Service Manual 92-96_lude

instluctions
. . . . . . . 1 - 1 2
. 2 l E C
C: Saitama
Factory n
CAREFULLY.
B:
CABL€
REEL
.
versionof t he label s used on cars with lront
passenger
irbag.
HARM.
MINUTES.
TALLY DEPLOYED,
AN SEBIOUSLYHURT
F O L L O W
S E R V I C E M A N U A I - I N S T R U C T I O N S
CAREFULLY.
!u4rt
1-7
OWNER'S MANUAL.
DATE
OF
HONDADEALER.
IS FIRSTTURNEDON:
AIRBAG AND
A FRONT
AFTER
HONDA
DEALER.
I
spare tile and trunk lid are to
be
removed,
plac€
additional
cal, the
center of
on tho hoist.
supponed.
car a.e con-
"Dacro"
NOTE:
a
by
a
green
tion. This ype ot bolt s
calleda
"Torqu6r"
bolt,
a
and
l .
type.
ths specifications
brush. Foroignmatter in the threads
may
and bolts will be ndicated
v a
l* I
4 7 . r 4
( 1 . 8 5 6 )
Valve spring
nterlerence
j o u r n a l s
_
No. 3
ON"
F22A1 ,
seconds
205
(6.93,
1 .0-7 .0
Dressure t 2.OO0 om
i n E o r E p o s i t r o n
800
8.0 ,
1141
throttle
1.88-2.00O.O74-O.079)
1.95-2.O5
O.077-O.O81
2.55-2.65
O.089-0.093)
1.95-2.O5
0.077-0.081
2.25-2.35
O.089-0.0931
s1.
r
zat
Until
1 .2589 -1 .2595 )
2 . 9
3 .3
0 .130)
2 .6
0 .102)
0 .9
41.3
1
626)
Caftier-to-pinionclearance
o-10
o-o.4)
30
{3.O,
.61
50
5.0,
11.Ol
Gearbox
min./idle. Do not run for more than 5 s€conds}.
kPa
{kg/cm2,
psi}
7.O00-8,OOO
70-80,
or tension to new values. Run the
engine for 5
used belt values.
-o"
Coil r€sistance
2
I
2 7 . O c m z x 2
|
Mechanical
actuating,
rear
two
whsel
brakes
Size
' 1 :
185/70
14
ndex
and
various
wolk
pro-
cedures(suchasAssemb|y /Reassemb|Y,RepIacement ,overhau | , Ins ta | |a t ion ,e tc . )conta ined ineachsec t ion .
l
I
' l
SAE
viscosity:
1 0 W - 3 0 o r 1 O W - 4 0
Honda
Premium
Formula
Aulomatic
Transmission
Fluidor
N N A : ;
u J ; E
o . 9
L l l
3 . e
e 9
1 e : - -
E
; P :
E
, , i . r c 9 ; ; :
e

F
( J : ( ' l ' ! r < o o o
z
- x
^ F
E <
F :
i$:EsiEi
; ,
t : 6 ! - € ; =
c
i€
i:!i;
< , i d d c i , i i , !
9 E
.. . . . . . . . . . . . .
f o c k . . . . . . .
or h€ating he airlfuelmixture.
The
s of a one-barrel
1 O . O : 1
VTEC
Outline
Theeng ine isequ ippedwi thmu| t .p |ecamIobespercy | inder ,p rov id ingoneva|ve t im ingandva|ve I i f tp ro ' i |ea t Iowspe
and
performance
Racing ngines sve
rpm iming
s better han n
both he valve
Asshown, thepr imaryandsecondaryrocke la rmsa lenotconnected to themidrockerarmbuta ledr ivenseparSte |yby
cam|obesAandBatd i f fe ren t t imrngandI i f t .A | thoughthemidrockera .mis fo | |ow ing thecentercam|obewi th the |os t -
motion
assembly,
lobes
ddve
the
rocker
arma
sepsrot6lY
HYDRAULIC
PISTON
AI
RETURN
SPftNG
STOPPER
ISTON
At
High
W h e n d r i v i n ga t h i g h r p m , p l st o n l A ) m o v e s i nt h e d i r e c t i o n s h ow n b Y t h e a r r o w i nt h e f i g u r e b a | o w . A sa r e s u | t , t h €
pr imary .secondary ,andmidrockerarmsare I inkedby2hydrau | icp is tons( | i keaskewer landthe3rockerarmsmoveas
a
single
unit.
spoeds'
th€
lost
motion
m e c h a n i s mk e e p s t h e m i d r oc k e r a r m i n c o n t ac t w i t h t h e h i g h . s pe e d c a m | o b e ' A t hi g h s p 6 € d s , t h e | os t m o t i o n
mechanism
cts
as
part
ho
EcMopsnstheVTEcso |eno idva |ve .The increasedo i |p ressurecauses thehydrau | icp is tons to |ock thep ' imary ,sgcon
dary,
and
mid
tocker
arms
ogether.
signsl.
i
I'
s
while ncreasing
iming.
EXHAUST
CAMSHAFT
INTAKE
CAMSXAFT
EXHAUST
ROCKER
RM
Gylinder
Head
Camshafts
T h e c a m s h a f t is a c a s t p i e c e . B y i mp r o v i n g d i m en s i o n a | a c c u r a c y, i t b e c a m e p o s s ib | e t o a c h i e v e mi n i m u m s p ac
tween
cams,
(4 .2 r
Belt
Tensioner
AUTO.
for
TIMING
BELT
Outline
Thetens ioners fo r thebaIancersha ' td r ivebe | tandthe t im ingbe| ta rear ranged inpara | |e |onas ing |eax is fo ramoleco
pact
configuration,
5 -13
8 . 6 4 3
iEff
od bearings
Oil
Flow
(cont'd)
ENGINEOIL
COOLER
o i | p u m p e d t ot h e c y | i n d e r h e a ds e r v e s t w o p u r p o s es ; t o | u b ' i c a t e t h e c om p o n e n t s a n d t oo p e r a t e t h e V T E C . oi | i s
pumped in to thecamshaf tho |der to Iub ' i ca te the journa |s ,and i tsprays l fomor i f i ces in theho|der to |ubr ica te therocker
arms
and
valves.
oil
lO
N.m
11.0
kg-m,
I
rb-trl
10 N.m
10
.m
(1.o
kg-m,
10
N.m
(1.0
kg-m,
7
tb-ft}
22 N.m
. . . . . . . . . . . . . . . . . . . . . . . . . . .
or damago the contacl
the No.
(TDC).
2.
Remove
camshaft holdorbolts,
sprir€s and rocksl
4. Using he 8 mm bolts
suppliedwith the
tool, mount
cylinderh6adatthe end
two
uprights.
compressor
attach-
the spa.k
closod whils
compr€ssing
cross shaft so
compres-
tor the
falling into
the cylindsr
keepers n
shaft so the
retainer or the
page
6-16).
17.

