CIVIC 4/5D MAINTENANCE, REPAIR & CONSTRUCTION 01 · 2020. 4. 30. · MANUAL CIVIC CIVIC 4/5D...

SERVICEMANUALCIVICCIVIC 4/5DMAINTENANCE, REPAIR &CONSTRUCTION 01

How to Use This Manual

How to Use This ManualThis manual is divided into 23 sections. The first page ofeach section is marked with a black tab that lines up with itscorresponding thumb index tab on this page.You can quickly find the first page of each section withoutlooking through a full table of contents. The symbols printedat the top corner of each page can also be used as a quickreference system.Each section includes:1. 1. A table of contents, or an exploded view index

showing:Parts disassembly sequence.Bolt torques and thread sizes.Page references to descriptions in text.

2. 2. Disassembly/assembly procedures and tools.3. Inspection.4. Testing/troubleshooting.5. Repair.6. Adjustments.

Safety MessagesYour safety and the safety of others, is very important. To helpyou make informed decisions, we have provided safetymessages and other safety information throughout thismanual. Of course, it is not practical or possible to warn youabout all the hazards associated with servicing this vehicle.You must use your own good judgement.You will find important safety information in a variety of formsincluding:

Safety Labels - on the vehicle.Safety Messages - preceded by a safety alert

symbol and one of three signal words,DANGER, WARNING or CAUTION.

These signal words mean:

DANGERYou WILL be KILLED or SERIOUSLY HURT if you donot follow instructions.

WARNINGYou CAN be KILLED or SERIOUSLY HURT if you donot follow instructions.

CAUTIONYou CAN be HURT if you do not follow instructions.

Instructions - how to service this vehicle correctlyand safely.

All information contained in this manual is based on the latestproduct information available at the time of printing. Wereserve the right to make changes at any time without notice.No part of this publication may be reproduced, stored inretrieval system, or transmitted, in any form by any means,electronic, mechanical, photocopying, recording, or otherwise,without the prior written permission of the publisher. Thisincludes text, figures and tables.

General InfoSpecificationsMaintenanceEngine ElectricalEngineCoolingFuel and Emissions*Transaxle*SteeringSuspesion*Brakes (Including ABS)* Body*Heating, Ventilation and Air Conitioning* Body Electrical*Restraints

How to Use This Manual

As you read this manual, you will find information that is

preceded by a symbol. The purpose of thismessage is to help prevent damage to your vehicle, otherproperty, or the environment.

First Edition 7/2000 2494pages

HONDA MOTOR CO.,LTD.

All Rights Reserved Service PublicationOffice

As sections with *include SRS components;special precautions are required when servicing.

A Few Words about Safety

A Few Words about SafetyService Information

IMPORTANT SAFETY PRECAUTIONS

The service and repair information contained in this manual isintended 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 couldalso damage the vehicle or create an unsafe condition.This manual describes the proper methods and procedures forperforming service, maintenance and repairs. Some proceduresrequire the use of specially designed tools and dedicatedequipment. 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 safeoperation of the vehicle.If you need to replace a part, use genuine Honda parts withthe correct part number or an equivalent part. We stronglyrecommend that you do not use replacement parts of inferiorquality.FOR YOUR CUSTOMER'S SAFETYProper service and maintenance are essential to thecustomer's safety and the reliability of the vehicle. Any error oroversight while servicing a vehicle can result in faultyoperation, damage to the vehicle, or injury to others.

WARNINGImproper service or repairs can create an unsafecondition that can cause your customer or othersto be seriously hurt or killed.Follow the procedures and precautions in thismanual and other service materials carefully.

FOR YOUR SAFETYBecause this manual is intended for the professional servicetechnician, we do not provide warnings about many basic shopsafety practices (e.g., Hot parts - wear gloves). If you have notreceived shop safety training or do not feel confident aboutyour knowledge of safe servicing practices, we recommend thatyou do not attempt to perform the procedures described in thismanual.

WARNINGFailure to properly follow instructions andprecautions can cause you to be seriously hurt orkilled.Follow the procedures and precautions in thismanual carefully.

Some of the most important general service safety precautionsare given below. However, we cannot warn you of everyconceivable hazard that can arise in performing service andrepair procedures. Only you can decide whether or not youshould perform a given task.

Make sure you have a clear understanding of allbasic shop safety practices and that you are wearingappropriate clothing and using safety equipment.When performing any service task, be especiallycareful of the following:

Read all of the instructions before you begin, andmake sure you have the tools, the replacement orrepair parts and the skills required to perform thetasks safely and completely.Protect your eyes by using proper safety glasses,goggles or face shields any time you hammer, drill,grind, or work around pressurised air or liquids, andsprings or other stored-energy components. If thereis any doubt, put on eye protection.Use other protective wear when necessary, forexample gloves or safety shoes. Handling hot orsharp parts can cause severe burns or cuts. Beforeyou grab something that looks like it can hurt you,stop and put on gloves.Protect yourself and others whenever you have thevehicle up in the air. Any time you lift the vehicle,either with a hoist or a jack, make sure that it isalways securely supported. Use jack stands.

Make sure the engine is off before you begin anyservicing procedures, unless the instruction tells youto do otherwise. This will help eliminate severalpotential hazards:

Carbon monoxide poisoning from engine exhaust.Be sure there is adequate ventilation whenever yourun the engine.Burns from hot parts or coolant. Let the engine andexhaust system cool before working in those areas.Injury from moving parts. If the instruction tells youto run the engine, be sure your hands, fingers, andclothing are out of the way.

Gasoline vapours and hydrogen gases from batteriesare explosive. To reduce the possibility of a fire orexplosion, be careful when working around gasolineor batteries.

Use only a non-flammable solvent, not gasoline toclean parts.Never drain or store gasoline in an open container.Keep all cigarettes, sparks and flames away fromthe battery and all fuel-related parts.

Introduction - Introduction

file:///C|/...0EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivHtml/0-3.htm[8/25/2012 6:43:25 PM]

IntroductionSupplemental Restraint System (SRS)

The Civic SRS includes a driver's airbag in the steering wheel hub and a passenger's airbag in the dashboard above the glove boxand seat belt tensioners in the front seat belt retractors. Information necessary to safely service the SRS is included in this ShopManual. Items marked with an asterisk (*) on the contents page include, or are located near, SRS components. Servicing,disassembling or replacing these items will require special precautions and tools, and should therefore be done by an authorisedHonda dealer.

WARNINGTo avoid rendering the SRS inoperative, which could lead to personal injury or death inthe event of a severe frontal collision, all SRS service work must be performed by anauthorised Honda dealer.Improper service procedures, including incorrect removal and installation of the SRS,could lead to personal injury caused by unintentional deployment of the airbags.SRS electrical wiring harnesses are identified by yellow colour coding. Relatedcomponents are located in the steering column, front console, dashboard, dashboardlower panel, and in the dashboard above the glove box. Do not use electrical testequipment on these circuits.

General Information - General Information


General Information

Chassis and Engine Numbers - 4-Door KE, KG, KQ Models 1-2Chassis and Engine Numbers - 4-Door KK, KM, KP, KXModels

1-4

Chassis and Engine Numbers - 4-Door KB, KH, KU, KV,KW, KY Models

1-6

Chassis and Engine Numbers - 4-Door KF, KN, KT Models 1-8Chassis and Engine Numbers - 5-Door Model 1-10Identification Number Locations 1-12Warning/Caution Label Locations 1-13Lift and Support Points 1-15Towing 1-16Service Precautions 1-17Abbreviations 1-24



General InformationChassis and Engine Numbers

4-Door KE, KG, KQ Models

1-2



General InformationChassis and Engine Numbers (cont'd)

Applicable Area Code/VIN/Engine Number/Transmission Number ListMODEL APPLICABLE

AREA CODEGRADENAME

TRANSMISSIONTYPE

VEHICLEIDENTIFICATIONNUMBER

ENGINENUMBER

TRANSMISSIONNUMBER

CIVIC KE 1.4S 5MT JHMES45301S200001- D14Z5-1000001-

SLW-1000001-

4AT JHMES46301S200001- D14Z5-1000001-

SLXA-1000001-

1.6SE 5MT JHMES55401S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56401S200001- D16W7-1000001-

SLXA-1000001-

KG 1.4S 5MT JHMES45301S200001- D14Z5-1000001-

SLW-1000001-

4AT JHMES46301S200001- D14Z5-1000001-

SLXA-1000001-

1.6LS 5MT JHMES55401S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56401S200001- D16W7-1000001-

SLXA-1000001-

5MT JHMES55501S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56501S200001- D16W7-1000001-

SLXA-1000001-

1.6ES 5MT JHMES55701S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56701S200001- D16W7-1000001-

SLXA-1000001-

5MT JHMES55901S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56901S200001- D16W7-1000001-

SLXA-1000001-

KQ GLI 5MT JHMES15501S200001- D17Z1-1000001-

SLW-1000001-

4AT JHMES16501S200001- D17Z1-1000001-

SLXA-1000001-

VTI 5MT JHMES15901S200001- D17A2-1000001-

SLW-1000001-

4AT JHMES16901S200001- D17A2-1000001-

SLXA-1000001-

5MT JHMES15001S200001- D17A2-1000001-

SLW-1000001-

4AT JHMES16001S200001- D17A2-1000001-

SLXA-1000001-

1-3




4-Door KK, KM, KP, KX Models

1-4





AREA CODEGRADENAME

TRANSMISSIONTYPE

VEHICLEIDENTIFICATION NUMBER

ENGINENUMBER

TRANSMISSION

NUMBERCIVIC KK DX 5MT JHMES85101S200001- D15Y5-

1000001-SLW-1000001-

4AT JHMES86101S200001- D15Y5-1000001-

SLXA-1000001-

5MT JHMES85201S200001- D15Y5-1000001-

SLW-1000001-

4AT JHMES86201S200001- D15Y5-1000001-

SLXA-1000001-

LX 5MT JHMES15501S200001- D17A1-1000001-

SLW-1000001-

4AT JHMES16501S200001- D17A1-1000001-

SLXA-1000001-

5MT 1HGES15501L500001- D17A3-1400001-

SLW-1000001-

4AT 1HGES16501L500001- D17A3-1400001-

BMXA-5000001-

5MT 2HGES155*1H750001- D17A3-1400001-

SLW-1000001-

4AT 2HGES165*1H750001- D17A3-1400001-

BMXA-5000001-

EX 5MT JHMES15701S200001- D17A2-1000001-

SLW-1000001-

4AT JHMES16701S200001- D17A2-1000001-

SLXA-1000001-

5MT 1HGES15701L500001- D17A4-1400001-

SLW-1000001-

4AT 1HGES16701L500001- D17A4-1400001-

BMXA-5000001-

5MT 2HGES157*1H750001- D17A4-1400001-

SLW-1000001-

4AT 2HGES167*1H750001- D17A4-1400001-

BMXA-5000001-

KM LX-B 5MT 93HES15301Z000001- D17A3-1400001-

SLW-1000001-

LX 5MT 93HES15501Z000001- D17A3-1400001-

SLW-1000001-

4AT 93HES16501Z000001- D17A3-1400001-

BMXA-5000001-

EX 5MT 93HES15801Z000001- D17A4-1400001-

SLW-1000001-

4AT 93HES16801Z000001- D17A4-1400001-

BMXA-5000001-

KP LX 5MT 93HES15501Z000001- D17A3-1400001-

SLW-1000001-

4AT 93HES16501Z000001- D17A3-1400001-

BMXA-5000001-

EX 5MT 93HES15801Z000001- D17A4- SLW-1000001-

1-5



1400001-4AT 93HES16801Z000001- D17A4-

1400001-BMXA-5000001-

KX LX 5MT IHGES15501L900001- D17A3-1400001-

SLW-1000001-

4AT IHGES16501L900001- D17A3-1400001-

BMXA-5000001-

EX 5MT IHGES15701L900001- D17A4-1400001-

SLW-1000001-

4AT IHGES16701L900001- D17A4-1400001-

BMXA-5000001-




4-Door KB, KH, KU, KV, KW, KY Models

1-6





AREA CODEGRADENAME

TRANSMISSION

TYPE

VEHICLEIDENTIFICATION NUMBER

ENGINENUMBER

TRANSMISSIONNUMBER

CIVIC KB 1.4S 5MT JHMES45301S200001- D14Z5-1000001-

SLW-1000001-

4AT JHMES46301S200001- D14Z5-1000001-

SLXA-1000001-

1.6ES 5MT JHMES55701S200001- D16W7-1000001-

SLW-1000001-

4AT JHMES56701S200001- D16W7-1000001-

SLXA-1000001-

KH EXI VTI

4AT JHMES86801S200001- D15Y2-1000001-

SLXA-1000001-

JHMES56801S200001- D16W8-1000001-

SLXA-1000001-

KU EXI 5MT JHMES85801S200001- D15Y6-1000001-

SLW-1000001-

4AT JHMES86801S200001- D15Y6-1000001-

SLXA-1000001-

EXI-H 5MT JHMES85801S200001- D15Y6-1000001-

SLW-1000001-

4AT JHMES86801S200001- D15Y6-1000001-

SLXA-1000001-

VHI-H 5MT JHMES85901S200001- D15Y4-1000001-

SLW-1000001-

HMM JHMES86901S200001- D15Y4-1000001-

MLXA-1000001-

VTI 5MT JHMES85901S200001- D15Y4-1000001-

SLW-1000001-

HMM JHMES86901S200001- D15Y4-1000001-

MLYA-1000001-

VTI-S 5MT JHMES15901S200001- D17A2-1000001-

SLW-1000001-

HMM JHMES16901S200001- D17A2-1000001-

MLYA-1000001-

5MT JHMES15001S200001- D17A2-1000001-

SLW-1000001-

HMM JHMES16001S200001- D17A2-1000001-

MLYA-1000001-

KV LXI 5MT JHMES853*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES863*1S400001- D15Y3-1000001-

SLXA-1000001-

EXI 5MT JHMES857*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES867*1S400001- D15Y3-1000001-

SLXA-1000001-

VTI 5MT JHMES158*1S400001- D17A5-1000001-

SLW-1000001-

4AT JHMES168*1S400001- D17A5- SLXA-1000001-

1-7



1000001-KW EXI 5MT JHMES85801S200001- D15Y3-

1000001-SLW-1000001-

4AT JHMES86801S200001- D15Y3-1000001-

SLXA-1000001-

KY LXI 5MT JHMES853*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES863*1S400001- D15Y3-1000001-

SLXA-1000001-

5MT JHMES854*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES864*1S400001- D15Y3-1000001-

SLXA-1000001-

EXI 5MT JHMES857*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES867*1S400001- D15Y3-1000001-

SLXA-1000001-

5MT JHMES858*1S400001- D15Y3-1000001-

SLW-1000001-

4AT JHMES868*1S400001- D15Y3-1000001-

SLXA-1000001-

VTI 5MT JHMES158*1S400001- D17A5-1000001-

SLW-1000001-

4AT JHMES168*1S400001- D17A5-1000001-

SLXA-1000001-

5MT JHMES159*1S400001- D17A5-1000001-

SLW-1000001-

4AT JHMES169*1S400001- D17A5-1000001-

SLXA-1000001-




4-Door KF, KN, KT Models

1-8





AREA CODEGRADENAME

TRANSMISSIONTYPE


ENGINENUMBER

TRANSMISSIONNUMBER

CIVIC KF LXI 5MT JHMES85301S200001- D15Y3-1000001-

SLW-1000001-

4AT JHMES86301S200001- D15Y3-1000001-

SLXA-1000001-

EXI 5MT JHMES85701S200001- D15Y3-1000001-

SLW-1000001-

4AT JHMES86701S200001- D15Y3-1000001-

SLXA-1000001-

KN 150I 5MT JHMES85401S200001- D15Y3-1000001-

SLW-1000001-

4AT JHMES86401S200001- D15Y3-1000001-

SLXA-1000001-

170I 5MT JHMES15901S200001- D17A5-1000001-

SLW-1000001-

4AT JHMES16901S200001- D17A5-1000001-

SLXA-1000001-

KT LXI 5MT JHMES85301S200001- D15Y3-1000001-

SLW-1000001-

4AT JHMES86301S200001- D15Y3-1000001-

SLXA-1000001-

EXI 5MT JHMES85701S200001- D15Y3-1000001-

SLW-1000001-

4AT JHMES86701S200001- D15Y3-1000001-

SLXA-1000001-

1-9


file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivHtml/1-10.htm[8/25/2012 6:43:30 PM]


5-Door Model

1-10





AREA CODEGRADENAME

TRANSMISSIONTYPE


ENGINENUMBER

TRANSMISSIONNUMBER

CIVIC KE 1.4S 5MT JHMEU57201S200001- D14Z5-1000001-

SLW-1000001-

1.4LS 5MT JHMEU57401S200001- D14Z5-1000001-

SLW-1000001-

1.6S 5MT JHMEU67201S200001- D16W7-1000001-

SLW-1000001-

4AT JHMEU68201S200001- D16W7-1000001-

SLXA-1000001-

1.6LS 5MT JHMEU67401S200001- D16W7-1000001-

SLW-1000001-

4AT JHMEU68401S200001- D16W7-1000001-

SLXA-1000001-

1.6ES 5MT JHMEU67701S200001- D16W7-1000001-

SLW-1000001-

4AT JHMEU68701S200001- D16W7-1000001-

SLXA-1000001-

KQ VI 5MT JHMEU37301S200001- D17A2-1000001-

SLW-1000001-

4AT JHMEU38301S200001- D17A2-1000001-

SLXA-1000001-

VTI 5MT JHMEU37501S200001- D17A2-1000001-

SLW-1000001-

4AT JHMEU38501S200001- D17A2-1000001-

SLXA-1000001-

5MT JHMEU37701S200001- D17A2-1000001-

SLW-1000001-

4AT JHMEU38701S200001- D17A2-1000001-

SLXA-1000001-

5MT JHMEU37801S200001- D17A2-1000001-

SLW-1000001-

4AT JHMEU38801S200001- D17A2-1000001-

SLXA-1000001-

KT EXI 5MT JHMEU67401S200001- D16V2-1000001-

SLW-1000001-

4AT JHMEU68401S200001- D16V2-1000001-

SLXA-1000001-

1-11



General InformationIdentification Number Locations

1. Build Date and Vehicle TypeExcept KK, KX, KY models

2. Vehicle Identification Number (VIN)3. Engine Number4. Transmission Number (Manual)5. Certification Plate

(KK, KX models)6. Certification Plate

(KY model)7. Transmission Number (Automatic)8. Transmission Number (Honda Multi Matic)

1-12



General InformationWarning/Caution Label Locations

1. STEERING COLUMN NOTICE2. PASSENGER AIRBAG CHILD SEAT

CAUTION(KE model)

3. SRS INFORMATION(KG, KK, KX models)

4. SRS INFORMATION(KE, KN, KQ models)

5. PASSENGER AIRBAG CHILD SEATCAUTION(KG model)

6. FRONT PASSENGER MODULEDANGER

7. FRONT SEATBELT TENSIONERWARNING

8. PASSENGER AIRBAG CHILD SEATCAUTION(KQ model)

9. DRIVE MODULE DANGER10. CABLE REEL CAUTION11. MONITOR NOTICE12. SIDE AIRBAG INFORMATION

Located on driver's and passenger'sdoor jamb (not shown)

1-13



General InformationWarning/Caution Label Locations (cont'd)

1. ENGINE COOLANT INFORMATION AND SERVICEINFORMATION(Under-hood Emission Control Label)

2. SRS WARNING LABEL3. AIR CONDITIONING INFORMATION4. TYRE INFORMATION

(KQ model)5. TYRE INFORMATION

(KE, KT models)6. TYRE INFORMATION

(LH model)7. RADIATOR CAP CAUTION8. BATTERY CAUTION

1-14



General InformationLift and Support Points

NOTE: If you are going to remove heavy components such assuspension or the fuel tank from the rear of the vehicle, firstsupport the front of the vehicle with tall safety stands. Whensubstantial weight is removed from the rear of the vehicle, thecentre of gravity can change and cause the vehicle to tipforward on the hoist.Frame Hoist1. 1. Position the hoist lift blocks (A), or safety stands,

under the vehicle's front support points (B) and rearsupport points (C).

2. 2. Raise the hoist a few inches and rock the vehiclegently to be sure it is firmly supported.

Safety StandsTo support the vehicle on safety stands, use the same supportpoints (B and C) as for a frame hoist. Always use safety standswhen working on or under any vehicle that is supported only bya jack.

Floor Jack1. 1. Block the rear wheels when raising the front of the

vehicle; block the front wheels when raising the rearof the vehicle.

Place the blocks behind and ahead of the wheels.2. 2. Raise the vehicle high enough to insert the safety

stands.3. Adjust and place the safety stands so the vehicle will

be approximately level, then lower the vehicle ontothem.

1-15



General InformationTowing

If the vehicle needs to be towed, call a professional towingservice. Never tow the vehicle behind another vehicle with justa rope or chain. It is very dangerous.Emergency TowingThere are 3 popular methods of towing a vehicle.Flat-bed Equipment - The operator loads the vehicle onthe back of a truck. This is the best way of transporting thevehicle.To accommodate flat-bed equipment, the vehicle is equippedwith a towing hook (A) and tie down hook hooking slots (B).The towing hook can be used with a winch to pull the vehicleonto the truck and the tie down hook hooking slots can beused to secure the vehicle to the truck.

Wheel Lift Equipment - The tow truck uses 2 pivoting armsthat go under the tyres (front or rear) and lift them off theground. The other 2 wheels remain on the ground.Sling-type Equipment - The tow truck uses metal cableswith hooks on the ends. These hooks go around parts of theframe or suspension and the cables lift that end of the vehicleoff the ground. The vehicle's suspension and body can beseriously damaged if this method of towing is attempted.If the vehicle cannot be transported by flat-bed, it should betowed with the front wheels off the ground. If due to damage,the vehicle must be towed with the front wheels on theground, do the following:

Release the parking brake.Start the engine.Shift to position, then position.Turn off the engine.

It is best to tow the vehicle no farther than 50 miles (80 km),and keep the speed below 35 mph (55 km/h).

Improper towing preparation will damage thetransmission. Follow the above procedure exactly. Ifyou cannot shift the transmission or start the engine(automatic transmission), the vehicle must betransported on a flat-bed.Trying to lift or tow the vehicle by the bumpers willcause serious damage. The bumpers are notdesigned to support the vehicle's weight.

1-16



General InformationService Precautions

General

CAUTIONObserve all safety precautions and notes whileworking.

Protect all painted surfaces and seats against dirtand scratches with a clean cloth or vinyl cover.

Work safety and give your work your undividedattention. When either the front or rear wheels are tobe raised, block the remaining wheels securely.Communicate at frequently as possible when workinvolves 2 or more workers. Do not run the engineunless the shop or working area is well ventilated.

Before removing or disassembling parts, they mustbe inspected carefully to isolate the cause for whichservice is necessary. Observe all safety notes andprecautions and follow the proper procedures asdescribed in this manual.

Mark or place all removed parts in order in a partsrack so they can be reassembled in their originalplaces.

Use the special tool when use of such a tool isspecified.

Parts must be assembled with the proper torqueaccording to the maintenance standards established.When tightening a series of bolts or nuts, begin withthe centre or large diameter bolts and tighten them incriss-cross pattern in 2 or more steps.

1-17



General InformationService Precautions (cont'd)

Use new packings, gaskets, O-rings and cotter pinswhenever reassembling.Do not reuse parts that must be required to replace.Always replace them.

Use genuine HONDA parts and lubricants or theirequivalent. When parts are to be reused, they mustbe inspected carefully to make sure they are notdamaged or deteriorated and are in good usablecondition.

Coat or fill parts with specified grease as specified(see page 3-2). Clean all removed parts with solventupon disassembly.

Brake fluid and hydraulic componentsWhen replenishing the system, use extreme care toprevent dust and dirt from entering the system.Do not mix different brands of fluid, as they maynot be compatible.Do not reuse drained brake fluid.Because brake fluid can cause damage to paintedand resin surfaces, care should be taken not tospill it on such materials. If spilled accidentally,quickly rinse it with water or warm water frompainted or resin surfaces.After disconnecting brake hoses or pipes, be sureto plug the openings to prevent loss of brake fluid.Clean all disassembled parts only in clean BRAKEFLUID. Blow open all holes and passages withcompressed air.Keep disassembled parts from air-borne dust andabrasives.Check that parts are clean before assembly.

Avoid oil or grease getting on rubber parts andtubes, unless specified.Upon assembling, check every part for properinstallation and operation.

1-18




Electrical Troubleshooting InformationBefore Troubleshooting1. 1. Check applicable fuses in the appropriate fuse/relay

box.Check the battery for damage, state of charge and clean andtighten the connections.

Do not quick-charge a battery unless the batteryground cable has been disconnected, otherwise youwill damage the alternator diodes.Do not attempt to crank the engine with the batteryground cable loosely connected or you will severelydamage the wiring.

Check the alternator belt tension.Handling Connectors

Make sure the connectors are clean and have noloose wire terminals.Make sure multiple cavity connectors are packed withgrease (except watertight connectors).All connectors have push-down release type locks(A).

Some connectors have a clip on their side used toattach them to a mounting bracket on the body or onanother component. This clip has a pull type lock.Some mounted connectors cannot be disconnectedunless you first release the lock and remove theconnector from its mount bracket (A).

Never try to disconnect connectors by pulling on theirwires; pull on the connector halves instead.Always reinstall plastic covers.

Before connecting connectors, make sure theterminals (A) are in place and not bent.

1-19




Check for loose retainer (A) and rubber seals (B).

The backs of some connectors are packed withgrease. Add grease if necessary. If the grease iscontaminated, replace it.

Insert the connector all the way and make sure it issecurely locked.Position wires so that the open end of the coverfaces down.

Handling Wires and HarnessesSecure wires and wire harnesses to the frame withtheir respective wire ties at the designated locations.Remove clips carefully; do not damage their locks(A).

Slip pliers (A) under the clip base and through thehole at an angle, then squeeze the expansion tabs torelease the clip.

After installing harness clips, make sure the harnessdoes not interfere with any moving parts.Keep wire harnesses away from exhaust pipes andother hot parts, from sharp edges of brackets andholes and from exposed screws and bolts.Seat grommets in their grooves properly (A). Do notleave grommets distorted (B).

1-20




Testing and RepairsDo not use wires or harnesses with broken insulation.Replace them or repair them by wrapping the breakwith electrical tape.After installing parts, make sure that no wires arepinched under them.When using electrical test equipment, follow themanufacturer's instructions and those described inthis manual.If possible, insert the probe of the tester from thewire side (except waterproof connector).

Use a probe with a tapered tip.

Refer to the instructions in the Honda Terminal Kitfor identification and replacement of connectorterminals.

1-21




When checking any control module(s) or unit(s) connector terminals, gently slide the sharp tester probe from the wire side into theconnector until it comes in contact with the terminal end of the wire.

1. DIGITAL CIRCUIT TESTER(Commercially available) or 07411-0020000

2. Any CONTROL MODULE or UNIT3. SHARP TESTER PROBE

CAUTIONPuncturing the insulation on a wire can cause poor or intermittent electricalconnections.For testing at connectors, bring the tester probe into contact with the terminal fromthe connector side of wire harness connectors in the engine compartment. For femaleconnectors, just touch lightly with the tester probe and do not insert the probe.

1. RUBBER SEAL2. TESTER PROBE3. TERMINAL4. WIRE HARNESS

1-22




5-step Troubleshooting1. 1. Verify The Complaint

Turn on all the components in the problem circuit to verifythe customer complaint. Note the symptoms. Do not begindisassembly or testing until you have narrowed down theproblem area.

2. 2. Analyse The SchematicLook up the schematic for the problem circuit. Determinehow the circuit is supposed to work by tracing the currentpaths from the power feed through the circuit components toground. If several circuits fail at the same time, the fuse orground is a likely cause.Based on the symptoms and your understanding of thecircuit operation, identify one or more possible causes of theproblem.

3. 3. Isolate The Problem By Testing The CircuitMake circuit tests to check the diagnosis you made in step2. Keep in mind that a logical, simple procedure is the keyto efficient troubleshooting. Test for the most likely cause offailure first. Try to make tests at points that are easilyaccessible.

4. 4. Fix The ProblemOnce the specific problem is identified, make the repair. Besure to use proper tools and safe procedures.

5. 5. Make Sure The Circuit WorksTurn on all components in the repaired circuit in all modesto make sure you have fixed the entire problem. If theproblem was a blown fuse, be sure to test all of the circuitson the fuse. Make sure no new problems turn up and theoriginal problem does not recur.

Wire Colour CodesThe following abbreviations are used to identify wire colours inthe circuit schematics:

WHT…………… WhiteYEL……………. YellowBLK……………. BlackBLU……………. BlueGRN…………… GreenRED……………. RedORN…………… OrangePNK……………. PinkBRN……………. BrownGRY…………… GreyPUR……………. PurpleLT BLU………… Light BlueLT GRN……….. Light Green

The wire insulation has one colour or one colour with anothercolour stripe. The second colour is the stripe.

1-23



General InformationAbbreviations

List of automotive abbreviations, which may be used in shopmanual.

