Acura TL Service Manual

ACURA TL Service Manual 2004A Few Words About Safety Service Information ‘The service and repair information contained in this ‘manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. ‘This manual describes the proper methads and procedures for performing service, maintenance, and repairs, Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda, ‘must determine the risks to their personal safety and, the safe operation of the vehicle. you need to replace a part, use Honda parts with the ‘correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. FOR YOUR CUSTOMER'S SAFETY Proper service and maintenance are essential to the ‘customer's safety and the reliability of the vehicle. Any terror or oversight while servicing a vehicle can result in faulty operation, damage to the vehic'e, or injury to others. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this ‘manual and other service materials carefully. FOR YOUR SAFETY Because this manual is intended for the professional service technician, we do not provide warnings about ‘many basic shop safety practices (e.g., Hot parts—wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this ‘manual Failure to properly follow instructions and ] | precautions can cause you tobe seriously hurt or | kites || Follow the procedures and precautions in this |_ manual earetully ‘Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you ‘can decide whether or not you should perform a given task. IMPORTANT SAFETY PRECAUTIONS + Make sure you have a clear understanding of all basic shop safety practices, and that you are wearing appropriate clothing and using safety equipment. ‘When performing any service task, be especially careful of the following: = Read all ofthe instructions before you begin, and make sure you have the taols, the replacement or repair parts, and the skills required to perform the tasks safely and completely. ~ Protect your eyes by using proper safety glasses, ‘goggles, or face shields anytime you hammer, drill, ‘rind, or work around pressurized air or liquids and ‘springs, or other stored-energy components. ff there is any doubt, put on eye protection. ~ Use other protective wear when necessary, for ‘example, gloves or safety shoes. Handling hot or sharp parts can cause severe buns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. ~ Protect yourself and others whenever you have the vehicle up in the air. Anytime you lift the vehicle, either with a hoist or a jack, make sure that itis. always securely supported. Use jack stands. ~ Protect yourself by wearing an approved welding helmet, gloves, and safety shoes anytime you are welding. You can receive burns from hot parts, allow the parts to cool before working in that area. ~ Protect yourself from paints and harmful chemicals by wearing an approved respirator, eve protection, and gloves whenever you are painting. Spray paint only in an approved paint booth that is well ventilated. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: = Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. = Burns from hot parts or coolant. Let the engine and. ‘exhaust system cool before working in those areas. ~ Injury from moving parts. If the instruction tells you torun the engine, be sure your hanés, fingers, and, clothing are out of the way, Gasoline vapors and hydrogen gases from batteries are explosive, To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. = Use only a nonflammable solvent, not gasoline to clean parts, ~ Never drain or store gasoline in an open container. = Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts,7 oF INTRODUCTION Now to Use This Manual “This manual ie divided into 22 eections. The frst page of each section is marked witha black tab that lines up with ts Corresponding thumb index ab on this page and the back cover You can quickly find the frst page of each section without looking through afl table of contents, The symbols printed at ‘the top corer of each page can also be uted as quick ‘ference system. Ech section includes: 1. table of contents, r an exploded view indax showing * Parts disassembly sequence, + Bott torques and thread sizes. + Page references to descriptions intext 2, Disassembiyiassembiy procedures and tools 3. Inspection, Safety Messages Your safty, and the safety of others, ie very important. To help YYou make informed decisions, we have provided safety eseages, and other safety information throughout this manual (Ofcourse, iti not practical or possible to warn you about alle hazards associated with servicing this vehicle, You must Use ‘aur own good judgment. ‘You will find important safety information in 8 variety of forme including: ="Gafety Labels ~ on the vehicle. + Safety Messages ~ preceded by a safety alert symbol fk and (one of three signal words, DANGER, WARNING, or CAUTION, ‘These signal words mean: PTAVERE You WiLL be KILLED or SERIOUSLY HURT if you dan't follow instructions PRUNING You CAN be KILLED or SERIOUSLY HURT if You don’ follow instructions. FREMTTENY You CAN ve HURT ityou don't follow instructions, + Instructions — how to service this vehicle corectly and safely Allinformation contained in this manual is based on the latost product information avalabie atthe time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, or stored in a rtrioval ‘systom, oF tranemittad, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior writen permission ofthe publisher. This includes text, figures, and tables. ‘As you read this manu, your wil fing information that is preceded by a NOTICE] symbol. The purpose ofthis message fs to help prevent damage to your vehicle, ther property, oF he First Edition 08/2003.2,176 pages “HONDA MOTOR CO..LTD, All Rights Reserved ‘Serves Publetion Office ‘Speeleations apply toUSA, and Coneda ‘As sections with * include SRS components special precautions are required when servicing, General Info ra Specifications g acs | Maintenance Ea ——_—— Engine Electrical Engine pet cooing = ss A Fuel and Emissions Pa *Transaxle *Steering CH *Brak {including VSA) nn *Heating, Ventilation and Air Conditioning *Restraints EaSUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘The Acura TL SRS includes a driver's airbag in the steering wheel hub, passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof, and side irbags in the oat seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk (* | an the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items requires special precautions and tools, and should be done only ky an authorized Acura dealer. + To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event ofa severe frontal collision, all SRS service work must be Performed by an authorized Acura dealer Improper service procedures, including incorrect removal and installation ofthe SRS, could lead to personal injury caused by wnintentional deployment ofthe airbags and/or side airbags. Do not bump or impact the SRS unit, front impact sonsors, side impact sensors whenever the ignition switch is ON (I), oF for atleast 3 minutes after the ignition switch is turned OFF. Otherwise, the system may fail in acolision, ‘or airbags may deploy. 'SRS electrical connectors are identified by yellow color coding. Related components ace located in the steering Colum, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, inthe {ont seats, inthe oof side, and around the floor. Donot use electrical test equipment on these circuits.General Information Chassis and Paint Codes Identification Number Locations... Warning/Caution Label Locations Under-hood Emission Control Label .. Lift and Support Points... Towing . Parts Marking .General Information Chassis and Paint Codes Vehicle Identification Number Engine Number 19U UAB 5 5 * 4 A 000001 DT b cdefgh ‘4. Manufacturer, Make and Type of Vehicle QU: HONDA OF AMERICA MFG., INC. U.S.A. ACURA passenger vehicle b. Line, Body and Engine Type UAB: ACURA TLJ32A3 ¢. Body Type and Transmission Type 4-door Sedan/6-speed Manual .4-door Sedan/S-speed Automatic d. Vehicle Grade (Series) 2:TL with 5-speed AT 5:TL with 6-speed M/T 6: TL with 6-speed MT and summer tre Check Digit ‘Model Year 4:2004 9. Factory Code AcMarysville, Ohio Factory in U.S.A. h. Serial Number ‘900001—: U.S. mode! 800001: Canada mode! Safety Standerd Certifeation 1-2 3.2uliter SOHC VTEC Sequential Muttiport Fuel-injected engine ». Serial Number ‘Transmission Number ECE - 1800001 - ‘a. Transmission Type DECE: 6-speed Manual BDGA: 5-speed Automatic . Serial Number Paint Cade Code Color Canada NH-603P) ie Diamond Pearl 3 [NH-623M_| Satin Silver Metallic o-| NH-643M _| Anthracite Metallic © B-82PV [Nighthawk Black Pearl [© |O B-527P | Abyss Blue Peart oTé G-516P__| Deep Green Pearl o R522P | Redondo Red Pearl © | _O YR-536M | Desert Mist Metallic ©Identification Number Locations Vehicle Mdentifieation Number (VIN) > “Transmission Transmission Number ‘Number (Automatic) (Manual 1-3General Information Warning/Caution Label Locations NOTE: FRONT PASSENGER (CHILD SEAT) AIRBAG. WARNING TAG is on the glove box in the U.S. model. Front Passenger’s Compartment: ‘SRS WARNING INFORMATION SRS INFORMATION US: modal FRONT PASSENGER MODULE DANGER STEERING ‘SIDE MODULE. cotuM BANGER NOTICE” moNITOR SIDE AIRBAG AND SIDE NOTICE GURTAIN AIRBAG Located on drivers and passenger's doorjamb Rear Passenger’s Compartment: ROOF SIDE MODULE DANGER 1-4 Steering Wheel: CABLE REEL ‘CAUTION.AR ‘covomonins INFORMATION SERVI {Under OR CAP CAUTION ICE INFORMATION LABEL, ‘TIRE INFORMATION.General Information Engine and Evaporative Families: Engine Family: 4 HNXV 032 CKR iff 7 ab cd e , Model Year ‘THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5. 4:2004 REGULATIONS APPLICABLE TO 2004 MODEL YEAR. b. Manufacturer Subcode NEW PASSENGER CARS AND CALIFORNIA, HINX: HONDA REGULATIONS APPLICABLE TO 2004 MODEL YEAR. , Family Type NEW LEV II ULEV PASSENGER CARS. v:LDV Displacement ‘Sequence Characters Evaporative Family 4 HNX R 0140 BBA LTT T ab cd e Model Year 4: 2004 b, Manufacturer Subcode HNX: HONDA ©. Family Type Rr EVAP/ORVR 4. Canister Work Capacity ‘Sequence CharactersLift and Support Points NOTE: If you are going to remove heavy components ‘such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall, safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can ‘change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2, Raise the hoist 2 few inches, and rock the vehicle gently to he sure itis firmly supported. 4, Raise the hoist to full height, and inspect the lift points for solid contact with the lft blocks. Safety Stands ‘To support the vehicle on safety stands, use the same support points (8 and C) as for a frame hoist. Always. use safety stands when working on or under any vehicle that is supported only by @ jack Floor Jack 11. When lifting the front of the vehicle, set the parking brake. When lifting the rear of the vehicle, put the ‘gearshift lever in reverse for manual transmission, ‘or in the P position for automatic transmission. 2. Block the wheels that are not being lifted. 3. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (8). Center the jacking bracket in the jack lft platform (C) and jack Up the vehicle high enough to fitthe safety stands under it 4 Position the safety stands under the support points, ‘and adjust them so the vehicle is level. 5. Lower the vehicle onto the stands.General Information Towing Ifthe vehicle needs to be towed, calla professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. Itis very dangerous. Emergency Towing ‘There are three popular methods of towing a vehicle, two of which are recommended and one that is not. Flat-bed Equipment — The operator loads the vehicle fon the back of a truck. This is the best way of transporting the vehicle, To accommodate fat-bed equipment, the vehicle is. ‘equipped with a rear towing hook (A) and rear tie down hook slots (8). ‘The rear towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots ‘can be used ta secure tha vehicle to the truck. NOTE: The rear tie down hook slots use rubber plugs to cover the openings. 1-8Front Towing Hook Installation Use the front tow hook for very short distances such as freeing the car, use the detachable towing hook that ‘mounts on the anchor in the front bumper. + To avoid damage to the vehicle use the towing hook for straight flat ground towing only. Do not towas an angle. + The tow took should not be used to tow the vehicle onto a fat bed. Do not use it as a tio down. 1. Remove the cover (A) from the front bumper. 2. Remove the towing hook, hook extension, and wheel wrench from the tool case in the spare tire. 3. Using the wheel wrench, fasten the extension into the bolt hole in the anchor. _ S 4, Screw the towing hook into the extension, and tighten it securely by hand. (cont'd 1-9General Information Towing (cont'd) Whee! Lift Equipment — The tow truck uses two pivoting arms that go under the tires (front or rear) and lifts them off ground. The other two wheels remain on the ground. This is an acceptable way of towing the vehicle. Sling type Equipment ~ The tow truck uses metal cables with hooks on the ends. Thase hooks go around parts of the frame or suspension and the cables lift that ‘end of the vehicle off the ground. The vehicle's ‘suspension and body can be seriously damaged i this ‘method of towing is attempted. Do not use this method of towing, Ifthe vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. if due to damage, the vehicle must be towed with the front wheels on the ground, do the following: ‘Manual Transmission + Release the parking brake. + Shift the transmission to neutral. ‘Automatic Transmission + Release the parking brake. + Start the engine. + Shift to the D position, then to the N position. + Tura off the engine. Itis best to tow the vehicle no farther than 80 km (50 miles), an keep the speed below 5 ken/h (25 mph. [NOTICE] + Improper towing preparations will damage the transmission. Follow the above procedure exactly. If ‘you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flatbed. + Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not ‘designed to support the vehicle’s weight. 