or this
you
oth6.
widng
dston
is
at
and evaDorative
when removing
12N.m
1.2
THROTTLE
CONTROL
CABLE
(A/T
onlyl
CRUISE
22 N.m
.
pump
belt
(see
untllall
bohs
the camshaft
n )
stem),
you
must
make
a
second
I
lb-ftl
RETAINING
OLT
8
1O
N.m
1.0
g-m,
1 2 N m ( 1 . 2 k g - m ,
I tb-ft)
UPPER
OVER
AELT
ADJUSTING
OLT
10
N.m
:3
r
10 t{.m
22 N.m
33 tb-fr)
12 N.m
RUBBER EALS
bolt and he
Inserttheboh
mm bolt from the rear balancer
haft.
12
N.m
1.2
45 N.m
12 N.m
N o , 2 N o .
1
@-€
6-54
o
--fl'------------
o
6-38
engino coolant tomporaturedrop6 b€low
100oF
(38ocl
betoro
gaskets
when
reassembling.
12 N.m
lO N.m
7 N.n
orifice beJore nstalling.
suppliedwith the ool, mount
cylinder as shown.
compres-
sor
or the
spring boing
oft stands
and fall
contact
othor
wir-
ing
12
.ft
11.2
CO
ECTOR
12
rr|
{1.2
kgn,
housing.
tho timing
until
end
play.
blue compound,should
(closer
you
600 cuttef to
a
cutter to
cutter to
limit, replace
1 5 . 1 9 5 - . 1 9 9 n l
Valve
Movement
Measure
he
guide-to-stem
learance
with
€ dial
ndicstor
while
rocking
haust valv€
criss-cross
altern
n
ning with the innernuts.
t r u
1 2 N m ( 1 . 2 k g - m ,
45
N.m
{4.5
kg-m,
12
N.m
1 o N m ( 1 . o k g - m ,
7 tb-ft)
pipe.
O-RING
Replace.
10.
Remove
he
pulley
12N.m
1.2
12 N.m
12
N.m
1.2
mm bolt o lock
bolt.
l b , f t )
(38oC)
before
removing
h.
NOTE:
a
parts
n
12N.m
1
2kg,m)
10
N.m
CLAMP
WASHER
Apply
liquid
13 tb-ft)
2 6 N m { k 2 . 6 k g - m ,
't
9
lb,ftl
12 N.m
1 .2
RUBBER
CAP
Replace
when
damaged
r
2 2 N m ( 2 . 2 k o J n -
qo.'
r
o
ru--ttt
12
N.m
1
tho VTEC aolonold vdv6.
connoctoa torminal and body
.
rub.iltuto
r
known-good
ECM
l2 N.m
1 .2
g -m,
12 N.m
22 N.m
22N,n
12.2
g-r'|,,
in th6
holo ot
26 N.m
Remove
been eplaced,
supported on
n)
36.323
mm
{1.43OO
nl
SECONDARY
34.971
mm
(1.3768
n)
34.683mm
{1.3655
n}
105.OO- 05.30
out with
guide
breaks,
Remove
VALVE GUIDESEAL NSTALLER
guides,
and
Whenvalvesandspringsare n
proper
use
hammer.
rip
bottom).
NOTE:
Tap
o
original ocations.
passing
he
rocker
arm
shaft
installing
he
rockerarms.
n
the
rock-
rocker
arm
shaft
and
and exhaustare different.The oriticesmust be in-
stalled n the original ocations.
o
piston
thr6e
steps.
lst
{10.O
kg-m,
.
the lst step.
CYUNDER EADBOLTS OROUE
16 tb-ft)
manifold and
with the
16 b-ft)
22 N.m
0
N.m
4 5 N m 1 4 . 5 k g - m ,
33 tb-ft)
16 b-fr)
are ace up, then
CAMSHAFT
HOLDERS
IITTAKE
7 .
a
26 N.m
12 N.m
CAMSHAFTPULLEY
6 x l . O m m
1 0 N m { 1 . 0 k g - m , 7 l b - f t )
WASHER
LOWER
OVER
Romove
'l2
N.m
(1.2
kg,m,
9
lb-ft)
CAMSHAFT
PULLEYS
10
N.m
ALTERNATOR
6 5 N m ( 6 . 5 k g - m ,
47 tb-fr)
12 N.m
1 .2
12 N.m
1 2 N m ( 1 . 2 k g - m ,
9 tb-ft)
new
Replace.
26. Align he rear
ool.
Scribe
a
12
N.m
(1.2
kg-m,9
lb-ft1
'12
N.m
1.2
g-m,
lb-ft}
PULLEY
6-114
o bring
No. 4
12N.m
11.2
12 t{.m
throada.
NOTEr
12
N.rn
t.2
kg-m,9lb'ftI
BAFFLEPLATE
AEARING
CAP
BRIOGE
12Nrn
(1.2
9IEftI
PIN
OIL
PUMP
12 $m
tighten he
i l c learance,
he bear ings
in the car).
incor-
Clsan hem only with
hold the rear balsncsr
va mm {2.9
re at
the op.
with their respective
hard
carbon
around
pastons
ut .
CAUTION:
contlct turflcc of
irt
(H22Al
placo
cylinder
od
cates he
ourna ls
o make
service imit.
cy l ind6rbore
and
Y
at
Read h€ l€tters rom lelt-to' right
for No. 1
{3.3458
(3.3i165
3.3i168n)
(3.'1252
3.i1256n)
are beyond
o
l inor ussr FRM
as shownon
remeasurehe
bores,
2.
(for
nonf6rrousmetals)
.
5 cyclos.
lean he
dry and oil
t will only redistribute
our
in -
gernail
grit
or broksn.
the
grit
enough to catch
6nOine.
piston
pin
driver.
in takemani fo ld
tolerance anges
t 's
then stamped
with a
numberor bar
or
greater
han
F22A1
e n g i n e :0 . 0 2 4m m
{ 0 . 0 0 0 9
n ) H 2 3 A 1 ,
H 2 2 A 1
engines:0,026 m
Measure he
gauge:
lf
the
gap
f
you
have
the
proper
imit, he cylinder
blockmust be rebored.
Pistoo Ring End-Gap:
roken ing
edge.Makesure hey
around
he
main bear ings .
od bear ings
12 N.m
12N.m
11.2
g-m,
of the balancer
gear
then
12N.m
1.2
g.h,
9
rb-ft}
11 .
45N.m
4.5
g.m.
f ron t )
pump
housing
OIL
SCREEN
H23A1,
H22At
engin$:
ENGINE
12N.rn
1.2
g-m.9
b-ft)
WASHER
Replace.
DRAIN
BOLT
14
12N.m
11.2
g-m,9lb-ft|
BAFF1T
PLATE
EEARING
CAP
BRIDGE
OILJET
BOLT
12 N.m
he
t )
atter
engine
overhaul.
H23A1
ngine:
4.3
(4.5
US
qt,
o i l f i l te r shou ld
be
w i th the spec ia l
o i l
wrench.
Inspect
seal
by
hand.
he o i l f i l te r
clockwise ith
the specialtool.
Tighten: 7/8
turn clockwise
when
the
rubber
be t igh tened
nt i t he
pressure
shouldbe :
Engine
Oil
(3.5
kg/cm,,
50
p3il
minimum
p ressure
spec i f i ca t ions ,
inspect
NOTE:Replace
7 N.m
12 N.m
No. 1
F 2 2 A 1
n g i n e :
a g e
6 - 2 8 ,
engine:
age
6-62,H2241engine:
age
6-106).
Remove
(F22A1
ngine:
page
6-29,
H23A1
ngine:
page
6-63,
age
6-'l07).
Remove he t im ing be l t ens ioner nd he t im ing
balancer
R e m o v e h e
m o u n t i n g
b o l t sa n d h e o i l
p u m p
pump
clearance n
the oumo
he se t o f
inner
and
c learance
exceeds he
12 N.m
of the balancer
gear
bolt, hen
attern.
a
Intake
Manifold/Exhaust
ystem
Intake
Manifold
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 2
Exhaust
Manifold
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gaskot.
a
H2341, H2241 engines:
12 N.m
22 N.m
22 N.m
22 N.m
22 N.tn
22 N.m
22 N'm
the
gasket.
a
22 N.m
55 N.m
releasing
scaldingcoolant,
re-
the electlical
NOTE:
a
Check
bleoding.
6ge
l0-6
Leak
est,
page
1O-7
core fins with compregsed
10 N.m
10 N.m
rder of removal:
a
in the thetmostat
of the ti l ler
neck
with
et it
bring the level back up to the bottom ot the
filler
neck.
11.
run
heater,
he n
a
g€nuine
(3 .7
neck.
'12
N'm
11.2
kg-m,
9
12 N.m
{1 .2
kg -m,
12
.m

. . . . . . . . . . . - . . . .
. . . . . .
. , . . . . . . . . . . . . . , . . . . . . . . . , .
onnect ions
rocedures , , , . . . . . . . . , . , . . . . . .
' l
42
i l l
N o t
1
x y g e n
e n s o r , , . . . . . . . . . . , . . . . . . . . . . . .
1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
oad
/ B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a lve
i9na1
AutomStic
Transaxle
G e a r o s i t i o n
i g n a l . . . . . . . . . . . . . . .
. . . . . . . .
S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
6
Power
SteeringPressufe
T h e r m o
a l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - 1 0 9
S t a r t i n g i r
V a l v e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e t t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - l
11-132
11-1
33
onvener . . . . . . - . . . . . . . . . .
Exhaust
vs tem
3 5 ,
6 5
Replacomedt,
age
11-119
1 1 - 1 3
o o o o o o o o o o o o o
o o o o o o o o
o o o o o o o o

c425
(Frorn
.g.
1l-141
lFrom
p.g.
I
f5-l
wxr
l-6''I"*t----.',
REO/6LU
3
a
LX
ASSt
FEOr'GFN
LKI''EL
IA65)
5
|6'TREo/BIK
c321
to) tRED/Blx I
16loRNi------l
FT-,--__l
l
2
1 RE O/ 6LU
c103

c461
2
ALK
3
GRNTYEL
12
3
Y€ L
RED/BLK
3
AtK'/EL
YEL
12
LIJ/FEO
BLK
ALU
YEL/BLK
BLU/FED
BLU/ALK
8LU/GAN
REO/ALK
n
tartingwith
O.
Find he symptom n the left column, ead across o the
most likely source, hen refer
to
the
page
istedat the op of that column, t inspection hows he system
s
OK,
O,
etc,
ndicated,
blinking
code
s
displayed
MlL
stays
oes
away,
replace
76 7A 80 a2
l l l
1 3 1
1 5 3
1 4 9
following:
umper
The MIL ndicates code by the lengthand numberof blinks.The MIL
can
1 through
43 are ndicated y a series f longand shon blinks.
The
number
of
he
second
digit.
h
USA:
CANADA:
MALFUNCTION
CHECK
INDICATOR
ENGINE
LAMP
LIGHT
{MIL}
S6pa1.t.
Ptobl.mr:
Shon
O seconds
preset
1.
preset
lf codesother han those isted
aboveare ndicated, erif y he code. t the code ndicated s not l istedabove, eplace
the
EcM.
a
may light simultaneously hen the code blinks6, 7 and 17.
Check
ystem roubleshooting,hen recheck he
D4 indicator ight. f
does
not
come on when there s a maltunction n the A/T Fl signal
or slectricsl
osd detector
DIAGONOSTIC
TROUBLE
coDE
(DTC)
1 3
VEHICLE
PRESSUREWITCH*
6-77
23
or a
Unbolt he ECM
ode(s) isted
{cont'd)
DIGITALMULTIMETER
KS-AHM-32-003
o o o o o o o o
o o o o o o o o
o o o o o o o o o o o
11-45
poor
or
probo
start to
you
the
shortest
distance.But
be-
Fdfibxl
Asks
you
ou
and decisions. esc ribes tinal repairactionand sometimes
irects
you
to
ndicator amp
a
wire
an
poseo
o.
a
heck he test ha.ness
uration,
he A/C compressor
he ECM
ECMcuts
ground
t
Portorm .oubloshootingon
Connect he
Measure voltage between body
ther-
moltat
Inspect tuel
+-
ooooo ooo
o o o o o o d o o o
o o o
o o
Measure
voltage
between
body
ground
page
ON .
Measure
o o o o
I
o o o o o o o o m o o o o o o o o o o
o o o o o
o o o o o
o o o l o o o o o o o o
ls the fuse
car, and
recheck he
With rervica
chock connoctol
t indi-
ls there 1O-4O 0?
otigil_
nal
ECM.
o o o o o o o o
o o o o o o o o
Connoct
Intlrmlttdrt t
ilurc, ly.tom
is OK
26
a n d A 2 6
( - )
3 l -
nal ECM.
I
o o o
o v o o o o o o o o o o o
I
(cont'd)
voltage
between
RED/
WHT
a n d
_ l
{To
page
a n d D 2 1
( - )
( + l
t e r m i n a l a n d
D 2 1
indi-
um
gauge
021
- }
8 l -
-
rom
the
mtnals,
8:16
350-7OOO?
o
o o o o o o o o o o o o
I
o
o
I
o o o o o o o o o o
o
B1l-
350-7ooo?
ooooooooooo
350-7000?
812
11-71
(locrt-
it indi
OFF.
Disconnect
a n d D 2 2
( - )
11-73
As
-
at
indicate ode 7?
Disconnect he 3P connector rom
the
TP
sensor.
Measure voltage between YEL/
( + )
{ - )
o o o o o o o o o o
o o o
o o o o o o o o o
Turn the
ignition switch
the
ECM
{ + )
( - ,
thrott le,and approx.4.5 V
is depressgd.
open
throttl€?
hrott le?
thermistor).
air temoerature ncreases s shown below.
RESISTANCE
KO}
THERMISTOR
-
Intermitl.nt tailu.o, sydom iB OK
at thir tims
llAT
indicate od6 10?
the iAT sensor.
Measure esistanc6between the
Subrtitut. . known-good ECM
wirebotween CM
D15}.nd
ground.
Turn
he
Turn he ignit ion
{ + }
t e r m i n a f a n d D 2 2
l )
terminal.
11-77
-\
-
ON .
GRN wir.
botwoon tho ignition
nals
shorted.
damag6d.
A 22l+t 426
o o o o o o
I o o o o o o o o & r u f f i
ooooooooooooo oooooooo oooooooo
-
croseo.
at
parking
oI the ca r and support with
sale-
ON .
slowly rotate eft lront wheel
and
measurevoltage
between
{ + }
t e r m i n a l a n d
A 2 6
a n d A 2 6
( - )
8nd
ECM.
ON .
Measure
( - l
terminal.
cd undor
- l
. l
l-
the
wilo
botween ECM
SYMPTOM
conditioning
ystem.
several
relay.
A26
-t
Clicklng?
Vigw
| |
l o o o o c
I l o o o o o o o o o o o o Q I
o o o o c
r - - - - - - - - - - - - - - - -
I
A26
t_l
Air
' l
the ECM
turnedon
4.5 V?
?
D 9
terminal
+ l
A26

