
Connector to Fuse/Relay Box lndex
(cont'dl
Auxiliary Under-hood Fuse Box
Socket Ret Terminal Connects to
B
2
1
2
3
Lef t engi ne compar t ment wi r e har ness
( seepage22- 16)
Lef t enqi ne comDar t ment wi r e har ness
( seepaqe22- 16)
22-34
Power Distribution
J )
J )
Fuse to Components Index
Main Under-hood Fuse/Relay Box
*
1: ' 00- 01 model s
*
2:
' 02-03
model s
Fuse
Number
Amps Wire Color Component{s} or Circuit{s} Protected
41 100 A Battery, Power di stri buti on
4 0 A WHT l gni ti on swi tch {BAT}
43 204 B E DAr'r'HTDayti me runni ng l i ghts control uni t
(Canada),
Ri ght headl i ght
(hi gh/l ow
oeam,
44
Not used
45 20A' RED/YEL Dayti me runni ng l i ghts control uni t
(Canada),
Gauge assembl y, Hi gh beam
i ndi cator l i ght, Hi gh beam cut rel ay
(Canada),
Left headl i ght
(hi gh/l ow
beam)
46 1 5 A WHT/GRNData l i nk connector
(DLC),
PGM-Fl mai n rel ay
47
' r 0 A* ' l
WHT/GRN ABS modul ator uni t, Brake l i ghts, Crui se control uni t, ECM, Hl gh mount
brake l i ght, Horn(s)
1 5 4 * 2
48 2 0 A WHT/GRNABS modul ator uni t
49 1 0 A WHTi BLK Hazard warni ng l i ghts
50 3 0 A WHT/BLU ABS modul ator uni t
40A WHT/BLK No. 17 and 18 fuses
(i n
the under-dash fuse/rel aV box)
52 204 GRY/REDRi ght converti bl e top motor
53
Not used
54 3 0 A YEL No.22,29! 24,25, 26 and 27 fuses
(i n
the under-dash fuse/rel av box)
55 204 GRY Left converti bl e top motor
56 40A BLU,^/VHTBl ower motor
57 20A. BLU/BLK Radi ator fan motor
58 204 BLUIYEL Condenser fan motor
BLU/RED A,/C compressor cl utch
59 Not used
frnn]q
L__l Ll Ll
42
t5d car
u
L\Zl
I ll-- )
53 l 5ol E l tr-rl ?
* -F.]f
I t\
lill [i]ro:lrr I
E ta.l:l
u
x
Fll rr &ra
I I | | 1611 It
I l s l 4 l 9
)
(cont' d)
5
J
22-3
Power Distribution
{
{
{
Under-dash Fuso/Relay Box
syst em l i ght , Crui se cont rol uni t ,
Crui se cont rol mai n swi t ch, ELD uni t , EVAP bypass sol enoi d val ve' EVAP cani st er vent
15A 8Lf i EL
--pr"". - "l @l ay,
Condenser f an rel ay, Heat er cont rol
A-udi o-uni t l i ght , Crui se cont rol mai n swi t ch l i ght , Front parki ng l i ght s, Gauge l ' ght s'
Hazard warn; ng swi t ch l i ght , Heat er cont rol
panel l i ght s, Keyl ess doot l ock cont rol un' t '
Li cense
pl at e l i ght , Opt i on connect or, Conveni bl e t op swi t ch l i ght s, Radi o remot e
Ecl t 4- . Gur ge assumbl v. Hpal er cont r ol
panel l mmobi l i l er
Fuse to Components
Index
(cont'dl
f13l f27l
f12l f26l
ro f21l
- el f 23l
f 8l f r r l
f 21-
T1 - 1
= =
L' l
Tr r - . ]
fl
1_l
!
33ls
I l
I ,
'
'I
r[ t [ l
L_J L-J
,-H
22-36
Fuse
Numbor
Amps Wire Color Component(s) or Circuit(s) Protected
60A WHT Ai r
pump
el ectri c current sensor
EPS control uni t
7 0 A WHT/RED
34 20^' WHT/GRN Rear wi ndow defogger
Not used
36
Not used
Auxiliary Under.hood Fuse Box
22-37
Ground
Distribution
I
{
Ground to Components Index
Ground
Component or ci rcui t
grounded
,
Battery
Engi ne bl ock
Enqi ne bl ock
G2
G4 EPS
qearbox
G 1 0 1 CKP sensor . Dat a l i nk connect or
( DLC) ,
ECM
( PG1
and PG2 ar e BLK; LG l and LG2 ar e BHN/ YEL) , I AU
val ve, l qni ti on coi l s, l mmobi l i zer recei ver uni t, PGM-Fl mai n rel ay, vss, vTEc oi l
pressure swi tch
shel i l ng between the EcM these components have BRNryEL wi res: cKP sensor, TDC sensor 1 and 2
{cMP sensor A and B). Pri marv HO2S. Secondarv HO2S, Knock sensor
G 201 Bl r."r "r"t"r *E C-d"*"r f"n motor, ELD uni t, EPS control uni t, Front parki ng l i ght
(ri ght),
Front
t ur n si gnat t i ght
( r i ght ) ,
Radi at or f an mot or , Ri ght headl i ght
( l ow
beam) , si de t ur n si gnal l i ght
( r i ght ) ,
Wi ndshi el d washer mot or
G301 Al r
pu-p tl a,/, Br"Le fl ui d l evel swi tch, crui se control actuator, Front parki ng l i ght
(l eft),
Front turn
si gnal i i ght fi eft),
Radi ator fan swi tch, Left headl i ght
(l ow
beam), Si de turn si gnal l i ght
(l eft),
Wi ndshi el d
wi per motor, l ntermi ttent wi per rel ay
(' 02-03
model q)
G302 Ai r
pump
ABS modul at or uni t
( 2
wi r es)
G303
u55 | EPS COnt rOl Unt t
G401 CtLrtct'
p"aat posi ti on swi tch, Cl utch i nterl ock swi tch, Combi nati on l i ght swi tch, Data l i nk connector
(DLC),
l gni ti on key swi tch, Intermi ttent wi per rel ay {' oo-01
model s). Turn si gnal l haza.d rel ay
'
Wi ndshi el d wi per/washer swi tch, Rear wi ndow defogger swi tch
(' 00-01
model s)
G402 di se cortrrohj ni t, Da' 1i me runni ng l i ghts control uni t
(Canada) (2
wi res), EPS control uni t, Heater
control Danel , Converti bl e top control uni t
(3
wi res). Po*er transi stor
G 501 crul "" | .nai n s*i rcr' , Dri ver' s door key cyl i nder swi tch, Dri ver' s door l ock actuator, Engi ne start swj tch,
Gauge assembl y
(2
wi res), Keyl ess door l ock control uni t, Power mi rror swi tch, Passenger' s wi ndow
swi tch, Power wi ndow master swi tch. converti bl e top control uni t, Radi o remote swi tch, Rear wi ndow
defoqqer swi tch
(' 02-03
model s)
Audi o uni t
G601 AcceCory
power sockd, Dri ver' s seat bel t swi tch, Fuel gauge sendi ng uni t
(2
wi res), Hi gh mount brake
l l ght, Trunk opener sol enoi d/l atch swi tch, Rear wi ndow defogger subharness connector
(opti on)
(' 00-01
model s). Condenser and Di ode
(for
rear wi ndow defogger change ci rcul t) {' 02-03
model s), Rear
wi ndow defoqqer
(converti bl e top for' 02-03 model s).
pl us
eveMhi ng
grounded through G901
aa"l "up l i gt' t
(i efvri ght).
Li cense
pl ate l i ght, Rear turn si gnal l i ght {l efvl i ght).
Rear si de marker l i ght
l l efr/ri oht). Tai l l i oht
(l efu
ri oht)
G801 SRS uni t
( 2
wi r es)
G 901 conrerri bl " t.D di ""bl " swi tch, Rear wi ndow defogger rel ay
(' 00-01
model s),
pl us everythi ng
grounded
Rear wi ndow defoqqer G902
22-38
-
Battery
Battery Test
Use ei ther a JCI or Bear ARBST tester, and fol l ow the
manufacturer' s procedures.
l f you
don' t have one of
these computeri zed testers, fol l ow thi s conventi onal
test procedure:
1. Be sure the temperature of the el ectrol yte i s
between 70' F
(21' C)
and 100' F
(38"C).
2. Inspect the battery case for cracks or l eaks.
.
l f the case i s damaged, repl acethe battery.l
.
l f the case l ooks OK, go
to step3.
3. Check the i ndi cator EYE.
.
l f the EYE i ndi catesthe battery i scharged, goto
step 4.
.
l f t he EYE i ndi cat esa l owchar ge, got ost ep7.
4. Appl y a 300 amp l oad for 15 seconds to remove the
surface charge.
5. Wai t 15 seconds, then appl y a test l oad of 280 amps
for 15 seconds.
6. Record baftery vol tage.
.
l fvol tage i s above 9.6 vol ts, the baftery i s OK.l
.
l f vol t age i s bel ow9. 6vol t s, got ost ep7.
7. Charge the battery on Hl gh
(40
amps) unti l the EYE
shows the battery i s charged, pl us an addi ti onal 30
mi nutes. l f the battery charge i s very l ow, i t may be
necessary to bypass the charger' s pol ari ty
protecti on
ci rcui try.
.
l f the EYE i ndi cates the battery i s charged wi thi n
3 hours, the battery i s OK.l
.
l f the EYE i ndi cates the battery i s not charged
wi thi n 3 hours. repl ace the battery.I
A battery can expl ode i f
you
do not fol l ow the
proper procedure,
causi ng seri ous i nj ury to anyone
nearby. Fol l ow al l procedures
careful l y and keep
sparks and open fl ames away from the battery.
22-39
Relays
Power Relay Test
Use thi s chart to i dentl fy the type of rel ay, then do the
test l i sted for i t.
NOTE: For the turn si gnal /hazard rei ay i nput test
(see
page 22-781.
*
1:
' 00- 01
model s
*
2: ' 02- 03 model s
Rel ay Test
Accessorv
power
socket rel ay
See
page 22-40
Nor mal l y open
type A
AJC comDressor cl utch rel ay
Condensor {an rel av
Headl i qht rel av 1
Headl i qht rel av 2
Hi qh beam cut rel ay
(Canada)
Hor n r el ay
l G2 r el av
Radi ator fan rel av
Starter cut rel ay
Tai l l i qht r el ay
Rear wi ndow defoqqer rel ay
Bl ower motor rel ay See
page 22-41
Nor mal l y open
tvDe B
l ntermi ttent wi oer rel av
*
2 See
page 22-41
Fi ve termi nal
tVDe A
Inl ermi ttent wi per rel ay
*
1 See
page 22-42
Fi ve termi nal
type B
Rear wi ndow defogger
chanqe rel av
*
2
Rear wi ndow defogger
(elav *
2
22-40
Normally-open type A:
Check for conti nui ty between the termi nal s.
.
There shoul d be conti nui tv between the No. 1 and
No.2 termi nal s when power and ground are
connected to the No. 3 and No. 4 termi nal s
.
There shoul d be no conti nui w between the No. 1 and
No. 2 termi nal s when
power
i s di sconnected.
Five-terminal type B:
Check for conti nui ty between the termi nal s.
.
There shoul d be conti nui ty between the No, 1 and
No. 2 t er mi nal s when power and gr ound
ar e
connected to the No. 3 and No. 5 termi nal s.
.
There shoul d be conti nui ty between the No. 1 and
No. 4 termi nal s when power i s di sconnected.
Intermi ttent wi per rel ay
(' 00-01
model s)
Rear wi ndow defogger rel ay
(' 02-03
model s)
Rear wi ndow defogger change rel ay {' 02-03 model s)
il
l,-a
\5y
{cont' d)
22-41
Relays
Power Relay Test
(cont'd)
Normally-open type B:
Check for conti nui ty between the termi nal s.
'
There shoul d be conti nui ty between the No. 1 and
No. 3 termi nal s when
power and ground are
connected to the No. 2 and No. 4 termi nal s.
.
There shoul d be no conti nui w between the No. 1 and
No. 3 termi nal s when
power
i s di sconnected.
22-42
Five-terminal type A:
Check for conti nui l y between the termi nal s.
.
There shoul d be conti nui ty between the No. 1 and
No. 2 termi nal s when
power and
ground are
connected to the No. 3 and No. 5 termi nal s.
.
There shoul d be conti nui w between the No.2 and
No. 4 termi nal s when Dower i s di sconnected.
Intermittent wiper relay
('02-03
models)
lgnition Switch
J
rest
SRS components are l ocated i n thi s area. Revi ew the
SRS component l ocati ons, precauti ons,
and
procedures
i n the SRS secti on before performi ng repai rs or servi ce
(see page
23-10).
1. Make sure you have the anti -theft code for the radi o,
then wri te down the frequenci es for the radi o' s
preset buttons.
2. Di sconnect the battery negati ve cabl e.
3. Di sconnect the 7P connector from the under-dash
fuse/rel ay box.
ORN
(IG2.A)
WHT
(BAT-A}
BLK/RED
(IG2.B}
BLK/YEL
0G 1-B)
WHT/BLK
(BAT-B)
BLK/ YEL {I G1. A)
\ _ t
4. Check for conti nui ty between the termi nal s i n each
swi tch posi ti on accordi ng to the tabl e.
\rorminal
t."'t..1\
WHT/
RED
tacc)
Er1
"t+, WHT
{BAT.
A)
BLK/
YEI-
l t Gl - A)
l t Gl - B)
ORN
tG2-A)
o {LocK)
I tacc) o-
--o
toN) C+ o o-
l f the conti nui ty checks do not agree wi th the tabl e,
repl ace the el ectri cal swi tch.
After reconnecti ng the battery, enter the anti -theft
code for the radi o, then enter the customer' s radi o
statron
presets.
22-43
Gauges
a
a
Component Location Index
ENGINE OIL PRESSURE SWITCH
page 8-4
VEHICLE SPEED SENSOR {VSS}
Troubl eshoot i ng,
page 22-53
Repl acement ,
page 22 52
GAUGE ASSEMBLY
Bul b Fepl acement , page 22 46
Repl acement , page 22 52
FUEL GAUGE SENDI NG UNI T
page 11- 1 19
PARKING BRAKE SWITCH
page 19' ' l I
BRAKE FLUID LEVEL SWITCH
page 19 1l
22-44
I
D9' ' . . . . --> D16
A1. . . - - - . . - . > A6
A7. . . . . . .
. >
A14
B1- . . . . - . - - - - -
>
85
86- ' . . . . . . - . - > 812
c 1 .
. > c 1 0
c11. . . - - - - - - - . > C20
Gauge/Tarminal Location Index:
CONNECTOR A CONNECTOR D
CONNECTOR C
FUEL GAUGE
22-45
Gauges
Gauge Bulb Replacement
GAUGE LIGHTS {2,0 W}
SEAT BELT
REMINDER
LTGHT {1.12
W)
SRS INDICATOR
LTGHT 11. 12 Wl
LOW FUEL INDICATOR
Lr GHT { 1. 12 Wl
LI GHT
(3.0 W x 3)
MALFUNCTION INDICATOR
LEFT TURN SIGNAL
INDICATOR LIGHT
t 1. 12 W)
ABS INDICATOR
LI GHT {1. 12 WI
BRAKE SYSTEM
LTGHT
(1.12
Wl
CHARGING SYSTEM
LTGHT {1.12
W)
LOW ENGINE OIL PRESSURE
I NDI CATOR LI GHT
(1. 12
W)
DRL INDICATOR
LTGHT
(1.12
W)
(Canadal
LAMP
(Mt L)
{1. 12 W)
IMMOBILIZER INDICATOR
LTGHT { 1. 12 Wl
DOOR INDICATOR
LrGHT
(1.12W) MAINTENANCE REOUIBED INDICATOR {REMINDER}
LTGHT {1. 12
W}
TRUNK INDICATOR
LTGHT t1.12Wl
CRUISE INDICATOR
LTGHT {1.4 W}
HI GH BEAM
INDICATOR
LTGHT 11. 12 Wt
EPS INOICATOR
LTGHT {1. 12W1
GAUGE LIGHTS 13.O W)
22-46
Ci rcui t Di agram
lEt
ECM
DAvllME
:
rcM
RUNNING
I
IIGHTS I
CONTEOL
. . u! L. . _. . - J
(cont' d)
MAINUNDER HOOD fUSE/BILAY BOX
I
I
m l
DRL
!DrcATON
UGI{T
l1.r2w)
22-47
Gauges
Circuit Diagram
(cont'dl
.
E?S
c0rvn0t
UI{IT
'
co[vEFn&t
T0t
c0Nnot
UMT
.
cSulsE
MMIOL
UI{IT
l "
I
I
G501
22-48
rcYESS
DOOF LOCK
CONIFOL
UI\IIT
8lx
I
G6o1
RED/l{r{r
t,
/'F\ lcl'llllol'l
[ - l ]
r GY
Y SWITCH
11
qo$d.
8Ll(
I
I
I
_o
Gr01
( cont ' d)
22-49
Gauges
Circuit Diagram
(cont'd)
aBs sns
MODUIATOS UI{II
UI{IT
GAUCE ASSEMEIY
22-50
I'{0.6{1541
FUSE
\7
I
-
EUNr' ltNG
^Di,,orn _,2 |
ucHrs
\
CONTBOT
{Cdrdal
22-51
Gauges
2.
?
Gauge Assembly Replacement
1 . Lower the steeri ng col umn, and remove the dri ver' s
ai rbag, steeri ng wheel . steeri ng col umn covers
cabl e reel , and combi nati on swi tch assembl y {see
page 17- 9) .
Remove the i nstrument panel (see page 20 80).
Remove the screws
(A)from
the
gauge assembl y
{B),
and spread a protecti ve cl oth
(C}
on the
steenng col umn.
c A
Di sconnect the connectors
(D),
and remove the
gauge assembl y.
Remove the screws and the
gauge
assembl y
brackets,
6. l nstal l i n the reverse order of removal .
22-52
VSS Replacement
1 .
3.
Rai se the vehi cl e, and make sure i t i s securel y
su
pported.
Di sconnect the 3P connector from the vehi cl e
speed sensor
(VSS).
Remove the mounti ng bol t, then remove the VSS.
l nstal l i n the reverse order of removal .
J )
J )
Vehicle Speed Signal Circuit Troubleshooting
Note; l f the MIL i ndi cator i s ON, troubl eshoot the PGM-
Fl probl em fi rst.
1. Rai se t he vehi cl e, and make sur e i t i s secur el y
supponed.
2. Di sconnect the VSS 3P connector.
3. Tur n t he i gni t i on swi t ch ON { l l } .
Check for vol tage between the VSS 3P connecl or
No. 3 t er mi nal and body
gr ound.
VSS 3P CONNECTOR
l s thete l ess than 1 V?
YES Go to step 5.
NO Repai r open or hi gh resi stance i n the BRN/
YEL wi re between the VSS and G 101. I
)
___a-
J
22-53
5. Measure vol tage between the VSS 3P connector
No. 1 t er mi nal and body gr ound
VSS 3P CONNECTOR
ls thete apptox. 5 V?
YES Go to step 6.
NO- Repai r shon i n the YEUBLU wi re between
t he VSS and t he ECM. I
(cont' d)
Gauges
Vehicle Speed Signal Circult
Troubleshooting
(cont'dl
Reconnect the VSS 3P connector, and put the car i n
neutral wi th the i gni ti on swi tch ON
(l l ).
Sl owl y rotate the
propel l er
shaft.
Measure vol tage betr,/veen the gauge assembl y
connector C
(20P)
No. 3 termi nal and body ground.
GAUGE ASSEMBLY CONNECTOB C {2OP}
Does voltage pulse trcm 0 to approx. 5 V?
YES Check connecti ons, and i f necessary, repl ace
the
pri nted ci rcui t board.l
NO Go to step 9.
Turn the i gni ti on swi tch OFF.
Di sconnect the 3P connector from the vehi cl e
speed sensor l VSS).
Tur n t he i gni t i on swi t ch ON
( l l ) .
Measure the vol tage between the vss 3P
connector No.2 termi nal and body ground.
ls there approx. 5 V?
YES Repl ace the VSS. !
NO
--
Repl ace the short to ground or open i n the
BLU,^/vHT wi re. t
7.
8.
9.
10.
1 1 .
12.
Wi r e si de of f emal e t er mi nal s
22-54
Mai ntenance Requi red Indi cator
Reset Procedure
How to Reset:
Push and hol d the tri p button. turn the i gni ti on swi tch
ON
( l l ) ,
and cont i nue hol di ng t he t r i p but t on I or mor e
than 10 seconds.
At 5,900
(9,440)
to 6.100
(9.760
Bl i nks f or 10 seconds when t he
Comes on and stays on whi l e At 7, 400
( 11, 840)
1 . 600 t 12. 1
) J
Tachometer Circuit
Troubl eshooti ng
NOTE: l f the MIL i ndi cator i s on, troubl eshoot the PG l M-
Fl Drobl em fi rst.
1. Remove the gauge assembl y
(see page 22-52).
2. Di sconnect the gauge assembl y connector C
(20P)
and t he ECM connect or A
( 32P)
3. Check for conti nui ty between the gauge assembl y
connector C {20P) No. 5 termi nal and ECM
connect or A { 32P) No. 19 t er mi nal .
CAUGE ASSEMBTY CONIVECTOF C I2OPI
J )
l s thete conti nui ty?
YES Go to step 4.
NO Repai r open i n the BLU wi re between the
gauge
assembl y and t he EcNi l . l
Check for conti nui ty between the gauge assembl y
connect or C
( 20P)
No. 5 t er mi nal and body gr ound.
l s thete conti nui ty?
YES Repai r shor t t o
gr ound i n t he BLU wi r e
between the gauge assembl y and the ECl vl .I
NO Go to step 5.
Reconnect the gauge assembl y connector C
(20P)
and the ECM connector A {32P).
Check the EPS system tot DfC 22 ot 23.
l s DTC 22 or 23 present?
YES Go to the EPS system Troubl eshooti ng Index.
l f OK, substi tute a known-good ECM and rel est the
ci r cui t . l f OK, r epl ace t he ECl M. l
NO Check for conti nui ty between the gauge
assembl y connect or A14 t er mi nal and t he EPS
conl r ol uni t connnect or 812 t er mi nal , and t he
gauge assembl y connect or C5 t er mi nal and t he EPS
cont r ol uni t connect or B5 t er mi nal . l f OK. r epl ace
the mai n pri nted
ci rcui t board i n the gauge
assembl y. l
4.
5.
6.
)
I
J
22-55
2.
3.
Coolant Temperature Gauge Circuit
Troubl eshooti ng
1 . Check for PGM-Fl DTCS.
l s DT C P01 16, P0117, or P0118 i ndi cat ed?
YES Go t o t he ECM DTC Tr oubl eshoot i ng I ndex. l
NO Go to step 2.
Remove t he gauge assembl y { see
page
22- 52) .
Di sconnect the gauge assembl y connecter C
(20P)
and the ECM connecter A {32P).
Check for conti nui ty between the gauge assembl y
connect or C
( 20P)
No. 7 t er mi nal and ECM
connect or A
( 32P)
No. 1 t er mi nal .
GAUGE ASSEMBLY CONNECTOR C {2OP}
l s there conti nui ty?
YES Go to step 5.
NO Repai r open i n the YEVGRN wi re between the
gauge assembl y and t he ECM. I
Check for conti nui ty between the gauge assembl y
connect or C
( 20P)
No. 7 t er mi nal and body gr ound.
l s there conti nui ty?
YES Check the output from the ECM fi rst, i f OK,
repai r shon to body
ground i n the YEL/GRN wi re
bet ween t he gauge assembl y and t he ECM. I
NO Check connect i ons, l f OK, r epl ace t he mai n
pr i nt ed ci r cui t boar d i n t he gauge assembl y. I
Wi re si de of f emal e t ermi nal s
Wi re si de of f emal e t ermi nal s
Lights-on, Key-in, Seat Belt Reminder System
MAIN UNOEi.IIOOO FUSARELAY EOX IGNIIION SWITCH
Circuit Diagram
ORIVEBS
SEAT 6ELT
stvtlcS
fctcad: l
L',Ylrn unhctLd J
OFIVEF'S
D@R
swrTcH
fc56.d: I
Looo. opan J
22-56
J
1 .
2.
System lnput Test
Remove the gauge
assembl y
(see page
22-52).
Inspectthe al l connectors and socket termi nal s to be surethey are al l maki ng good
contact.
.
l f t he t er mi nal ar e bent , l oose, or cor r oded, r epai r t hem as necessar y. and r echeckt he syst em.
.
l f the termi nal s l ook OK,
go
to step 3.
GAUGE ASSEMBLY CONNECTOR A I 14PI
BLU/ RED
f emal e t er mi nal s
GAUGE ASSEMBLY CONNECTOR B I 12P)
,,7*
J
Wi re si de of
femal e termi nal s
GAUGE ASSEMBLY CONNECTOR C {2OP}
RED/WHT
f emal e t ermi nal s
{cont' d)
REO/ BLK
22-57
Lights-on, Key-in, Seat Belt Reminder System
System Input Test
(cont'dl
Wi th the connectors connected, back
probe
the connectors and make these i nput tests.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the i nput tests
prove OK, the gauge assembl y must be faul ty; repl ace i t.
Cavity Wi re Test condition Test: Desird resull Possible cause il result is not obtained
B4 YEL l gni ti on swi tch
oN
( l r )
Check for vol tage to
ground:
There shoul d be battery vol tage.
.
Bl own No. 5
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box
.
An oDen i n the wi re
B5 WHT/REDUnder al l
condi ti ons
Check tor vol tage to
ground:
There shoul d be battery vol tage.
Bl own No. 25
(7.5
A) fuse i n the
under-dash f use/rel ay box
An oDen i n the wi re
B3 RED/BLK Combi nati on
l i ght swi tch
ON
Check for vol tage to ground:
There shoul d be battery vol tage.
Bl own No. 23
(10
A) fuse i n the
under-dash fuse/rel ay box
Faul ty tai l l i ght rel ay
Faul ty combi nati on l i ght swi tch
An ooen i n the wi re
RED,A/VHTl gni ti on key i s
i nserted i nto
t he i gni t i on
swi tch
Check for vol tage to
ground:
There shoul d be 1 V or l ess.
Faul ty i gni ti on key swi tch
Poor gr ound ( G401)
An open i n the wi re
l gni ti on key
not i n i qni ti on
Check for vol tage to
ground.
There shoul d be 5 V or more.
Faul ty i gni ti on swi tch.
Short to
qround
i n the wi re.
A'1 BLU/RED l gni ti on swi tch
ON
( l l )
and
dri ver' s seat
bel t unbuckl ed
Check for vol tage to
ground:
There shoul d be
' 1
V or l ess.
Faul ty dri ver' s seat bel t swi tch
Poor gr ound
( G601)
An open i n the wi re
l gni ti on swi tch
ON
( l l )
and
dri ver' s seat
bel t buckl ed
Check for vol tage to
ground.
There shoul d be 5 V or more.
Faul ty dri ver' s seat bel t swi tch.
Short to
ground i n the wi re.
B8 BLK Under al l
condi ti ons
Check for conti nui ty to
ground:
There shoul d be conti nui w.
.
Poor gr ound ( G501)
.
An oDen i n the wi re
Ito GRN Dri ver' s door
oDen
Check for vol tage to ground:
There shoul d be 1 V or l ess.
Faul ty dri ver' s door swi tch
An ooen i n the wi re
Dri ver' s door
ctoseo
Check for vol tage to
ground.