1-10 Parts Marking ‘To deter vehicle thett, certain major components are, marked with the vehicle identification nurnber (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engine or transmission VIN plate is transferred toareplacemant engine ar transmission and attached with break-off bolts. NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the pant,Specifications Standards and Service Limits Engine Electrical Engine Assembly Cylinder Head Engine Block Engine Lubrication Cooling Fuel and Emissions... Cluteh = = Manual Transmission and M/T Differential Automatic Transmission and A/T Differential Steering Suspension oes 2-10 Automatic Transmission Steering Suspension Brakes Tires Air Conditioning Electrical Ratings: sm. Body Specifications IlustrationsStandards and Service Limits Engine Electrical em ‘Measurement ‘Gualiication tandard or New [Service Limit ignton coil | Ratedvoroge av Fig ordar eae Sparkpog | Tre NGK THOR DENSO: 2008 NN4 _ oe —}io= 111mm (e896 in) Tritton ting ‘tide (check | AIT(in Nor P positon): 10:+2° BTC —~ _ the redmart__| MT Gana 102 2°8TDC “Brn. | Tosion aut Aut tention compressor bt _| ‘aterator | Out 188 Ved poral engine 7308 temper Cel rotor oon RerGIO ska Siping OD. L 144mmiS7ini idm Osin| Brushlength [08mm oat ind 18mm (008i) Brush ving tension - 321 (0394gf, 0791 Sire Output “8K Comma mies dep 24- 0mm (00E-0In) OAS mmIOdOE A Commuter runout 2 mm 10.001 in) mn 0.6 mn (00028) Commutsto’ OD. [0 28. mn (.12 1.108in) | 27.5 mm 1.088 Brush length “1BB~ 162 mm (0.82-O.84in.) [Ae enn 10.43 ted Brush sping tenaon Tow 167—T77NIe0~ 180g 369~3.7 Ih Engine Assembly _ [tem Messurement ‘ialfcation | ___ Standard or New [_Serviee Limit Compression Posse Ticimum | a0RPH Stale, 250 — Check the engine withthe tater | Maximum | 20087 2.0K 28 px — rmting, vacation 2-2Cylinder Head tm ‘vaieaon Sandor few Serie Td —— 2.05 mn 8.02 ind : THiS a mT ATESIT | — Cana 005-028 mm 00%2-0068in) [620mm B06Tny Cars ldr o clearnce 00-0686 a020- 00135 Ia) 018 mm 0005) Tat runout 603mm DOT in) ve 804m 928m) Carnie a ide primary [25047 mn 378 = ioe mid 95445 rm (448m) = ihe, 35.284 mm (3887 in} = wonton Exhost [26386 mm = Vale eran ah intake [920-024mm 006 -0028i—) | — Exhaust | 028-038 mm @oN1—oorsin) | — Sen in B55 95 mn 07159-0716) | SAB nm OTA [estat [4505.60 mm 0 146-02150in) | 20 am 2Kot in Tani pie dears ithe 020-048 mm {8a008~0.0018 In) 08m (0003 in Exh] 0.055050 mm (60220 O05 in) [0.9 mn 04 in Tae wiih ia. 125-185 nml0045-c9stin) | 2e0mm(O97Sinh Exhaust [125-155 mm 10045—0081 in) [2.00 mm 07m} Siaincaled rahe intake S375-¥755 mm VBA 187ein] 478mm 87m) Echo [456847 48mm 8961888 in) [4778 mM inh Vane ng | Fler th Bistmm 20z8in} Exheust [51.06 mm 2010 = Vale ais [78 inne S515. 5580nm 027 -O277in) | SBM WAWind Exiga |B 815-£590mm(02171-07777in) [Ss mm (028m) Taal ae intake 22-2220 nm (0g —EATEIN) | Echo |2060-21.60mm att o8ein) | — Tope cance ro | G26=0061 mm(6. 0010-0002 in] | ane mm WORInd [Exhaust [0260 77 mo 0.616 0000in) | 4077 mm 0.030 in 2-3Standards and Service Limits Engine Block em Maan Sec Ln Bio Warpge a deck Ee mm Gootiny Bore iometer 33.065 mm 065) Boreas = 808 mmi800zin) akring ik = 028 mm nh Fata Ski 0.0. at 155 mm ATTA TOM 750mm SOS BBORSTn| 88.95 mm (38007) betiom ot earacein onder z 0G OHO OOTTBTn) BO mm STAD fing groove with Tee 2401260 mm (6.0488 00887 in} | 127 mm(005ind Second $2201290mm (00490-0484) [1.28 nm 0089 oi 2052825 mm TT6¢=01TTZin} | 2SmMiG In) Tiong | Rngtgraovederaice op] 0085060 mn 6.00220 00nd [0.15 mm (6.0083 Second 1.630=0.65 mm 661200027 in} [0.13 mm (0.08ind Tipendanp Tee 020-035 nm (0008-20t¢in | oBbrmm i atin) Second 040088 mm (0016=0872in) [070mm (0028 int oi 020=1.70 mm (0080-0 028 In [050m (O03t ink Faionsia (00 21-92-21 S65 01648-08618 | 2.84 mn 0.964375] Pirie ionclonace =0.008b(0 +6010 mm 108 mm 000 (aootz0 6 09000) Convesina rod | nterod eae 005-0 6002-OBHE in) OTH iam OORT Smalend bore matt 21370=21 576 mm (0.800.968 Large endboredanetr opine [80 mm 22sin3 = | End lay inal on rar 018-035 mm 0306-OaT4in) | eamlODIwinI ianishat | Mainjournal diameter 73878-72000 mm (24997 -288in)| —— Fount leer 54576 £5.00 184-2 15tind| — Rdmin jure per 0.08 ram (00 in) max 070m ann journal out found 0.005 mn (0.0002 i.) max. (0.010 mm (0.0004 in) ‘010-0:5mm(0.006-0.074in) | A45mmiO018in | 11025 mn 00010) max 068 mm (000%zin} ‘anishat | Moin sng our ol Gerace 1020-0044 mm {068 EOOTIn 0080 mm O02 in tearing Fodbesing saree = BS4 rm (0.0006-O0TTini | 0050 mm Oi 2-4Engine Lubrication tT Messirenenr unification Sian or New Series Uni Traiteo | Caoaty Engine overha_|SOURSUS a 7 : [oitchang 434145 US a _ inelacng ite Oichangs, | SOERZUS a without : Oirpiing [nirvana 2G4- 0 mm (OOR2—9908in) [O70 mm OHO) Pump housing t-outer tor clearence £100.19 mm (0.90¢~0.007 in) [20mm 10008in) Pump housing outer tora 002-697 mm{O001-9.003in) J ox2mm(0006in) Oil pressure with altemperature at | Atial 7OKPa (0:7 kaon, TO pai —_ - 5 a0) {a3000%9m [490 ¥Pa a kg. ps Cooling ‘tem “Measurement | Qualification ‘Standard or New: Tadiator | Coclantcapacty ude engine, | Engine overaut [AT moder 81 F186US a) eater hoses and eer TMT mov: 7 90183 US a | Coolntchonge [ATT mode- 648 (68 US gt MT moe: 634167 US at exert | Cia coast as810SUS a) = | Resiatorcap | Opering presse ~~ |s5- 125i 095-128 aD Thermostat] Opening trpertire Bogie open | 169—T7eF 76-80) Fullyopen [19a GO) [Va aay oe [0.0 mm 639ini min 25Standards and Service Limits Fuel and Emissions tem ‘Mieseurement ‘Gualiction Standard or New Fuel pressure | Pressure 400-— 450 kPa (4.04.5 kglem, BB —B4 psi) | regulator Fuel tank Capaciy - 4911771 US gal ~ 7 Engine icle | Ile speed withoutload TWiT in neutral | 750350 pm - AMTInNorP position idle speed with high eleciviclosd | MTinnautral | 760280 om ‘with HVAC on) ATinNorP | position ‘Clutch ‘tem Measurement ‘Qualification ‘Standardor Naw: ‘Service Limit) ‘Guich pedst | Height rom floor 1eimm(7S2in) — ‘Siroke 190 140 mm (6.12 85tin Phy. 10= 18 mm (038-071 in) — [Disengagement height from floor_ {90.5 mm (3:56 in, min. — [Fiywest uncut on cluih mating surface [05 mm (0.0020) max 0:18 mm (0006in.) Cutch aise [Rivet head depth “10 mm (0.039n.) 22mm0.m08in} [ “Thickness ‘868-953 mm 0342—0376in) | 7.2 mmi028in) Pressure plate | Warpage (0.08 rm (0.00% in) max 0.15 (0.006 in.) (0.8 mm (0.02 in} max (08mm (003in) 2-6 eit of iaphragin spring fingors ‘measured with special ool and fooler |vauge lManual Transmission and M/T Differential em Messurement Oualeton Standard orfow Senet TFonsmissln” | Copecly Fuidchonge [22 7B30S ot . fia Use Honds mre ‘Ouehaut [258 60S Mainshakt | Endploy 0.4 021mm 0005-0008) = iat flict bearing auc 18.957 — 19.90 mm 07861-07665) 1991 mem iO7BEin) Diameter of ah and eh gore [96796 000 mm (4168 1.4173 in 3599 mm (415i) distance colar | Diameter of bal Barna cotta FRG Ba. OT mm 104110] BFE am ADIT (catch noving sie! ‘Diameter of reele beating conact "SA 60 mn BT BERS] Bm LETT Diameter of 6h ger discs ek 2867-3 0 mm (FATT in| BHA MAA | Diameter fal bering contact 30.907 31.000 mm (.2200-.205ini| 9038 mm (1238in) | ranamision hosing sda _ nowt 02 mm aU in me 0 mm 007i) ‘ansba 0. ~~ 009= 7.025 (1.9507 AE | 47.08 mn (1.854). rd goa End pay [208-019 mmi0002-0067in) 03mm (001 ind “Thickness 7309-7397 mm 0941-844 in} | 238mm (094in) amaha 1 7.05702 rm. 8507-19514] 4.08 1.954 in) Anand 5h overs [End lay 206-019mm(0002-0007in) [3mm (00m) Thickness 7239-7247 mm 0881-0896in) | 723.4 038 in) Wainsba—[1. 4.00844. 025 rn (1. 7926— 17208) 44.08 rm (1.735 0). Bn ger End pay 7 006-019mm 0662-009Tin) [adm eatin Thickness F99= 715 rm 962-0865 in) | 71.8 mn 0.6). Cauniersha® | Bomete feed bearing oract 8.974980 1.7319 17T9 W497 1.72818) cic housing ie) | Diameter of distance calor conc GETS ABER am (.OSTO™ BOR] HA wn DIN Diameter of ball befng contact 36002 S007 mm (1819 Hin] BABE MM TON |(wonamisionnusing sa) - ‘Diretr of counters vee ger ESA WE 95 nO BGT | LE In) Aunoat 62mm (0001 nd ma. 105 mm 008 in) 35 mim ahimso-beong 04-0.10 mmioo16-0008) | Adve Counts : H.910- B79 mm aS —2BIin| HHaaMMERATIN| gear 206-011 mm (0002-0007in) 1 028mm(00rt in} z2s1- 2298 mm 902 0905in) 17286 mm 0300 in)_| oneal 9.010 57.029 min 2445-2265 57.08 (2247 in) and ge Endplay 04-0: mm 0Ge2-o00Tin) [0.28 mm 0014 in) Thekoess 71-7259 mm 902 -0305in) | 22.98mm O800in) Coonietna (10. 4597045 588 mm (1800818108) 46.06 mm (1.873in} everson [05 3198752000 mm (2046720472) 51.99 mm 04 in) I" Length e308 mm 10907-0908) | — Cournot —[10. 2.990 48,000 rn. 6985 16929) 13.0 EA) arageer (00. 1.505.000 mm (046820472 in 5. 9¢ mm 065m) dines cotar {engin 203-7208 0.907008 n) | — (cones) 2-7Standards and Service Limits Manval Transmission and M/T Differential (cont'd) tem Mesburement uaification ‘Standard or New, [Service unit | Mainsnet | iD. f [36,002 36.012 mm (1.4174 1.4178 in)] 36.06 mm (1.420 in ‘ty and 5th gears [O. {1.989 42.000 rym (7.6851 ~ 1.6535 in. 84.94 mm (1.651) stance collar | Length a 1995 80.05 mm (1.967-1570in) — |—— “| a a | ’ , - 5 2285- 72.68 mm (0.887 GARIN) |— ’ Yr Mainshatt iB, ‘Bb02 38072 mm 1200812087 in] 3808 mm 1 BOBIn) etn gear OD, 38,989 ~ 28.00 mm (1.5360 1.5854 in| 38.94 mm (1.533 in) distance collar [Length 22.08~72.08 mm (0863-868 in) | ——_ Reversegear | OD. 19.989 ~20.000 mm (0.7670—0.7874n}} 9.93 mem (O.7BBIN shaft Reverse drive | 1D, "25.007 25.020 mm (0.9645 0.98BD in] 25.07 me (0.98 in) riven: Sth synchro ing | Ring-o-9earcoarance Ting pushed | 070~%40mm 0028 0.059in) | OAmm(0078in) against gear ‘synchro ring | Rivato-gear clearance ing pushed | 073~1.44 mm (0029-0067 in) | QAmm (0076 In) 7 against gear Dovbiecone | Outer synchro ingtoavnchro cone [Ring pushed [0.70.19 mm(0028-0047in) | oSmmVOT2iny synchro clearance _| sgainer gear ‘Synchro eone-o-gear clearance Ring pushed] 050—104mmO020--O0a1in) | 3mm(O0T2im) against gear ‘Qitereynahvo ing to-gearcone | ing pushed | 035~168mm/(0037-0086in) | 08mm (0.024in) clearance against gear “itiripl cone | Outer synchro ing toynchro cana | Ring pushed [0.70 1.19mm(0028-00«7 in) | 6Smm|0072im) synchro clearance gsines gear - _| ‘Synchro cone-to-gear clearance Ring pushed) OE. 14 mmiO01@—O046in) | O3mm(O0TZIm) L sgainst gear “Gutersynahroving e-gear cone | Ringpushed | L12-168mm00ei—0066in) | 06mm (0024in) —_ cleerance against goar _ ‘2rd tiple cone | Outer synchro ing tosynchrosene [Ring pushed [070-119 mm(0028-O047in) | O3mm(O0T2In) syncho clearance | aosiner gear _| ‘Synchro cone-to-gear clearance Ring pushed | 980 1.88 mmi0024—0074in) | ©3mm(O0.0T2im) againstgear | - ‘Outer eynchro ing te-gear cone | Ring pushed | 087—182mm(003—0072In) | O6mm(002¥In} |__ clesranco against goar Tana, Fingor thickness t [787.6 rm 1029-03010. = rat, Forkto-synchro alcove learance (0.35=0.5 mm (0074~0.026in) | LO mm(0030in) Sth Shit fork - Reverse shit | Fingor thickness 62-64 mmi0ae 028 in) = | fork Forkto-eynchro sleeve Gearance (0.35=0.65 mm (0,014=0.026in) | 1.0mm (0.03910). Reverse shift | Finger thickness LC 6.400 6,650 mm (0.2520 0.2618 n)_|— lever ‘Shitteverto-sift fork desrance (0.05=050 mm (0.002-0.020in) | 06 mm (0.024 in) ‘Shift over giameter at contact area 1307 13.2mm(051-.82in) — Shift lovertomteroek clearance: {204mm 0-0015in) ‘25mm 0.020%) ‘Shiftplecs (LD. "4.000 = 14.088 rm (05812-08859 in| —— _ ‘Shi York ameter at contact area 128 180 mm (0.50051 in) —— Shift pieceto-siftfork clearance. (02-06 mm (0.008 -0.024in) [07 em 0028 nd 2-8item Measurement | Qualification ‘Standard or New ‘Service Limit Shitam [1D | 3.75005 mm 062890550 Shiltpis damstorat conta 739-1ommiast-ossin) | — _ Shinar tosis cleronce 205-025 mm 0002-0010in) [aS mmiGa20in) ‘Select arm 10. 11.01 11.05 mm (0.433 0.436 in.) = into dametar at one aan 129-190 (050-05tin) ————— Selec or toinariek clearance 105-025 mm 602-0010in} [06mm l0000in) ‘iin | Opump trust clearance 009-0.13mm{o001_OaISin} — [0.18mm 0006in} [ovterrotorso boy earance (01-02 mm(0006-0008in) [02mm 0008in) | Inne retr o-oo rotor clearance 2.1mm (0006 na me 92 mm 008m} i pump inna rotor. 174-172 0067-088in) | — |__ Oi pump se 0 168-17.0mm'06-06rin) ——|—— WT dieroniat[Baoklash 0413 mm\05%6—0051in) = care Drives contac aaa 3009530045 yn 1821180] — Carrer bearing starting torque (prelead) 343-451Ne (3548 kgher, 30-40 Ibfin) ‘AajustStandards and Service Limits Automatic Transmission and A/T Differential ikem Measurement ‘Qualfetion ‘Standard or New. ~ [Series Lime ‘ATF tatomatc | Capacity Fiuidcnenge | 308208 at “Transmission Fuel | Use Honda ATE-Z1 ‘Overhul 700 (7.4US qb "ATF pressure | Line pressure "At 2,000 prin | 900-860 KPa woe | NoxP postion _| 8.28. katlom’ 130—140 ps) (2.7 kom’, 120 pit Sih chah pressure "At 2,000 cpm in| 690870 6Pa Baka Myostion —_| (91-99 kgHlen, 130-140 psi) (8.6 katlom’ 120 psi) “th clutch pressure "At 2,000 min | €90~970¥Pa ‘B40 KPa Mposiion __| (1-99 ken’, 190-140 psi (8.6 oem’, 120 psi 3d dutch pressure ‘At 2,000 prnin | 690~870KPa B40a Mposiion __|(9.1-9.9katlem’ 190140 ps (@.8katlem’, 120 pai ‘2adltch pressure ‘At 2,000¢pm in| 690970 B40 kPa Moston __|(8~¢.8afem’, 190~ 140 psd (@.8kaflem’ 120 ps) Tt clutch pressure ‘&t2,000 min | €90~B7OKPa BHOWPs Mposition | (9.1-9: kgtem’, 130~140 ps (.6kgtem, 120psi)_} Tet hold elath pressure ‘At2,000 rprnin | 760630 kPa 710163 position (2.785 halle 110-120 ps) (7.2 kate, 10 pat “Torque converter | Sal speed 2,000 rpm 11850~2.180 pe L ‘Check with vehicle on level ground ute {clutch end plate-to-op-dise st = a= 1amm clearance (0.043~0.051 in) 2d — (0851.05 mm _ 10.033-0041 in) ad = 07-09 mm 10228-0035 in) ash = (055-075 mm | (01022-0030 in) Tethald = 05-09mm (@.020-0035in) _| ‘latch return spring fee Tenath tet wesmm 269i) 663mm 261in! 2nd Smm 210in) 'Si.¢mm(202in.) 3a 52.0 mm (206 in) 50.0 mm (197 in} [an 335mmi132in) 315 mm (126m) _ [sn a7Ammi147 in} 35.4 mm(1.39in) ‘lutch aise thickness 194mm (0076 in} — ‘Clute pate thickness 58mm (0.0650) ‘When dacalanad 2:3 mm (0.097 in) ‘When ciscolored 2.0 mm (0.079in) When discolored 1.8mm (007tin) Wien discolored ‘et lish endplate hicks 310mm 0.122in) [When discolored | 320mm (0.126i0.) ‘When discolored 330mm (0.190in.), [When discolored 340 mm (0.138in) ‘When discolored "3.50 men 0.198 in.) When discolored "3.60 men(0.142 in) Wien discolored 270mmi0.UGin) ‘When discolored 380mm (0.150%n) ‘Wher diacoirod 390mm (0.168in) ‘When discolored] [evo uth end pate thickne 5.00 mm (0.197 in) When discoloreditem ‘Weasurement ‘unieation | SiandardorNew | — Serdea um —] Giuch “ndeuteh ond plate ines Mark Bid (0.089%) Wen discolored 2.20 (0.087 in) When dolores 2:30 mn (0.098i8) ~[ When icoored 20 rm (0.096 in) When discolored 2.50 mm (0088in) When discord 2.60 mm(0.102in) When declared 2.70 mn (0106in) When dsolored 280 mm (0.110in) When dcolores | [280 mmo. t14in) When dissoloed ‘ed lh end plate ices 2.0m (0.083in Winendcolores | 2.20 mm 007 nt [nen icolores 2.30/mm (0.091in) Wien discolored Fata mm 0.09¢i0 When dolores 150mm (058in) When decolord 2.60 mn (0.1021) When cicoloed 270mm (010618) When declores 280mm (0.41015) ‘When discolored 290mm{0118in) When diclore 00mm 0.118in) [jwnenaiscolored | Mater iomm@.22in)— When ciscolored [sand buh end plate ickness | Mare? 210mm (0.083) Wher dolores Mark 2.20 mn (0.07 in) When declored 2.30 (0.09% in) ‘When dolores 240 mm 0.09¢in) Wine diclored 250mm (.098in Whe ieoloed 2.60 mm (0102in) When ciscolored 210m (0.105in) When discolored | 250 mn (0.410i8) When declared 7 Mans 250 mm (.414in) When discolored [RTF pump | Stor aha needle bering contact. | Torque converter | 27000-77021 me 06501 938in| When worn or anaged } side oo CATE pump ide | 28000 29,2% me (1 5417— 1.408 When wor or damaged "ATE pump goar thas claarance ~Jaas=0.6 nm (6.001-0.062inj [007 mm Oon3in) | "ATF pump gero-bodyceerance | Dive gear [0210-0285 mm 0.0083~O0104in)_|— vr brven gear | 0070=0,125 mm (.0028=0.0049 in TATE pnp dive geo. "H.0T6- 14.034 men (5516 0.525 no When wor daraged | ATE pump driven gear soit OD. 18,900 13.00 mm (05504—0.508 in| When worn cr camaped Feverseahit | Fork finger thickness $906.00 mm(0232-0226in) | 840mm (02T3in} fork : | Pack gear and = ‘When wun odanaped aw 7 _ “ Servo body | Shift fork shat bore 10 74.000— 14 0mm 05512-O55i6in] Shi fork shat valve bore LD _ "7.00 = 97.029 mm (1.4867 — 1.489 in 3745 mm 1-85 Regulater valve | Sealing ring const. 