posltlon.
BATTERY
A26
(-t
Connect
he
depressing
ECM
see
page
11-45).
b.twoon

l , u u r E J l l ! ! t l , r
I I
l g f l t . , Y v v r r q l
I
This signals
Moasure
ls ther6 more
known-
good
o o o o o o o o
o o o Q o o o o
o o o o o o o o o o
swtTcH

fast idle
plunger.
When
he
surround-
so thst
the engine
lnspection
H23A1
engino
USA:
1. Remove
he intake
air duct
completely
thermo vslve
an d

fast idle hermo
{engine
lf not, replace he
the
s
completely
losed.
Checkenginecoolant
evel
and
gine
coolingsystem
(see
section
lO).
It
OK,
edal
slightly
depressed.
tabilize
re
off.
ldle

ldle he engine
at
Hl
he y
ikely
system

fuel
pressure
when the engine s
he bat-
caD.
wrench
with
anotherwrench.
6
mm
servicebolt.
servicebolt one complete
mm servicebolt hole.
removed.
11-114
12
N.m
{1.2
urn he gnition
on again
PLUNGER
SEAL
llocat-
indi
10 seconds f cranking
s t he re1 .5 -2 .5
O?
body
ground.
(To
page
11-118 )
{To
page
and f o l l ow ing
termrnal:
.
o o o o o
o o o o o o o o
o o o o o o o o
o o o o o o o o o o
1 1 - 1 1 8

fuel

install the
intaks manifold.
the connectorwith the
16. C onnect he vacuumhose o the tuel
pressure
the fuel injectorsand
N. but do not operate he starter.
After the fuel
two
or
see
page
11-115) .
le impeller'
port
with
tha ignition
switch OFF
betore disconnecting
tho wiles.
away ttom
pump.
4.
eplace he relay and
29
o ooooooo
lfitoHruffs{sl
o o o
o o

llame
away
from
your
and support
he drainbolt and drain he fuel into an aooroved ontainer,
3.
switch OFF before
disconnecting he wires.
hosos
as
straps
pplied o its mount. To remove, aretully
pry
38
I
he n
column.
f
@,
the Air Cleaner

provides ground
intako solenoid
valv6. This
intake
control
diaphragm.
BLK
I
I
Measurs
YEL
{+ l
and body

Ropair
opoo
the ECM and connectors
OFF.
{To
page
propor
def lec t ion hou ld e 1O- 12 mm
(O.39-0 .47
throt-
tle cable n the throttle inkage nd nstall he cable
housing
n
(0.1
tion/adjustment.
DEFLECTION
1O.39-O.47
n. )
as speci-
you push
tle valve o be
ype.
gine
adjusting
and
IDLEADJUSTING
SCREW
Inspection
CAUTION:
Do
It
i3
presot
ating emperature
(to
the
EVAP
contro
canister)
rom
n the
slightly
rom
idle.
a
lf
the
gauge
port
is
cable
at
full
close
position.

is non-adiustable,
(s66
path
ByDass
tA,Bl
ratves.
High
torque
4,800 rpm
valve.
YEL
wlre bctwaon th! 2P
Turn
the
ignilion
swatch
OFF.
Reconnect
main
Substhuto a known-good ECM
or bindingor
n
across
he n
istedat the
@.

nd
eaterblower,

visiblearea
etween
-.-_:- /--\
road for
2P con-
lTo
page
and
D22
l - )
terminal.
ls
appli.d?

System
EVAPcont ro |can is te rpurg |ng isaccomp| ishedbydrawing f resha i r th roughtheEVAPcont ro |can is te rand in toa
por ton the thro t t |ebody .Thepurg ingvacuumiscont ro | |edby theEVAPpurgecont ro |d iaphragmva|veandthe
EVAP
putge
control
solenoid
alve

Inspoct vacuum
normal
operatingemperature
th6
adia-
ls theremanifold
beiw€en ECM
good
ptom

comoloto.
Evaoorativo
cap.
the fuel tank
{O.4
to
mm Hg
valve
and
retest.
VACUUM
GAUGE
A973X-
o4'l