There shoul d be 5 V or more.
.
Faul ty dri ver' s door swi tch.
.
Short i n the wi re.
B4 YEL l gni ti on swi tch
ON
( l l )
and t r i p
reset button
oresseo
Check the beeper operati on.
The beeper shoul d come on.
Faul ty beeper
Poor
gr ound ( G501)
An open i n the wi re
Faul tv
qauoe
assembl v
B5 WHT/RED
B8 BLK
22-58
Exterior Lights
Component Location lndex
HEADLIGHT RELAY 1
{Rightl
Test , page 22-40
MAIN UNDER-I{OOD
FUSE/RELAY BOX
HEADLIGHTS/FRONT PARKING LIGHTS
Repl acement , Daqe 22-71
HI D Bul b Remova-I , page
22-69
Adj ust ment , page 22-72
HfD Troubfeshooting, page 22-68
SI DE TURN SI GNAL LI GHT
Repl acement , page 22' 74
FRONT TURN SIGNAL LIGHT
HIGH MOUNT
BRAKE LIGHT
Repl acement, page 22-75
LICENSE PLATE LIGHT
Repl acement , page
22-75
(cont' d)
r ) A f - , - -
r i
n n l
- - i ;
f =
LJ t _I L L r L=r Lr
L : i i
1 - I l L
SIDE MARKER LIGHT
22-59
Exterior Lights
Component Location Index
(cont'd)
DASH LIGHTS BRIGHTNESS
CONTROLLER
I nput Test , page 22-85
-
HIGH BEAM CUT RELAY
(Canadal
fWi re
col ors: RED/BLU, oRN,
I
LBLU
and BLU/RED
.l
Test, page 22-40
BEAM I NOI CATOR LI GHT
Bul b Locat i ons,
page 22 46
DRL INDICATOR LIGHT {Canada)
Bul b Locat i ons, page 22-46
n
COMBINATION LIGHT
swtTcH
TesVRepl acement ,
page 22-65
DAYTIME RUNNING
LIGHTS CONTROL
UNI T {Canadal
I nput Test , page 22-66
IG2 RELAY
fWi re
col ors: 8Ll (RED, YELI
LBLUAVHT
and LT BLU
l
Test, page 22-40
AILLIGHT RLAY
[Wi re
col ors: RED/BLK, WHT/GRN,
I
LWHT/GRN
and BLU
I
Test, page 22-40
-
L
-
,
=
-l
--
-
T-t
t l
l l
22-60
Circuit Diagram
-
USA
HEl0!o1T
li$*)
;15s199
fff*
LlGNI
, . , ?' d5-i
22-61
Exterior Lights
Ci rcui t Di agram
-
Canada
DRL
INDICATOF
LIGIII
V
I
SLUN.|.iHI
RGNT
HEADLIGHT
(Hioh
beaml
i5sw)
I ^ L
I*-I
I
.CONVERTIBLE
I iHh*'
I
i,lfltu
I Y
GRNWHI G8I']]WF]I
l_r
@isu+,
I
I Le'..' ue l
I
I
-
HEADL|GHT
' -i-_-
(35W)
OAYTIME FUNN NG LIGNTS CONTROL UN]T
MA N UNOR-HOOO FUSE/FELAY 8OX
LEFT
NEADLIGHT
(3sw)
UNOER-OASH
FIJSE/RELAY
BOX
NEAOLIGHT
FELAY 1
UNOER DASH
FUSE/REUYEOX
''"-'T;_:
t t
? J
( P ]
I RIGHT I L]CENSE
I TA LIIGHT I PTITE
lou lii8il
t l
LX BLK
H
BIK
{
G5m
ED/BLK 8ED/BLK RO/8I( RED/BIK BEO/AIX 8EI
t t t t l
.r\ /r\ ,+\ ,,r\ i
( 9 ( 9 ( 9 ( 9 ( t ) (
liF[* l:A'd; lh',[ llt"^{ l!i['o'.,
I
P^8(NG
I
p^R!|iG
I
SD!
|
SrqE
| {5!v)
I LIGHT I LGHT I [^R(EF I MAFKEF I
lo, l,*, lllff, liiil |
BLK BLK 8LK BLK 8LK 8
l l
t l
I t
; :
G30J G201 G401
Exterior Lights
MAIN UMEN HOOO
FUSE/BELAY BOX
Circuit Diagram
-
Brake Lights
22-64
t{A|t ut{0ln-8000
FUSE/8ELIY BOX
Circuit Diagram
-
Back-up Lights
BAC(-UP
LIGHT
1
RGHT
_/ ucxr
i
i21wl
i
{21W1
J )
1 .
2.
3.
4.
Combination Light Switch Test/Replacement
Remove the steeri ng col umn covers
(see page
17-9).
Di sconnectthe 16P connector
(A)trom
the combi nati on l i ght swi tch {B).
Remove the two screws, then
pul l
out the combi nati on l i ght swi tch.
Inspect the connector termi nal s to be sure they are al l maki ng good
contact.
.
l f the termi nal s are bent, l oose or corroded, repa i r them as necessa ry, a nd recheck the system.
' l f t het er mi nal sl ookOK, checkf or cont i nui t ybet weent het er mi nal si neachswi t chposi t i onaccor di ngt ot he
tabl es.
-
l f the conti nui ty i s not as speci fi ed, repl ace the swi tch.
Light switch:
Uin"l
Position
6 4 12 13
Headl i ght swi t ch
OFF
o-
LOW
o
o
HIGH
Passing switch
OFF
ON
Turn signal switchi
l--___Ig-'9
Position
2 1 1 10
LEFT o
NEUTRAL
RIGHT
o
J )
) r ,
___-.4.
22-65
Exterior Lights
Daytime Running Lights Control Unit Input Test
-
Canada
1. Di sconnectthe 14P connector
(A)
from the dayti me runni ng l i ghts control uni t
(B).
2.
BLU/RED RED/BLU YEL/BLK
Wi re si de of {emal e termi nal s
Inspect the connector and socket termi nal s to be sure they are al l maki ng
good contact'
.
l f the termi nal s are bent, l oose orcorroded, repai rthem as necessary, and recheckthe system'
.
l f the termi nal s l ook OK. go to step 3.
22-66
3. Make these i nput test at the connecror.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em,
.
l f al l the i nput tests prove
OK,thecontrol uni t must befaul ty; reprace rr.
Cavity Wi re Test condition Test: Desired result Possible cause if result is not obtained
2 RED/BLU Under . al l
condt t t ons
Check for vol tage to ground:
There shoul d be battery vol tage.
Bl own No.54
(30
A) fuse i n the
under-hood fuse/rel ay box
Bl own No. 27
(10
A) fuse i n the
under-dash fuse/rel ay box
An open i n the wi re
12 YEUBLK l gni ti on swi tch ON
flr)
Check for vol tage to ground:
There shoul d be battery vol tage.
.
Bl own No. 19
(7.5
A) fuse i n the
under-dash fuse/rel ay box
.
Faul t y l G2 r el ay
. An ^nah i n t ha \ ^, i r 6
4 BLK Under al l
condi ti ons
Check for conti nui ty to ground:
There shoul d be conti nui tv.
.
Poor ground (G402)
.
An open i n the wi re
7 BLK U nder al l
condi t i ons
Check for conti nui ty to ground:
There shoul d be conti nui tv.
.
Poor gr ound ( c402)
.
An open i n the wi re
3 RED/YEL Combi nat i on l i ght
swi tch ON
(=D)
Check for vol tage to ground;
There shoul d be battery vol tage.
Bl own No. 45
( 20
A) f use i n t he
under-hood fuse/rel ay box
Faul t y headl i ght r el ay 2
Faul ty combi nati on l i ght swi tch
An open i n the wi re
5 REDA/VHTCombi nat i on l i ght
swi tch ON
(3D)
Check for vol tage to ground:
There shoul d be baftery vol tage.
El own No. 43
(20
A) fuse i n the
under-hood fuse/rel ay box
Faul ty headl i ght rel ay 1
Faul ty combi nati on l i ght swi tch
An open i n the wi re
1 REDANHT Combi nati on l i ght
swi tch ON
(=D),
and di mmer swi t ch
i n HI GH
Connect a
j umper
wi re between
No. 3 and No. 1 t er mi nal s.
Lef t headl i ght ( Hl cH)
and hi gh
beam i ndi cator l i ght shoul d
come on.
j
.
Bl own bul b
I
.
Faul ty hi gh beam cut rel ay
.
Faul ty combi nati on l i ght swi tch
.
Poor gr ound ( G401)
.
An open i n the wi re
1 1 RED/ORN Combi nat i on l i ght
swi tch ON
(=D),
and di mmer swi tch
i n HI GH
Connect a
j umper
wi re between
No. 5 and No. 11 t er mi nal s.
Ri ght headt i ght ( HI GH)
shoul d
come on.
Bl own bul b
Faul ty hi gh beam cut rel ay
Faul ty combi nati on l i ght swi tch
Poor gr ound ( G401)
An open i n the wi re
1 0 RED/BLU Com bi nat i on l i ght
swi tch ON {=D},
and di mmer swi t ch
i n HI GH
Check for conti nui ty to ground:
There shoul d be conti nui ty.
.
Faul ty hi gh beam cut rel ay
.
Faul ty combi nati on l i ght swi tch
.
Poor gr ound ( c401)
-
An open i n the wi re
6 G R NA/VHT Parki ng brake l ever
up
Check for conti nui ty to ground:
Ther e shoul d he c. j nt i nr r i i w
Faul ty parki ng
brake swi tch
Ah ^ n6h i ^ +l ' - . ^ , i . ^
I BLU/ REDUnder al l
condi t i ons
Check for vol tage to
ground:
There shoul d be batterv vol taoe.
Faul ty headl i ght rel ays
An open i n t he wi r e
9 BLU/'|/HT l gni ti on swi tch ON
{ | | )
Bl own bui b
An open i n the wi re
Bl own bul b
-
An open i n t he wi r e
1
Attach to ground;
The DRL i ndi cat or l i ght shoul d
come on.
Attach to ground:
The brake system l i ght shoul d
come on.
GRN/ REDl gni t i on swi t ch ON
flr)
22-67
Exterior
Lights
HID Lamp System
Troubl eshooti ng
Never turn on the combi nati on l i ght swi tch before
fi tti ng the HID bul bs to thei r bul b sockets and
compl et i ng t he r eassembl y of t he headl i ght
assembl y.
1. Check t he No. 43
( 20
A) and No 45
( 20
A) f usei n
the mai n under-hood fuse/rel ay box.
Are the fuses OK?
YES Go to step 2.
NO Repl ace the fuse
(s),
and recheck l
2. Substi tute a known-good HID bul b and recheck.
Does the headlight low beam come on?
YES Repl ace t he HI D bul b. l
NO Go to step 3.
3. Turn the combi nati on l i ght swi tch ON
4. Measure the vol tage between the No 2termi nal of
the i nverter uni t 2P connector and body
ground.
TNVERTER UNI T 2P CONNECTOR
-l
1 2
Wi re si de ol femal e l ermi nal s
Is l here bauery vol tage?
YES Go to step 5.
NO Repai r open i n the wi re between the
under-hood fuse/rel ay box and the i nverter uni t.l
22-68
5. Check f or vol t age bet ween t he No. l t er mi nal of t he
i nverter uni t 2P connector and bbdy
ground.
I NVERTER UNI T 2P CONNECTOR
2
Wi r e si de of l emal e t er mi nal s
l s there l ess than 1 V ?
YES Substi tute a known-good i nverter, and
recheck. l f the symptom/i ndi cati on
goes away,
r epl ace t he or i gi nal i nver t er uni t . I
NO Repai r open i n the wi re between the i nverter
uni t and body
ground. l f the wi re i s OK, check for
poor gr ound at G201 or G301. t
HID Bulb Removal
A transi ent hi gh tensi on
(25,000
V) occurs at the
bul b sockets of the hi gh i ntensi ty di scharge
(Hl D)
l amps when the combi nati on l i ght swi tch i s turned
ON. l t may cause seri ous el ectri cal shock or
el ectrocuti on i f you
do not observe the cauti ons
bel ow.
.
Never turn on the combi nati on l i ght swi tch
bel ore l i tti ng the HID bul bs to thei r bul b sockets
and compl eti ng the reassembl y ofthe headl i ght
assemotv.
.
Do not servi ce the headl i ghts assembl y i n wet
condi ti ons, such as rai n or snow, near a spri nkl er
system. or when your hands are wet to prevent
el ectrocuti on.
.
Do nottouch the surface ofthe HID bul bs wi th
your
bare hands and do not stai n i t wi th anv oi l s
and fats.
.
Do not di sassembl e the i nvener uni t and the
i gni ter uni t.
.
Do not turn on the HID bul b by usi ng a
power
source other than the battery mounted i n your
vehi cl e.
1. Make sure you
have the
anti -theft code for the radi o.
then write down the frequencies for the radio,s
preset
buttons.
2. Turn the combi nati on l i ght swi tch OFF.
3. Di sconnectthe
battery negati ve cabl e, then
disconnect the positive
cable.
4. Remove the front part
of the i nner fender as
necessary (see page 20-105).
5. Di sconnect 2P connector
(A)trom
the i nverter uni t.
Remove the Torx bol t usi ng a tamper-proof Torx
T25 bit.
Turn the cover
(B)
45o countercl ockwi se to remove
i t from the headl i ght assembl y.
7.
(cont' d)
22-69
Exterior
Lights
HID Bulb Removal
(cont'dl
8. Pul l the retai ni ng spri ng
(A)
away from the bul b
(B),
then remove the socket and the bul b
(C).
9. Turn the bul b 45" countercl ockwi se to remove i t
from the socket.
22-70
10. l nstal l the new bul b i n the reverse order of removal .
11. After reconnecti ng the battery, enter the anti -theft
code for the radi o, then enter the customer' s radi o
statron Dresets.
Headl i ght Repl acement
Headl i ghts become very hot duri ng use; do not
t ouch t hem or any at t achi ng har dwar e i mmedi at el y
after they have been turned off.
1 .
2.
Remove the front bumper
(see page 20-92).
Remove the front part of the i nner fender as
necessary
(see page 20-105).
Di sconnect the connectors
(A)
from the headl i ghts.
4. Remove the four bol ts, then remove the corner
upper beam
(B).
Headlight (High)i
Headl i ght
(Low):
Front Turn Si gnal Li ght:
Front Parking Light:
3.
55W
3 5 W
21 W
5 W
5. Remove the four bol ts, then remove the headl i ght
assemot y.
6.
7.
Instal l the headl i ght i n the reverse order of removal .
After repl acement, adj ust the headl i ghts to l ocal
requi rements
(see page
22-721.
22-71
Exterior Lights
tl
!a
Headlight Adiustment
Betore adiusting tho headlights:
'
Parkthe vehi cl e on a l evel surface.
.
Make sure the ti re
pressures are correct.
.
The dri ver or someone who wei ghts the same shoul d
si t i n the dri ver' s seat.
1, Cl ean the outer l ens so that
you
can see the center
oi the headl i ghts
(A).
Headl i ghts become very hot duri ng use; do not
touch them or any attachi ng hardware i mmedi atel y
after thev have been turned off.
22-72
1
Park the vehicle 7.5 m
(25
ft) awa.y from a wall or a
scren
(A).
3. Open the hood.
7.5 m
(25
ftl
Turn the l ow beams on.
Determi ne i f the headl i ghts are ai med properl y.
Vertical adiustment:
Measure the hei ght ofthe headl i ghts
(A).
The l i ghts
shoul d refl ect 52 mm
(2.1
i n.) bel ow headl i ght
hei ghr
{ B) .
6. l f necessary, adj ust the he,adl i ghts to l ocal
requi rements by turni ng the verti cal adj uster
(A).
A
..",4<7
22-73
Exterior Lights
Si de Turn Si gnal Li ght Repl acement
1. Push t he si de t ur n si gnal l i ght ( A) f or war d, t hen
remove i t from the fender.
Si de Turn Si gnal Li ght Bul b: 5 W
2. Di sconnect the 2P connector
(B)from
the l i ght.
22-7 4
Tai l l i ght Repl acement
NOTE; For bul b repl acement, see the owner' s manual .
1. Open t he t r unk l i d and
pul l back t he t r unk t r i m
panel (see page 20-73).
2. Di sconnect the connectors
(A)from
the tai l l i ght.
Brake/Tai l l i ght: 2115W
Back-up Li ght: 21W
Turn Si gnal Li ght: 21W
Side Marker Light: 5 W
Remove the four mounti ng nuts
(B),
then pul l out
t he t ai l l i ght .
Before i nstal l i ng the tai l l i ght, check the gasket. l f i t
i s di storted or stays compressed, repl ace i t.
Instal l the tai l l i ght i n the reverse order of removal .
After i nstal l i ng the tai l l i ght. run water over i t to
make sure i t does not l eak,
]t
5.
6.
Hi gh Mount Brake Li ght
Replacement
4.
Open t he t r unk l i d.
Di sconnect the 2P connector
(A)
from the hi gh
mount br ake l i ght
( B) .
Remove the fi ve mounti ng nuts, then
pul l
out the
hi gh mount brake l i ght.
Instal l the hi gh mount brake l i ght i n the reverse
order of removal .
After i nstal l i ng the hi gh mount brake l i ght, run
water over i t to make sure i t does not l eak.
1 .
2.
License Plate Light Replacement
1 . Remove the l i cense
pl ate
l i ght assembl y, and
di sconnect the 2P connector from i t.
Li cense Pl ate Li ght Bul b;5 W
:
2. Take the l ens off. then reol ace the bul b.
22-75
Turn Si gnal /Hazard
Fl asher
4
{
Component Location Index
UNDER.DASH
FUSE/RELAY BOX
TURN SIGNAL INDICATOR LIGHTS
(l n
the gauge assembl y)
Bul b Locati ons,
page 22 46
COMBINATION LIGHT/
TURN SIGNAL SWITCH
Test , page 22-65
HAZARD WARNING SWITCH
Test , page 22 79
TURN SIGNAL/HAZARD RELAY
I nput Test ,
page 22' 78
-i\
- - .
r ' \ r
\ " ' =
, - 9
=
'-
-
I
=
L J
L ]
=
I
22-76
a
Ci rcui t Di agram
UNDR.OASH
FUSE/FLAY BOX
6\ t * " , . 1
v| ni < o-; LN' ; LT=r-t
\:-/
L
",,..,
N0.23 (r0A)
I
BI-K
G3OJ c:301
BLX
@2
MAIN UNOEF-HooO 'USAREL^Y 80X
I
I
l l
r J
DASH LIGHTS
BRIGNTI{ESS
co.lTRol.lER
/{n
th. ga'{6\
SLK 8\K
11
LEFTIURN SIGM! LIGHT
G501 Cr20r c20r c6o2
Turn Si gnal /Hazard
Fl asher
Turn Signal/Hazard
Relay Input Test
1. Remove the turn si gnal /hazard rel ay {A)from the under-dash fuse/rel ay box
(B)
InsDect the connector and socket termi nal s to be sure they are al l maki ng
good contact.
.
l f the termi nal s are bent, l oose, orcorroded, repai rthem as necessary, and recheckthe system
.
l f the termi nal s l ook OK, go to step 3.
Make these i nput tests at the fuse/rel ay box.
. l f anvt est i ndi cat esaDr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the i nput tests
prove OK,theturn si gnal /hazard rel ay must befaul ty; repl ace i t.
Cavity Test condiiion
Test: Desired result Possible cause if result is not obtained
2 Under al l condi t i ons Check for conti nui ty to ground:
There shoul d be conti nui ty.
Poor
gr ound ( G401)
An open i n t he wi r e
3 l gni t i on swi t ch ON
( l l )
Check for vol tage to ground:
There shoul d be batterY vol tage.
Bl own No. 7
( 7. 5
A) f use i n t he under
dash fuse/rel ay box
Faul ty hazard warni ng swi tch
An oDen i n t he wi r e
Hazard warni ng swi tch
ON, i gni ti on swi tch
OFF
Check for vol tage to ground:
There shoul d be battery vol tage.
Bl own No. 49
(10
A) fuse i n the under-
hood fuse/rel ay box
Faul ty hazard warni ng swi tch
An oDen i n the wi re
1 Hazard warni ng swi tch
ON and connect No. 1
and No. 2 t er manal s
Hazar d l i ght s shoul d come on. Poor gr ound ( G201,
G301. G501,
G 602)
Faul ty hazard warni ng swi tch
Faul ty turn si gnal swi tch
An open i n the wi re
l gni t i on swi t ch ON
( l l )
and connect No. 1 and
No. 2 t er mi nal s; t ur n
si gnal swi t ch i n r i ght or
l eft Dosi ti on.
Ri ght or l eft turn si gnal l i ghts
shoul d come on,
22-78
Hazard Warning Switch Test
1. Remove the center consol e
(see page
20-76),
2. Di sconnect the I0P connector
(A)
from the hazard
warni ng swi tch
(B).
Remove the two screws and the hazard warni ng
SWI TCN.
Check for conti nui ty between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
4.
l f the conti nui ty i s not as speci fi ed, repl ace the
i l l umi nat i on bul b { C) or t he swi t ch.
\
Termi nal
;""tta" \
2 4 8 9 10
OFF
"l
o o
-o
ON o o
-o
o o
o
-@
O
22-79
Interior Lights
Component Location Index
DRIVER'S DOOR SWTCH
DOOR SwlTCH
TRUNK LATCH SWITCH
Test, page 22-83
22-80
Ci rcui t Di agram
UNDEB.DASIT
FUSE/FELAY BOX
' .r.' Fl -wHrBruT
t l
I
s*t,"^
|
,Y"
l_i
I
f
cbsd:
I
L lrunk lid oten.J
TBUNK
LAICFl
swtTcH
OSI VEBS
000R
SW]TCN
fobsed l
gIU/ALK
+
BLK
G60t
GRN
t
I
MA N UNDEB HOOD FUSE/BELAYEOX
d
OFF
MIDDLE
22-81
Interior Lights
Cei l i ng/Spotl i ght Test
Turn the cei l i ng/spotl i ghts swi tch OFF.
Pry off the l ens {A).
Cei l i ng/Spotl i ght Bul b: 5W
1 .
2.
3,
4.
Remove the two screws and the cei l i ng/spotl i ght
hous I ng.
Di sconnect the 4P connector
(B)
from the housi ng
(c).
22-82
5. Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to thdtabl e.
\
Termi nal
;il;
---tl\
1 2
BODY
GROUND
CEI LI NG LI GHT
OFF
MIDDLE
re'o
ON o r @
----o
SPOTLIGHTS
ON
R I
OFF
,
- o N
OFF
G
- - o
G
-----o
l f the conti nui ty i s not as speci fi ed, repl ace the
bul bs or t he l i ght .
Trunk Light Test
Open t he t r unk l i d.
Pr y out t he t r unk l i ght assembl y.
Trunk Li ght Bul b: 5W
3, Di sconnect the 2P connector from the housi ng.
4. Open the trunk l i ght cover.
5. Check f or cont i nui t y bet ween t he No. 1and No. 2
t er mr nal s.
6. l f there i s no conti nui ty, repl ace the bul b or the l i ght.
1 .
2.
Trunk Lid Latch Switch Test
1. Open t he t r unk l i d.
2. Di sconnect the 3P connector from the trunk l atch.
Check for conti nui ty between the termi nal s i n each
t r unk l i d posi t i on accor di ng t o t he t abl e.
\
Termi nal
ill'l";-ll\
2
OPEN
o o
cLosEo
4. l f the conti nui ty i s not as speci fi ed, repl ace the
t r unk l at ch.
22-83
Dash Lights Brightness Controller
| /,il\
L-+r
>F 8rx/YEL
\ l c1-r/
Circuit Diagram
t
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c{01
MAIN UItDEfi HOOOFUSE/BEIAY 8OX
UiIDER DASH
FUS[/NELAYEOX
22-84
Controller Input Test
1. Remove the gauge
assembl y
(see page
22-52).
2. I nspect t hegaugeassembl yconnect or B( 12P) t er mi nal st obesur et heyar eal l maki ng good
cont act .
.
l f the termi nal s are bent, l oose, orcorroded. repai rthem as necessary, and recheck the system.
.
l f the termi nal s l ook OK. go to step 3.
RED/BLK YEL WHT/RED
Wi re si de of
f emal e t ermi nal s
J
)
A
(cont' d)
J
22-85
Dash Lights Brightness Gontroller
1
1
Controller Input Test
(cont'dl
3. Reconnect the connectors to the gauge assembl y.
4. Back probe the connector and make these i nput tests.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
. l f al l t hei nput t es t s pr ov eOK, t hec ont r ol l er s wi t c hboar dor t hemai npr i nt edc i r c ui t boar di nt hegauge
assembl y must be faul ty; repl ace i t.
Cavitv Wi re Test condition Test: Desired result Possible cause if result is not obtained
B3 RED/BLK Combi nat i on
l i ght swi tch
ON {)00!) or
Check for vol tage to ground:
There shoul d be battery vol tage.
Bl own No. 23 { 10 A) f use i n t he
under-dash fuse/rel ay box
Faul t y t ai l l i ght r el ay
Faul ty combi nati on l i ght swi tch
Poor gr ound
{ G401)
An oDen i n t he wi r e
B4 YEL l gni ti on swi tch
oN
( I )
Check for vol tage to ground:
There shoul d be battery vol tage.
Bl own No. 5
( 7. 5
A) f use i n t he
underdash fuse/rel ay box
An open i n the wi re
B5 WHT/REDUnder al l
condi ti ons
Check for vol tage to ground:
There shoul d be battery vol tage.
.
Bl own No. 25
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box
.
An ooen i n t he wi r e
B8 BLK Under al l
condi ti ons
Check for vol tage to ground:
There shoul d be l ess than 1 V.
Poor gr ound ( G501)
An oDen i n t he wi r e
B9 BLK Under al l
condi ti ons
Check for vol tage to ground:
There shoul d be l ess than 1 V.
Poor gr ound ( G501)
An ooen i n t he wi r e
810 RED Combi nati on
l i ght swi tch
ON
(i 001)
or
Connect to ground:
Dash l i ght s shoul d come on f ul l
bri ght.
An open i n t he wi r e
22-86
-
Audio System
I
Gomponent Location Index
RADIO REMOTE SWITCH
Test, page 22-90
ACCESSORY POWER SOCKET RELAY
[Wi .e
col ors: WHT/BED, LT BLU;l
LYEL/RED
and BLUAVHT
l
Test, page
22-40
\
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,.,\
r,,
AUDIO UNIT
Removal , page 22-89
Connector Bepl acement, page
22-89
LEFT TWEETER {'02-03 modelsl
Repl acement, page 22-91
TWEETER
('02-03
modelsl
Repl acement , page 22-91
PASSENGER'S DOOR SPEAKER
Repl acement, page 22-91
ORI VER' S DOOR SPEAKER
Fepl acement , page 22-91
ANTENNA
Repl acement , page 22 92
/
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1
ANTENNA LEAD
Audio System
Ci rcui t Di agram
DlsH Lictlls
BB|GHflESS
c0f{Ti0tun
E SIE
srAiT
slvtTcH
v
I
G502
MAINUNOEN HOOD FUSgffIAY 8OX
AUOIOUl{T
o @ o @
LINTWEETEB' DRIVEI'S PASSEIGETS ftGHITWEEIIS'
0008 sPflxES Doons'urcn
LIGHT |
-
l0.55wril
lij
a
lu' ]lnu ]l:r*" ll"',
22-88
1 .