2. 000- 2.025 mm (1.25981 208i] 82.050 12618 ody ‘Aceutlatr | Sealing Wing contac, 00085005 min (137801 TED IAI] 38 mM TTBBIN body Sistorshat | Sealing ring cone 5002.08 mpm 1.109] 28060 mm 1-137 toon 2-11‘Standards and Service Limits Automatic Transmission and A/T Differential (cont’d) Rem Mosturerent ~[_Quslifestion ‘Standard ot New Service Limit ‘ainehatt Diameter of needle bearing contact | Alstator shaft | 223984 73.000 mmn(0.9048 0.9085 in| Whan wor or damegad rea ‘Atéth gear | 52875 52.991 mm (2.0856 2.0863 When wom or mage | Att gear cata | 38.975—38.991 mm (13876= 1.3982.) When worn or damages 1D of ah gear - 59.000 69.019 mm 2.3228 2.3236), When wom of dameged LD. of Sth goer "40.000 40.016 mm (1.5748 ~1.5754n)| When worn or damaged | End play of ath goat _ (0.03031 mm (0.001=0012in) [End ply of sh gear (0.10022 mm(00¢= 0.009) | —— {14.73 mm thrust shim thickness | Na? 7.85 mm (0.309 i) When wom or damaged No.2 7.90 mm{0311 in) When worn or tara No.3 7.95 mm (0313in) When worn or damaged | Nod 800mm (0315in) ‘When worn or damaged No.6 {05 mm (0377 in Wien worn or damaged No.6 Tato mm oan! When worn or damaged | “Thrust woshor thickness —___—_|27 x47 «5mm | 5.00 mm (0.197 in) When worn or damaged Longth of th gor collar '585~58.6 mm (2308-2307 in) | — ‘Sth gor elle flange thickness 445460 mm (0.175 —0.18tin.) | When wom or damaged ‘Sealing ring thickness ‘Samm 187=1.97 mm (0074-0078 in) | 1800 mm (0.071) | seating veg, 29mm 187137 mm (0074 -0078in} | 1.800 mm (O07 In) sealing ring Wath of sealing ring groove 2.025 2.060 ra (0.080--0.081 in.) | 2.080 ran 0.0820 luted pie O.. ‘theltch 3.97598 mm (0.2850~0.2356in) | 595mm (02343in.) th eluten 11.67 11.48 mn (0.4576 ~0.4520 in) _| 11.45 mm (0.4508 in) (hutch fed pipe bushing 1D. ‘inetuioh | 6078 6.090 mm (0.2969 0.2374} | 6.085 mm (0.2300in) | ‘th euteh 11300-11518 mm "1.530 mn (0.4539 i.) (0.4528 0.4535 in) 2-12item essrement ualetion ‘Standardor New Sevieetint | Couriers | Diameter of needle bearing contact’ [Arsh gear | 30975-24901 mn(1.2770—13776in| Whe worn or aaged ae ‘and gear | 995794000 mm (1574—1575in) | When wornor ane | ‘park gear | #.954—4,90 rn 1.652% 1.6528 | When worn or aged Atrightend | 88505=38.15 mm .5169="L5169 in) When wom or damaged ot Rh gear 000 4.016 min (18142 1.8148) When won rdaaned | LD-of 3d gear - '0,000—60.016 mm (1.9685 — 1.9691 In| When worn or damaged UD. ofreversegear 46,000 ~ 46.016 mm (1.8110— 1.8116 in.)] When worn or damaged [End pay oft eer 00-0. mm (00-0018) End ply of th gear ‘04-027 mm a02-0011n) | — End ply of dg ‘2015-0015 mm namo6-000%8in) | — End pay ofrverse oar 110-025 nm 1004-0010) /31*69.5x85mmsplined washer [A 4509-3515 mm g379—0.1904in)_| When wor erage diference 3 2.490 2.502 men (015740.1979in) | When ern or dared c 3. 477~8.489 ym (0988 ~0.1374in) | When womnor drape _ > 2.404 2.475 men (0 964—0.1969 in) | When rn of arg eng of dite colar SXAIE [AREER 178iN) | — 35x 47x a mm [692 S96mm ORD oz86in) —_|— Cotter hicks 1.99202 mm (.0789,090 in) Reverse selector ub OD. ‘55.87 56.90 mm (2.18982 2008n) ‘When worn or damped | Clutch fed pipe 00, {497 ~B99 mm 0:353-0354 in [cue ed pipe busing {9.000 9.015 mm (0.354~0,95 in} ‘8.95 mm (0362in) | 9.030 mm 0:56 in (cones) 2-13Standards and Service Limits Automatic Transmission and A/T Differential (cont'd) [___ttem Measurement ‘usifiation| ‘Standard or New ‘Service Limit aa78 Secondary shaft | Diameter t needle bearing contact | At tet ge 7983 mm (.4951~ 1.4955 in| When wom or aomeged ee {AtBnd year | 28868-28969 (.3580=1 965i] Whe anor aged i of gear 4.04408 1 728-1.749 | Whe wor or mad 0 ofand ger 2.000— 40 16mm (1.5748 —15754 | Whe nono dae [Enda oft gor 007-838 mm(E008- Onin) | — Endl fn geo 7 at= 058m 0t8a= 0.006 n3 | — 38x58 mm pled washer ines | Ne-T 8.8 mm (0270in) ‘Wenn mage No? 90mm (0272in) | Wena draped No.3 898 nm (0274 in} Wen wero omeped Not] 700mm 078i [er we doped No.8 Tosmmiga7sin} Wheto or omg No.6 2x0 mm 0280 in) er nr a draped STE rahi knees [Not 490mm 013m) her na maped No £95mmi098in} en weno amaped | No. 500m. er wr raped | No.4 | 05mm 9nd Wr wen or raged Nos Simm (azsti Wr wn drape No.8 Si5mm 022zin} ier won aged No.7 [Sao mm 0205in} here draped 198-202 mn 0-OORIA) 1880-1950 mm(0.0T 0877 in) [1800 mm UTD ‘With of ling ring pore as =2.080 mm t0.850081 in) | 208 mm 0.082} ch ed pre 0. 7a7=Ta mm (03108-03142in) [785 mm 03o0in} Gites bie busing IB 5000-8615 mm 03160-03168) [8050 mm OT6TIND Teves lar | Doms of needle eating coset A voor War | 8.08014 000m (0.580 851i] When wor diged goer even eerste Endl [8-8 rm 06200] —_|— o 106718629 mn (07089-07084 Wn war donne | Tv water ines “raremieon [088-104 mm Ot 09¢Tin) housing side Fever ger 097188 HB BOAT) | — |store “ a6 adv STA OER Wen wa 1D-oftareision bousing of revese 6160247 (0881405821) ‘Mar goarshatecontact area 2-14item Measurement ‘Gualfcation | ‘Standard orNew 7 WireDiameter| 0.0. | Freetangth | No ofGoie Wain vive body | ShIRaWeBapring 07mm [65mm | 3a.7mm | 128 soring (see pape tooreiny | 10260in) _| (327m) 16260) Shikvalve Capring ‘o8mm [66mm | 4atmm [217 L oosriny _|10260in) | n933in) Kick down vale pring asmm [66mm | 49.1mm | ZiT . (o03riny | 260ie) | 1.993 in0 Modulator valve spring [38am Todmm —|xasmm [98 (o068iny | o4osin) _| ar9iny Relief valve seving 12mm Timm [380mm [88 tooeriny —_|roasriny | (1596%m) _ Toakup ait vale spring ‘ogmm [76mm | 6.0mm | 224 |_ (oa26iny _|10280in) | r4aniny | Cooler check valve spring asmm semm [145mm | 68 (o024iny | @z2sin) | 10571109 Torave converter check 12mm [8mm [34mm - valve sring ooeriny | o33¢in)_| narsind Serve conto/vave sping ‘09mm [64mm [328mm [175 10035in) | 10282ia1 | .280in0 averse GPC valve Sing ‘o7mm [1mm — | 178mm | 79 (o028iny __|10240in) | (0701 in equator valve | Stator reaction spring ‘45mm 354mm 323mm | 21 body spring (see coxtiny —_[erse4iny [182i page 14266) [Regulator valve spring A 19mm 147mm | 806mm | Yet oorsin) | osveiny | 1739 [Regulator valve srng B tem 92mm [44mm | 125 _ tooesiny —_|roseziny | (1732%ny Tod contol valve spring ‘o7mm [66mm [28mm | 183 ‘oozeins —_|10260%n) _|(1.689in) | oakp ing valve spring assmm 66mm sham | vat (oneein) | 0260in) | 1.370%m9 Sevabody | CPC vaive 8 spring Tormm [61mm [178mm 179 spring (se page o02ein) | (02401) _| o70rin) 16267) | eRe vave Rowing o7mm [61mm [78mm [78 coozeiny _|i0240iny_| (0701) - Shi valve 8 pring oamm [86mm [421mm [a7 | coosriny —_|10260%n) | (933%) | ‘Shit vive A spring ‘o8mm Sem | 421mm | BT wastin) _|(0260in) _| 1.933in) Top Shit vale E spring [osm [71mm [0mm 172 seceumstor - {o0stiny | ozaniny | 1929100 ody sring ie | CPC valve ering O1mm [61mm | vamm [78 age 14-268) toazsiny _|10240in) _| (0701) _| ‘ih acsumulator spring A 22mm 164mm [757mm | AE L (oar iny —_|10846iny | c2980in ‘th accumulator ring 20mm womm — |455mm | 116 _ (oorsiny | 0384iny _| in. 7911n9 “Ais old seumuletor spring 34mm 196mm —|Si4mm |B toraeiny | w0772iny | @a60in) 2-15Standards and Service Limits \utomatic Transmission and A/T Differential (cont'd) ‘tem Measurement ‘Qualification | ‘Standard or New [Wire Diameter! 0.0. | Free Length | No.of Colle ‘Accumulator | et accumulator spring B 23mm mm 20mm 99 body soring tee (o.091in) | 0486in) | (2.658) page 14263) | Tstaccumuator spring A 24mm 195mm [677mm | 102 _ eatin) —_|10.768in) | 665i.) “nd acoumulator spring B 26mm taomm [440mm [80 (or02iny | fost2iny | 1.732%m0 - 2d aosumulator spring A 25mm 196mm [87.7 mm 195 — |to.0seiny | o772iny | 2z72ind 3rd accumulator | ed secumulator sping 31mm Tamm [294mm 65 Spring (see page (orzziny — | (oz72ing | (2.85110) 14-270) em Measurement Cualcation ‘Standard or New ‘Service Limit ‘ATT dioreniat | Pinion shaft contact area. ~ | 3BH0= 18.628 mn (0:7091 ~0:7006 ind) — cation ‘Carierto-pinion shat clearance (0.023 =0.057 mm (0.0008 - 10022 n.)_[ 0-1 mmm (0.008in) | Driveshaft contact ares 1D, 28.025 30.056 mm (1.108-—1.104i0.)_ | — Carrirto-driveshat clearance (0.045 0.096 mm (0.002=0,00¢in) | 0-12 mm (0.005 mn) Corrierto intermediate shaft clearance ~~ .080= 0.116 me (0.003 -0.008in.) | —— “Tapered roller bearing starting torque | For new bearing | 29-41 Nm Adjust (preload) (3042 kgtem, 26-96 fin) 26-36NNm ‘Adjust _ (27-29 katem, 23-34 loin) _ ‘ATT diferetia! | Backah (0.05 =0.15 mm (0.002=0.006in.) | — piniongear [10 16042 .006 mm (0.7103 0.717318), —— Pinion gear to pinion shaft clearance (0.055 0.095 mm (0.0022-S.0037 in| 0.12 men (005i 2-16Steering oa Tiana Goatees Sanaa ‘Steering wheel | Rotational play measured at outside 0=10 mm (0-0.39in) sages cgi runing i ing eo mene NGL BEA eure ge henge unig Gabor | glock guide eo eoened we tem te potion, | mom pu retire wi aaa vahe 70S SOW TBO TGVER OTRO aT dle Power steering | Capacity Reservoir 0.32 0 (0.33 US at) as Use onda Power Steering hid |especty Srtor ovo [HATO = Dive ba fa nse! ‘Suspension I Ticeaament aan Sina oer Tene Vial sigan | Canin [Font raed s feat Sy 30 ta om ars - ‘Total Toe-in ~ Front 02mm (00.08 in.) fr WN? Fmim(0082 68H) Tot aboaltrina oe ini wheel —| 306" Gatide whed |S nero el Taina wd ana fat 0-07 nn G03) Tam OAD Tdi 3-07 mm 10=B08in} {im On) ‘Wheel bearing | End play Front feStandards and Service Limits Brakes te Measurement ‘ualeaton Standard or ew Sere int Parking bake | Distance ravelod when over pulled Bio Wels tever with 961 (20 igh 4b force ‘rake pedal | Peal height earet removed! MT made! | 7mm 673in} ‘ATmodel | 170mm (688in) Freely 1= 5mm (@04~020in) Master yinder_| Pietorto-pahvod clearance t i adusiment Brake dae | Thickness Front 718-28. ym .i0-1T i) ommend wat mode Front 9 25:1 mm 058 O99In) womm@atind | wt mode ——— |__| fear 9-81 mm (0360 0388in) | 7mm I030Im) Rano Front = {10 mm O004in) Rear — 2:10mm(0.04n) Paral Frontand rar [— {0.015 mm (00060) Brake ped | Thickness Front Toad mm OAT OadIn *.6mm(0.08in) wt mod) Z Front 38=100 mm (035-029im) Temm O8in) WT mode Rear a5-35mmOH-0a7IN) TSmm (Gein) Conditioning item Messarement ‘Guaeation Standard or New Refrigerant | Type, “HFC-134a (R-1340) Copechy oan — 00~$60 g 7.6 TBA od atigerant oi [Type TOENSO NO-O1 8/N 38857 PT. AOTAN or S00-PRT-AOT) Capacity of components ‘Condenser (25 m& (5/6 fl oz) - Evaporator [46m (020g ach ine and | 10 ma (3 foe). howe _ Compressor | 120— 135 ma da V2 Moa) ~ a Compreaoor | Fld collresoace ‘meeF GOO) [39-43 __[Puteyo-peesure pata — 0.20-08smmi@012=OuRin) Divebet [Tension ‘Ano tensione 2-18Design Specifications Tem Measurement ‘Gualiication Speafication DIMENSIONS | Overllionath “2730 am (188.2) ‘vec width 7.895 mem (722 at (Overall height _ 5441 mm 1562 in) - 2740 mm (1073in) Front 41577 mm (62.10) 7 ear 1.576 mm (620in) - __[ Seating capaci ive 8) _—_ WEIGHT (USA) | Gross Vehicle Weight Rating 4525 bs L icvwal 4.435 bs WEIGHT (Gross Vehicle Weight Rating 2.050 kg (canana) | evn 2010s ENGINE Toe ‘Water coved, stroke SORE VTEC engine Cylinder arrangement ‘0 vé-eyiinder,ransverso ‘Bore ond stoke 19.0 86.0 mm (3.80 %3.391n) Displacement 3.210 em (196.60 n) - Compression ratio 110 Valve ain Belt drive, SOHC VTEC & valves par ayinder “Lubrication system Forced, wot sump, with rochoid pump ‘Oil pump displacoment ‘ALS00 rpm min | 52.84 (55.8 US axl 7 ‘Water pump displacement 'At 6,000 rpm (min) | 820187 US atvminute Fuel required ‘Premium UNLEADED gasoline with 81 pump octane numbor corhigher _ STARTER Toe - ‘Gear reduction - Normal output 184 ‘Nominal votags r wv. [Hour ating s0seconds | Rotation of direction ‘Clockwise as viewed from gear ena cuTeH ‘Clutch type [arr ‘Single pate dry. diaphragm spring 7 at 3-)slement rave converter with lockup clutch ‘lutch Fetion material suroce | MT 264 cm 40.86 sqm) MANUAL ‘Tye ‘Synchronized, 6apeed forward 1 reverse TRANSMISSION [Primary reduction Direet 11 _ Gear ratio i 3.909 | 2nd 2078 Sea 1300 ah 1250 sth 0975 | ath 0790 _ Reverse 4.00 7 | Final reduction Type ‘Single helical gear (Geer ratio 3.285 (eon 2-19Design Specifications (cont'd) eet Measurement Qualification ‘Spectcation ‘muTOMATIC [Type vorealy controlled automatic, speed forward, Levers TRANSMISSION | Primary reduction —_—_ Gear ratio 1 ‘nd Sed ‘th 0.66 Eo ‘0.480 Reverse 1846 Final reduetion Type Single halen gear (Geer ratio 428 ‘STEERING [Type Power assisted rack end pinion ‘Overavatio ise “Ture, loko look 2n ‘Steering whee! aiameter ‘380 mm (150m) "SUSPENSION | Type Front Independent double wishbone with able, collsring Rear Independent multlinkwith stabilizer, col sping ‘Shock asearber Front Telescope, hydraulic, nitrogen gas-filed Rear Telescopic, hydraullc nitrogen gas filed ‘BRAKES Type afeervioe brake Front Power-asssted se adjusting ventilated ise Re ~[Power assisted sol adjusting solid die Type of parking brake ‘Mechanica actuating ear wheols ad fiction surface FrontiarTmedell | $52em! x2 882sqin.x2) Front (M/T modell | 74.0? «211.47 sqin. x2 Rear 27.9em'x2 (433ain.x2) TiRES Sie 'P285/45A17 SW or 2354817 83W (optional Size of spare tire ‘Ait model "T135/60816 1010 MIT mode! “T145/70R17 106M a Corapressor ‘Tye Piston CcONDTONING ‘Capocity 188 mé (1.47 cu inirew. ‘Maximum speed | 7.922rpm ‘Lubricant capacity | 120 mé a flex) - — [ubfeanttype DENSOND-OILE Condens Type ‘Corrugated fin Evaporator Type. (Corrugatadfin [Blower “Type Radia - ‘Motor ype 250 WV, - ‘Speed control Infinite variable Maximum capacity | 560m (10,780 607) “Temperature control Alrembxtype. ‘Compressor clutch [vee Dry. single pate poly Vbel drive Electrical power | 42 W maximum at 12V consumption at 63 oe) Reirigerant yoe HFC Taao (1348) Copecity {500-550 9 (17.6— 19.4 02), 2-20Tem ‘Measurement ‘Guslcation| Speciation TLECTRICAL [Batty T2V=65 ARO hours RATINGS ‘Starter T2v=18 kW ‘Alternator - 12V= 1900 Fuses ‘Under-hood fuse! | 1208, 50A, 40A,30A, 208, TBA, TOA, 7.5A relay box Under dash fuse’ | 308,208, 15A, 0A, TR relay box Tightbuibe Headlighthigh beem_| 12 —asWiHID) Heclightlow beam | 12 —35W (HID) Frontfog lights (US. | 12-51 W (HB) mode : Daytime running | 12V=60W (HBS) lights (Canada model Front Turnaignal | 2V—2W lights Front parking ights_| ¥2V-8 Front sigemarker [LED | lights _| Rear side merker | LED lights Reerturnsignal | 2V-21W [ghee — Stoptailights| 1 Tallights to High-mount brake [LED light Backup lights Teva vense late ight | 12V=3.p, Ceiling ight mav=5W - ‘Map ight TV 400, “Trunk ght T2v-sw Door courtsayights_| 12V=2ep Glove boxlight | 12V=14W Vanity miro ights_|¥2V=8W. Gauge likes uD indestor ghia | LED Console box ight | 12V=14W 2-21Body SpecificationsMaintenance Lubricants and Fluids Maintenance Multi-information Service Informati Resetting the Multi-information Display Maintenance Main Items... Maintenance Sub ItemsLubricants and Fluids For details of lubrication points and type of lubricants to be applied, refer to the strated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, tc.) contained in each section. LUBRICATION POINTS LUBRICANT Engine Honda Motor Oil: PIN 08798-9015 Use 5W-20 motor oil, Look for the API Certification seal on the. oll container as shown below. Make sure it says “For Gasoline Engines.” SAE Viscosity: See chart below. | Manual Transmission [Automatic Transmission Honda Manual Transmission Fluid (MTF): PIN 08798-8016 Always use Honda MTF. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Honda Automatic Transmission Fluid (ATF-Z1): PIN 08200-9001 ‘Always use Honda ATF-21. Using a non-Honda ATF can affect shift quality © | Brake system (includes VSA line) Honda DOT 3 Brake Fluid P/N 08798-9008 Always use Honda DOT '3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. D | Clutch Tine Honda DOT 3 Brake Fluid: PIN 08798-9008 ‘Always use Honda DOT 3 Brake Fluid. Using a non-Honda, brake fluid can cause corrosion and decrease the life of the systom. - E_| Power steering gearbox ‘Steering grease: P/N 08733-BO70E F | Shift and select cable ends (WT) Silicone grease | Throttle cable end (dashboard lower panel hole) H_| Brake booster clevis ‘Multiparpose grease 1 | Clutch master cylinder cl J. | Release fork K_ | Shift lever (manual transmission) L_| Battery terminals M | Pedal linkage N | Fuel fill door © | Hood hinges and hood latch P| Door hinges, upper and lower [0 | Trunk hinges _ _ _ R__| Caliper piston boat, caliper pins and boots _| Honda Caliper Grease: P/N 08C30-B0236M —] ‘S| Power steering system Honda Power Steering Fluid Always use Honda Power Steering Fluid. Using any other type | ‘of power steering fluid or automatic transmission fluid can __| cause inereased wear and poor steering in cold weather. T | Airconditioning compressor ‘Compressor cit: DENSO ND-OIL 8 (P/N 38897-PR7-AD1AH or '38899-PR7-AD1) for refrigerant HFC-134a (R-134a) 3-2 Ripe itcesn ts emoencumewanen angesary 3-3Maintenance Minder Multi-information Display The Maintenance Minder is an important feature of the Multi-information Display. Based on engine operating conditions and accumulated engine revolutions. The TL’s onboard computer (ECM/PCM) calculates the remaining engine oil life. The system also displays the code for other scheduled maintenance items needing service. MULTLINFORMATION DISPLAY 3-4Service Information 1. The remaining engine oil life is displayed as a percentage on the mult-information display when the ignition is turned to ONIN). inp tien ee ey 2, When the remaining engine oil fe is at 15 percent, the maintenance message “SERVICE DUE SOON”, along with the maintenance items currently requiring service will be displayed. + Complete list of maintenance main items “A” (see page 3-7) + Complete list of maintenance sub items “B” (see page 38) ow ‘When the remaining oil life is less than 5 percent, ‘the maintenance message "SERVICE DUE NOW”, along with the items shown in “SERVICE DUE ‘SOON will display. At this point, the indicated maintenance must be performed as soon as. possible. le aes ee 3-5Maintenance Minder Resetting the Multi-information Display 1. Turn the ignition switch to ON(N, 2. Press the SELECTRESET button repeatedly unti the oil life is displayed (it more than 15 %) or the maintenance message is displayed (i of if is less than 15%). NOTE: Ifyou are resetting the display when the oll life is more than 15 %, the maintenance message “SERVICE DUE SOON’ will be displayed. Make sure the maintenance items requiring service have been performed before resetting this display. 3. Press and hold the SELECT/RESET button for 10 seconds until you see the maintenance message or “MAINTENANCE RESET”. Ifthe nance message is displayed, press and hold the SELECT/ RESET button again for 10 seconds until you see “MAINTENANCE RESET”, + To reset the display, press the SELECT/RESET button to select “OK”. The next time the ignition ‘switch is turned to "ON", the display will show “OIL LIFE 100% + Ifyou do not want to reset the display, press the side of the INFO button to select “Cancel”. 3-6 NOTE: + Ifthe required service is performed and the display is not reset or ifthe display is reset without performing the service, the system will not show the proper maintenance levels. This can lead to serious mechanical problems because there will be no record of when ‘maintenance is neaded. Ifthe indicated maintenance service fs not performed and the remaining ehgine oil ife is less than 0 percent, “SERVICE PAST DUE" will display, have the service performed immediately and make sure to reset the display as previously described.oy Maintenance Main Items I the message “SERVICE DUE NOW” does not appear more than 12 months after the display is reset, change the engine oil every year. NOTE: + Independent of the mainter snce messages in the Multi-information Display, replace the brake fluid every 3 years. + Inspect idle speed every 160,000 miles (256,000 km). + Adjust t vvalves during services A, B, 1,2 or 3 if they are noisy. [Symbol A ‘Maintenance Main items Replace engine oil see page 86). Capacity: without oil filter: 4.0.0 (4.2 US qt). Replace engine oil and oil filter (see page 8-6) Capacity: with ol filter: 4.3 9 (4.5 US qv. Rotate tires, and check tire inflation and condition. Follow the pattern shown in the Owner's Manual. Check front and rear brakes (see page 19-3). * Check pads and discs for wear {thickness), damage, and cracks. + Check calipers for damage, leaks, and tightness of mount bolts. ‘Check parking brake adjustment (see page 19-7). __Number of clicks (6 to 10) when the parking brake lever is pulled with 196 N (20 kgf, 4 Ibf) of force. Visually inspect the following items: + Check for correct installation and position, check for cracks, deterioration, rust, and leaks. | + Check tightness of screws, nuts, and joints. If necessary, retighten. Inspect tie rad ends, steering gearbox, and gearbox boots (see page 17-8). * Check rack grease and steering linkage. + Check boots for damage and teaking grease. + Check fluid fines for damage and leaks. Inspect suspension components (see page 183). + Check bolts for tightness. + Check condition of ball joint boots for deterioration and damage. Tnspect driveshaft boots (see page 16:4). Check boots for cracks and boot bands for tightness. inspect brake hoses and lines including VSA (see page 19-37) Check the master cylinder, and VSA modulator for damage and leakage. Tnspect all uid levels and condition of ids. +" utomatic transmission fluid (ATF-21) (see page 14-203). + Manual transmission fluid (MTF) (ee page 13-10). + Clutch fluid (see step 11 on page 12-12) + Power steering fluid (see page 17-12) ( tuid (see page 199). + Windshield washer fuid + Engine coolant (see page 10-6). inspect exhaust system (see page 957” ‘Check catalytic converter heat shields, exhaust pipes, and muffler for damage, leaks, ond tightness. inspect ful lines and connections (see page 11-249). Check for loose connections cracks, and deterioration; retighten loose connections and replace damaged parts. NOTE: According to state and federal regulations, failure to do the maintenance tems marked with an asterisk (*) will ‘not void the customer's emissions warrar . However, Honda recommends that all maintenance services be done at the recommended interval, to ensure long-term reliability, 3-7Maintenance Minder Maintenance Sub Items ‘Symbol Maintenance sub items 1 | Rotate tires, and check tire inflation and condition. Follow the pattern shown in the Owner's Manual. 2 | Replace air cleaner element (see page 11-273). If you drive primarily in dusty conditions, replace every 15,000 miles (24,000 km! Replace dust and pollen filter (see page 21-74). ‘+ Replace the filter at 15,000 miles (24,000) km intervals ifthe vehicle is driven mostly in urban areas ‘that have high concentrations of soot inthe air from industry and diesel-powered vehicles. + Replace the filter whenever airflow from the heating and coolingiclimate control system is less than normal Inspect drive belt (see page 429), Look for cracks and damage, then check belt deflection by pushing on the belt about 98 N (10 kgf, 22 Ib midway between the pulleys. 3 | Replace automatic transmission fluid (see page 14-208), + Driving in mountainous areas at very low vehicle speed requires transmission fluid changes more frequently than recommended by the Maintenance Minder. f you regularly drive your vehicle under this conditions, have the transmission fluid changed at 60,000 miles (96,000 km}, then every 30,000 smiles (48,000 km). | + Capacity: 3.0 0 (3.2 US gt); use Honda ATE _ Replace manual transmission fluid (see page 13-10). Capacity: 2.20 (2.3 US qt}, use Honda MTF. 3-8 © | Replace spark plugs (see page 421). Use IZFR6K-11 (NGK) or SKJ20DR-M11 {DENSO), Roplace timing belt (see page 6-14), i the vehicle is regularly driven in very high temperatures (over 110, 43°), or in very low temperatures ( under —20F, 23%), replace every 60,000 miles (U.S.)/ | 100,000 km (Canada) and inspect water pump (see page 10-5). Inspect the valve clearance (cold) (see page 6-8). + Otherwise adjust only if noisy. + Intake: 0,200.24 mm (0,008—0,009 in.), Exhaust: 0.28 0.32 mm (0.010.013 in. | Replace engine coolant (see page 10-6). Capacity (including the reserve tank): MT: 6.3 0 (6.7 US qtl, A/T: 6.4 0 (6.8 US qui: use Honda All ‘Season Antifreeze/Coolant Type 2.Engine Electrical Engine Electrical Special Tools .. Starting System Component Location Index... 4-3 ‘Symptom Troubleshooting Index Circuit Diagram Starter Circuit Troubleshooting Clutch Interlock Switch Test Starter Solenoid Test .. Starter Performance Test .. Starter Replacement Starter Overhaul. 4-10 an Ignition System Component Location index .... 4-16 Circuit 417 Ignition Timing Inspection ..... 4-18 Ignition Coil Removal/ Installation Ignition Coil Relay Circ Troubleshooting Spark Plug Inspection 4.20 421 Charging System Component Location Index .... 4-22 Symptom Troubleshooting Index Circuit Diagram Charging Circuit Troubleshooting /e Belt Inspection Drive Belt Replacement .. Drive Belt Auto-tensioner Inspection . Drive Belt Auto-tensioner Replacement . Tensioner Pulley Replacement Alternator Replacement Alternator Overhaul 4-23 424 425 4-29 4-29 4-30 431 431 432 4-34 Cruise Control Component Location Index .... 4-38 Circuit Diagram... . 4-39 Symptom Troubleshooting Index 4-40 Cruise Control Input Test nue 4-47 Cruise Control Combination Switch Test/Replacement .... 4-43 Cruise Control Combination Switch Illumination Bulb Replacement . 4-83 Clutch Pedal Position Switch Test .. 444 Engine Mount Control System Component Location Index .... 4-45 Circuit Diagram . 4-46 Troubleshooting . 4-47Engine Electrical Special Tools Ref. No. ‘Tool Number ~ Description Oty, D | ASTEX041-XXXXX Vacuum Pump/Gauge, 0-30 in.Hg 1 ® | 07746-0010300 ‘Attachment, 42 x 47 mm 1 @ _ | 07749-0010000 Driver 1Starting System Component Location Index UNDER-DASH FUSE/RELAV BOX STARTER CUTRELAY Test, page 22-75. starrer CLUTCH INTERLOCK SWITCH (MT) Stat Ccult Troubleshooting, page 48 Festipape ee Scion Tet page 8 Repinconort.pape 0 TRANSMISSION RANGE SWITCH (A/T) zl ca page raat poe el Replacement, page 14-242 43Starting System Symptom Troubleshooting Index. ‘Symptom Diagnostic procedure: ‘iso check for] Engine does not start (Check for loose battery terminals or connections. * Poor ground at G107, {does not crank) Test the battery for a low charge (see page 22-74). 18102 (A/T) or G503 Check the starter (see page 4-6) wn) Check the starter cut relay (see page 22-78). Check the transmission range switch (A/T) (see page 14- 240). Check the clutch interlock switch (M/7) (see page 4-8). ‘Check the ignition vaitch or wire (see page 22-77), Troubleshoot the immobilizer systam (see page 22-328). Test the fuel pump (see page 11-241). Check for plugged or damaged fue! line (see page 11- 249), Check for plugged fuel filter (see page 11-256). Check the throttle body (see page 11-272). Check for PGM-FI DTC's. ‘Check for low engine compression (see page 6-6). Check for damaged or broken timing belt. Test the fuel pump (see page 11-241) Check for plugged or damaged fuel line {see page 11- 249). Check for plugged fuel filter (see page 11-256). Check for restricted three way catalytic converter (TWC) or exhaust system, | 5. Check for PEM-IDTC’s. Engine cranks, but does not start Engine is hardto start 4-4Circuit Diagram rae 5 el | | aeee i $e 4 ——~—--2 Ss ag s8y i 7 | ul | fa i . ii ! ttt 2 va 5 bn er et i at z a ns z 2] z Tul i . ii qi i 87 45Starting System Starter Circuit Troubleshooting NOTE: + Air temperature must be between 58° and 100 (15° ‘and 38°C) during this procedure. + Alter this inspection, you must reset the engine. control module (ECM)/powertrain control module (PCM), using the Honda Diagnostic System (HDS) (see page 11-4), otherwise the ECM/PCM will Continue to stop the fuel injectors from operating. + The battery must be in good condition and fully charged, Recommended Procedure: + Use a starter system tester. + Connect and operate the equipment in accordance with the manufacturer's instructions. Alternate Procedure 1, Remove the left side engine compartment cover, (see step 3 on page 5-2) 2. Hook up the following equipment: + Ammeter, 0— 4008 + Voltmeter, 0-20 V {accurate within 0.1 volt) ‘3. Connect the HDS to the data link connector (DLC) (see step 2 on page 11-3). 4. Select PGM-I, then INSPECTION, then ALL INJECTORS OFF function on the HDS. 4-6 5. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to start (Il) Did the starter crank the engine normally? ‘YES~ The starting system is OK. Go to step 12. NO~Goto step 6. 6. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables and the starter far looseness and corrosion. Then try ‘cranking the engine again, Did the starter crank the engine? ‘YES Repairing the loose connection corrected the problem. The starting system is OK. Go to step 12. NO— Check the following: + Ifthe starter will not crank the engine at all, go to step 7. Hitcranks the engine erratically or too slowly, 90 to step 9. If itwon't disengage from the flywheel or torque converter ring gear when you release the key, check the following: ~ Solenoid plunger and switch malfunction = Dirty drive gear or damaged overrunning clutcha ENGINE 17. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire from the starter ‘solenoid § terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal. Did the starter crank the engine? YES—Go to steps. NO—Remove the starter, and repair or replace as necessary. 8. Check the following items in the order listed until, you find the open circuit: + The BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter. + The ignition switch (see page 22-77). + The transmission range switch and connector (AMT (see page 14-240) or the clutch interlock switch and connector (M/T) (see page 4-8) + The starter cut relay (see page 22-75). 