12-8 .0
nd wisting.
10 N.m
CAUTION:
l
qylindor
piston
and
push
rod,
the
release
clutch
the c lu tch
he clutch
the spec i f ied t rokeand he igh t
a t the c lu tch
Deoat .
3.
'12lurn
further.
boardan d
depressed
paint.d
sur-
NOTE:Plug he end of the res€rvoir ose,
and cap
1. Remove he reservoir ose rom
the clutch
master
cv l inder nd dra in he brake lu id n to a su i tab le
contarner,
NOTE:The
brake
luid
5. Removehe clutchmast€r
CLUTCH
MASIER
CYLINDER
0ll.rn
11.0
e-m,
order of
(see
psge
12-6t.
CLUTCH
MASTER
CYLINDER
RESERVOIR
paintod
3u.facos,
NOTE:Plug he end of the res€rvoir ose ,and cap
the end of
Remove he slave ylinder
grease.
1 .
Install
and suspend
Makesure
here
s
the master ylinder,hen slowly
the bleed-
Useonlv
DOT
solvsnt.
pattern
feeler
burnedb lackor o i l
soaked.
surface
torque the mounting
at te rn
Ins ta l l he
c lu tchd isc us ing he spec ia l oo ls as
shown.
HANDI.I
07936
3710100
Push he flywheel
washer learance.
installed.
Standard
Nowl:
0.05
mm
{0.002
lywhee lmount ingbo l ts
n a
operation.
n x 16
fdl on
protection
cir-
cuit .
hs cus-
7. Disconnecthe back- up ight switch
connectors nd
WIRE
BACK.UP
IGHT
WITCH
HARNESS
STARTEB
MOTOR
STARTER
MOTOR
CABLES
9.
10 .
TRANSMISSION
GROUNDCABI.T
cables
rom
er .
CAUTION:
Take
crre
not
VSS)
onnec-
pipe.
(cont'd)
CLUTCH
HOSE
SLAVECYLINDEB
damper
(see
ection
18).
l0
N.m
1,0
g-m,
'10
N.m
11.0
10N.m
11.0
g-m,
10
N.rn
1.0
kg-m,
7
tb-ft)
FLOATING
OLLAR
12 N.m 1.2
'12
N.m
11.2
g-m,
9
tb-ft}
SHIFT
ARM
COVER
SHIFT
ARM
29 N.m
15N.m
11.5
g-m,
LOCK
WASHEB
Replace.
DOWELPINS
SELEGT
EVER
13-12
12N.m
1.2
g-m,9lb-ft|
12 N.m
, /
15
N.m
1.5
29 N.m
arm.and
nterlock.
he
leas t30
rom the hitting
criss-
cross
pattern
n
severalsteps.
BACK.UP
IGHT
swlTcH
all
bear-
sealant.
Remove
gear
and
ork.
imit, measure
tork.
13.3mm
{0.512
groove
groove
l f the w id th exceeds he s tandard ,
eDlace
he
reverse hift ork with a new one.
l f the w id th i s w i th in the s tandard ,
eo lace
NOTE:Tape he mainshaft pline before emoving
the mainshaft nd countershait ssemblies.
MAINSHAFT SSEMBLY
STOPPER
ING
3RD/irTH
NEEDLE EARING
distance
the spacer ollar
the serv ice
one.
(cont'd)
1 .
synchro leeve nd hub as a set.
Support he bearing
nner race with
a socketan d
gears.
imit. measure
gear
limit, replace
and 5th
imit,
measure
distance
Standard: 26.03 26.08
thickness f sth
press
and
iaw.typ€
puller
puller
as
shown.
BEARING
ULLER
BALLBEARING
BAI-L
BEARING
STOPPER
RING
MAINSHAFT
5TH
GEAR
gear
limit, eplace th
l I the th ickness f 5 th
gear
limit, eplace
Drsss
In the same manneras above, upport he 3rd
gear
press
3rd/4thsvnchro hub as shown.
the service
Inspector runout.
Standard: 0.02
Suppor t he ma inshaf ta t bo th ends
as
snown.
service imit, reolace
Inspectoi l
ins ta l l he 3rd /4 th ynchro
hub
tools and a
3rd/
4th
synchro
hub
set.
M2L5,M2S4
T..nsmi$ion
Typol:
PRESS
3RD/4TH
press
07?46 0010300
LOCKNUT
Replsce.
130
B
23922-PG1
000
1.99
mm
(0.0783
n)
23923-PG1-000
2.02mm
(0.0795
n)
D 2 3 9 2 4 - P G 1 - 0 0 0
2.05mm
(0.0807
n)
E
B 2 39 18 -P 2 ' r - 0 1 0
29.07
29.09mm
(1.1445
1.1453
n)
I
springwasher,
1s t /2ndsynchro
at
points
Inspector runout.
he
Inspector wear
ollarusing
DRIVER
077€
gear
fingerswith 2nd
a
press
as
shown.
Install
orque, h€n
stake he ocknut
LOCKNUT
Replace.
1 .
o
BENCH
vtsE
t
wooD
Bl-ocKs
13-27
Standard:
the standard, eplace
lf the thickness f the shift ork finger s
within the
standard, eplace
one.
lf
the
width
less
he stan-
piece
with
NOTE: nstalling he synchrosleeve
Ins ta l leach synchro
hub in i t s mat ing
synchro
ub
gear.
teeth
and
matching
off).
2 .
GOOD
WORN
teeth
gears
or
unevenwear.
scoring,
alling,
Measure
and
gear
he
gear
han the serv ice
Remove he ba l l bea. ing
wi th the spec ia l oo l as
snown.
using
DRIVER
07749
001(x)00
HAMMER
{Comm.rci.lly
.v.il.blc)
ATTACHMEN?,
U2x17
mm
07746
- (x)l0300
Aq,USTABLE
BEARING
sideusing he specialtools s shown.
BALLBEABING
AALLBEARING
ATTACHMENT,
62x68mm
077a6
- (X)105(x)
AALL
AEARING
Mainshaft
(Commc.cially
vailrblel
ADJUSTAB1IBEARING
NOTE:Positionhe needle
guide plate
synchro hub, and ball bear ing on the mainsh aft,
then
nstall
I n g .
12
N'm
{1.2
housing
gauge.
proper
bearing
spring
washer).
-3.
(For
example)
AD 2 3 97 0 - PK s -00 0 2.07mm
{0.0815
n
AE
thrus t
main-
Tap
he
follows:
NOTE:
o
loosen he two hex bolts.
.
g r o o v e
a t t h e i n s i d eo f t h e m a i n s h a f t
splines,hen
a
plastic
ammer.
-10.
Dase.
-1
lla-F.
l:vli
ffir"
MAINSHAFT
HOLDER
O?GAJ
PG2O11O
MAINSHAFT
has reached ts
the standard.
he clear-
the clutch
15N'm
11.5
gutterplate
cure a t leas t
30 minutes
he mount
bracket nd
1 4 .
55 N.m
10N.m
1.0
g-m,
nsta l l ing he s ta r te r
motor cab le ,
l0
't0
N.m
11.0
g-m,7
10 N.rn
10N.m
1.0
g-m,7
b-ft|
I
Front
1
36
'147
A/T
Dolcrlptlon
otv
PagoRoferanca
o
ri
o
o
Oriver
Attachment
1+127
1+142
0
a
'0
Must be usedwith commercially vailable /8 in, x 16 throads/in. lid6nammer.
14-2
tripls-shaft electronicaly
engine urns. Around th€
gear
which
st8rt6d. The antir€ torque
and
gears
st EndHler.
Th6 secondary
clutches,and
gesrs
providing
4th
gear
and the secondaryshaft. When
panol
the
psss6ng6r's
Hydr8ullc
Conilol
body, hrottl€ vsve
The main vslve
ock-up shift vafue, ock-up
CPC
valve
andoil
shift
vafu€,
body contains hs throttle valve
B and relief valve.
Fluid rom the regulator
control valves.
activate.
pressure,
ear,
and
I
D3
torque converter
B.
are
mounted
lcont'dl
14-3
vehicle
speed
1st
on
mechanism
omes
nto
operstion
n
LP1Jposition
For rapidacceleration t highwayspeedsand
vehicle
speed
position.
DownshiJts hrough 2nd o 1st on dsceler€tion o stop. The lock-up mechsnism omes
nto
operation
For enginebrsking;stays n lst does not
shift up.
Automatlc Transaxlo
consore.
14-4
gears.
plstes
ogether. ocking hem so they don't slip. Power is then transmitted the through the
engaged lutch
gear
o
spin
st
gear,
The
lst
clutch
s
oined
pressure
the
countershaft,
ust
behind
gear,
and s locatedat the center of th6 secondaryshaft, The hd clutch is
oined
back-
supplied lutch
internal ydraulic
The 3rd clutch s
alve body,
4th Clutch
c6nt6r of
the msinshaft.The
proasura
3rd
gear
provides
up
when
power
istransmitted
,
with the 1st clutch still6ngaged.
COUNTERSHAFT ST GEAA
piston
against he convertsr cover. As a resuh, he converter urbine
s locked o the
LOCK.UP
of CLUTCHON.
piston
Engine
tirive
plate
J
Torque
pow6r
lock-upars sloctronicslly ontrollsd
panelon
he
passengar's
ida,
is
shown
Lock-upContlol
From
sensor
nput signals, he TCM determineswhether to turn the lock-up ON or OFFand activates ock-up control solenoid
valve A and/orB accordingly.
The combination t drivingsignalso lock-upcontrolsolenoid alvesA and B is shown
in th6 table below.
r
s|rtFl oiTior
rocx utco{nol
' / ; s c s
by
the
ine
pressure
1)
spe€d.As the
speed of th6
resuh, he 1-2
to the 1-2,2-3 and 3-4 shift
valves s the same
As the speedof
(shift
he 3-4 shitt
port
clutch s turned on.
no
power
shift
pr€scribed
alu€, he
olt
(shitt
As this takos
place,
3-4
shift valve s moved o th€ left and uncovers ho oil
port
2-3
shift
clutch,
2nd and 3rd sDeed.
circuit is the samess
valve
{3),
causing
n the rovorsedirection,
8s n 3rd speed nLqllor
I
D3
I
position.
valve and
m:Ei[alvalve
a
speed
right side.Th6 ine
ow6r
vatueare not operated.
th;o6h an oil
Togetherwhh
throttle valve B'
modulstor
pressure
changes.
14-23
,p--nt-iu"V";
(cont'd)
!3:i",3,3"J:'&?."
O N V E R T E R
C H E C K A L V E
14-25
O N V E R T E R
C X E C K
A L V E
14-26
O N V E R T E R
C H E C K
A L V E
V A L V E
MOOULATOR
RESSURE
14-27
r
climbing
Torque
throttle load.
Ar9 421
h€
by individual hort blinks,codes
10 throught 15 8re
muhipon tuel
the
presets
a
particular
ailure
code
requires
he
3,
and/or
of the Test Harnessare
o o ol io o o o o
oo
qo
o o o o 6to o o o o r o o o ) c
CLOCK
RADIOFUSE
presets
UI{DER-HOOD
sensorwire
Fauhv
ECTsensor
Fauhy gnition
t wilt be
or stays it
presets
'
tor trom the TCM,
Msasure he vohago
uDconlrol olonold valvo A.
Turn he ignition witch
torg. It nacollgry,
o .
the A6
trol 3olonold rlva A.
trolsolenoidvafue
Meaaur6 ho vohago
up control
tweon th€ A4
o r T C M ! n d
rachack.
control aoLnold valva
wlra baiwaon
Chock whothor tho Malfunc-
"4"
arfr
"D"
the TCM
Mosgurs hs vohsg€
ECM.
"A"
snd
"0"
th6 D7 snd A2tA26 torminal€.
R.pdr op.n or thon
FEulty TP sonsor
4.75-
A2 6
14-40
cle speed s.nlor
tho TCM
1+35).
snd
Dg and A2ryA26 terminats.
do€snot tum,
lor3. lf n€ceaaary,
'
.
(cont'd)
1441
Obs€rve
ho A/T
lightwh€n
tors {'l+3$.
nals.
Chock
to.
th. A/T
ll nacallary. aubtthula a
na|s.
wlr. belw..n tho A19 tormlnll rnd th.
A/T
.ubrtltut. t
Bsnery vohaoo?
I
A19 A25
YES
To
paga
betwoon th. Al7 t.rmln.l
TCM connoc-
tor!.It noco$ary,
nd tho
nals.
tho A13 t.rmlnal and he
A/T
GRN/W}|T
lf nocorsa.y. rubrtltuto a
Battery vohag6?
A2 6
A2 6
426
a2 6
t:ltoooojs9$:*:occD.gol
ooo
o
oo
o oo
th6
/REDwlr.
batwaan
lnd
rochodr.
o o o o o o o o O o o o
{cont'dl
1445
o r
iechack.
trom
Measure he vohag€
o r T C M o n d
rachack.
vave assembv.
the 43
mlnal and the
(1+63).
wl.g
'
Rapllr boaa tarmlnrl or opan
In
apaad anror.
ior. lf r|.c...Jy,
.
l n o w n - g o o d T C M l n d
rachad(.
400
600
0?
1449
A? 5
o o o o o o o o
check
.
wh.
temp6ratuao tho
tor3
n6anoa8.
o o o o o o o Q o o o
Approx.5
v?
Check for continuity
b€tw€sn
t h e D 1 8 a n d A 2 5 l A 2 6
torminals
{FAS}
rcchack.
sonaor'
To
psg€
D 1 9
ls h€ resistance
between
D 1 9 t e r m i n a l
a n d t h e
mainshaf
sp6edsensor.
R.palr
b€tw66n
O 1 2 t e r m i n a l
a n d t h 6
mainshaf
spg6dsensor.
Rep.ir
Run E l . c l r i c s l
T roub l c -
and
rachack.
o o o o o 9 o o o o o
D'
I
400-600
0?
(cont'dl
14-55
i s
to r 2
rechock.
o o o Q o o o o o o o o
(cont'd)
14-57
whon.vd
eng6g6.
trom
torminalsid€.
l.Ep.ctlon
'
depresssd.
Rrplh
op.n
In
GRN/WHT
aociion
23}.
o o o o o o o o o o