Audi o Uni t Removal
Make sure you have the anti -theft code for the radi o.
then wri te down the frequenci es for the radi o' s
preset buttons.
Remove the radi o panel (see page 20-80).
Remove the four mounti ng screws
(A).
Di sconnect the 20P connector {B) and antenna l ead
( C) f r om
t he audi o uni t .
Instal l i n the reverse order of removal .
Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on presets.
2.
3.
5.
6.
Audio Unit Connector Replacement
When repl aci ng an audi o uni t connector, match the
wi r es t o t he cavi t i es l i st ed i n t he f ol l owi ng t abl e.
Cavi t i es 4, 5, 6, 11, 12, 13, 15 and 16 ar e not used.
Cavitv Wire Connect to
1 YEL/ GRN Ant enna ampl i f i er
2 WHT/REDACC
(Mai n
stereo power
suoDr v,
3 GRN/ REDRadi o remote swi tch
7 GRN/ BLKPassenger' s door speaker
(+
),
RI G HT Tweet er
( +
) '
8 GRNI/EL Dri ver' s door speaker
(+
),
LEFT Tweet er
( +) '
9 RED/ BLK Li ohts-on si onal
1 0 WHT/BLU Constant
power
1 4 YEL/BLU Radi o remote swi tch
(MUTEI
17 LT GRN Passenger' s door speaker
(
)
RI GHT Tweet er
(
) '
1 8 GRY/REDDri ver' s door speaker
(
)
LEFT Tweeter
(
)'
l q
RED Dash l i ghts bri ghtness
cont r ol l er
20 BLK G r ound { G502)
: ' 02- 03 model s
22-89
Audio System
J
J
1 .
Radio Remote Switch Test
Remove the i nstrument panel (see page 20-80).
Di sconnect the 6P connector
(A)
from the swi tch.
Remove the three mounti ng screws
(B).
Measure resi stance between the No. 5 and No.6
termi nal s i n each swi tch
posi ti on accordi ng to the
tabl e.
l f the resi stance i s not as speci fi ed, repl ace the
swi tch.
t
3.
4.
Position Resistance
OFF Aoorox. 10 k Q
VOL. UP
( +)
Approx. 307.3 k Q
VOL, DOWN
( )
Approx.46.8 k Q
CH ADDr ox. 906. 6 k Q
MODE Aoorox. 2.6 k O
22-90
I
5. Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e.
l f the conti nui ty i s not as speci fi ed, repl ace the
i l l umi nati on bul b{s)
(B)
or the swi tch.
\
Terminal
t ""-
----- ----\
3 1
COMBINATION LIGHT SWITCH ON
G o
COMBINATION LIGHT SWITCH OFF
Wi th the MUTE swi tch ON, check for conti nui ty
between the No.2
(+)
and No. 1
(
) termi nal s.
There shoul d be conti nui ty. l f there i s no conti nui ty,
reol ace the swi tch.
J
Speaker Replacement
Speaker:
1. Remove the door panel (see page
2O-4).
2. Remove the three mounti ng screws.
J 3. Di sconnect the 2P connector from the soeaker.
Tweeter
('02-03
modelsl:
1. Remove the door panel (see page
20-4).
2. Remove the two screws.
3. Di sconnect the 2P connector from the tweeter.
22-91
Audio System
1 ,
2.
Mast Antenna Replacement
Open the trunk l i d.
Remove the ri ght si de trunk tri m
panel (see page
20-731.
Di sconnect the 2P connector from the antenna
ampl i f i er .
22-92
4. Remove the antenna
(A).
r
7.
Remove the antenna nut
(B)
and spacer
(C).
Di sconnect the antenna l ead
(D)
from the antenna
ampl i f i er .
Loosen the mounti ng bol t from the antenna
ampl i f i er .
Remove the antenna amPl i fi er.
5.
6.
Accessory Power Socket
J
Component Location Index
t
ACCESSORY POWER SOCKET
TesVRepl acement, page 22-95
ACCESSORY POWER SOCKET RELAY
[Wi re
col ors: WHT/RED, YEURED,
J
LBLUMHT
and LT BLU
l
Test, page 22-40
) z
,,
Accessory Power Socket
Gi rcui t Di agram
IGN TION SW TCH
6;\\
afrl
I
I
WHTi REO
WHT.+ WHT/8LK
ACCESSOFY
POWER
SOCKET
MAIN UNDER,HOOO FUSE/ RELAY BOX
WBT/NED
BLK
I
I
--
G50t
ENGINE
SIART
swlTcH
V
V
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8LU,'WHT
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t l
l l
ELUAVHT 8LU/WIiT
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.4
-
IG? RLAY
'
SIARTEF CUI
BEL^Y
LT BLU
-J-
CLU]CH
INTERLOCK
swtTcH
22-94
J
Test/Replacement
1 .
2.
3.
Remove the rear consol e
(see page 20-78).
Di sconnect the 2P connector.
Inspect the connector termi nal s to be sure they are
al l maki ng good
contact.
.
l f the termi nal s are bent, l oose or corroded,
repai r them as necessary, and recheck the
system.
.
l f t het er mi nal s l ook OK, go
t o st ep 4.
WHT/RED
Wi re si de of femal e termi nal s
Turn the i gni ti on swi tch ACC
(l ),
and check for
vol tage between the No.
' 1
and No. 2 termi nal s.
.
There shoul d be battery vol tage.
.
l f there i s no battery vol tage, checkfor:
-
bl own No. 9
( 10
A) f use i n t he under - dash
fuse/rel ay box.
-
faul ty accessory power
socket rel ay
-
poor gr ound ( c401,
G60' 1)
-
an open i n t he wi r e.
) J
4 .
)
A
J
22-95
5. Remove the housi ng and socket.
Horn
Component Location Index
HORN{l ow)
(' 00-03
model s)
Test / Bepl acement , page 22' 97
MAI N UNDER. HOOD
FUSE/RELAY BOX
: t
l l l l r r
, / \
(' 02-03 model s)
TesVRepl acement ,
page 22-97
22-96
J
Ci rcui t Di agram
)
) J
22-97
2.
3.
Horn Test/Replacement
1 . Remove the front bumper
(see page
20-92)
(' 00-03
model s).
Open the hood
(' 02-03
model s).
Di sconnect the 1P connector
(A),
and remove the
hor n
( B) .
Test the horn by connecti ng battery
power
to the
termi nal
(A)
and groundi ng
to the bracket {B). The
hor n shoul d sound.
5. l f i t fai l s to sound, repl ace i t.
Horn
2.
1 .
Horn Switch Test
Remove t he st eer i ng col umn upper and l ower
cover {see
page 17-9).
Di sconnect the dashboard wi re harness B 4P
connector
(A)
from the cabl e reel
(B).
Check for conti nui ty between the cabl e reel No. 2
t er mi nal and body gr ound i n each swi t ch
posi t i on
accordi ng to the tabl e.
.
l f there i s conti nui ty. the horn swi tch i s OK.
.
l f there i s no conti nui ty,
go to step 4.
\
Terminal
Position
2 Body ground
Pushed o-
--11
Released
3.
22-98
4. Remove the dri ver' s ai rbag
(see page 23-65).
Check for conti nui ty between the cabl e reel No. 2
termi nal
(A)
and the horn swi tch
posl ti ve termi nal
( B) .
.
l f t her e l s nocont i nui t y, r epl acet hecabl e r eel
(see page 23-72) and check for
proper operati on.
.
l fthere i s conti nui ty, repl ace the horn swi tch.
Trunk Li d Opener
Component Location Index
TRUNK OPENER SWITCH
Test, page 22-' 101
f
,_,
/t
''
'//
ltt
"
-'t'
':':'t':'
\ :
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"-'-..-=-
-r I
( . ,
TRUNK OPENER SOLENOIO/
LATCH SWITCH
Sol enoi d Test ,
paqe
22 101
Lat ch Swi t ch Test page 22-83
.l
{
Trunk Lid Opener
UNOER.DASH
FUSAFEUY 8OX
MAIN UNDER.HOOO
FUSE/BEUY 8OX
TRUNK INDICATOR
uGHl
TRUNKLI GHT
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SLU/8LK
KEYLESS
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D@N L@K
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co.{?Rol t2
v q
t l
BIfiEL BLfiEL
r l
r l
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8L&YEL
Circuit Diagram
soLENo,D jl
:*sl-
BLK
G601
22-100
Trunk Opener Switch Test
Remove the rear consol e
(see p age 20-78| | .
Di sconnect the 2P connector from the swi tch.
3. Check for conti nui ty between the No. l and No.2
t er mi nal s.
.
There shoul d be conti nui ty when the swi tch i s
pusneo.
.
There shoul d be no conti nui ty when the swi tch i s
rel eased.
4. l f the conti nui ty check i s not as speci fi ed, repl ace
the swi tch.
1 .
2.
1 .
Trunk Opener Solenoid Test
Open the trunk l i d.
Di sconnect the 3P connector from the trunk l atch.
Termi hal si de of
mal e t ermi nal s
3. Check sol enoi d operati on by connecti ng power
and
ground
accordi ng to the tabl e. To prevent
damage
to the sol enoi d, appl y battery vol tage onl y
momentari l y.
\
Termi nal
iltfi." \
1 2
UNLOCK
e e
l f the sol enoi d does not operate as speci fi ed,
repl ace i t.
22-101
Power Mirrors
Component Location Index
POWER MIRROR SWITCH
Test, page 22-105
POWER MIRROR
Functi on Test,
Page
22-104
Actuator Test,
Page
22-105
Reol acement, Daqe 20-21
Aci uator Repl acehent,
Page
22 106
,/
22-102
Ci rcui t Di agram
MAiN UNOR HooD 'USE/BEUY BOX
UNDEE.DASH
FUSE/8ELAY EOX
LEFT
I
22-103
Power Mirrors
I
{
1 .
Function Test
Remove the dri ver' s door
panel (see page 20-4).
Di sconnect the 10P connector {A) from the
power
mi rror swi tch
(B),
and i nspect the termi nal s. l f the
termi nal s are OK,
go to step 3.
RED GRN/WHT RED/BLU YEL/BLK
3. Choose the appropri ate test based on the
symptom:
.
Both mi rrors don' t work,
go to step 4.
.
Left mi rror doesn' t work, go to step 6.
.
Ri ght mi rror doesn' t work, go to step 7.
Both mirrors
4. Reconnect the 10P connector, and check for vol tage
between the No. 9 termi nal and body
ground wi th
t he i gni t i on swi t ch ON
( l l ) .
There shoul d be battery vol tage.
l vl ove the mi rror sel ector swi tch to the l eft or ri ght
and hol d down the mi rror swi tch i n any di recti on.
.
l f there i s no batteryvol tage, check for:
-
bl own No.
' 19
{7.5
A) fuse i n the under-dash
fuse/rel ay box.
-
an open i n t he YEVBLK wi r e.
.
l f there i s battery vol tage, go to step 5.
22-104
-
5. Check for conti nui ty between the No. 10 termi nal
and body
ground.
Move the mi rror sel ector swi tch to the l eft or ri ght
and hol d down the mi rror swi tch i n any di recti on
There shoul d be l ess than 1 V.
.
l fthere i s no more than 1 V, check for:
-
an open i n t he BLK wi r e.
-
poor ground (G50' l
).
.
l f there i s l ess than 1 V, check both mi rrors
i ndi vi dual l y as descr i bed i n t he next col umn.
Left miror
6, Connect the No. 9 termi nal to the No. 7 termi nal .
and the No. 5
(or
No. 4) termi nal to body
ground
wi th
j umper
wi res. The l eft mi rror shoul d ti l t down
(or
swi ng l eft) wi th the i gni ti on swi tch ON
(l l ).
'
l f the mi rror does not ti l t down
(or
does not swi ng
l eft), check for an open i n the GRN/WHT
(or
RED)
wi re between the l eft mi rror and the 10P
connector. l f the wi re i s OK, check the l eft mi rror
actual or.
.
l f the mi rror nei ther ti l ts down nor swi ngs l eft,
repai r the REDI/EL wi re.
.
l f the mi rror works
properl y, check the mi rror
swi tch.
Right mirror
7. Connect the No. 9 termi nal to the No. 6 termi nal ,
and t he No. 5
( or
No. 3) t er mi nal t o body gr ound
wl th
j umper
wi res. The ri ght ml rror shoul d ti l t
down
(or
swi ng l eft) wi th the i gni ti on swi tch ON
(l l ).
.
l f t he mi r r or does not t i l t down { or does not swi ng
l eft), check for an open i n the GRNMHT
(or
BLU/
WHT) wi re between the ri ght mi rror and the 10P
connector,
l f the wi re i s OK, check the ri ght mi rror actuator.
.
l f the mi rror nei therti l ts down nor swi ngs l eft,
repai r the RED/BLU wi re.
.
l f t he mi r r or wor ks
pr oper l y, checkt he mi r r or
swi tch.
Power Mirror Switch Test
1. Remove t he dr i ver ' s door panel ( seepage20- 4) .
2. Di sconnect the 10P connector from the power
m i r r or swi t ch.
Check for conti nui tV between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
3.
4.
\
Termi nal
F;ani";ll\
3 4 5 6 7 9 10
UP
Dol/vll
L. LEFT
RI GHT
OFF
G-
: , ,
^ I
o-
c---.
-
o-_
_{-+-{l
I U P
.
DoryN
R LTI
RIGHT
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orp-
, Fo
--.-.--
-o
- --::
---t-O
!
- o
o
: ]
o-
r
o
o
-a
l f the conti nui ty i s not as speci fi ed, repl ace the
swi tch.
Power Mirror Actuator Test
1. Remove the door panel (see page
20-4).
2. Di sconnect the 3P connector from the Dower mi rror.
f emal e t ermi nal s
Check actuator operati on by connecti ng power
and
ground
accordi ng to the tabl e.
r,_ ]1ry1
Position
1 2
TILT UP
J @
TILT DOWN
o o
SWING LEFT o o
SWI NG RI GHT
o o
l f the mi rror fai l s to work properl y, repl ace the
mtrror acIual or.
4.
22-105
Power Mirrors
2.
3.
Power Mirror Actuator Replacement
' t .
Remove the
power mi rror from the door
(see page
20-21).
Record the termi nal l ocati ons and wi re col ors.
Cutthe wi re harness wi th a wi re cutter.
Careful l y
pul l out the bottom edge of the mi rror
hol der by hand.
Separate the mi rror hol der from the actuator by
sl owl y
pul l i ng them apart.
22-106
7.
6. Remove the screws and the actuator from the
housr ng.
Rovte the wi re harness of the new actuator through
the hol e of the mi rror housi ng, then i nstal l the new
actuator i n the reverse order of removal .
l nsert the termi nal s i nto the connector i n the
ori gi nal arrangement as shown bel ow.
Lsft and right
Termi nal si de o{ mal e termi nal s
Reassembl e the mi rror i n the reverse order of
di sassembl y.
Be careful not to break the mi rror hol der when
rei nstal l i ng i t to the actuator.
Operate the
power mi rror to check that the actuator
works smoothl y.
8.
9.
' 10.
Wiper/Washer
J
Component Location Index
J )
WINOSHIELD WASHER TUBE
Repl acement, page 22-1 15
WINDSHIELO WIPER ARMS
and LINKAGE
Repl acement, page 22-1 14
WIPER/WASHER SWITCH
TesVRepl acement , page 22-l 1 1
INTERMITTENT WIPER RELAY
{' 00-01 model s)
fwi re
col ors: GRN/BLK,
I
I GRN,
BLK, GRN/ RED
I
Land
BLU/WHT
I
Test, page 22 40
INTERMITTENT WIPER CIRCUIT
(l n
the gauge assembl y)
I nput Test , page 22- 110
WINDSHIELD WASHER MOTOR
Test . page 22-112
WI NDSHI ELD WI PER MOTOR
Test , page 22-' 112
Repl acement . page
22 114
)
INTERMITTENT WIPER RELAY
(' 02-03
model s)
fwi re
col ors: cBN/BLK,
' l
I GRN, BLK, GRN/ RED
La nd BLU,/WHT l
Test, page 22-40
J
22-107
Wiper/Washer
Ci rcui t Di agram
GBNTBLK
GRN/8LK
rl
I
G5N/BLK
tr.$fl 6:rtunr
I\1A N UNDER NOOD FUSE/RELAY BOX
No4r (r00aj No 12
{rcA)
UNOEE OASFl
FUSE/BELAY BOX
BLKryfiI
I l - F - - + - - J \
ool " '
I
dl ut f ouu,
No 13 ( 7 5A)
WINDSIIIELD WIPEN MOTOR
UNDEF OASH
FUSEFELAY BOX
G20r
22-108
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f33loo^)
F*
UNOER DASH
FUSE/FELAYEOX
G50r
22-109
Wiper/Washer
{
{
Intermittent Wiper Control Circuit Input Test
1. Remove the
gauge assembl y {see
page 22' 52).
2. l nspect the al l connectors and socket termi nal s to be sure they are al l maki ng good contact.
.
l f the termi nal s are bent, l oose, or corroded, repa i r th em as necessa ry, and recheck the system
.
l f the termi nal s l ook OK,
go to step 3.
GAUGE ASSEMBLY CONNECTOR B
(I2P) GAUGE ASSEMSI.Y CONNECTOB C {2OP)
YEL WHT/ REO
? 3 4 5
6 7 8 I 1 0 11
8LK GRN BLU/ORN
Wi r e si de of f emal e t er mi nal s Wi r e si de of f emal e t er mi nal s
3. Make these i nput tests at the connector.
. l f anvt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l the l nput tests
prove
OK, the
gauge assembl y must be faul ty; repl ace i t.
1 2 3 5 6 1 8
,/ r/
11 12 t c
,/ ,/
WHT/BLK
BLU/ BLK
Cavi ty Wi re Test condition Test: Desired result Possible cause if resuh is not obtained
B4 YEL l gni t i on swi t ch ON
0r )
Check for vol tage to ground:
There shoul d be battery
vol taoe.
Bl own No. 5
(7.5
A) fuse i n the
under-dash fuse/rel ay box
An open i n the wi re
B5 WHT/REDU nder al l
condi t i ons
Check for vol tage to
ground:
There shoul d be battery
vol tage.
Bl own No. 54 { 30
A) f use i n t he
mai n under-hood fuse/rel ay box
Bl own No. 25
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box
An ooen i n the wi re
B8 BLK Under al l
condi ti ons
Check for conti nui ty to
gr ound;
There shoul d be conti nui tv
.
Poor gr ound ( G501)
.
An open i n the wi re
B9
B1' l GRN l gni t i on swi t ch ON
flr)
Check {or vol tage to
ground:
There shoul d be battery
vorrage.
Bl own No. 8
( 20
A) f use i n t he
under-dash fuse/rel ay box
Faul ty Intermi ttent wi per rel ay
An open i n t he wi r e
c' 11 BLU/ ORNl gni ti on swi tch ON
(
)
Check for vol tage to
ground:
There shoul d be battery
vol tage.
Bl own No. 13
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box
Faul ty wi per motor
An open i n t he wi r e
c12 BLU/BLK l gni ti on swi tch ON
( l l )
and wi per
swi tch at INT
Check for vol tage to
ground:
There shoul d be battery
vol tage.
Bl own No. 12
( 15
A) f use i n t he
under-dash fuse/rel ay box
Faul ty wi per swi tch
An open i n the wi re
c 13 WHT/BLK l gni ti on swi tch ON
( l
l ) and washer
swi tch ON
Check for vol tage to ground:
There shoul d be battery
vol tage.
Bl own No. 12
( 15
A) f use i n t he
under-dash fuse/rel ay box
Faul ty washer swi tch
An ooen i n the wi re
22-110
J
J
J
Wiper/Washer Switch Test/Replacement
1. Lower the steeri ng col umn, and remove the steeri ng col umn covers
(see page 17-9).
2. Di sconnect the
' 14P
connector from the wi Der/washer swi tch.
3. Remove the two screws, then pul l
out the wi per/washer swi tch.
4. Check for conti nu i ty betwee n the term i na l s i n each swi tch posi ti on
accord i ng to the ta bl e. l f the conti nui ty i s not as
speci fi ed, repl ace the swi tch.
\
Terminal
t""--
--l
4 1 4 13 12 1 1
OFF
o-
--o
INT
o-
(-/-
LO
o-
--o
HI
o-
Mist switch ON
o-
--u
Washer switch ON
.a
J
22-111
Wiper/Washer
1
J
Wiper Motor Test
1. Open the hood and remove the cap nuts and the
wi per arms
(see page 22-1' 14]-.
2. Remove the hood seal and cowl cover
(see page
22-114],.
3. Di sconnect the 5P connector from the wi per motor.
Test the motor by connecti ng battery power and
ground
accordi ng to the tabl e. l f the motor does not
run or fai l s to run smoothl y, repl ace i t.
Position
Terminal
1 2 4
LOW SPEED o @
HIGH SPEED o o
5. Connect an anal og vol tmeter between the No. 5
(
+
)
and No. 3
(
) termi nal s, and run the motor at l ow
or hi gh speed. The vol tmeter shoul d i ndi cate 0 V
and 5 V or more al ternatel y. l f i t does not, repl ace
the motor,
22-112
-
Washer Motor Test
Remove the ri ght i nner tender {see
page 20-105).
Di sconnect the 2P connector
(A)
from the washer
mot or
( B) .
Test the washer motor by connecting battery
power
to termi nal No. 1 and ground to termi nal
No. 2.
l f the motor does not run or fai l s to run smoothl y,
repl ace the motor.
1 .
Washer Reservoir Replacement
1. Pul l away the ri ght i nner fender.
2. Di sconnect the washer tube
(A)
and washer motor
2P connector
(B).
USA:
9.8 N.m (r.0tgr.ln, 7.2lbtft)
3. Remove the bol ts, then separate and remove the
fi l l er neck
(C)
from the washer reservoi r
(D).
4. Remove the washer reservoi r.
5. Instal l i n the reverse order of removal . Check the
washer motor operati on.
9. 8 N m 110t gt m, 7, 2l bl hl
22-113
WiperlWasher
I
4
Wiper Motor Replacement
1 . Open the hood, and remove the cap nuts and the
wrper arms.
2.
?
Remove the hood seal and cowl cover.
Di sconnect the 5P connector
(A)
from the wi per
motor
(B).
4. Remove the bol ts, then remove wi ndshi el d wi per
l i nkage assembl y
( C) .
10 x 1. 25 mm
18 N m {1. 8 kgf . m, 13l bf . f t l
6 x 1 , 0 mm
9. 8 N. m
(1. 0
kgf m, ?. 2 l bf . f t )
22-114
J
5. Remove the three mounti ng bol ts and nut from the
wi per l i nkage
(A)
to remove the wi per motor
(B).
6. Instal l i n the reverse order of removal , and note
these i tems:
.
Grease al l movi ng
parts.
.
Before rei nstal l i ng the wi per arms, turn the wi per
swi tch oN, then OFF to return the wi per shafts to
the park posi ti on.
.
l f necessary, repl ace any damaged cl i ps
.
Check the wi per motor operati on,
{1. 5 kgf . m, 11l bf . f t l
)
t
Washer Tube Replacement
1. Remove the front bumper and the ri ght i nner fender
(see page
20-105).
2. Remove the washer nozzl es and cl i Ds, then remove the tube.
3. I nst al l i nt her ever seor der of r emoval , Takecar enot t opi ncht hewasher t ube. Checkt hewi ndshi el dwasher
oDeraI| on.
J
/a- \
la+
-mr
22-115
lmmobilizer System
Component Location Index
IMMOBILIZER RECEIVER UNIT
Troubl eshooti ng, page 22-' 120
Repl acement, page 22- 121
TRANSPONDER
(Bui l t
i nt o t he i gni t i on key)
IGNITION KEY
(Mast er
and val et keys)
IMMOBILIZER INDICATOR LIGHT
Bul b Locat i on, page 22-46
22-116
\
"l
J
J
System Description
The vehi cl e i s equi pped wi th an i mmobi l i zer system that wi l l di sabl e the vehi cl e unl ess the proper i gni ti on key i s used.
Thi s system consi sts of a transponder l ocated i n the i gni ti on key, an i mmobi l i zer recei ver uni t, an i ndi cator Ii ght, and
t he EcM.
The vehi cl e has two ki nds of kevs.
.
The bl ack master key for:
-
i gni ti on swi tch.
-
door l ocks.
-
trunk l ock.
.
The gray val et key for:
-
i gni ti on swi tch.
-
door l ocks.
When the key i s i nserted i n the i gni ti on swi tch and turned to the
(l l ) posi ti on,
the i mmobi l i zer recei ver uni t sends
power
to the transponder i n the i gni ti on key. The transponder then sends a coded si gnal back through the i mmobi l i zer
recei ver uni t to the ECM.
.
The i mmobi l i zer system can store up to si x key codes,
. l f i t i snecessar yt or ewr i t et heECl vl , t hedeal er needst hecust omer ' svehi cl e. al l
i t s mast er keys and val et keys, and
the Honda PGM Tester equi pped wi th an i mmobi l i zer program
card wi th the l atest versi on of PGM Tester software.
Any key that i s not l earned duri ng rewri ti ng wi l l no l onger start the engi ne, except keys dupl i cated wi th the l l co Code
Key Dupl i cator.
. l f t hecust omer hasl ost hi skey, andcannot st ar t t heengi ne, cont act HondaCust omer Rel at i ons.
.
l t i s possi bl e
to add ONE new key wi thout reprogrammi ng al l of the keys
(fol l ow
the prompts i n the PGM Tester
l Ml \4OBl menu).
I
I MMOBI LI ZER RECEI VER UNI T
\
FUEL SUPPLY
SYSTEM
22-117
lmmobilizer System
{
4
System Description
(cont'd)
. l f t hepr oper keyhasbeenused, t hei mmobi l i zer i ndi cat or l i ght wi l l come on f or about 2 seconds, t hen
go
of f .
. l f t hewr ongk ey has beenus edor t hec odewas not r ec ei v edor r ec ogni z edby t heECM. t hei ndi c at or l i ght wi l l c ome
on for about 2 seconds, then i t wi l l bl i nk unti l the i gni ti on swi tch i s turned OFF. For accurate i mmobi l i zer system
di agnosi s,
get as much i nformati on from the customer as
possi bl e. A bl i nki ng i ndi cator l i ght means the key was not
recogni zed.
. l f
t he i gni t i on swi t ch i st ur ned OFF, t he i ndi cat or wi l l bl i nk f or about 5 seconds t o si gnal t hat t he i mmobi l i zer syst em
has been set correctl y, then the i ndi cator wi l l go off,
NOTE: Large metal obj ects, key fobs, other i mmobi l i zer keys. and other transponders can i nterfere wi th the
i mmobi l i zer si gnal . l f an i ntermi ttent
probl em i s suspected, remove the i gni ti on key from the key ri ng
Probl em Part set PGM-Tester
reoui i ed 7
O Master or val et key has been l ost or addi ti onal
master or val et kev i s reoui red.
Bl ank key YES
CD Al l master and val et keys have been l ost. Bl ank kev x 2. or 3 YES
t l mmobi l i zer recei ver uni t does not work. l mmobi l i zer r ecei ver uni t NO
@ ECNI does not work. ECM YES
O l gni ti on swi tch does not work. l gni ti on swi tch
Master keys, and val et key
(rekey
al l l ock
cvl i nders to the new kev).