ABS Anti-lock Brake SystemA/C Air Conditioning, Air ConditionerACL Air CleanerA/F Air Fuel RatioALR Automatic Locking RetractorALT AlternatorAMP Ampere(s)ANT AntennaAPI American Petroleum InstituteAPPROX. ApproximatelyASSY AssemblyA/T Automatic TransmissionATDC After Top Dead CentreATF Automatic Transmission FluidATT AttachmentATTS Active Torque Transfer SystemAUTO AutomaticAUX Auxiliary

BARO BarometricBAT BatteryBDC Bottom Dead CentreBTDC Before Top Dead Centre

CARB CarburettorCAT Catalytic Converteror CATACHG ChargeCKF Crankshaft Speed FluctuationCKP Crankshaft PositionCO Carbon MonoxideCOMP CompleteCPB Clutch Pressure Back upCPC Clutch Pressure ControlCPU Central Processing UnitCVT Continuously Variable TransmissionCYL CylinderCYP Cylinder Position

DI Distributor IgnitionDIFF DifferentialDLC Data Link Connector

EPR Evaporator Pressure RegulatorEPS Electrical Power SteeringEVAP EvaporativeEX Exhaust

F FrontFIA Fuel Injection AirFL Front LeftFP Fuel PumpFR Front RightFSR Fail Safe RelayFWD Front Wheel Drive

GAL GallonGND GroundGPS Global Positioning System

H/B HatchbackHC HydrocarbonsHID High Intensity DischargeHO2S Heated Oxygen Sensor

IAB Intake Air BypassIAC Idle Air ControlIACV Idle Air Control ValveIAR Intake Air ResonatorIAT Intake Air TemperatureICM Ignition Control ModuleID IdentificationID or I.D. Inside DiameterIG or IGN IgnitionIMA Idle Mixture Adjustment

Integrated Motor Assist

IMMOBI. Immobilizer (Immobiliser)IN IntakeINJ InjectionINT Intermittent

KS Knock Sensor

L LeftL/C Lock-up ClutchLCD Liquid Crystal DisplayLED Light Emitting Diode

1-24



General InformationAbbreviations (cont'd)

MAP Manifold Absolute PressureMAX. MaximumMBS Mainshaft Brake SystemMCK Motor CheckMCU Moment Control UnitMIL Malfunction Indicator LampMIN. MinimumMPI Multi Point InjectionM/S Manual SteeringM/T Manual Transmission

N NeutralNox Oxides of Nitrogen

OBD On-board DiagnosticO2S Oxygen SensorOD or O.D. Outside Diameter

P ParkPAIR Pulsed Secondary Air InjectionPCM Powertrain Control ModulePCV Positive Crankcase Ventilation

Proportioning Control ValvePDU Power Drive UnitPGM-FI Programmed-fuel InjectionPGM-IG Programmed IgnitionPH Pressure HighPL Pilot Light or Pressure LowPMR Pump Motor RelayP/N Part NumberPRI PrimaryP/S Power SteeringPSF Power Steering FluidPSP Power Steering PressurePSW Pressure Switch

Qty Quantity

R RightREF ReferenceRGB Red, Green, BlackRH Right HandRHD Right Hand DriveRL Rear Left

SPEC SpecificationS/R Sun RoofSRS Supplemental Restraint SystemSTD StandardSW Switch

T TorqueTB Throttle BodyT/B Timing BeltTC Torque ConverterTCM Transmission Control ModuleTCS Traction Control SystemTDC Top Dead CentreTFT Thin Film TransistorT/N Tool NumberTP Throttle PositionTWC Three Way Catalytic Converter

VC Viscous CouplingVIN Vehicle Identification NumberVSS Vehicle Speed SensorVTEC Variable Valve Timing & Lift Valve Electronic

ControlVVIS Variable Volume Intake System

W WithW/O WithoutWOT Wide Open Throttle

2WD Two Wheel Drive4WD Four Wheel Drive2WS Two Wheel Steering4WS Four Wheel Steering4AT 4-speed Automatic Transmission5MT 5-speed Manual Transmission6MT 6-speed Manual Transmission

ParkReverseNeutralDrive (1st through 4th gear)

Drive (1st through 3rd gear)

SecondFirstDrive

1-25



RON Research Octane NumberRR Rear Right

SAE Society of Automotive EngineersSCS Service Check SignalSEC Second

Secondary

SOHC Single Overhead CamshaftSOL Solenoid

SecondLow

O/D Over Drive

1ST Low (gear)

2ND Second (gear)

3RD Third (gear)

4TH Fourth (gear)

5TH Fifth (gear)

6TH Sixth (gear)

Specifications - Specifications


Specifications

Standards and Service Limits

Engine Electrical 2-2Engine Assembly 2-3Cylinder Head 2-4Engine Block 2-6Engine Lubrication 2-7Cooling 2-8Fuel and Emissions 2-9Clutch 2-10Manual Transmission and Differential 2-11Automatic Transmission and A/T Differential 2-13Honda Multi Matic Transmission and HMMDifferential

2-19

Steering 2-24Suspension 2-24Brakes 2-25Air Conditioning 2-25

Design Specifications

Dimensions 2-26Weight 2-26Engine 2-27Starter 2-28Clutch 2-28Manual Transmission 2-28Automatic Transmission 2-28Honda Multi Matic Transmission 2-28Steering 2-28Suspension 2-28Wheel Alignment 2-29Brakes 2-29Tyres 2-29Air Conditioning 2-29Electrical Ratings 2-30

Body Specifications

Illustration 2-31

Specifications - Standards and Service Limits


Standards and Service LimitsEngine Electrical

Item Measurement Qualification Standard or New Service Limit

Ignition coil Rated voltage 12 V

Firing order 1 - 3 – 4 - 2

Spark plug Type D14Z5, D15Y6, D15Y4,D16W7 engines

NGK: ZFR5J-11DENSO: KJ16CR-L11

D17A1, D17A2, D17Z1,D17Z4 engines

NGK: ZFR6J-11DENSO: KJ20CR-L11

D17A5, D17Z5 engines NGK: ZFR6J-11DENSO: KJ20CR-L11

D15Y2, D15Y3, D16W8,D16W9 engines

NGK: BKR5E-11DENSO: K16CR-L11

D17Z2, D17Z3 engines NGK: ZFR6J-11,ZFR7J-11DENSO: KJ20CR-L11,KJ22CR-L11

D14Z6, D16V1 engines NGK:ZFR5J-11,ZFR6J-11DENSO: KJ16CR-L11,KJ20CR-L11

Gap 1.0-1.1 mm (0.039-0.043 in.) -Ignition timing At idle (check the red mark) M/T (in neutral): 8+2° BTDC at 700+50 rpm (min-1)

A/T HONDA MULTI MATIC (in or ): 8+2°BTDC at 700+50 rpm (min-1)

Alternator belt NOTE: Adjust a newbelt to the new beltspec., run the enginefor 5 minutes, thenreadjust it to the usedbelt spec.

Deflection with 98 N (10 kgf,22 lbs) applied midwaybetween pulleys

Without A/C (with A/C, see"Compressor belt" in theA/C table)

Used belt: 8.5-11.0 mm (0.33-0.43 in.)

New belt: 6.5-8.5 mm (0.26-0.33 in.)

Tension (measured with belttension gauge)

Without A/C (with A/C, see"Compressor belt" in theA/C table)

Used belt: 340-490 N (35-55 kgf, 77-110 lbs)

New belt: 540-740 N (55-75 kgf, 120-170 lbs)

Alternator Output At 13.5 V and normalengine temperature

70 A

Coil (rotor) resistance at 68°F (20°C) 1.84-2.10 ohms

Slip ring O.D. 22.7 mm (0.89 in.) 21.7 mm (0.85 in.)

Brush length 19.0 mm (0.75 in.) 5 mm (0.20 in.)

Brush spring tension 3.3-4.1 N (1.6-1.8 kgf, 3.5-4.0 lbs)

Starter for D15Y2,D16W7 (KG model),D16W8, D17Z1(Except Malaysiamodel), D17A1,D17A2 (ExceptMalaysia model),D17A5 (ExceptIndonesia model)engines (DENSO)

Output 1.0 kW

Commutator mica depth 0.50-0.75 mm (0.020-0.030in.)

0.2 mm (0.008 in)

Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in)

Commutator O.D. 27.9-28.0 mm (1.098-1.102in.)

27.0 mm (1.063 in.)

Brush length 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm (0.35 in)

Brush spring tension 13.7-17.7 N (1.4-1.8 kgf,3.09-4.00 lbf)

2-2



Standards and Service LimitsEngine Electrical (cont'd)


Starter for D15Y3(Philippine model),D16W9 (Philippinemodel), D17Z1(Malaysia model),D17Z5, D17A2(Malaysia model),D17A5 (Indonesiamodel) engines(MITSUBISHI)

Output 0.8 kW


0.2 mm (0.008 in.)

Commutator runout 0.05 mm (0.002 in.) max 0.4 mm (0.02 in).


27.0 mm (1.063 in.)

Brush length 9.7-10.3 mm (0.38-0.41 in.) 6.0 mm (0.24 in)

Brush spring tension 13.7-17.7 N (1.4-1.8 kgf,3.09-4.00 lbf)

Starter for ExceptD15Y2, D15Y3(Philippine model),D16W7 (KG model),D16W8, D16W9,D17Z1, D17A1,D17A2, D17A5engines (DENSO)

Output 0.8 kW


0.2 mm (0.008 in.)

Commutator runout 0.05 mm (0.002 in.) max. 0.4 mm (0.02 in.)


27.0 mm (1.063 in.)

Brush length 9.7-10.3 mm (0.35-0.41 in.) 6.0 mm (0.24 in.)

Engine AssemblyItem Measurement Qualification Standard or New Service Limit

Compression Pressure check at 250 rpm(min-1) with wide openthrottle. (See Design Specsfor ratio.)

Minimum 930 kPa (9.5 kgf/cm2, 135psi)

-

Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) -

2-3



Standards and Service LimitsCylinder Head


Head Warpage - 0.05 mm (0.002 in.)

Height 92.95-93.05 mm (3.659-3.663 in.)

-

Camshaft End Play 0.05-0.15 mm (0.002-0.006in.)

0.5 mm (0.02 in.)

Camshaft-to-holder oilclearance

0.050-0.089 mm (0.0020-0.0035 in.)

0.15 mm (0.006 in.)

Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)

Cam lobe height for D15Y4engine

VTEC intake, primary 38.427 mm (1.5129 in.) -

VTEC intake, secondary 32.292 mm (1.2713 in.) -

VTEC exhaust 38.784 mm (1.5269 in.) -

Cam lobe height for D16W7engine




Cam lobe height for D17A2,D17A5 engines




Cam lobe height for D16W8engine


VTEC intake, mid 38.274 mm (1.5068 in.) -



Cam lobe height for D14Z5engine

Intake 34.158 mm (1.3448 in.) -

Exhaust 36.488 mm (1.4365 in.) -

Cam lobe height for D15Y2,D15Y3, D15Y5, D15Y6,D17A1, D17Z1 engines

Intake 35.299 mm (1.3897 in.) -

Exhaust 37.281 mm (1.4678 in.) -

2-4



Standards and Service LimitsCylinder Head (cont'd)


Valve Clearance (cold) Intake 0.18-0.22 mm (0.007-0.009in.)

-

Exhaust 0.23-0.27 mm (0.009-0.011in.)

-

Stem O.D. Intake 5.48-5.49 mm (0.2157-0.2161 in.)

5.45 mm (0.215 in.)

Exhaust 5.45-5.46 mm (0.2146-0.2150 in.)

5.42 mm (0.213 in.)

Stem-to-guide clearance Intake 0.02-0.05 mm (0.0008-0.0020 in.)

0.08 mm (0.003 in.)

Exhaust 0.05-0.08 mm (0.0020-0.0031 in.)

0.11 mm (0.004 in.)

Valve seats Width Intake 0.85-1.15 mm (0.033-0.045in.)

1.60 mm (0.063 in.)

Exhaust 1.25-1.55 mm (0.049-0.061in.)

2.00 mm (0.079 in.)

Stem installed height Intake 53.17-53.64 mm (2.093-2.112 in.)

53.89 mm (2.112 in.)

Exhaust 53.17-53.64 mm (2.093-2.112 in.)

53.89 mm (2.112 in.)

Valve springs Free length for D15Y4,D16W7, D17A2, D17A5engines

VTEC intake 56.49 mm (2.224 in.) -


Free length for D16W8engine

VTEC intake 58.02 mm (2.284 in.) -


Free length for D14Z5,D15Y2, D15Y3, D15Y5,D15Y6, D17A1, D17Z1engines

Intake 58.70 mm (2.311 in.) -

Exhaust 58.70 mm (2.311 in.) -

Valve guides I.D. Intake 5.51-5.53 mm (0.217-0.218in.)

5.55 mm (0.219 in.)

Exhaust 5.51-5.53 mm (0.217-0.218in.)

5.55 mm (0.219 in.)

Installed height Intake 17.85-18.35 mm (0.703-0.722 in.)

-

Exhaust 18.65-19.15 mm (0.734-0.754 in.)

-

Rocker arms Arm-to-shaft clearance Intake 0.017-0.050 mm (0.0007-0.0020 in.)

0.08 mm (0.003 in.)

Exhaust 0.018-0.054 mm (0.0007-0.0021 in.)

0.08 mm (0.003 in.)

2-5



Standards and Service LimitsEngine Block


Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)

Bore diameter 75.00-75.02 mm (2.9528-2.9535 in.)

75.07 mm (2.9555 in.)

Bore taper - 0.05 mm (0.002 in.)

Reboring limit - 0.5 mm (0.02 in.)

Piston Skirt O.D. at 13 mm (0.5 in.)from bottom of skirt

74.98-74.99 mm (2.9520-2.9524 in.)

74.97 mm (2.9516 in.)

Clearance in cylinder 0.010-0.040 mm (0.0004-0.0016 in.)

0.05 mm (0.002 in.)

Ring groove width forD15Y3, D17A5 engines

Top 1.020-1.030 mm (0.0402-0.0406 in.)

1.05 mm (0.041 in.)

Second 1.220-1.230 mm (0.0481-0.0484 in.)

1.25 mm (0.049 in.)

Oil 2.805-2.820 mm (0.1104-0.1110 in.)

2.85 mm (0.112 in.)

Ring groove width forexcept D15Y3, D17A5engines

Top 1.020-1.030 mm (0.0402-0.0406 in.)

1.05 mm (0.041 in.)

Second 1.220-1.230 mm (0.0481-0.0484 in.)

1.25 mm (0.049 in.)

Oil 2.005-2.020 mm (0.0789-0.0795 in.)

2.05 mm (0.08 in.)

Piston rings Ring-to-groove clearancefor except D15Y3, D17A5engines

Top 0.035-0.055 mm (0.0014-0.0022 in.)

0.13 mm (0.005 in.)

Second 0.030-0.055 mm (0.0012-0.0022 in.)

0.13 mm (0.005 in.)

Ring-to-groove clearancefor D15Y3, D17A5 engines

Top 0.035-0.060 mm (0.0014-0.0024 in.)

0.13 mm (0.005 in.)

Second 0.030-0.055 mm (0.0012-0.0022 in.)

0.13 mm (0.005 in.)

Ring end gap for exceptD15Y3, D17A5 engines

Top 0.15-0.30 mm (0.006-0.012in.)

0.60 mm (0.024 in.)

Second 0.30-0.45 mm (0.012-0.018in.)

0.60 mm (0.024 in.)

Oil 0.20-0.80 mm (0.008-0.031in.)

0.90 mm (0.035 in.)

Ring end gap for D15Y3,D17A5 engine

Top 0.15-0.30 mm (0.006-0.012in.)

0.60 mm (0.024 in.)

Second 0.30-0.45 mm (0.012-0.018in.)

0.60 mm (0.024 in.)

Oil 0.20-0.70 mm (0.008-0.028in.)

0.80 mm (0.031 in.)

Piston pin O.D. 18.996-19.000 mm (0.7479-0.7480 in.)

-

Pin-to-piston clearance 0.010-0.020 mm (0.0004-0.0008 in.)

-

Connecting rod Pin-to-rod interference 0.016-0.036 mm (0.0006-0.0014 in.)

-

Small-end bore diameter 18.96-18.98 mm (0.746-0.747 in.)

-

Large-end bore diameter(Nominal)

D14Z5 engine 43.0 mm (1.69 in.) -

2-6



D15Y2, D15Y3, D15Y4,D15Y5, D15Y6 engines

45.0 mm (1.77 in.) -

D16W7, D16W8, D17Z1,D17A1, D17A2, D17A5engines

48.0 mm (1.89 in.) -

End play installed oncrankshaft

0.15-0.30 mm (0.006-0.012in.)

0.40 mm (0.016 in.)



Standards and Service LimitsEngine Block (cont'd)


Crankshaft Main journal diameter D14Z5, D15Y2, D15Y3,D15Y4, D15Y5, D15Y6engines

44.976-45.000 mm (1.7707-1.7717 in.)

-


54.976-55.000 mm (2.1644-2.1654 in.)

-

Rod journal diameter D14Z5 engine 39.976-40.000 mm (1.5739-1.5748 in.)

-


41.976-42.000 mm (1.6526-1.6535 in.)

-


44.976-45.000 mm (1.7707-1.7717 in.)

-

Rod/main journal taper 0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)

Rod/main journal out-of-round

0.0025 mm (0.0001 in.) 0.005 mm (0.0002 in.)

End play 0.10-0.35 mm (0.004-0.014in.)

0.45 mm (0.018 in.)

Runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)

Crankshaft bearings Main bearing-to-journal oilclearance for D14Z5,D15Y2, D15Y3, D15Y4,D15Y5, D15Y6 engines

No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.)

0.05 mm (0.002 in.)

No. 5 journal

No. 2 journal 0.020-0.038 mm (0.0008-0.0015 in.)

0.05 mm (0.002 in.)

No. 3 journal

No. 4 journal

Main bearing-to-journal oilclearance for D16W7,D16W8, D17Z1, D17A1,D17A2, D17A5 engines

No. 1 journal 0.018-0.036 mm (0.0007-0.0014 in.)

0.05 mm (0.002 in.)

No. 5 journal

No. 2 journal 0.024-0.042 mm (0.0009-0.0017 in.)

0.05 mm (0.002 in.)

No. 3 journal

No. 4 journal

Rod bearing clearance 0.024-0.042 mm (0.0009-0.0017 in.)

0.05 mm (0.002 in.)

Engine LubricationItem Measurement Qualification Standard or New Service Limit

Engine oil Capacity D15Y4, D17A2 (KU, KQmodels), D17A5 (KN model)engines

4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul3.5 l (3.7 US qt, 3.1 Imp qt) for oil change, includingfilter3.3 l (3.5 US qt, 2.9 Imp qt) for oil change, without filter

Except D15Y4, D17A2 (KU,KQ models, D17A5 (KNmodel) engines

4.2 l (4.4 US qt, 3.7 Imp qt) for engine overhaul3.2 l (3.4 US qt, 2.8 Imp qt) for oil change, includingfilter3.0 l (3.2 US qt, 2.6 Imp qt) for oil change, without filter

Oil pump Inner-to-outer rotor clearance 0.06-0.18 mm (0.002-0.007in.)

0.20 mm (0.008 in.)

Pump housing-to-outer rotorclearance

0.10-0.18 mm (0.004-0.007in.)

0.20 mm (0.008 in.)

Pump housing-to-rotor axialclearance

0.02-0.07 mm (0.001-0.003in.)

0.15 mm (0.006 in.)

Oil pressure with oiltemperature at 80°C (176°F)

At idle 70 kPa (0.7kgf/cm2, 10 psi) min.at 3,000 rpm (min-1) 340 kPa (3.5 kgf/cm2, 50 psi) min.

2-7



Standards and Service LimitsCooling


Radiator Coolant capacity (Includesengine, heater, hoses andreservoir)

M/T: engine overhaul 5.1 l (5.4 US qt, 4.5 Imp qt)

M/T: coolant change 4.0 l (4.2 US qt, 3.5 Imp qt)

A/T, HONDA MULTI MATIC:engine overhaul

5.0 l (5.3 US qt, 4.4 Imp qt)

A/T, HONDA MULTI MATIC:coolant change

3.9 l (4.1 US qt, 3.4 Imp qt)

Reservoir Coolant capacity 0.4 l (0.4 US qt, 0.4 Imp qt)

Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi)

Thermostat Opening temperature Begin to open 76-80°C (169-176°F)

Fully open 90°C (194°F)

Valve lift at fully open 8.0 mm (0.31 in.) min.

Radiator fan switch Thermoswitch "ON"temperature

91-95°C (196-203°F)

Thermoswitch "OFF"temperature

Subtract 3-8°C (5-15°F) from actual "ON" temperature

2-8



Standards and Service LimitsFuel and Emissions


Fuel pressureregulator

Pressure with fuel pressuregauge connected

270-320 kPa (2.8-3.3 kgf/cm2, 40-47 psi)

Fuel tank Capacity 45 l (11.9 US gal, 9.9 Imp gal)

Engine idle for D14Z5,D16W7, D17Z1engines (4-doormodel)

Idle speed with headlightsand radiator fan off

M/T in neutral 700+50 rpm

A/T in or 650+50 rpm

Fast idle M/T in neutral 1,300+50 rpm

A/T in or 1,300+50 rpm

Idle CO% 0.1 max.

Engine idle for D15Y3,D17A5 engines (4-door model)



CVT, A/T in or 750+50 rpm



Idle CO% 0.5 max.

Engine idle for D15Y5,D15Y2, D16W8,D17Z1, D17Z2,D17Z5, D17A2,D17Z3 engines (4-door model)






Idle CO% 0.1 max.

Engine idle for D14Z5,D16W7 engines (5-door model)






Idle CO% 0.1 max.

Engine idle for D15Y5,D15Y2 D16W8,D17A1, D17Z1,D17Z2, D17Z5,D17A2, D17Z3engines (5-doormodel)






Idle CO% 0.1 max.

Engine idle for D16V2engine (5-door model)



CVT, A/T in or 750+50 rpm



Idle CO% 0.5 max.

2-9



Standards and Service LimitsClutch


Clutch pedal Height from the floor 198 mm (7.8 in.) -

Stroke 130-140 mm (5.1-5.5 in.) -

Play 8-18 mm (0.3-0.7 in.) -

Disengagement height fromthe floor

113 mm (4.4 in.) min. -

Flywheel Runout on clutch matingsurface

0.06 mm (0.002 in.) max. 0.15 mm (0.006 in.)

Clutch disc Rivet head depth D17A engine 1.65-2.25 mm (0.065-0.089in.)

0.8 mm (0.03 in.)

Except D17A engine 1.2-1.7 mm (0.047-0.067 in.) 0.2 mm (0.01 in.)

Thickness 8.3-9.0 mm (0.33-0.35 in.) 5.7 mm (0.22 in.)

Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)

Height of diaphragm springfingers

Measure with feeler gaugeand special tool

D16W7,D16W8,D16W9, D16V2engines

0.6 mm(0.02 in.)max.

0.8 mm (0.03 in.)

Except D16W7,D16W8,D16W9, D16V2engines

0.6 mm(0.02 in.)max.

1.0 mm (0.04 in.)

2-10



Standards and Service LimitsManual Transmission and Differential


Transmission oil Capacity For fluid change: 1.5 l (1.6US qt, 1.3 Imp qt)

For overhaul: 1.6 l (1.7 US qt,1.4 Imp qt)

Mainshaft End play 0.11-0.18 mm (0.004-0.007in.)

Adjust

Diameter of ball bearingcontact area (clutch housingside)

25.977-25.990 mm (1.0227-1.0232 in.)

25.92 mm (1.021 in.)

Diameter of spacer collarcontact area

28.980-28.993 mm (1.1409-1.1415 in.)

28.930 mm (1.1390in.)

Diameter of needle bearingcontact area

34.984-35.000 mm (1.3773-1.3780 in.)

34.93 mm (1.375 in.)

Diameter of ball bearingcontact area (transmissionhousing side)

25.987-26.000 mm (1.0231-1.0236 in.)

25.93 mm (1.020 in.)

Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Mainshaft 3rd and 4thgears

I.D. 39.009-39.025 mm (1.5358-1.5364 in.)

39.070 mm (1.5382in.)

End play 3rd gear 0.06-0.21 mm (0.002-0.008in.)

0.33 mm (0.013 in.)

4th gear 0.06-0.19 mm (0.002-0.007in.)

0.31 mm (0.012 in.)

Thickness 3rd gear 27.92-27.97 mm (1.099-1.101 in.)

27.85 mm (1.096 in.)

4th gear 27.02-27.07 mm (1.064-1.066 in.)

26.95 mm (1.061 in.)

Mainshaft 5th gear I.D. 39.009-39.025 mm (1.5358-1.5364 in.)

39.070 mm (1.5382in.)

End play 0.06-0.19 mm (0.002-0.007in.)

0.31 mm (0.012 in.)

Thickness 28.92-28.97 mm (1.139-1.141 in.)

28.85 mm (1.136 in.)

Countershaft Diameter of needle bearingcontact area (clutch housingside)

34.000-34.015 mm (1.3386-1.3392 in.)

33.95 mm (1.337 in.)

Diameter of ball bearingcontact area (transmissionhousing side)

24.980-24.993 mm (0.9835-0.9840 in.)

24.93 mm (0.981 in.)

Diameter of 1st gearcontact area

37.984-38.000 mm (1.4954-1.4961 in.)

37.934 mm (1.493 in.)

Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Countershaft 1st gear I.D. 43.009-43.025 mm (1.6932-1.6939 in.)

43.070 mm (1.6957in.)

Endplay 0.03-0.10 mm (0.001-0.039in.)

0.22 mm (0.009 in.)

Thickness 26.91-26.94 mm (1.059-1.061 in.)

-

Countershaft 2nd gear I.D. 45.009-45.025 mm (1.7720-1.7726 in.)

45.070 mm (1.7744in.)

End play 0.04-0.12 mm (0.002-0.005 0.24 mm (0.009 in.)

2-11



in.)

Thickness 27.41-27.46 mm (1.079-1.081 in.)

27.36 mm (1.077 in.)

Countershaft 2nd gearspacer collar

I.D. 34.000-34.010 mm (1.3386-1.3390 in.)

34.040 mm (1.3402in.)

O.D. 39.989-40.000 mm (1.5744-1.5748 in.)

39.930 mm (1.5720in.)

Length 27.53-27.56 mm (1.084-1.085 in.)

27.51 mm (1.083 in.)



Standards and Service LimitsManual Transmission and Differential (cont'd)


Mainshaft 4th and5th gears spacercollar

I.D. 29.002-29.012 mm(1.1418-1.1422 in.)

29.060 mm(1.1441 in.)

O.D. 34.989-35.000 mm(1.3775-1.3780 in.)

34.930 mm(1.3752 in.)

Length A 51.97-52.03 mm(2.046-2.048 in.)

-

B 24.03-24.06 mm(0.946-0.947 in.)

-

Reverse idler gear I.D. 15.016-15.043 mm(0.5912-0.5922 in.)

15.080 mm(0.5937 in.)

Gear-to-reverse gear shaft clearance 0.032-0.077 mm(0.0012-0.0030 in.)

0.140 mm (0.0055in.)

Synchro ring Ring-to-gear clearance Ring pushedagainst gear

0.85-1.10 mm (0.033-0.043 in.)

0.4 mm (0.016in.)

Dual conesynchro

Outer synchro ring-to-synchro cone clearance Ring pushedagainst gear

0.5-1.0 mm (0.02-0.04in.)

0.3 mm (0.01 in.)

Synchro cone-to-gear clearance Ring pushedagainst gear

0.5-1.0 mm (0.02-0.04in.)

0.3 mm (0.01 in.)

Outer synchro ring-to-gear cone clearance Ring pushedagainst gear

0.95-1.68 mm (0.037-0.066 in.)

0.6 mm (0.02 in.)

Shift fork Finger thickness 1st-2nd and 3rd-4th forks

7.4-7.6 mm (0.29-0.30in.)

-

5th fork 6.7-6.9 mm (0.26-0.27in.)

-

Fork-to-synchro sleeve clearance 0.35-0.65 mm (0.014-0.026 in.)

1.00 mm (0.039in.)

Reverse shift fork Pawl groove width 13.8-14.1 mm (0.543-0.555 in.)

15.5 mm (0.610in.)

Fork-to-reverse idler gear clearance 1.6-2.2 mm (0.06-0.09in.)

2.8 mm (0.11 in.)

Shift arm I.D. 13.973-14.000 mm(0.5501-0.5512 in.)

-

Shift fork diameter at contact area 12.9-13.0 mm (0.508-0.512 in.)

-

Shift arm-to-shift lever clearance 0.2-0.5 mm (0.008-0.020 in.)

0.62 mm (0.024in.)

Select lever Finger width 14.75-14.95 mm(0.581-0.589 in.)

-

Shift lever Shaft-to-select lever clearance 0.05-0.40 mm (0.002-0.016 in.)

0.6 mm (0.024in.)

Groove (to select lever) 15.00-15.15 mm(0.591-0.596 in.)

-

Shaft-to-shift arm clearance 0.013-0.07 mm(0.0005-0.003 in.)

0.1 mm (0.004in.)

M/T differentialcarrier

Pinion shaft contact area I.D. 18.010-18.028 mm(0.7091-0.7098 in.)

-

2-12



Carrier-to-pinion shaft clearance 0.027-0.057 mm(0.0011-0.0022 in.)

0.100 mm (0.0039in.)

Driveshaft contact area I.D. 26.025-26.045 mm(1.0246-1.0254 in.)

-

M/T differentialpinion gear

Backlash 0.05-0.15 mm (0.002-0.006 in.)

-

I.D. 18.042-18.066 mm(0.7103-0.7113 in.)

-

Pinion gear-to-pinion shaft clearance 0.059-0.095 mm(0.0023-0.0037 in.)

0.150 mm (0.0059in.)



Standards and Service LimitsAutomatic Transmission and A/T Differential


ATF (AutomaticTransmission Fluid)

Capacity Use genuine Honda ATF-Z1 For fluid change: 2.7 l (2.9 US qt, 2.4 Imp qt)

For overhaul: 6.0 l (6.3 US qt, 5.3 Imp qt)

ATF pressure Line pressure At 2,000 rpm (min-1) in

or position

880-930 kPa (9.0-9.5kgf/cm2, 120-130 psi)

830 kPa (8.5 kgf/cm2,120 psi)

4th clutch pressure At 2,000 rpm (min-1) in position

850-900 kPa (8.7-9.2kgf/cm2, 120-130 psi)

800 kPa (8.2 kgf/cm2,120 psi)

3rd clutch pressure At 2,000 rpm (min-1) in

position

850-900 kPa (8.7-9.2kgf/cm2, 120-130 psi)

800 kPa (8.2 kgf/cm2,120 psi)

2nd clutch pressure At 2,000 rpm (min-1) in s

position

850-900 kPa (8.7-9.2kgf/cm2, 120-130 psi)

800 kPa (8.2 kgf/cm2120 psi)

1st clutch pressure At 2,000 rpm (min-1) in position

880-930 kPa (9.0-9.5kgf/cm2, 120-130 psi)

830 kPa (8.5 kgf/cm2,120 psi)

1st-hold clutch pressure At 2,000 rpm (min-1) in s

position

880-930 kPa (9.0-9.5kgf/cm2, 120-130 psi)

830 kPa (8.5 kgf/cm2,120 psi)

Torque converter Stall speed Check withvehicle on level ground

D14Z5 engine 2,550 rpm (min-1) 2,400-2,700 rpm (min-1)

D15Y2, D15Y3, D15Y5,D15Y6 engines

2,650 rpm (min-1) 2,500-2,800 rpm (min-1)

D16W7 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)

D16W8 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)

D17A1, D17Z1 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)

D17A2, D17Z5 engine 2,800 rpm (min-1) 2,650-2,950 rpm (min-1)

Valve body Stator shaft needle bearingcontact I.D.

Torque converter side 27.000-27.021 mm (1.063-1.064 in.)

When worn ordamaged

ATF pump side 29.000-29.013 mm (1.1417-1.1422 in.)

When worn ordamaged

ATF pump gear thrustclearance

0.03-0.06 mm (0.001-0.002in.)

0.07 mm (0.003 in.)

ATF pump gear-to-bodyclearance

Drive gear 0.105-0.1325 mm (0.004-0.005 in.)

-

Driven gear 0.0350-0.0625 mm (0.001-0.002 in.)

-

ATF pump driven gear I.D. 14.016-14.034 mm (0.5518-0.5525 in.)

When worn ordamaged

ATF pump driven gear shaftO.D.

13.980-13.990 mm (0.5504-0.5508 in.)

When worn ordamaged

Reverse shift fork Fork finger thickness 5.90-6.00 mm (0.232-0.236in.)

5.4 mm (0.213 in.)

Park gear and pawl When worn ordamaged

Servo body Shift fork shaft bore I.D. 14.000-14.010 mm (0.5512-0.5516 in.)

-

Shift fork shaft valve boreI.D.

37.000-37.039 mm (1.4567-1.4582 in.)

37.045 mm (1.4585in.)