12 N.m
bling he mainshaftand
12
N.m
1.2
kem
Shift control solenoidvalves A and B must be remov€d/
reolaced s an assemblv.
solenoid ave A/8.
(solenoid
terminal
solenoid
th€ r€sistance
the standard,connsct the
control solenoid
the battery
assembly f no clicking
control solenoid
control solenoid
6 x 1 . O m m
12 N.m
a new
or oil, and recon-
N
SliDs
qesr
n
"D4"
Dosition,
.ock-uo
Transmission
q6ars
worrvdsmaosd.
Modulator
alve
stuck.
by improper €pairor assembly.
"D3"
or
"D4"
position.
enginesection
lf th€ l8roeclutch oiston O-rino s broken, nsoact he Diston
qroove
cfutch
psck
is seizedor is exceasivelyworn, inspect he oth€r clutchgs or wear, and chsck th6 orifice
controlvefuesand hrottle valves or free movem€nt.
lf throttle valve B is stuck. insoect he clutches or wear.
lf
the
I
2
shift
v8lve s stuck closed, h6 transmissionwill not upshift. f stuck open, he transmission as no
lst oaer.
2nd and
clutch Dscks
or wear.
the clutch oressure ontrolvalve is stuck closed. h€ trsnsmissionwill not shift out of lst
qe8r.
main vav€ body snd torqus conv€rt€r ho$ing may
causo oil
pump
seizure.
The
svmbtoms er6 mostlv en rom-rdletgd tickino noise or d hioh-Ditchod sdueek-
tf the ATF strainer s clog€edwith
particles
pump
pinion
sheft- f both 616OK snd no caus6lor the conteminetion s {ound. roolece he tordua convertor.
M. lf th€ lst clutch
feedpipe
guide
ball
be8ring or €xc6ssiv6mov6m6nt n tho transmission ousing, f OK, roplaco h6 right sid6cov6r as t is dsntad.
Th€ O-rinound€r ho ouide s Drobablvwo.n.
N. Replaco
he mainshaft J he bushing or th€ 4th feedpipe s oose
or
round,
oplacs
t.
Bsplsce
h€
countershaft
or dsmsged.
or
damgod.
lf the 1st f66doiDe s damaodd r out of round. sDlacs .
o. A worn or damagad pragclutch is mostly a result oJ shitting he transmission n
"D3"
or
"D4"
posrtion
while
the wheels otato n aoverse. uch as rockino he caa n snow.
nsDect
4. Differential
or swirlmsrks.
Replacetems 1, 2, 3 and 4 it worn or damaged.f transmissionmskesclicking,
grinding
lf differential
lf bottom oJ
gear
noise,
and inal
driven oeer-
R. 86 very care ful not to damage he torque converter
housingwhen replaclng h€ main bsll besring.You may
also damage he oil
pump
when
you
torque down the main valve body. This will resuh n oil
pump
f
t into the torqus converter housing
until t bottoms out. h willblock the oil return Dassaoe nd resuft n damaoe.
r. Harsh downshifts when coasting
o a
stop
with zero throttle may be cauaed by a bent-in throttlo valve
retainer/cam tooDer.Throttle cablesdiustmentmav clear his Drobl€m.
U. Check f servo
stopper cap
is installed. f it was not installod, h€ check vave may have been
pushed
(internal)
tfectinq
sllforward
qears.
or
proper
operationof
shift
points
quality
will
resuh
b6ing oo low for th6 amount of engine orque nput
into the trsnsmissionand m8y
n too
high hrottle
orque
Throttlc
porhlon
Fu[throttlo
-8 6
F22Al Engln.:l Da
of'l
{cont'd)
Throftlo
porhlon
km/h
2'
26
grldo,
wlnd,
oic.
grada,
26
km/h
14-69
.Downsh i f t
14-'17
km/h
1
8-
22
4thJzd)
grado,
grade,
117 127
km/h)
lE+-J
Park
car
not move.
5. Check
n the following
r clutchslippago.
position.
[7
(2nd
hat there s no abnormal
oise
or
n his
or mors than 1O ocond! at r tlma,
.
.
2, Connect
4. After the enginehas warmed up to normaloperating empersture
(the
6.
loil,
[Tl
n
L91l
lst
gesr
one-wayclutch
stallrpmow "
[D;l
.E ,
f
a.a
opsrsting emperaturs
{yellow
3. Insert hs diDstick nto
th€
trsnsmission,
shouH
DIPSTICK
DIPSTICK
YELLOW
OOPI
I
A
Ell-
UPPER
LOWER
below the lower mark,
add luid into tho
14-72
ChEnglng
normal
car.
ground,
paee
thon
dipstick.
'
th6
TOROUE: 18 N.m
Botora oltlng, bo surc tho tra]lmirlion fluld lr flled
to tho
connect a tachometer.
partlcl$
-
N
or
E
position
NOTE:
Highsr
rossures
FLUIDPRESSURE
-3.
rom
the throttle control lev6r and set the throttle control l€ver n full throttle
position.
THROTTLE
PRESSURC
totatlng front wheals.
and
support
-4,
{8.0-8.5
kgy'cm'
114-121
securety.
-2.
-3.
the
unhook the
temperature
the
position.
-7.
and record the
throttle control l6v€r
possible
FLUIDPRESSURE
(5.3-8.5
ksy'cm,
75-121
psi)
damaged
wirlng.
NOTE:
The
speedsensor/power
21 .
r
SELF.LOCKING
UT
Roploco.
rY
od.
rsmovo he shift
cablswith the controllsvsr.
whils
30.
SHIFTCABLE
DRIVE
PLATE
31.
Plsce
8
jack
transmission
ack.
TRANSMISSION
OUSING
I x 1 .25
Joint Boft
14-89
18
N.m
1.8
8
x
1.25mm
14-91
each shaft locknut
press
idlsr
gesr
is
cleansr
housing, roplace he
see
page
14-94.
g€ar
go8r,
reverse
gear,
the countershaft and
4. Remove the lock bott socuring he shift fork, then
romovs ths fork with tho rav€rse
s€lector
from the
8nd
6.
Romove
.
.
servo
2.
securing
NOTE;
prsvsnt
s€rvo
unscrewing he
removs he
sarvo body
body,
then
soparator
plata.
8.
then remove
he rsgulator
arm, thsn
converter
housing.
shalt from the
th6n r€move h€ mainvalve body.
Remove he
Remove he oil
marks. Use
the ATF-
ATF-soaked
60O
paper
and
valve.
Twist
and secur€with ths rollsr.
VALVEBODY
ROLLER
Sst the spring n the valv6 and nstallth6m n tha valvs
body. Push th€ spring in with 8 scrowdrivor, th6n
instsll he springssat.
installedwith
with th6 smsller ip toward
th8 inside ot the
body.
guide.
oil
pump
driven
gear
oil
pumD
drive
and
driven

ir. Blow out all
f any
f any ail to slide
reely, seeVafueBody
MODULATORAIVE
CPCVALVE
SEAT
\n
U
SHIFT
3-2
o
fail to slide reely, see
Vave Body Rep8ir
h may magnatizo
LJ
V
U
l-l
-_\)v,
CHECKSALLS
CHECKBALLS
O
f any
Valve Body Repairon
2.
with the hole n th€ valve
body; hsn
REGULATOR
SPRINGCAP
STOPPER
OLT
12 N.m
Cleanall
parts
horoughly n solventor carburetorcleaner,anddry with compross€d ir. Blow out all
passagas.
Repair
on
page
14-98.
parts
THROTTLE OI{GVALVE
comprsssadair, Blow out all
CAUTIO
to temoya the cfiack bal!; h may megnotlzo
tho bals.
or
galling
prevent
2NDGEAR
REVERSEELECTOR
CONICAL
SPRINGWASHER
RsDhca.
REVERSE
SELECTOR

with tape to
gear
collar,
gaar,
one-way
clutch,
hrust
3rd
gaar,
then
press
press
to
provant

prying
Ireelv.
or
galling
BEARII{G

he direction
free of dirt or
sDecisltoolss shown,
the housing, sing he specialtoolsas shown.
ATTACHMENT,
62x68mm
07746-(xrlos(x,
DRIVER
07749-OOl(xXX'
3.
toolas shown.
![de hammai
specialtoolsas shown.
bearingby heating he
bearing alls
(1OOoCl.
specialtools
s
shown.
DRIVER
07749-OO10000
BEARING
O-0.03
mm
(0-0.01
n)
2.
5.
OILGUIDEPLATE
14-128
HOUSING
and secondary
t's necesaary o
Push he bearingdown
into the transmission
groovas.
.
2 Bohs
2 Bohs
ATF STRAINER
SERVO ODY
pumpgears
ndoil
pump
driven
ear
haft.
NOTE:
Install he main vafue bodv whh tour bohs. Maks sure
the oil
operating direction and oil
directions.
shatt do not move treely, oosen he main valve body
bohs, realign he oil
CAUTION:
pump
drlva
getl
01
oil
pump
driven
gear
shalt.
OILPUMPORIVEN
GEARSHAFT
OILPUMP
DRIVEGEAR
Installthe
bodv with seven bohs.
main valve
spring
Install h6 oil fosd
the 4th 8ccumulator
Install he servo dotont base with two bohs and new
lock w8shers.
REVERSEELECTOR
14
N.m
1.4
kg-m
transmission housing
convert€r housing.
(5.5
kg-m,
rlo
n
the
pattern
shown.
gesr
12 N.m
shaft,
loosely with
,Adlafu
ge81
while
14 N.m
' l
- T r
on
psges
14-142
and143.
housing, nd
pins
n
DOWEL IN
jack,
mountingbohs and ntake maniJold racket botts.
Roplaca.
BRACKETBOLTS
tighten the nuts to
plats
with
75 N'm
on the
control shaft,
ho shlft cEHo.
11 lnstall he lock boh with a new lock washer, hen bend
ths lock tab.
14 N'm
rubber ushings.
be8m.
12 N'm
NOTE:
When
installing
crimped side ot the ring terminal is facing out
(see
Connect the
connect the
29.
parking
(see
I
or
I
P
I
position,
34.
pages
glasses
beforeusing.
It
wear
or
il lthe tank with 21 ounces
(approximately
3
full)
of
biodegradablelushing
luid
(J35S44-20).
pressurize
kpa
5.
lineot the transmission ooler
transmission ooler using
bucketor floordrain,
valves oft, attach
the wat€r
completoly
plugged.
annot
luid into thg
1S
(8.45
you
to rinss the
13.
14. Turn he air
out with airJo r
two Jull minutes or
16.
lposition.
0.95 0
return
hose o the transmission.
Refil l he transmission ith ATF to t he orooer evel
(see
p89e
ino to
the orifice may be
side and
ll
DArtS.
14-143
12
N.m
1
kem
12 N.m
COTTER
IN
Rspbca.
removal,
the short connector
it
h!3
,,J:::$
ature the
with the th.ottle
the throttle
THROTTLECABLE
trom tho throttls