YES
6) Door kev cvl i nder i s broken. Door kev cvl i nder
(rekev
the cvl i nder) NO
22-118
-
MAINUNOTR XOOO FUS/RELIY 8OX
Circuit Diagram
IGY
<--l fl
---1__J
I
No5{7.54)
FUST
) -
rcn EP2 ti/toco tMotN
ECM
UIDER-0ASli
FUST/8ELIY 8OX
) -
22-119
lmmobilizer System
{
Troubleshooting
Fol l ow thi s
procedure i f the vehi cl e does not start. or
after rewri ti ng the ECM wi th the PGM-Tester and the
vehi cl e does not start.
Note these items belore troubleshooting:
.
Due to the acti on of the i mmobi l i zer svstem, the
engi ne takes sl i ghtl y more ti me to start than a vehi cl e
wi thout an i mmobi l i zer system.
.
When the system i s normal , and the proper key i s
i nserted, the i ndi cator l i ght comes on for 2 seconds,
then i t wi l l go off.
.
l f t he i ndi cat or st ar t st o bl i nkaf t er 2seconds, or i f t he
engi ne does not start, repeat the stani ng
procedure.
l f the engi ne sti l l does not start, troubl eshoot the
system.
1. Usi ng a scan tool . check for a Di agnosti c Troubl e
Code
( DTC) ( see page 11- 3) .
l s DTC P1607 i ndi cated?
YES Repl ace t he ECM
( see page 11- 4) . 1
NO Go to step 2.
Turn the i gni ti on swi tch ON
(l l )
wi th the
proper key.
Check to see i f the i mmobi l i zer i ndi cator Ii ght
comes on.
Does the indicatot tight blink?
YES Go to step 4.
NO Check for these probl ems:
.
an open i n the PNK wi re between the gauge
assembl y and ECM.
.
a f aul t y i mmobi l i zer i ndi cat or l i ght . l
2.
3.
22-120
J
Check for vol tage between the No. 1 termi nal and
body
ground wi th the i gni ti on swi tch turned ON
(
l l l .
ls there battety voltage?
YES Go to step 6.
NO Check for these probl ems:
.
a bl own No. 2
( 15
A) f use i n t he under - dash
fuse/rel ay box,
.
a bl own No. 46
(15
A) fuse i n the mai n under-
hood fuse/rel ay box.
.
an open i n the YEL/BLK wi re between the PGM-FI
mai n rel ay and i mmobi l i zer recei ver uni t.
.
afaul ty PGI\4-Fl mai n rel ay.t
RED/BLU
Wi re si de of f emal e t ermi nal s
) J
)
6. Check for conti nui ty between the No. 4 termi nal
and body gr ound.
l sthere conti nui ty?
YES Go to step 7.
NO Repai r open i n the BRN wi re between the
i mmobi l i zer r ecei ver uni t and G 101. t
7. Check for conti nui ty between the No. 2 termi nal
and t he ECM.
l s there conti nui ty?
YES Go to step 8.
NO Repai r open i n the RED/BLU wi re between the
i mmobi l i zer uni t and ECI Vl . l
8, Check for conti nui ty between the No. 3 termi nal
and ECM.
ls there continuity?
YES Repl ace the i mmobi l i zer recei ver uni t. l f the
engi ne sti l l won' t start. substi tute a known-good
ECM, and r echeckl
NO Repai r open i n the PNVBLU wi re between the
i mmobi l i zer uni t and ECM. I
) J
22-121
l mmobi l i zer Recei ver Uni t
Replacement
1 .
5.
6.
Remove the steeri ng col umn covers
(see page 17-
Di sconnect the 5P connector
(A)
from the
i mmobi l i zer r ecei ver uni t
( B) .
Di sconnect the 7P connector
(C)
from the i gni ti on
key swi tch.
Remove the four screws, and remove the
i mmobi l i zer recei ver uni t from the i gni ti on key
cyl i nder .
Instal l i n the reverse order of removal .
After repl acement, make sure the i mmobi l i zer
i ndi cator l i ght bl i nks correctl y.
NOTE: The Ecl vl does not need to be
reprogrammed i f onl y the recei ver has been
reptaceo.
Power Windows
Component Location Index
PASSENGER'SWINDOW SWITCH
TesVRepl acement,
page 22-128
PASSENGER'S WINDOW MOTOR
Test, page 22-129
POWER WINDOW MASTER
swtTcH
(Has
bui l t -i n cont rol uni t )
I nput Test , page 22-125
f est ,
page22- 124
=
Y- . ) ' . ' i
; - \ . "
\ - /
, /
' - - . , r /
Q\
DRIVER'S WINDOW MOTOR
f e$,
page 22-129
22-122
MAIN UNDEF.FiOOO FUSSRELAY 8OX IGNITION SWITCH
COI{VERIIBLE
'r0P
CONTROL
UNIT
f7
I
ELLI/ORN
Gircuit Diagram
Pou/EF WtNoow MASTEn SWTTCH
)
BLK
BLK
I
G501
IGS VgU VMPI IJP DN PWOFO
POWER WINOOW CONTNOL UNIT
cND ue@ or@ PLs SGND
REOTYEL
I
DRIVER'S WINDOWMOTOR
CONVEFfIBLE TOP COIITFOL UNII
22-123
Power Windows
{
{
{
Master Switch Test
2.
1 . Remove the dri ver' s door panel (see page 20-4).
Di sconnect the 14P connector from the
power
wi ndow master swi tch.
2 3 4 5 6
7 t1 9 10 11 12 t 3 t 4
22-124
3. Check the master
passenger' s swi tch for conti nui ty
between the termi nal s i n each swi tch
posi ti on
accordi ng to the tabl e.
Dri ver' s Swi tch
NOTE: The dri ver' s swi tch i s combi ned wi th the
control uni t so you cannot i sol ate the swi tch to test
i t. l nstead, run the master swi tch i nput test
procedures (see
step5 on
page 22-1261.
Passenger' s Swi tch
\
Termi nal
1 3 4 6 12
Posirion
Slili"n
\
OFF
ON
OFF
G o
PASSENGER' S
swtTcH
UP
ON o-t-o
__ 'o
OFF
PASSENGER' S
swtTcH
DOWN
ON CF ff
OFF
l f the conti nui ty i s not as speci fi ed. repl ace the
swi tch.
1 .
2.
Master Switch Input Test
Remove the door panel (see page
20-4).
Remove the power wi ndow master swi tch
(A)
from the door
panel .
GRN/ ALK
RED/BLK
Wi re si de of
femal e termi nal s
?
BLU/ ORN
GRN/WHT
RED/WHT
BLU/REO
Di sconnect the 14P connector
(B)
and the l Op connector
(C)
from the
power
wi ndow master swi tch.
Inspect the connectors and socket termi nal s to be sure they are al l maki ng good
contact.
.
l f the termi nal s are bent, l oose o r corroded, repai rthem as necessary, and recheck the svstem.
.
l f the termi nal s l ook OK, go to step 5,
(cont' d)
22-125
Power Windows
{
{
Master Switch Input Test
(cont'd)
Wi th the master swi tch sti l l di sconnected, make these i nput tests at the 14P connector'
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesyst em.
.
l f al l t he i nput t est s
pr oveOK, got o st ep6
Cavitv Wire Test condition Test: Desired result Possible cause if result is not obtained
4 GRN/ BLK l gni t i on swi t ch ON
flr)
Check for vol tage to
g rou nd:
There shoul d be battery
vol taqe.
.
Bl own No. 8
( 20
A) f use i n t he
under-dash fuse/rel ay box
.
An open i n the wi re
BLK U nder al l
condi t i ons
Check for conti nui ty to
gr ound:
Ther e shoul d be cont i nui t v.
.
Poor gr ound
( G501)
.
An open i n the wi re
BLU/RED Connect the No. 4
t er mi nal t o t he
No. 13 t er mi nal
and connect the
No. 4 t er mi nal t o
t he No. 12 t er mi nal ,
then turn the
i gni ti on swi tch ON
(
l l ) .
Check for passenger' s
wi ndow motor:
It' s shoul d run
(the
wi ndow
moves up) .
Bl own No. 18
(20
A) f use i n the
under-dash fuse/rel ay box
Faul ty
passenger' s wi ndow motor
Faul ty passenger' s wi ndow swi tch
Faul ty converti bl e top control uni t
Poor
gr ound ( G501)
An open i n the wi re
RED/1/VHT
o BLU,^/VHTConnect the No. 4
termi nal to the
No. 6 t er mi nal .
Check for
passenger' s
wi ndow motor:
It' s shoul d run
(the
wi ndow
moves oown,.
12 REDivVHT
11 GRNA//HTUnder al l
condi ti ons
Check for vol tage to
gr ouno:
There shoul d be battery
vol taoe.
.
Bl own No. 17
(20
A) fuse i n the
under-dash fuse/rel ay box
.
An open i n t he wi r e
5 RED/BLK Connect the No. 5
(2)
termi nal to the
No. 11 t er mi nal
and connect the
No. 3 t er mi nal t o
t he No. 1 t er mi nal .
Check for dri ver' s wi ndow
motor:
It shoul d run
(the
wi ndow
moves up).
Faul ty dri ver' s wi ndow motor
An open i n the wi re
3 REDI/EL Connect the No. 3
termi nal to the
No. 11 t er mi nal
and connect the
No. 5 t er mi nal t o
t he No. 1 t er mi nal .
Check for dri ver' s wi ndow
motor:
It shoul d run
(the
wi ndow
moves oownl .
22-126
J
6. Reconnect the master swi tch, and perform
the fol l owi ng i nput tests.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesvst em.
.
l f al l the i nput tests prove
OK, go
to step 7.
7. l fal l the i nput tests proveOK,the power wi ndow master swi tch mustbefaul ty; repl ace i t,
Cavi ty Wire Test condition Test: Desired result Possible cause if result is not obtained
8 BLU Whi l e oper at i ng
the dri ver' s
wi ndow swi tch
Check for vol tage between
t he No. 8 and No. 2
I er m I na t s:
Ther e shoul d be 0- 5 V or
more re0eatedl v.
Faul ty dri ver' s wi ndow motor
Faul ty power
wi ndow master
swtrcn
An open i n t he wi r e
2
BLK Under al l
condi ti ons
Check for conti nui ty to
gr ouno;
There shoul d be conti nui tv.
.
Faul ty power
wi ndow master
swrl cn
'
An open i n the wi re
1 4 BLU/ ORNl gni ti on swi tch ON
( l l ) ,
and conver t i bl e
top swi tch ON.
Pa rki ng brake l ever
UP,
Check for vol tage between
t he No. 14 and No. 1
t er mi nal s;
Ther es houl dbe0 SVor
more reoeatedl v.
Faul ty converti bl e top control uni t
Faul ty power
wi ndow master
swrl cn
An open i n the wi re
22-127
Power Windows
Passenger's Window Switch Test/Replacement
1. Remove the swi tch and swi tch
panel from the door
pa n el .
Di sconnect the 6P connector from the swi tch,
Remove the two mounti ng screws from the swi tch
pa nel .
2.
3.
22-128
4. Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e.
Teiminal
Position
1 2 1
UP o-
_o
OFF
o
oo
DOWN
aF-r--
_o
_o
l f the conti nui ty i s not as speci fi ed, repl ace the
swi tch.
t
Driver's Window Motor Test
Moior Test:
1. Remove the dri ver' s door panel (see page
20-4).
2. Di sconnect the 4P connector from the wi ndow
moror.
Test the motor i n each di recti on by connecti ng
battery power
and ground accordi ng to the tabl e.
When the motor stops runni ng, di sconnecl one
l ead i mmedi atel y.
\
Terminal
or**r""
I]
1 2
UP o o
DOWN @ o
4, l f the motor does not run or fai l s to run smoothl y,
reptace tt.
Detect Circuit Test;
5. Connect the test l eads of an anal og ohmmeter to
t he No. 3 and No. 4 t er mi nal s.
6. Run the motor by connecti ng power and ground
to
t he No. 1 and No. 2 t er mi nal s. The ohmmet er
needl e shoul d move back and fonh al ternatel y. l f i t
does not, repl ace the motor.
1 .
Passenger's Window Motor Test
Remove the
passenger' s
door
panel (see page 20-
4t .
Di sconnect the 2P connector from the wi ndow
moIor.
Check wi ndow motor operati on by connecti ng
power
and ground accordi ng to the tabl e. When the
motor stops runni ng, di sconnect one l ead
i mmedi atel y,
\
Tel mi nal
Direction
1 2
UP @ o
DOWN o o
l f the motor does not run or fai l s to run smoothl y,
repl ace i t.
22-129
Keyless/Power
Door Locks
{
J
Component Location Index
LOCK BUTTON
UNLOCK BUTTON
TRUNK BUTTON
PANIC BUTTON
TRANSMITTER
Test , page 22 138
Proqrammi ng,
page 22-' 138
IGNITION KEY SWITCH
Test, page 22-135
PASSENGER'S DOOR SWITCH
TRUNK OPENER SOLENOI O
Test , page 22-101
DRIVER'S DOOR
KEY CYLINDER SWITCH
Test, page 22-137
DRIVER'S DOOR LOCK ACTUATOR/
KNOB SWITCH
Actuator Test, page 22-136
Knob Swi tch Test, page 22-136
ORIVER'S DOOR SWITCH
KEYLESS DOOR LOCK CONTROL UNIT
Input Test, page 22-132
PASSENGER'S DOOR LOCK ACTUATOR
fesI, page 22 137
22-130
4
r t J
Ci rcui t Di agram
/ f ; \ ' | *; "01
*"\'rj|- BL,(YEL
f\-o-f
YEL-
- - t
HoRN FFi Av
I
Y
oaN
I
rF-L
Y5L
IGNITONSWITCH
UNOI.DASH
FUSEiBELAYBOX
8LK/YEI-
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rGNlTtoN
./
!ilt." l-
ELrcwHr
'
lclosd
(ev
n r.redl
V
0008 s$/rTcH
f vi agaqe\
MAIN UNOER.HOOD FUSE/FELAY BOX
TBUNK
OPENER
swtTcH
17
I
BLfiEI
ELICYET
+
TBUNK
OPENEB
SOLENOO
0008 LocK xioB
n
onrvens W
KEY
IiJ,NDER
i._cf
Il
swrrcH j
-
r--i_]
2l UN! oCK
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1 1
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' " j l
oFIVEF'S I
oOOR LOCK I
ACIUATOR 1
No 23 110 )
FUSE
V
L
^ro^*
G^ucE
l-,-.-- *
-l
^ssEMBrY
I iniN3i.r,-rnen I
V
I
REDA/VHI
I
l-
REoMHT
REOA''/HT
cEtUNG/
SPOILIGHTS
V
Lnr*r,
G501
->\7
I
I
LI
UNLOCX
KEYLESS
O@R LOCK
CONTROT UNIT
8LK
G()l
22-131
Keyless/Power
Door Locks
.i
I
Keyless Door Lock Control Unit Input Test
1. Di sconnect t he 18P connect or f r om t he keyl essdoor l ockcont r ol uni t '
GRN/ YEL
RED/BLK
PNK/BLK
BLK/YEL YEL/GRN
RED/WHT
WHT
YEL/BLK BLK/WHT
YEL
Inspect the connector and socket termi nal s to be sure they are al l maki ng
good contact'
.
l f the termi nal s are bent, l oose or corroded, repai rthem as necessary, and rech eck the system '
.
l f the termi nal s l ook OK,
go to step 3.
22-132
I
3, Make these i nput tests at the connector.
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecause, t henr echeckt hesvst em.
.
l f al l t he i nput t est s pr oveOK, got ost ep
4.
)
*
1;
' 00- 01
model s
*
2:
' 02-03
model s
)
Cavi ty Wire Test condition Test: Desired result Possible cause it result is not obtained
1 7 BLK Under al l
condi ti ons
Check for conti nui ty to
grou nd:
There shoul d be conti nui tv
Poor gr ound ( G501)
An open i n the wi re
5 BLVYEL Under al l
condi ti ons
Check for conti nui ty to
ground:
There shoul d be conti nui tv.
Faul ty trunk opener sol enoi d
Poor gr ound ( G601)
An open i n the wi re
8 WHT Under al l
condi ti ons
Check for vol tage to ground:
There shoul d be battery
vol taqe.
Bl own No. 26
( 15
Al f use i n t he
under-dash fuse/rel ay box
An ooen i n the wi re
t o YEL l gni ti on swi tch ON
flr)
Check for vol tage to ground:
There shoul d be battery
vol tage.
Bl own No. 5
( 7. 5
A) f use i n t he
under-dash fuse/rel ay box
An open i n the wi re
7 YEVGRN Connect l he No. 7
termi nal to the
No. 8 t er mi nal , and
the No. 6 termi nal
to the No. 17
t er mi nal
momentari l v.
Check door l ock operati on:
The dri ver' s door shoul d
untoct(.
Faul ty actuator
Bl own No. 26
( 15
Al f use i n t he
under-dash fuse/rel ay box
An open i n the wi re
18 PNI(BLU Connect the No. 18
termi nal to the
No. I t er mi nal , and
t he No. 6 t er mi nal
to the No. 17
t er mi nal
momentari l y.
Check door l ock operatl on:
The passenger' s
door shoul d
unl ock.
PNI(BLK Connect the No. 6
termi nal to the
No. 8 t er mi nal , and
t he No. 7 and
No. 18 t er mi nal s t o
the No. 17 termi nal
momenl ant v.
Check door l ock operati on:
Both doors shoul d l ock.
RED/BLK Li ghti ng swi tch ON Check for vol tage to ground:
There shoul d be battery
vol tage.
Bl own No. 23
( 10
A) f use i n t he
under-dash fuse/rel ay box
Faul ty tai l l i ght retay
An open i n the wi re
ORN Under al l
condi t i ons
Check for vol l age to ground:
There shoul d be battery
vottage.
Bl own No. 47
( 10
A) " or
( 15
A) ' '
fuse i n the under-hood fuse/
rel ay box
Faul ty horn rel ay
An open i n the wi re
{cont' d)
J
22-133
Keyless/Power
Door Locks
J
I
Keyless Door Lock Control Unit Input Test
(cont'd)
4. Beconnect the connector to the control uni t, and
perform the fol l owi ng i nput tests at the keyl ess door l ock control
uni t connector,
. l f anyt est i ndi cat esapr obl em, f i ndandcor r ect t hecauset henr echeckt hesyst em'
'
l f al l the i nout tests
prove
OK, the control uni t must be faul ty; repl ace i t'
Cavity Wi re Test condition Tsst: Desired result Possible cause it result is not oblained
1 4 B LK/VVHT Dri ver' s or
passenger' s door
oDeneo
Check for vol tage to
ground:
There shoul d be 1 V or l ess.
.
Faul ty door swi tch
.
An open i n t he wi r e
2 GRNI/EL Al l doors cl osed
and cei l i ng/
spotl i ght swi tch
oosi ti on
"MIDDLE"
Check for vol tage to
ground:
There shoul d be battery
vol tage.
Bl own No. 24
(7.5
A) fuse i n the
under-dash fuse/rel ay box
Bl own cei l i ng/spoti i ghts bui b
An oDen i n the wi re
1 0 YEUBLK Dri ver' s door l ock
knob i n LOCK
Check for vol tage to ground:
There shoul d be 1 V or l ess.
Faul ty dri ver' s door l ock
actuator
Poor ground
{G50' 1)
An ooen l n the wi re
I YEL Dri ver' s door l ock
knob i n UNLOCK
1 3 RED,A/VHTl gni ti on key i s i n
the i gni ti on swi tch
Check for vol tage to ground:
There shoul d be 1 V or l ess.
Faul ty i gni ti on key swi tch
Poor gr ound
( G401)
An open i n the wi re
l 5 WHT Key cyl i nder
swi tch
posi ti on
" UNLOCK"
Check for vol tage to
ground:
There shoul d be 1 V or l ess.
Faul ty dri ver' s key cyl i nder
switch
Poor gr ound
( G501)
An open i n the wi re
22-134
lgnition Key Switch Test
2.
1 . Remove the steeri ng col umn upper and l ower
covers
(see page
17-9).
Di sconnect the 7P connector.
3. Check for conti nui ty between the No. 1 and No.3
t er mi nal s.
.
There shoul d be conti nui ty wi th the key i n the
i gni ti on swi tch.
.
There shoul d be no conti nui ty wi th the key
removed from the i gni ti on swi tch.
4. l f the conti nui ty i s not as speci fi ed, repl ace the
i gni ti on key swi tch.
J
22-135
Keyless/Power Door Locks
J
I
.a
Driver's Door Lock Knob Switch
Test
1. Remove t he dr i ver ' s door
panel ( seepage20- 4) .
2. Di sconnect the 3P connector
(A)
from the door l ock
act uat or
( B) .
Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e.
\
Terminal
Position
A1 A2 A3
LOCK H
UNLOCK
o-
_ O
l f the conti nui ty i s not as speci fi ed, repl ace the door
l ock actuator assembl Y.
22-136
Driver's Door Lock Actuator Test
1. Remove t he dr i ver ' s door
panel ( seepage20- 4)
2. Di sconnect the 2P connector
(A)from
the actuator
t B) .
Check actuator operati on by connecti ng
power and
ground accordi ng to the tabl e, To prevent damage
to the actuator, appl y battery vol tage onl y
moment ar i l y.
Tel mi nal
Posilion
B1 82
LOCK @ o
UNLOCK o o
It the actuator does not operate as speci fi ed,
reDl ace the door l ock actuator assembl y.
4.
)
Passenger's Door Lock Actuator
Test
' 1.
\
Termi nal
Posi t i on
,l
2
LOCK
UNLOCK
@
o
o
o
4.
Remove the passenger' s
door panel (see page
20-
4) .
Di sconnect the 2P connector
(A)
from the actuator
( B) .
Check actuator operati on by connecti ng power
and
ground
accordi ng to the tabl e. To prevent
damage
to the actuator, appl y battery vol tage onl y
moment ar i l y.
l f the actuator does not operate as speci fi ed,
repl ace the door l ock actuator assembl y.
)
1 .
2.
Driver's Door Key Cylinder Switch
Test
Remove the door panel (see page
20-4).
Di sconnect the 2P connector
(A)
from the key
cyl i nder swi tch.
3. Check for conti nui ty between the termi nal s i n each
swi tch posi ti on
accordi ng l o the tabl e.
Termi nal
Position
2
OFF
UNLOCK H
4. l f the conti nui ty i s not as speci fi ed, repl ace the
swrtch.
.
22-137
Keyless/Power
Door Locks
Transmitter Test
NOTE:
.
l f the doors unl ock or l ock wi th the transmi tter, but
the LED on the transmi tter does not come on, the LED
i s faul ty; repl ace the transmi tter.
.
l f anydoor i s open,
you cannot l ockt he door wi t ht he
transmi tter.
.
l f you unl ocked the doors wi th thetransmi tter, but do
not open any of the doors wi thi n 30 seconds, the
doors rel ock automati cal l y.
.
The doors do not l ock or unl ock wi th the transmi tter i f
the i gni ti on key i s i nserted i n the i gni ti on swi tch.
1. Press the l ock or unl ock button fi ve or si x ti mes to
reset the transmi tter.
.
l f the l ocks work, the transmi tter i s OK.l
.
l f the l ocks don' twork,
goto step 2.
2. Open the transmi tter and check for water damage.
.
l f you f i nd any wat er damage, r epl ace t he
transmi tter.l
.
l f t her e i s nowat er damage,
got o st ep 3.
3. Repl ace the transmi tter battery
(A)wi th
a new one,
and try to l ock and unl ock the doors wi th the
transmi fter by pressi ng the l ock or unl ock button
fi ve or si x ti mes.
.
l f the doors l ock and unl ock, thetransmi tter i s
oK. a
.
l f t hedoor s don' t l ockand unl ock, got ost ep 4.
Reprogram the transmi fter, then try to l ock and
unl ock the doors.
.
l f the doors l ock and unl ock, the transmi ner i s
oK. t
.
l f the doors don' t l ock and unl ock, repl ace the
transmi tter.l
22-138
Transmitter Programming
Stori ng transmi tter codes: The codes of up to three
transmi tters can be programmed i nto the keyl ess
recei ver uni t memory.
(l f
a fourth code i s stored, the
code whi ch was i nput fi rst wi l l be erased.)
NOTE: l t i s i mpor t ant t o mai nt ai n t he t i me l i mi t s
kretween the steps. Make sure the doors, the hood and
the trunk are cl osed.
1, Tur n t he i gni t i on swi t ch ON
( l l ) .
2. Wi thi n 1 to 4 sec.,
push the transmi tter l ock or
unl ock button wi th the transmi tter ai med at the
recei ver uni t behi nd the dri ver' s si de dash.
3, Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
4. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch ON
(l l ).
5. Wi thi n 1 to 4 sec.,
push
the transmi tter l ock or
unl ock button wi th the transmi tter ai med at the
recei ver uni t behi nd the dri ver' s si de dash.
6. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
7. Wi thi n 4 sec., turn the i gni ti on swi tch ON
(l l ).
8. Wi thi n 1 to 4 sec., push the transmi tter l ock or
unl ock button wi th the transmi tter ai med at the
recei ver uni t behi nd the dri ver' s si de dash.
9. Wi thi n I to 4 sec., turn the i gni ti on swi tch OFF.
10. Wi t hi n 4 sec. . t ur n t he i gni t i on swi t ch ON
( l l ) ,
1 1. Wi thi n 1 to 4 sec.,
push the transmi tter l ock or
unl ock button wi th the transmi tter ai med at the
recei ver uni t behi nd the dri ver' s si de dash.
Confi rm you can hear the sound of the door l ock
actuators. Wi thi n
' l
to 4 sec.,
push the transmi tter
l ock or unl ock button agai n. The keyl ess recei ver
uni t i s now i n the
program mode. You must push
the transmi tter l ock or unl ock button of the fi rst
transmi tter agai n to
program that remote.
Wi thi n 10 sec., ai m the transmi tters
(up
to two
addi ti onal ones) whose codes
you want to store at
the recei ver uni t, and Dress the transmi tter l ock or
unl ock buttons.
Confi rm that
you
can hear the sound of the door
l ock actuators after each transmi tter code i s stored.
14. Tur n t he i gni t i on swi t ch OFF, and pul l out t hekey,
15. Confi rm proper operati on of the transmi tters wi th
the new code{s).
12.
Convertible Top
Component Locati on Index
DRIVER'S WINDOW MOTOR
fest, page 22 129
Test, page 22-143
TOP SWITCH
CONVERTIBLE TOP
CONTROL UNIT
Input Test, page 22-' 144
CONVERTIBLE TOP MOTOR
EMERGENCY CONNECTOR
PASSENGER'S WINOOW MOTOR
fe$, page 22-129
RIGHT CONVERTIBLE TOP MOTOR
Test, page22-147
LEFT CONVERTIBLE TOP MOTOR
fesl , page22-147
22-139
Convertible Top
Ci rcui t Di agram
vss srcNrl
DBrV[\lG
CFCUII
f7
Y
I
l "
T
C0l'IVEFTIELI
TOP MOTOF
EM8GII'ICY
CONNECIOR
22-140
I{o.l2l1sAl
UiDEN DASH FUST/8ELIY 8OX
FUSE
MASTIF
swtTc|l
22-141
f - - - 1
DEFOGGER
CHANGT SEIAY
\-7
T
I
r l
Gt01
CONVERNBLT
IOP DISASLT
swIc1r
lolor.d l
Convertible
Top
{
System Description
The convertj bl e top can automati cal l y be opened and
cl osed by operati ng the converti bl e top swi tch
The converti bl e top system consi sts of the converti bl e
top swi tch, control uni t and the motors l ocated on the
converti bl e top assembl y. The top swi tch outputs open
and cl ose si gnal s to the control uni t. The control uni t
opens the dri ver' s and the
passenger' s power wi ndows
then about 0.5 second after the wi ndows start to open,
the control uni t operates the top motors to open or
cl ose the toD.