2-13



Regulator valve body Sealing ring contact I.D. 35.000-35.025 mm (1.3780-1.3782 in.)

35.050 mm (1.3799in.)

Stator shaft Diameter of needle bearingcontact area

ATF pump side 29.000-29.013 mm (1.1417-1.1422 in.)

When worn ordamaged

Torque converter side 27.000-27.021 mm (1.0630-1.0638 in.)

When worn ordamaged



Standards and Service LimitsAutomatic Transmission and Differential


Clutch Clutch end plate-to-top discclearance

1st and 2nd 0.65-0.85 mm (0.026-0.033 in.)

3rd and 4th 0.4-0.6 mm (0.016-0.024 in.)

1st-hold 0.5-0.8 mm (0.020-0.031 in.)

Clutch return spring freelength

1st, 2nd, 3rd and 4th 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)

1st-hold 34.6 mm (1.36 in.) 32.6 mm (1.28 in.)

Clutch disc thickness 1.94 mm (0.076 in.) -

Clutch plate thickness 1st, 1st-hold 1.6 mm (0.06 in.) When discoloured

2nd, 3rd and 4th 2.0 mm (0.079 in.) When discoloured

1st, 2nd, 3rd and 4thclutches end plate thickness

Mark 1 2.1 mm (0.083 in.) When discoloured









1st-hold clutch end platethickness





No Mark 2.5 mm (0.098 in.) When discoloured



2-14



Standards and Service LimitsAutomatic Transmission and Differential(cont'd)


Mainshaft Diameter of needle bearingcontact area

at stator shaft 22.980-22.993 mm (0.9047-0.9052 in.)

When worn ordamaged

at 2nd gear 35.975-35.991 mm (1.4163-1.4169 in.)

When worn ordamaged

at 4th gear collar 31.975-31.991 mm (1.2589-1.2595 in.)

When worn ordamaged

at 1st gear collar 30.975-30.991 mm (1.2195-1.2201 in.)

When worn ordamaged

I.D. of gears 1st gear 35.000-35.016 mm (1.3780-1.3786 in.)

When worn ordamaged

2nd gear 41.000-41.016 mm (1.6142-1.6148 in.)

When worn ordamaged

4th gear 38.000-38.016 mm (1.4961-1.4967 in.)

When worn ordamaged

End play of gears 1st gear 0.08-0.19 mm (0.003-0.007in.)

-

2nd gear 0.05-0.13 mm (0.002-0.005in.)

-

4th gear 0.075-0.185 mm (0.003-0.007 in.)

-

4th gear collar length 49.50-49.55 mm (1.9488-1.9508 in.)

-

4th gear collar flangethickness

4.435-4.525 mm (0.1746-0.1781 in.)

-

1st gear collar length 27.00-27.05 mm (1.063-1.065 in.)

-

36.5 x 55 mm thrust washerthickness

No. 1 4.00 mm (0.157 in.) When worn ordamaged










Thrust washer thickness 26 x 45 x 3 mm 2.95-3.05 mm (0.116-0.120in.)

When worn ordamaged

1st gear, 26 mm 2.43-2.50 mm (0.096-0.098in.)

When worn ordamaged

2-15



Clutch feed pipe O.D. 1st clutch feed pipe at 15mm (0.6 in.) from end

8.97-8.98 mm (0.535-0.354in.)

8.95 mm (0.352 in.)

4th clutch feed pipe at 30mm (1.2 in.) from end

5.97-5.98 mm (0.2350-0.2354 in.)

5.95 mm (0.234 in.)

Sealing ring thickness 35 mm sealing ring 1.87-1.97 mm (0.074-0.078in.)

1.8 mm (0.071 in.)

29 mm sealing ring 1.87-1.97 mm (0.074-0.078in.)

1.8 mm (0.071 in.)

Clutch feed pipe bushingI.D.

1st clutch 9.000-9.015 mm (0.3543-0.3549 in.)

9.03 mm (0.356 in.)

4th clutch 6.018-6.030 mm (0.2369-0.2374 in.)

6.045 mm (0.2380 in.)

Width of sealing ring groove 2.025-2.075 mm (0.0797-0.0811 in.)

2.095 mm (0.082 in.)





Countershaft Diameter of needle bearingcontact area

at left end 36.004-36.017 mm (1.4175-1.4180 in.)

When worn ordamaged

at 3rd gear 35.980-35.996 mm (1.4165-1.4172 in.)

When worn ordamaged

at 4th gear 27.980-27.993 mm (1.1016-1.1021 in.)

When worn ordamaged

at reverse gear collar 31.975-31.991 mm (1.2589-1.2595 in.)

When worn ordamaged

at 1st gear collar 31.975-31.991 mm (1.2589-1.2595 in.)

When worn ordamaged

I.D. of gears 1st gear 38.000-38.016 mm (1.4961-1.4967 in.)

When worn ordamaged

3rd gear 41.000-41.016 mm (1.6142-1.6148 in.)

When worn ordamaged

4th gear 33.000-33.016 mm (1.2992-1.2998 in.)

When worn ordamaged

Reverse gear 38.000-38.016 mm (1.4961-1.4967 in.)

When worn ordamaged

End play of gears 1st gear 0.1-0.5 mm (0.004-0.020 in.) -

3rd gear 0.05-0.17 mm (0.002-0.007in.)

-

4th gear 0.10-0.18 mm (0.004-0.007in.)

-

Reverse gear 0.10-0.25 mm (0.004-0.010in.)

-

28 mm distance collarlength

No. 1 39.00 mm (1.535 in.) -

No. 2 39.10 mm (1.539 in.) -

No. 3 39.20 mm (1.543 in.) -

No. 4 39.30 mm (1.547 in.) -

No. 5 39.05 mm (1.537 in.) -

No. 6 39.15 mm (1.541 in.) -

No. 7 39.25 mm (1.545 in.) -

No. 8 38.90 mm (1.531 in.) -

No. 9 38.95 mm (1.533 in.) -

3rd gear collar length 20.65-20.70 mm (0.8130-0.8150 in.)

-

Reverse gear collar length 14.5-14.6 mm (0.571-0.575in.)

-

Reverse gear collar flangethickness

2.4-2.6 mm (0.094-0.102 in.) When worn ordamaged

1st gear collar length 14.5-14.6 mm (0.571-0.575in.)

-

1st gear collar flangethickness

2.4-2.6 mm (0.094-0.102 in.) When worn ordamaged

3rd gear splined washerthickness

4.95-5.00 mm (0.195-0.197in.)

When worn ordamaged

3rd clutch feed pipe O.D. At 15 mm (0.6 in.) from end 7.97-7.98 mm (0.3138-0.3142 in.)

7.95 mm (0.313 in.)

2-16



3rd clutch feed pipe bushingI.D.

8.000-8.022 mm (0.3150-0.3158 in.)

8.03 mm (0.316 in.)

Reverse selector hub O.D. 51.87-51.90 mm (2.042-2.043 in.)

When worn ordamaged

1st gear I.D. of one-wayclutch contact area

83.339-83.365 mm (3.2810-3.2821 in.)

When worn ordamaged

Park gear diameter of one-way clutch area

66.685-66.698 mm (2.6254-2.6259 in.)

When worn ordamaged





Reverse idler gear Reverse idler gear shaftdiameter at needle bearingcontact area

13.990-14.000 mm (0.5508-0.5512 in.)

When worn ordamaged

I.D. 18.007-18.020 mm (0.7089-0.7094 in.)

When worn ordamaged

End play 0.05-0.18 mm (0.002-0.007in.)

-

I.D. of reverse idler gearshaft holder

14.416-14.434 mm (0.5676-0.5683 in.)

When worn ordamaged

Sub-shaft Diameter of needle bearingcontact area

at transmission housing 25.991-26.000 mm (1.023-1.024 in.)

When worn ordamaged

at 4th gear collar 23.9935-23.0065 mm(0.9446-0.9058 in.)

When worn ordamaged

4th gear I.D. 32.000-32.016 mm (1.2600-1.2605 in.)

When worn ordamaged

4th gear end play 0.05-0.17 mm (0.002-0.007in.)

-

4th gear collar length 24.0-24.1 mm (0.945-0.949in.)

-

4th gear collar flangethickness

2.95-3.10 mm (0.116-0.122in.)

When worn ordamaged

4th gear thrust washerthickness

2.93-3.00 mm (0.115-0.118in.)

When worn ordamaged

1st-clutch feed pipe O.D. at 15 mm (0.6 in.) from end 7.97-7.98 mm (0.3138-0.3142 in.)

7.95 mm (0.313 in.)

Item Measurement Qualification Standard or NewWire

DiameterO.D. Free

LengthNo. of Coil

Main valve bodysprings (see page14-183)

Relief valve spring 1.1 mm(0.043 in.)

8.6 mm(0.339 in.)

37.1 mm(1.4161 in.)

13.4

Modulator valve spring 1.4 mm(0.055 in)

9.4 mm(0.370 in.)

33.8 mm(1.331 in.)

10.9

CPB valve spring 1.0 mm(0.039 in.)

8.1 mm(0.319 in.)

40.9 mm(1.610 in.)

16.2

1-2 shift valve spring 0.9 mm(0.035 in.)

7.6 mm(0.299 in.)

41.3 mm(1.626 in.)

16.3

2nd orifice control valvespring

0.7 mm(0.028 in.)

6.6 mm(0.260 in.)

34.8 mm(1.370 in.)

22.0

Servo control valve spring 1.0 mm(0.039 in.)

8.1 mm(0.319 in.)

52.1 mm(2.051 in.)

20.8

Regulator valve bodysprings (see page14-186)

Stator reaction spring 4.5 mm(0.177 in.)

35.4 mm(1.394 in.)

30.3 mm(1.193 in.)

1.9

Regulator valve spring A 1.9 mm(0.075 in.)

14.7 mm(0.579 in.)

77.4 mm(3.047 in.)

15.2

Regulator valve spring B 1.8 mm(0.071 in.)

9.6 mm(0.378 in.)

44.0 mm(1.732 in.)

12.6

Cooler relief valve spring 1.0 mm(0.039 in.)

8.4 mm(0.331 in.)

33.8 mm(1.331 in.)

8.2

Torque converter check valvespring

1.0 mm(0.039 in.)

8.4 mm(0.331 in.)

33.8 mm(1.331 in.)

8.2

Lock-up control valve spring 0.8 mm 6.0 mm 38.4 mm 30.3

2-17



(0.031 in.) (0.236 in.) (1.512 in.)




Item Measurement Qualification Standard or New

WireDiameter

O.D. FreeLength

No. ofCoil

Secondary valve bodysprings (see page 14-187)


7.6 mm(0.299 in.)

57.0 mm(2.244 in.)

26.8


7.6 mm(0.299 in.)

57.0 mm(2.244 in.)

26.8

4th exhaust valve spring 0.9 mm(0.035 in.)

6.1 mm(0.240 in.)

36.4 mm(1.433 in.)

19.5

3-4 orifice control valvespring

0.7 mm(0.028 in.)

6.6 mm(0.260 in.)

37.5 mm(1.476 in.)

24.6

Servo body springs(see page 14-188)

1st accumulator spring 2.1 mm(0.083 in.)

16.0 mm(0.630 in.)

89.1 mm(3.508 in.)

16.2

4th accumulator spring A 2.6 mm(0.102 in.)

17.0 mm(0.669 in.)

88.4 mm(3.480 in.)

14.2

4th accumulator spring B 2.3 mm(0.091 in.)

10.2 mm(0.402 in.)

51.6 mm(2.031 in.)

13.8

3rd accumulator spring A 2.8 mm(0.110 in.)

17.5 mm(0.689 in.)

94.3 mm(3.713 in.)

15.6

3rd accumulator spring B 2.1 mm(0.083 in.)

31.0 mm(1.220 in.)

38.2 mm(1.504 in.)

2.4

2nd accumulator spring C 2.2 mm(0.087 in.)

14.5 mm(0.571 in.)

68.0 mm(2.677 in.)

13.9

2nd accumulator spring A 2.4 mm(0.094 in.)

29.0 mm(1.142 in.)

39.0 mm(1.535 in.)

2.9

3rd sub accumulator spring 2.7 mm(0.106 in.)

17.0 mm(0.669 in.)

39.0 mm(1.535 in.)

6.3

Lock-up valve bodysprings (see page 14-189)

Lock-up shift valve spring 0.9 mm(0.035 in.)

7.6 mm(0.299 in.)

73.7 mm(2.902 in.)

32.0

Lock-up timing valve spring 0.9 mm(0.035 in.)

8.1 mm(0.319 in.)

80.7 mm(3.177 in.)

54.2

Item Measurement Qualification Standard or New Service LimitA/T differential carrier Pinion shaft contact area I.D. 18-010-18.028 mm (0.709-

0.710 in.)-

Carrier-to-pinion shaftclearance

0.023-0.057 mm (0.001-0.002 in.)

0.1 mm (0.004 in.)

Driveshaft contact area I.D. 26.025-26.045 mm (1.0246-1.0254 in.)

-

Carrier-to-driveshaftclearance

0.045-0.086 mm (0.002-0.003 in.)

0.12 mm (0.005 in.)

Set ring-to-carrier bearingouter race clearance

0-0.15 mm (0-0.006 in.) Adjust

A/T differential piniongear

Backlash 0.05-0.15 mm (0.002-0.006in.)

-

I.D. 18.042-18.066 mm (0.7103-0.7113 in.)

-

Pinion gear-to-pinion shaftclearance

0.055-0.095 mm (0.0022-0.0037 in.)

0.15 mm (0.006 in.)

2-18



Standards and Service LimitsHonda Multi Matic Transmission and HMMDifferential


HMM TransmissionFluid

Capacity Use genuine Honda ATF-Z1 For fluid change: 3.1 l (3.3 US qt, 2.7 Imp qt)

For overhaul: 5.6 l (5.9 US qt, 4.9 Imp qt)

Hydraulic pressure Forward clutch pressure At 1,500 rpm (min-1) in position

1.4-1.75 MPa (14.3-17.8 kgf/cm2, 203-253 psi)

Reverse brake pressure At 1,500 rpm (min-1) in position

1.4-1.75 MPa (14.3-17.8 kgf/cm2, 203-253 psi)

Drive pulley pressure At 1,500 rpm (min-1) in

position

0.2-0.7 MPa (2.0-7.1 kgf/cm2, 28-101 psi)

Driven pulley pressure At 1,500 rpm (min-1) in

position

1.5-2.3 MPa (15.3-23.5 kgf/cm2, 218-334 psi)

Lubrication pressure At 3,000 rpm (min-1) in

position

Above 0.2 MPa (Above (0.2 kgf/cm2, 30 psi)

Torque converter Stall speed Check withvehicle on level ground

D15Y4 engine in position

2,500 rpm (min-1) 2,350-2,650 rpm (min-1)

D15Y4 engine in ,

and positions

3,000 rpm (min-1) 2,800-3,100 rpm (min-1)

D17A2 engine in position

2,500 rpm (min-1) 2,350-2,650 rpm (min-1)

D17A2 engine in ,

and positions

2,800 rpm (min-1) 2,600-2,900 rpm (min-1)

ATF pump ATF pump drive gear shaftO.D.

9.98-9.99 mm (0.3929-0.3933 in.)

When worn ordamaged

ATF pump driven gear shaftO.D.

9.98-9.99 mm (0.3929-0.3933 in.)

When worn ordamaged

ATF pump body bushingI.D.

Drive gear shaft 10.0-10.015 mm (0.3937-0.3944 in.)

When worn ordamaged

Driven gear shaft 10.0-10.015 mm (0.3937-0.3944 in.)

When worn ordamaged

ATF pump gear sideclearance

0.015-0.035 mm (0.0006-0.0014 in.)

-

ATF pump gear-to-bodyclearance

Drive gear 0.035-0.0505 mm (0.0014-0.0020 in.)

-

Driven gear 0.035-0.0505 mm (0.0014-0.0020 in.)

-

2-19



Standards and Service LimitsHonda Multi Matic Transmission and HMMDifferential (cont'd)


Clutch Clutch end plate-to-top discclearance

Forward clutch 0.6-0.8 mm (0.024-0.031 in.) -

Start clutch 0.5-0.7 mm (0.020-0.028 in.) -

Reverse brake 0.45-0.75 mm (0.018-0.030in.)

-

Clutch return spring freelength

Forward clutch 30.5 mm (1.20 in.) 28.5 mm (1.12 in.)

Start clutch 40.9 mm (1.61 in.) 38.9 mm (1.53 in.)

Reverse brake 29.4 mm (1.16 in.) 27.4 mm (1.08 in.)

Clutch disc thickness Forward clutch 1.94 mm (0.076 in.) -

Start clutch 1.94 mm (0.076 in.) -

Reverse brake 2.00 mm (0.079 in.) -

Clutch plate thickness Forward clutch 2.00 mm (0.079 in.) When discoloured

Start clutch 2.3 mm (0.091 in.) When discoloured

Reverse brake 1.35 mm (0.053 in.) When discoloured

Forward clutch end plate Mark 14 3.4 mm (0.134 in.) When discoloured














Reverse brake end plate Mark 1 3.6 mm (0.142 in.) When discoloured








2-20





Input shaft Diameter of needle bearingcontact area

Flywheel side 19.987-20.000 mm (0.7869-0.7874 in.)

When worn ordamaged

Forward clutch side 19.987-20.000 mm (0.7869-0.7874 in.)

When worn ordamaged

Thrust clearance ATF pump driven sprockethub

0.37-0.65 mm (0.015-0.026in.)

-

Planetary carrier 0.05-0.11 mm (0.002-0.0043in.)

-

Feed pipe O.D. Drive pulley feed pipe 6.97-6.98 mm (0.274-0.275in.)

6.95 mm (0.274 in.)

Forward clutch feed pipe 11.47-11.48 mm (0.4516-0.4520 in.)

11.45 mm (0.451 in.)

Feed pipe bushing I.D. Drive pulley feed pipe 7.00-7.015 mm (0.2756-0.2762 in.)

7.030 mm (0.277 in.)

Forward clutch feed pipe 11.5-11.518 mm (0.4528-0.4535 in.)

11.533 mm (0.454 in.)

Sealing ring groove width 2.00-2.10 mm (0.079-0.083in.)

2.105 mm (0.083 in.)

Thrust shim, 22 x 28 mmthickness (ATF pump drivensprocket hub)

C 1.15 mm (0.045 in.) When worn ordamaged

D 1.40 mm (0.055 in.) When worn ordamaged

E 1.65 mm (0.065 in.) When worn ordamaged

F 1.90 mm (0.075 in.) When worn ordamaged

G 2.15 mm (0.085 in.) When worn ordamaged

H 2.40 mm (0.095 in.) When worn ordamaged

Thrust shim, 25 x 31 mmthickness (Planetary carrier)

A 1.050 mm (0.041 in.) When worn ordamaged

B 1.12 mm (0.044 in.) When worn ordamaged







I 1.61 mm (0.063 in.) When worn ordamaged

J 1.68 mm (0.066 in.) When worn ordamaged

2-21



K 1.75 mm (0.069 in.) When worn ordamaged

L 1.82 mm (0.072 in.) When worn ordamaged

M 1.085 mm (0.0427 in.) When worn ordamaged

N 1.155 mm (0.0454 in.) When worn ordamaged

O 1.225 mm (0.0482 in.) When worn ordamaged

P 1.295 mm (0.0510 in.) When worn ordamaged

Q 1.365 mm (0.0537 in.) When worn ordamaged

R 1.435 mm (0.0565 in.) When worn ordamaged

S 1.505 mm (0.0593 in.) When worn ordamaged

T 1.575 mm (0.0620 in.) When worn ordamaged

U 1.645 mm (0.0648 in.) When worn ordamaged

V 1.715 mm (0.0675 in.) When worn ordamaged

W 1.785 mm (0.0703 in.) When worn ordamaged





Drive pulley shaft Diameter of needle bearingcontact area

Flywheel side 24.007-24.020 mm (0.945-0.946 in.)

When worn ordamaged

Forward clutch side 24.007-24.020 mm (0.945-0.946 in.)

When worn ordamaged

I.D. at sealing ring 24.007-24.020 mm (0.945-0.946 in.)

When worn ordamaged

Driven pulley shaft Diameter of needle bearingcontact area

Start clutch side 43.981-43.991 mm (1.7315-1.7319 in.)

When worn ordamaged

Thrust clearance Start clutch side 0-0.13 mm (0-0.005 in.) -

Cotter, 25.5 mm thickness(Start clutch hub)





Starter clutch feed pipeO.D.

End cover side 6.97-6.98 mm (0.274-0.275in.)

6.95 mm (0.274 in.)

Flywheel housing side 8.97-8.98 mm (0.353-0.354in.)

8.95 mm (0.352 in.)

Driven pulley shaft feed pipeO.D.

11.47-11.48 mm (0.4516-0.4520 in.)

11.45 mm (0.451 in.)

Start clutch feed pipebushing I.D.

End cover side 7.00-7.015 mm (0.2756-0.2762 in.)

7.030 mm (0.277 in.)

Flywheel housing side 9.0-9.015 mm (0.354-0.355in.)

9.03 mm (0.356 in.)

Driven pulley shaft feed pipebushing I.D.

11.50-11.518 mm (0.4528-0.4535 in.)

11.533 mm (0.454 in.)

Start clutch end plate I.D. 88.90-88.935 mm (3.500-3.501 in.)

When worn ordamaged

Secondary gear shaft Thrust clearance 0-0.15 mm (0-0.006 in.) -

Thrust shim, 25 x 35 mmthickness









I 3.60 mm (0.142 in.) When worn ordamaged

2-22



J 3.70 mm (0.146 in.) When worn ordamaged

K 3.80 mm (0.150 in.) When worn ordamaged

Sealing ring groove width 2.50-2.65 mm (0.098-0.104in.)

2.655 mm (0.105 in.)

Park gear and pawl When worn ordamaged





HMM differentialcarrier

Pinion shaft contact areaI.D.

18.010-18.028 mm (0.709-0.710 in.)

-

Carrier-to-pinion shaftclearance

0.023-0.057 mm (0.001-0.002 in.)

0.1 mm (0.004 in.)

Driveshaft contact area I.D. 26.025-26.045 mm (1.0246-1.0254 in.)

-

Carrier-to-driveshaftclearance

0.045-0.086 mm (0.002-0.003 in.)

0.12 mm (0.005 in.)

Set ring-to-carrier bearingouter race clearance

0-0.15 mm (0-0.006 in.) Adjust

HMM differentialpinion gear

Backlash 0.08-0.15 mm (0.003-0.006in.)

-

I.D. 18.042-18.066 mm (0.7103-0.7113 in.)

-

Pinion gear-to-pinion shaftclearance

0.055-0.095 mm (0.0022-0.0037 in.)

0.15 mm (0.006 in.)

2-23



Standards and Service LimitsSteering


Steering wheel Rotational play measure atoutside edge

With engine running 0-10 mm (0-0.39 in.) -

Starting load measured atoutside edge

With engine running 29 N (3.0 kgf, 6.6 lbs) -

Gearbox Angle of rack guide screwloosened from lockedposition

20° Max.

Pump Output pressure with shut-off valve closed

Engine speed at 3,000 rpm(min)

7,600-8,300 kPa (78-85 kgf/cm2, 1,110-1,210 psi)

290-1,100 kPa (3-11 kgf/cm2, 43-156 psi)

Power steering fluid Capacity Use Genuine Honda powersteering fluid

For reservoir capacity: 0.3 l (0.32 US qt, 0.26 Imp qt)

For system capacity: 1.0 l (1.06 US qt, 0.88 Imp qt)

Power steering pumpbelt NOTE: Adjust anew belt to the newbelt spec, run theengine for 5 minutes,then readjust it to theused belt spec.

Deflection with 98 N (10 kgf,22 lbs) applied mid-waybetween pulleys

Used belt: 13.0-16.5 mm (0.51-0.65 in.)

New belt: 9.0-11.0 mm (0.35-0.43 in.)


Used belt: 390-540 N (40-55 kgf, 88-121 lbs)

New belt: 740-880 N (75-90 kgf, 165-198 lbs)

SuspensionItem Measurement Qualification Standard or New Service Limit

Wheel alignment Camber Front 0°00'+45°Rear -0°45'+45'

Caster Front 1°33'+1°Total Toe Front 0+3 mm (0+0.12 in.)

Rear Adjust: IN 2+2-1 mm (0.08+0.08-0.04 in.)Inspect: IN 2+3 mm (0.08+0.12 in.)

Front wheel turning angle Inside wheelD15B engine 40°00'+2°D17A engine 38°00'+2°Outside wheelD15B engine 31°00' (Reference)D17B engine 30°00' (Reference)

Aluminium wheel Runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.)Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.)

Steel wheel Runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.)Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.)

Wheel bearings End play Front 0-0.05 mm (0-0.002 in.)Rear 0-0.05 mm (0-0.002 in.)

2-24



Standards and Service LimitsBrakes


Parking brake lever Distance travelled whenpulled with 196 N (20 kgf,44 lbs) of force

4-door Rear drum brake 6-7 clicks, Rear disc brake 7-8 clicks

5-door 8-9 clicks

Brake pedal Pedal height (Carpetremoved)

M/T 4-door 184 mm (7.24 in.), 5-door 180 mm (7.09 in.)

A/T 4-door 188 mm (7.40 in.), 5-door 184 mm (7.24 in.)

Free play 0.4-3.0 mm (0.016-0.118 in.)

Master cylinder Piston-to-pushrodclearance

0-0.4 mm (0-0.02 in.)

Brake disc Thickness Front 20.9-21.8 mm (0.82-0.86 in.) 19.0 mm (0.75 in.)

Rear 8.9-9.1 mm (0.350-0.358 in.) 8.0 mm (0.31 in.)

Runout - 0.10 mm (0.004 in.)

Parallelism - 0.015 mm (0.0006 in.)

Brake pads Thickness Front KX model 9.5-10.5 mm (0.37-0.41 in.) 1.6 mm (0.06 in.)

Except KX model 9.0-10.0 mm (0.35-0.39 in.) 1.6 mm (0.06 in.)

Thickness Rear 8.5-9.5 mm (0.33-0.37 in.) 1.6 mm (0.06 in.)

Brake drum I.D. 4-door 199.9-200.0 mm (7.870-7.874in.)

201 mm (7.91 in.)

5-door 219.9-220.0 mm (8.657-8.661in.)

221 mm (8.701 in.)

Brake shoes Lining thickness 4-door 4.0 mm (0.16 in.) 2.0 mm (0.08 in.)

5-door 4.5 mm (0.18 in.) 2.0 mm (0.08 in.)

Brake booster Vehiclewith ABS

Characteristics at 196 N (20kgf, 44 lbf) pedal force

Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)kPa (mmHg, inHg) (1) (2)0 (0, 0) 98 (10, 22) 0 (0, 0) 0 (0, 0)

294 (30, 66) 1700 (17,240)

1600 (16,230)

66.7 (500, 19.7) 98 (10, 22) 4600 (47,670)

4200 (43,610)

294 (30, 66) 10500(107,1500)

10300(105, 1500)

Brake booster Vehiclewithout ABS

Characteristics at 196 N (20kgf, 44 lbf) pedal force

Vacuum N (kgf, lbf) kPa (kgf/cm2, psi)kPa (mmHg, inHg) (3) (4) (5)0 (0, 0) 98 (10, 22) 0 (0, 0) 0 (0, 0) 0 (0, 0)

294 (30, 66) 1700 (17,240)

1600 (16,230)

1800 (18,260)

66.7 (500, 19.7) 98 (10, 22) 4400 (45,640)

4100 (42,600)

4800 (49,700)

294 (30, 66) 10500(107,1500)

10300 (105,1500)

9800 (100,1400)

(1) Except 4-door KQ models(2) 4-door KQ model(3) Except 4-door KQ, PA models and KK (VIN) model(4) 4-door KQ model and KK (VIN) model(5) 4-door PA model

2-25



Air ConditioningItem Measurement Qualification Standard or New

Refrigerant Type HFC-134 a (R-134 a)

Capacity or system 500-550 g (17.6-19.4 oz)

Refrigerant Oil Type SANDEN: SP-10 (P/N 38897-P13-003 or38899-P13-A01)

Capacity of components Condenser 25 m l (5/6 fl oz, 0.9 Imp oz)Evaporator 45 m l (1 ½ fl oz, 1.3 Imp oz)Each line and hose 10 m l (1/3 fl oz, 0.4 Imp oz)Receiver 10 m l (1/3 fl oz, 0.4 Imp oz)Compressor 130-150 m l (4 1/3 fl oz, 3.7 Imp oz-5 fl oz, 4.5 Imp oz)

Compressor Starter coil resistance at 68°F (20°C) 3.05-3.35 ohmsPulley-to-pressure plateclearance

0.5+0.15 mm (0.02+0.006 in.)

Compressor beltNOTE: Adjust a newbelt to the new beltspec., run the enginefor 5 minutes, thenreadjust it to the usedbelt spec.

Deflection with 98 N (10 kgf,22 lbs) applied mid-waybetween pulleys

Used belt: 8.5-11.0 mm (0.33-0.43 in.)New belt: 5.0-6.5 mm (0.20-0.26 in.)


Used belt: 440-590 N (45-60 kgf, 100-130 lbs)New belt: 930-1,125 N (95-115 kgf, 210-255 lbs)

Specifications - Design Specifications


Design Specifications

Item Measurement Qualification Specification

DIMENSIONS Overall length 4-door 4,460 mm (175.6 in.)*1

4,450 mm (175.2 in.)*2

4,435 mm (174.6 in.)*3 *4

5-door 4,285 mm (168.7 in.)

Overall width 4-door 1,715 mm (67.5 in.)

1,720 mm (67.7 in.)*3

1,695 mm (66.7 in.)*4

5-door 1,695 mm (66.7 in.)

Overall height 4-door 1,445 mm (56.9 in.)

1,440 mm (56.7 in.)*2 *3 *4

5-door 1,495 mm (58.9 in.)

1,585 mm (62.4 in.)*5

Wheelbase 4-door 2,625 mm (103.3 in.)

2,620 mm (103.1 in.)*2 *3 *4

5-door 2,680 mm (105.5 in.)*6

2,685 mm (105.7 in.)*7

Track Front (4-door) 1,471 mm (57.9 in.)

1,470 mm (57.9 in.)*2 *3 *4

Front (5-door) 1,470 mm (57.9 in.)*6

1,472 mm (58.0 in.)*7

Rear (4-door) 1,478 mm (58.2 in.)

1,470 mm (57.9 in.)*2 *3

1,465 mm (57.7 in.)*4

Rear (5-door) 1,470 mm (57.9 in.)*6

1,489 mm (58.6 in.)*7

Ground clearance 104 mm (4.10 in.)