bear ing u te r
race
.
preload
.
rotation. f tapered oller
Dr ive he tapered o l le rbear ings n
unt i l
ATTACHMENT,
otl
sEAt_
Replace.
1 .
2 .
CLUTCHHOUSING
ORIVER
07749
OOl(Xno
07715
(X)10400
BEARING
OUTEF
RACE
THRUST
SHIM
:'----J)-4
07746
replaced,
ac e
hi m
1. Remove he bear ingouter raceand th rus t sh im
from the ransmission ousing
ing outer rrco wls drivcn out,
NOTE:Let he transmission ool to t he room tem-
perature
f
oller
bearing
reload.
2 . F i rs t ry the same s ize hrus t sh im tha t was re -
moved.
THRUSTSHIM
I
TRANSMISSION
OUSING
C
install
he
.
Check ha t there s no c learance e tween
bearing uter
Wi th the mainshaf tand countershaf t emo '
ins ta l l he d i f fe ren t ia l ssembly , nd to rque
clutch
housing
('1.5
kg-m, 20 b-ft1
NOTE: t i s no t necessaryo use sea l inga(
betlveenhe housings.
to seat
STANDARD:
both directions.
directions
r decreaseapered
1.90mm
(0.075
n)
B 4 1 3 8 2 - P X 5 - 0 0 0
1.93mm
(0.076
n)
c 4 1 3 8 3 - P X 5 - 0 0 0
1.96mm
{0.077
n)
4 1 3 8 4 - P X s - 0 0 0
'1.99
mm
(0.078
n)
E
41385-PX5-000
2.02mm
(0.079
nl
F
4 1 3 8 6 - P X s - 0 0 0
2.05mm
(0.081
n)
41387-PXs-000
2.08mm
(0.082
n)
H
4 1 3 8 8 - P X s - 0 0 0
2.11
mm
(0.083
n)
4 1 3 8 9 - P X 5 - 0 0 0
2.14
mm
(0.084
n)
J
4 1 3 9 0 - P X s - 0 0 0
2.17
mm
{0.085
n}
PX5-000
2.20mm
(0.087
n)
L
4 1 3 9 2 - P X s - 0 0 0
2.23
mm
(0.088
n)
M
4 1 3 9 3 - P X s - 0 0 0
2.26
mm
(0.089
n)
N
4 1 3 9 4 - P X 5 - 0 0 0
2.29
mm
{0.090
n)
o
41395-PXs-000
2.32
mm
(0.091
n)
P
41396-PXs-000
2.35
mm
(0.092
n)
4 1 3 9 7 - P X 5 - 0 0 0
2.38mm
(0.094
n)
R
4 1 3 9 8 - P X s - 0 0 0
2.41mm
(0.095
n)
4 1 3 9 9 - P X 5 - 0 0 0
2.44mm
(0.096
n)
pre load
ub t rac t
sh im
f ive
sizes hicker
han standard
lush with the transmission
Attachment,
' t .
P lace he d i f fe ren t ia l ssembly n V-b locks
installboth axles.
gears.
Standard
Nowl:
select
ew
pinion
washers
rom
P G I
- 0 0 0
000
4 1 3 5 6 - P G l - 0 0 0
41357
PG1
000
rough rotation.
s not necessary.
Remove he taper
bottom.
bearing.
smallend
or
transmission
ousing
as a set.
reload
whenever
s
no
carner.
15-14
ferential arrier.
side
gears,
of equalthickness.
tableon
page
15-14.
5.
It sti l l out of tolerance, eplac€ oth hrustwash-
ers.
lf
sti l l out of tolerance. eplace he side and
pin-
ion
gears,
ory.
gear.
TRANS|sstotrl
HOUSI G
housing.
1 .
from the ransmission
when tho outer
.
room tempera ture e fo re
ad jus t ing he bear ing
preroao.
HEAT
GUN
below so that
adiust tho bearing
(0.087
n)
B 4 1 4 4 2 - P K 4 - 0 0 0 2.25
mm
(0.089
n)
4 1 4 4 3 - P K 4 - 0 0 0 2.30mm
(0.091
n)
D
4 1 4 4 4 - P K 4 - 0 0 0
2.35mm
(0.093
n)
E 4 1 4 4 5 - P K 4 - 0 0 0 2.40
m
(0.094
n)
F
4 1 4 4 6 - P K 4 - 0 0 0 2.45
mm
(0.096
n)
G
4 1 4 4 7 - P K 4 - 0 0 0 2.50
mm
(0.098
n)
n
4 1 4 4 8 - P K 4 - 0 0 0 2.55
mm
(0.100
n)
4 1 4 4 9 - P K 4 - 0 0 0 2.60
mm
(0.102
n)
J
4 1 4 5 0 - P K 4 - 0 0 0 2.65
mm
(0.101
PK4-000
2.70
mm
(0.106
n)
L 4 1 4 5 2 - P K 4 - 0 0 0
2.75mm
(0.108
n)
M
4 1 4 5 3 - P K 4 - 0 0 0 2.80
mm
(0.110
n)
N
4 1 4 5 4 - P K 4 - 0 0 0
2.85mm
{0.112
n)
o
41455-PK4-000
2.90mm
(0.114
n l
4 1 4 5 6 - P K 4 - 0 0 0
2.95mm
(0.116
n)
4 1 4 5 7 - P K 4 - 0 0 0 3.00
mm
n)
R 4 1 4 5 8 - P K 4 - 0 0 0
3.05mm
(0.120
n)
outsr race,shim and t
of the d i f fe ren t ia l
assembly
ith
wrench.
STANDARD:
will
give
increase
he
torque,
con-
.
converter ous-
ing side.
raceand bearing.
Ins ta l l he new bear ing u te r
ace lushwi th the
us ing he
DRTVER
07749
00ltXXtO
nto
TAPERROLLER HEATGUN
cracks,damage,
leaking
grease
or
loose
he boot.
Spline Looseness
and
oint
are
not
excessivelyoose.
he inboard
twisted or cracked.
nut
is
he ball
past
he
groove,
joint.
pry
with a screwdriver nd raise he end of the band.
CAUTION: Tak€ care not to damage he boots.
NOTE: Carelullv clamp the drives haft n a vise
with solf
heiroriginal
positions.
STOPPER
ING
Wrap he splineswith vinyl ape o
prevent
damage
IADE.
OUTBOARO
OOT
groove,
markson the spiderand end of the driveshaft .
Fit he circlip nto he driveshaft
roove.
SPIDER
STOPPERRING
CIRCLIP
b
crease Ouantity.
facing outward.
ginal posilions
g
(O.O4-O.O5
oz)
of the
onto
the
driveshaftor
in -
th6 drivoshatt is
rderof removal.
07746-OO10400
HUB
DIS/
oTGAF-SD40700
2.
Seat
he
. . . . . .. . . . . . . . .
. .
ys tem
Troubleshooting
(Power
Steering
System)
Troubleshooting
4WS)
o c a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connec tor oca t ions , . . , . . , . . , . , . . . . . . . . . . . . . . . .
Cilcuit Diagram
. . . . . . . . . . . . . . . . . . . .
Diagnostic
ioubleCodes
DTCsl:
Diagnostic
Diagnostic
rouble
Codes
DTCsl:
DTC} :
1
7
5
FluidReplacement ,..,..
17
77
P u m p r e s s u r eh e c k . . . . , . . . . . . . . . , . . , , . . , . , . . .7
7
lay . - . . . . . . - . . - . . .7 -79
Power Assist Chsck
Power
Steering
7 - 8 1
SteeringColumn
R e m o v a l. . . . . . . . . . . . . . . . . . . 7 - 8 9
fnsoec t ion
7 -93
SteeringPump
Beolacement
P u l l e y e p l a c e m e n t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Valve
ValveBodyUni r
. . . . . . . . . . 7 -106
ndex . . . . . . . . . . 7
117
O v e r h a u l. . . . . . . . . . . . . . . . . . 7 - 1 1 8
fns ta l la t ion
. . . . . . . . . . . . . . . .7
134
R e m o v a l. . . . . . . , . . . . . . . . . . ,
7 - 1 3 8
. . . . . . . . . . . . . . . . . .7 - 1 4 1
144
1
5
- . . - - . . . . . - . . - . . - . . - . . .7 -146
Sub
1 3 2
17
120,
123
17
' t
3
o
/g)
\Z'cfp
Frontsteering
Rearactuator
emoval/installation
Front
On modelsequipped
ower
4WS system o be sure hat it is electronically nd
mechanicallyn neutral
mm/O.02
nl .
{2)
eutral:
position.
Electronic
eutral
position
traight, heckwhether
t was
misalignment f the lront and
rear wheels. Check he
n
correct
earmainsteering nglesensors, nd he
grease.
a
Thephrase
the
n
horizontal
ngle.
a
he engineand urn the steer-
ing wheel ully right and
left
is OFF. When the engine
is
staned,
front whoelangle. We recommend hat the
steeringsystem
lock
pin
sot
in
the
might be damagedwhsn the
lock
Din
Component
Location
Index
(2WS/4WS)
NOTE: lf an intac t driver's airbagassemblyhas been removed rom a s crapped
ar or
see
section
23}.
STEERING
WHEEL
Removal
2WS/4WS).
page
17'81
Disassembly/Reassembly,
age
17-83
Installation
2WS},
page
17-84
Installation
4wS},
page
17-86
STEERINGCOLUMN
Removal,
age
17-89
Inspection,
6ge
17-92
Installation,
age'l7-93
gearbox.
piston
regulatinghe strokeof the 4 wa y
valve.The operation
t the
pressure,
pressure
ontrol
valve,sensororifice
and
power
reference
ressure
pressure
the
pressure
of car. This
gain
controlvalve.Theseorifices
ro-
The reduced
regulating he luid
reservoirhrough he cooler.
VALVE EODY UNIT
toward the discharge
their or iginal
posi t ion
the discharge
the
the
orifice.
When
pressure
builds up, it
compartment. he
fluid and
the filter/reservoir
Holder s a
n
the
4-way
valve.
the steeringwheel
pinion
holder
pin
nsutral.
leel by increasing esistance t lef t and right ock.
Control
n
"assist"
hydraulic
ump
gear
response to the car's speed.
Bv introducing
PRESSURE ONTROL
Theretore he
reservoir ide,
fluid
s in the
reduces
he
pressure
power
are connected
that
he rearwheels o be
set at any desigrated
urning
angle,
rearwheels.
(System
power
detected y the rearmainsteering ngle ensor,
nd
the
rear
ed steeringangleof the rearwheelsand
rearwheels
n
he
higher peed,
directionas the front
ives
wheel s rotated.
s
mountedat the rearoI the car o steer he rearwheels.The motor,built nt o he actuator, s made
up
mountedon the sameaxisas h e steering haft
screw,
anglesensorand
electric
wheels o the straight-ahead
motor.
REARSUBSTEERING
ANGLESENSOR
ACTUATOR
HOUSING
STATOR
ANGLESENSOB
RETURN
PRING
screw
moves o right or lef t. When the motor is OFF,
the stesringshaft screw
f it is below
lug .
i l i s
he
he
plug
anglesensor
The front sub steeringanglesensor s mountedon the
front stgering
The front sub steering angle sensor uses a spring-
loaded
plunger
groove
tront
sub steering angle
o change teering
17-22
n
this
slowly o
DTC)
indicator ight o notify
heck connector er
wire
under
he dash.The code s readas blinksof th e 4WS indicator iqht.
4WS INDICATOR
osition
spunby the
movementof the steering haft.This causes he motor o ac t as
a
generator.
he
voltage
generated
y
this
This
causes
forceot the returnspr-
ln other
words , thesYstem,s ' ron tandrea lsensorsmustS igna | tha t thewhee|sarepo in teds t ra igh taheadwhenthewhee|sare
mgchsnically
ointed
straight
ahead.
The
a
a
proper
evel?
a
no assist
4 way valve
Repair s necessary.
l{ there are
no bubbles, check
ing, and
clean or
replace as
with the
speed sensor
Air in reservoir
and sealson both ends ot
the
pump
pump
housing
mating
surfaces
w i t h
f the J low
OK, rep lace
ga in
un i t and
transmission,
he
In io
on e
b o t h
s i d e s a r e l e a k i n g .
T o
troubleshoot, remove
both boots,
s e e
he
gearbox
s e e
valve body or
Replace
he
valve
body.
leaks, replace
Reservoir
Pul lo l t
from around cap,
L e a l r n g b e c a u s e
o l
delef ioralron,
leaking.
the
prpe
or
vaive
theft
protection
circuit.
Be
sure
o
get
the
customer'scode
numberbetore
12PCONNECTOR
27 28
1 6
1 1
2 4 2 5 2 6 2 8 2 9
1
3
4 6 7
t 0 12
1 3 1 4 l 5 1 6 1 7 1 8
con-
nector
con-
nector
No.
Wire
20
GRN
Rearmain
steering
anglesensorZ
phase
While
actuator
motor
DC
approx .
3 .0
2 9 1 7
ground
The normalvoltage s the value when the system s working
properly.
17-35
under-hood
use/relay
ox
central
processing
(CPUS)
hen repeat he cycle.
both CPUs
urning OFF he
once.
7-36
Precautions
(DTC):
The DTC s memo.izedwhen the 4WS cont rol unit detects an abnormality,
ven f it was a temporarycondition.To
troubleshoot, sk
4WS ndicatorightcameon, and ry to duplicate
thoseconditions
not
come
not
continue
rocedures
harness.
tc .
problem,
ignition
RA-
DIO
(10
use/relay
ox.
It
a
problem
part
of
ight.
NOTE:
temporary
problem
ystem, t cannot
be canceledby simply
DTC s 71 72,
these codes
iumoed.
TemporaryDrivingconditions:
4WS control and
straight
driving
O N
7 1
The car
by
parking
brakeON .
snoorng
ON and
pul l
use
110
tw€€n rhe No. 13 METER
uso
110
Al
.nd
f u s e O K ?
{To
page
(1 0
A) in
s the
Pf{K wlrc! b6-
twcon
(Frompage
17-43)
Measure
tho
unh
and
dlc.tcd.
anglesensor onnector,
Measure esistancebgtween the
he
(To
page
17-46)
17
45
sonsor.
12P
connector.
controlunit and body
th€ tront sub
4WS CONTROL
sor
12P connector.
4WS
controlunit
No.
tho sub steeJingangle sensor.
SENSOR IDECONNECTOR
gle
measure oltage
etweenNo. 22
List6d Voltage?
Analog ester
AC range
/-\rFP /z\ -r_
\"/ \"/
\
I
.4 -
.4
he
4WS
conlrolunit
12P connector.
R6pairopon in tho GRY wir6 b6-
twoon the
4WS
sor
Check or continuity between he
4WS controlunit No. 29 terminal
(GRY)
YES
RoDair
hort
View from terminal rde,
4WS
sor connector No. 3 terminal
(GRY/BLK)
4WS
hw€6n the 4WS controlunitsnd
tho rotr
{GRY/BLK)
Ropair
op.n
in
th€ roaasub
are
indicated.
and tho tront main stoeringangle
sonsor.
4WS controlunit
18P
connector.
4WS
and
aonsor.
18P
connector.
the front main sloo.ing anglo
DiagnosticTrouble
Codes
DTCsl:
20,
the sen-
sor connectol
Connect he 4WS control unit
18P
connector.
Ropair
opon
and
No. 1 terminal
and the reaamain
4WS control unit side No.3 termi
nal
{WHT/GRN}
w
Continuitv?
p
R6pai.op.n in the BLU/GRN
tho ioaa main
)
the rear main
{To
page
17-62)
been memorized
checker.
he
4WS
controlunit.
4WS
CONTROL
View from terminal ide
tho vohicle
Does the speedometer
l9 terminal
wh€
4WS
Measure
botwoon
tha
4WS
View from terminal sade
indiclt.d.
Stop
trom
wi?o
bltwa.n
4WS CONTFOLUNIT
18P CONNECTOR
View trom
terminal ide
Troubleshooting
4WS)
Diagnostic
roubleCode
DTCI:
33
NOTE: Problem ode 33 is memorized hen the front wheelsare urnedat a
speedot 30 km/h for 2 minuteswith the
lront wheels
3
V
V
(pag6
'19-541
-The
Stop he engino.Then urn the
ig-
the
4WS
unit
car,
if
th6
DTC
doos
18P
con-
iro.
lh6
POWER TEERING
N
(35-70