22-142
\a
Basic Operation
1. Pul l t he
par ki ng br ake l ever uP.
2. Turn the i gni ti on swi tch ON
(l l ).
NOTE: The vehi cl e must be parked or travel i ng at
no more than 3 mph
(5
Km/h).
3- Rei ease the converti bl e top l ock handl es.
4. The top opens whi l e
pressi ng the top swi tch to the
OPEN
posi ti on.
5. The top cl oses whi l e pressi ng the top swi tch to the
CLOSE
posi ti on.
6. Rel ease the top swi tch to stop the operati on of the
top.
J
Convertible Top Switch Test
1. Removethe centerconsol e
(see page 20-761,
2. Di sconnect the 6P connector
(A)
from the swi tch.
3. Check for conti nui ty between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
\
Terminal
Position \
2 3
OPEN
G
oo
o-
--o
CLOSE
G
_o
4. l f the conti nui ty i s not as speci fi ed, repl ace the
i l l umi nat i on bul b
( B)
or t he swi t ch,
22-143
Convertible Top
Convertible Top Control Unit Input Test
Remove the
passenger' s
dashboard l ower cover
(see page 20-81).
Di sconnect the 14P connector
(A)
and 10P connector
(B)
from the converti bl e top control uni t
(C).
1 .
2.
Wi re si de of
f emal e t ermi nal s
*:
Wi th HardtoP
Inspect the connector and socket termi nal s to be sure they are al l maki ng
good contact.
.
l f the termi nal s are bent, l oose or corroded, repai rthem as necessary, and recheckthe system
.
l f the termi nal s l ook OK, go to step 4.
RED/WHT
A'I M A4 A5 A6
A8 A9 At0Al l 412A13
RED/BrK
/ dLr iwxiliii
WHT,/BLK BLU/REO
22-144
4. With the connectors still disconnected, make these input tests at the connectors.
.
l f any t est i ndi cat es a probl em, f i nd and correct t he cause, t hen recheck t he syst em.
.
lf all the input tests prove OK, go to step 5.
Wire Test condition Test: Desired result Possible cause if result isnotobtained
BLU/BLK Under al l condi t i ons Check f or vol t age t o ground:
There should be battery voltage.
Bl own No. 18
(20
A)f use i n t he
under-dash f use/ rel ay box
An ooen i n t he wi re
A13 WHT/REDUnder al l condi t i ons Check f or vol t age t o gr oundl
There should be baftery voltage.
El own No. 25
( 7. 5A) f use
i nt he
underdash f use/ rel ay box
An ooen i n t he wi re
A1
A8
4 1 1
BLK Under al l condi t i ons Check f or cont i nui t y t o ground:
There shoul d be cont i nui t y.
Poor ground (G402)
An open i nt hewi re
810 BLK Under al l condi t i ons check f or cont i nui t y t o
ground:
The. c shor l . l be. ont i nr i r v
.
Poor ground (G501)
.
An ooen i n t he wi re
A6 GRY/ REDUnder al l condi t i ons Check { or vohage t o gr ound:
There should be battery voltage.
El own No. 52 { 20 A) f { r se i n t he
mai n under hood f use/ r el ay box
An ooen i n t he wi r e
A3 GRY Under al l condi t i ons Check f or vol t age t o ground:
There shoul d be bat t ery vol t age.
El own No. 55
(20A)
f use i nt he
mai n under-hood f use/ rel ay box
An ooen in the wire
A5 RED /VHT Di sconnect t he l ef t t op mot or 2P
connect or.
Connect t he A5 t ermi nal t o t he 46
t ermi nal {power) and 44 t ermi nal t o t he
A11 t ermi nal
(ground).
Assist the left side of the top with your
Check t he ri ght t op mot or
operat i on:
I t shoul d run {t he t op moves
opens),
Faul t y ri ght t op mot or
An open i n t he wi re
LT GRN/
RED
Disconnect the left top motor 2P
connect or,
Connect t he A4 t ermi nal t o t he A6
t ermi nal
(power)
and A5 t e. mi nal t o t he
A11 t ermi nal
(ground).
Assi st t he l ef t si de of t he t op wi t h your
Check t he ri ght t op mot or
operat ron:
I t shoul d run
(t he
t op moves
croses, .
Faul t y ri ght t op mot or
An open i n t he wi re
A2 RED/ BLU Di sconnect t he ri ght t op mot or 2P
Connect t he A2 t ermanal t o t he 43
t ermi nal
(power)and
A1 t ermi nal t o t he
A7 t ermi nal l ground).
Assi st t he ri ght si de ot t het opwi t h your
Check the left top motor
oper at i on:
I t shoul d r un
( t he
t op moves
opens) .
Faulty left top motor
An open i n t hewi r e
RED Disconnect the right top motor 2P
connect or ,
Connect t he A1 t er mi nal t o t he 43
t er mi nal
( power i
and 42 t er mi nal t o t he
47 t er mi nal
( gr ound) .
Assi st t he r i ght si de of t he t op wi t h your
Checkthe left top motor
operat i on:
I t shoul d run
(t he
t op moves
.
Faulty left top motor
.
An open i n t hewi re
B5* LT GRN Conver t ; bl e t oD di sabl e swi t ch cl osed Check f or cont i nui t y t o ground:
There shoul d be cont i nLri t y.
Faul t y conveni bl e t op di sabl e
Poor ground (G60' 1,
G901)
An oDen i nt hewi re
*:
With Hardtop
( cont ' d)
22-145
Gonvertible Top
.rl
J
Convertible Top Control Unit Input Test
(cont'd)
RED/WHT
RED/BLU GRN/RED
A1 A2 A3 A4 A5 A6
A O
A9 41041
't
N2 413414
RED/BLK BLK
5, Reconnect t he connect ors t o t he cont rol uni t , and make t he i nput t est s at t he connect ors.
. l f anvt est i ndi cat esaprobl em, f i ndandcorrect t hecause, t henrecheckt hesyst em
.
l f al l t he i nput t est s
prove
OK, t he cont rol uni t must bel aul t y; repl ace i t .
GRY RED YEL
BLU/ORN RED/BLU
GRY/RED
BLU/BLK
Wi re si de of
t emal e t ermi nal s
WHT
BLK BLK
slr neoivel cRN/wHT
WHT/RED
RED
B1 82 B3 B4
B6 87 BB B9 810
/BLK /
BLU/RED
BLU/WHT
RED/BLU
Cavitv Wire Test condition Test Oesired result Possible cause ifresult is notobtained
B3 BED/BLU Connect t he 83 t ermi nal t o t he Al 4
t ermi nal and 84 t ermi nal t o t he 810
t ermrnal ,
Check t he passenger' s wi ndow
motor operationi
I t shoul d run
(t he wi ndow
Fauhy passenger' s wi ndow
mot or
An open i n t he wi re
B4 RED Connect t he B4 t ermi nal t o t he A14
t ermi nal and 83 t ermi nal t o t he 810
Check the passenger's window
motor operalron:
I t shoul d run
(t he
wi ndow
Faulty passenger's window
moror
An open i n t he wi re
B1 YEL l gni t i on swi t ch ON { l l ) Check for voltage to ground:
There should be battery voltage.
Bl own No. 5
(7. 5
A) f use ant he
undeFdash fuse/relay box.
An ooen i n t he wi re
412 GRN,ryVHTParki ng brake l ever up Check f or cont i nui t y t o ground:
There should be continuitv.
'
Faulty parking brake switch
.
An onen i n t he wi re
A9 RED/ BLK lgnition switch ON
(ll),
top switch OPEN Checkl or vol t age t o ground:
There should be batterv voltaoe.
Bl own No. 12
(15
A) f use i n t he
under-dash f use/ rel ay box
Faul t yt op swi t ch
An ooen i n t hewi re
A10 RED/YEL l gni t i on swi t ch ON {l l ), t op swi t ch CLOSE Check for voltage to
ground:
Tha.c <hoDl.l hc haterv voltaoe.
B7 BLUAVHT lgnition switch ON
(ll), power window
mast er swi t ch mai n swi t ch ON, and
nassenocr's win.lows switch DOWN.
Check t or vol t age t o gr ound:
There should be battery voltage.
El own No. 8
( 20A) f use
i nt he
undeFdash fuse/relay box
Faul t y power powerwi ndow
master swttcn
Faul t v passenger' s wi ndow
An onen i n t he wi r e
B8 8LU/ RED l gni t i on swi t ch ON {l l },
power wi ndow
mast er swi t ch mai n swi t ch ON, and
passenger's window switch UP.
Check f or vol t age t o ground:
There should be battery voltage.
B9 RED/BLU l gni t i on swi t ch ON
(l l ), power wi ndow
master switch main switch ON
Checkf or vol t age t o ground:
There should be battery voltage.
Faul t y power wi ndow mast er
Faul t y passenger' s wi ndow
An d6en i n t he wi r e
Wire Testcondition Test: Desired rGsult Possible caure if resuh ia not obtainod
82 BLU/ ORN l gni t i on swi t ch ON
( l l ) , par ki ng br ake
lever up, operate the toP switch
Check for voltage between the
92 and bodygr ound:
Ther e s houl d be 0 SVor mor e
Faul t y t oP cont r ol uni t
Faul t y power wi ndow mast er
An ooen i n t he wi r e
B6 WHT/BLK l gni t i on swi t ch ON {l l ), rai se t he rear of
the vehicle. and rotate one wheel slowlv
Check f or vol t age on t he B6 and
A8 t ermi nal s:
There shoul d be 0 5 V or more
Faulty VSS
Faul t y VSS si gnal dri vi ng ci rcui t
An open i n t he wi re
22-146
I
Convertible Top Motor Test
Right Top Motor:
l . Remove the ri ght corner gusset (see page 20-38).
2. Di sconnect the 2P connector
(A)
from the ri ght top
mot or
( B) .
Ter mi nal si de of mal e t er mi nal s
Assi st the l eft si de of the top wi th
your
hands.
Test the motor i n each di recti on by connecti ng
battery
power
and
ground
accordi ng to the tabl e.
Te. mi nal
Direction
I
OPEN
@ o
CLOSE
o e
l f the motor does not operate as speci fi ed, repl ace
the motor.
l f the top does not work because of a top motor
fai l ure. go
to step 7 to cl ose the top manual l y.
3.
6.
1. Remove the
passenger' s dashboard l ower cover
( see page 20- 81) .
Di sconnect the converti bl e top motor emergency
2P connector
(A).
9. Cl ose t he t op manual l y.
(cont' d)
22-147
Convertible Top
Convertible Top Motor Test
(cont'dl
Left Top Motor:
1. Remove the l eft corner
gusset (see page 20-38).
2. Di sconnect the 2P connector
(A)from
the l eft top
motor {B).
3. Assi st the ri ght si de of the top wi th your hands.
4. Test the motor i n each di recti on by connecti ng
battery
power and ground accordi ng to the tabl e.
Terminal
Position
1 2
OPEN
o @
CLOSE
@ o
l f the motor does not operate as speci fi ed, repl ace
the motor.
l f the top does not work because of a top motor
fai l ure, go to step 7 to cl ose the top manual l y.
Termi nal si de of mal e t ermi nal s
22-148
7. Remove the
passenger' s dashboard l ower cover
(see page 20-81).
Di sconnect the converti bl e top motor emergency
2P connector
(A).
9. Cl ose the toD manual l v.
8.
Removable Hardtop
J
Component Location Index
CONTROL UNIT
Input Test, page 22' 144
J
CONVERTIBLE TOP DISABLE SWITCH
Test , page 22 150
Removable Hardtop
J
{
Convertible Top Disable Switch Test
NOTE: For the converti bl e top di sabl e swi tch ci rcut
di agram, refer to the Converti bl e Top Ci rcui t Di agram
{see
page 22-140}and the RearWi ndow Defogger
Ci r cui t Di agr am
( see page 22- 153) .
1. Remove the l eft rear si de tri m
(see page 20-70).
2. Di sconnectthe 2P connector
(A)
from the
converti bl e top di sabl e swi tch {B).
\ ' - - i 9
-l'(\
-----,-..J-lr
22-150
3. Push the converti bl e top di sabl e swi tch.
Termi nal si de of mal e termi nal s
Check for conti nui ty between the No. I and No. 2
t er mi nal s.
There shoul d be conti nui ty.
l f the conti nui ty i s not as speci fi ed, repl ace the
swtl cn.
Rear Window Defogger
Component Location Index
I
REAR WINDOW DEFOGGER RELAY
! 02-03
model s)
Wi re col ors: BL(RED, WHT/ GnN,
I
LYEUBLU and YEUBLK I
Test, page 22'40
UNDER-OASH
FUSE/RELAY AOX
REAR WINOOW DEFOGGER SWITCH
( ' 02
03 model s)
Test , page 22 155
I
REAR WINDOW OEFOGGER SWITCH
{ 00-01 rnodel s)
Test , page 22-155
(cont' d)
22-151
Rear Window Defogger
\.
{
Component Location Index
(cont'd)
REAB WINDOW DEFOGGER
Functi on Test, page 22-156
Defogger Wire Repait, page 22-157
CONDENSER DIODE
(' 02-03
model s) 1' 02-03 model s)
REAR WINDOW DEFOGGER
CHANGE RELAY
(' 02-03
model s)
Test , page 22-40
22-152
J
Ci rcui t Di agram
' 00-01
model s
CLI]TCH
INTESLOCK
UNDEB DASN
sw TcH
FUSABELAY
80x
No23( 10
)
FLJSE
f7
I
I
swtTcH
) - l
GNtTtONSWTTCTI UNOEN,HooD FUSgEELAY 8OX
Nolr (r@
)
N0.12 (10
)
22-153
) t
Rear Window Defogger
MAIN UNDER.HOOO
FUSE,NELAY BOX
Circuit Diagram
(cont'd)
'02-03
models
IGNITION SWITCH
wirT--F wHT/slK
--l-g<lor-,
I
I I
uf BUdrEo
1-,,*,
l9+Jo,.^|
'
O_t BrK"vFl
UNDEF.DASH
FUSENELAY
80x
No.A {10 )
FUSE
V
I
I
F 7
oAsN Lto.frs
BRIi]HTNESS
CONIFOLLER
th
rho
9il4.1
YE!&K
BIJ(
'-.E
t <l
F
8LK
T
G601
I
i
coNoENsEs
I
BtK
I
REAR
OEFOCEF
REUY
FEAN
ICONVERTIBTEI
COIIVERTlBLE
TOP DISABLE
stvtTcH
(oc. d:
I
lHaftIopin I
[y'a
on vdridJ
GAUGE
ASSEMELY
CLUICH
INTEFLOCK
swtTcH
22-154
Switch Test
?0-01 models:
1. Remove the center consol e
(see page 20-55).
2. Remove the rear wi ndow defogger swi tch
(A)
from
the center consol e, then di sconnect the 5P
connector {B}.
3. Check for conti nuty between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
\
Termi nal
Pi.iti""
-ll\
1 2 3 1 5
OFF
o-
-@- -o
o-
-o
ON
o o o-
-o-
o
l f the conti nui ty
j s
not as speci fi ed, repl ace the
i l l umi nati on bul bs
(C)
or the swi tch
( )
47
a
\
I 2 3 4 5
-\
)
'02-03
models:
1. Remove t he i nst r ument panel ( seepage20- 57) .
2, Remove the rear wi ndow defogger swi tch
(A),
then
di sconnect the 6P connector
(B).
3. Check for conti nuty between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
\ Termi na
Position \
2 3 I 5
OFF o o o @ o
ON o O G
rl
o- o
l f the conti nui ty i s not as speci fi ed, repl ace the
i l l umi nat i on bul bs
( C)
or t he swi t ch.
22-155
Rear Window Defogger
J
Y
Function Test
NOTE: Be careful not to scratch or damage the defogger
wi res wi th the tester
probe.
1. Check for vol tage between the posi ti ve termi nal
(A)
and body ground wi th the i gni ti on swi tch and
defogger swi tch ON.
There shoul d be battery vol tage.
.
l f there i s no vol tage, check for:
-
faul ty defogger rel ay.
-
faul ty defogger change rel ay
(' 02-03
model s).
-
f aul t y di ode
( ' 02- 03
model s) .
-
an open i n t he wi r e.
.
l fthere i s battery vol tage,
go to step 2.
Hardtop:
Convertible Top {'02-03
models):
A t +)
B { )
22-156
Check for conti nui ty between the negati ve termi nal
( B)
and body gr ound.
l f there i s no conti nui ty, check for an open i n the
defogger
ground wi re.
Touch the vol tmeter posi ti ve probe to the hal fway
poi nt of each defogger wi re, and the negati ve
probe to the negati ve termi nal ,
There shoul d be approxi matel y 6 V wi th the
i gni ti on swi tch and the defogger swi tch ON.
.
l f t hevol t age i s as speci f i ed, t he def ogger wi r e i s
oK.
.
l f the vol tage i s not as speci fi ed, repai r the
defogger wi re.
-
l f i t i s more than 6 V, there i s a break i n the
negati ve hal f of the wi re.
-
l f i t i s l ess than 6 V, there i s a break i n the
posi ti ve hal f of the wi re.
Defogger Wire Repair
NOTE: To make an effecti ve repai r, the broken secti on
must be no l onger t han one i nch.
' 1.
Li ghtl y rub the area around the broken secti on
(A)
wi th fi ne steel wool , then cl ean i t wi th al cohol .
2. Careful l y mask above and bel ow the broken Dorti on
of the defogger wi re
(B)
wi th cel l ophane tape
(C).
Thoroughl y mi x the si l ver conducti ve pai nt
usi ng a
smal l brush, appl y a heavy coat of the pai nt
extendi ng about 1/8" on both si des ofthe break.
Al l ow 25 mi nutes to drv.
Check for conti nui ty i n the repai red wi re.
Appl y a second coat of pai nt i n the same way. Let i t
dry 3 hours before removi ng the tape.
22-157
Restraints
Restraints
Speci al Tool s
. . . . . . . . . . . . . 23-2
Seat Belts
Component Locat i on I ndex . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23-3
Seat Bel t Repl acement
. . . . . . . . . . . . . . . . . . . . . . . 23-4
f nspect i on
. . . . . . . . . . . . . . . . . . 23-7
SRS
(Supplemental
Restraint Systeml
Component Locat i on I ndex . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . , . . . . .
23-9
Precaut i ons and Procedures
. . . . . . . . . . . . . 23-10
General Troubl eshoot i ng l nf ormat i on . . . . . . . . , , , , , . . . . . , , , . , 29-17
Erasi ng t he DTC Memory
. . . . . . . . . . . . . . . . . . . 23-19
Troubl eshoot i ng I nt ermi t t ent Fai 1ures . . . . . . . . . . . . . . . . . . . . . . . 23-19
DTC Troubl eshoot i ng
I ndex
. . . . . . . . . . . . . . 23-20
Sympt om Troubl eshoot i ng
I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-21
Syst em Descri pt i on . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 23-22
Ci rcui t Di agram
. . . . . . . . . 2g-23
DTC Troubl eshoot i ng
. . . . . . . . . . . . . . .
. . . . . . . . . . 23-24
SRS l ndi cat or Ci rcui t Troubl eshoot i ng
. . . . . . . . . . . . . . . . . . . . . . . 23-55
Component Re p
lace m ent/ln spectio n
Af t er Depl oyment . . . . . . . . . . . . . . . . . . . .
. . . . . . . 23-64
Dri ver' s Ai rbag Repl acement
. . . . . . . . . . . . 23-65
Passenger' s Ai rbag Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-67
Ai rbag Di sposal . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 23-69
Cabl e Reef Repl acement
. . . . . . . . . . . . . . . . . . . . 23-72
SRS Uni t Repl acement
. . . . . . . . . . . . . . . . . . . . . . . 23-75
) { ,
Restraints
* 1:
l ncl uded i n SRS Tool Set 07MAZ- SM50008
*2:
Use wi th the stacki ng
patch cords from T/N 07SAz-001000A, Backprobe Set.
o
ai
o
Special Tools
Ref.No. Tool Number
Description Oty
o-'
at
@
@
aa*?
07HAZ-SG00500
07PAz- 0010100
07SAZ.TB4011A
07TM-52501 1A
07TAZ-001020A
Depl oyment Tool
SCS Servi ce Connector
SRS Infl ator Si mul ator
SRS Si mul at or Lead C
Backorobe AdaDter, 17 mm
1
1
1
1
23-2
Seat Belts
J
Gomponent Location Index
SEAT BELT
Repl acement, page
23 4
Inspecti on, paqe 23-8
J
SEAT BELT BUCKLE
step
' l
on page 23-6
J
23-3
Seat Belts
Seat Belt Replacement
SRS components are l ocated i n thi s area. Revi ew the
SRS component l ocati ons {see
page 23-9) and the
precauti ons and
procedures (see page 23-' 10) i n the SRS
secti on before
performi ng repai rs or servi ce.
NOTE: Check the seat bel ts for damage, and repl ace
them i f necessary. Be careful not to damage them
dur i ng r emoval and i nst al l at i on.
Seat Belt
NOTE:
.
Make sure you have the anti -theft code for the radi o,
then wri te down the frequenci es for the preset
butl ons.
.
Di sconnectthe negati ve cabl e from the battery, and
wai t at l east 3 mi nutes before begi nni ng work
2.
1 . Remove these i tems:
.
Seat {see
page 20-86)
.
Rear si de tri m
(see page 20-70)
.
Spare ti re cover
(see page 20-73) and spare ti re
.
Rear tray/rol l bar and upper tri m assembl y
(see
page 20-711
Remove the seat bel t and retractor i n numbered
sequence.
23-4
-
OROLL
BAR and
UPPER TRIM ASSEMBLY
iZ]UPPER ANCHOR BOLT
7/ 16- 20 UNF
32 N m
(3.3 kgf.m, 24l bf.ft)
LOWER
)RETRACTOR/
SEAT BELT
, OUPPER
"ta
ANcHoR cAP
' 00-01
model s
snape
o
o
Di sconnect
t he seat
t ensi oner
connect or,
ORETRACTOR
BOLT
7/16-20 UNF
3 2 Nm
ANCHOR BOLT
7/16-20 UNF
32 N.m
13.3
kgf.m.
24 tbf.ft)
{3.3 kof m. 24 lbf ftl
a RETRACTOR MOUNTING
-
scREw
6 x 1 . 0 mm
, l
N. m
{0.4
kgf.m, 3 lbf ftl
'02-03
models
snape
(t
LOWER
ANCHOR BOLT
7/ 16-20 UNF
32 N. m
(3. 3 kgf . m,
24lbl.lrl
a- y
I I
/-
3. Instal l the bel t i n the reverse order of removal , and
note these i tems:
.
Check that the retractor l ocki ng mechani sm
functi ons
(see page
20-8).
.
Assembl e the washers, col l ar and busi ng on the
upper and l ower anchor bol ts. Refer to the
Anchor Bol t Constructi on
(see page
20,7).
.
Appl y l i qui d thread l ock to the anchor bol ts
before rei nstal l ati on.
.
Before i nstal l i ng the anchor bol ts, make sure
there are no twi sts or ki nks i n the seat bel t.
.
Make sure the seat bel t tensi oner connecl or i s
pl ugged
i n properl y.
.
Reconnect the negati ve cabl e to the battery.
.
Enter the anti -theft code for the radi o, then enter
the customer' s radi o stati on presets.
.
Reset the cl ock.
.
Dothe PCM i dl e l ean procedure (see page 11-
100) .
(cont' d)
23-5
Seat Belts
J
a
Seat Belt Replacement
(cont'd)
Seat Belt Buckle
1. Remove the seat
(see page 20-86).
NOTE: To
get
to the seat bel t swi tch connector, remove the seat cushi on from the i nner seat track.
2. Remove the seat bel t buckl e i n numbered sequence
3. Instal l the buckl e i n the reverse order of removal , and note these i tems:
.
Assembl e the washers on the center anchor bol t. Refer to the Anchor Bol t Constructi on
.
Appl y l i qui d thread l ock to the center anchor bol t before rei nstal l ati on.
.
Appl y l i qui d thread l ock to the seat mounti ng bol ts before rei nstal l ati on
OSEAT
BELT
SWITCH CONNECTOR
Detach.
O Pul l up t he seat cushi on.
Do not
pul l
up i t i n t oo f ar.
a! ) 10 x 1. 25 mm
,t?
N.m
(4. 8 kgl . m,
35 tbt.ft)
I
6)8
x 1. 25 mm
22 N.m 12.2 kgl m,
16 tbf.ftl
]CENTER ANCHOR BOLT
7/16-20 UNF
34 N.m 13.5 ksI.m,25 l bf.ft)
23-6
Center anchor boh construciion:
WAVEWASHER COLLAR
TOOTHED
LOCK WASHER
CENTER ANCHOR
BOLT
23-7
'02-03
models
WAVE WASHER
\
CENTER ANCHOR
BOLT
TOOTHED
LOCK WASHER
TOOTHEO
LOCK WASHER
COLLAR
| , /
roorneo
\ I /
LOCKWASHER
\ qt /
le /IlYil
"v --r
/ \
LOWER SPRING
ANCHOR WASHER
BOLT
SPRI NG
WASHER
BUSHING
Seat Belts
./
{
Inspection
SRS components are l ocated i n thi s area. Revi ew the
SRS component l ocati ons
(see page 23-9) and the
Drecauti ons
and
procedures
(see page 23-10) i n the SRS
secti on before
performi ng repai rs or servi ce.
Retractor
' 1.
Before i nstal l i ng the retractor, check that the seat
bel t can be
pul l ed out freel y.
2. Make sure that the seat bel t does not l ock when the
retractor
(A)
i s l eaned sl owl y up to 15' from the
mounted
posi ti on. The seat bel t shoul d l ock when
the retractor i s l eaned over 40' . Do not attempt to
di sassembl e the retractor.
l nsi de
. i oi . *"
. 15' , ' 40'
'{
Forwgrd
Repl ace the seat bel t wi th a new assembl y i f there
i s any abnormal i ty. Do not di sassembl e any
part of
the seat bel t for any reason.
l-1-
t'i\t- |
l r P l
t , ) |
t-Tl-r
\ f 1 r
23-8
-
ln-vehicle
1. Check that the seat bel t i s not twi sted or caught on
anyl n I ng.
2. After i nstal l i ng the anchors, check for free
movement on the anchor bol ts. l f necessary,
remove the anchor bol ts and check that the
washers and other
parts are not damaged or
i mproperl y i nstal l ed.
3. Check the seat bel ts for damage or di scol orati on.
Cl ean wi th a shop towel i f necessary. Use onl y
soap and water to cl ean.
NOTE: Di rt bui l d-up i n the l oops of the upper
anchors can cause the seat bel ts to retract sl owl y.
Wi pe the i nsi de of the l oops wi th a cl ean cl oth
dampened i n i sopropyl al cohol .
4. Check that the seat bel t does not l ock when pul l ed
out sl owl y. The seat bel t i s desi gned to l ock onl y
duri ng a sudden stop or i mPact.
Make sure that the seat bel t wi l l retract
automati cal l y when rel eased.
On the
passenger' s seat bel t, check the seat bel t
retractor l ockl ng mechani sm ALR
(automati c
l ocki ng retractor). Thi s functi on i s for chi l d seats:
-1
Pul l the seat bel t al l the way out to engage the
ALR. The seat bel t shoul d retract wi th a
ratcheti ng sound, but not extend. Thi s i s
nor mal .