Seating capacity Five

WEIGHT Curb Weight 4-door (M/T) 1,077-1,144 kg (2,374-2,522 lbs)

1,100-1,135 kg (2,425-2,502 lbs)*2

4-door (A/T) 1,106-1,170 kg (2,438-2,579 lbs)

1,125-1,160 kg (2,480-2,557 lbs)*2

4-door (HMM) 1,140-1,145 kg (2,513-2,524 lbs)

5-door (M/T) 1,130-1,195 kg (2,491-2,634 lbs)

1,160-1,190 kg (2,557-2,623 lbs)*2

5-door (A/T) 1,164-1,221 kg (2,566-2,692 lbs)

1,185-1,215 kg (2,612-2,679 lbs)*2

Max. permissible Weight 4-door

4-door (KY model) 1,555 kg (3,428 lbs)

Max. loaded Vehicle Weight(ADR)*2

4-door 1,580 kg (3,483 lbs)

5-door (M/T) 1,640 kg (3,616 lbs)

5-door (A/T) 1,660 kg (3,660 lbs)

*1: European model*2: Australian model

2-26



*3: Saudi Arabia model*4: Hong Kong model*5: With Roof Antenna*6: European model (MPW Condition)*7: Except European model



Design Specifications(cont'd)


ENGINE Type D17A5, D17A4, D17A2,D16V2, D16W8, D16W7,D15Y4 engines

Water-cooled, 4-stroke SOHC VTEC engine

D17A3, D17A1, D17Z1,D15Y6, D15Y5, D15Y3,D15Y2, D14Z5 engines

Water-cooled, 4-stroke SOHC engine

Cylinder arrangement Inline 4-cylinder, transverse

Bore and stroke D14Z5 engine 75 x 79 mm (2.95 x 3.11 in.)


75 x 84.5 mm (2.95 x 3.33 in.)

D16V2, D16W8, D16W7engines

75 x 90 mm (2.95 x 3.54 in.)

D17A5, D17A4, D17A3,D17A2, D17A1, D17Z1engines

75 x 94.4 mm (2.95 x 3.72 in.)

Displacement D14Z5 engine 1,396 cm3 (85 cu in.)


1,493 cm3 (91 cu in.)

D16V2, D16W8, D16W7engines

1,590 cm3 (97 cu in.)

D17A5, D17A4, D17A3,D17A2, D17A1, D17Z1engines

1,668 cm3 (102 cu in.)

Compression ratio D14Z5 engine 10.4

D15Y5, D15Y3, D15Y2engines

9.0

D15Y6 engine 9.4

D15Y4 engine 9.9

D16V2, D16W8 engines 9.4

D16W7 engine 10.4

D17A3, D17A1, D17Z1engines

9.5

D17A4, D17A2 engines 9.9

D17A5 engine 9.5

Valve train D17A5, D17A4, D17A2,D16V2, D16W8, D16W7,D15Y4 engines

Belt driven, SOHC VTEC 4 valves per cylinder

D17A3, D17A1, D15Y5,D15Y3, D15Y2, D14Z5engines

Belt driven, SOHC 4 valves per cylinder

2-27





ENGINE Lubrication system Forced, wet sump, with trochoid pump

Oil pump displacement at 6,000 engine rpm 36.4 l (38.5 US qt, 32.0 imp qt)/minute

Water pump displacement at 6,000 engine rpm 130 l (137 US qt, 114 imp qt)/minute

Fuel required KQ, KK, KX, KP, KV, KH,KN, KU models

UNLEADED gasoline with 86 research octane numberor higher

KE, KG, KB models Premium UNLEADED gasoline with 93 researchoctane number or higher

KY, KF, KW, KT models LEADED gasoline with 86 pump octane number orhigher (RON of 86 UNLEADED gasoline may also beused)

STARTER Type Gear reduction

Normal output M/T 1.0 kW

A/T 1.2 kW

Hour rating 30 seconds

Direction of rotation Clockwise as viewed from gear end

CLUTCH Clutch M/T Single plate dry, diaphragm spring

A/T Torque converter

Clutch friction materialsurface area

M/T 176 cm3 (102 sq in.)

MANUALTRANSMISSION

Type Synchronised, 5-speed forward, 1 reverse

Primary reduction Direct 1:1

Gear ratio 1st D14/D17 engines 4-door and D16 engine 3/4-door3.142 Other engines 3.461

2nd D14 engine 4-door 1.750 other engines 1.869

3rd 1.241

4th KU D15 engine 0.911 other engines 0.969

5th KU D15 engine 0.756 other engines 0.805

Reverse 3.230

Final reduction Type Single helical gear

Gear ratio 4.411

AUTOMATICTRANSMISSION

Type Electronically controlled automatic, 4-speed forward, 1reverse


Gear ratio 1st 2.722

2nd KU D17A2 engine model: 1.516, other model: 1.468

3rd KU D17A2 engine model: 1.078, other model: 0.975

4th KU D17A2 engine model: 1.516, other model: 0.674

Reverse 1.955


Gear ratio KU D15Y6 engine model: 4.066, other model: 4.357

HONDA MULTIMATICTRANSMISSION(CVT)

Type Electronically controlled continuously variabletransmission


Gear ratio Low-high 2.466-0.449

Reverse 2.466


2-28



Gear ratio 4.562

STEERING Type 4-door Rack and pinion, with electrical powerassistance/hydraulic power assistance

5-door Rack and pinion, with electrical power assistance

Overall ratio 14.49

Turns, lock-to-lock 2.83

Steering wheel diameter 380 mm (15.0 in.)

SUSPENSION Type Front (4-door) Strut

Front (5-door) Strut

Rear Double wishbone

Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled





WHEEL ALIGNMENT Camber Front 0°

Rear -0°45'

Caster Front 1°33'

Total toe Front 0 mm (0 in.)

Rear In 2 mm (1/16 in.)

BRAKE Type of service brake Front Power-assisted self-adjusting ventilated disc

Rear Power-assisted self-adjusting solid disc or drum

Type of parking brake Mechanical actuating, rear wheels

Pad friction surface area Front 35 cm2 x 2 (5.4 sq in. x 2)

Shoe friction surface area Rear 67 cm2 x 2 (10.3 sq in. x 2)

TYRES Size of front and rear tyre(4-door)

KE (1.4S), KG (1.4S, 1.6LS), KB, KQ (GLI), KH(EXI), KN (150I), KU (EXI),KY, KF, KV, KT models

184/70R14 88H

KK, KX models 185/70R14 86H M + S

KM, KP models 185/65R15 88H

KE (1.6SE), KG (1.6LS,1.6ES) KQ (VTI), KH (VTI),KN (170I) KU (VTI, VTI-S)models

195/60R15 88H

Size of front and rear tyre(5-door)

KE (1.4S, 1.4LS), KTmodels

185/70R 14 88H

KE (1.6S, 1.6LS, 1.6ES),KQ models

195/60R 15 88H

Size of spare tyre KQ, KN, KU, KX models T125/70D15 95M

AIR CONDITIONING Cooling capacity 3,870 kcal/h (15,400 BTU/h)

Compressor Type/manufacturer Scroll/SANDEN

Number of cylinders -

Capacity 85.7 m l/rev. (5.23 cu in./rev.)

Maximum speed 12,000 rpm

Lubricant capacity 130 m l (4 1/3 fl oz)

Lubricant type SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01)

Condenser Type Corrugated fin

Evaporator Type Corrugated fin

Blower Type Radial fan

Motor type 190 W/12 V

Speed control 9-speed

Maximum capacity 480 m3/h (16,900 cu ft/h)

Temperature clutch Air-mix type

Compressor clutch Type Dry, single plate, poly-V belt drive

Electrical powerconsumption at 20°C (68°F)

42 W maximum at 12 V

Refrigerant Type HFC-134a (R-134a)

Quantity 500-550 g (17.5-19.5 oz)

2-29





ELECTRICALRATINGS

Battery 12 V-36 AH/5 hours

12 V – 45 AH/20 hours

12 V – 38 AH/5 hours*1

12 V – 47 AH/20 hours*1

Starter DENSO 12 V – 1.0 kW

MITSUBA 12 V – 1.2 kW

Alternator 12 V – 70 A

Fuses Under-hood fuse/relay box 80 A, 40 A, 30 A, 20 A, 15 A, 7.5 A

Under-dash fuse/relay box 20 A, 15 A, 10 A, 7.5 A

Light bulbs Headlight high beam 12 V – 60 W

Headlight low beam 12 V – 55 W

Front turn signal/Front sidemarker lights

12 V – 21 W/5 W

Front position lights 12 V – 5 W/3 CP*2 (candlepower)

Front parking lights 12 V – 5 W

Side turn signal lights 12 V – 21 W*2

Rear turn signal lights 12 V – 21 W

Brake/Taillights/Rear sidemarker light

12 V – 21W/5 W

Rear for light 12 V – 21 W

Inner taillight 12 V – 5 W

High mount brake light 12 V – 21 W

Back-up light 12 V – 21 W

License plate light 12 V -3 CP

Ceiling light 12 V – 8 W

Trunk light (4-door) 12 V – 5 W

Luggage area light (5-door) 12 V – 5 W

Individual map light 12 V – 8 W

Spotlights 14 V – 8 W

Gauge light 14 V – 1.4 W

Indicator light 12 V – 1.12 W

2-30

Specifications - Body Specifications


Body Specifications

Unit: mm (in.)

*1: European model*2: Australian model*3: Saudi Arabia model*4: Hong Kong model

2-31

Specifications - Body Specifications


Body Specifications(cont'd)

Unit: mm (in.)

*1: With Roof Antenna*2: European model (MPW condition)*3: Except European model

2-32

Maintenance - Maintenance


Maintenance

Lubricants and Fluids 3-2Maintenance Schedule for Normal Conditions (For EuropeanModel)

3-4

Maintenance Schedule for Severe Conditions (For EuropeanModel)

3-6

Maintenance Schedule for Normal Conditions (For Australia andNew Zealand Models)

3-8

Maintenance Schedule for Severe Conditions (For Australia andNew Zealand Models)

3-10

Maintenance Schedule for Normal Conditions (Except European,Australia and New Zealand Models)

3-12

Maintenance Schedule for Severe Conditions (Except European,Australia and New Zealand Models)

3-14

Maintenance - Lubricants and Fluids


Lubricants and Fluids

For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures(such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

NO. LUBRICATION POINTS LUBRICANT1 Engine Always use fuel-efficient that says "API service SG, SH or SJ"

SAE Viscosity See chart below.2 Transmission Manual Genuine Honda Manual Transmission Fluid (MTF) *1

Automatic Genuine Honda ATF-Z1 (ATF) *2Honda Multi Matic

3 Brake system (includes ABS line) Brake fluid DOT 3 or DOT 4 *34 Clutch line Brake fluid DOT 3 or DOT 4 *35 Power steering gearbox Steering grease P/N 08733-B070E67

Release fork (manual transmission)Shift and select cable ends (Manual transmission)

Super High Temp Urea Grease (P/N 08798-9002)

8 Throttle cable end (dashboard lower panel hole) Silicon grease9 Throttle cable end (throttle link) Multi-purpose grease

10 Brake master cylinder pushrod11 Clutch master cylinder pushrod12 Shift lever13 Pedal linkage14 Battery terminals15 Fuel fill lid16 Rear brake shoe linkage Honda White Lithium Grease17 Hood hinges and latch18 Trunk hinges and latch (4-Door model)

Tailgate hinges and latch (5-Door model)19 Door hinges, upper and lower20 Door opening detent21 Calliper piston boot, calliper pins and boots Silicone grease22 Brake line joints (front and rear wheelhouse) Rust preventatives23 Power steering system Honda Power Steering Fluid *424 Air conditioning compressor Compressor oil: SANDEN: SP-10 (P/N 38897-P13-003 or

38899-P13-A01)For refrigerant: HFC-134a (R-134a)

Recommended Engine OilEngine oil viscosity for ambient temperature ranges

CAUTIONUsed engine oil may cause skin cancer if repeatedly left in contact with the skin for prolongedperiods. Although this is unlikely unless you handle used oil on a daily basis, it is still

3-2



advisable to thoroughly wash your hands with soap and water as soon as possible afterhandling used oil.

*1: Always use genuine Honda Manual Transmission Fluid (MTF). Using motoroil can cause stiffer shifting because it does not contain the proper additives.

*2: Always use genuine Honda ATF-Z1 (ATF). Using a non-Honda ATF canaffect shift quality.

*3: We recommend Genuine Honda Brake Fluid. Using a non-Honda brake fluidcan cause corrosion and decrease the life of the system.

*4: Always Honda Power Steering Fluid. Using any other type of power steeringfluid or automatic transmission fluid can cause increased wear and poorsteering in cold weather.



Lubricants and Fluids(cont'd)

4-door

5-door

3-3

Maintenance - Maintenance Schedule for Normal Conditions


Maintenance Schedule for NormalConditions

(European Model)

Listed by Distance/TimeFollow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe ConditionsMaintenance Schedule on 3-6 and 3-7 do not apply.

Service at the indicated distance or timewhichever comes first.

km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120

Replace engine oil

Replace engine oil filter

Replace air cleaner element

Inspect valve clearance

Replace fuel filter

Replace spark plugs

Replace timing belt, and inspect water pump Every 120,000 km (72,000 miles) or 96 months

Inspect and adjust drive belts

Inspect idle speed

Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafterevery 100,000 km (60,000 miles) or 60 months

Replace transmission fluid Manual Transmission Every 120,000 km (72,000 miles) or 96 months

Automatic Transmission 120,000 km (72,000 miles) or 96 months, thereafter every80,000 km (48,000 miles) or 48 months

Inspect front and rear brakes

Replace brake fluid Every 36 months

Check parking brake adjustment

Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months

Check light alignment

Test drive (noise, stability, dashboard operation)

Visually inspect the following items:

Tie rod ends, steering gearbox and boots

Suspension components

Driveshaft boots

Brake hoses and lines (including ABS)

All fluid levels and condition of fluid

Exhaust system

Fuel line and connections

Tyre condition

3-4




(European Model) (cont'd)

NOTES SECTION and PAGE

(see page 8-5)

(see page8-6)

(see page 11-147) (see page 11-147)

Check the valve clearance. (see page 6-14)

(see page 11-138) (see page 11-296)(see page 11-438) (see page 11-571)

(see page 4-25)

Check water pump for signs of seal leakage. (see page 6-18) (see page 6-22) (seepage 10-7)

Check for cracks and damage.Check deflection and tension.

(see page 17-23)


Check specific gravity for freezing point. (see page 10-8)

Use genuine Honda MTF (Manual Transmission Fluid). (see page 13-3)

Use genuine Honda AFT-Z1 (ATF). (see page 14-122)

Check the brake pad and disc thickness. Check for damage orcracks.Check the wheel cylinder for leaks.Check the brake linings for cracking, glazing, wear orcontamination.Check the callipers for damage, leaks and tightness.

(see page 19-3)

Use only DOT 3 brake fluid. (We recommend Genuine Honda Brake Fluid.) Checkthat Brake fluid level is between the upper and lower marks on the reservoir.

(see page 19-7)

Check the parking brake operation. (see page 19-6)

-

Check the position of the headlight. (see page 22-114)

Check for road stability, noise, vibrations and dashboard operation. -

Check for correct installation and position, check for cracks,deterioration rust and leaks.Check tightness of screws, nuts and joints. If necessary, retighten.

-

Check rack grease and steering linkage. Check the boot fordamage and leaking grease.Check the fluid line for damage and leaks.

(see page 17-5)

Check the bolts for tightness.Check all the dust covers for deterioration and damage.

(see page 18-3)

Check the boot and boot band for cracksCheck rack grease.

(see page 16-3)

Check the master cylinder, proportioning control valve and ABS modulator andleakage.

(see page 19-48)

Check for leaks. -

Check the catalytic converter heat shield, exhaust pipe and muffler for damage,leaks and tightness.

(see page 9-5)

3-5



Check fuel lines for loose connections, cracks and deterioration. Retighten looseconnections and replace any damaged parts


Check for pressure, puncture or cuts and irregular tread wear. -

Maintenance - Maintenance Schedule for Severe Conditions


Maintenance Schedule for SevereConditions

(European Model)

Listed by Distance/Time


km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Every 10,000 km (6,000 miles) or 6 months




Replace fuel filter

Replace spark plugs

Replace timing belt and inspect water pump


Inspect idle speed

Replace engine coolant 200,000 km (120,000 miles) or 120 months,thereafter every 100,000 km (60,000 miles) or60 months

Replace transmission fluid Manual Transmission Every 60,000 km (36,000 miles) or 48 months

AutomaticTransmission

60,000 km (36,000 miles) or 48 months,thereafter every 40,000 km (24,000 miles) or24 months

Inspect front and rear brakes Every 10,000 km (6,000 miles) or 6 months



Replace air conditioning filter Every 30,000 km (18,000 miles) or 12 months




Tie rod ends, steering gearbox and boots Every 10,000 km (6,000 miles) or 6 months


Driveshaft boots



Exhaust system


Tyre condition

Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the followingconditions:

3-6



Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.Driving in extremely hot over 35°C (95°F) conditions.Extensive idling of long periods of stop-and-go-driving.Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.Driving on muddy, dusty, or de-iced roads.




(European Model) (cont'd)


(see page 8-5)

(see page 8-6)




(see page 4-25)



(see page 17-23)





Check the brake pad and disc thickness. Check for damage orcracks.Check the wheel cylinder for leaks.Check the brake linings for cracking, glazing, wear orcontamination.Check the calipers for damage, leaks and tightness.

(see page 19-3)


(see page 19-7)


-




-


(see page 17-5)

Check the bolts for tightness.Check all dust covers for deterioration and damage.

(see page 18-3)


(see page 16-3)


(see page 19-48)

Check for leaks. -


(see page 9-5)

3-7






NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow the Normal ConditionMaintenance Schedule on pages 3-4 and 3-5.




(Australian and New Zealand Models)

Listed by Distance/TimeFollow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe ConditionsMaintenance Schedule on 3-10 and 3-11 do not apply.

Service at the indicated distance ortime whichever comes first.

km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120





Replace fuel filter

Replace spark plugs



Inspect idle speed

Replace engine coolant 200,000 km (120,000 miles) or 120 months, thereafter every100,000 km (60,000 miles) or 60 months

Replace transmission fluid Manual Transmission

Automatic Transmission 120,000 km (72,000 miles) or 96 months, thereafter every80,000 km (48,000 miles) or 48 months

CVT

Inspect front and rear brakes






Tie rod ends, steering gearbox and boots


Driveshaft boots



Exhaust system


3-8



Tyre condition




(Australian and New Zealand Models) (cont'd)


(see page 8-5)

(see page 8-6)




(see page 4-25)



(see page 17-23)






Check the brake pad and disc thickness. Check for damage orcracks.Check the wheel cylinder for leaks.Check the brake linings for cracking, glazing, wear orcontamination.Check the calipers for damage, leaks and tightness

(see page 19-3)


(see page 19-7)





-


(see page 17-5)


(see page 18-3)


(see page 16-3)


(see page 19-48)

Check for leaks. -


(see page 9-5)

3-9




(Australian and New Zealand Models)



km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120


Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months



Replace fuel filter

Replace spark plugs

Replace timing belt, and inspect water pump


Inspect idle speed

Replace engine coolant 200,000 km (120,000 miles) or 120 months,thereafter every 100,000 km (60,000 miles) or 60months


Automatic Transmission

CVT









Driveshaft boots



Exhaust system


Tyre condition

Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the following

3-10



conditions:Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.Driving in extremely hot over 35°C (95°F) conditions.Extensive idling of long periods of stop-and-go-driving.Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.Driving on muddy, dusty, or de-iced roads.




(Australian and New Zealand Models) (cont'd)


(see page 8-5)

(see page8-6)

(see page 11-147) (seepage 11-147)



(see page 4-25)



(see page 17-23)







(see page 19-3)


(see page 19-7)





-


(see page 17-5)


(see page 18-3)


(see page 16-3)


(see page 19-48)

Check for leaks. -


(see page9-5)

3-11






NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow the Normal ConditionMaintenance Schedule on pages 3-8 and 3-9.




(Except European, Australian and New ZealandModels)


Service at the indicated distance or time whichever comesfirst.

km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120

Replace engine oil Unleaded type: Every 10,000 km (6,000miles) or 12 months

Leaded type: Every 5,000 km (3,000 miles)or 6 months

Replace engine oil filter Unleaded type: Every 20,000 km (12,000miles) or 12 months

Leaded type: Every 10,000 km (6,000miles) or 6 months

Clean or replace air cleaner element Every 20,000 km (12,000 miles)

Inspect valve clearance with catalyticconverter

Every 40,000 km (24,000 miles)

without catalyticconverter


Replace fuel filter

Replace spark plugs Non-Platinumtype

with catalyticconverter




Platinum type Every 100,000 km (60,000 miles)



Inspect idle speed with catalyticconverter


Replace engine coolant 200,000 km (120,000 miles) or 120 months,thereafter every 100,000 km (60,000 miles)or 60 months



Honda Multi Matic

Inspect front and rear brakes Every 100,000 km (60,000 miles) or 6months

3-12





Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)




Driveshaft boots



Exhaust system


Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe ConditionsMaintenance Schedule on 3-14 and 3-15 do not apply.




(Except European, Australian and New ZealandModels) (cont'd)


(see page 8-5)

(see page 8-6)




(see page 4-25)



(see page 17-23)






Check the brake pad and disc thickness. Check for damage orcracks.Check the wheel cylinder for leaks.Check the brake linings for cracking, glazing, wear orcontamination.Check the callipers for damage, leaks and tightness.

(see page 19-3)


(see page 19-7)


The suggested rotation method is shown in the diagram of the Owner's Manual. -


-

Check rack grease and steering linkage. Check the boot fordamage and leaking grease,Check the fluid line for damage and leaks.

(see page 17-5)

Check the bolts for tightnessCheck all the dust covers for deterioration and damage.

(see page 18-3)


(see page 16-3)


(see page 19-48)

Check for leaks. -


(see page 9-5)

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)

3-13



connections and replace any damaged parts. (see page 11-432) (see page 11-565)




(Except European, Australian and New ZealandModels)


Service at the indicated distance or time whichevercomes first.

km x 1,000 20 40 60 80 100 120 140 160 180 200

miles x 1,000 12 24 36 48 60 72 84 96 108 120

months 12 24 36 48 60 72 84 96 108 120


Replace engine oil filter Every 10,000 km (6,000 miles) or 6 months

Clean or replace air cleaner element Every 20,000 km (12,000 miles)

Inspect valve clearance with catalytic converter Every 40,000 km (24,000 miles)

without catalytic converter Every 20,000 km (12,000 miles)

Replace fuel filter

Replace spark plugs Non-Platinum type with catalytic converter Every 40,000 km (24,000 miles)

without catalytic converter Every 20,000 km (12,000 miles)

Platinum type Every 100,000 km (60,000 miles)



Inspect idle speed with catalytic converter

without catalytic converter

Replace engine coolant 200,000 km (120,000 miles) or 120 months,thereafter every 100,000 km (60,000 miles) or 60months



Honda Multi Matic




Rotate tyre (Check tyre inflation and condition at least once per month) Every 100,000 km (60,000 miles)




Driveshaft boots



3-14



Exhaust system


Follow the Severe Conditions Maintenance Schedule if the customer's vehicle is driven MAINLY under one or more of the followingconditions:

Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.Driving in extremely hot over 35°C (95°F) conditions.Extensive idling of long periods of stop-and-go-driving.Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.Driving on muddy, dusty, or de-iced roads.




(Except European, Australian and New ZealandModels) (cont'd)


(see page 8-5)

(see page 8-6)




(see page 4-25)

Check water pump for signs of leakage. (see page 6-18) (see page 6-22) (seepage 10-7)


(see page 17-23)







(see page 19-3)


(see page 19-7)


The suggested rotation method is shown in the diagram of the Owner's Manual. -


-


(see page 17-5)


(see page 18-3)


(see page 16-3)


(see page 19-48)

Check for leaks. -


(see page 9-5)

Check fuel lines for loose connections, cracks and deterioration. Retighten loose (see page 11-132) (see page 11-290)

3-15



connections and replace any damaged parts (see page 11-432) (see page 11-565)

NOTE: If the customer's vehicle is driven OCCASIONALLY under severe condition, you should follow Normal ConditionMaintenance Schedule on pages 3-12 and 3-13

Engine Electrical - Engine Electrical


Engine Electrical

Special Tools 4-2Starting System

Component Location Index 4-3Circuit Diagram 4-4Starter Circuit Troubleshooting 4-5Clutch Interlock Switch Test 4-7Starter Solenoid Test 4-7Starter Performance Test 4-8Starter Replacement 4-9Starter Overhaul 4-10

Ignition System

Component Location Index 4-20Circuit Diagram 4-21Ignition Timing Inspection 4-22Ignition Coil Troubleshooting 4-23Ignition Coil Removal/Installation 4-24Spark Plug Inspection 4-25

Charging System

Component Location Index 4-26Circuit Diagram 4-27Charging Circuit Troubleshooting 4-28Alternator Replacement 4-31Alternator Overhaul 4-32Alternator-Compressor Belt Inspection and Adjustment 4-37Alternator Belt Inspection and Adjustment 4-38

Cruise Control

Component Location Index 4-39Circuit Diagram 4-40Symptom Troubleshooting Index 4-41Cruise Control Communication Circuit Troubleshooting(A/T)

4-43

Control Unit Input Test 4-44Main Switch Test/Replacement 4-46Set/Resume/Cancel Switch Test/Replacement 4-46Actuator Test 4-47Actuator/Cable Replacement 4-48Actuator Cable Adjustment 4-49Clutch Pedal Position Switch Test 4-49

Engine Electrical - Engine Electrical


Engine ElectricalSpecial Tools

Number Tool Number Description Qty

123

07JGG-001010007746-001040007749-0010000

Belt Tension GaugeDriver Attachment, 52 x 55 mmHandle Driver

111

4-2

Engine Electrical - Starting System


Starting SystemComponent Location Index

1. STARTER CUT RELAY2. Test, page 23-79UNDER-DASH

FUSE/RELAY BOX3. CLUTCH INTERLOCK SWITCH

(KX model with M/T)Test, page 4-7Switch Position Adjustment, page12-4

4. STARTERStarter Circuit Troubleshooting, page4-5Solenoid Test, Page 4-7Performance Test, page 4-8Replacement, page 4-9Overhaul, page 4-10

5. TRANSMISSION RANGE SWITCH(A/T)Test 4-door, page 14-159 or

6. 5-door, page 14-160Replacement,page 14-161TRANSMISSIONRANGE SWITCH (HONDAMULTIMATIC)Test, page 14-342Replacement, page 14-343

4-3



Starting SystemCircuit Diagram

4-4



Starting SystemStarter Circuit Troubleshooting

NOTE:

Air temperature must be between 15o and 38oF (59o

and 100oF) during this procedure.After this test, or any subsequent repair, reset theEngine Control Module (ECM)/Powertrain ControlModule (PCM) to clear any Diagnostic Trouble Codes(DTCs), 4-door (see page 11-3) or 5-door (see page11-3).

Recommended Procedure:Use a starter system tester.Connect and operate the equipment in accordancewith the manufacturer's instructions.

Alternate Procedure1. 1. Hook up the following equipment:

Ammeter, 0 - 400 AVoltmeter, 0 - 20 V (accurate within 0.1 volt)Tachometer, 0 - 1200 rpm (min-1)

2. 2. Remove the No. 46 (15 A) fuse from the under-dashfuse/relay box.

3. 3. With the shift lever in N or P (A/T, HONDA MULTIMATIC), or the clutch pedal pressed (M/T with KXmodel), turn the ignition switch to start (III).

Did the starter crank the engine normally?YES - The starting system is OK. NO - If the starter will not crank at all, go to step 4. If itcranks the engine erratically or too slowly, go to step 7. If itwill not disengage from the flywheel or torque converter ringgear when you release the key, check for the following untilyou find the cause.

Solenoid plunger and switch malfunctionDirty drive gear or damaged overrunning clutch

1. 4. Check the battery condition. Check electricalconnections at the battery and the starter forlooseness and corrosion. Then check the starteragain.

Did the starter crank the engine?YES - The starting system is OK. NO - Go to step 5.

2. 5. Make sure the transmission is in neutral, thendisconnect the BLK/WHT wire (A) from the startersolenoid (B). Connect a jumper wire from the batterypositive terminal to the solenoid terminal.

Did the starter crank the engine?YES - Go to step 6.NO - Remove the starter, and diagnose its internalproblems.

3. 6. Check the following items in the order listed until youfind the open circuit.

Check the BLK/WHT wire and connectorsbetween the under-dash fuse/relay box and theignition switch, and between the under-dashfuse/relay box and the starter.Check the ignition switch (see page 22-83).With A/T, HONDA MULTIMATIC, check thetransmission range switch and connector. WithM/T (KX model), check the clutch inter lock switchand connector.Check the starter cat-relay (A/T, HONDA MULTIMATIC, and M/T [KX model]).

4-5



Starting SystemStarter Circuit Troubleshooting (cont'd)

1. 7. Check engine speed during cranking.Is engine speed above 100 rpm (min-1)?YES - Go to step 8.NO - Remove and disassemble the starter, and check forthe following until you find the cause.

Excessively worn starter brushesOpen circuit in commutator brushesDirty or damaged helical splines or drive gearFaulty drive gear clutch

2. 8. Check the cranking voltage and current draw.Is cranking voltage no less than 8.0 volts (D15Y2, D16W7(KG model), D16W8, D17Z1 (Except Malaysia model),D17Z2, D17Z3, D17A1, D17A2 (Except Malaysia model),D17A5 (Except Indonesia model) engines) or 9.0 volts(Except D15Y2, D16W7 (KG model), D16W8, D17Z1(Except Malaysia model), D17Z2, D17Z3, D17A1, D17A2(Except Malaysia model), D17A5 (Except Indonesia model)engines) and current draw no more than 200 amps (D15Y2,D16W7 (KG model), D16W8, D17Z1 (Except Malaysiamodel), D17Z2, D17Z3, D17A1, D17A2 (Except Malaysiamodel), D17A5 (Except Indonesia model) engines) or 150amps (Except D15Y2, D16W7 (KG model), D16W8, D17Z1(Except Malaysia model), D17Z2, D17Z3, D17A1, D17A2(Except Malaysia model), D17A5 (Except Indonesia model)engines)?YES - Go to step 9.NO - Remove and disassemble the starter, and check forthe following until you find the cause.

Open circuit in starter armature commutatorsegmentsStarter armature draggingShorted armature windingExcessive drag in engine

3. 9. Remove the starter and inspect its drive gear and theflywheel or torque converter ring gear for damage.Replace any damaged parts.

4-6



Starting SystemClutch Interlock Switch Test

Starter Solenoid Test

1. 1. Disconnect the clutch interlock switch 2P connector.

2. 2. Remove the clutch interlock switch (A).3. 3. Check for continuity between the terminals according

to the table.

4. 4. If necessary, replace the switch or adjust the pedalheight (see page 12-4).

1. 1. Check the hold-in coil for continuity between the Sterminal (A) and the armature housing (ground).There should be continuity.

If there is continuity, go to step 2.If there is no continuity, replace the solenoid.

2. 2. Check the pull-in coil for continuity between the Sterminal (A) and M terminal (B). There should becontinuity.

If there is continuity, the solenoid is OK.If there is no continuity, replace the solenoid.

4-7



Starting SystemStarter Performance Test

1. 1. Disconnect the wires from the S terminal and the Mterminal.

2. 1. 12V BATTERY2. BODY (GROUND)

3. 2. Make a connection as described below using asheavy a wire as possible (preferably equivalent tothe wire used for the vehicle).