it
oft
20
locknut o about25
see
page
from
the
ensorwire harness
4. Loosen the rack
25 N.m
17-76
2. Connect
th e
he shuto f f va lve u l l y .
Open he
Close he shut
pressure
control
valve
gradually
lmmedia te ly
pen he shuto l f va lve u l l y .
CAUTION:
valve
closed
gauge
pump.
VALVE
l
posi-
wheel
tires begin
o turn.
SPRING CALE
The scaleshould
bypass
ube
oint.
on
tires begin
o turn.
POWER
STEERING
idling o bleedair
rom the system.
impropelly stored
cause
sedous
injury.
CAUTION:
a
Eefore
parts.
a
Caretully
remove
with the
propol
assemblyhas been
ound
defec-
that shows
impropo.ly
when the
bag assembly.
ment mark
for
with the alignment
the
col-
ngle
system
rearwheelsareat the
to
properly
ment
The arrow
with
the
column
and
left
center of the
the straight
Dins
(i.e.
as
tollows.
1)
spokesat a horizontal ng le.
2) Turn he steeringwheel until
he mark s facing
push
wneet.
FRONT
pos i t i on ,
be ing ca re fu l
no t t o make i t
o f f
A l i gn he
ho le n t he s l ee r i ngwhee l w i t h t he
p in
reel.
a
A l i gn t he s tee r i ng
whee l w i t h t he se f i a t i ons
wh ich
makes the spoke ang le c l oses t t o
ho r i zon ta l .
CABLE
REEL
horizontal,
then
push
the steer
when
pushing
and rea r whee l s o r
a l i gnmen t
and
perform
column shaft ol the car.
When the
at tho olectrically
spociliod
installation
position.
assembly it has an open circuit or damagsd
wiring.
NOTE:
protection
cir-
cuit.
adio
oDeratlon.
whee l
mechanism
or
proper
movement
and
damage.
17-92
enginecom-
partment
steering haft,
steering
oint
an d
angle sensor
(4WS
on ly ) ,comb ina t i on w i t ch assemb ly nd u rn s i gna l
cance l i ng l eevew i th a c i r c l i p .
NOTE:
a
Be
a
A l i gn he s l o t s n he t u rn s i gna l
ance l i ng l eeve
w i th t he t abs on t he f r on t ma in
s tee r ;ngang le
sensor ,
FRONT
TURN
SIGNALCANCELING
SLEEVE
FRONT
UPPER OLUMN
11. Ins ta l l he s teer ingwhee l
and dr iver ' s a i rbag
assembly
see
age
Pu l leY
hreads .
UNIVERSAL
OLDER
07725-O030000
PULLEY
UT
Left-hand
hread
Reinstall
he
th e
edgesof the
pump
and out smoot hly.
he flow control
d I
(o .7083-O.7085)
1 7 . 9 9 6 -1 8 . O O 1
(o .7085-O.7087)
the tlow cont rol
um. Be careful not to damago h€m
wh6n
sorvicing.
O.RING
Replace.
SIOEPLATE
ROLLER
he
press
and
special

not to damago
hem when servicing'
n
place
rease
{Honda
/N
08733-Bo7oE) .
pump
and 54 x 1 9
mm O-ringson the side
hole n
on the
the
side
plate.
5
the
"O"
groove
vanes s
in contact
,,O"
" : "
Apply clean
mm
68.5 x 1 .9 mm O-r ingon the
pump
cover.
€--=.-
emove he
the valve body unit, its l ines,and that
end of
Jrom
he
8: To
C:
D: From
mm flangebolts,
2. Remove he cap seal rom the valve body cap.
Remove
he
pressure
ontrol
valveandvalve
p lay .
slides
pray.
and then the other.
.om
the
sure
it
slides
body, and
valvebodyunit
(valve
body,
pressure
ontrol
valve,
gain
oriJice nd 3.4 m O-ring,
1 4 .
a
a
e€al
pl8cs,
unit
(valve
body.
pressure
ontrolvalve,
gain
control
valve,
with
power
steering
luid,
and
install
plungers,
cap.
1O. nstall he valve body cap on the valve body with
6
valve body and cap are
flush
VALVE BODYCAP
{cont 6
power
steering
steeringwheel
warm
lsee
page
17-771.