9, While cranking the engine, check the cranking voltage and current draw. Is cranking voltage greater than or equal to 8.5 V and current draw less than or equal to 380A? YES—Go to step 10, NO Replace the starter, or remove and disassemble it, and check the following: + Starter armature dragging + Shorted armature winding + Excessive drag in engine 10. Check the engine speed while cranking the engine. Is the engine speed above 100 rpm? YES~Goto step 11. NO—Replace the starter, or remove and disassemble it, and check the following: m= + Open circuit in starter armature commutator segments + Excessively worn starter brushes + Open circuit in commutator brushes + Dirty or damaged helical splines or drive gear + Faulty drive gear clutch 11, Remove the starter, and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts. 12, Select ECM/PCM reset \see page 11-4) to cancel the ALL INJECTORS OFF function on the HDS. 13. Reinstall the left side engine compartment cover (see step 68 on page §-22) 47Starting System 4-8 Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector wy. Terminal side of sale terminals, 2. Remove the clutch interlock switch (B), 3. Check for continuity between the terminals according to the table. + Ifthe continuity is not as specified, replace the clutch interlock switch. + IfOK, install clutch interlock switch and adjust ‘he padal height (see page 12-6). as 4 2 Clutch interlock Switch PRESSED o—}—o RELEASED Starter Solenoid Test 1. Check the hold-in coil for continuity between the terminal and the armature housing (ground). “There should be continuity. + Hf there is continuity, go to step 2. + Hf there is no continuity, replace the solenoid, 2. Check the pullin coil for continuity between the S terminal and M terminal. There should be continuity. + If there is continuity, the solenoid is OK. + If there is no continuity, replace the solenoid.Starter Performance Test sonnect the wire from the M terminal. 2. Make a connection as shown using as heavy a wire 2s possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, ever leave the battery connected for more than 10 seconds. 3. Connect the battery as shown. Be sure to isconnect the starter motor wire from the solenoid. Ifthe starter pinion moves out, itis working properly. A 7 ® ©] | ihren I (SrouNn) 4, Disconnect the battery from the M terminal. If the pinion does not retract, the holdin coil of the solenoid is working properly. 5. Disconnect the battery from the starter body. If the pinion retracts immediately, itis working properly. A | @ Oo wv BATTERY 6. Clamp the starter firmly in a vise. 7. Reconnect the wire to the M terminal. 8. Connect the starter to the battery as shown in the diagram, and confirm that the motor starts and keeps rotating wv BATTERY 9. Ifthe electric current and motor speed meet the ‘specifications when the battery voltage is at 11.5, the starter is working properly. Specifications Electric current: &0A or less Motor speed: 2,600 rpm or more 49Starting System Starter Replacement 1. Make sure you have the anti-theft code for the radio, ‘and the navigation system, then write down the XM radio channel presets, Make sure ignition switch OFF, 2. Remove the left side engine compartment cover (see step 3 on page 5-2), 3, Disconnect the negative cable from the battery first, then disconnect the positive cable. 4, Remove the battery hold-down bracket, then remove the battery and battery tray. 5. Remove the harness clamp (Al. 6. Disconnect the starter cable (B) from the B terminal, ‘hen disconnect the BLK/WHT wire (C) from the Sterminal. 7. Remove the two bolts holding the starter, then remove the starter. 4-10 8, Install in the reverse ordor of removal. Make sure: the crimped side of the ring terminalis facing out. 9. Connect the battery positive cable and negative cable to the battery. 10. Start the engine to make sure the starter works property. 11. Enter the anti-theft codes for the radio and the ion system, then enter the customer's XM radio channel presets. 12, Setthe clock.Starter Overhaul Disassembly/Reassembly RUSH ARMATURE HOUSING END COVER, BRUSH HOLDER nur Nim (0.9 kghim, 7 bt) {Apply moyen va vent Tus ae “Wage Za sem wun ce ‘SOLENOID LEVER / GEAR HOUSING OVERRUNNING (CLUTEH ASSEMBLY GEAR HOUSING cover (cont'd) 4-11Starting System Starter Overhaul (cont'd) Armature Inspection and Test 1. Remove the starter see page 4-10), 2. Disassemble the starter as shown at the beginning 3, Inspect the armature fot wear or damage from contact with the permanent magnet. Ifthere is wear ‘of damage, replace the armature. 4. Check the commutator (A) surface. Ifthe surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #800 or #600 sandpaper (B). 5. Check the commutator diameter. Ifthe diameter is below the service limit, replace the armature. Commutator Diameter ‘Standard (New: 28.0~28.1 mm (1.102—1.106 in.) 27.5 mm (1.083 in.) Service Limit: 6. Measure the commutator (A) runout. + Ifthe commutator runout is within the service ‘imi, check the commutator for carbon dust or brass chips between the sogments. + Ifthe commutator runout is not within the service limit, replace the armature. Commutator Runout ‘Standard (New!: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002:in.) 4-127. Check the mica depth (A) Ifthe mica is too high (B), undercut the mica with 2 hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should ‘not be too shallow, too narrow, or V-shaped (0). Commutator Mica Depth 9, Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. Hf the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Repiace the armature. 8 c 8 Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature. 10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature, (cont'd) 4-13Starting System Starter Overhaul (cont'd) Starter Brush Inspection 11. Measure the brush length. ifit is not within the ‘service limit, replace the brush holder assembly. Brush Length ‘Standard (Now): 15.8—16.2 mm (0.62—0.64 in.) Service Limit: 11.0 mm (0.43: 4-14 ‘Starter Brush Holder Test 12. Check that there is no continuity between the (-+) brush holdes (A) and (—) brush holder (B). there is continuity, replace the brush holder assembly. Brush Spring inspection 13, Insert the brush (A) into the brush holder, and bring the brush into contact with the commatator, ther attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. Ifthe spring tension is not within ‘specification, replace the spring. ‘Spring Tension: 15.7—17:7 N (1.60~1.80 kgf, 3.53—3.97 Ib)ENGINE 114, Pry back each brush spring with a screwdriver, then | Overrunning Clutch Inspection position the brush about halfway out of its holder, and release the spring to hold it there. 17. Slide the overrunning clutch afong the shaft. Replace it fit does net slide smoothly. NOTE: To seat now brushes, slipa strip of #500 or # 600 sandpaper, with the grit side up, between the | 18, Rotate the overrunning clutch (A) both ways. fit commutator and each brush, and smoothly rotate does not lock in either direction or it locks in both the armature. The contact surface of the brushes directions, replace it. will be sanded to the same contour as the ‘commutator. 15. Install the armature in the housing. Next, pry back each brush spring again, and push the brush down nti it seats against the commutator, then release ‘the spring against the end of the brush, in 19, tthe starter dive goar (8 is worn or damaged, i zeplace the overrunning clutch assembly; the gear is not available separately. NOTE: Check the condition of the torque converter ring gear to see if the teeth are damaged. i) 20. Reseomete sarin th rvere oar of Scoot. 18, ns anarond cover orth bush reIgnition System Component Location Index UNDER-DASH FUSE/RELAY BOX IGNITION Col RELAY Test, page 22-75, ‘SPARK PLUG Inspection, page 4-21 IGNITION co amovalineatencn, page 238 4-16Circuit Diagram ® wn satu in , u os ufo i re i sxe exh sae ce ae i , 1) >< >< >< >< >< a 4-17ignition System Ignition Timing inspection 1 Connect the Honda Diagnostic System (HDS) ‘0 the data link connector (DLC) (see step 2 on page 11-3), ‘and check for DTC's. fa DTC is present, diagnose ‘and repair the cause before inspecting the ignition, timing. 2. Start the engine. Hold the engine at 3,000 rpm with ro load (in Neutral! until the radiator fan comes on, then letitidle. . Check the idle speed (see page 11-238). Select “SCS” mode using the HDS. Remove the right side engine compartment cover, (s2e step 1 on page 4-29) Connect the timing light to the service loop. 4-18 7. Aim the light toward the pointer (A) on the timing bolt cover. Check the ignition timing under no load condition: headlights, blower fan, rear window defogger, and air conditioner are not operating. Ignition Timing M/T: 10°+2°BTDC (RED mark {B) at idle in Neutral A/T: 10°::2°BTDC (RED mark (B)) at idle in 8, Ifthe ignition timing differs from the specification, ccheck cam timing. If cam timing is OK, update the engine control module (ECM\/powertrain control ‘module (PCM) ift does not have the latest software (see page 11-6), or substitute a known-good ECM/ PCM (see page 11-7), then recheck. Ifthe system ‘works properly, and the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171) 9. Disconnect the HDS and the timing light.Ignition Coil Removal/installation 1, Remove the intake manifold cover. 2, Remove the right side engine compartment cover (A), then remove the left rear engine compartment cover (B) and right rear engine compartment cover (C). 3, When removing the No. 6 coll you must remove the reserve tank heat shield and reserve tank. 4, Disconnect the ignition coil connectors (A), then remove the ignition coils (B). 5. Install the ignition coils in the reverse order of removal. 4-19Ignition System 1. Check the No. 2(18A) fuse relay box. the under-dash fuse/ Is the fuse OK? YES—Goto step 2. NO—Replace the fuse. 2. Remove the ignition coil relay from the under-dash fuse/relay box and test it (see page 22-75). Is the retay OK? YES—Go to step 3. NO—Replace the ignition coil relay. 3, Measure the voltage between ignition coil relay 4 ‘sacket terminal No. 1 and body ground, then terminal No. 4 and body ground. IGNITION COIL RELAY 4P SOCKET ‘Terminal side of female terminals Is there battery voltage? YES—Goto step 4. NO~Replace the under-dash fuse/relay box.m 4-20 n Coil Relay Circuit Troubleshooting 4. Check for continuity between ignition coil relay 4P socket terminal No. 2 and the No. 1 ignition coil 3P connector terminal No. 3. IGNITION CoM. RELAY a? SOCKET H ‘Terminal side of female terminals G7) aterm [2 3 [No.1 IGNITION COWL 3° CONNECTOR Is there continuity? YES~Goto step 5. NO—Repair an open in the wire between ignition coil relay 4P socket terminal No. 2 and ignition coil '3P connector terminal No. 3. 8. Check for continuity between ignition coil relay 4P socket terminal No. 3 and body ground. IGNITION COIL RELAY 4P SOCKET Terminal side of female terminals Is there continuity? YES—Ropair a short in the wire between ignition coil relay 4P socket terminal No, 3 and ECM/PCM.m NO~Repair an open in the wire between ignition ‘oil relay 4P socket terminal No. 3 and ECM/PCM.‘sy ENGINE Spark Plug Inspection 1. Inpect the electrodes and ceramic insulator, + Burned or worn electrodes may be caused by: = Advanced ignition timing = Loose spark plug = Plug heat range too hot = Insufficient cooling + Fouled plug may be caused by: = Retarded ignition timing = Olin combustion chamber = Incorrect spark plug gap = Plug heat range too cold ~ Excessive idling/low speed running = Clogged air cleaner element = Deteriorated ignition coils Worn or detormed loctrodes { :!mproper gap ices 1 | :2itbon déposie 2, Do not adjust the gap (A) of iridium tip plugs ; replace the spark plug ifthe aap is out of specification. Electrode Gap ‘Standard (Neve: 1.0—1.1 mm (0.039-0.043 in.) 3, Replace the plug at the specified interval or ifthe center electrode is rounded (A). Use only the spark plugs as listed. ‘Spark Plugs NGK: —IZFRGK.11 DENSO: SKJ200R-M11 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 1B Nem (1.8kgfim, 13 IBF. 4-21Charging System Component Location Index (CHARGING SYSTEM INDICATOR (inthe gauge assembly) LUNDER-HOOD FUSE/RELAY BOX {Was builtin ELECTRICAL LOAD DETECTOR (ELD) UNIT BATTERY ‘Test, page 22-74 a 10 Inspection, page #30 Moublanootng sage £25 Replacement, page 4-31 ag Replacement page, 22 Gvormaul page 434 RIVE BeLT Inspection. page 429 4-22a ENGINE Symptom Troubleshooting Index ‘Symptom sgnostie procedur ‘Also check for Charging system indicator stays on ‘Troubleshoot the charging system indicator circuit (see page 4-25), 2. Check or a broken drive belt (see page 4-2) 3. Check the drive belt auto-ensioner (see page 4-30). a age 4:25) _ Battery discharged 1. Check for poor connection, open or shorted wits) in charging systom, 2. Check or electrical currnt draw. 3. Check or a broken drive bolt (see page 4-29). 44 Check the drive bolt auto-tensioner (see page 4-20) 5. Testtho alternator (see page +25). 6. Troubleshoot the alternator control system (see page 425) 7. Check for poor connection at battery terminal 8._Test the battery (see page 22-74), Battery overchoroed 1. Test the alternator (see page 425) 2. Troubleshoot the alternator control system (see page 425). 3._Test the battory (see page 22-74) 4-23Charging System Circuit Diagram a ase Fc a on ‘or en moan ‘Lee = te I Fh } c = LI Lt A tetttt | 4-24Charging Circuit Troubleshoo' g Ifthe charging system indicator does not come on or does not go off, or the battery is dead or low, test the following items in the order as listed: + Battery (see page 22-74) + Charging system indicator test + Alternator and regulator circuit test + Alternator control system test Charging System Indicator Test 1, Turn the ignition switch ON (I). Does the charging system indicator come on? /ES—Goto step 2. NO-Goto step 3. 2. Start th gine. Does the charging system indicator go off? YES~Charging system indicator circuit is OK. Go to the Alternator and Regulator Circuit Test. NO~Go to step3. 3, Troubleshoot the multiplex integrated control system (see page 22-108). 1s the multiplex integrated control system OK? YES~Goto step 4, NO—Repair the multiplex integrated control systorn.m 4, Run the gauge control module self-diagnostic function (see page 22-262). Does the charge indicator flash? YES ~Goto step 5. NO— Replace the gauge control module (see page 22-265). 5. Turn the ignition switch OFF. 6. Disconnect the alternator 4P connector. 7. Turn the ignition switch ON (th, 8, Measure the voltage between alternator 4P ‘connector terminal No. 1 and body ground, ALTERNATOR 4P CONNECTOR Ic (BLK ve) Is there battery voltage? YES—Goto step 9 NO~Check for a blown No. 18 (15A) fuse in the tunder-dash fuse/relay box. If the fuse is OK, repair ‘open in the wire between the alternator and under- dash fuse/relay box. ‘8. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC). Turn the ignition switch (ON (IN, and jump the SCS line with the HDS, then turn the ignition switch OFF, NOTE: This step must be done to protect the engine control module (ECMl/powertrain control module (PCM) from damage. 