-2
To di sengage the ALR, rel ease the seat bel t and
al l ow i t to ful l y retract, then
pul l the seat bel t
out
part-way. The seat bel t shoul d retract and
extend normal l y.
Repl ace the seat bel t wi th a new assembl Y i t there
i s any abnormal i ty. Do not di sassembl e any
part of
the seat bel t for any reason.
6.
1 .
sRs
Component Location Index
CAALE REEL
Repl acement , page 23-72
INDICATOR LIGHT
Troubl eshoot i n g, page 23-55
PASSENGER'S AIRBAG
Repl acement, page 23-67
Di sposal , page 23-69
DATA LINK
CONNECTOR
{DLCI
(16PI
UNIT
Repl acement , page
23, 75
PASSENGER'S SEAI BELT
TENSIONER
Reol acement . oaae 23-4
Di i posal , page
23' -59
DRIVER'S SAT EELT TENSIONER
Repl acement , page 23-4
Di sposal , page 23-69
I
23-9
sRs
Precautions and Procedures
General Precautions
Read the fol l owi ng
precauti ons careful l y before
performi ng ai rbag system servi ce. Observe the
i nstructi ons descri bed i n thi s manual , or the ai rbags
coul d acci dent al l y depl oy and cause damage or i nj ur i es.
.
Exceptwhen
performi ng el ectri cal i nspecti ons,
al ways turn the i gni ti on swi tch OFF, di sconnect the
negati ve cabl e from the battery, and wai t at l east 3
mi nutes before begi nni ng work.
NOTE: The memory i s not erased even i f the i gni ti on
swi i ch i s turned OFF or the battery cabl es are
di sconnected from the battery.
.
Use repl acement
parts whi ch are manufactured to the
same standards and
qual i ty
as the ori gi nal
parts. Do
not i nstal l used SRS
parts from another vehi cl e. Use
onl y new
parts when maki ng SRS repai rs.
.
Careful l y i nspect any SRS
part
before
you i nstal l i t.
Do not i nstal l any part that shows si gns ot bei ng
dropped or i mproperl y handl ed, such as dents, cracks,
or deformati on.
Before removi ng any of the SRS
parts (i ncl udi ng
di sconnecti on of the connectors), al ways di sconnect
the SRS connector.
23-10
.
Use onl y a di gi tal mul ti meter to check the system l f i t
i s not a Honda mul ti meter, make sure i ts output i s 10
mA {0.01 A) or l ess when swi tched to the l owest val ue
i n the ohmmeter range. A tester wi th a hi gher output
coul d cause acci dental depl oyment and
possi bl e
i nj ur y.
.
Do not
put
obj ects on the
passenger' s ai rbag.
.
The ori gi nal radi o has a coded theft
protectl on ci rcui t.
Be sure to
get the customer' s radi o code and wri te
down the frequenci es for the radi o
preset stati ons
before di sconnecti ng the battery cabl e.
.
Before returni ng the vehi cl e to the customer, enter
the customer' s radi o code, and radi o stati on
preset,
and set the cl ock.
Steering-related Precautions
Cabl e Reel Al i gnment
.
Mi sal i gnment of t he cabl e r eel coul d cause an open i n
the wi ri ng, maki ng the SRS system and the horn
i noperati ve. Center the cabl e reel whenever the
fol l owi ng i s performed (see
step 6 on page 23-73).
-
Instal l ati on ofthe steeri ng wheel
-
Instal l ati on of the cabl e reel
-
Instal l ati on ofthe steeri ng col umn
-
Other steeri ng-rel ated adj ustment or i nstal l ati on
.
Do not dl sassembl e the cabl e reel .
.
Do not appl y
grease to the cabl e reel .
.
l f the cabl e reel shows any si gns of damage or
contami nati on, repl ace i t wi th a new one. For
exampl e, i t does not rotate smoothl y.
Airbag Handling and Storage
Do not di sassembl e an ai r bag. l t has no ser vi ceabl e
parts.
Once an ai rbag has been depl oyed, i t cannot be
repai red or reused.
For temporary storage of an ai rbag duri ng servi ce,
observe the fol l owi ng precauti ons.
.
Store the removed ai rbag wi th the pad surface up.
Never put
anyt hi ng on t he r emoved ai r bag.
To prevent
damage to the ai rbag, keep i t free from
any oi l , gr ease,
det er gent , or wat et .
.
Store the removed ai rbag on a secure, fl at surface
away from any hi gh heat source
(exceedi ng
200' F/
93' C).
Never perform
el ectri cal i nspecti ons to the ai rbags,
such as measuri ng resi stance,
Do not posi ti on yoursel f i n front of the ai rbag duri ng
removal , i nspecti on. or repl acement.
Refer to the scrappi ng procedures
for di sposal of a
damaged ai rbag.
(cont' d)
23-11
sRs
Precautions and Procedures
(cont'dl
SRS Unit Precautions
.
Be careful not to bumo or i moact the SRS uni t
whenever the i gni ti on swi tch i s ON
(l l ),
or for at l east
for 3 mi nutes after the i gni ti on swi tch i s turned OFF.
.
Dur i ng i nst al l at i on or r epl acement , becar ef ul not t o
bump
(by
i mpact wrench, hammer, etc.) the area
around the SRS uni t. The ai rbags coul d acci dental l y
depl oy and cause damage or i nj ury.
After a col l i si on i n whi ch the ai rbags were depl oyed,
repl ace the SRS uni t and other rel ated components
(see page 23-64). After a col l i si on i n whi ch the ai rbags
were not depl oyed, i nspect for any damage or any
deformati on on the SRS uni t. l f there i s any damage,
reDl ace the SRS uni t.
.
Do not di sassembl e the SRS uni t.
.
Turn the i gni ti on swi tch OFF, di sconnect the battery
negati ve cabl e, and wai t at l east 3 mi nutes before
begi nni ng i nstal l ati on or repl acement of the SRS uni t.
or di sconnecti ng the 18P connector from the SRS uni t.
.
Be sure the SRS uni t i s i nstal l ed securel y wi th the
mount i ng bol t s t or qued t o 9. 8 N. m
( 1. 0
kgf . m,
7.2 tbfittl.
.
Do not spl l l water or oi l on the SRS uni t, and keep i t
away from dust.
.
Store the SRS uni t i n a cool
(l ess
than 104"F/40' C)
and dry
(l ess
than 807o rel ati ve humi di ty, no
mol sture) area.
23-12
Wring Precautions
Some of the SRS wi ri ng can be i denti fi ed by a speci al
yel l ow outer coveri ng, and the SRS connectors can be
i denti fi ed bv thei r vel l ow col or.
Observe the i nstructi ons descri bed i n thi s secti on.
.
Never attemptto modi fy. spl i ce, or repai r SRS wi ri ng.
l f t her e i s an open or damage i n SRS wi r i ng, r epl ace
the harness.
Be sure to i nstal l the harness wi res so they do not get
pi nched,
or i nterfere wi th other
pans.
.
Make sure al l SRS ground l ocati ons are cl ean, and
grounds
are securel y fastened for opti mum metal -to-
metal contact. Poor groundi ng
can cause i ntermi ttent
probl ems
that are di ffi cul t to di agnose.
Precautions for Electrical Inspections
.
When usi ng el ectri cal test equi pment, i nsertthe
Drobe of the tester i nto the wi re si de of the connector.
Do not i nsert the Drobe of the tester i nto the termi nal
si de of the connector, and do not tamper wl th the
connecror.
Use a U-shaped probe. Do not i nsert the probe
fo rci bl y.
Use speci fi ed servi ce connectors i n troubl eshooti ng,
Usi ng i mproper tool s coul d cause an error i n
i nspecti on due to
poor
metal -to-metal contact.
sRs
Precautions and Procedures
(cont'd)
Spring-loaded Lock Connector
Some SRS system connectors have a spri ng-l oaded
l ock.
Disconnecting
To rel ease the l ock, pul l the spri ng-l oaded sl eeve
(A)
toward the stop {B) whi l e hol di ng the opposi te hal f of
the connector. Then pul l the connector hal ves apart. Be
sure to Dul l on the sl eeve and not on the connector.
Connecting
1. To reconnect, hol d the
pawl -si de
connector, and
oress on the back of the sl eeve-si de connector i n
the di recti on shown. As the two connector hal ves
are pressed together, the sl eeve
(A)
i s pushed back
by the
pawl (C).
Do not touch the sl eeve.
When the connector hal ves are compl etel y
connected, the
pawl
i s rel eased, and the spri ng-
l oaded sl eeve l ocks the connector.
23-14
Backprobing Sprin
g-loaded Lock Connectors
When checki ng vol tage or resi stance on thi s type of
connector the fi rst ti me, vou must remove the retai ner
(A)
to i nsert the tester
probe
from the wi re si de.
NOTE: l t i s not necessary to rei nstal l the removed
retai ner; the termi nal s wi l l stay l ocked i n the connector
hous i no.
To remove the retai ner {A), i nsert a fl at-ti p
screwdri ver
(B)
between the connector body and the
retai ner, then careful l y
pry
out the retai ner. Take care
not to break the connector.
Disconnecting System Connectors
Before removi ng the ai rbag or SRS rel ated devi ces
(the
SRS uni t, the cabl e reel , and the seat bel t tensi oner
connectors), di sconnecti ng connectors from rel ated devi ces, or removi ng the dashboard or the steeri ng col umn,
di sconnect the ai rbag connectors and seat bel t tensi oner connectors to
prevent
acci dental depl oyment.
Turn the i gni ti on swi tch OFF, di sconnect the negati ve cabl e from the battery, and wai t at l east 3 mi nutes before
begi nni ng the fol l owi ng procedures.
.
Bef or edi sconnect i ngt heSRSuni t connect or ( 18P)
( A) f r omt he
SRS uni t , di sconnect bot h ai r bag 2Pconnect or s
( C,
D) and both seat bel t tensi oner 2P connectors
(E,
F).
.
Before di sconnecti ng the cabl e reel 2P connector
(B),
di sconnect the dri ver' s ai rbag 2P connector
(C).
sRs
4
Precautions and Procedures
(cont'd)
1. Di sconnect the battery negati ve cabl e, and wai t at
l east 3 mi nutes.
Driver's Airbag
2. Remove the access panel from the steeri ng wheel ,
then di sconnect the dri ver' s ai rbag 2P connector
(A)from
the cabl e reel .
Passenger's Airbag
3. Remove the
passenger' s
dashboard l ower cover
(see page
20-81), then di sconnect the passenger' s
ai rbag 2P connector {A} from the SRS mai n harness.
':-
-
"-^\'.
l
\
--""'=-\
\''
23-16
!,
Seat Belt Tensionar:
4. Remove the rol l bar uppertri m
(see page 20-7' l ),
then di sconnect the seat bel t tensi oner 2P
connector {A) from the SRS mai n harness.
J
General Troubleshooting Information
DTC
(Diagnostic
Trouble Codesl
The sel f-di agnosti c functi on of the SBS al l ows i t to l ocate the causes of system probl ems
and then store thi s
i nformati on i n memory. For easi er troubl eshooti ng, thi s data can be retri eved vi a a data l i nk ci rcui t,
.
When you
turn the i gni ti on swi tch ON
(l l ),
the SRS i ndi cator wi l l come on. l f i t goes off after 6 seconds, the system i s
nor mal .
. l f t her ei sanabnor mal i t y, t hesyst eml ocat esanddef i nest hepr obl em. st or est hi si nf or mat i oni nmemor y, andt ur ns
the SRS i ndi cator on. The data wi l l remai n i n the memory even when the i gni ti on swi tch i s turned off or i f the battery
i s di sconnected.
.
When you connect the Honda PGM Tester to the 16P data l i nk connector
(DLC)to
short the SCS termi nal , and turn
the i gni ti on swi tch ON
(l l ),
the SRS i ndi cator wi l l i ndi cate the di agnosti c troubl e code
(DTC)
by the number of bl i nks.
.
When you connect the Honda PGM Tester to the 16P data l i nk connector
(DLC), you can retri eve the DTC i n the
Honda Syst ems
" SRS"
menu.
.
After readi ng and recordi ng the DTC, proceed wi th the troubl eshooti ng procedure for the code i ndi cated.
Precautions
.
Use onl y a di gi tal mul ti meter to check the system. l f i t i s not a Honda mul ti meter, make sure i ts output i s 10 mA
{0.01 A) or l ess when swi tched to the smal l est val ue i n the ohmmeter range. A tester wi th a hi gher output coul d
damage the ai rbag ci rcui t or cause acci dental ai rbag depl oyment and possi bl e i nj ury.
.
Whenev er t hei gni t i ons wi t c hi s ON{ l l } , or has beent ur nedOFFf or l es s t han3mi nut es , bec ar ef ul not t obumpt he
SRS uni t; the ai rbags coul d acci dental l y depl oy and cause damage or i nj uri es.
.
Before you remove the SRS mai n harness, di sconnect the dri ver' s ai rbag connector, the
passenger' s
ai rbag
connector, and seat bel t tensi oner connectors.
.
Ma ke su re the batte ry i s suff i ci entl y ch a rged. l f the battery i s dead or l ow, the measured val ues wi l l notbecorrect.
' Donot t ouc hat es t er pr obet ot het er mi nal s i nt heSRSuni t or har nes s c onnec t or s , anddonot c onnec t t het er mi nal s
wi th a
j umper
wi re. Use onl y the backprobe set and speci al tool s.
Reading the DTC
When the SRS i ndi cator i s on, read the DTC usi ng ei ther of the fol l owi ng methods:
PGM Tester
"SRS"
Menu Method
Connect the Honda PGM Tester
(A)
to the 16P data l i nk connector
(DLCXB),
and fol l ow the Tester' s
prompts
i n the
"SRS"
menu. l f the Tester i ndi cates no DTC, DTC 9-1, or DTC 9-2, doubl e-check by usi ng the
"SCS"
menu method.
{cont' d )
\
23-17
sRs
General Troubleshooting Information
(cont'd)
PGM Tester
"SCS"
Menu Method
(Retrieving
the flash codes)
The SRS i ndi cator i ndi cates the DTC by the number of bl i nks when the Honda PGM Tester i s connected to the DLC
(data
l i nk connector)
(16P).
1. Make sure the i gni ti on swi tch i s OFF.
2. Connect rhe Honda PGM Tester
(A)
to the data l i nk connector
(16PXB),
and fol l ow the Tester' s prompts i n the
"SCS"
menu to ground the SCS l i ne
(see
the Honda PGM Tester Operator' s Manual ).
3. Make sure the SCS l i ne i s
grounded, then turn the i gni ti on swi tch ON {l l ).
The SRS i ndi cator
(C)
shoul d come on
for about 6 seconds, and then
go
off. Then i t wi l l bl i nk to i ndi cate the DTC
(see
the tabl e bel ow).
. I ncl udi ngt hemost r ecent pr obl em, upt ot hr eedi f f er ent DTCScanbedi spl ayed.
.
In case of a conti nuous fai l ure, the DTC wi l l be i ndi cated repeatedl y
(see
exampl e 1 bel ow).
. l ncaseof ani nt er ml t t ent f ai l ur e. t heSRSi ndi cat or wi l l
i ndi cat et he DTC onet i me, t hen i t wi l l st ayon( see
exampl e 2 bel ow).
. l f acont i nuousandani nt er mi t t ent f ai l ur eoccur , bot hDTCSwi l l be i ndi cat ed as cont i nuous f ai l ur es.
' I ncaset hesyst emi snor mal ( no
DTc) , t he sRS i ndi cat or l i ght wi l l st ay on
( see
exampl e 3) '
1. Continuotls failur, SRS lndic8tor blinks likethis:
1 2 5 1 2 5 , l n ? q
Sr Second
3S 0.3s
Subcode {3)
OFF
Bulb chock
period
OFF
Bulb chock
priod
DTC 2-1
Mon r6c6nt ploblom
lndications
failure.
Mei n code { 2) subcode 11l Mai n code { l l Mai n cod6 { 11 Subcode
( l }
DTC 1-1
Scond-mostracsnt Third-mostrocsnt
problem problem
DTC 1-3
2. lntormittent tsilure, SRS Indic.tor blinks lik this:
ON
DTC 5-1
3. Normal {no feilure), SRS Indicatot blinks likethis:
ON
Read the DTC.
Turn the i gni ti on swi tch OFF, and wai t tor 10 seconds.
Di sconnect the Honda PGM Tester from the DLc
(' l 6P).
Do the troubl eshooti ng
procedure for the DTC.
OFF
Bulb chck
period
4.
5,
o,
7.
0.3 s
23-18
Erasing the DTC Memory
Special Tools Required
SCS Servi ce Connector 07PAZ-0010100
To erase the DTC(S) from the SRS uni t, use a Honda
PGM Tester
(see
the Honda PGM Tester SRS Vehi cl e
System Suppl ement) or the fol l owi ng
procedure.
1. Make sur e t he i gni t i on swi t ch i s OFF.
2. Connect the speci al tool
(A)
to the MES 2P
connector
(B).
Do not use a
j umper
wi re.
3. Tur n t he i gni t i on swi t ch ON
( l l ) .
4. The SRS i ndi cator wi l l come on for about 6 seconds,
and then go off. Remove the SCS servi ce connector
from the MES connector wi thi n 4 seconds after the
i ndi cator
goes
off.
5. The SRS i ndi cat or wi l l come on agai n. Reconnect
the SCS servi ce connector to the MES connector
wi thi n 4 seconds after the i ndi cator comes on.
6. When the SRS i ndi cator goes off, remove the SCS
servi ce connector from the MES connector wi thi n 4
seconos.
7. The SRS i ndi cat or wi l l bl i nk t wo t i mes i ndi cat i ng
that the memory has been erased.
8. Tur n t he i gni t i on swi t ch OFF, and wai t f or 10
seconds.
9. Tur n t he i gni t i on swi t ch ON
( l l )
agai n. The SRS i s
OK i f the SRS i ndi cator comes on for about 6
seconds and then
goes off.
Troubleshooting Intermittent Failures
l f there was a mal functi on, but i t doesn' t recur, i t wi l l be
stored i n the memory as an i ntermi ttent fai l ure, and the
SRS i ndi cator wi l l come on.
After checki ng the DTC, troubl eshoot as fol l ows:
1. Read the DTC
(see
"Readi ng
the DTC").
2. Erase the DTC memory
(see
"Erasi ng
the DTC
Memory").
3. Wi th the shi ft l ever i n neutral , startthe engi ne, and
l et i t i dl e.
The SRS i ndi cator wi l l come on for about 6 seconds
and then go off.
Shake the wi re harness and the connectors, take a
test dri ve
(qui ck
accel erati on,
qui ck
braki ng,
corneri ng), turn the steeri ng wheel ful l y l eft and
ri ght, and hol d i ttherefor 5to 10 seconds. l f the
probl em recurs, the SRS i ndi cator wi l l come on.
l f
you
can' t dupl i cate the i ntermi ttent fai l ure, the
svstem i s oK at thi s ti me.
23-19
sRs
{
DTC Troubleshooting Index
DTC Detsction ltem Notes
ODen i n dri ver' s ai rbaq i nfl ator
(see
Daoe 23-24)
1-2 l ncreased resi stance i n dri ver' s ai rbao i nfl ator
(see
oaqe 23-241
1-3 Short to another wi re or decreased resi stance i n dri ver' s ai rbaq i nfl ator {see Daoe 23-26)
1- 4 Short to oower i n dri ver' s ai rbaq i nfl ator
(see
Daqe 23-28)
t - c Short to
qround
i n dri ver' s ai rbaq i nfl ator {see Daoe 23-30)
2-1 ODen i n oassenqer' s ai rbaq i nfl atol
(see
oaoe 23-32)
, _')
Increased resi stance i n oassenqer' s ai rbaq i nfl ator
(see
oaoe 23-32)
2-3 Short to another wi re or decreased resi stance i n passenger' s ai rbag
i nfl ator
(see page 23-33)
2-4 Short to Dower i n Dassenqer' s ai rbaq i nfl ator {see Daqe 23-35)
2-5 Short to oround i n Dassenoer' s ai rbao i nfl ator
(see paqe 23-36)
3-1 Ooen i n dri ver' s seat bel i tensi oner
(see paqe
23-38)
3-2 l ncreased resi stance i n dri ver' s seat bel t tensi oner
(see
oaqe 23-38)
Shon to another wi re or decreased resi stance i n dri ver' s seat bel t tensi oner {see
page
23-40)
3-4 Short to Dower i n dri ver' s seat bel t tensi oner
(see
oaoe 23-42)
3-5 Shon to
qround
i n dri ver' s seat bel t tensi oner
(see
Daoe 23-44)
4-1 Ooen i n oassenoer' s seat bel t tensi oner {see
page 23-46)
4-2 l ncreased resi stance i n oassenoer' s seat bel t tensi oner
(see
Daqe 23-46)
4-3 Short to another wi re or decreased resi stance i n passenger' s seat bel t
tensi oner
(see page 23-48)
4-4 Short to oower i n oassenoer' s seat bel t tensi oner
(see paqe
23-50)
4-5 Short to oround i n oassenoer' s seat bel t tensi oner
(see paqe
23-52)
5-1 l nternal fai l ure of SRS uni t
NOTE:
Before troubl eshooti ng DTCs 5-1 through 8-6, check battery/system vol tage.
l f vol tage i s l ow, repai r the chargi ng system before troubl eshooti ng the
SRS.
(see page 23-54)
5-2
5-3
5-4
o - l
6-2
6-3
6-4
6 - l
a-2
8-3
8- 4
8-6
9-1 Internal fai l ure of the SRS uni t. l f i ntermi ttent, i t coul d mean i nternal fai l ure
of the uni t or a Jaul ty i ndi cal or l i ght ci rcui t. Refer to Troubl eshooti ng
Intermi ttent Fai l ures
(see page 23-19).
NOTE: Before troubl eshooti ng DTC 9-1, check battery/system vol tage. l f the
vol taoe i s l ow. reDai r the charqi nq svstem before troubl eshooti nq the SRS.
(see
page 23-54)
9-2 Internal fai l ure of the SRS uni t. l f i ntermi ttent, i t coul d mean i nternal fai l ure
of the
power
suppl y
(VB
l i ne). Refer to Troubl eshooti ng Intermi ttent
Fai l ures
(see page 23-19).
NOTE: Betore troubl eshooti ng DTC 9-2. check battery/system vol tage. l f the
vol taqe i s l ow. reoai r the charqi nq svstem before troubl eshooti nq the SRS.
10- 1 Seat bel ttensi oners l and ai rbao(s)) deDl oved.
(see pase
23-54)
23-20
I
Symptom Troubleshooting Index
svmptom Diagnostic
procedure Also check for
SRS i ndi cator doesn' t come on SRS I ndi cat or Tr oubl eshoot i ng
( see
steo 1 on Daqe 23-55)
SRS i ndi cator stays on when i n
"SCS"
menu method
SRS l ndi cator Troubl eshooti ng
(see
step 1 on page 23' 57)
Inabi l i ty to retri eve DTCS wi th the
PGM Tester. Retri eve the fl ash
codes usi ng the SCS menu method
{ see Daoe 23- 18) .
) J
23-21
sRs
System Description
SRS Components
Airbags
The SRS i s a safety devi ce whi ch, when used wi th the seat bel t, i s desi gned to hel p protect the dri ver and passenger i n
a frontal i mpact exceedi ng a certai n set l i mi t. The system consi sts ofthe SRS uni t, i ncl udi ng a safi ng sensor and an
i mpact sensor
(A),
the cabl e reel
(B).
the dri ver' s ai rbag
(C)
and the passenger' s ai rbag
(D).
Seat Belt Tensioners
The seat bel t tensi oner 1E) i s l i nked wi th the SRS ai rbags to further i ncrease the effecti veness of the seat bel t. In a
front-end col l i si on, the tensi oner i nstantl y retracts the bel t fi rml y to secure the occupants i n thei r seats.
SRS Operation
The mai n ci rcui t i n the SRS uni t senses and
j udges
the force of i mpact and, i f necessary, i gni tes the i nfl ator charges. l f
battery vol tage i s too l ow or power i s di sconnected due to i mpact, the vol tage regul ator and the back-up power ci rcui t
respecti vel y wi l l keep vol tage at a constant l evel .
For the SRS to operate:
(1)
The i mpact sensor must acti vate and send el ectroni c si gnal s to the mi croprocessor.
{2)
The mi croprocessor must compute the si gnal s and send them to the ai rbag i nfl ators
(and
seat bel t tensi oners).
{3)
The i nfl ators must i gni te and depl oy the ai rbags
(and
acti vate the tensi oners).
Y
Self-diagnosis System
A sel f-di agnosi s ci rcui t i s bui l t i nto the SRS uni t; when the i gni ti on swi tch i s turned ON
(l l ),
the SRS i ndi cator comes on
and goes off after about 6 seconds i f the SRS i s operati ng normal l y.
l f the i ndi cator does not come on, or does not go
off after 6 seconds, or i f i t comes on whi l e dri vi ng, i t i ndi cates an
abnor mal i t y i n t he SRS. The SRS must be i nspect ed and r epai r ed as soon as
possi bl e.
For better servi ceabi l i ty, the SRS uni t memory stores a DTC that rel al es to the cause of the mal functi on, and the uni t i s
connected to the data l i nk connector
(DLC).
Thi s i nformati on can be read wi th the Honda PGM Tester when i t i s
connected to the DLC
(16P) (see page 23-11).
23-22
Ci rcui t Di agram
MAIN UNDEN-HOOO FUSE/8ILAY MX GNITION SWTCH
! -' oo-ozt voo"t t
[ , ' ornooe
UNDEn-oaslr
FUSE/RTLAY
BOX
lGl lOT in 0N lll)
DASHSOAFD
WIFEHAFNESS
DASHSOAFD
WBEHANNESS
SFS T\IOICATOF CFCUIT
I
T
I
SFS MAIN
HANNtSS
OASHEOAFO
hASt'tEss a
-
t l
NEO 8LK
| ,'--r I
u-' ..1-J
\,
PASSENGEE' S
SEATEELT
TENSIONEF
G501
t l
1l
r l
sFsMAr N
HANflESS
MEMORY ERASE
SIGNALIMES)
CONNECTOB
)
TEBMII{ALNUMEEB
\ I iEldi'i
: t , '
F
t \
I MAI_E
I
TTRIIIINAT
)
23-23
sRs
DTG Troubleshooting
DTC 1-1: Open i n Dri ver' s Ai rbag I nf l at or
DTC 1-2: Increased Resistance in Driver' s
Ai rbag I nf l at or
Special Tools Requirod
.
SRS i nfl ator si mul ator 07SAZ-T840' 11A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SBS indicatot stay on?
YES- Go to step 3.
NO Intermi ftent fai l ure. system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23-19).
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s ai rbag 2P connector from
the cabl e reel
(A).
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the cabl e reel .
23-24
10.
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 1-1 or DTC 1-2 i ndi cated?
YES Go to step 9.
NO-Open or i ncreased resi stance i n the dri ver' s
ai rbag; repl ace the dri ver' s ai rbag
{see
page
23-65).1
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the cabl e reel 2P connector from the
SRS mai n harness
(A).
07TAZ-S2501 1A
..->^_
\\/
"rt^.^;;mj
1 1 .Connect the SRS i nfl ator si mul ator
(2
Q
and the si mul ator l ead to the SRS mai n
Reconnect the battery negati ve cabl e.
Erase the DTC memory.
connector)
harness,
12.
13.