3. Connect the battery as shown. If the starter pinionpops out, it is working properly. To avoid damagingthe starter, do not leave the battery connected formore than 10 seconds.

4. Disconnect the battery from the M terminal. If thepinion does not retract, the hold-in coil is workingproperly. To avoid damaging the starter, do notleave the battery connected for more than 10seconds.


1. 5. Disconnect the battery also from the body. If thepinion retracts immediately, it is working properly. Toavoid damaging the starter, do not leave the batteryconnected for more than 10 seconds.


3. 6. Clamp the starter firmly in a vice.7. Connect the starter to the battery as described in the

diagram below, and confirm that the motor starts andkeeps rotating.

4. 1. STARTER2. 12V BATTERY

5. 8. If the electric current and motor speed meet thespecifications when the battery voltage is at 11.5 V,the starter is working properly.

Specifications:Maker Electric current Motor speed

DENSO(1.0 Kw)

90 A or less 3,000 rpm (min-1)or more

DENSO(0.8 Kw)

50 A or less 6,000 rpm (min-1)

MITSUBISHI(0.8 Kw)

53 A or less 6,000 rpm (min-1)or more

4-8



Starting SystemStarter Replacement

1. 1. Make sure you have the anti-theft code for the radio,then write down the frequencies for the radio's presetbuttons.

2. Disconnect the battery negative cable, thendisconnect the positive cable, and wait at least 3minutes.

3. Remove the resonator.4. Disconnect the starter cable (A) from the B terminal

on the solenoid, then disconnect the BLK/WHT wire(B) from the S terminal.

2. 5. Remove the two bolts holding the starter, thenremove the starter.

1. 6. Install in the reverse order of removal. Make sure thecrimped side of the ring terminal (A) is facing out.

2. 7. Connect the battery positive cable and negativecable to the battery.

3. 8. Enter the anti-theft code for the radio, then enter thecustomer's radio station presets.

4-9



Starting SystemStarter Overhaul

Disassembly/Reassembly - D15Y2, D16W7 (KG model), D16W8, D17Z1 (Except Malaysia model), D17Z2,D17Z3, D17A1, D17A2 (Except Malaysia model), D17A5 (Except Indonesia model) engines

1. STARTER SOLENOID2. MOLYBDENUM DISULPHIDE3. SOLENOID LEVER4. GEAR HOUSING5. OVERRUNNING CLUTCH

ASSEMBLY6. ARMATURE7. ARMATURE HOUSING8. MOLYBDENUM DISULPHIDE9. MOLYBDENUM DISULPHIDE

10. BRUSH HOLDER11. END COVER

4-10



Starting SystemStarter Overhaul (cont'd)

Disassembly/Reassembly - D15Y3 (Philippine model), D16W9 (Philippine model), D17Z1 (Malaysia model),D17Z5, D17A2 (Malaysia model), D17A5 (Indonesia model) engines

1. STARTER SOLENOID2. MOLYBDENUM DISULPHIDE3. STARTER LEVER4. GEAR HOUSING5. FRONT BEARING6. MOLYBDENUM DISULPHIDE7. OVERRUNNING CLUTCH

ASSEMBLY8. ARMATURE9. END COVER

10. BRUSH11. BRUSH HOLDER12. BRUSH SPRING13. ARMATURE HOUSING

4-11




Disassembly/Reassembly - Except D15Y2, D15Y3 (Philippine model), D16W7 (KG model), D16W8, D16W9,D17Z1, D17Z2, D17Z3, D17A1, D17A2, D17A5 engines

1. STARTER SOLENOID2. MOLYBDENUM

DISULPHIDE3. SOLENOID LEVER4. GEAR HOUSING5. FRONT BEARING6. MOLYBDENUM

DISULPHIDE7. OVERRUNNING

CLUTCH ASSEMBLY8. ARMATURE9. END COVER

10. REAR BEARING11. MOLYBDENUM

DISULPHIDE12. BRUSH HOLDER

INSULATOR13. ARMATURE HOUSING14. BRUSH15. BRUSH HOLDER16. BRUSH SPRING

4-12




Armature Inspection and Test1. 1. Remove the starter (see page 4-9).

2. Disassemble the starter as shown at the beginning ofthis procedure.

3. Inspect the armature for wear or damage fromcontact with the permanent magnet. If there is wearor damage, replace the armature.

2. 4. Check the commutator (A) surface. If the surface isdirty or burnt, resurface with emery cloth or a lathewithin the following specifications, or recondition with#500 or #600 sandpaper (B).

1. 5. Check the commutator diameter. If the diameter isbelow the service limit, replace the armature.

Commutator Diameter

Standard (New): 27.9 - 28.0 mm (1.09 - 1.10 in.)

Service Limit: 27.0 mm (1.06 in.)

2. 6. Measure the commutator (A) runout.If the commutator runout is within the servicelimit, check the commutator for carbon dust orbrass chips between the segments.If the commutator runout is not within the servicelimit, replace the armature.

Commutator RunoutD15Y2, D16W7 (KG model), D16W8, D17Z1 (ExceptMalaysia model), D17A2, D17Z3, D17A1, D17A2(Except Malaysia model), D17A5 (Except Indonesiamodel) engines:

Standard (New): 0.02 mm (0.001 in.) max.


Except D15Y2, D16W7 (KG model), D16W8, D17Z1(Except Malaysia model), D17Z2, D17Z3, D17A1,D17A2 (Except Malaysia model), D17A5 (ExceptIndonesia model) engines:



4-13




1. 7. Check the mica depth (A). If the mica is too high (B),undercut the mica with a hacksaw blade to theproper depth. Cut away all the mica (C) between thecommutator segments. The undercut should not betoo shallow, too narrow, or V-shaped (D).

Commutator Mica Depth



2. 8. Check for continuity between the segments of thecommutator. If an open circuit exists between anysegments, replace the armature.

1. 9. Place the armature (A) on an armature tester (B).Hold a hacksaw blade (C) on the armature core. Ifthe blade is attracted to the core or vibrates whilethe core is turned, the armature is shorted. Replacethe armature.

2. 10. Check with an ohmmeter that no continuity existsbetween the commutator (A) and armature coil core(B), and between the commutator and armature shaft(C). If continuity exists, replace the armature.

4-14




Starter Brush Inspection1. 11. Measure the brush length. If it is not within the

service limit, replace the armature housing assembly.Brush LengthD15Y2, D16W7 (KG model), D16W8, D17Z1 (ExceptMalaysia model), D17Z2, D17Z3, D17A1, D17A2(Except Malaysia model), D17A5 (Except Indonesiamodel) engines:

Standard (New): 14.0 - 14.5 mm(0.55 - 0.57 in.)





Starter Field Winding Test1. 12. Check for continuity between the brushes (A). If

there is no continuity, replace the armature housing(B).

D15Y2, D15Y3 (Philippine model), D16W7 (KGmodel), D16W8, D16W9, D17Z1, D17Z2, D17Z3,D17A1, D17A2, D17A5 engines:

Except D15Y2, D15Y3 (Philippine model), D16W7(KG model), D16W8, D16W9, D17Z1, D17Z2,D17Z3, D17A1, D17A2, D17A5 engines:

2. 13. Check for continuity between each brush (A) and thearmature housing (B). If there is continuity, replacethe armature housing.

4-15




Starter Brush Holder Test:1. 14. Check that there is no continuity between the (+)

brush holder (A) and (-) brush holder (B). If there iscontinuity, replace the brush holder assembly.

D15Y2, D16W7 (KG model), D16W8, D17Z1(Except Malaysia model), D17Z2, D17Z3, D17A1,D17A2 (Except Malaysia model), D17A5 (ExceptIndonesia model) engines:

D15Y3 (Philippine model), D16W9 (Philippinemodel), D17Z1 (Malaysia model), D17Z5, D17A2(Malaysia model), D17A5 (Indonesia model)engines:

Brush Spring Inspection (D15Y2, D16W7 (KGmodel), D16W8, D17Z1 (Except Malaysia model),D17Z2, D17Z3, D17A1, D17A2 (Except Malaysiamodel), D17A5 (Except Indonesia model) engines)1. 15. Insert the brush (A) into the brush holder, and bring

the brush into contact with the commutator, thenattach a spring scale (B) to the spring (C). Measurethe spring tension at the moment the spring lifts offthe brush.

SpringTension:

13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 -4.00 lbf)

4-16




Overrunning Clutch Inspection1. 16. Slide the overrunning clutch along the shaft.

Replace it, if it does not slide smoothly.17. Rotate the overrunning clutch (A) both ways.

Does it lock in one direction and rotate smoothly inreverse ? If it does not lock in either direction or itlocks in both directions, replace it.

D15Y2, D16W7 (KG model), D16W8, D17Z1(Except Malaysia model), D17Z2, D17Z3, D17A1,D17A2 (Except Malaysia model), D17A5 (ExceptIndonesia model) engines:


2. 18. If the starter drive gear (B) is worn or damaged,replace the overrunning clutch assembly; the gear isnot available separately.

Check the condition of the flywheel or torque converter ringgear if the starter drive gear teeth are damaged.

Starter Reassembly (D15Y3 (Philippine model),D16W9 (Philippine model), D17Z1 (Malaysia model),D17Z5, D17A2 (Malaysia model), D17A5 (Indonesiamodel) engines)1. 19. Pry back each brush spring with a screwdriver, then

position the brush about halfway out of its holder,and release the spring to hold it there.

2. 20. Install the armature in the housing and install thebrush holder. Next, pry back each brush springagain, and push the brush down until it seats againstthe commutator, then release the spring against theend of the brush.

NOTE: To seat new brushes, slip a strip of #500 or #600sandpaper, with the grit side up, between the commutatorand each brush, and smoothly rotate will be sanded to thesame contour as the commutator.

4-17




1. 21. Install the washer (A) starter end cover (B) to retainthe brush holder (C).

Starter Reassembly (D15Y2, D16W7 (KG model),D16W8, D17Z1 (Except Malaysia model), D17Z2,D17Z3, D17A1, D17A2 (Except Malaysia model),D17A5 (Except Indonesia model) engines)1. 22. Pry back each brush spring with a screwdriver, then

position the brush about halfway out of its holder,and release the spring to hold it there.

2. 23. Install the armature in the housing and install thebrush holder. Next, pry back each brush springagain, and push the brush down until it seats againstthe commutator, then release the spring against theend of the brush.


4-18




1. 24. Install the starter end cover (A) to retain the brushholder (B).

Starter Reassembly (Except D15Y2, D15Y3(Philippine model), D16W7 (KG model), D16W8,D16W9, D17Z1, D17Z2, D17Z3, D17A1, D17A2,D17A5 engines)1. 25. Install the armature in the housing, and install the

brush holder, then install the tach brush in theholder.


2. 26. Compress the spring, and install it in the brushholder.

3. 27. Install the brush holder insulator (A) and end cover(B).

4-19

Engine Electrical - Ignition System


Ignition SystemComponent Location Index

1. SPARK PLUGInspection, page 4-25

2. IGNITION COILTroubleshooting, page 4-23Removal/Installation, page 4-24

4-20



Ignition SystemCircuit Diagram

4-21



Ignition SystemIgnition Timing Inspection

1. 1. Start the engine. Hold the engine at 3,000 rpm (min-

1) with no load Shift lever in Park or Neutral, until theradiator fan comes on, then let it idle.

2. Check the idle speed, and adjust it if necessary:4-door(KB, KE, KG, TR models) (see page 11-125).4-door(except KB, KE, KG, TR models) (see page11-285).5-door(KE model) (see page 11-425).5-door(except KE models) (see page 11-560).

2. 3. Short the SCS terminal to ground:Using the SCS short connector (KB, KE, KG, TRmodels) (see page 19-55).Using the DLC terminal box (except KB, KE, KG,TR models) (see step 1 on page 19-57).Using the Honda PGM Tester (except KB, KE,KG, TR models) (see step 1 on page 19-57).

3. 4. Connect the timing light to the No. 1 ignition coilwire.

1. 5. Point the light toward the pointers (A) on the timingbelt cover. Check the ignition timing under a no loadconditions: headlights, blower fan, rear windowdefogger, and air conditioner are not operating. If theignition timing differs from the specification below,replace the ECM/PCM, 4-door (see page 11-3) or 5-door (see page 11-311).

Ignition Timing:M/T: 8o + 2o BTDC (RED mark (B))

during idling in neutral

A/T, HONDAMULTI MATIC:

8o + 2o BTDC (RED mark (B))during idling in P or N

2. 6. Disconnect the SCS short connector.

4-22



Ignition SystemIgnition Coil Troubleshooting

NOTE: Perform an ignition coil test after finishing thefundamental tests for the ignition system and the fuel andemissions system.1. 1. Remove the ignition coil cover.

2. Disconnect the four ignition coil 3P connectors.3. Measure the voltage at the No. 3 terminal of each

ignition coil 3P connector with the ignition switch ON(ll).

IGNITION COIL 3P CONNECTOR

Wire side of female terminalsIs there battery voltage?YES - Go to step 4.NO - Repair open in the wire between ignition coil and No.1 (15A) fuse in the under-dash fuse/relay box.

2. 4. Turn the ignition switch OFF.5. Check for continuity between the No. 2 terminal of

each ignition coil 3P connector and body ground.IGNITION COIL 3P CONNECTOR

Wire side of female terminalsIs there continuity?YES - Go to step 6.NO - Repair open in the wire between ignition coil andbody ground (G101).

1. 6. Disconnect ECM/PCM connector A (31P).7. Check for continuity between the body ground and

ECM/PCM connector terminals A27, A28, A29 and/orA30 individually.

ECM/PCM CONNECTOR A (31P)

Wire side of female terminalsIs there continuity?YES - Repair short in the wire between ignition coil andECM/PCM.NO - Go to step 8.

2. 8. Connect the ECM/PCM connector A (31P).9. Measure the voltage at the No. 1 terminal of each

ignition coil 3P connector with the ignition switch tostart (lll).


Wire side of female terminalsIs there approx. 0.5 V?YES - Replace the ignition coil. NO - Repair open in the wire between ignition coil andECM/PCM.

4-23



Ignition SystemIgnition Coil Removal/Installation

1. 1. Remove the ignition coil cover (A), then remove theignition coils (B).

2. 2. Install the ignition coils in the reverse order ofremoval.

4-24



Ignition SystemSpark Plug Inspection

1. 1. Inspect the electrodes and ceramic insulator.Burned or worn electrodes may be caused by:

Advanced ignition timingLoose spark plugPlug heat range too hotInsufficient cooling

Fouled plug may be caused by:Retarded ignition timingOil in combustion chamberIncorrect spark plug gapPlug heat range too coldExcessive idling/low speed runningClogged air cleaner elementDeteriorated ignition coils

2. 1. Cracked insulator2. Damaged gasket3. Worn or deformed electrodes4. Improper gap

Oil-foulingCarbon depositsCracked centre electrode insulator

3. 2. Do not adjust the gap of platinum tip plugs (A);replace the spark plug if the gap is out ofspecification.

Electrode Gap:



1. 3. Replace the plug at the specified interval, or if thecentre electrode is rounded (A). Use only the sparkplugs listed below.

Spark Plugs:Engine Type Spark Plug TypeD14Z5, D15Y6,D15Y4, D16W7

ZFR5J-11 (NGK)KJ16CR-L11 (DENSO)

D15Y5, D17A1,D17A2, D17Z1,D17Z4

ZFR6J-11 (NGK)KJ20CR-L11 (DENSO)

D17A5 BKR6E-N11 (NGK)K20PR-L11 (DENSO)

D15Y2, D15Y3,D16V2, D16W8

BKR5E-11 (NGK)K16CR-L11 (DENSO)

D17Z2, D17Z3 ZFR6J-11 (NGK)ZFR7J-11 (NGK)KJ20CR-L11 (DENSO)KJ22CR-L11 (DENSO)

2. 4. Apply a small quantity of anti-seize compound to theplug threads, and screw the plugs into the cylinderhead finger-tight. Then torque them to 18 Nm (1.8kgf/m, 13 lbf/ft).

4-25

Engine Electrical - Charging System


Charging SystemComponent Location Index

1. UNDER-HOOD FUSE/RELAYBOX(Has built-in ELECTRICAL LOADDETECTOR (ELD) UNIT*)

2. CHARGING SYSTEMINDICATOR(In the gauge assembly)

3. Test, page 22-84ALTERNATOR-COMPRESSOR BELTInspection and Adjustment, page4-37

4. ALTERNATORTroubleshooting, page 4-28

5. Replacement, page 4-31Overhaul,page 4-32BATTERYTest, page 22-79

*: KU, KT, KX, KK models

4-26



Charging SystemCircuit Diagram

4-27



Charging SystemCharging Circuit Troubleshooting

If the charging system indicator does not come on or does notgo off, or the battery is dead or low, test the following items inthe order listed below:Battery (see page 22-79)Charging system indicatorAlternator and regulator circuitAlternator control system (KU, KT, KX, KK models)Charging System Indicator Test1. 1. Turn the ignition switch ON (II).

Does the charging system indicator come on?YES - Go to step 2.NO - Go to step 3.

2. 2. Start the engine.Does the charging system indicator go off?YES - Charging system indicator circuit is OK. NO - Go to step 3.

3. 3. Turn the ignition switch OFF.4. Troubleshoot the multiplex control system (see page

22-273).Is the multiplex control system OK?YES - Go to step 5.NO - Check the multiplex control system as indicated bythe DTC (see page 22-273).

4. 5. Disconnect the alternator 4P connector from thealternator.

6. Measure the voltage at the No. 1 terminal of thealternator 4P connector with the ignition switch ON(II).

ALTERNATOR 4P CONNECTOR

Wire side of female terminals

Is there battery voltage?YES - Go to step 7.NO - Check for a blown No. 4 (10A) fuse. If the fuse is OK,repair open in the wire between the alternator and theunder-dash fuse/relay box.

1. 7. Turn the ignition switch OFF8. Disconnect ECM/PCM connector B (24P)9. Check continuity between the ECM/PCM connector

terminal B10 and alternator 4P connector terminalNo. 3.

ECM/PCM CONNECTOR B (24P)

ALTERNATOR 4P CONNECTORWire side of female terminals

Is there continuity?YES - Go to step 10.NO - Repair open in the wire between the alternator andthe ECM/PCM.

2. 10. Check continuity between the ECM/PCM connectorterminal B10 and body ground.


Wire side of female terminalsIs there continuity?YES - Repair short in the wire between the alternator andthe ECM/PCM. NO - Go to alternator and regulator test.

4-28



Charging SystemCharging Circuit Troubleshooting (cont'd)

Alternator and Regulator Circuit Test1. 1. Be sure the battery is sufficiently charged (see page

22-79).2. Hook up the following equipment:

Ammeter, 0-400AVoltmeter, 0-20V (accurate within 0.1 V)

2. 3. Start the engine. Hold the engine at 3,000 rpm (min-

1) with no load shift lever in Park or Neutral, until theradiator fan comes on then let it idle.

3. 4. Raise the engine speed to 2,000 rpm (min-1) andhold it there.

5. Turn the headlights (high beam) on, and measurevoltage at the alternator terminal.

Is the voltage between 13.9 and 15.1V?YES - Go to step 6.NO - Repair the alternator components (see page 4-32).

1. 6. Read the voltage at 13.5 V.NOTE: Adjust the voltage by turn the blower motor, rearwindow defogger, brake lights and etc. on.Is the amperage 60A or more?YES - Alternator/regulator operation is OK. NO - Repair the alternator components (see page 4-32).

4-29



Charging SystemCharging Circuit Troubleshooting (cont'd)

Alternator Control System Test (KU, KT, KX, KKmodels)1. 1. Check for proper operation of the ELD by checking

the MIL 4-door (see page 11-3) or 5-door (see page11-309).

2. Disconnect the alternator 4P connector from thealternator.

3. Start the engine, and turn the headlights (high beam)ON.

4. Measure voltage between the alternator 4P connectorterminal No. 2 and the positive terminal of thebattery.

BATTERY

ALTERNATOR 4P CONNECTORWire side of female terminals

Is there 1 V or less?YES - Go to step 8.NO - Go to step 5.

2. 5. Turn the headlight and ignition switch OFF.6. Disconnect ECM/PCM connector B (24P).

1. 7. Check for continuity between ECM/PCM connectorterminal B18 and body ground.


Wire side of female terminalsIs there continuity?YES - Repair short in the wire between the alternator andECM/PCM.NO - Substitute a known-good ECM/PCM, and recheck(see page 11-3) or 5-door (see page 11-309). If prescribedvoltage is now available, replace the original ECM/PCM.

2. 8. Turn the headlight and ignition switch OFF.9. Disconnect ECM/PCM connector B (24P).

10. Check for continuity between ECM/PCM connectorterminal B18 and alternator 4P connector terminalNo. 2.


ALTERNATOR 4PCONNECTOR

Wire side of female terminalsIs there continuity?YES - Repair the alternator (see page 4-32). NO - Repair open in the wire between the alternator andECM/PCM.

4-30



Charging SystemAlternator Replacement

1. 1. Make sure you have the anti-theft code for the radio,then write down the frequencies for the radio's presetbuttons.

2. Disconnect the battery negative terminal.3. Remove the adjust plate mounting bolt (A), locknut

(B), and mounting bolt (C), then remove the powersteering (P/S) pump belt (D) and pump withoutdisconnecting the P/S hoses (P/S).

2. 4. Disconnect the 4P connector (A) and alternator cable(B) from the alternator.

1. 5. Loosen the adjusting bolt (A), and remove the lockbolt (B) and mounting bolt (C), then remove thealternator belt and alternator.

2. 6. Install in the reverse order of removal.7. Adjust the alternator belt tension (see page 4-38) or

the alternator-compressor belt tension (see page 4-37).

8. Enter the anti-theft code for the radio, then enter thecustomer's radio station presets.

4-31



Charging SystemAlternator Overhaul

Exploded View1. BEARING RETAINER2. FRONT BEARING3. DRIVE-END HOUSING4. PULLEY LOCKNUT5. PULLEY6. ROTOR7. REAR BEARING8. REAR HOUSING ASSEMBLY9. TERMINAL INSULATOR

4-32



Charging SystemAlternator Overhaul (cont'd)

Special Tools RequiredHandle driver, 07749-0010000Driver attachment, 52 x 55 mm, 07746-0010400

NOTE: Refer to the Exploded View as needed during thisprocedure.1. 1. Test the alternator and regulator before you remove

them (see page 4-28).2. Remove the alternator (see page 4-31).3. Remove the four through bolts.

2. 4. Heat the rear bearing seat with a 1,000 W hair drierfor about 5 minutes (50 - 60oC, 129 - 140oF).

1. 5. Separate the rear housing from the drive-endhousing by inserting a flat tip screwdriver into theopenings and prying them apart.

NOTE: Be careful not to damage the stator with the tip ofthe screwdriver.

2. 6. Separate the rear housing (A) and drive-end housing(B) with the stator (C) attached to the rear housing.

4-33




1. 7. If you are not replacing the front bearing and/or rearbearing, go to step 15. Clamp the rotor in a soft-jawed vice, then remove the pulley locknut.

2. 8. Remove the rotor using a puller as shown.

3. 9. Inspect the rotor shaft for galling, and inspect thebearing journal surface in the drive-end housing forseizure marks.

If either the rotor or drive-end housing isdamaged, replace the alternator.If both the rotor and the drive-end housing areOK, go to step 10.

1. 10. Remove the rear bearing using the puller as shown.

2. 11. Use a hand press to install the new rear bearing.Apply pressure only on the inner race to avoiddamaging the bearing.

4-34




1. 12. Remove the front bearing retainer plate.

2. 13. Support the drive-end housing in a vice, and driveout the front bearing with a brass drift (A) andhammer.

1. 14. With a hammer and the special tools, install a newfront bearing in the drive-end housing.

Alternator Brush Inspection2. 15. Measure the length of both brushes with a vernier

calliper.If either brush is shorter than the service limit,replace the rear housing assembly.If brush length is OK, go to step 16.

Alternator Brush Length:Standard (New): 19.0 mm (0.75 in.)

Service Limit: 5 mm (0.2 in.)

4-35




Rotor Slip Ring Test1. 16. Check that there is continuity between the slip rings

(A).If there is continuity, go to step 17.If there is no continuity, replace the rotorassembly.

2. 17. Check that there is no continuity between each slipring (A) and the rotor (B) and the rotor shaft (C).

If there is no continuity, replace the rear housingassembly, go to step 18.If there is continuity, replace the rotor assembly.

Alternator Reassembly3. 18. If you removed the pulley, put the rotor in the drive-

end housing, then tighten its locknut to 111 Nm (11.3kgf/m, 81.7 lbf/t).

19. Remove any grease or any oil from the slip rings.20. Push the brushes (A) in, then insert a pin or drill bit

(B) (about 1.8 mm (0.77 in.) diameter) to hold themthere.

1. 21. Heat the rear bearing seat with a 1,000 W hair drierfor about 5 minutes (50 - 60oC, 129 - 140oF).

22. Put the rear housing assembly (A) and drive-endhousing/rotor assembly (B) together, tighten the fourthrough bolts (C) and pull put the pin (D).

2. 23. After assembling the alternator, turn the pulley byhand to make sure the rotor rotates smoothly andwithout noise.

24. Reinstall the alternator, and adjust its belt tension(see page 4-37).

4-36



Charging SystemAlternator-A/C Compressor Belt Inspection andAdjustment

Special Tools RequiredBelt Tension Gauge, 07JGG-0010100Belt Tension Gauge MethodInspection1. 1. Attach the belt tension gauge to the belt and

measure the tension. Follow the gaugemanufacturer's instructions. If the belt is worn ordamaged, replace it. If the belt needs adjustment, goto step 2.

Tension:

Used Belt: 390 - 540 N (40 - 55 kgf, 88 - 120 lbf)

New Belt: 830 - 980 N (85 - 100 kgf, 190 - 220 lbf)

Adjustment2. 2. Loosen the mounting bolt (A),lock bolt (B) and lower

bracket mounting bolt mounting bolt (C).3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14

lbf.ft).4. Turn the adjusting bolt (D) to obtain the proper belt

tension, then retighten the lock bolt, mounting boltand lower bracket mounting bolt.

5. Recheck the belt tension.6. If you installed a new belt, run the engine for 5

minutes, then readjust the belt to the used beltspecification.

7. Check the power steering pump belt adjustment (seepage 17-12).

Deflection MethodInspection1. 1. Apply a force of 98 Nm (10 kgf, 22 lbf), and measure

the deflection at the mid point (A) between thealternator and crankshaft pulley. If the belt is worn ordamaged, replace it. If the belt needs adjustment, goto step 2.

Deflection:Used Belt: 8.5 - 11.0 mm (0.33 - 0.43 in.)

New Belt: 5.6 - 6.5 mm (0.20 - 0.26 in.)

Adjustment2. 2. Loosen the mounting bolt (B),lock bolt (C) and lower

bracket mounting bolt mounting bolt (D).3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14

lbf.ft).4. Turn the adjusting bolt (E) to obtain the proper belt

tension, then retighten the lock bolt, mounting boltand lower bracket mounting bolt.




4-37


file:///C|/...4%20EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivHtml/4-38.htm[8/25/2012 6:51:58 PM]

Charging SystemAlternator Belt Inspection and Adjustment

Special Tools RequiredBelt Tension Gauge, 07JGG-0010100Belt Tension Gauge MethodInspection1. 1. Attach the belt tension gauge to the belt and measure the

tension. Follow the gauge manufacturer's instructions. Ifthe belt is worn or damaged, replace it. If the belt needsadjustment, go to step 2.

Tension:Used Belt: 340 - 490 N (35 - 50 kgf, 77 - 110

lbf)New Belt: 540 - 740 N (55 - 75 kgf, 120 - 170

lbf)

Adjustment2. 2. Loosen the mounting bolt (A),lock bolt (B) and lower

bracket mounting bolt mounting bolt (C).3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14 lbf.ft).4. Turn the adjusting bolt (D) to obtain the proper belt tension,

then retighten the lock bolt, mounting bolt and lowerbracket mounting bolt.

5. Recheck the belt tension.6. If you installed a new belt, run the engine for 5 minutes,

then readjust the belt to the used belt specification.7. Check the power steering pump belt adjustment (see page

17-12).

Deflection MethodInspection1. 1. Apply a force of 98 Nm (10 kgf, 22 lbf), and measure

the deflection at the mid point (A) between thealternator and crankshaft pulley. If the belt is worn ordamaged, replace it. If the belt needs adjustment, goto step 2.

Deflection:Used Belt: 8.5 - 11.0 mm (0.33 - 0.43 in.)New Belt: 6.5 - 8.5 mm (0.26 - 0.33 in.)

Adjustment2. 2. Loosen the mounting bolt (B),lock bolt (C) and lower

bracket mounting bolt mounting bolt (D).3. Torque the mounting bolt to 20 N.m (2.0kgf.m,14

lbf.ft).4. Turn the adjusting bolt (E) to obtain the proper belt

tension, then retighten the lock bolt, mounting bolt andlower bracket mounting bolt.




4-38

Engine Electrical - Cruise Control


Cruise ControlComponent Location Index

1. CLUTCH PEDAL POSITIONSWITCH (M/T)Test, page 4-49Clutch Pedal Adjustment, page 12-4

2. CRUISE CONTROL INDICATOR(Built into gauge assembly)Bulb Locations, page 22-87

3. SET/RESUME/CANCEL SWITCHTest/Replacement, page 4-46

4. CRUISE CONTROL UNITInput Test, page 4-44

5. BRAKE PEDAL POSITIONSWITCHTest, page 22-122Pedal HeightAdjustment, page 19-5

6. MAIN SWITCHTest/Replacement, page 4-46

7. ACTUATOR CABLEAdjustment, page 4-44

8. TRANSMISSION RANGE SWITCH(A/T)Test 4-door, page 14-159 or5-door, page 14-160

9. ACTUATORTest, page 4-47Replacement, page4-48

4-39



Cruise ControlCircuit Diagram

4-40



Cruise ControlSymptom Troubleshooting Index

NOTE:The numbers in the table show the troubleshooting sequence.Before troubleshooting.

check the No. 10 (7.5 A) and No. 4 (10 A) fuses in the under-dash fuse/relay box, and the No. 7 (15 A) fuse in theunder-hood fuse/relay box.check that the horn sounds.check the tachometer to see if it works properly.