10. Disconnect ECM/PCM connector é (31P). (cont'd 4-25Charging System Charging Circuit Troubleshooting (cont'd) 114. Check for continuity between ECM/PCM connector terminal E11 and alternator 4P connector terminal No. 3 ECM/PCM CONNECTOR E (31P) C1, T[27T3]4]5]6]7} [els Folia] Tiafislie| 7ps]ig|z2o| 27 22iapl24 (25126) [2 7l28|29|301 31 ACT (WHT BLU) = (4 | 2) avreavaton heenaaan 3 [4) “enn Wire side of female terminals Is there continuity? YES~Go to step 12. NO—Repair an open in the wire between the alternator and the ECM/PCM. 12, Check for cantiuity between ECM/PCM connector terminal E11 and body ground, ECM/PCM CONNECTOR E (21P) TT2T3[4[s[6l7] [al iol if'2]Trafislie| sy 920 1 22jasle4l [2s|26] [27/28|29/30/ 31 ALTL a“ Wire side of female terminals. N|o| Is there continuity? YES~Repair a short in the wire between the alternator and the ECMVPCW. NO— Goto the Alternator and Regulator Circuit Test. 4-26 Alternator and Regulator Circuit Test 1. Be sure the battery connections are good, and that the battery is sufficiently charged (see page 22-74). 2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting). LOAD ADJUSTER FOU.FIELO TESTER (CARBON PILE) {isd (BLU) VOLTMETER NEGATIVE EAD (aLK) VOLTMETER Posmive LEAD (RED) TERMINAL GABLE VBLiC Posmve TERMINAL GABLE (RED) INDUCTIVE, PICK-UP (GRN) INDUCTIVE Pick 3. Shift to Park or Neutral, and start the engine. Hold the engine at 3,000 rpm, with no load until the radiator fan comes on, then let it idle. 4, Raise the engine speed to 2,000 rpm, and hold it there. Is the voltage over 15.1 V7 ‘YES — Replace the alternator (see page 4-32) or rear housing assembly (see page 4-34). NO-Goto step 5.+ ENGINE 5. Release the accelerator pedal, and let the engine idle. 6. Make sure all accessories are turned off. Turn the selector switch to position 2 (charging). 7. Remove the inductive pick-up, and zero the 8, Place the inductive pick-up over the B terminal wire Of the alternator so that the arrow points away from the alternator. 9, Raise the engine speed to 2,000 rpm, and hold it there. Is the voltage less than 13.5 V? YES~Go to Alternator Control System Test. NO-Go to stop 10. 10. Apply a load with the VAT-40 until the battery voltage drops to between 12—13.5V. 1s the amperage 87.5A or more? ‘YES—The charging system is OK. NOTE: Ifthe charge system indicator is stil on, replace the alternator (see page 4-32). NO— Repair or replace the alternator (see page 4- Alternator Control System Test 1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC), and check for DTC's. Ifa DTC is present, diagnose and repair the cause before continuing with this test. 2. Disconnect the alternator 4P connector from the alternator. 3, Start the engine, and turn the headlights ON to high beam. 4, Measure voltage between alternator 4P connector terminal No, 2 and the positive terminal of the battery. BATTERY \c (WHT/GRN) I avtennaron {1 ‘a@Pconnector [214 Isthero 1 V or less? YES—Go to step 5. NO-Go to step, ‘5, Jump the SCS line with the HDS, then turn the ignition switch OFF. NOTE: This step must be done to protect the engine ‘control module (ECM)/powertrain control module (PCM) from damage. 6. Disconnect ECM/PCM connector E (31P). (conta) 4-27Charging System Charging Circuit Troubleshooting (cont'd) 7. Check for continuity between ECM/PCM connector terminal £24 and body ground. ECM/PCM CONNECTOR E (31P) c—1 Tj23T4]s[éel7 819 roy ifi2| Mansel 8[i9]20[21 22|zaleal [2526] [27lze|zo{a0l 31 Wire side of female ereninale Is there continuity? YES— Repair short in the alternator and ECM/PCM. mt fe between the INO— Updote the ECM/PCM if it does not have the latest software (see page 11-8), or substitute a known-good ECM/PCM (see page 11-7), then fecheck. I the symptom/indication goes away with ‘2 known-good ECM/PCM, replace the original ECM/ FCM (see page 11-171). 8, Jumpthe SCS line with the HDS, then turn the ignition switch OFF. NOTE: This step must be done to protect the engine ‘control module (ECM)/powertrain control module (PCM) from damage. 9. Disconnect ECM/PCM connector E (31P). 4-28 10. Check for continuity between ECM/PCM connector terminal E24 and alternator 4P connector terminal No.2. ECM/PCM CONNECTOR E (31P) C7} 1[2]3[4[5[6[7 89 iol ii2]Trafisiie| i718] 9]20[21 zalza|ea). [2s|26). [27/z8/29130] 31 axe L_@-——_¢ (WHT/GRN) (WHT/QRN) Wire side of female terminate Isthere continuity? jeplace or repair the alternator (see page 4 NO Repair an open in the wire between the alternator and ECM/PCM. mtDrive Belt Inspection 1, Remove the right side engine compartment cover. Drive Belt Replacement 1. Remove the right side engine compartment cover. 2. Inspect the belt for cracks or damage. If the beltis, cracked or damaged, replace it. ‘Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If itis out of the ‘standard range, replace the drive belt (see page 4- 29). 3, Install the new belt in the reverse order of removal, 4-29Charging System Drive Belt Auto-tensioner Inspection 1. Remove the right side engine compartment cover (see step 1 on page 42}. 2. Check the position of the auto-tensioner indicator’s pointer (A), start the engine, then check the position of the pointer again. If the position changes, replace the auto-tensioner. ‘3. Check for abnormal noise from the tensioner pulley. I you hear abnormal noise, replace the auto- tensioner pulley (see page 4-31) 4, Remove the drive belt see page 4-28). 5, Move the autoensioner within its limit with the ‘wrench in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. I the tensioner does not move ‘smoothly or there is abnormal noise, replace the ‘auto-tensioner (see page 4-31), 4-30 6. Remove the auto-tensioner (see page 4-31). 7. Clamp the auto-tensioner (A) by using a 10 mm bolt {81,8 mm bolt (C) and a vise (D) as shown. Do not clamp the auto-tensioner itself. 8 Attach a torque wrench (A) to the pulley bolt. ‘measure the torque when the tensioner is turned counterclockwise. If the torque is less than the specified value, replace the auto-tensioner (see page 4-31). 50.5 Nem (5.15 kgfm, 37.2 Ibf-f)Drive Belt Auto-tensioner Replacement 1. Remove the drive belt (see page 4-29). 2, Remove the splash shield, 3, Remove the auto-tensioner. (22 Kotm. 16 oF 4, Install the auto-tensioner in the reverse order of removal. Tensioner Pulley Replacement 1. Remove the auto-tensioner (see page 431). 2. Remove the pulley bolt (A) (left-hand threads), and remove the tensioner pulley (B). A 40x15 mm BON e.2 kgf, 59 bE) 3, Install the tensioner pulley in the reverse order of removal. 4-31Charging System Alternator Replacement 1. Make sure you have the anti-theft code for the radi and the navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Disconnect the fan motor connector (A) and compressor clutch connector (B), then remove the coserve tank (C). E 6x 1.0mm T2N-mIT 2 ktm, 3.7 IEA) 4. Remove the two bolts (D), and loosen bolt (E), then remove the condenser fan shroud. 4-32 5. Remove the drive belt (see page 4-29). 6. Disconnect the slternator connector (A) and BLK wire (B) from the alternator. AZ Nien Beg on 8.7 ot) 7. Remove the bolt (C) securing the harness bracket.. ENGINE 8. Remove the mounting bolt (A) and alternator bracket mounting bolt (B), then remove the alternator. 5 Bilan Bot ft) . a ™ 41.25 mm 44 Nein 1B Eg, 33 WEA 9, Install the alternator and drive belt in the reverse order of removal 10. Connect the battery positive cable and negative cable to the battery. 11, Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel presets. 12, Set the clock. 4-33Charging System Alternator Overhaul Exploded View BEARING RETAINER & FRONT BEARING ® TO VASE aust ngLDER ( i 0) eae =~. DRIVE-END HOUSING & ® ‘TERMINAL INSULATOR, REAR HOUSING ASSEMBLY ROTOR 4-34/hment, 42 x 47 mm 07746-0010300 NOTE: Refer ta the Exploded View as needed during this procedure, 1, Test the alternator and regulator before you remove them (see page #25), 2. Remove the alternator {see page 4-32). 3. Ifthe front bearing needs replacing, remove the pulley focknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench. 5. Remove the end cover (A) and the insulator (B). cont'd 4-35Charging System Alternator Overhaul (cont'd) 7. Remove the four bolts, then remove the rear housing assembly (A) and washer (8) &. you are not replacing the front bearing, go to step 13, Remove the rotor from the drive end housing. 4-36 9. Inspect the rotor shatt for scoring, and inspect the bearing journal surface in the drive end housing for seizure marks. ‘It the rotor is damaged, replace the rator assembly. + Ifthe rotor is OK, go to step 10. 10. Remove the front bearing retainer plate. 11. Drive out the front bearing with a brass drift and hammer.12. With a hammer and special tools, install a new front bearing in the drive end housing. Alternator Brush inspection 18, Measure the length of both brushes (A) with vernir calipers (8). + Ifeither brush is shorter than the service fimit, replace the brush holder assembly. +H brush length is OK, goto step 14, Alternator Brush Length ‘Standard (New): 10.5 mm (0.41 in.) Service Limit: 1.5 mm (0,06 in.) Rotor Slip Ring Test 14. Check that there is continuity between the slip rings. (A. + Hf there is continuity, go to step 15. + Ifthere is no continuity, replace the rotor assembly. 18. Check that there is no continuity between each slip 19 and the rotor (B) and the rotor shaft (C). + there is no continuity, replace the rear housing assembly, and go to step 16. + If there is continuity, replace the rotor assembly. 16. Assemble the alternator in reverse order of disassembly, and note these Items: + Be careful not to get any grease or oif on the slip, rings. + ifyou removed the pulley, tighten its locknut to 110 N-m (11.2 kgf-m, 81.0 IbFft) when you reinstall it. 4-37Cruise Control Component Location Index _— €RUISE CONTROL INDICATOR ittinto gauge assembly). cauise conTmot, COMBINATION SWITCH ‘YeovReplecement pope 449 ENGINE cowrRo. MODULE (ECan, IATRAIN CONTROL ‘MODULE (Pew) ‘CRUISE CONTROL MAIN INDICATOR PEDAL POSITION SWITCH M7 {Guilt into gauge ascermaiy) guru Temtpoge st itch Badal Adjustment, page 126 BRAKE PEDAL POSITION SWITCH Test page 2.181 Pedal Height Adjustment, page 19-6, TRANSMISSION RANGE SWITCH (A/T) Testpage 14-240, 4-38Circuit Diagram 4-39Cruise Control Symptom Troubleshooting Index NOTE: Before troubleshooting. + Check for PGM-Fl and body DTC's. + Check the No. 13 (20A) fuse in the under-hoot fuse/relay box, and the No, 18 (16) fuse in the under-dash fuse/relay box. + Check that the horn sounds. + Check the speedometer to see if it works properly. Symptom _ Diagnostic procedure ‘iso check for ‘Grulse conttol cannot be set | Perform the eruise control input test (sos pago #7). Cruise control can be set, but | Perform the cruise control input test ses page 4-1). cruise main indicator does | net came on Cruise control canbe set, but | Perform the er cruise contol indicator does noteome on _ Vehicle does nat decelerate | Perform the cruise contol input test (soe page ©) or accelerate accordingly when SET/RESUME/CANCEL button is pressed ‘Set speed does not cancel | Perform he eral coniral Input test (soe page #41) when brake pedal is pressed Set speed does not eancel | Perform the cruise control input test (see page b-. when MASTER button is | turned OFF ‘Sot speed dose nat cancal | Perfarm the orulse contol input teat (see page #47) when CANCEL button is, pressed Set speed will nt resume | Perfor the cruise control input test (see page 4-47). wihon RESUME button is pressed (with MASTER button ON, and set speed temporarily canceled by pressing the brake pedal) With the ignition swith ON (i, ana she tghting sitoh ON, the cruise control combination switch iluminetion does not come on J control input test (see page 4-47) place the cruise control combination switch lumination bulb(s) (see page 4-43) 4-40+ ENGINE Cruise Control Input Test 1 Connect the Honda Diagnostic System (HDS) to the data link connector (DLC). 2. Gota B-CAN System Diagnosis Test Mode A and check for DTC's, 3. Goto PGM-Fl and check for DTC's. 4, Turn the ignition switch ON (I). '5, Perform the following tests while monitoring parameters in the PGM-FI DATA LIST with the HDS. ‘Signal tobe tested | ___Test condition ‘Parameter: Desired resi Possible cause i results not objained Brake switch | Brake pedal pressed, | CRUISE BRK SW * Faulty brake pedal position switch signal then released should indicate OFF | + Blown No. 18 (15A) fuse in the when the brake pedal is | _under-dash fuse/r pressed and ON should | » An open in the wit be indicated when the | PCM and the brake pedal position switch brake pedal is released. | + A wire shorted to ground between the ECM/PCM and the brake pedal position switch Clutch pedal | Clutch pedal pressed, | SHIFT/CLUTCH SW | Faulty clutch pedal position switch position then released should indicate OFF | « An open in the wire between the ECM switch signal when the clutch pedal | andthe clutch pedal position switch is pressed and ON + Awire shorted to ground between the should be indicated ECM and the clutch pedal position when the clutch pedal | switch is released. + Poor ground G803 Transmission | Shiftin D ord TRANS RANGE SW | « Faulty transmission range switch range switch | position should indicate OFF in| + An openin the wire between the PCM signat P,R, andN position and the transmigsion range switch and ON in D and2 + Awire shorted to ground between the position, PCM and the transmission range switch | + Poor ground G101, 6102 Cruise contrat | Cruise control ‘CRUISE MASTER SW = Faulty cruise control combination switch master button | master button ON | shout indicateON —_| + An open in the wite between the gauge signal and OFF when the cruise control | assembly and the cruise control master button is turned | combination switch ON and OFF when the | + Awire shorted to ground between the cruise control master | gauge assembly and the cruise controf button isturned OFF. | combination switch + An open in the wire between the cruise Control combination switch and the ground Satbutton | Set button pressed | CRUISE SET SW * Faulty cruise control combination switch signal ‘and released should indicate ON __| + An open in the wire between the gauge when the set button is pressed and OFF when the set button is released. ‘assembly and the cruise control ‘combination switch + Awire shorted to ground between the gauge assembly and the cruise control ‘combination switch cont'd) 4-41Cruise Control Cruise Control Input Test (cont’d) when the cancel ‘buttons pressed ‘and OFF when the ‘cancel button is ‘Signal tobe tested Test condition ‘Parameter Desired result | Possible cause results not obtained Resume Resume button CRUISE RESUME | = Faulty cruise control combination switch button signal | pressed and released | SW should indicate | + An open in the wire between the gauge ON when the resume | assembly and the cruise control button is pressed combination switch ‘and OFF when the resume button is ‘gauge assembly and the cruise control roleased. __|_comibination switch —_| Cancel button | Cancel button pressed | CRUISE CANCEL SW | + Faulty cruise control combination awitch signal and released should indicate ON control is set and OFF when the cruise contol is cancelled. drive the vehicle to speeds over 25 mph | (#0 km/h) with the Cruise control set and cancel the cruise control | + Awire shorted to ground between the | - released. - Cruise contrat | Startthe engine, turn | CRUISE LIGHT * Faulty gauge assembly indicator the cruise contro should indicate ON | + A burntcruise control indicator bulb signal master button on and | when the cruise 4-42Cruise Control Combination Switch Test/Replacement 1, Remove the driver's airbag (see page 23-128) 2, Remove the two screws, then disconnect the ‘connector, and remove the switch. Cruise Control Combination Switch Illumination Buib Replacement 1, Remove the driver's airbag (see page 23-128). 