14. Read the DTC.
l s DTC 1-1 or DTC 1-2 i ndi cated?
YES- Go t o st ep 15,
15.
16.
NO Open or i ncreased resi stance i n the cabl e reel ;
repl ace the cabl e reel
(see page
23-72).1
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the passenger' s ai rbag 2P connector
(A)
and both seat bel t tensi oner 2P connectors
(B).
. t
J
23-25
17. Di sconnect the SRS uni t 18P connector
(A)
fromthe
SRS uni t. Do not di sconnect the speci al tool from
t he SRS mai n har ness.
' 1
8. Check resi stance between the No. 1 and No. 13
t er mi nal s of t he SRS uni t l 8P connect or . Ther e
shoul d be 2. 0 3. 0 Q.
SRS UNI T 18P CONNECTOR
lt
5 6 1 8 9
l r o I r i r z i l r
3 1 4 t 5 1 7 t o
GRN
Wi r e si de of f emal e t er mi nal s
l s the rcsi stance as speci l i ed?
YES
-
Faul ty SRS uni t or poor contact at the SRS
uni t 18P connect or and t he SRS uni t . Check t he
connecti on between the connector and the SRS
uni t . l f t he connect i on i s OK, r epl ace t he SRS uni t
( see page 23- 75) . 1
NO Open or i ncreased resi stance i n the SRS mai n
har ness; r epl ace t he SRS mai n har ness. l
sRs
DTG Troubleshooting
(cont'd)
DTC 1-3: Short to Another Wire or Decreased
Resi st ance i n Dri ver' s Ai rbag I nf l at or
Special Tools Required
.
sRs i nf l at or si mul at or 07sAz- TB4o11A
.
SRS si mul at or l ead C 07TM- S25011A
' 1.
Erase the DTC memory {see
page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes
off.
Does the SRS i ndi cator stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23-19).
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the dri ver' s ai rbag 2P connector from
the cabl e reel
(A).
07TAZ-S25011A
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the cabl e reel .
Reconnect the battery negati ve cabl e.
Erase the DTC memory.
6.
1 .
23-26
8. Read the DTC.
l s DTC 1-3 i ndi cated?
YES Go to step 9.
NO Short i n the dri ver' s ai rbag; repl ace the dri ver' s
ai rbag
(see page 23-65). !
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the cabl e reel 2P connector from the
SRS mai n har ness
( A) .
07TAZ-S25011A
---.-----.._--.-
\
-.--------
-\N
\v
I t
,--'1,=ft'.fi
07sAz-TB4o'l'lA
:
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the SRS mai n harness.
Reconnect the battery negati ve cabl e.
Erase the DTC memory.
Read the DTC,
l s DTC 1-3 i ndi cated?
YES Go to step
' 15.
NO Shon i n the cabl e reel ; repl ace the cabl e reel
( see page 23- 72) . 1
9.
10.
{
' t
1.
13.
14.
J
t 5 .
16.
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the passenger' s
ai rbag 2P connector
(A)
and both seat bel t tensi oner 2P connectors
(B).
.\ :l
J
23-27
17.
18.
Di sconnect the speci al tool from the SRS mai n
har ness.
Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Check resi stance between the No. 1 and No. 13
termi nal s of the SRS uni t 18P connector. There
shoul d be an open ci r cui t , or at l east 1 M 0.
SRS UNI T 18P CONNECTOR
' 19.
5 6 l 7 I I
t : v | " t ]
l,o I
rr
I
rz
ilr
1 4 l o 1 7 t 8
GRN
Wi re si de of femal e termi nal s
ls the rcsistance as specilied?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23-75).I
NO Short i n the SRS mai n harness; repl ace the
SRS mai n har ness. l
1 E
16.
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the passenger' s
ai rbag 2P connector
(A)
and both seat bel t tensi oner 2P connectors {B).
17. Di sconnect the SRS uni t 18P connector {A)from the
SRS uni t .
18. Di sconnect the speci al tool from the SRS mai n
harness.
19. Reconnectthe battery negati ve cabl e.
20. Turn the i gni ti on swi tch ON {l l ).
21. Check for vol tage between the No. l termi nal ofthe
SRS uni t 18P connector and body ground,
and
between the No. 13 termi nal and body ground.
There shoul d be 0.5 V or l ess.
SRS UNIT 18P CONNECTOR
Wi re si de of l emal e t ermi nal s
ls the voltage as specified?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23- 75) . I
NO
' .
Short to power i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. l
23-29
sRs
DTC Troubleshooting
(cont'd)
DTC 1-5: Short t o Ground i n Dri ver' s Ai rbag
l nf l at or
Special Tools Required
.
SRS i nfl ator si mui ator 07SAZ-T8401' l A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swl tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes off.
Does the SRS i ndi cator stay on?
YES Go to step 3.
NO l ntermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s ai rbag 2P connector l rom
the cabl e reel
(A).
07TAZ-SZ501rA
Connectthe SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the cabl e reel .
Reconnect the battery negati ve cabl e.
Erase the DTC memory,
6.
7.
23-30
9.
10.
Read the DTc.
l s DTC 1-5 i ndi cated?
YES
-
Go to step 9.
NO Shortto
ground i n the dri ver' s ai rbag; repl ace
the dri ver' s ai rbag
(see page 23' 65).1
Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the cabl e reel 2P connector from the
SRS mai n har ness
( A) .
07TAZ-S25011A
----R(N
\p
_---_--n.#
07sAz-T84011A
'-'
t
1 1 .Connectthe SRS i nfl ator si mul ator
(2
Q
and t he si mul at or l ead t o t he SRS mai n
Reconnect the battery negati ve cabl e.
Erase the DTC memory.
connector)
har ness.
13.
14. Read the DTC.
l s DTC 1-5 i ndi cated?
YES
-
Go to sl ep 15.
NO Shortto ground
i n the cabl e reel ; repl ace the
cabl e reel
(see page
23-72).I
15. Turn the i gni ti on swi tch OFF, then dj sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
16. Di sconnect the passenger' s
ai rbag 2P connector
(A)
and both seat bel t tensi oner 2P connectors
(B).
17. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Di sconnect the speci al tool from the SRS mai n
har ness.
Check resi stance between the No. 1 termi nal of the
SRS uni t 18P connector and body ground,
and
between the No. 13 termi nal and body ground.
There shoul d be an open ci rcui t, or at l east 1 M e .
SRS UNIT 18P CONNECTOR
18.
19.
Wi re si de of I emal e t ermi nal s
ls the resistance as specified?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23- 75) . I
NO- Shor t t o gr ound i n t he SRS mai n har ness;
r epl ace t he SRS mai n har ness. l
23-31
sRs
DTC Troubleshooting
(cont'dl
DTC 2-1: Open i n Passenger' s Ai rbag l nf l at or
DTC 2-2: I ncreased Resi st ance i n Passenger' s
Ai rbag I nf l at or
Speci al Tool s Requi red
.
SRS i nfl ator si mul ator 07SAZ-T840' l 1A
.
SRS si mul at or l ead C 07TM' S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cat or l i ght comes on f or about 6 seconds
and then goes off.
Doesthe SRS i ndi cator l i ght stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the
passenger' s ai rbag 2P connector
f r om t he SRS mai n har ness
( A) .
Connect t he SRS i nf l at or si mul at or
( 2
Q connect or )
and t he si mul at or i ead t o t he SRS mai n har ness.
5.
23-32
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 2-1 or 2-2 i ndi cated?
YES Go to step 9.
NO Open or i ncreased resi stance i n the
passenger' s ai rbag; repl ace the passenger' s ai rbag
(see page 23-67).I
9. Turn the i gni ti on swi tch OFF, then di sconnectthe
battery negati ve cabl e, and wai t for 3 mi nutes.
10. Di sconnect t he dr i ver ' sai r bag 2Pconnect or
( A)
and
both seat bel t tensi oner 2P connectors
(B).
\|
12.
1 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t. Do not di sconnect the sDeci al tool from
the SRS mai n harness.
Check resi stance between the No. 10 and No. l 4
termi nal s of the SBS uni t
' l 8P
connector. There
shoul d be 2. 0 3. 0 Q.
SRS UNIT 18P CONNECTOR
Wi re si de of femal e termi nal s
lsthe resistance as specified?
YES Faul ty SRS uni t or poor
contact at the SRS
uni t connector. Check the connecti on; i f the
connecti on i s OK, repl ace l he SRS uni t
(see page
23-751.f
NO Open or i ncreased resi stance i n the SRS mai n
harness; repl ace the SRS mai n harness.!
DTC 2-3: Short to Another Wire or Decreased
Resistance in Passenger' s Airbag Inflator
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011,A
1. Erase the DTC memory
(see page 23- 19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SRS indicator stay on?
YES- Go to step 3.
NO
-
Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF. then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the passenger' s
ai rbag 2P connector
from the SRS mai n harness
(A)
07TAZ-S25011A
/____n
'r^r-r;;,-El]fi
Connecl the SRS i nfl ator si mul ator
(2
0 connector)
and the si mul ator l ead to the SRS mai n harness.
(cont' d)
23-33
sRs
DTC Troubleshooting
(cont'dl
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 2-3 i ndi cated?
YES Go to step 9.
NO Short i n the passenger' s ai rbag; repl ace the
passenger ' s ai r bag
( see page 23- 67) . 1
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
' 10.
Di sco n nect the d ri ver' s a i rbag 2P con nector {A) and
both seat bel t tensi oner 2P connectors
(B).
23-34
' l
1. Di sconneci the speci al tool from the SRS mai n
har ness.
Di sconnect the SRS uni t
' l 8P
connector
(A)
from the
SRS uni t .
12.
13. Check resi stance between the No. 10 and No. 14
termi nal s of the SRS uni t 18P connector.There
shoul d be an open ci rcui t. or at l east 1 M Q .
SRS UNIT 18P CONNECTOR
wi re si de of femal e termi nal s
ls the resistance as sqecified?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23- 75) . I
NO Short i n the SRS mai n harness; repl ace the
SRS mai n har ness. l
I 3 4 5 6 7 8 I
10 12 I J 1 4 1 5 1 6 1 1
' 18
GRN
DTC 2-4: Short to Power in Passenger' s
Ai rbag I nf l at or
Special Tools Required
.
SRS i nfl ator si mul ator 07SM-TB401' 1A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory {see
page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes
off.
Does the SRS i ndi cator stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page
23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the passenger' s
ai rbag 2p connector
f r om t he SRS mai n har ness
1A) .
5. Connect the SRS i nfl ator si mul ator
(2
e connecl or)
and the si mul ator l ead to the SRS mai n harness.
6. Reconnecl the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 2-4 i ndi cated?
YES Go to step 9.
NO Short to power
i n the passenger' s
ai rbag;
repl ace the passenger' s
ai rbag
(see page 23-67). t
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
10. Dj sconnect the dri ver' s ai rbag 2P connector
(A)
and
both seat bel t tensi oner
(B).
sRs
15.
13.
14.
DTC Troubleshooting
(cont'd)
' 11.
Di scon nect t he S RS uni t l 8Pconnect or ( A) f r omt he
SRS uni t.
Di sconnect the speci al tool from the SRS mai n
haress.
Reconnect the battery negati ve cabl e.
Tur n t he i gni t i on swi t ch ON
( l l ) .
Check for vol tage between the No. 10 termi nal of
the SRS uni t 18P connector and body ground, and
between the No. 14 termi nal and body
ground.
Ther e shoul d be 0. 5 V or l ess.
SRS UNIT 18P CONNECTOB
Wi re si de of femal e termi nal s
ls the voltage as specified?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23-15).a
NO Shortto
power i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. I
23-36
DTC 2-5: Short to Ground in Passenger' s
Ai rbag I nf l at o r
Speci al Tool s Requi red
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the l gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SRS i ndi cator staY on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnectthe
battery negati ve cabl e, and wai t for 3 mi nutes.
4, Di sconnect the
passenger' s ai rbag 2P connector
f r om t he SRS mai n har ness
( A) .
Connect the SBS i nfl ator si mul ator
(2
0 connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
5.
6. Reconnect the battery negative cable.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 2-5 i ndi cated?
YES Go to step 9.
NO
-
Short to ground
i n the passenger' s
ai rbag;
repl ace the passenger' s
ai rbag
(see page
23-67).1
Turn the i gni ti on swi tch OFF. then di sconnect the
battery negative cable, and wait for 3 minutes.
Di sconnect the dri ver' s ai rbag 2P connector
(A)
and
both seat bel t tensi oner 2P connectors
(B).
10.
11. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t.
Di sconnect the speci al tool from the SRS mai n
harness.
Check resi stance between the No, 10 termi nal of
the SRS uni t 18P connector and body ground,
and
the No. 14 termi nal and body ground. The.e shoul d
be an open ci rcui t, or at l east 1 M Q .
SRS UNIT 18P CONNECTOR
' t 2.
13.
Wi re si de of f emal e t ermi nal s
ls the resistance as specified?
YES
-
Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23-75).1
NO- Shont o gr ound
i n t he SRS mai n har ness;
repl ace the SRS mai n harness.l
,l
3 4 5 6 1 I I
10 l 1 12 t o 1 4 t 5 1 6 1 7 18
GRN GRN
23-37
sRs
DTC Troubleshooting
(cont'd)
DTC 3-1: Ooen in Driver' s Seat Belt Tensioner
DTC 3-2: Increased Resistance in Driver' s
Seat Bel t Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SM-TB4011A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23- 19).
2. Turn the i gni ti on swi tch ON
(l l ).
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes off.
Does the SRS indicator staY on?
YES Go to steD 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness {A).
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and the si mul ator l ead to the SRS mai n harness.
07TAZ-S25011A
23-38
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 3-1 or DTC 3-2 i ndi cated?
YES-Go to step 9.
NO-Open or i ncreased resi stance i n the dri ver' s
seat bel t tensi oner; repl ace the dri ver' s seat bel t
(see
Page
23-4).1
9. Turn the i gni ti on swi tch OFF, then di sconnecl the
battery negati ve cabl e, and wai t for 3 mi nutes.
10. Di sconnect the dri ver' s ai rbag connector
(Al .
passenger' s
ai rbag connector
(B),
and
passenger' s
seat bel t tensi oner connector
(C).
1 1 . Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t. Do not di sconnect the sDeci al tool from
the SRS mai n harness.
12. Check resi stance between the No. 4 termi nal and
the No. 11 termi nal of the SRS uni t 18P connector.
Ther e shoul d be 2. 0- 3. 0 Q.
SRS UNIT 18P CONNECTOR
\
GRN
-
+ 5 6 7 8 9
q
lofulTllts
1 4 t 3 t o 1 7 1 8
lcnrv
Wi re si de ot temal e termi nal s
ls the resistance as specified?
YES
-
Faul tv SRS uni t or
poor
contact at the SRS
uni t 18P connector and the SRS uni t. Check the
connecti on; i f the connecti on i s OK, repl ace the
SRS uni t
(see page 23-75).1
NO-Ooen or i ncreased resi stance i n the SRS mai n
harness; repl ace the SRS mai n harness.l
23-39
sRs
DTC Troubleshooting lcont'd)
DTC 3-3: Short to Another Wire or Decreased
Resi st ance i n Dri ver' s Seat Bel t Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-TB4011A
.
SRS si mul ator l ead C 07TM-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes off.
Does the SRS i ndi cator stay on?
YES Go to steD 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng l ntermi ttent Fai l ures
(see
page
23-19).
3. Turn the i gni ti on swi tch OFF, then di sconnectthe
battery negati ve cabl e, and wai t for 3 mi nutes.
4, Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
rr^rt;am
23-40
6. Reconnect the battery negati ve cabl e.
Erase the DTC memory. 1.
8. Read the DTC.
l s DTC 3-3 i ndi cated?
YES Go to step 9.
NO Short i n the dri ver' s seat bel ttensi oner;
repl ace the dri ver' s seat bel t
(see page 23-4).t
9. Turn the i gni ti on swi tch OFF, then di sconnectthe
battery negati ve cabl e, and wai t for 3 mi nutes,
{
10. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and passenger' s
seat bel t tensi oner connector
(C).
1
'1.
Di sconnect the speci al tool from the SRS mai n
harness.
Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Check resi stance between the No. 4 termi nal and
the No. 1 1 termi nal of the SRS uni t 18P connector.
There shoul d be an oDen ci rcui t, or at l east 1 M o.
SBS UNI T I 8P CONNECTOR
Wi re si de of femal e termi nal s
ls the resistance as specified?
YES
-
Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23- 75) . 1
NO Short i n the SRS mai n harness; repl ace the
SRS mai n har ness. l
1 '
13.
23-41
sRs
DTC Troubleshooting
(cont'd)
DTC 3-4: Short to Power in Driver' s Seat Belt
Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SRS indicator stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page
23-19).
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
Connect the SRS i nfl ator si mul ator
(2
O connector)
and the si mul ator l ead to the SRS mai n harness.
.r.^r6;am
23-42
6. Reconnectthe battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 3-4 i ndi cated?
YES-Go to step 9.
NO- Short to
power i n dri ver' s seat bel t tensi oner;
repl ace the dri ver' s seat bel t
(see page 23-4). !
9. Turn the i gni ti on swi tch OFF. then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
t
10. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector {B), and passenger' s
seat bel t tensi oner connector
(C).
, / :
---------:-\
J
23-43
12.
1 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t.
Oi sconnect the speci al tool from the SRS mai n
harness.
Reconnect the battery negati ve cabl e.
Turn the i gni ti on swi tch ON
(l l ).
Check for vol tage between the No. 4 termi nal of the
SRS uni t 18P connector and body ground. and the
No. 11 termi nal and body ground. There shoul d be
0.5 V or l ess.
SRS UNIT 18P CONNECTOR
Wi re si de of f emal e t ermi nal s
ls the voltage as specitied?
YES-Faul ty SRS uni t; repl ace the SRS uni t
(see
page
23-75).I
NO Short to
power
i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. l
13.
14.
15.
sRs
DTC Troubleshooting
(cont'd)
DTC 3-5: Short to Ground in Driver' s Seat Belt
Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes
off.
Does the SRS indicatot stay on?
YES Go to step 3.
NO- Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23-19).
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the dri ver' s seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
Connectthe SRS i nfl ator si mul ator
(2
O connecl or)
and the si mul ator l ead to the SRS mai n harness.
23-44
6. Reconnectthe battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
ls DTC 3-5 indicated?
YES- Go to step 9.
NO Short to
ground i n the dri ve/s seat bel t
tensi oner; repl ace the dri ver' s seat bel t
(see page
23-4l.a
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
3
10. Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s ai rbag connector
(8),
and
passenger' s
seat bel t tensi oner connector
(C).
\ . ]
)
23-45
11. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
12. Di sconnect the speci al tool from the SRS mai n
harness.
Check resi stance between the No. 4 termi nal of the
SRS uni t 18P connector and body ground, and the
No. 11 t er mi nal and body
gr ound. Ther e shoul d be
an open ci rcui t, or at l east 1 M Q .
SRS UNIT 18P CONNECTOR
Wi re si de ot I emal e t ermi nal s
ls the resistance as specitied?
YES
-
Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23- 75) . 1
NO Short to
ground i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. l
sRs
DTC Troubleshooting
{cont'd)
DTC 4-1: Open in Passenger' s Seat Belt
Tensi oner
DTC 4-2: Increased Resistance in Passenger' s
Seat Bel t Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Erase the DTC memory
(see page
23-19).
2. Tur n t he i gni t i on swi t ch ON
( l l ) ,
and check t hat t he
SRS i ndi cator comes on for about 6 seconds and
then
goes
off.
Does the SBS i ndi cator stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23-' 19).
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the
passenger' s
seat bel t tensi oner 2P
connector from the SBS mai n harness
(A).
07TAZ-S25011A
\orroa.rroor,,o
Connect the SRS i nfl ator si mul ator
(2
O connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
23-46
6. Reconnectthe battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 4-1 or DTC 4-2 i ndi cated?
YES Go to step 9.
NO-Open or i ncreased resi stance i n the
passenger' s
seat bel t tensi oner; repl ace the
passenger' s
seat bel t
(see page 23-4).1
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
\
10. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector {B), and dri ver' s seat
bel t tensi oner connector
(C).
A
J
11. Di sconnect t he SRS uni t 18P connect or
( A) f r om
t he
SRS uni t. Do not di sconnect the speci al tool from
t he SRS mai n har ness.
Check resi stance between the No. 5 termi nal and
t he No. 12 t er mi nal of t he SRS uni t 18P connect or .
Ther e shoul d be 2. 0 3. 0 Q.
SRS UNI T 18P CONNECTOR
GRN
1 ! L , . l o
+ l s ti 1 8 9
o
l , o l
r r
l r z ] r s I
r a15 1 6 1 7
llcRN
Wi re si de of femal e termi nal s
ls the tesistance as specilied?
YES Faul ty SRS u ni t or poor contact at the SRS
uni t
' l 8P
connect or and t he SRS uni t . Check t he
connecti on; i f the connecti on i s OK, repl ace the
SRS uni t { see
page
23- 75) . 1
NO Open or i ncr eased r esi st ance i n t he SRS mai n
har ness; r epl ace t he SRS mai n har ness. l
sRs
DTC Troubleshooting
(cont'd)
DTG 4-3: Short to Another Wire or Decreased
Resistance in Passenger' s Seat Belt
Tensi oner
Speci al Tool s Requi red
.
SRS i nfl ator si mul ator 07SAZ-T84011A
.
SRS si mul ator l ead C 07TM-S250114
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SFIS indicator stay on?
YES Go to step 3.
NO Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures {see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the
passenger' s
seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
AZ-S25011A
\or"or-r"oorro
Connect the SRS i nfl ator si mul ator
(2
0 connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
23-48
6. Reconnectthe battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 4-3 i ndi cated?
YES Go to step 9.
NO-Shon i n the passenger' s
seat bel ttensi oner;
repl ace the
passenger' s
seat bel t
(see page 23-4).1
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes,
' 10.
Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
bel t tensi oner connector
(C).
1 1 .Di sconnectthe speci al tool
(2
Q connector) from
t he SRS mai n har ness.
a
23-49
13.
12. Di sconnect the SRS uni t 18P connector 1A)from the
SRS uni t .
Check resi stance between the No. 5 termi nal and
t he No. l 2 t er mi nal of t heSRS uni t 18Pconnect or .
There shoul d be an oDen ci rcui t, or at l east 1 M Q .
SRS UNI T 18P CONNECTOR
Wi re si de of femal e termi nal s
ls the resistance as specified?
YES Faul ty SRS uni t; repl ace the SRS uni t {see
page
23-7 5l .a
NO Short i n the SRS mai n harness; repl ace the
SRS mai n har ness. l
sRs
DTC Troubleshooting
(cont'dl
DTC 4-4: Short to Power in Passenger' s Seat
Bel t Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T840' l 1A
.
SRS si mul ator l ead C 07TAZ-S25011A
1. Er ase t he DTC memor y
( see page 23- 19) .
2. Tur n t he i gni t i on swi t ch ON
( l l ) ,
and check t hat t he
SRS i ndi cator comes on for about 6 seconds and
then
goes off.
Does the SRS i ndi catot stay on?
YES Go to step 3.
NO
-
Intermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the passenger' s seat bel t tensi oner 2P
connector from the SRS mai n harness.
AZ-S25011A
\
orror-r"oor ro
Connect t he SRS i nf l at or si mul at or
( 2
Q connect or )
and t he si mul at or l ead t o t he SRS mai n har ness.
23-50
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 4-4 i nd i cated?
YES Go to step 9.
NO Short to power i n the
passenger' s seat bel t
tensi oner; repl ace the
passenger' s seat bel t
(see
page 23- 4) . 1
9. Turn the i gni ti on swi tch OFF, then di sconnectthe
battery negati ve cabl e, and wai t for 3 mi nutes.
10. Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
bel t tensi oner connector
(C),
11. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t.
Di sconnect the speci al tool from the SRS mai n
harness,
Reconnect the battery negati ve cabl e.
Turn the i gni ti on swi tch ON
(l l ).
Check for vol tage between the No. 5 termi nal of the
SRS uni t 18P connector and body ground,
and the
No.
' 12
termi nal and body ground.
There shoul d be
0. 5 V or l ess.
SRS UNI T 18P CONNECI OR
t 5 .
13.
14.
Wi re si de of f emal e t ermi nal s
ls the voltage as specilied?
YES Faul ty SRS uni t; repl ace the SRS uni t {see
page
23- 75) . I
NO Short to power i n the SRS mai n harness;
r epl ace t he SRS mai n har ness. l
23-51
3t-'r
..
:r
sRs
DTC Troubleshooting
(cont'd)
DTC 4-5: Short to Ground in Passenger' s Seat
Bel t Tensi oner
Special Tools Required
.
SRS i nfl ator si mul ator 07SAZ-T8401 1A
.
SRS si mul ator l ead C 07TM-S25011A
1. Erase the DTC memory
(see page
23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then goes off.
Does the SRS indicator stay on?
YES Go to step 3.
NO- Intermi ftent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng Intermi ttent Fai l ures
(see
page 23- 19) .
3. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
4. Di sconnect the passenger' s
seat bel t tensi oner 2P
connector from the SRS mai n harness
(A).
Az-SZs011A
\orro.-rrnorro
Connect the SRS i nfl ator si mul ator
(2
Q connector)
and t he si mul at or l ead t o t he SRS mai n har ness.
23-52
TL
f , \
6. Reconnect the battery negati ve cabl e.
7. Erase the DTC memory.
8. Read the DTC.
l s DTC 4-5 i ndi cated?
YES- Go to step 9.
NO
-
Short to ground i n the passenger' s seat bel t
tensi oner; repl ace the passenger' s seat bel t
(see
page
23-4).1
9. Turn the i gni ti on swi tch OFF, then di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
\
10. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and dri ver' s seat
bel t tensi oner connector
(CI.
1. ,
) r ,
23-53
1' 1. Di sconnect the SRS uni t 18P connector
(A)
from the
SRS uni t .
Di sconnect the speci al tool from the SRS mai n
harness.
Check resi stance between the No. 5 termi nal of the
SRS uni t 18P connector and body ground,
and the
No. 12 t er mi nal and body gr ound. Ther e shoul d be
an open ci rcui t, or at l east 1 M Q.
SRS UNIT 18P CONNECTOR
12.
t 5 .
Wi re si de of f emal e t ermi nal s
Is the resi stance as speci fi ed?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23- 75) . 1
NO Shor t t o gr ound i n t he SRS mai n har ness;
r epl ace t he SRS mai n har ness. I
sRs
DTG Troubleshooting
(cont'd)
DTC 5-1, 5-2, 5-3, 5-4, 6-1, 6-2, 6-3, 6-4,7-1,7
-2,
7-3,8-1,8-2,8-3, 8-4, 8-6, 9-1, 9-2: Internal
Fai l ure of t he SRS Uni t
NOTE: Before troubl eshooti ng any of these DTCs, check
the battery/system vol tage. l f the vol tage i s Iow, repai r
the chargi ng system before troubl eshooti ng the SRS. l f
the battery/system vol tage i s now OK, ask the customer
i f the battery ever went dead.
1. Erase the DTC memory
(see page 23-19).
2. Turn the i gni ti on swi tch ON
(l l ),
and check that the
SRS i ndi cator comes on for about 6 seconds and
then
goes off.
Does the SRS indicator stay on?
YES
-
Repl ace the SRS uni t
(see page 23-75).I
NO- l ntermi ttent fai l ure, system i s OK at thi s ti me.
Go to Troubl eshooti ng l ntermi ttent fai l ures
(see
page 23- 19) .