Symptom Diagnostic procedure Also check forCruise control cannot beset

1. 1. Check main switch (see page 4-46)2. Check SET/RESUME/CANCEL switch (see page 4-46)3. Check brake pedal position switch and mounting (see

page 19-5)4. Check clutch pedal position switch and mounting (M/T)

(see page 4-49)5. Check transmission range switch (A/T) (see page 14-

160)6. Check control unit (see page 4-44)

Poor ground:G101(A/T),G401(M/T), G501Open circuit,loose ordisconnectedterminals: LTGRN, BLK/ORN,GRY/RED, BLU,LT BLU,BLU/WHT

Cruise control can be setbut indicator light does notgo on

1. 1. Check dimming circuit in gauge (see page 22-88)2. Check control unit (see page 4-44)

Poor ground:G501Open circuit,loose ordisconnectedterminals: YEL,BLK/YEL

Cruise speed is noticeablyhigher or lower than whatwas set

1. 1. Check vehicle speed sensor (VSS) (see page 22-96)2. Check actuator (see page 4-47)3. Check control unit (see page 4-44)

Excessive overshooting orundershooting when tryingto set speed

1. 1. Check actuator (see page 4-47)2. Check vehicle speed sensor (VSS) (see page 22-96)3. Check control unit (see page 4-44)

Speed fluctuation on a flatroad with cruise controlset

1. 1. Check vehicle speed sensor (VSS) (see page 22-96)2. Check actuator (see page 4-47)3. Check control unit (see page 4-44)

Vehicle does notdecelerate or accelerateaccordingly whenSET/RESUME/CANCELbutton is pushed

1. 1. Check SET/RESUME/CANCEL switch (see page 4-46)2. Check control unit (see page 4-44)

Open circuit, loose ordisconnected terminals:GRY/RED, LT GRN/BLK

Set speed not cancelled(engine rpm stays high)when clutch pedal ispushed (M/T)

1. 1. Check clutch pedal position switch and mounting (seepage 4-49)

2. Check control unit (see page 4-44)

Short to ground in the LT BLUwire

Set speed not cancelledwhen shift lever is movedto Neutral position (A/T)

1. 1. Check transmission range switch (see page 14-160)2. Check control unit (see page 4-44)

Short to ground in the LT BLUwire

Set speed not cancelledwhen brake pedal ispushed

1. 1. Check brake pedal position switch and mounting (seepage 19-6)


Open circuit, loose ordisconnected terminals:WHT/BLK

4-41



Cruise ControlSymptom Troubleshooting Index (cont'd)

Symptom Diagnostic procedure Also check for

Set speed, does notcancel when main switch ispushed OFF

1. 1. Check main switch (see page 4-46)2. Check control unit (see page 4-44)

Short to power in the LTGRN wire.

Set speed, does notcancel when CANCELbutton is pushed

1. 1. Check SET/RESUME/CANCEL switch (see page4-46)


Open circuit, loose ordisconnected terminals:GRY/RED, LT GRN/BLK

Set speed will not resumewhen RESUME button ispushed (with main switchon, when set speed istemporarily cancelled)

1. 1. Check SET/RESUME/CANCEL switch (see page4-46)


Open circuit, loose ordisconnected terminals: LTGRN/BLK

The transmission shiftsdown slower than normalwhen going up a hill withthe cruise control on (A/T)

1. 1. Troubleshoot the cruise control communicationcircuit (see page 4-43)

4-42



Cruise ControlCruise Control Communication CircuitTroubleshooting (A/T)

1. 1. Start the engine.2. Turn on the cruise control main switch, then drive the

vehicle to speeds over 25 mph (40 km/h) with thecruise control.

Does the cruise control operate?YES - Go to step 3.NO - Check the cruise control unit (see page 4-44) orcruise control actuator.

2. 3. Turn the ignition switch OFF.4. Disconnect ECM/PCM connector E (31P) and cruise

control unit 14P connector.5. Check for continuity between ECM/PCM connector

terminal E12 and body ground.ECM/PCM CONNECTOR E (31P)

Wire side of female terminalsIs there continuity?YES - Repair short to ground in the wire between PCMconnector terminal E12 and the cruise control unit 14Pconnector terminal No. 8. NO - Go to step 6.

3. 6. Reconnect ECM/PCM connector E (31P) and thecruise control unit 14P connector.

1. 7. Connect a voltmeter between the No. 8 terminal ofthe cruise control unit 14 P connector and bodyground. Test-drive the vehicle at speeds over 25mph (40 km/h) with the cruise control set, and watchthe voltmeter.

CRUISE CONTROL UNIT 14P CONNECTOR

Wire side of female terminalsIs there about 1 V?YES - Go to step 8.NO - Replace the cruise control unit.

2. 8. Connect a voltmeter between ECM/PCM connectorterminal E12 and body ground. Drive the vehicle atspeeds over 25 mph (40 km/h) with the cruisecontrol set, and watch the voltmeter.

ECM/PCM CONNECTOR E (31P)

Wire side of female terminalsIs there about 1 V?YES - Check for loose connectors. If necessary replace theECM/PCM and recheck (see page 11-3) or 5-door (seepage 11-309). NO - Repair open in the wire between ECM/PCMconnector terminal E12 and the control unit 14P connectorterminal No. 8.

4-43



Cruise ControlControl Unit Input Test

SRS components are located in this area. Review the SRS component locations (see page 23-25), precautions and procedures(see page 23-25) in the SRS before performing repairs or service.1. 1. Remove the driver's dashboard lower cover.

2. Disconnect the 14P connector from the control unit.3. Inspect the connector and socket terminals to be sure they are all making good contact.

If the terminals are bent, loose, or corroded, repair them as necessary and recheck the system.If the terminals look OK, go to step 4.

1. 14P CONNECTOR2. CRUISE CONTROL UNIT3. Wire side of female terminals

2. 4. With the 14P connector disconnected, make these input tests.Cavity Wire Test condition Test: Desired result Possible cause if result is

not obtained1 BRN/WHT Connect battery power Check the operation of the magnetic

clutch: Clutch should click and outputlink should be locked.

Faulty actuatorPoor ground (G301)An open in the wire

2 BLU Ignition switch ON (II), mainswitch ON and brake pedalpressed, then released

Check for voltage to ground:There should be 0 V with the pedalpressed and battery voltage with thepedal released.

Faulty brake pedalposition switchAn open in the wire

3 BLK Under all conditions Check for continuity to ground:There should be continuity.

Poor ground (G501)An open in the wire

4-44



Cruise ControlControl Unit Input Test (cont'd)

Cavity Wire Test condition Test: Desired result Possible cause if result isnot obtained

4 BLK/ORN Ignition switch ON (II) Check for voltage to ground:There should be battery voltage.

Blown No. 4 (10 A)fuse in the under-dash driver'sfuse/relay boxAn open in the wire

5 WHT/BLK Brake pedal pressed, thenreleased

Check for voltage to ground:There should be battery voltage with thepedal pressed, and 0 V with the pedalreleased.

Blown No. 7 (15 A)fuse in the under-hood fuse/relay boxFaulty brake pedalposition switchAn open in the wire

6 GRY/RED Set button pushed Check for voltage to ground:There should be battery voltage.

Blown No. 7 (15 A)fuse in the under-hood fuse/relay boxFaulty horn relayFaultyset/resume/cancelswitchFaulty cable reelAn open in the wire

7 LT GRN/BLK Resume button pushed

8 BLU/ORN Reconnect the cruisecontrol unit 14Pconnector, start theengine, turn the mainswitch ON and drive thevehicle to speeds over 25mph (40 km/h) with thecruise control set.

Check for voltage to ground: Thereshould be about 1V

Faulty cruise controlunitShort to ground

9 BRN Connect battery power tothe BRN terminal andground to the BRN/YELterminal

Check the operation of the actuatormotor: You should be able to hear themotor

Faulty actuatorAn open in the wire11 BRN/YEL

10 BLU/YEL Ignition switch ON (II) Attach to ground:Cruise indicator light in the gaugeassembly should comes on.

Blown bulbBlown No. 10 (7.5A) fuse in theunder-dashfuse/relay boxFaulty dimmingcircuit in the gaugeassemblyAn open in the wire

12 BLU/WHT Ignition switch ON (II) andmain switch ON; raise thefront of the vehicle, androtate one wheel slowlywhile holding the otherwheel

Check for voltage between theBLU/WHT (+) and BLK (-) terminals:There should be 0 5 V or morerepeatedly.

Faulty ECM/PCMAn open in the wire

13 LT GRN Ignition switch ON (II) andmain switch ON

Check for voltage to ground:There should be battery voltage.

Blown No. 4 (10 A)fuse in the under-dash fuse/relay box

4-45



Faulty main switchAn open in the wire

14 LT BLU A/T: Shift lever in or

M /T: Clutch pedalreleased

Check for continuity to ground:There should be continuity.NOTE: There should be no continuitywhen the clutch pedal is pressed orwhen the shift lever is in other positions.

Faulty transmissionrange switchFaulty clutch pedalposition switchPoor ground (M/T:G401, A/T: G101)An open in the wire

1. 5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, thecontrol unit must be faulty; replace it.



Cruise ControlMain Switch Test/Replacement

4-46Set/Resume/Cancel Switch Test/Replacement

1. 1. Carefully pry the switch panel -assembly out of theinstrument panel.

Terminal side of male terminals

2. 2. Disconnect the 5P connector from the main switch,then remove the switch.

3. Check for continuity between the terminals in eachswitch position according to the table. If there is nocontinuity, replace the switch.

1. 1. Remove the two screws, then remove the switch.

Terminal side of male terminal.2. 2. Check for continuity between the terminals in switch

position according to the table.If there is continuity, and it matches the table, butswitch failure is occurred on the cruise controlunit input test, check and repair the wire harnesson the switch circuit.If there is no continuity in one or both positions,replace the switch.



Cruise ControlActuator Test

1. 1. Disconnect the 4P connector (A) from the actuator(B).

Terminal side of male terminals2. 2. Remove the cover (A), and check the output linkage

(B) for smooth movement.

3. 3. Connect the battery power to the No. 2 terminal andground to the No. 1 terminal.

4. 4. Check for a clicking sound from the magnetic clutch.The output linkage should be locked.

5. If the output linkage is not locked, replace theactuator assembly.

1. 6. Check the operation of the actuator motor in eachoutput linkage position according to the table. Youshould be able to hear the motor.

Battery powerpolarities

Output linkage position

(+) (-) FULLCLOSE

MIDDLEPOSITION

FULLOPEN

No. 4Terminal

No. 3Terminal

Themotorruns.

The motorruns.

Themotorstops.

No. 3Terminal

No. 4Terminal

Themotorstops.

The motorruns.

Themotorruns.

2. 1. FULL OPEN2. OUTPUT LINKAGE3. FULL CLOSE4. MIDDLE POSITION

4-47



Cruise ControlActuator/Cable Replacement

1. 1. Loosen the locknut (A), then disconnect the actuatorcable (B) from the throttle linkage.

2. 2. Disconnect the 4P connector (A) from the actuator.

3. 3. Remove the two mounting bolts, and remove theactuator assembly (B).

1. 4. Remove the actuator cover.

2. 5. Remove the actuator cable from the actuator.

3. 6. Install the reverse order of removal, and adjust thefree play at the throttle linkage after connecting theactuator cable.

4-48



Cruise ControlActuator Cable Adjustment

Clutch Pedal Position Switch Test

1. 1. Check that the actuator cable (A) moves smoothlywith no binding or sticking.

2. 2. Measure the amount of movement of the outputlinkage (B) until the engine speed starts to increase.At first, the output linkage should be located at thefully closed position (C). The free play (D) should be3.75 + 0.5 mm (0.15 +0.02 in.).

3. If the free play is not within specs, loosen thelocknut, and turn the adjusting nut until the free playis as specified, then retighten the locknut.

1. 1. Disconnect the 2P connector from the clutch pedalposition switch (A).

CLUTCH PEDAL POSITION SWITCH 2P CONNECTOR

2. 2. Remove the clutch pedal position switch.3. Check for continuity between the terminals according

to the table.

3. 4. If necessary, replace the clutch pedal position switchor adjust the pedal height (see page 12-4).

4-49

General Information - Engine Assembly


Engine Assembly

Special Tools 5-2Engine Removal 5-3Engine Installation 5-13Cylinder Head 6-1Engine Block 7-1Engine Lubrication 8-1Intake Manifold/Exhaust System 9-1Engine Cooling 10-1



Engine AssemblySpecial Tools

Ref. No. Tool Number Description Qty

1 07KAK-SJ40101 Engine Tilt Hanger Set 1

5-2



Engine AssemblyEngine Removal

NOTE:Use fender covers to avoid damaging paintedsurfaces.To avoid damage, unplug the wiring connectorscarefully while holding the connector portion.Mark all wiring and hoses to avoid misconnection.Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.

1. 1. Secure the hood in the wide open position (supportrod in the lower hole).

2. Make sure you have the anti-theft code for the radio,then write down the frequencies for the radio's presetbuttons.

3. Disconnect the battery negative terminal first, thenthe positive terminal.

4. Remove the intake resonator.

1. 5. Remove the battery and battery base.6. Remove the battery cables (A) from the fuse box and

remove the harness clamps (B).

2. 7. Remove the intake air duct (A) and ground cable (B).

5-3



Engine AssemblyEngine Removal (cont'd)

1. 8. Remove the clutch slave cylinder (A) and clutch linebracket mounting bolt (B) (M/T).

2. 9. Remove the shift cable (A) and select cable (B)(M/T).

1. 10. Remove the shift cable (Honda multi matic).

2. 11. Relieve fuel pressure, 4-door (see page 11-130), or5-door (see page 11-430).

12. Remove the evaporative emission (EVAP) canisterhose.

5-4




1. 13. Remove the brake booster vacuum hose.RHD models: (4-door)

RHD models: (5-door)

LHD models:

1. 14. Remove the glove box stops, then open the glovebox.

15. Disconnect the engine control module(ECM)/powertrain control module (PCM) connectors.

RHD models:

LHD models:

5-5




1. 16. Remove the harness clamps (A) and grommet (B),then pull the engine wire harness through thebulkhead.

RHD models:

LHD models:

1. 17. Remove the throttle cable (A) and cruise controlcable (B) by loosening the locknuts (C), then slippingthe cable ends out of the accelerator linkage. Takecare not to bend the cables when removing them.Always replace any kinked cable with a new one.

2. 18. Remove the adjust plate mounting bolt (A), lock nut(B) and mounting bolt (C), then remove the powersteering (P/S) pump belt (D) and pump withoutdisconnecting the P/S hoses (P/S).

5-6




1. 19. Remove the alternator (see page 4-31).2. 20. Remove the air conditioning (A/C) hose bracket (A)

and P/S hose bracket (B).

3. 21. Remove the alternator lower bracket (A), thenremove the A/C compressor (B) withoutdisconnecting the A/C hoses.

1. 22. Remove the radiator cap.23. Raise the hoist to full height.24. Remove the front tyres/wheels.25. Remove the splash shield.

2. 26. Loosen the drain plug in the radiator, drain theengine coolant (see page 10-8).

27. Drain the transmission fluid. Reinstall the drain plugusing a new washer:

Manual transmission (see page 13-3).Automatic transmission (see page 14-122).Honda multi matic (see page 14-312).

3. 28. Drain the engine oil. Reinstall the drain bolt using anew washer (see page 8-5).

5-7




1. 29. Disconnect the primary heated oxygen sensor(primary HO2S) connector (A) (D14Z5, D15Y2,D15Y4, D16W7, D16W8, D17A2, D17Z3 engines).

2. 30. Disconnect the secondary heated oxygen sensor(secondary HO2S) connector (B) (D14Z5, D15Y4,D16W7, D17A2 engines).

31. Remove exhaust pipe A (C) (D14Z5, D15Y2, D15Y3,D15Y4, D16V2, D16W7, D16W8, D17A2, D17A5,D17Z3 engines).

32. Remove the exhaust pipe/muffler assembly (D15Y5,D15Y6, D17A1, D17Z1, D17Z2 engines).

1. 33. Remove the shift cable covers (A), then remove theshift control cable (B) (A/T).

2. 34. Disconnect the suspension lower arm ball joints andstabiliser links (see page 18-18).

35. Remove the driveshafts (see page 16-3). Coat allprecision finished surfaces with clean engine oil. Tieplastic bags over the driveshaft ends.

5-8




1. 36. Lower the hoist.2. 37. Remove the ground cable (A), upper radiator hose

(B), lower radiator hose (C) and heater hose (D).

1. 38. Remove the heater hose.RHD models:

LHD models:

5-9




1. 39. Remove the ATF cooler hoses, then plug the ATFcooler hoses and lines (A/T. Honda multi matic).

2. 40. Attach the engine tilt hanger set (commerciallyavailable tool for EU models) to the engine asshown.

1. 41. Remove the front mount mounting bolt.

2. 42. Remove the side engine mount bracket mountingnuts.

5-10




1. 43. Remove the transmission mount bracket mountingbolt/nuts.

M/T:

A/T:

HONDA MULTI MATIC:

1. 44. Make sure the hoist brackets are positioned properly.Raise the hoist to full height.

45. Remove the rear mount mounting bolts.

5-11




1. 46. Use a marker to make alignment marks on thereference lines (A) that align with the centres of therear sub-frame mounting bolts (B).

2. 47. Remove the front sub-frame.

1. 48. Check that the engine/transmission is completely freeof vacuum hoses, fuel and coolant hoses andelectrical wiring.

49. Slowly lower the engine approximately 150 mm (6in.). Check once again that all hoses and wires aredisconnected from the engine/transmission.

50. Lower the engine all the way. Remove the chainhoist from the engine.

51. Remove the engine from under the vehicle.

5-12



Engine AssemblyEngine Installation

1. 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.1. REAR STIFFENER

(D15Y4,D17A2 enginesM/T, HONDAMULTIMATIC)

2. REAR STIFFENER(D17A2 engine A/T)

3. P/S PUMP BRACKET(P/S)

4. ENGINE MOUNTBRACKET

5. A/C COMPRESSORBRACKET

6. STIFFENER(Except D15Y4, D17A1engines)

7. FRONT STIFFENER(D15Y4, D17A2engines)

5-13



Engine AssemblyEngine Installation (cont'd)

1. 2. Position the engine under the vehicle. Attach thechain hoist to the engine, then lift the engine intoposition in the vehicle.

Reinstall the mounting bolts/support nuts in the sequencegiven. Failure to follow this sequence may cause excessivenoise and vibration and reduce bushing life.

2. 3. Install the sub-frame (A). Align the reference lines (B)on the sub-frame with the bolt head centre, thentighten the bolts.

1. 4. Tighten the rear mount mounting bolts.

2. 5. Lower the hoist.3. 6. Tighten the side engine mount bracket mounting

nuts.

5-14




1. 7. Tighten the transmission mount bracket mountingbolt/nuts.

M/T:

A/T:

HONDA MULTI MATIC:

1. 8. Tighten the front mount mounting bolt.

2. 1. 12x1.25mm64 Nm (6.5 kgf/m, 47 lbf/ft)Replace.

3. 9. Remove the chain hoist from the engine.10. Raise the hoist to full height.11. Install a new spring clip on the end of each

driveshaft, then install the driveshafts. Make sureeach clip ''clicks'' into place in the differential andintermediate shaft.

12. Connect the suspension lower arm ball joints andstabiliser links (see page 18-18).

13. Install the shift control cable (A), then install the shiftcable covers (B) (A/T).

5-15




1. 14. Install exhaust pipe A (A): use new gaskets (B) andnew self-locking nuts (C) (D14Z5, D15Y2, D15Y3,D15Y4, D16V2, D16W7, D16W8, D17A2, D17A5,D17Z3 engines).

2. 1. C10x 1.25 mm33 Nm (3.4 kgf/m, 25 lbf/ft)Replace.

3. 15. Connect the primary HO2S connector (D) D14Z5,D15Y2, D15Y4, D16W7, D16W8, D17A2, D17Z3engines).

16. Connect the secondary HO2S connector (E) (D14Z5,D15Y4, D16W7, D17A2 engines).

17. Install the exhaust pipe/muffler assembly (A); use anew gasket (B) (D15Y5, D15Y6, D17A1, D17Z1,D17Z2 engines).

1. 18. Install the splash shield.

2. 19. Install the front tyres/wheels.20. Lower the hoist.21. Install the ATF cooler hoses (A/T, Honda multi

matic).

5-16




1. 22. Install the heater hose.RHD models:

LHD models:

1. 23. Install the upper radiator hose (A), lower radiatorhose (B), heater hose (C) and ground cable (D).

5-17




1. 24. Install the A/C compressor (A), then install thealternator lower bracket (B).

2. 25. Install the A/C hose bracket (A) and P/S hosebracket (B).

1. 26. Loosely install the alternator.27. Adjust the alternator belt tension (see page 4-38) or


28. Loosely install the P/S pump belt and pump.29. Adjust the P/S pump belt (see page 17-23).30. Push the ECM/PCM connectors through the

bulkhead, then install the grommet (A).RHD models:

LHD models:

2. 31. Install the harness clamps (B).

5-18




1. 32. Connect the PCM connectors.RHD models:

LHD models:

2. 33. Install the glove box stops.

1. 34. Install the cruise control cable, then adjust the cable(see page 4-48).

35. Install the throttle cable, then adjust the cable (seepage 11-148).

36. Install the brake booster vacuum hose.RHD models (4-door):

RHD models (5-door):

LHD models:

5-19




1. 37. Install the EVAP canister hose.

2. 38. Install the shift cable (A) using the plastic washer (B),washer (C) and spring pin (D) (Honda multi matic).

1. 39. Install the select cable (A) and shift cable (B) usingthe plastic washers (C), washers (D) and new cotterpins (E) (M/T).

2. 40. Install the clutch slave cylinder (A) and clutch linebracket mounting bolt (B) (M/T).

5-20




1. 41. Install the battery base.2. 42. Install the intake air duct (A) and ground cable (B).

3. 43. Install the battery cable (A) on the under-hoodfuse/relay box, then install the harness clamps (B).

1. 44. Install the intake resonator.

2. 45. Clean the battery posts and cable terminals withsandpaper, then assemble them and apply grease toprevent corrosion.

46. Move the shift lever to each gear and verify that theA/T gear position indicator, follows the transmissionrange switch (A/T, Honda multi matic).

47. Check that the transmission shifts into gear smoothly(M/T).

48. Inspect for fuel leaks. Turn ON (II) the ignition switch(do not operate the starter) so that the fuel pumpruns for approximately 2 seconds and pressurisesthe fuel line. Repeat this operation 2 or 3 times, thencheck for fuel leakage at any point in the fuel line.

49. Refill the engine with engine oil (see page 8-5).50. Refill the transmission with fluid:

Manual transmission (see page 13-3).Automatic transmission (see page 14-122).Honda multi matic (see page 14-312).

3. 51. Refill the radiator with engine coolant, and bleed airfrom the cooling system with the heater valve open(see page 10-8).

52. Check the wheel alignment (see page 18-4).53. Enter the anti-theft code for the radio, then enter the

customer's radio station presets.

5-21

Engine Mechanical - Cylinder Head


Cylinder HeadSpecial Tools

Ref. No Tool Number Description Qty

12345678910111213

07HAH-PJ7010007JAA-001020007JAB-001020007JAB-001040007LAJ-PR3010107LAJ-PR3020107MAB-PY3010007NAJ-P07010007PAD-001000007ZAJ-S5A020007406-007000107742-001010007757-0010000

Valve Guide Reamer, 5.525 mmSocket Wrench, 19 mmHandlePulley Holder Attachment, HEX 50 mmValve Inspection SetAir StopperPulley Holder Attachment, HEX 50 mmOil Pressure Gauge AttachmentStem Seal DriverHose, Oil PressureLow Pressure GaugeValve Guide Driver, 5.5 mmValve Spring Compressor

1111111111111

6-2



Cylinder HeadComponent Location Index

1. CYLINDER HEAD COVER2. HEAD COVER GASKET3. UPPER COVER4. RUBBER SEAL5. LOWER COVER6. CRANKSHAFT PULLEY

Replacement, page 6-167. TDC SENSOR8. CAMSHAFT PULLEY9. CRANKSHAFT PULLEY BOLT

Replacement, 6-1610. TIMING BELT

Removal, page 6-18Inspection, page 6-18Installation, page 6-22

11. AUTO-TENSIONER12. TIMING BELT DRIVE PULLEY13. Install with concave surface facing in.14. CKP SENSOR15. SIDE ENGINE MOUNT BRACKET

6-3



Cylinder HeadComponent Location Index (cont'd)

1. WATER PASSAGE2. CYLINDER HEAD BOLT3. DOWEL PIN4. O-RING5. CYLINDER HEAD GASKET6. GASKET

6-4




D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3 engines:1. CYLINDER HEAD PLUG2. O-RING3. ROCKER ARM ASSEMBLY

Overhaul, page 6-35Inspection, 6-38

4. DOWEL PIN5. CAMSHAFT

Inspection, page 6-406. INTAKE VALVE SPRING7. SEAL8. CAMSHAFT PULLEY9. INTAKE VALVE SEAL

Replacement, page 6-4210. VALVE GUIDE

Replacement, page 6-4411. BACK COVER12. RUBBER SEAL13. EXHAUST VALVE

Removal, page 6-42Installation, page 6-48

14. INTAKE VALVE15. CYLINDER HEAD


16. VALVE GUIDE17. VALVE SPRING SEAT18. EXHAUST VALVE SEAL19. EXHAUST VALVE SPRING20. SPRING RETAINER21. VALVE KEEPERS22. VTEC SOLENOID VALVE FILTER23. VTEC SOLENOID VALVE24. OIL CONTROL ORIFICE25. O-RING

6-5




D16W8 engine:1. LOST MOTION ASSEMBLY2. LOST MOTION HOLDER3. ROCKER ARM ASSEMBLY

Overhaul, page 6-36Inspection, page 6-38


Inspection, page 6-406. INTAKE VALVE SPRING7. SEAL8. CAMSHAFT PULLEY9. INTAKE VALVE SEAL






16. VALVE GUIDE17. VALVE SPRING SEAT18. EXHAUST VALVE GUIDE19. EXHAUST VALVE SPRING20. SPRING RETAINER21. VALVE KEEPERS22. VTEC SOLENOID VALVE

FILTER23. VTEC SOLENOID VALVE24. CYLINDER HEAD PLUG25. O-RING26. OIL CONTROL ORIFICE27. O-RING

6-6




D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:1. CYLINDER HEAD PLUG2. O-RING3. ROCKER ARM ASSEMBLY

Overhaul, page 6-37Inspection, page 6-38


Inspection, page 6-406. VALVE SPRING7. SEAL8. CAMSHAFT PULLEY9. INTAKE VALVE SEAL






16. VALVE GUIDE17. VALVE SPRING SEAT18. EXHAUST VALVE SEAL19. VALVE SPRING20. SPRING RETAINER21. VALVE KEEPERS22. OIL CONTROL ORIFICE

6-7



Cylinder HeadEngine Compression Inspection

1. 1. Warm up the engine to normal operating temperature(cooling fan comes on).

2. 2. Turn the ignition switch OFF.3. Remove the air cleaner housing (see step 6 on page

6-29).4. Disconnect all four injector connectors.5. Start the engine and let it run until it stalls.6. Remove the all four ignition coils (see page 4-24).7. Remove the all four spark plugs.8. Attach the compression gauge to the spark plug hole.

1. 9. Connect a tachometer.10. Open the throttle fully, then crank the engine with the

starter motor and measure the compression.Compression Pressure:Above 930 kpa (9.5 kgf/cm2, 135 psi)-250rpm (min-1)

11. Measure the compression on the remainingcylinders.

Maximum variation:Within 200 kPa (2.0 kgf/cm2, 28 psi)

12. If the compression is not within specifications, checkthe following items, then remeasure thecompression.

Damaged or worn valves and seatsDamaged cylinder head gasketDamaged or worn piston ringsDamaged or worn piston and cylinder bore

6-8



Cylinder HeadVTEC Oil Pressure Switch Replacement

VTEC Rocker Arm Test

1. 1. Remove the resonator (see step 5 on page 6-29).2. 2. Remove the bolt (A) and loosen the bolt (B) securing

the VTEC solenoid valve, then remove the harnessbracket (C) from the VTEC solenoid valve.

3. 3. Remove the harness clamp (D) from the connectingpipe.

4. Disconnect the VTEC oil pressure switch connector,then remove the VTEC oil pressure switch (A).

4. 5. Install the VTEC oil pressure switch using a new O-ring (B).

Special Tools RequiredAir Stopper, 07LAJ-PR30201Valve Inspection Set, 07LAJ-PR30101

D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3engines:1. 1. Remove the resonator (see step 5 on page 6-29).

2. Remove the ignition coil cover, then remove the fourignition coils (see page 4-24).

3. Remove the throttle cable clamps and harnessholder from the cylinder head cover (see step 9 onpage 6-19).

4. Remove the cylinder head cover (see step 10 onpage 6-19).

5. Set the No. 1 piston at TDC (see step 3 on page 6-18).

6. Verify that the intake secondary rocker arm (A)moves independently of the intake primary rockerarm (B).

If the intake secondary rocker arm does notmove, remove the primary and secondary rockerarms as an assembly and check that the pistonsin the secondary and primary rocker arms movesmoothly. If any rocker arm needs replacing,replace the primary and secondary rocker armsas an assembly and retest.If the intake secondary rocker arm moves freely,go to step 7.

2. 7. Repeat step 6 on the remaining intake secondaryrocker arms with each piston at TDC. When all thesecondary rocker arms pass the test, go to step 8.

6-9



Cylinder HeadVTEC Rocker Arm Test (cont'd)

1. 8. Check that the air pressure on the shop aircompressor gauge indicates over 400 kPa (4kgf/cm2, 57 psi).

2. 9. Inspect the valve clearance (see page 6-14).10. Cover the timing belt with a shop towel to protect the

belt.11. Plug the relief hole with the air stopper.

3. 12. Remove the sealing bolt (A) from the inspection hole(B) and connect the valve inspection set.

1. 13. Loosen the valve on the regulator and apply thespecified air pressure:

Specified Air Pressure:250 kPa (2.5 kgf/cm2, 36 psi)NOTE: If the synchronising piston does not move afterapplying air pressure, move the primary or secondaryrocker arm up and down manually by rotating thecrankshaft counter-clockwise.

2. 14. Move the intake secondary rocker arm (A) for theNo. 1 cylinder. The primary rocker arm (B) andsecondary rocker arm should move together.

If the intake primary rocker arm does not move,remove the primary and secondary rocker armsas an assembly and check that the piston in thesecondary and primary rocker arms movesmoothly. If any rocker arm needs replacing,replace the primary and secondary rocker armsas an assembly and retest.

3. 15. Remove the special tools.16. After inspection, check that the MIL does not come

on.

6-10




D16W8 engine:1. 1. Remove the resonator (see step 5 on page 6-29).

2. Remove the ignition coil cover, then remove the 4ignition coils (see page 4-24).

3. Remove the throttle cable clamps and harnessholder from the cylinder head cover (see step 9 onpage 6-19).

4. Remove the cylinder head cover (see step 10 onpage 6-19).

5. Set the No. 1 piston at TDC (see step 3 on page 6-18).

6. Move the intake secondary rocker arm (A) movesindependently of the intake mid rocker arm (B) andintake primary rocker arm (C).

If the intake secondary rocker arm does notmove, remove the mid, primary and secondaryrocker arms as assembly and check that thepistons in the mid and primary rocker arms movesmoothly. If any rocker arm needs replacing,replace the mid, primary and secondary rockerarms as an assembly and retest.If the intake secondary rocker arm moves freely,go to step 7.

2. 7. Repeat step 6 on the remaining intake secondaryrocker arms with each piston at TDC. when all thesecondary rocker arms pass the test, go to step 8.

1. 8. Check that the air pressure on the shop aircompressor gauge indicates over 400 kPa (4 kgf/cm,57 psi).