2. Remove the two screws, then disconnect the ‘connector, and remove the switch. ‘Terminal side of ‘male terminals 3. Check for continuity between the terminals in each ‘switch position according to the table. + Ifthere is continuity, and it matches the table, but switch failure occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. + If there is no continuity in one or both positions, replace the switch. Terminal coo ti2fa] las MASTER Ow) | O--O [MASTER (OFF) SET (ON) 5 RESUME (ON) oto. cance (oN CLT ro | illumination bulb. 4, Install in the reverse order of removal. 4-43Cruise Control Clutch Pedal Position Switch Test 1. Disconnect the 3P connector from the clutch pedal position switch (A). Terminal side of 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. + ifthe continuity s nat as specified, replace the clutch pedal pasition switch, + IFOK, install the clutch pedal position switch and adjust the pedal height (see page 12-6). Terninat lutch Pedal ' 2 : Position Switch PRESSED RELEASED o—}—o 4-44Engine Mount Control System Component Location Index ENGINE CONTROL / MODULE: Mot oan? REAR MOUNT POWERTRAIN CONTROL MODULE from) Troubleshooting, page 447 FRONT MOUNT ENGINE MOUNT CONTROL SOLENOID VALVE Troubleshooting, page 4-47 4-45Engine Mount Control System Circuit Diagram wero rea neziU ma 4-46 oe, ) ‘orn Betas ‘alt | am sueTroubleshooting ‘Special Tools Required Vacuum pumpigauge, 0-30 in.Hg ABTBX-081-XXXXXK NOTE: Check the vacuum hoses and lines for damage ‘and proper connections before troubleshooting. Follow this procedure if the engine vil when idling, (es excessively 1. Start the engine and let it idle (see page 11-238). 2, Raise the engine speed from idling to 2,000 rpm. ‘3. Check the MOUNT CTRL SOL in the PGM-FI DATA LIST with the Honda Diagnostic System (HDS). Is ON indicated at idling and OFF indicated at 2,000 rpm? YES~Go to step 4. NO—Update the engine control module (ECM) / powertrain control module (PCM) if it does not have the latest software (see page 11-6), or ‘substitute a known-good ECMIPCM (see page 11-71, then recheck. ifthe engine mount control system ‘works properly, and the ECM/PCM was updated, the troubleshooting is complete. If the ECM/PCM ‘was substituted, replace the original ECM/PCM (see page 11-171). 4, Shift the transmission to park (A/T), oF neutral (M/T) position. 5. Disconnect the engine mount control solenoid valve 2P connector from the engine mount control solenoid valve, 6, Measure voltage between engine mount control solenoid valve 2P connector terminal No. 2 and body ground. ENGINE wouNT CONTROL SOLENOID VALVE 2 CONNECTOR ot Is there battery voltage? YES~Go to step7. No—Repair an open in the wire between engine ‘mount control solenoid valve and No. 18 (15A) fuse inthe under-dash fuse/relay box. 7, Measure voltage between engine mount control ‘solenoid valve 2P connector terminals No. 1 and No. 2, with the engine at idl. ENGINE MOUNT CONTROL SOTENOtD VALVE 3° CONNECTOR Is there battery voltage? YES~Go to step 8. NO—Repair an open in the wire between ECM/PCM (B7) and the engine mount control solenoid valve 2P connector. If the wire is OK, update the ECM/ PCM if it does not have the latest software (see ‘page 11-6), or substitute a known-good ECM/PCM (see page 11-7), and recheck. Ifthe engine mount control system works properly, and the ECM/PCM was updated, the troubleshooting is complete. If the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171). cont'd) 4-47Engine Mount Control System Troubleshooting (cont'd) 8, Raise the engine speed above 1,000 rpm. 9. Measure voltage between engine mount control solenoid valve 2P connector terminals No. 1 and No. 2. ENGINE MOUNT CONTROL, SOLENOID VALVE 2P CONNECTOR Mes. aa (BLU /veL) (eukrveL) Is there battery voltage? ‘YES —Repair a short to body ground in the wire between ECM/PCM (87) and the engine mount control solenoid valve. If the wire is OK, update the ECMIPCM if it does not have the latest software (see page 11-6), oF substitute a known-good ECM/ PCM (see page 11-7), and recheck. Ifthe engine ‘mount control system works properly, and the ECM/PCM was updated, the troubleshooting is ‘complete. If the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171). NO-Gotostep 10. 4-48 10. Disconnect the vacuum hose (A) that is closest to the solenoid connector from the engine mount control solenoid valve (BI, and connect a vacuum pump/gauge to the hose. Apply about 20 in.Hg of vacuum, and wait for 20 seconds. a B AGTEX-041 XXX Does the engine mounts hold vacuum? YES—Goto step 11. NO~Either the vacuum hose or one of the engine mount has a vacuum leak. Repair as needed. ma ENGINE 11, Release the vacuum, then apply vacuum agai {s there a noticeable change in idle smoothness with and without vacuutn applied? YES—Go to step 12 NO—Replace the front engine mount and/or rear ‘engine mount. 12. Connect a vacuum pump/gauge to the engine ‘mount control solenoid valve port (A) that is closest, to the solenoid connector. —_ 972.061.1000 |s there manifold vacuum at idle, and a decrease ‘in manifold vacuum when you raise the engine ‘speed above 1,000 rpm? YES—The system is OK. NO—Replace the engine mount control solenoid valve. 4-49Engine Mechanical Engine Assembly Engine Removal Engine Installation... Engine Mount Replacement Cylinder Head .... Engine Block . Engine Lubrication . Intake Manifold and Exhaust System ..Engine Assembly Engine Removal ‘Special Tools Required + Front subframe adapter VS802C000016 + Engine support hanger, A and Reds AAR-T-12666 (available through Honda Tool and Equipment program, 888-424-6857) . aur Pros + Engine hanger balance bar VSB02000019 NOTE: + Use fender covers to avoid damaging painted surface: + To avoid damage, unplug the wiring connectors. carefully while holding the connectar portion. + Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring, hoses, or interfere with other parts. 1, Make sure you have the anti-theft codes for the radio and navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 2, Disconnect the support struts from both sides of the pivot ball (bolted to the hood). Secure the hood (A) ina vertical position, Remove the right si vot ball and install it into the lower threaded hole (B), then reattach the support strut. NOTE: Do not attempt tv close the hood with the support strutin the vertical position, a it will damage the support strut and hood. 5-2 ‘3. Remove the left side engine compartment cover (A) ‘and the left rear engine compartment cover (B) 4, Remove the right side engine compartment cover (A), then remove the right rear engine ‘compartment cover (8).5, Remove the intake manifold cover. 11, Remove the harness clamp (A). 6. Drain the power steering system fluid (see page 17- 12), 7. Disconnect the negative cable from the battery, then disconnect the positive cable. 8, Remove the battery. 8. Remove the air cleaner housing (see page 11-273). 10, Remove the resonator {see page 11-274). 12. Remove the four bolts, then remove the battery base (8). 13, Remove the battery cables (A) from the under-hood use/relay box, then disconnect the harness ‘connector (B). 114, Remove the under-hood fuse/relay box (C) from the body. (cont'd) 5-3Engine Assembly Engine Removal (cont'd) 15, Remove the harness clamp (A), and remove the two 6 mm bolts (B), then remove the strut brace (C). 117, Remove the brake booster vacuum hose (Al, evaporative emission (EVAP) canister hose (B). 16, Relieve fuel pressure (see page 11-245). 5-4 18. Remove the harness clamp (A), and disconnect the engine wire harness connectors (8) an the left side of the engine compartment.19, Remove the three bolts securing the shift cable holder, then remove the shift cable and select cable. Do not bend the cables excessively (M/T} (see step 17 on page 13-16). 20, Remove the clutch slave cylinder and clutch line bracket mounting bolt. Do not operate the clutch ppedal once the slave cylinder has been removed (MM (see step 19 on page 13-16). 21. Remove the drive belt (see page 4-29). 22. Remove the power steering (P/S) pump inlet hose (A) and P/S pump outlet hose (8) from the P/S. pump, 23, Remove the P/S hose from the clamp. 24. Remove the steering joint cover (A). 25. Lock the steering wheel. Make a reference mark (B) ‘across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt C), and disconnect the steering joint from the steering ‘gearbox pinion shaft (D). To prevent damage tothe cable reel, do not turn the steering wheel once the steering joint has been removed. (cont'd) 5-5Engine Assembly Engine Removal (cont'd) 26. Disconnect the fan motor connector (A) and. compressor clutch connector (B), and remove the reserve tank (C). Wipe up any spilled engine coolant immediately. 27. Remove the two bolts (D), loosen the bottom bolt {€), then remove the condenser fan shroud. 28, Remove the four bolts securing the A/C compressor. 29, Remove the radiator cap. 30. Raise the vehicle on the hoist to full height. 81, Remove the front tires/wheels. 5-6 32, Remove the engine under cover.34, 35. a, g a a2, 43. Loosen the drain plug in the radiator, and drain the engine coolant (see page 10-6). Drain the transmission flu + Manual transmission (see page 13-10). + Automatic transmission (see page 14-204). Drain the engine oil (see page 8-6). Disconnect the stabilizer links (see page 18-22). 3. Remove the damper fork (see page 18-25). . Disconnect the tie-rod end ball joints (see step 10 ‘on page 17-30), . Disconnect the suspension lower arm ball joints (see page 18-20). Remove the driveshafts (see step 11 on page 16-5) Coat all precisior-finished surfaces with clean tengine oil Tie plastic bags over the driveshaft ends. Remove the shift cable. Do not bend the shift cable excessively (AT) (soe step 48 on page 14-212). Romove exhaust pipe A. 44, Remove the P/S hose (A). 45, Disconnect the power steering pressure switch connector. (cont'd) 5-7Engine Assembly Engine Removal (cont’d) 46, Remove the nuts securing the transmission lower front mount and transmission lower rear mount. 47. Lower the vehicle on the hoist. 48. Remove the upper radiator hose (A) and lower, radiator hose (8. 48. Remove the heater hoses. 50. Remove the two bolts securing the side engine ‘mount bracket.5. Lift and support the engine with engine hanger (A) and engine balancer bar (8). Attach the front arm (C) to the front cylinder head with a spacer (D) and the connector bracket bolt. (10x 1.25 mm) (E). Attach the rear arm (F) to the rear cylinder head with the harness clamp bracket. bolt (8 x 1.25 mm) (G). 52. Remove the ground cable (A). mt: 153, Remove the transmission upper mount bracket (B), and remove the vacuum hose (C). (cont'd) 5-9Engine Assembly Engine Removal (cont'd) 54, Remove the front mount stop (A), then remove the front mount bolt (B) 56. Remove the rear mount stop (A), then remove the rear mount bolt (B). ‘damper (M77). 5-10 57. Remove the vacuum hose (C). 58. Remove the two bolts securing the shift cable bracket (MT).59. Make sure the hoist brackets are positioned properly. Raise the vehicle on the hoist to full height. 60. Make the appropriate reference lines (A) at both ‘ends of the subframe (B) that line up with the edge 61. Attach the special too! to the subframe by hanging the belt (A) over the front of the subframe (B), then secure the belt with its stop (C). 62. Raise the jack and fine up the slots in the special oof arms with the bolt holes on the jack base, then securely attach them with four bolts. 3, 65. 70. 2. Slowly raise the vehicle about 150 mm (6: Remove the subframe mid-mounts. Check that the engine/transmission is completely free of vacuum hoses, fuel and caatant hoses, and electrical wiring. Lower the vehicle and securely support the ‘engine and transmission assembly. . When the engine and transmission is securely supported, and there is no tension on the engine support hanger, remove the engine hanger from the engine. ) Check once again that all hoses and wires are disconnected from the engine/transmission assembly. Raise the vehicle all the way. Remove the engine/transmis from under the vehicle. ion assembly 5-11Engine Assembly Engine Installation ‘Special Tools Required + Front subframe adapter VSBO2C000016 + Engine support hanger, A and Reds NAR-T-12566 (available through Honda Tool and Equipment program, 888-426-6857) + Engine hanger balance bar VSB02000019 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques. 8x3.25 mm MeSkgtm, _REARENGINE. hizo" MOUNT BRACKET PIS PUMP BRACKET 121.25 mm BNmisokatm, seibery Replace ENGINE MOUNT BRACKET ‘Alc COMPRESSOR ‘Racker FRONTENGINE MOUNT BRACKET, (am 1044.25 mm Stim eS ktm, 40 IF ft) ae Fepice 1oxi250m 10x125 mm Mhumisetotm, aire teBeatem ‘urn sin Repice. 5-12b=] 2, Position the engine/transmission assembly under the vehicle. Lift and support the engine with engine hanger (A) and engine balancer bar (8. Attach the front arm (C) to'the front cylinder head with a spacer (D) and the connector bracket bolt (10x 1.25 mm) {E). Attach the rear arm (F) to the rear cylinder head with the harness clamp bracket, bolt (8x 1.25 mm) (G). ifthe engine into postion in the vehicle a taan-r-12566) [NOTICE] Reinstall all mounting bolts/support nuts in the sequences given. Failure to follow this may cause excessive noise and vibration, and reduce bushing life. 3, Attach the special tool to the subframe by hanging the belt (A) over the front of the subframe (B), then secure the belt with its stop (C). Raise the subframe Up to the body with a jack. 4. Loosely install the four subframe mounting bolts (A) and four 12 x 1.25 mm bolts (8), (C) with the stiffeners. 2x125mm ©. Shine exiz5mm ex15mm SB kgtm, im Taam’ be” —Seigim, — Hosagtm, sony” etme Replace. Replace. 5. Loosely install the subframe mid mounts, then remove the special tool 1041.25 mm 22x 125mm SNe eokgim, — da Nm (as kghm, semen 33 ibe nd place, Replace. (cont'd) 5-13Engine Assembly Engine Installation (cont'd) 6. Align the reference marks (A) with edge (B) of both rear stiffener (C), and tighten the rear subframe ‘mounting bolts, then front bolts, and tighten the stiffener bolts to the specified torque. 7. Tighten the bolts securing the subframe mid- mounts, 8. Tighten the nuts securing the transmission lower, front mount and trarnsmission lower rear mount. 10x1.25 mm aR (83 kom, 33 bet) Replace. 98, Remove the jack and front subframe adapter. 