23-54
DTC 10-1: Ai rbags and/ or Seat Bel t
Tensi oners Depl oyed
The SRS uni t must be repl aced after any ai rbags and/or
tensi oners have depl oyed
(see page 23-75).
SRS Indicator Circuit Troubleshooting
The SRS Indicator Doesn' t Gome On
1. Tur n t he i gni t i on swi t ch ON
( l l ) ,
and see i f t he ot her
i ndi cators come on
(brake
system, etc).
Do the other indicators come on?
YES
-
Go to step 2.
NO
-
Go to step 8.
2. Turn the i gni ti on swi tch OFF, then remove the
gauge assembl y
(s
ee
page
22-521. Di sconnect
gauge
assembl y connector A and B from the gauge
assemDty.
Check resi stance between the No. I termi nal of
gauge assembl y connector B
(12P)
and body
gr ound. Ther e shoul d be 0- ' 1, 0 Q .
GAUGE ASSEMBLY CONNECTOR B {12P)
Wi r e si de of f emal e t er mi nal s
ls the resistance as specified?
YES Go to step 4.
NO Open i n t he BLK wi r e of dashboar d wi r e
har ness A or f aul t y body gr ound t er mi nal
( G501) .
l f
the body ground
termi nal i s OK, repi ace dashboard
wi r e har ness A. I
2 J 4 5
6 1 8 9 10 t l
BLK
6)
4. Check for vol tage between the No. 4 termi nal of
gauge assembl y connector A
(14P)
and body
ground wi thi n the fi rst 6 seconds afterturni ng the
i gni ti on swi tch ON
(l l ).
There shoul d be 8.5 V or l ess.
GAUGE ASSEMBLY CONNECTOR A
(14P}
ls the voltage as specified?
YES Faul ty SRS i ndi cator ci rcui t i n the gauge
assembl y; repl ace the gauge assembl y.l
NO Go to step 5.
Turn the i gni ti on swi tch OFF.
(cont' d)
Wi re si de of f emal e t ermi nal s
23-55
sRs
SRS Indicator Circuit Troubleshooting
(cont'd)
6. Di sconnect SRS uni t connector 18P connector
(A)
from the SRS uni t
23-56
7. Di sconnect gauge assembl y connector A
(14P).
Connect a vol tmeter between the No. 4 termi nal of
gauge assembl y connector A
(14P)
and body
ground. Turn the i gni ti on swi tch ON
(l l ),
and
measure vol tage. There shoul d be 0.5 V or l ess.
GAUGE ASSEMBLY CONNECTOR A {lirP)
ls the voltage as specified?
YES Faul ty SRS uni t; repl ace the SRS uni t
(see
page 23-75).r
NO Short to power i n the PNK wi re of dashboard
wi re harness A or i n the SRS mai n harness; repl ace
the faul ty harness.l
Turn the i gni ti on swi tch OFF. Check the No. 5
(7.5A)
Juse i n the under-dash fuse/rel ay box,
l s the fuse bl own?
YES Go to step 10.
NO Go to step 9.
8,
Wi re si de of f emal e t ermi nal s
-0
9. Connect a vol tmeter between the No. 4 termi nal of
gauge assembl y connector B
(12P)
and body
ground, Turn the i gni ti on swi tch ON fl l ), and
measure the vol tage. There shoul d be battery
vol tage.
GAUGE ASSEMBLY CONNECTOR B {12P)
ls there battery voltage?
YES Faul ty SRS i ndi cator ci rcui t i n the gauge
assembl y or poor
contact at gauge
assembl y
connector B { 12P) and the gauge
assembl y; i f the
connecti on i s OK, repl ace the gauge assembl y.l
NO Open i n the under-dash fuse/rel ay box No. 5
(7.5A)
fuse ci rcui t, or open i n the YEL wi re of
dashboard wi re harness. l f the under-dash fuse/
r el ay box i s OK, r epl ace t he f aul t y har ness. I
Repl ace the No. 5
(7.5A)
fuse, then check to see i f
the i ndi cators comes on.
Do the indicators come on?
YES The system i s OK at thi s ti me. t
NO Repai r shont o gr ound i n t he under - dash f use/
r el ay box No. 5 { 7. 5A) f use ci r cui t . l
10.
Wi re si de of f emal e t ermrnal s
The SRS Indicator Stays On When ln
"SCS"
Menu Method
NOTE:
.
l f you
retri eve DTCS wi th the PGM Tester usi ng the
SRS menu method, retri eve fl ash codes wi th the
Tester i n SCS mode
(see page 23-18).
.
A new SRS uni t must sense the enti re system i s OK
before compl eti ng i ts i ni ti al sel f-test. The most
common cause of an i ncompl ete sel f-test i s the
fai l ure to repl ace al l depl oyed parts after a col l i si on,
i n pani cul ar,
seat bel t tensi oners.
.
An i ncompl ete sel f-test prevents
the PG M Tester from
retri evi ng DTCS, al though fl ash codes are avai l abl e i n
the Tester' s SCS mode.
1. Erase the DTC memory usi ng the MES connector
{ see
page 23- 19) .
Does the SBS indicator go off while you are
erasi ng the DTC memory?
YES Go to step 37.
NO Go to step 2.
2. Chec k t he No. 1( 10A) f us ei nt heunder - das h
fuse/rel ay box.
l s the f use OK?
YES Go to step 17.
NO Go to step 3.
3. Repl ace t he No. 1
( 10
A) f use.
4. Turn the i gni ti on swi tch ON
(l l ),
and wai t for 30
seconds. Then turn the i gni ti on swi tch OFF.
5. Check t he No. 1
( 10
A) f use.
l s the tuse OK?
YES The sysrem i s OK at thi s ti me. t
NO Go to step 6.
6. Repl ace t he No. 1
( 10
A) f use.
(cont' d)
23-57
sRs
SRS Indicator Circuit Troubleshooting
lcont'd)
7. Turn the i gni ti on swi tch OFF. Di sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
Di sconnect the dri ver' s ai rbag connector
(A),
passenger' s ai rbag connector 1B), and both seat
bel t tensi oner 2P connectors
(C).
23-58
9. Di sconnectthe SRS uni t 18P connector
(A)from
the
SRS uni t.
10.
1 1 .
Reconnect the battery negati ve cabl e.
Turn the i gni ti on swi tch ON
(l l ),
and wai t for 30
seconds. Then turn the i gni ti on swi tch OFF.
Check the No. 1
(10
A) fuse i n the under-dash
fuse/rel ay box.
ls the tuse OK?
YES
-
Short to
ground i n the SRS uni U repl ace the
SRS uni t
(see page 23-75).1
NO Go to step 13.
Repl ace the No. I
(10
A) fuse i n the under-dash
fuse/rel ay box.
Di sconnect the SRS mai n harness connector A
(2P)
from the under-dash fuse/ral ay box.
' t2.
13.
14.
-0
15. Turn the i gni ti on swi tch ON
(l l ),
and wai t for 30
seconds. Then turn the i gni ti on swi tch OFF.
' 16.
Check t he No. 1
( 10A) f use
i n t he under - dash
fuse/rel ay box.
l s the f use OK?
YES Short to ground i n dashboard wi re harness
A; repl ace dashboard wi re harness A.I
NO Short to ground i n the under-dash fuse/rel ay
box; repl ace the under-dash fuse/rel ay box.l
17. Turn the i gni ti on swi tch OFF. Dl sconnect the
battery negati ve cabl e, and wai t for 3 mi nutes.
18. Di sconnectthe dri ver' s ai rbag connector
(A),
passenger' s
ai rbag connector
(B),
and both seat
bel t tensi oner 2P connectors
(C).
(cont' d)
23-59
sRs
SRS Indicator Circuit Troubleshooting
(cont'd)
19. Di sconnet the SRS uni t 18P connector
(A)
from the
SRS uni t.
Reconnect the battery negati ve cabl e.
Connect a vol tmeter between the No.3 termi nal of
the SRS uni t 18P connector and body
ground. Turn
the i gni ti on swi tch ON l l l ), and measure vol tage.
There shoul d be battery vol tage.
20.
l s thete battery vol tage?
YES Go to step 25.
NO Go to step 22,
Turn the i gni ti on swi tch OFF.
SRS UNIT I8P CONNECTOR
Wi re si de of f emal e t ermi nal s
23-60
24.
23. Di sconnect SRS mai n harness connector A
(2P)
from the under-dash fuse/rel ay box.
Check resi stance between the No. 3 termi nal of the
SRS uni t
' l 8P
connector and the No. 1 termi nal of
SRS mai n harness connector A. There shoul d be
0 1 . 0 Q.
SRS MAIN HARNESS CONNECTOR A
(2P)
Wi re si de of femal e termi nal s
ls the resistance as specified?
YES
-
Open i n the under-dash fuse/rel ay box or
poor
contact at SRS mai n harness connector A;
check the connecti on. l f the connecti on i s OK,
repl ace the under-dash fuse/rel ay box.l
NO Open i n SRS mai n wi re harness; repl ace the
SRS mai n wi r e har ness. l
I
Wi re si de ol t emal e t ermi nal s
25.
26.
27.
28.
Turn the i gni ti on swi tch OFF.
Connect the No. 3 termi nal and the No. 6 termi nal
of the SRS uni t 18P connector wi th a
j umper
wi re.
SRS UNI T 18P CONNECTOR
Wi re si de ot f emal e t ermi nal s
Turn the i gni ti on swi tch ON
(l l ).
Check the SRS i ndi cator.
Di d the SBS i ndi cator go ofl ?
YES- Faul t y SRS uni t ; r epl ace t he SRS uni t . l
NO Go to step 29.
29. Turn the i gni ti on swi tch OFF.
30. Di sconnect the
j umper
wi re between the No. 3
t er mi nal and t he No. 6 t er mi nal of t he SRS uni t 18P
connector.
31. Checkt he No. 1
( 10A) f use
i nt he under - dash f use/
retay oox.
ls the f use OK?
YES- Go to step 35.
NO Go to step 32.
32. Repl ace the No. 1
(10A)
fuse.
-8
JUMPER WIRE
GRN GRN
3 4 5 6 7 I I
l 0 t1 12 13 t c 1 7 l o
4
34.
33. Remove the
gauge
assembl y
(see page 22-521, then
di sconnect gauge assembl y connector A from the
gauge assembl y.
A
Check resi stance between the No. 6 termi nal of the
SRS uni t 18P connector and body ground. There
shoul d be an oDen ci rcui t, or at l east 1 M Q.
Wi re si de of femal e termi nal s
ls the resistance as specilied?
YES Faul ty SRS i ndi cator ci rcui t i n the gauge
assembl y; repl ace the gauge assembl y.I
NO
-
Shon t o
gr ound i n t he SRS mai n har ness or i n
dashboard wi re harness A; repl ace the faul ty
har ness. l
(cont' d)
SRS UNIT 18P CONNCTOR
23-61
sRs
SRS Indicator Gircuit Troubleshooting
(cont'dl
35. Remove the
gauge assembl y
(see page 22-52), then
di sconnect gauge assembl y connector A from the
gauge assemDr y.
36. Check resi stance between the No. 4 termi nal of
gauge
assembl y connector A
(14P)
and No. 6
termi nal of the SRS uni t 18P connector. There
shoul d be 1 Q or l ess.
GAUGE ASSEMBLY CONNECTOR A
(14P)
ls the resistance as specified?
YES Faul ty SRS i ndi cator ci rcui t i n the
gauge
assembl y or poor contact at gauge assembl y
connector A
(14P);
Check the connecti on. l f the
connecti on i s OK, repl ace the gauge assembl y.l
NO Open i n t he SRS mai n har ness or i n
dashboard wi re harness A; repl ace the faul ty
har ness. I
PNK
l 2 3
|
^
l,zl/
1 I I 1 0
l
r l / l / l t +
o
Wi re si de ol l emal e t ermi nal s
GRN
3 4 5 6 1 I 9
10 11 12 t 5 o 1 7 18
SRS UNIT 18P CONNECTOR
23-62
37.
38.
Turn the i gni ti on swi tch OFF.
l f necessary, remove the SCS servi ce connector
from the MES connector.
Tur n t he i gni t i on swi t ch ON
( l l ) .
Does the SRS indicator come on lor about 6
seconds and then go otl ?
YES-The system i s OK at thi s ti me.I
NO Go to step 40.
Di sconnet the SRS uni t 18P connector
(A)
from the
SRS uni t .
41. Connect a Honda PGM Tester
(A)
to the data l i nk
connector
(B)
and fol l ow the Tester' s
prompts i n
the
"SCS"
menu
(see
the Tester' s operati ng
ma nuar r .
-e
42. Check resi stance between the No.9 termi nal ofthe
SRS uni t 18P connector and body
ground. There
shoul d be 0- 1. 0 Q .
ls the rcsistance as specitied?
YES
-
Faul ty SRS uni t or
poor
contact at the SRS
uni t 18P connector; check the connecti on; i f the
connecti on i s OK, repl ace the SRS uni t
(see page
23-751..
NO Open i n the SCS l i ne between the No. 9
termi nal of the SRS uni t 18P connector and the
No.9 termi nal
(BRN
wi re) ofthe data l i nk connector
(DLC)
or open between the No. 4 termi nal of the
DLC and body ground. Repai r the open wi re
(s).
SRS UNIT 18P CONNECTOR
Wi re si de of f emal e t ermi nal s
23-63
sRs
Component Replacement/lnspection After Deployment
NOTE: Before doi ng any SRS repai rs. use the PGM
Tester SRS menu method to check for DTCS; refer to the
DTC Troubl eshooti ng l ndex for the l ess obvi ous
depl oyed
parts (seat
bel t tensi oners, etc.)
After a col l i si on where the ai rbag(s) depl oyed, repl ace
these rtems:
.
SRS uni t
.
Depl oyed ai rbag{s)
.
Seat bel t tensi oners
Duri ng the repai r process, i nspect these areas:
.
I nspect al l t he SRS wi r e har nesses. Repl ace. don' t
repai r, any damaged harnesses.
.
I nspect t hecabl e r eel f or heat damage. l f t her e i s any
damage, repl ace the cabl e reel .
After the vehi cl e i s compl etel y repai red, turn the
i gni ti on swi tch ON
(l l ).
l f the SRS i ndi cator comes on for
about 6 seconds and then goes off, the SRS i s OK. l f the
i ndi cator does notfuncti on properl y,
use the PGM
Tester SRS Menu Method to read the DTC{S). l f thi s
doesn' t retri eve any codes, use the Tester' s SCS menu
method {see
page
23-18). l f you sti l l cannot retri eve a
code, go to SRS Indi cator Ci rcui t Troubl eshooti ng.
23-64
g
Driver's Airbag Replacement
Removal
1. Di sconnect the battery negati ve cabl e, and wai t at
l east 3 mi nutes before begi nni ng work.
2. Remove the access
panel (A)
from the steeri ng
wheel , then di sconnect the dri ver' s ai rbag 2P
connector
(B)
from the cabl e reel .
3. Remove the cover
(A)
from the steeri ng wheel ,
remove the two Torx bol ts
(B)
usi ng a Torx T30 bi t,
then remove the dri ver' s ai rbag {C).
Di sconnect the horn connector from the steeri ng
wneet .
(cont' dl
23-65
sRs
Driver's Airbag Replacement
(cont'd)
Installation
1. Pl ace the new dri ver' s ai rbag
(A)
i nthesteeri ng
wheel , and secure i twi th new Torx bol ts
(B).
Instal l
the covers
(C).
B
9.8 N.m {1.0 kgf.m,7.2 l bf.ft)
23-66
I
2. Connect the cabl e reel 2P co nnecto r to the dri ver' s
ai r bag
( A) ,
t hen i nst al l t he access panel ( C)
on t he
steeri ng wheel .
Connect the battery negati ve cabl e.
After i nstal l i ng the ai rbag, confi rm proper
system
operatron:
.
Turn the i gni ti on swi tch ON
(l l );
the SRS i ndi cator
shoul d come on for about 6 seconds and then go
off.
.
Make sure the horn works.
I
Passenger's Airbag Replacement
Removal
1. Di sconnectthe battery negati ve cabl e, and wai t at
l east 3 mi nutes before begi nni ng work.
2. Remove the passenger' s dashboard l ower cover
(see page 20-81 ). then di sconnect the passenger' s
ai rbag 2P connector
(A)
from the SRS mai n harness.
3. Remove the three mounti ng nuts
(A)
from the
bracket. Cover the l i d and dashboard wi th a cl oth.
and
pry careful l y wi th a screwdri ver to l i ft the
passenger' s ai rbag
(B)
out of the dashboard.
NOTE: The ai rbag l i d has
pawl s
on i ts si de that
attach i t to the dashboard.
(cont' d)
:---
'
23-67
sRs
Passenger's Airbag Replacement
{cont'dl
Installation
1. Pl ace the new passenger' s ai rbag
(A)
i nto the
dashboard. Ti ghten the passenger' s ai rbag
mounti ng nuts
{B).
B
9.8 N.m
{1.0 kgt.m, 7.2 l bf ft)
23-68
I
2. Connect the
passenger' s
ai rbag 2P connector
(Al to
t he SRS mai n har ness.
Attach the
passenger' s
ai rbag connector to the
connector hol der
(B),
then rei nstal l the passenger' s
dashboard l ower cover {see
page 20-81).
Reconnect the battery negati ve cabl e.
After i nstal l i ng the ai rbag, confi rm proper
system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator shoul d come on for about 6 seconds and
then
go
OFF.
Airbag Disposal
Speci al Tool Requi red
Depl oyment Tool 07HAZ-SG00500
Before scrappi ng any ai rbags
(i ncl udi ng
those i n a
whol e vehi cl e to be scrapped). the ai rbags must be
depl oyed. l f the vehi cl e i s sti l l wi thi n the warranty
peri od. the Honda Di stri ct Servi ce Manager must gi ve
approval and/or speci al i nstructi ons before depl oyi ng
the ai rbags
(and
seat bel t tensi oners). Onl y after the
ai rbags
(and
seat bel t tensi oners) have been depl oyed
{as
the resul t of vehi cl e col l i si on, i or exampl e), can they
be scrapped. l f the ai rbags
(and
seat bel t tensi oners)
appear i ntact
(not
depl oyed), treat them wi th extreme
cauti on. Fol l ow thi s procedure.
Deploying Airbags In the Vehicle
l f an SRS equi pped vehi cl e i s to be enti rel y scrapped, i ts
ai rbags
(and
seat bel t tensi oners) shoul d be depl oyed
whi l e sti l l i n the vehi cl e. The ai rbags
(and
seat bel t
tensi oners) shoul d not be consi dered as sal vageabl e
parts and shoul d never be i nstal l ed i n another vehi cl e.
l . Turn the i gni ti on swi tch OFF, di sconnect the battery
negati ve cabl e, and wai t at l east 3 mi nutes.
2. Confi rm that each ai rbag and each seat bel t
tensi oner i s securel y mounted
3. Confi rm that the speci al tool l sfuncti oni ng properl y
by fol l owi ng the check procedure on the tool l abel .
Driver's Airbag:
4. Remove the access
panel (A),
then di sconnect the
dri ver' s ai rbag 2P connector
(B)
from the cabl e reel .
Passenger's Airbag:
5. Remove the
passenger' s
dashboard l ower cover,
then di sconnect the
passenger' s
ai rbag 2P
connector
(A)from
the SRS mai n harness.
Seat Belt Tensioner:
6. Remove the seat bel t tensi oner
(see page 23-41,
then di sconnect the seat bel t tensi oner 2P
connector
(Al from
the SRS mai n harness.
(cont' d)
\
23-69
sRs
Airbag Disposal
lcont'd)
7. Pul l the seat bel t
(A)
out al l the way and cut i t.
Cut off the ai rbag or seat bel t tensi oner connector,
stri p the ends of the ai rbag wi res and seat bel t
tensi onerwi res
(A),
and connectthe depl oyment
tool al l i gator cl i ps
(A)
to the ai rbags and seat bel t
tensi oners. Pl ace the depl oyment tool at l east 30
feet {10 meters} away from the vehi cl e.
23-70
9. Connect a 12 vol t battery to the tool .
.
l f t he gr een l i ght ont het ool comeson, t he i gni t er
ci rcui t i s defecti ve and cannot deDl ov the
components. Go l o Di sposal of Damaged
Components,
.
l f the red l i ght on thetool comes on, the
component i s ready to be depl oyed.
10. Push the tool ' s depl oyment swi tch. The ai rbags and
tensi oners shoul d depl oy
(depl oyment
i s both
hi ghl y audi bl e and vi si bl e: a l oud noi se and r api d
i nfl ati on ofthe bag, fol l owed by sl ow defl ati on).
.
l f t he ai r bagsdepl oyandt he gr een l i ght ont he
tool comes on, conti nue wi th thi s
procedure.
.
l f an ai rbag doesn' t depl oy, yet the green l i ght
comes ON, i ts i gni ter i s defecti ve. Go to Di sposal
of Damaged Components.
.
Duri ng depl oyment, the ai rbags, can become hot
enough to burn you. Wai t 30 mi nutes after
depl oyment before touchi ng the ai rbags.
11. Di spose ofthe compl ete ai rbag. No part of i t can be
reused. Pl ace i t i n a sturdy pl asti c bag
(A)
and seal
i t securel y.
Deploying Components Out of the Vehicle
l f an i ntact ai rbag or seat bel t tensi oner has been
removed from a scrapped vehi cl e, or has been found
defecti ve or damaged duri ng transi t, storage, or servi ce,
i t shoul d be deDl oved as fol l ows:
Confi rm that the speci al tool i s functi oni ng properl y
by fol l owi ng the check
procedure
on thi s
page or
on t he t ool l abel .
2. Posi ti on the ai rbag face up, outdoors on fl at ground
at l east 30 feet
(10
meters)from any obstacl es or
Deool e.
3. Fol l owst epsSt hr ough 11of t he i n- vehi cl e
depl oyment procedure.
Disposal of Damaged Components
1. l f i nstal l ed i n the vehi cl e, fol l ow the removal
procedure for the dri ver' s ai rbag
(see page 23-65),
passenger' s ai rbag
(see page
23-67), and seat bel t
tensioner
(see page 23-4).
2. In al l cases, make a short ci rcui t by cutti ng,
stri ppi ng, and twi sti ng together the two ai rbag
i nfl ator wi res and seat bel t tensi oner wi res.
Package the ai rbag or seat bel t tensi oner i n the
same packagi ng that the new repl acement part
came an.
Mark the outsi de of the box
"DAMAGED
AIRBAG
NOT DEPLOYED,' oT
,,DAMAG
ED SEAT BELT
TENSIONER NOT DEPLOYED" so i t does not get
confused wi th your parts
stock.
Contact your Honda Di stri ct Servi ce Manager for
how and where to return i t for di sposal .
4.
Deployment Tool Check
' 1.
Connect the
yel l ow cl i ps to both swi tch
protector
handl es on the tool ; connect the tool to a battery.
2. Push the operati on swi tch:
green means the tool i s
OK; red means the tool i s faul ty.
3. Di sconnect the battery and the
yel l ow cl i ps.
23-71
sRs
Cabl e Reel Repl acement
Removal
1. Make sure the front wheel s are al i gned strai ght
ahead.
Di sconnect the battery negati ve cabl e and wai t at
l east 3 mi nutes.
Remove the dri ver' s ai rbag l see
page 23-65).
Remove the steeri ng wheel
(see page 17-6).
Remove the col umn cover screws
(A),
then remove
the col umn covers
(8,
C).
r
23-72
6. Di sconnect the SRS mai n harness 2P connector {A)
from the cabl e reel
(B),
then di sconnect the
dashboard wi re harness 4P connector
(C)
from the
cabl e reel .
' 1.
Remove the screws {A) from the cabl e reel , then
remove the cabl e reel from the col umn.
Installation
1. Before i nstal l i ng the steeri ng wheel , the front
wheel s shoul d be al i gned strai ght ahead.
2. Di sconnect the battery negati ve cabl e, and wai t at
l east 3 mi nutes,
3. Set the cancel sl eeve
(A)
so that the
proj ecti ons (B
)
are al i gned verti cal l y.
4. Car ef ul l y i nst al l t he cabl e r eel
( A)
on t he st eer i ng
col umn shaft. Then connect the 4P connector
(B)
to
the cabl e reel , and connect the 2P connector {C) to
t he SRS mai n har ness.
7.
Instal l the steeri ng col umn covers.
l f necessary, center the cabl e reel .
(New
repl acement cabl e reel s come centered.) Do thi s by
fi rst rotati ng the cabl e reel cl ockwi se unti l i t stops.
Then rotate i t countercl ockwi se
(aboul
2 1 /2 tu' ns)
unt i l t he ar r ow mar k on t he cabl e r eel l abel poi nt s
strai ght up.
Posi ti on the two tabs
(A)
of the turn si gnal
cancel l i ng sl eeve
( B)
as shown, and i nst al l t he
steeri ng wheel on to the steeri ng col umn shaft,
maki ng sur e t he st eer i ng wheel hub
( C)
engages
the
pi ns
i D) of the cabl e reel and tabs of the
cancel l i ng sl eeve, Do not tap on the steeri ng wheel
or st eer i ng col umn shaf t when i nsl al l i ng t he
steeri ng wheel .
(cont' d)
23-73
sRs
8.
Cable Reel Replacement
(cont'd)
Instal l the steeri ng wheel bol t
(A),
and ti ghten i t to
38 N.m
(3.9
kgf.m, 28 l bf.ft).
Connect the crui se control swi tch connector.
Instal l the dri ver' s ai rbag
(see page
23-66).
Reconnect the battery negati ve cabl e.
9.
10.
11.
23-7 4
12. After i nstal l i ng the cabl e reel , confi rm
proper
system operat| on:
.
Turn the i gni ti on swi tch ON
(l l );
the SRS i ndi cator
shoul d come on for about 6 seconds and then go
off.
.
After the SRS i ndi cator has turned off. turn the
steeri ng wheel ful l y l eft and ri ght to confi rm the
i ndi cator does not come on.
.
Make sure the horn works.
SRS Uni t Repl acement
Removal
1. Di sconnect the battery negati ve cabl e, and wai t at
l east 3 mi nutes before begi nni ng work.
2. Di sconnect the ai rbag connectors and seat bel t
tensi oner connectors
(see page 23- 16).
3. Remove the center consol e
(see page 20-76) and
audi o uni t
(see page 22-89).
4, Di sconnect t he SRS uni t 18P connect or
( A) f r om
t he
SRS uni t
( B) .
Remove the three Torx bol ts
(A)
from the SRS
then Dul l out the SRS uni t from the bracket.
unr t , 5.
lnstallation
1. I nst al l t he new SRS uni t
( A) wi t h
Tor x bol t s
( B) ,
t hen
connect the SRS uni t 18P connector
(C)
to the SRS
uni U push i t i nto posi ti on
unti l i t cl i cks.
NOTE: When ti ghteni ng the Torx bol ts to the
speci fi ed torque after repl acement. be careful to
t ur n t hem i n so t hat t hei r heads r est squar el y on t he
brackets.
Rei nst al l t he cent er consol e
( see page 20- 76) and
audi o uni t
( see page 22- 89) .
Reconnect the ai rbag connectors and seat bel t
t ensi oner connect or s
( see page 23- 16) .
Reconnect the battery negati ve cabl e.
After i nstal l i ng the SRS uni t, confi rm
proper
system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator shoul d come on for about 6 seconds and
t hen
go OFF.
2.
3.
4.
5,
9. 8 N. m {1. 0 kgf m, 7. 2l bf f t }
23-75