the ball
ball
oint
remover.
Separate
beam.
wrench
wrench
cover, hen remove
tie so
15. Remove
Pull the steering
rom the bulkhead.
Move he steering
Hold he steering
below he
remove t from the car.
CAUTION:
power
emove he
RACK
GUIDE
4WS:
5.
gearbox.
wrench
LOCK
WASHER
bolts.
Remove
p.ess
pinion.
housing.
damaging he
good
90
f
dirt
has
gonepast
pinion
holder.
PINIONHOLOER
I
GEAR
{OUSING
a
Check
O.RINGS
Replace.
SEAL
RETAINER
(cont 'd r
cylinde. nd seal.
the seal retainer
the cylinderhousing,
the steering rack
Screw each rack end
holding he lock washerso its tabs are n the slots
in the steering
wrench
COMMERCIALLY
VAILABLE
DRIFT
(Roll
rack
end.
qamps.
oint
piece
i.e.
stroke.
guide,
off
about
20
special
ool
guide
screw.
LOCKNUT
RENCH,43
m
RACKGUIDE
CREW
4WS:
groove
n
the
front
so that the
onions
a
When
damag€ the
cenain hat
the bootsare
LOCKING
RIGHT
Pass the
gearbox
assembly
Raise he
Loosely nstall
brscket
points
toward
7. Posi t ion he s teer ing ack centerof
its
strokes.
l5 0
reel
position
with
indicator.
a
yellow gear
mark
oint
groove
around
oint
bolt.
NOTE:
a
Connect
the
groove
n
the
pinion
shatt.
BOLT
HOLE
STEERING
OINT
STEERING
the stesring whesl
with the engine
60
see
age
17-77) .
shaft.
17. Install he exhaust
gasket.
Us€ the spocial ool
when removing the rear stee ng actuator. Tho special ool should remain nstalled
excopt whon
a
rear
lf the actuator is taulty, roplace t a3 an assembly.
a
st6o.ing
and adiustmont
ot the raar sub stee ng angle sensor aft€r installing hs rear steering actuator.
a
pin
5O-60
in the
tion
(straight
aheaddriving
position)
st€ering
the ste€ring
ing, the rear 6te€ringactuator
will
oporate,
damag-
ing
th€
oint
pin
pi n
Remover.
ball
oint
.emover.
Separate
nut with
TUBE CLAMP
tween the actuator
ool toward the
5. Hold he shaft screw end with the spscial ool
and
RACKEND
1/2
8 .
steeringangle
sensor.
REAR
the special ool be-
toward the housing.
snown.
55
the
groove
tightoning the
the
tlats
Install he b oot band so that th€ locking abs
oJ
LOCKING
TABS
RIGHTSOOT

NOTE:
a
{see
section20}.
grease.
pin,
hen
pack
th6
pin.
a
mat€rials o onter the
boot.
2 .
BOOT
NSTALLATTON
SECTION
and
TAPERED
4. Insta l l he new ball jo lnt boot us ing he specia l ool
as shown below.
oint,
apply
TIE.ROD
END
CAUTION:
ball
pin
tapered
section
fol
grease
shut
down
lully right
Be sure hat he steering
wheel
spokeangle
s
at
aneao.
Be sure hat the rear wheels are not st eered
to
in
imately3OOmm
{1
For
ront
(BLU
2P )
minalswith a
position
when
display-
ing
stored
problem
codes.
a
nition
in the insoection
position,
he
straightaheaddriving
position.
to
the
right
(1O,4
as
To determine hat the 4WS indicat or ight s oo
and
light
-
ed range on the steering
wheel
(see
page
(cont'd)
17-147
several imes
steeringwheel.
parking
13. Turn the ignition
-
-
(see
page
by hand,
ON when
range.Take care
The 4WS indicator ight might look as it it is
blinking
where
a
remove he
the turning
serration
to horizontal.
ment is completed.

sensors s-
be low
shown in the
in
point
near
the
*3:
steering ngle
scanceled.
*4:
properly.
adjust
not
ad -
iusted
properly,
a
psge
17-153.
a
NOTE: The rsarmainsteering ngle ensor annot
be
adjustsd.
is sbnormal, emove t and check t tor damage.
Sub Steering
steering angle
steeringangle
1. Jack up the ca. and raise all four wheels
off the
proper
oca-
(BLU
2P )
the
oosition
cover
CAUTION: Uso car6
by
hand, back t of f abo ut 3/4 turns and connect he
connector.
position
un -
clockwise. and c heck the
range Jrom where
he front sub steering nglesensor.Repeat
the step 11 s everal imes to set the sub steering
angle
range rom
srops.
wire.
the range: t18
ing anglesensorwire harness
with the clamp
does not in -
connecting
t.
17.
tie.
RearSub
SteeringAngle
Sensor
connector
(BLU

steering
anglesensor
anglesensor.
neutral
steeringactuator.
Camber . . . . . . . . . . . . . . 8 -5
Runout . . . . . . . . . . . . . . 18-9
Front Suspension
.... . . . . . . . . . . .
ndex . . . . . . . . . . . . . . . . . . . .8 -11
Replacement
. . . 18-15
r
I
ra-ro
1
r
I
ra-ra,
r
J
7
1
I
{--ru
:,.--l
I
H
| l
tr
or
damaged
sus-
pensron
omponents.
Rear
2wsl:
for
damaged
the adjusting bolt
position.
eading,
o
step
gnment
equipment.
:aster
rgle s adjusted.
place
(page
18-19).
e
d the casterangle
(O.1
re adjustment.
Check
straightahead
posation.
a After adjusting.
ighten he tie-rod
the turning
3. Turn the
wheel right and
re
45 N.m
the aluminum
hub and inside ot tbe brake disc.
a Before
remove
o
push
it
away
x
debris
in
your
oyos.
Remove
pin
oint.
Besure
hat
oint
pin
joint
pin
18-14
oint.
special
bea.ing
separalor.
solvent b€fore
press,
praaa
DRNE'
I
avoid
10 N.m
NOT€:Betore nstallinghe wheel,clean he mating
surlace
of
nuts.
43 .
{11
kg-m.
to turn
ho nut
DAMPER
FORK
NUT
{SELF-LOCKING
UTI
glound
bstoro any bolts or nuts conn€ct€d to rubbol mounts or bushing are
tightened.
NOTE:
at the ball
8re
not
with
"SL"
are
not
markedwith
"SR".
a
he
"FR"
car.
SELF"LOCKING
UT
'12
Align
DAMPERFORK
SELF-LOCKING
UT
CAUTION: Do not
grease.
pin.
a Do not allow dust. dirt, or othor toreign mata.i-
als to
Lowerball
oint:
iusting
bolt
position.
4 .
BALL
JOINT
BOOT
CLIP
GUIDE
ar m
arm.
SOCKET
BOL
hose mounting bolts
he
spring.
hrough a
DUSTCOVER
OAMPERUNIT
the spring
damper
ork.
NOTE:The boltsand
nut.
Secure
flange
nuts.
connocted o rubbor
mounls or bushings
OE
.m
16.5
50-60 tl.m
may
Before nsta lling he brakedisc, clean he matingsurfacesot the rear
hub
surtacesof
SELF-LOCKING
OLT
10
the spindle
Removehe caliper r acketmounting
pisce
ot
lrom th6 und6.-
arm
B
(2WSl
SEI.F.LOq(NG
IUTS
sensor, wheel sensor wire
unit and
spindle washer
on the
185 N,m
nuts
afte.;emoval.
you
nut
past
thoir
(O.1
kg-m, O.7 lb-ft) of torque to turn the nul on tho bolt).
a B€ caroful not to damage he balljoint boots.
SELF.LOCKING
UT
Replace.
Roplace.
{4wS
only)
bo
B is identiJied
are not symmetrical.
The left upper
arm is marked
65 N.|n
55 N.m
soctlon
with
giease.
Pack
grease.
als to ont€J he boot.
4. Install
balljoint
boot
clipsusing
th e
oint.
position.
pin
dimensionof the lower arm bushing.Press he lower arm
bushingusing he special ool and a
press.
arm.
Pr9!a
t
BUSHITIG
RIVER
on satety stands
COTTEB
PIIT
Replaco.
BOLT
9.
10.
Lower th8 raar susp€nsionand remov€ the dampgr
assemblv.
pressor
noceaaary o
the
a full stroke.
gas
compressor.
AssemHe he damper n revsrse order of disassem-
bly except
and sel{-
Position
with
stall he new selflocking nut.
Hold he dampershaft and tighten
he
self-locking
nut .
6 .
a
<LEFT:>
<RIGHT:
7 .
Raise
65
N.m
16.5
kg-m,
f neces-
gas
to
provent
ed and dr i l la
ho le
o t
{0.O8-0 .12
n l
d i -
gas.
PedalHeight
Adjustment
.... . . . . . 19-4
ParkingBrake
Adjustment
.... . . . . .1
9-5
Front Brake
1
Thicknessand
Parallelism
RearBrakePads
Thicknessand
Parallelism
Rgmoval/lnstallation,
sge
19-13
MastsrCylinder,
age
19-14
BrakgBooster19-15
PARKINGBFAKE
Adjustmont,
pago
| 9-5
Diaa$embly
p6g€
'l
oosen
he
brakeswitch
ocknut
pedal.
center
(with
AB S
BRAKE
swtrcH
4.
Screw
in
the
pedal
arm). Then back otf the swit ch 1/ 4 turn to
make O.3 mm
threadedend and
go
oft
play
by
pushing
he
pedal
PAD
19-4
bsnmrr
drag
of the rear brake
se e
a
a
CAUTION:
a
Do not spill brake luid on tho car; it may damage he
paint;
passages
particlas.
a
Replace
parts
a
Do
a
tluid.
NOTE:
a
Coat
piston,piston
a
-ffi:
Brakecyrinder
rease
P/N:
08733-Bo2oE)
10 x
' l .O
assemblies.
a
Remove
he
front
wheels.
pads
(O.49
n)
check
or
grooves
pads.
pads.
own nto
pads
ass€mbli9s.
paint,
and disconnect he brake
hose rom the calioer.
caliper.
SEALING
WASHERS
Replace.
CALIPERBOLT
19-9
4.
paint,
loroign mattor is
Do not mix different brands ot brake tluid as they
may
not
be
compatible,
a
luid.
and inspect
groove.
pads
in
sealingwashe

Documents

Service Manual 92-96_lude