5-14 10. Lower the vehicle on the hoist. 11. Install the shift cable, and tighten the two bolts securing the shift cable bracket (M/T). 12, Install the vacuum hose (A). 8 a 22x125m 11.25m BACT, Bet / Bae ihe inc 13, Tighten the rear mount bolt (B), then install the rear mount stop (C).114, Tighten the two bolts securing the rear engine damper (MIT). Replace. 16. Tighten the front mount bolt (A), then install the front mount stop (B. 2yz0m (ee eat, 47 tt) 8 aes eal A 40x 1.25 mm tm (55 kgtm, somen) Replace. 16. Tighten the two bolts securing the side engine mount bracket. 101.25 mm (cont'd) 5-15Engine Assembly Engine Installation (cont'd) 17. Install the transmission upper mount bracket (A), then tighten the bolts in the numbered sequence shown, mr: Sait? et SZnim 1 katm, sabi) OR ¥ 125mm sen eke 18, Install the vacuum hose (B). 19. Install the ground cable (Ci. 5-16 20. Raise the vehicle on the hoist to full height. 21. Connect the power steering pressure switch connector.23, Install exhaust pipe A (A) using new gaskets (B) and new self locking nuts (C) 10x1.25 mm 54Nm 22Nm 30x 1.25 mm (ekgtm, fazkgtm, 33 Nem (sakgtm, Somme reer 2eibtt 24, Install the shift cable (A/T) (see step 26 on page 14-221), 25. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring “clicks” into place in the differential and. intermediate shaft 26. Connect the suspension lower arm ball joints (see step 9 on page 18-21) 27. Connect the tie-rod end ball joints (see step 27 on page 17-56). 28. Install the damper fark (see step 2 on page 18-28). 29. Connect the stabilizer links (see page 18-22) 8x 1.9mm 2Nmi12 kgtm, 87 lot) 31. Install the engine under cover. 32, Install the front tires/wheels. NOTE: On MT models be careful not to damage or chip the paint of the brake calipers when installing the wheels. 33, Lower the vehicle on the hoist. cont'd) 5-17Engine Assembly Engine Installation (cont'd) 34, Install the heater hoses. 35, Install the upper radiator hose (A) and lower radiator hose (8). 5-18 36. install the A/C compressor. 37, Install the condenser fan shroud (A) and coolant reserve tank (B), then connect the fan motor connector (C} and compressor clutch connector (D).38, Align the reference mark (A) on the steering joint ‘and steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bole. 39. Install the steering joint cover (D). 40. Install the P/S pump inlet hose (Ai and P/S pump outlet hose (8) with @ new O-ring (C) 41. Install the P/S hose to the clamp. 42. Install the drive belt (see page 4-28). 43, Install the clutch stave cylinder and clutch line bracket mounting bolt (M/T) (see step 35 on page 1327) 44, Install the shift cable and solect cable, then tighten the three bolts securing the shift cable holder (M/T) (see step 36 on pags 13-28). 45. Connect the engine wire harness connectors (A), then instatf the harness clamp (B). (cont'd) 5-19Engine Assembly Engine Installation (cont'd) 46. Install the brake booster vacuum hose {A\,and evaporative emission (EVAP) canister hose (B). 47. Connect the fuel feed hose (see page 11-253), then Install the quick-connect fitting cover (A). 5-20 48, Install the strut brace (A), then instal the harness ‘clamp (B), and install the two 6 mm bolts (C). 49. Install the under-hood fuse/relay box (A), and. connect the harness connector (B). 8x10mm T2NmIT2 kal, 8.7 tf) 150. Install the battery cable (C),be] 51, Install the battery base (A), then install the harness, clamp (8), 52. Install the air cleaner housing (see page 11-273). 53, Install the resonator (see page 11-274. 54. Install the intake manifold cover. 55. 56, 51, 58. 59. 6 62, 63. Install the battery. Clean the battery posts and ie terminals with sandpaper, then assemble them and apply grease to prevent corrosion, ‘Move the shift lever to each gear, and verify that the ATT gear position indicator follows the transmission range switch (A/T). (Check that the transmission shifts into gear ‘smoothly (MT) Inspect for fuel leaks. Turn the ignition switch ON. } {do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line, Repeat this operation two or three times, then ‘check for fuel leakage at any point in the fuel line. Refi the engine with engine oll (see page 8-6) Refil the transmission with fluid: + Manual transmission (see page 13-10). + Automatic transmission (see page 14-204). Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open (see step 8 on page 10-7) Rofill the power steering system fluid (see page 17- 12, Perform the engine contro! module (ECM) powertrain control module (PCM) reset procedure (see page 17-4) Perform the crankshaft position (CKP) pattern clear/ CKP pattern learn procedure (see page 11-4). Inspect the idle speed (see page 11-238), 3. Inspect the ignition timing (see page 4-18). (cont'd) 5-21Engine Assembly Engine Installation (cont'd) 67. Install the right rear engine compartment cover (A), then install the right side engine compartment cover (8), 68. Install the loft rear engine compartment cover (A) and the left side engine compartment cover (8). 5-22 Enter the anti-theft codes for the radio and the ‘navigation system, then enter the customer's XM ‘channel presets. 1. Set the clock.Engine Mount Replacement 1241.25 mm Gam eskgtm, a7ibin 10x1.25 mm REAR MOUNT 54m 65 kgtm, a01bi ne) Replace 16Nm 16st, 12 IbF ft) a REAR ENGINE 2x i25mm GEN (oS Kgtm, 7 oe). ae inuwr 101.25 my [7 38m Shot, 2a wen Reploce 1041.25 mm Mm Ub gem, ssibit ‘TRANSMISSION UPPER MOUNT TRANSMussioN \\ TRANSMISSION LOWER tower mount \\ MOUNT «(M7T) tam FRONT MOUNT 10x1.25mm BAN skgtm, ‘omen Replace, 1041.25 mm 4aNim a5 kote, Stott) 10x125mm Roplace, LN eB kot, s31btR) 5-23Engine Mechanical Cylinder Head Special Tools ; Component Location Index... Engine Compression Inspection .. 66 VTEC Rocker Arm Test 6-7 Valve Clearance Adjustment . 68 Crankshaft Pulley Removal and Installation 612 Timing Belt Inspection 6-13 Timing Belt Removal 614 Timing Belt Installation . 6-16 Timing Belt Drive Pulley Replacement ...... . 6-26 Timing Belt Adjuster Replacement 6-26 Cylinder Head Cover Removal 627 Cylinder Head Cover Installation... 6-28 Cylinder Head Removal. 629 Camshaft Replacement . 6:33 Cylinder Head Inspection for Warpage Rocker Arm Assembly Removal. . Rocker Arm and Shaft Disassembly/Reassembly . Rocker Arm and Shaft Inspection Camshaft Inspection Valve, Spring, and Valve Seal Removal Valve Inspection Valve Stem-to-Guide Clearance Inspection 6-43 Valve Guide Replacement . 6-44 Valve Seat Reconditioning... 6-46 Valve, Spring, and Valve Seal Installation 6-48 Camshaft, Rocker Arm, Camshaft Seal, and Pulley Installation Cylinder Head Installation Sealing Bolt installation ..Cylinder Head Special Tools RefNo. | “Tool Number Description [ay @ | OTAALBNAATOO ‘ir Pressure Regulator 1 ® | o7HAH-PITATGA Valve Guide Reamer, 5.5mm 1 © | o7JAA-0010204 Socket, 18 mm 1 ® | 074a8-0010208 Holder Handle 1 © | o7MAB-PY3010A Holder Attachment, 50 mm, offset 1 ® | o7PAD-0010000 Stem Seal Driver 1 ® | O7VAJ-PBAOIOA VTEC Air Adapter 4 ® | o70as-0030100 VTEC Air Stopper 1 ® | 07742-0010100 Valve Guide Driver, 5.5 mm 1 30_|07757-PJ1010a. Valve Spring Compressor Attachment 1 6-2Component Location Index EAR UPPER COVER AUBBER SEAL AAUPPERCOVER 29 \ J \ LOWER covER [FRONT UPPER COVER ENGINE MOUNT of wa | 7 BACK COVER | ism eromeneey wramonn | ee mice, FF esones wucnrvulveos eases eee ~ (cont'd), 6-3Cylinder Head Component Location Index (cont'd) ICYLINDER HEAD COVER Removal, page 8-27, instalation age 6-26 ‘CYLINDER HEAD BOLT onines eh 3 a GASKET eyioen np 4 Ronen aoe cyulign nea Asner \ \ cMNDER HEAD GASKET vowér pm owen Pav O1L CONTROL ORIFICES, 6-4ay CORTES) /ROCKER ARM ASSEMBLY Digassembly/Reactombly, page 6-36 Inspection, page 6-37 ‘SPRING RETAINER LOST moTION ‘ASSEMBLY INTAKE VALVE SPRING. asnnee VALVE SPRING SEAT 8 sean seat INTAKE VALVE GUIDE Replacement, age 6-48 EXHAUST VALVE GUIDE Replacement, page 8-44 ‘S0U10 DOWEL PINS [Onthe camshaft thrust cover end! vouowGownms YE; {On the camshaft X ollseal and) a On SEAL \ CAMSHAFT x Replacement, page 6.33, Inapection, page 6-38 CYLINDER HEAD Removal, page 6-29 Inspection, page 635 seaenuiste ene EXHAUST VALVE Removal, page 8.42 Inspection: page 6-43 INTAKE VALVE, Installation, page 6-48 Removal, page 6-42 Inspector: page 643 Instat, pape 6-48Cylinder Head Engine Compression Inspection NOTE: After this inspection, you must select engine control module (ECMl/powertrain control module (PCM) reset using the Honda Diagnostic System (HDS) (see page 11-4), otherwise ECM/PCM will continue to ‘stop the fuel injectors from operating. 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 38. Connect the HDS to the data link connector (DLC) {see page 11-3). 4, Select PGM-I, select inspection, then select the ALL INJECTORS OFF function on the HDS. 6. Remove the six ignition colls (see page 4-19). 8. Remove the six spark plugs. 7. Attach the compression gauge to the spark plug hole. 6-6 10, " ‘Open the throttle fully, then crank the engine with the starter motor and measure the compression ‘Compression Pressure: Above 930 kPa (9.5 kaf/em’, 135 psi) ). Measure the compression on the remaining cylinders. Maximum variation: ‘Within 200 kPa (2.0 kgf/cm’, 28 psi) Ifthe compression is not within specifications, check the following items, then remeasure the compression. + Damaged or worn valves and seats + Damaged cylinder head gasket + Damaged or worn piston rings + Damaged or worn piston and cylinder bore ‘Select ECM/PCM reset (see page 11-4) to cancel the ALL INJECTORS OFF function on the HOS.be] VTEC Rocker Arm Test Special Tools Required “VTEC air adapter 07VAJ-PBA010A, “VTEC air stopper 0704)-0030100 + Air pressure regulator 07 AAJ-PNAA100 1. Startthe engine and let it run for 5 minutes, then turn OFF the ignition switch. 2. Remove the cylinder head covers (see page 6-27). 3, Set the No. 1 piston at top dead center (TDC) (see ‘step 3 on page 6-8). 4, Push on the intake mid racker arm (A) for the No. 1 cylinder. The mid rocker arm should move independently of the primary rocker arm (B) and secondary rocker arm (C), + Ifthe intake mid rocker arm does not move, remove the mid, primary, and secondary intake rocker arms as an assembly, then check that the pistons in the mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary, mid, and secondary rocker ‘arms as an assembly, and retest. Ifthe mid rocker arm moves freely, repeat the ‘above procedure for the remaining intake mid rocker arms with each piston at TDC. When all the mid rocker arms pass the test, go to step 5. 5. Check that the air pressure on the shop air compressor gauge indicates over 690 kPa (7.0 kgfiem’, 100 psi) 6. Inspect the valve clearance (see step 4 on page 69). 7. Remove the No. 1 and No. 6 intake rocker shaft ‘mounting bolts, then install and connect the special tools as shown. FRONT: cain O7VAs-PA010 REAR: O7VAL-PBADIOA, “4 OTARSPNARI00 070A5-0030100 8, Loosen the valve on the regulator, and apply the specified air pressure, ‘Specified Air Pressur 440540 kPa (4.5—5.5 kgf/om’, 64~78 psi) NOTE: Ifthe synchronizing pistons do not move after applying air pressure, move the primary or secondary rocker arm up and down manually. (cont'd) 6-7Cylinder Head VTEC Rocker Arm Test (cont'd) 9. Make sure that the intake primary rocker arm (A) ‘and intake secondary rocker arm (B) are mechanically connected by the piston and that the ‘mid rocker arm (C) does not move when pushed ‘manually. If any intake mid rocker arm moves independently of the primary and secondary rocker arms, replace the rocker arms as a set. 10, Remove the special tools. 11. Tighten the rocker shaft bolts to 24 Nim (2.4 kgf-m, TTF) 12. Install the cylinder head covers (see page 6-28) Valve Clearance Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100 (38°C). 1. Remove the right side engine compartment cover {eee step 1 on page 6-13). 2, Remove the cylinder head covers (see page 6-27). 3, Set the No. 1 piston at top dead center (TDC). Align the pointer (A) on the front upper cover with the No. 1 piston TDC mark (B) on the front camshaft pulley.4, Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.20~0.24 mm (0.008~0.009 in.) Exhaust: 0.28—0.32 mm (0.011~0.013 in.) Adjusting screw locations: REAR: EXHAUST Net No.2 Na 7) i si Sade ONNO C if Ml ot Ia Lng i} | Co or « oO OU oy 2 ASB SP Not No.2 Noe nTaKe FRONT: Not NSN. EXHAUST ‘gauge (A) between the adjusting snd of the valve stem on No. 1 jor and slide it back and forth; you should feel a slight amount of drag, 6. Ifyou feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 20 Nim 20 kgtm, 14 bt) 7. Tighten the locknut and recheck the clearance. Ropeat the adjustment, if necessary. (cont'd) 6-9Cylinder Head Valve Clearance Adjustment (cont'd) 8, Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 4 piston ‘TDC mark (B) on the front camshaft pulley. K Ssn, Sis 9. Check and, if necessary, adjust the valve clearance ‘on No. 4 cylinder. 10. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 2 piston TDC mark (B) on the front camshaft pulley. 12, Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. § piston ‘TDC mark (8) on the front camshaft pulley. 13. Check ang, if necessary, adjust the valve clearance on No. 5 cylinder. 14. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 3 piston ‘TOC mark (B) on the front camshaft pulley. 11. Check and, ifnecessary, adjust the valve clearance ‘on No. 2 cylinder. 6-10 1. Check and, if necessary, adjust the valve clearance on No. 3cylinder.16. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 6 piston ‘TDC mark (B) on the front camshaft pulley. 17. Check and, if necessary, adjust the valve clearance ‘on No. 6 cylinder. 18, Install the cylinder head covers (see page 6-28). 18. Install the right side engine compartment cover. 6-11Cylinder Head Crankshaft Pulley Removal and Installa’ Special Tools Required Holder handle 07JAB-0010208 ‘Holder attachment, 60 mm, offset O7MAB-PY3010A, ‘Socket, 19 mm 07JAA-001020A, or a commercially available 19 mm socket Removal 1. Remove the right front tirefwheel. 2. Remove the splash shield. ‘3. Remove the drive belt isee page 4-28). 4. Hold the pulley with the holder handle (A) and holder attachment (8). © 7sAA-0010208 (orcommercially available) & 7a8-0010208 8. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar, then remove the crankshaft pulley, 6-12 Installation 1. Clean the pulleys (A), cranksahft (B), bolt (C), and washer (0). lubricate with new engine oil as shown. @: Lubricate with new engine oil O:ctean 2. Install the crankshaft pulley, and tighten the bolt to 245 Nem (25.0 kgf-m, 181 Ibf-ft). Do not use an impact wrench. 1 Hold the pulley with the holder handle (A) and holder attachment (B). 2 Tighten the bolt with a torque wrench and 191mm socket (C). Franv-coro20e 3. Install the drive bot (see page 4-28). 4 Install the splash shield 5. Install he right front tree NOTE: On MIT models be careful not to damage chip the paint of the brake calipers when inetalling the wheels.

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