9. Inspect the valve clearance (see page 6-14).10. Cover the timing belt with a shop towel to protect the

belt.11. Plug the relief hole with the air stopper.

2. 12. Remove the sealing bolt (A) from the inspection holeA (B) and connect the valve inspection set.

6-11




1. 13. Loosen the valve on the regulator and apply thespecified air pressure.

Specified Air Pressure:250 kPa (2.5 kgf/cm2, 36 psi)

2. 14. With the specified air pressure applied, push up thetiming plate (A); the synchronising piston will pop outand engage the intake primary rocker arm (B) andintake secondary rocker arm (C).

NOTE:The synchronising piston (D) can be seen in thegap between the secondary and primary rockerarms.When the timing plate is engaged in the groove A(E) on the timing piston (F), the piston will belocked in the pushed out piston.

1. 15. Stop applying air pressure and push up the timingplate (A); the synchronising piston (B) will return toits original position with a click.

Visually check the disengagement of the synchronisingpiston. Replace the intake rocker arms as an assembly ifthere is any abnormality.NOTE: When the timing plate is pushed up, it releases thetiming piston (C), letting the return spring (D) move thesynchronising piston to its original positions.

2. 16. Remove the valve inspection set from the inspectionhole A, then tighten the sealing bolt.

17. Remove the sealing bolt (A) from the inspection holeB (B) and connect the valve inspection set.

6-12




1. 18. Loosen the valve on the regulator and apply thespecified air pressure.

Specified Air Pressure:250 kPa (2.5 kgf/cm2, 36 psi)

2. 19. Make sure that the intake primary rocker arm (A) andsecondary rocker arm (B) are mechanicallyconnected by piston and that the intake mid rockerarm (C) does not move when pushed manually. Ifany intake mid rocker arm moves independently ofthe intake primary and intake secondary rocker arms,replace the rocker arms as a set.

1. 20. Remove the special tools, then tighten the sealingbolt.

21. Use a 10 mm (0.39 in.) diameter rod (A) to depresseach lost motion assembly through its full movement,replace any lost motion assembly that does movesmoothly.

2. 22. After inspection, check that the MIL does not comeon.

6-13



Cylinder HeadValve Clearance Adjustment

NOTE: Adjust the valves only when the cylinder headtemperature is less than 38oC (100oF).1. 1. Remove the ignition coil cover, then remove

the four ignition coils (see page 4-25).2. Remove the throttle cable clamps and

harness holder from the cylinder head cover(see step 9 on page 6-19).

3. Remove the cylinder head cover (see step 10on page 6-19).

4. Remove the grommet from the upper coverand disconnect the TDC sensor connector.Remove the upper cover (see step 1 on page6-57).

5. Set the No. 1 piston at TDC. The ''UP'' mark(A) on the camshaft pulley should be at thetop and the TDC marks (B) on the pulleyshould line up with the top edge of the head.

1. 6. Select the correct thickness feeler gauge for the valves youare going to check.Intake: 0.18 - 0.22 mm (0.007 - 0.009 in.)Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 in.)

Adjusting screw location:INTAKE

EXHAUST2. 7. Insert the feeler gauge (A) between the adjusting screw (B)

and the end of the valve stem and slide it back and forth;you should feel a slight amount of drag.

6-14



Cylinder HeadValve Clearance Adjustment (cont'd)

1. 8. If you feel too much or too little drag, loosen thelocknut (A) and turn the adjusting screw (B) until thedrag on the feeler gauge is correct.

D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3engines:

D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1,D17Z1, D17Z2 engines:

2. 9. Tighten the locknut and recheck the clearance.Repeat the adjustment if necessary.

1. 10. Rotate the crankshaft 180o counter-clockwise(camshaft pulley turns 90o). The ''UP'' mark (A) onthe camshaft pulley should be toward the exhaustside of the head.

2. 11. Check and if necessary, adjust the valve clearanceon No. 3 cylinder.

12. Rotate the crankshaft 180o counter-clockwise tobring No. 4 piston to TDC. TDC marks (A) are visibleagain.


6-15



Cylinder HeadValve Clearance Adjustment (cont'd)

Crankshaft Pulley Removal and Installation

1. 14. Rotate the crankshaft 180o counter-clockwise tobring No. 2 piston to TDC. The ''UP'' mark (A) shouldbe on the intake side of the head.


16. Install the cylinder head cover (see page 6-55).

Special Tools RequiredSocket, 19 mm, 07JAA-001020AHandle, 07JAB-0010200Pulley holder attachment, HEX 50 mm, 07JAB-0010400Pulley holder attachment, HEX 50 mm, 07MAB-PY30100

Removal1. 1. Hold the pulley with holder handle (A) and holder

attachment (B).With P/S:

With EPS:

2. 2. Remove the bolt with a 19 mm socket (C) andbreaker bar.

6-16



Cylinder HeadCrankshaft Pulley Removal and Installation(cont'd)

Installation1. 1. Remove any oil from the pulleys (A), guide plate (B),

crankshaft (C), bolt (D) and washer (E). Clean andlubricate as shown below.

O: CleanX: Remove any oil

: Lubricate

1. 2. Install the crankshaft pulley and hold the pulley withholder handle (A) and holder attachment (B).

With P/S:

With EPS:

2. 3. Tighten the bolt to 20 Nm (2.0 kgf/m, 14 lbf/ft) with atorque wrench and 19 mm socket (C). Do not use animpact wrench.

4. Tighten the pulley bolt an additional 90o.

6-17



Cylinder HeadTiming Belt Inspection

Timing Belt Removal

1. 1. Remove the ignition coil cover, then remove the fourignition coils.

2. 2. Remove the throttle cable clamps and harnessholder mounting bolts.

3. Remove the cylinder head cover.4. Inspect the timing belt for cracks and oil or coolant

soaking. Replace the belt if it is oil or coolant soaked.Remove any oil or solvent that gets on the belt.

3. 5. After inspecting, retorque the crankshaft pulley bolt(see page 6-17).


1. 1. Make sure you have the anti-theft code for the radio,then write down the frequencies for the radio'spreset buttons.

2. Disconnect the battery negative terminal.3. Turn the crankshaft pulley so its TDC mark (A) lines

up with the pointers (B).

2. 4. Remove the front tyres/wheels.5. Remove the splash shield.

6-18



Cylinder HeadTiming Belt Removal (cont'd)

1. 6. Remove the adjust plate mounting bolt (A), locknut(B) and mounting bolt (C), then remove the powersteering (P/S) pump belt (D) and pump withoutdisconnecting the P/S hoses.

2. 7. Remove the alternator (see page 4-32).8. Remove the four ignition coils (see page 4-24).9. Remove the throttle cable clamps (A) and harness

holder (B) from the cylinder head cover.

1. 10. Remove the cylinder head cover.

6-19




1. 11. Hold the pulley with holder handle (A) and holderattachment (B).

With P/S

With EPS

2. 12. Remove the bolt with a 19 mm socket (C) andbreaker bar.

1. 13. Support the engine with a jack and wood blockunder the oil pan.

14. Remove the upper bracket.

2. 15. Remove the grommet (A) from the upper cover anddisconnect the TDC sensor connector (B).

3. 16. Remove the upper cover (C) and lower cover (D).

6-20




1. 17. Remove the side engine mount bracket.

2. 18. Remove the CKP sensor from the oil pump withoutdisconnecting the connector.

1. 19. Move the auto-tensioner to remove tension from thetiming belt, then remove the timing belt.

6-21



Cylinder HeadTiming Belt Installation


NOTE: If you are removing the auto-tensioner, refer to theauto-tensioner installation procedure.1. 1. Clean the timing belt pulleys and the upper and lower

covers.2. Set the crankshaft to TDC. Align the TDC mark (A)

on the timing belt drive pulley with the pointer (B) onthe oil pump.

1. 3. Clean the camshaft pulley and set it to TDC.1. The ''UP'' mark (A) on the camshaft pulley should

be at the top.2. Align the TDC marks (B) on the camshaft pulley

with the top edge of the head.

2. 4. Install the timing belt in a counter-clockwisesequence, starting with the drive pulley.1. Drive pulley (A).2. Tensioner pulley (B).3. Water pump pulley (C).4. Camshaft pulley (D).

6-22



Cylinder HeadTiming Belt Installation (cont'd)

1. 5. Install the CKP sensor.

2. 6. Install the all bolts loosely, then tighten the mountingbolts as the numbered sequence shown.

1. 7. Install the lower cover.

2. 8. Clean the pulley bolt and washer.9. Clean all oil off the inside face (A) of the crankshaft

pulley and apply lubricant to the pulley bolt (B) andwasher (C).

O: CleanX: Remove any oil

: Lubricate

6-23




1. 10. Install the crankshaft pulley and hold the pulley withholder handle (A) and holder attachment (B).

With P/S:

With EPS:

2. 11. Tighten the bolt to 20 Nm (2.0 kgf/m, 14 lbf/ft) with atorque wrench and 19 mm socket (C). Do not use animpact wrench.

12. Tighten the pulley bolt an additional 90o.

1. 13. Rotate the crankshaft pulley about 5 or 6 turnscounter-clockwise so that the timing belt positions onthe pulleys.

14. Turn the crankshaft pulley so its TDC mark (A) linesup with the pointers (B).

2. 15. Check the camshaft pulley marks (A)If the camshaft pulley marks are also at TDC, goto step 16.If the camshaft pulley marks are not at TDC,remove the timing belt and repeat steps 2 through12.

6-24




1. 16. Install the upper cover (A), then connect the TDCsensor connector (B) and install the grommet (C).

2. 17. Install the upper bracket (A), then tighten the nuts inthe numbered sequence shown.

1. 18. Install the cylinder head cover (see page 6-55).19. Install the harness holder (A) and throttle cable

clamps (B).



22. Loosely install the P/S pump belt and pump.23. Adjust the P/S pump belt (see page 17-23).24. Install the splash shield.25. Install the front tyres/wheels.26. Clean the battery posts and cable terminals with

sandpaper, then assemble them and apply grease toprevent corrosion.


6-25



Cylinder HeadAuto-Tensioner Removal/Installation

Removal:1. 1. Remove the timing belt (see page 6-18).

2. Remove the auto-tensioner.

Installation:1. 1. Clean the timing belt pulleys and the upper and

lower covers.2. Set the crankshaft to TDC. Align the TDC mark (A)

on the timing belt drive pulley with the pointer (B) onthe oil pump.

2. 3. Clean the camshaft pulley and set it to TDC.1. The ''UP'' mark (A) on the camshaft pulley should

be at the top.2. Align the TDC marks (B) on the camshaft pulley

with the top edge of the head.

6-26



Cylinder HeadAuto-Tensioner Removal/Installation (cont'd)

1. 4. Align the holes on the tensioner pulley (A) andtensioner base (B), then insert 3.0 mm (0.12 in.)diameter pin (C) into the holes.

2. 5. Install the tensioner spring (A) on the auto-tensioner(B).

1. 6. Install the auto-tensioner, then tighten the auto-tensioner mounting bolt (A) to 9.8 Nm (1.0 kgf/m, 7.2lbf/ft).

2. 7. Loosen the auto-tensioner mounting bolt 180o.8. Install the timing belt in a counter-clockwise

sequence, starting with the drive pulley.1. Drive pulley (A).2. Tensioner pulley (B).3. Water pump pulley (C).4. Camshaft pulley (D).

6-27



Cylinder HeadAuto-Tensioner Removal/Installation (cont'd)

Cylinder Head Removal

1. 9. Install the tensioner spring on the tensioner bolt.

2. 10. Rotate the crankshaft pulley 2 turns counter-clockwise so that the timing belt positions on thepulleys.

11. Set the No. 1 piston at TDC.12. Tighten the auto-tensioner mounting bolt (A) to 44

Nm (4.5 kgf/m, 33 lbf/ft), then remove the pin (B)from the auto-tensioner.

3. 13. Install the remaining parts.

NOTE:Use fender covers to avoid damaging paintedsurfaces.To avoid damage, unplug the wiring connectorscarefully while holding the connector portion.To avoid damaging the cylinder head, wait until theengine coolant temperature drops below 38oC(100oF) before loosening the cylinder head bolts.Mark all wiring and hoses to avoid misconnection.Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.


2. Disconnect the battery negative terminal.3. Drain the engine coolant (see page 10-8).4. Remove the throttle cable (A) and cruise control

cable (B) by loosening the locknuts (C), then slippingthe cable ends out of the accelerator linkage. Takecare not to bend the cables when removing them.Always replace any kinked cable with a new one.

6-28



Cylinder HeadCylinder Head Removal (cont'd)

1. 5. Remove the intake resonator.

2. 6. Disconnect the intake air temperature (IAT) sensorconnector (A) and remove the breather hose, thenremove the air cleaner housing (B).

1. 7. Remove the brake booster vacuum hose (A) andpositive crankcase ventilation (PCV) hose (B).

2. 8. Relieve fuel pressure, 4-door (see page 11-129), or5-door (see page 11-427).

9. Remove the EVAP canister hose.

6-29




1. 10. Remove the ground cable (A), upper radiator hose(B), lower radiator hose (C), heater hose (D) andwater bypass hose (E).

2. 11. Remove the two bolts securing the connecting pipe,then remove the connecting pipe from the waterpassage.

1. 12. Remove the adjusting plate mounting bolt (A),locknut (B) and mounting bolt (C), then remove thepower steering (P/S) pump belt (D) and pumpwithout disconnecting the P/S hoses.

2. 13. Remove the alternator (see page 4-31).14. Remove the air conditioning (A/C) hose bracket (A)

and P/S hose bracket (B).

6-30




1. 15. Remove the engine wire harness connectors andwire harness clamps from the intake manifold.

Idle air control (IAC) valve connectorThrottle position sensor connectorManifold absolute pressure (MAP) sensorconnectorEvaporative emission (EVAP) canister purge valveconnector (Except KT, KW models)Engine coolant temperature (ECT) sensorconnectorRadiator fan switch connectorCKP sensor connectorTDC sensor connectorExhaust gas recirculation (EGR) connector(D14Z5, D15Y4, D16W7, D17A2 engines)VTEC solenoid valve connector (D15Y4, D16V2,D16W7, D17A2, D17A5, D17Z3 engines)VTEC oil pressure switch connector (D16W7engine)Oil pressure sensor connector

2. 16. Support the engine with a jack and wood blockunder the oil pan.

17. Remove the upper bracket.

1. 18. Remove the cover (A), then remove the exhaustmanifold (B).

D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:

Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2engines:

6-31




1. 19. Remove the intake manifold.

2. 20. Remove the four ignition coils (see page 4-24).21. Remove the throttle cable clamps (A) and harness

holder (B) from the cylinder head cover.

1. 22. Remove the cylinder head cover.

2. 23. Remove the timing belt (see page 6-18).

6-32




1. 24. Remove the camshaft pulley (A) and back cover (B). 1. 25. Remove the cylinder head bolts. To preventwarpage, unscrew the bolts in sequence 1/3 turn ata time; repeat the sequence until all bolts areloosened.

CYLINDER HEAD BOLTS LOOSENINGSEQUENCE:

2. 26. Remove the cylinder head.

6-33



Cylinder HeadCylinder Head Inspection for Warpage

Rocker Arm Assembly Removal

NOTE: If camshaft-to-holder oil clearances (see page 6-40) arenot within specifications, the cylinder head cannot be resurfaced.If camshaft-to-holder oil clearances are within specifications,check the cylinder head for warpage.Measure along the edges and three ways across the centre.

If warpage is less than 0.05 mm (0.002 in.) cylinderhead resurfacing is not required.If warpage is between 0.05 mm (0.002 in.) and 0.2 mm(0.008 in.), resurface cylinder head.Maximum resurface limit is 0.2 mm (0.008 in.) based ona height of 93 mm (3.7 in.).

Cylinder Head Height:

Standard (New): 92.95 - 93.05 mm (3.659 - 3.663in.)

1. 1. PRECISION STRAIGHT EDGE

1. 1. Loosen the adjusting screws (A).

2. 2. Remove the bolts and the rocker arm assembly.1. Unscrew the camshaft holder bolts 2 turns at a

time, in a criss-cross pattern, to preventdamaging the valves or rocker arm assembly.

2. When removing the rocker arm assembly, donot remove the camshaft holder bolts. The boltswill keep the camshaft holders, the springs andthe rocker arms on the shafts.

CAMSHAFT HOLDER BOLT LOOSENINGSEQUENCE:

6-34



Cylinder HeadRocker Arms and ShaftsDisassembly/Reassembly

NOTE:Identify parts as they are removed to ensure reinstallation in original location.Inspect the rocker shafts and rocker arms (see page 6-38).The rocker arms must be installed in the same positions if reused.When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep theholders, springs and rocker arms on the shaft.Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.

D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3 engines:1. RUBBER BAND2. INTAKE ROCKER SHAFT3. COLLAR B4. INTAKE ROCKER ARM

ASSEMBLY5. COLLAR A6. No. 1 CAMSHAFT HOLDER7. EXHAUST ROCKER ARM A8. Letter "A" is stamped on the rocker

arm.9. EXHAUST ROCKER SHAFT

10. Letter "B" is stamped on the rockerarm.

11. SPRING12. EXHAUST ROCKER ARM B13. No. 5 CAMSHAFT HOLDER14. No. 4 CAMSHAFT HOLDER15. No. 3 CAMSHAFT HOLDER16. No. 2 CAMSHAFT HOLDER

6-35



Cylinder HeadRocker Arms and ShaftsDisassembly/Reassembly (cont'd)

NOTE:Identify parts as they are removed to ensure reinstallation in original location.Inspect the rocker shafts and rocker arms (see page 6-38).The rocker arms must be installed in the same positions if reused.When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep theholders, springs and rocker arms on the shaft.Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.Bundle the rocker arms with rubber bands to keep them together as a set.

D16W8 engine:1. RUBBER BAND2. INTAKE ROCKER ARM

ASSEMBLY3. INTAKE ROCKER SHAFT4. COLLAR B5. SPRING6. TIMING PLATE7. RETURN SPRING8. COLLAR A9. No. 1 CAMSHAFT HOLDER

10. EXHAUST ROCKER ARM A11. Letter "A" is stamped on the

rocker arm.12. EXHAUST ROCKER SHAFT13. Letter "B" is stamped on the

rocker arm.14. SPRING15. EXHAUST ROCKER ARM B16. No. 5 CAMSHAFT HOLDER17. No. 4 CAMSHAFT HOLDER18. No. 3 CAMSHAFT HOLDER19. No. 2 CAMSHAFT HOLDER

6-36



Cylinder HeadRocker Arms and ShaftsDisassembly/Reassembly (cont'd)

NOTE:Identify parts as they are removed to ensure reinstallation in original location.Inspect the rocker shafts and rocker arms (see page 6-38).The rocker arms must be installed in the same positions if reused.When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep theholders, springs and rocker arms on the shaft.Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.

D14Z5, D15Y2, D15Y3, D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:1. COLLAR2. Letter "B" is stamped on the

rocker arm.3. INTAKE ROCKER ARM B4. INTAKE ROCKER SHAFT5. INTAKE ROCKER ARM A6. Letter "A" is stamped on the

rocker arm.7. SPRING8. No. 1 CAMSHAFT HOLDER9. EXHAUST ROCKER ARM A

10. Letter "A" is stamped on therocker arm.

11. EXHAUST ROCKER SHAFT12. Letter "B" is stamped on the

rocker arm.13. SPRING14. EXHAUST ROCKER ARM B15. No. 5 CAMSHAFT HOLDER16. No. 4 CAMSHAFT HOLDER17. No. 3 CAMSHAFT HOLDER18. No. 2 CAMSHAFT HOLDER

6-37



Cylinder HeadRocker Arms and Shafts Inspection

1. 1. Measure the diameter of the shaft at the first rockerlocation.

2. 2. Zero the gauge (A) to the shaft diameter.

1. 3. Measure the inside diameter of the rocker arm andcheck it for an out-of-round condition.

Rocker Arm-to-Shaft Clearance:Standard (New):

Intake: 0.017 - 0.050 mm(0.0007 - 0.0020 in.)

Exhaust: 0.018 - 0.054 mm(0.0007 - 0.0021 in.)


2. 1. Inspect rocker arm face for wear.

3. 4. Repeat for all rockers and both shafts. If theclearance is over the limit, replace the rocker shaftand all overtolerance rocker arms. If any VTECintake rocker arm needs replacement, replace rockerarms (primary and secondary as a set, or primary,mid and secondary as a set).

6-38



Cylinder HeadRocker Arms and Shafts Inspection (cont'd)

1. 5. Inspect the synchronising piston (s) (A) and timingpiston (B). Push it manually. If it does not movesmoothly, replace the rocker arm assembly.

NOTE:When reassembling the primary rocker arm (C),carefully apply air pressure to its oil passage.Apply oil to the pistons when reassembling.

D15Y4, D16V2, D16W7, D17A2, D17A5, D17Z3engines:

D16W8 engine:

1. 6. Assemble each timing plate (A) and return spring (B)on its camshaft holder as shown (D16W8 engine).

6-39



Cylinder HeadCamshaft Inspection

NOTE:Do not rotate the camshaft during inspection.Remove the rocker arms and rocker shafts.

1. 1. Put the camshaft and the camshaft holders on thecylinder head, then tighten the bolts to the specifiedtorque.

Specified torque:8 mm bolts: 20 Nm (2.0 kgf/m, 14 lbf/ft)

Apply engine oil to the boltthreads.

6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)Apply engine oil to the boltthreads.

6 mm bolts: (11), (12), (13), (14)

2. 2. Seat the camshaft by pushing it away from thecamshaft pulley end of the cylinder head.

3. Zero the dial indicator against the end of thecamshaft, then push the camshaft back and forth andread the end play.

Camshaft End Play:Standard (New): 0.05 - 0.15 mm

(0.002 - 0.006 in.)


1. 4. Unscrew the camshaft holder bolts 2 turns at a time,in a criss-cross pattern. Then remove the camshaftholders from the cylinder head.

5. Lift the camshaft out of the cylinder head, wipe themclean, then inspect the lift ramps. Replace thecamshaft if any lobes are pitted, scored, orexcessively worn.

6. Clean the camshaft journal surfaces in the cylinderhead, then set the camshaft back in place. Place aplastigage strip across each journal.

7. Install the camshaft holders, then tighten the bolts tothe specified torque as shown in step 1.

8. Remove the camshaft holders. Measure the widestportion of plastigage on each journal.

If the camshaft-to-holder clearance is withinlimits, go to step 10.If the camshaft-to-holder clearance is beyond theservice limit and the camshaft has been replaced,replace the cylinder head.If the camshaft-to-holder clearance is beyond theservice limit and the camshaft has not beenreplaced, go to step 9.

Camshaft-to-Holder Oil Clearance:Standard (New): 0.050 - 0.089 mm

(0.0020 - 0.0035 in.)


6-40



Cylinder HeadCamshaft Inspection (cont'd)

1. 9. Check the total runout with the camshaft supportedon V-blocks.

If the total runout of the camshaft is within theservice limit, replace the cylinder head.If the total runout is beyond the service limit,replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is stillout of tolerance, replace the cylinder head.

Camshaft Total Runout:



2. 1. Rotate camshaft while measuring.

1. 10. Measure cam lobe height.Cam Lobe Height Standard (New):

INTAKE EXHAUSTD15Y4 engine PRI 38.427 mm

(1.5129 in.)38.784 mm(1.5269 in.)

SEC 32.292 mm(1.2713 in.)

D16V2, D16W7 engines PRI 38.427 mm(1.5129 in.)

38.784 mm(1.5269 in.)

SEC 32.848 mm(1.2932 in.)

D17A2, D17A5, D17Z3engines

PRI 38.604 mm(1.5198 in.)

38.784 mm1.5269 in.)

SEC 32.848 mm1.2932 in.)

D16W8 engine PRI 36.662 mm(1.4434 in.)

38.008 mm(1.4964 in.)

MID 38.274 mm(1.5068 in.)

SEC 32.848 mm1.2932 in.)

D14Z5 engine 34.158 mm(1.3448 in.)

36.488 mm(1.4365 in.)

D15Y2, D15Y3, D15Y5, D15Y6,D17A1, D17Z1, D17Z2 engines

35.299 mm(1.3897 in.)

37.281 mm(1.4678 in.)

PRI: Primary SEC: SecondaryIN: Intake EX: Exhaust T/B: Timing Belt

D15Y4, D16W7, D17A2, D17A5 engines:

D16W8 engine:

6-41



Cylinder HeadValves, Springs and Valve Seals Removal

Valve Inspection

Special Tools RequiredValve Spring Compressor, 07757-0010000Identify the valves and valve springs as they are removed sothat each item can be reinstalled in its original position.1. 1. Using an appropriate-sized socket (A) and plastic

mallet (B), lightly tap the valve retainer to loosen thevalve keepers.

2. 2. Install the valve spring compressor. Compress thespring and remove the valve keepers.

Measure the valve in these areas.Except D15Y2, D15Y3, D16V2, D16W8, D17A5engines:Intake Valve Dimensions

A Standard (New): 29.85 - 30.15 mm(1.175 - 1.187 in.)

B Standard (New): 118.27 - 118.87 mm(4.656 - 4.680 in.)

C Standard (New): 5.480 - 5.490 mm(0.2157 - 0.2161 in.)

C Service Limit: 5.45 mm (0.215 in.)

Exhaust Valve Dimensions





6-42



Cylinder HeadValve Inspection (cont'd)

Valve Stem-to-Guide Clearance Inspection

D15Y2, D15Y3, D16V2, D16W8, D17A5 engines:Intake Valve Dimensions





Exhaust Valve Dimensions





1. 1. Slide the valve out of its guide about 10 mm, thenmeasure the guide-to-stem clearance with a dialindicator while rocking the stem in the direction ofnormal thrust (wobble method).

If the measurement exceeds the service limit,recheck it using a new valve.If the measurement is now within the service limit,reassemble using a new valve.If the measurement with a new valve still exceedsthe service limit, go to step 2.

Intake Valve Stem-to-Guide Clearance:



Exhaust Valve Stem-to-Guide Clearance:



2. 2. Subtract the O.D. of the valve stem, measured with amicrometer, from the I.D. of the valve guide,measured with an inside micrometer or ball gauge.

Take the measurements in 3 places along the valve stemand three places inside the valve guide.The difference between the largest guide measurement andthe smallest stem measurement should not exceed theservice limit.

Intake Valve Stem-to-Guide Clearance:



Exhaust Valve Stem-to-Guide Clearance:



6-43



Cylinder HeadValve Guide Replacement

Special Tools RequiredValve guide driver, 5.5 mm, 07742-0010100Valve guide reamer, 5.525 mm, 07HAH-PJ70100

1. 1. As illustrated below, use a commercially available air-impact valve guide driver (A) modified to fit thediameter of the valve guides. In most cases, thesame procedure can be done using the special tooland a conventional hammer.

2. 2. Select the proper replacement guides and chill themin the freezer section of a refrigerator for about anhour.

3. Use a hot plate or oven to evenly heat the cylinderhead to 150oC (300oF). Monitor the temperature witha cooking thermometer. Do not get the head hotterthan 150oC (300oF); excessive heat may loosen thevalve seats.

1. 4. Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (0.1in.) towards the combustion chamber. This will knockoff some of the carbon and make removal easier.Hold the air hammer directly in line with the valveguide to prevent damaging the driver.

5. Turn the head over and drive the guide out towardthe camshaft side of the head.

2. 6. If a valve guide will not move, drill it out with an 8mm (5/16 inch) bit, then try again. Drill guides only inextreme cases; you could damage the cylinder headif the guide breaks.

7. Remove the new guide(s) from the freezer, one at atime, as you need them.

6-44



Cylinder HeadValve Guide Replacement (cont'd)

1. 8. Apply a thin coat of clean engine oil to the outside ofthe new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified installed height (A)of the guide (B). If you have all 16 guides to do, youmay have to reheat the head.

Valve Guide Installed Height:Intake: 17.85 - 18.35 mm (0.703 - 0.722

in.)Exhaust: 18.65 - 19.15 mm (0.734 - 0.754

in.)

1. 9. Coat both reamer and valve guide with cutting oil.10. Rotate the reamer clockwise the full length of the

valve guide bore.

2. 11. Continue to rotate the reamer clockwise whileremoving it from the bore.

12. Thoroughly wash the guide in detergent and water toremove any cutting residue.

13. Check the clearance with a valve (see page 6-43).Verify that the valve slides in the intake and exhaustvalve guides without exerting pressure.

6-45



Cylinder HeadValve Seat Reconditioning

If the valve guides are worn (see page 6-43), replace them(see page 6-44) before cutting the valve seats.1. 1. Renew the valve seats in the cylinder head using a

valve seat cutter.

1. Carefully cut a 45o seat, removing only enoughmaterial to ensure a smooth and concentric seat.

2. Bevel the upper edge of the seat with the 30o

cutter and the lower edge of the seat with the67.5o cutter (Intake) or 60o cutter (exhaust).Check the width of the seat and adjustaccordingly.

3. Make one more very light pass with the 45o cutterto remove any possible burrs caused by the othercutters.

Valve Seat Width:Intake:



Exhaust:Standard (New): 1.25 - 1.55 mm

(0.049 - 0.061 in.)


1. 2. After resurfacing the seat, inspect it for even valveseating: Apply Prussian Blue compound (A) to thevalve face. Insert the valve in its original location inthe head, then lift it and snap it closed against theseat several times.

2. 3. The actual valve seating surface (B), as shown bythe blue compound, should be centred on the seat.

If it is too high (closer to the valve stem), youmust make a second cut with the 67.5o cutter(Intake) or 60o cutter (exhaust) to move it down,then one more cut with the 45o cutter to restoreseat width.If it is too low (closer to the valve edge), youmust make a second cut with the 30o cutter tomove it up, then one more cut with the 45o cutterto restore seat width.

NOTE: The final cut should always be made with the 45o

cutter.

6-46



Cylinder HeadValve Seat Reconditioning (cont'd)

1. 4. Insert the intake and exhaust valves in the head andmeasure the valve stem installed height (A).

Valve Stem Installed Height:Standard (New): 53.17 - 53.64 mm

(2.093 - 2.112 in.)


2. 5. If the valve stem installed height is over the servicelimit, replace the valve and recheck. If it is still overthe service limit, replace the cylinder head; the valveseat in the head is too deep.

6-47



Cylinder HeadValves, Springs and Valve Seals Installation

Special Tools RequiredStem seal driver, 07PAD-0010000Valve spring compressor, 07757-0010000

1. 1. Coat the valve stems with engine oil. Install thevalves in the valve guides.

2. Check that the valves move up and down smoothly.3. Install the spring seats on the cylinder head.4. Install the new valve seals (A) using the stem seal

driver (B).NOTE: Exhaust valve seal (C) has a black spring (D) andintake valve seal (E) has a white spring (F). They are notinterchangeable.

1. 5. Install the valve spring and valve retainer. Place theend of the valve spring with closely wound coilstoward the cylinder head.

6. Install the valve spring compressor. Compress thespring and install the valve keepers.

2. 7. Lightly tap the end of each valve stem 2 or 3 timeswith a plastic mallet (A) to ensure proper seating ofthe valve and valve keepers. Tap the valve stemonly along its axis so you do not bend the stem.

6-48



Cylinder HeadCamshaft/Rocker Arms, Camshaft Seal andPulley Installation

NOTE: To prevent the rocker arm assembly from coming apart,leave the camshaft holder bolts in the holes.1. 1. After wiping down the camshaft and the journals in

the cylinder head, lubricate both surfaces and installthe camshaft.

2. Clean and install the oil control orifice (A) with a newO-ring (B).

2. 3. Turn the camshaft until its keyway (C) is facing up(No. 1 piston TDC).

4. Loosen all the valve adjusting screws.5. Apply liquid gasket to the head mating surface

(shaded areas) of the No. 1 and No. 5 camshaftholders.

1. 6. Set the rocker arm assembly in place and looselyinstall the bolts. Make sure that the rocker arms areproperly positioned on the valve stems.

7. Tighten each bolt 2 turns at a time, in the sequenceshown below to ensure that the rockers do not bindon the valves.

Specified torque:8 mm bolts: 20 Nm (2.0 kgf/m, 14 lbf/ft)

Apply engine oil to the boltthreads.

6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)Apply engine oil to the boltthreads.

6 mm bolts: (11), (12), (13), (14)

6-49



Cylinder HeadCamshaft/Rocker Arms, Camshaft Seal and Pulley Installation (cont'd)

Cylinder Head Installation

1. 8. Align the marks (A) on the new cylinder head plug(B) with the top edge of the head, then install thecylinder head plug in the cylinder head.

2. 9. Install the back cover (A), then install the camshaftpulley (B).

Install the cylinder head in the reverse order of removal:1. 1. Clean the cylinder head and block surface.

2. Install the cylinder head gasket (A) and dowel pins(B) on the cylinder block. Always use a new cylinderhead gasket.

2. 3. Set the crankshaft to TDC. Align the TDC mark (A)on the timing belt drive pulley with the pointer (B) onthe oil pump.

6-50



Cylinder HeadCylinder Head Installation (cont'd)

1. 4. Clean the camshaft pulley and set it to TDC.

1. The ''UP'' mark (A) on the camshaft pulley should be atthe top.

2. Align the TDC marks (B) on the camshaft pulley with thetop edge of the head.

2. 5. Install the cylinder head on the block.

1. 6. Apply engine oil to the bolt threads and under thebolt heads of all the cylinder head bolts.

7. Tighten the cylinder head bolts sequentially in 3steps.

1st step torque: 20 Nm (2.0 kgf/m, 14 lbf/ft)2nd step torque: 49 Nm (5.0 kgf/m, 36 lbf/ft)3rd step torque: 67 Nm (6.8 kgf/m, 49 lbf/ft)

Use a beam-type torque wrench. When using a preset-typetorque wrench, be sure to tighten slowly and do notovertighten. If a bolt makes any noise while you are torquingit, loosen the bolt and retighten it from the 1st step.CYLINDER HEAD BOLTS TORQUE SEQUENCE:

6-51




1. 8. Install the timing belt (see page 6-22).2. 9. Adjust the valve clearance (see page 6-14).

10. Install the cylinder head cover (see page 6-55).11. Install the intake manifold (A) and tighten the

bolts/nuts in a criss-cross pattern in 2 or 3 steps,beginning with the inner nut. Always use a newintake manifold gasket (B).

3. 12. Tighten the three nuts securing the intake manifoldand brackets.

1. 13. Install the new exhaust manifold gasket (A) andexhaust manifold (B). Loosely install the new nuts,then install the cover (C) and loosely install the newbolts.

D15Y5, D15Y6, D17A1 D17Z1, D17Z2 engines:

Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2engines:

2. 14. Tighten the bolts/nuts in a criss-cross pattern in 2 or3 steps.

15. Install the exhaust pipe with a new gasket (D).16. Install the exhaust manifold bracket (E) (D15Y5,

D15Y6, D17A1, D17Z1, D17Z2 engines).

6-52




1. 17. Install the A/C hose bracket (A) and P/S hosebracket (B).



20. Loosely install the P/S pump belt and pump.21. Adjust the P/S pump belt (see page 17-23).22. Install the connecting pipe (A) with a new O-ring (B).

1. 23. Install the ground cable (A), upper radiator hose (B),lower radiator hose (C), heater hose (D) and waterbypass hose (E).

2. 24. Install the EVAP canister hose.

6-53




1. 25. Install the brake booster vacuum hose (A) and PCVhose (B).

2. 26. Install the air cleaner housing (A), then connect theIAT sensor connector (B) and breather hose.

1. 27. Install the intake resonator.

2. 28. Install the cruise control cable, then adjust the cable(see page 4-49).

29. Install the throttle cable, then adjust the cable (seepage 11-148).

30. After installation, check that all tubes, hoses andconnectors are installed correctly.

31. Clean the battery posts and cable terminals withsandpaper, then assemble them and apply grease toprevent corrosion.

32. Inspect for fuel leaks. Turn ON (II) the ignition switch(do not operate the starter) so that the fuel pumpruns for approximately 2 seconds and pressurisesthe fuel line. Repeat this operation 2 or 3 times, thencheck for fuel leakage at any point in the fuel line.

33. Refill the radiator with engine coolant and bleed airfrom the cooling system with the heater valve open(see page 10-8).


6-54



Cylinder HeadCylinder Head Cover Installation

1. 1. Thoroughly clean the head cover gasket and thegroove.

2. 2. Install the head cover gasket (A) in the groove of thecylinder head cover (B). Seat the head cover gasketin the recesses for the camshaft first, then work itinto the groove around the outside edges. Make surethe head cover gasket is seated securely in thecorners of the recesses (C) with no gap.

3. 3. Check that the mating surfaces are clean and dry.4. Apply liquid gasket, part No. 08C70-K0234M, 08C70-

K0334M or, 08C70-X0331S to the head cover gasketat the four corners of the recesses (A). NOTE: Do not install the parts if 5 minutes or morehave elapsed since applying liquid gasket. Instead,reapply liquid gasket after removing old residue.

1. 5. Hold the head cover gasket in the groove by placingyour fingers on the camshaft holder contactingsurfaces (top of the semicircles). Set the spark plugseals (A) on the spark plug tubes. Once the cylinderhead cover (B) is on the cylinder head, slide thecover slightly back and forth to seat the head covergasket.

2. 6. Inspect the cover washers (C). Replace any washerthat is damaged or deteriorated.

6-55



Cylinder HeadCylinder Head Cover Installation (cont'd)

1. 7. Tighten the bolts in 2 or 3 steps. In the final step,tighten all bolts, in sequence, to 9.8 Nm (1.0 kgf/m,7.2 lbf/ft).

2. 8. Install the harness holder (A) and throttle cableclamps (B).

1. 9. Install the ignition coils (see page 4-24).10. Check that all tubes, hoses and connectors are

installed correctly.11. After assembly, wait at least 30 minutes before filling

the engine with oil.

6-56



Cylinder Head

TDC Sensor Replacement1. 1. Remove the grommet (A) from the upper cover and

disconnect the TDC sensor connector (B).

2. 2. Remove the upper cover (C).3. Remove the TDC sensor from the cylinder head.

3. 4. Install the TDC sensor in reverse order of removal.

CKP Sensor Replacement1. 1. Remove the grommet (A) from the upper cover and

disconnect the TDC sensor connector (B).

2. 2. Remove the upper cover (C) and lower cover (D).3. Disconnect the CKP sensor connector, then remove

the CKP sensor from the oil pump.

3. 4. Install the CKP sensor in reverse order of removal.

6-57

Engine Mechanical - Engine Block

file:///C|/...EU3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivHtml/7-1.HTM[8/25/2012 6:52:21 PM]

Engine BlockSpecial Tools 7-2Component Location Index 7-3Flywheel Removal and Installation 7-5Drive Plate Removal and Installation 7-5Connecting Rod and Crankshaft End Play Inspection 7-6Crankshaft Main Bearing Replacement 7-7Connecting Rod Bearing Replacement 7-9Crankshaft and Piston Removal 7-11Crankshaft Inspection 7-13Block and Piston Inspection 7-14Cylinder Honing 7-16Piston, Pin and Connecting Rod Replacement 7-17Piston Ring Replacement 7-19Piston Installation 7-21Crankshaft Installation 7-22Oil Pan Installation 7-25Knock Sensor Replacement 7-26



Engine BlockSpecial Tools


12345

07LBA-PV0010007PAF-001000007PAF-001065007749-001000007948-SB00101

Ring Gear HolderPiston Pin Assembly Tool SetPilot Collar, O.D. 19 mmHandle DriverDriver Attachment, 96 mm

11111

7-2



Engine BlockComponent Location Index

1. DRAIN BOLT2. WASHER3. OIL PAN

Installation for Aluminium Oil Pan Type,page 7-24

4. FLYWHEEL (M/T)5. CRANKSHAFT

End play, page 7-6Runout, page 7-13Out-of-Round, page 7-13Removal, page 7-11Installation, page 7-22

6. CRANKSHAFT OIL SEAL,TRANSMISSION ENDInstallation, page 7-22

7. ENGINE BLOCK END COVER8. DOWEL PIN9. THRUST WASHERS

10. DOWEL PIN11. O-RING12. OIL PUMP

Overhaul, page 8-913. CRANKSHAFT OIL SEAL, PULLEY END

Installation, page 8-914. KNOCK SENSOR

Replacement, page 7-2615. MAIN BEARINGS

Oil clearance, page 7-7Selection, page 7-7

16. GASKET17. OIL SCREEN18. MAIN BEARING CAP BRIDGE19. OIL PAN

Installation for Steel Oil Pan Type, page7-25

7-3



Engine BlockComponent Location Index (cont'd)

1. PISTON RINGSReplacement, page 7-19

2. PISTONRemoval, page 7-11Measurement, page 7-14

3. PISTON PINRemoval, page 7-17Inspection, page 7-17Installation, page 7-17

4. ENGINE BLOCKCylinder bore inspection, page 7-14Warpage inspection, page 7-14Cylinder bore honing, page 7-16Ridge removal, page 7-11

5. CONNECTING ROD BEARING CAP6. CONNECTING ROD BEARINGS

Oil Clearance, page 7-9Selection, page 7-9

7. CONNECTING RODEnd play, page 7-6Small end measurement, page 7-17

7-4



Engine BlockFlywheel Removal and Installation

Drive Plate Removal and Installation

Special Tools RequiredRing Gear Holder, 07LAB-PV00100Remove the six flywheel bolts, then separate the flywheel fromthe crankshaft flange. After installation, tighten the bolts in acriss-cross pattern.

1. 1. Inspect ring gear teeth for wear or damage.

Remove the six drive plate bolts, then separate the drive platefrom the crankshaft flange. After installation, tighten the boltsin a criss-cross pattern.

7-5



Engine BlockConnecting Rod and Crankshaft End PlayInspection

1. 1. Measure the connecting rod end play with a feelergauge between the connecting rod and crankshaft.

Connecting Rod End Play:



2. 2. If the connecting rod end play is out-of-tolerance,install a new connecting rod and recheck. If it is stillout-of-tolerance; replace the crankshaft (see page 7-11).

3. Mount a dial indicator on the block so that it's tipcontacts the end of the crankshaft.

1. 4. Push the crankshaft firmly away from the dialindicator, and zero the dial against the end of thecrankshaft. Then pull the crankshaft firmly backtoward the indicator; the dial reading should notexceed the service limit.

Crankshaft End Play:



2. 5. If the end play is excessive, inspect the thrustwashers and thrust surface on the crankshaft.Replace parts as necessary. Thrust washer thicknessis fixed and must not be changed either by grindingor shimming.

7-6



Engine BlockCrankshaft Main Bearing Replacement

Main Bearing Clearance Inspection1. 1. To check main bearing-to-journal oil clearance,

remove the main caps and bearing halves.2. Clean each main journal and bearing half with a

clean shop towel.3. Place one strip of plastigage across each main

journal. NOTE: If the engine is still in the car when you boltthe main cap down to check the clearance, theweight of the crankshaft and drive plate will flattenthe plastigage further than just the torque on the capbolt and give you an incorrect reading. For anaccurate reading, support the crank with a jack underthe counterweights, and check only one bearing at atime.

4. Reinstall the bearings and caps, then torque thebolts. Do not rotate the crankshaft.

Tightening torque:D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6

Engines: 44 Nm (4.5 kgf/m, 33 lbf/ft)

D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,D17A1, D17A2, D17A5


1. 5. Remove the cap and bearing half, and measure thewidest part of the plastigage.

Main Bearing-to-Journal Oil Clearance:D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6Standard (New):

No. 1, 5: 0.018 - 0.036 mm(0.0007 - 0.0014 in.)

No. 2, 3, 4: 0.020 - 0.038 mm(0.0009 - 0.0017 in.)

Service Limit: 0.05 mm(0.002 in.)

D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,D17A1, D17A2, D17A5Standard (New):

No. 1, 5: 0.018 - 0.036 mm(0.0007 - 0.0014 in.)

No. 2, 3, 4: 0.024 - 0.042 mm(0.0009 - 0.0017 in.)


2. 6. If the plastigage measures too wide or too narrow,(remove the engine if it's still in the car), remove thecrankshaft, and remove the upper half of the bearing.Install a new, complete bearing with the same colourcode and recheck the clearance. Do not file, shim, orscrape the bearings or the caps to adjust clearance.

7. If the plastigage shows the clearance is stillincorrect, try the next larger or smaller bearing (thecolour listed above or below that one) and checkagain. If the proper clearance cannot be obtained byusing the appropriate larger or smaller bearings,replace the crankshaft and start over.

7-7



Engine BlockCrankshaft Main Bearing Replacement (cont'd)

Main Bearing SelectionCrankshaft Bore Code LocationLetters have been stamped on the end of the block as a codefor the size of each of the five main journal bores.Use them, and the numbers stamped on the crankshaft (codesfor main journal size), to choose the correct bearings. If thecodes are indecipherable because of an accumulation of dirtand dust, do not scrub them with a wire brush or scraper.Clean them only with solvent or detergent.

1. 1. No. 1 BORE (PULLEY END)2. No. 4 BORE (DRIVE PLATE END)

7-8



Engine BlockConnecting Rod Bearing Replacement

1. 1. Remove the connecting rod cap and bearing half.2. Clean the crankshaft rod journal and bearing half with

a clean shop towel.3. Place a strip of plastigage across the rod journal.4. Reinstall the bearing half and cap and torque the

bolts to 32 Nm (3.3 kgf/m, 24 lbf/ft). Do not rotate thecrankshaft.

5. Remove the rod cap and bearing half and measurethe widest part of the plastigage.

Connecting Rod Bearing-to-Journal Oil Clearance:



1. 6. If the plastigage measures too wide or too narrow,remove the upper half of the bearing, install a new,complete bearing with the same colour code andrecheck the clearance. Do not file, shim, or scrapethe bearings or the caps to adjust clearance.

2. 7. If the plastigage shows the clearance is stillincorrect, try the next larger or smaller bearing (thecolour listed above or below that one) and checkclearance again. If the proper clearance cannot beobtained by using the appropriate larger or smallerbearings, replace the crankshaft and start over.

7-9



Engine BlockConnecting Rod Bearing Replacement (cont'd)

Rod Bearing SelectionEach rod falls into one of four tolerance ranges (from 0 to0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments)depending on the size of its big end bore.It's then stamped with a number (1,2,3, or 4), indicating therange.You may find any combination of 1, 2, 3, or 4 in any engine.Normal Bore Size:D14Z5 engines: 43.0 mm (1.69 in.)D15Y2, D15Y3, D15Y4, D15Y5, D15Y6 engines: 45.0mm (1.77 in.)D16V1, D16W7, D16W8, D17Z1, D17Z2, D17Z3,D17A1, D17A2, D17A5 engines: 48.0 mm (1.89 in.)Inspect the connecting rod for cracks and heat damage.Connecting Rod Journal Code LocationsNumbers have been stamped on the side of each connectingrod as a code for the size of the big end. Use them, and theletters stamped on the crank (codes for rod journal size), tochoose the correct bearings. If the codes are indecipherablebecause of an accumulation of dirt and dust, do not scrub themwith a wire brush or scraper. Clean them only with solvent ordetergent.

1. 1. Half of number is stamped on bearing cap and the other halfis stamped on rod.

7-10



Engine BlockCrankshaft and Piston Removal

1. 1. Remove the oil pan.2. Remove the engine block end cover.

2. 3. Remove the oil screen (A), then remove the oil pump(B).

1. 4. Remove the bearing cap bolts. To prevent warpage,unscrew the bolts in sequence 1/3 turn at a time;repeat the sequence until all bolts are loosened.

BEARING CAP BOLTS LOOSENING SEQUENCE:

2. 5. Remove the bearing cap bridge/bearings. Keep allbearings in order.

6. Turn the crankshaft so No. 2 and No. 3 crankpinsare at the top.

7. Remove the rod caps/bearings. Keep allcaps/bearings in order.

8. Lift the crankshaft out of the engine, being carefulnot to damage the journals.

7-11



Engine BlockCrankshaft and Piston Removal (cont'd)

1. 9. Remove the upper bearing halves from theconnecting rods, and set them aside with theirrespective caps.

10. Reinstall the bearing cap bridge and bearings on theengine in the proper order.

11. If you can feel a ridge of metal or hard carbon aroundthe top of each cylinder, remove it with a ridgereamer (A). Follow the reamer manufacturer'sinstructions. If the ridge is not removed, it maydamage the pistons as they are pushed out.

2. 12. Use the wooden handle of a hammer (A) to drive outthe pistons (B).

3. 13. Reinstall the connecting rod bearing and caps afterremoving each piston/connecting rod assembly.

1. 14. To avoid mix-up on reassembly, mark eachpiston/connecting rod assembly with its cylindernumber.

NOTE: The existing number on the connecting rod does notindicate its position in the engine, it indicates the rod size.

7-12



Engine BlockCrankshaft Inspection

StraightnessNOTE:

Clean the crankshaft oil passages with pipe cleanersor a suitable brush.Check the keyway and threads.

1. 1. Support the crankshaft with a lathe-type tool or V-blocks.

2. Measure runout on all main journals to make surethe crank is not bent. Rotate the crankshaft twocomplete revolutions. The difference betweenmeasurements on each journal must not be morethan the service limit.

Crankshaft Total Indicator Runout:

Standard (New): 0.03 mm (0.001 in.) max.Service Limit: 0.04 mm (0.002 in.)

Out-of-Round and Taper1. 1. Measure out-of-round at the middle of each rod and

main journal in two places. The difference betweenmeasurements on each journal must not be morethan the service limit.

Journal Out-of-Round:


2. 2. Measure taper at the edge of each rod and mainjournal. The difference between measurements oneach journal must not be more than the service limit.

Journal Taper:


7-13



Engine BlockBlock and Piston Inspection

1. 1. Check the piston for distortion or cracks.2. Measure the piston diameter at a point 13 mm (0.5

in.) from the bottom of the skirt.Piston Diameter:



2. 1. SKIRT DIAMETER

Oversize Piston Diameter:0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 in.)0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 in.)

1. 3. Measure wear and taper in direction X and Y at 3levels in each cylinder as shown. If measurements inany cylinder are beyond the Oversize Bore ServiceLimit, replace the block. If the block is to be rebored,refer to step 6 after reboring.

Cylinder Bore Size:



Oversize:0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 in.)0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 in.)

Reboring limit: 0.5 mm (0.02 in.) max.

Bore Taper:

Limit: (Difference between first and thirdmeasurement) 0.05 mm (0.002 in.)

2. 1. First Measurement2. Second Measurement3. Third Measurement

7-14



Engine BlockBlock and Piston Inspection (cont'd)

1. 4. Scored or scratched cylinder bores must be honed.5. Check the top of the block for warpage. Measure

along the edges and across the centre as shown.Engine Block Warpage:


2. 1. PRECISION STRAIGHT EDGE

1. 6. Calculate the difference between the cylinder borediameter and the piston diameter. If the clearance isnear or exceeds the service limit, inspect the pistonand cylinder block for excessive wear.

Piston-to-Cylinder Clearance:



2. 1. PISTON-TO-CYLINDER CLEARANCE

7-15



Engine BlockCylinder Honing

Only a scored or scratched cylinder bore must be honed.1. 1. Measure the cylinder bores (see page 7-14).

If the block is to be reused, hone the cylinders andremeasure the bores.

2. Hone the cylinder bores with honing oil and a fine(400 grit) stone in a 60 degree cross-hatch pattern(A). Use only a rigid hone with 400 grit or finer stonesuch as Sunnen, Ammco, or equivalent. Do not usestones that are worn or broken.

2. 3. When honing is complete, thoroughly clean theengine block of all metal particles. Wash the cylinderbores with hot soapy water, then dry and oil themimmediately to prevent rusting. Never use solvent, itwill only redistribute the grit on the cylinder walls.

4. If scoring or scratches are still present in the cylinderbores after honing to the service limit, rebore thecylinder block. Some light vertical scoring andscratching is acceptable if it is not deep enough tocatch your fingernail and does not run the full lengthof the bore.

7-16



Engine BlockPiston, Pin and Connecting Rod Replacement

Special Tools RequiredPiston pin assembly tool set, 07PAF-0010000Pilot collar, O.D. 19 mm, 07PAF-0010650

Disassembly1. 1. Set the pilot collar (A) the piston pin assembly tool

set (B), then adjust the piston pin assembly tool setas shown.

2. 2. With the embossed mark facing up, place the pistonassembly (A) on the special tool (B). Be sure youposition the recessed flat on the piston against thelugs on the special tool.

3. 3. Press the pin (C) out with the driver (D), pilot collar(E) and a hydraulic press.

Inspection1. 1. Measure the diameter of the piston pin.Piston Pin Diameter:


2. 2. Zero the dial indicator to the piston pin diameter.

7-17



Engine BlockPiston, Pin and Connecting Rod Replacement(cont'd)

1. 3. Measure the piston pin-to-piston clearance.Piston Pin-to-Piston Clearance:


2. 4. Check the difference between the piston pin diameterand connecting rod small end diameter.

Piston Pin-to-Connecting Rod Interference:


Reassembly1. 1. Assemble the piston and connecting rod with the

connecting rod oil hole (A) facing the ''IN'' mark (B)side.

2. 2. Insert the pilot collar (A) into the piston andconnecting rod.

3. 3. With the embossed mark facing up, place the pistonassembly (B) on the special tool (C). Be sure youposition the recessed flat on the piston against thelugs on the base attachment.

4. Press the pin (D) in with the pin driver (E) and ahydraulic press.

7-18



Engine BlockPiston Ring Replacement

1. 1. Using a ring expander (A), remove the old pistonrings (B).

2. 2. Clean all ring grooves thoroughly with a squared-offbroken ring or ring groove cleaner with a blade to fitthe piston grooves.

The top ring groove is 1.0 mm (0.04 in.) wide. The secondring groove is 1.2 mm (0.05 in.) wide. The oil ring groove is2.8 mm (0.11 in.) wide (D15Y2, D15Y3, D16V2, D16W8,D17A5 engines) 2.0 mm (0.08 in.) wide (Except D15Y2,D15Y3, D16V2, D16W8, D17A5 engines).File down a blade if necessary.Do not use a wire brush to clean the ring grooves, or cutthe ring grooves deeper with cleaning tools.NOTE: If the piston is to be separated from the connectingrod, do not install new rings yet.

1. 3. Using a piston, push a new ring (A) into the cylinderbore 15 - 20 mm (0.6 - 0.8 in.) from the bottom.

2. 4. Measure the piston ring end-gap (B) with a feelergauge:If the gap is too small, check to see if you have theproper rings for your engine.If the gap is too large, recheck the cylinder borediameter against the wear limits (see page 7-14).

If the bore is over the service limit, the cylinder block mustbe rebored.

Piston Ring End-Gap:Top Ring



Second Ring



Oil RingD15Y2, D15Y3, D16V2, D16W8, D17A5 engines:



Except D15Y2, D15Y3, D16V2, D16W8, D17A5engines:



7-19



Engine BlockPiston Ring Replacement (cont'd)

1. 5. Install the top ring (A) and second ring (B) as shown.The manufacturing marks (C) must be facing upward.

1. 6. Rotate the rings in their grooves to make sure theydo not bind.

2. 7. Position the ring end gaps as shown:

3. 8. After installing a new set of rings, measure the ring-to-groove clearances:

Top Ring ClearanceD15Y2, D15Y3, D16V2, D16W8, D17A5 engines:



Except D15Y2, D15Y3, D16V2, D16W8, D17A5engines:



Second Ring Clearance



7-20



Engine BlockPiston Installation

If the crankshaft is already installed1. 1. Set the crankshaft to BDC for each cylinder.

2. Remove the connecting rod caps and slip shortsections of rubber hose (A) over the connecting rodbolts. Then install the ring compressor, and checkthat the bearing is securely in place.

2. 3. Position the arrow (B) facing the timing belt side ofthe engine.

4. Position the piston in the cylinder and tap it in usingthe wooden handle of a hammer (A). Maintain downward force on the ring compressor (B)to prevent the rings from expanding before enteringthe cylinder bore.

3. 5. Stop after the ring compressor pops free, and checkthe connecting rod-to-crank journal alignment beforepushing the piston into place.

6. Check the connecting rod bearing clearance withplastigage (see page 7-9).

7. Apply engine oil to the bolt threads, then install therod caps with bearings. Torque the nuts to 32 Nm(3.3 kgf/m, 24 lbf/ft).

If the crankshaft is not installed1. 1. Remove the connecting rod caps, then install the

ring compressor, and check that the bearing issecurely in place.

2. Position the arrow (A) facing the timing belt side ofthe engine.

2. 3. Position the piston in the cylinder and tap it in usingthe wooden handle of a hammer (A). Maintain downward force on the ring compressor (B)to prevent the rings from expanding before enteringthe cylinder bore.

3. 4. Position all pistons at top dead centre.

7-21



Engine BlockCrankshaft Installation

Special Tools RequiredHandle Driver, 07749-0010000Driver Attachment, 96 mm, 07948-SB00101

1. 1. Apply engine oil to the main bearings and rodbearings.

2. Install the bearing halves in the cylinder block andconnecting rods.

3. Hold the crankshaft so rod journal No. 2 and rodjournal No. 3 are straight up and lower the crankshaftinto the block.

4. Install the thrust washers (A) on both edges of theNo. 4 main bearing recess.

2. 5. Apply engine oil to the threads of the connecting rodbolts.

6. Seat the rod journals into connecting rod No. 1 andconnecting rod No. 4. Install the caps and nuts fingertight. Install the cap so the bearing recess is on thesame side as the recess in the rod.

7. Rotate the crankshaft clockwise and seat the journalsinto connecting rod No. 2 and connecting rod No. 3.Install the connecting rod cap and bolts finger tight.

8. Check the connecting rod bearing clearance withplastigage (see page 7-9).

9. Tighten the connecting rod bolts to 32 Nm (3.3 kgf/m,24 lbf/ft).

1. 10. Check the main bearing clearance with plastigage(see page 7-7).

2. 11. Install the bearing cap bridge. Coat the bolt threadswith engine oil.

12. Torque the cylinder head bolts sequentially in 2steps.

1st step torque: 25 Nm (2.5 kgf/m, 18 lbf/ft)2nd step torque:D14Z5, D15Y2, D15Y3, D15Y4, D15Y5, D15Y6


D16V2, D16W7, D16W8, D17Z1, D17Z2, D17Z3,D17A1, D17A2, D17A5 engines:

51 Nm (5.2 kgf/m, 38 lbf/ft)

NOTE: Whenever any crankshaft or connecting rod bearingis replaced, it is necessary after reassembly to run theengine at idling speed until it reaches normal operatingtemperature, then continue to run it for approximately 15minutes.

BEARING CAP BOLTS TIGHTENING SEQUENCE:

7-22



Engine BlockCrankshaft Installation (cont'd)

1. 13. The seal mating surface on the engine block endcover should be dry. Apply a light coat of grease tothe crankshaft and to the lip of the seal.

14. Drive the crankshaft oil seal squarely into the engineblock end cover.

2. 15. Confirm that the clearance is equal all the wayaround with a feeler gauge.

Clearance: 0.5 - 0.8 mm (0.02 - 0.03 in.)

1. 16. Clean and dry the engine block end cover matingsurfaces.

2. 17. Apply liquid gasket, part No. 08C70-K0234M,08C70-K0334M or 08C70-X0331S, evenly to theblock mating surface of the engine block end coverand to the inner threads of the bolt holes. Install thedowel pins (A), and the engine block end cover (B)on the cylinder block.

NOTE: Do not install the parts if 5 minutes or more haveelapsed since applying the liquid gasket. Instead, reapplyliquid gasket after removing the old residue.

3. 18. After assembly, wait at least 30 minutes before fillingthe engine with oil.

7-23



Engine BlockCrankshaft Installation (cont'd)

Oil Pan Installation

1. 19. Clean and dry the oil pump mating surfaces.20. Install the oil pump (A).

1. Install a new crankshaft oil seal in the oil pump(see step 12 on page 8-11).

2. Apply liquid gasket, part No. 08C70-K0234M,08C70-K0334M or 08C70-X0331S, evenly to theblock mating surface of the oil pump and to theinner threads of the bolt holes.

3. Grease the lip of the oil seal and apply oil to thenew O-ring (B).

4. Install the dowel pins (C), then align the innerrotor with the crankshaft and install the oil pump.

5. Clean the excess grease off the crankshaft andcheck the seal for distortion.

2. 21. Install the oil screen (D) with a new gasket (E).22. Install the oil pan (see page 7-24).

Aluminium Oil Pan Type:1. 1. Clean and dry the oil pan mating surfaces and bolt

holes.2. Apply liquid gasket, part No. 08C70-K0334M or

08C70-X0331S, evenly to the oil pan mating surfaceof the block and to the inner threads of the boltholes.

NOTE:Apply liquid gasket 4 mm wide.Apply liquid gasket doubly to the jointing point ofthe liquid gasket.

2. 1. Apply liquid gasket along the broken line.

3. 3. Install the oil pan.4. Tighten the bolts in 2 or 3 steps. In the final step,

tighten all bolts, in sequence to 12 Nm (1.2 kgf/m,8.7 lbf/ft).

4. 5. After assembly, wait at least 30 minutes before fillingthe engine with oil.

7-24



Engine BlockOil Pan Installation (cont'd)

Steel Oil Pan Type:1. 1. Clean and dry the oil pan mating surfaces and bolt

holes.2. Apply liquid gasket, part No. 08C70-K0334M or

08C70-X0331S, on the oil pump and engine blockend cover mating areas.

2. 1. Apply liquid gasket to these points.

3. 3. Apply liquid gasket, part No. 08C70-K0334M or08C70-X0331S, to the new oil pan gasket (A) at thefour corners of the recesses (B), then install the oilpan (C).

1. 4. Tighten bolts and nuts finger tight at six points asshown below.

2. 5. Tighten all bolts and nuts, stating from nut (1),clockwise in 3 steps. In the final step, tighten allbolts, in sequence to 12 Nm (1.2 kgf/m, 8.7 lbf/ft).

6. After assembly, wait at least 30 minutes before fillingthe engine with oil.

7-25



Engine BlockKnock Sensor Replacement

1. 1. Disconnect the knock sensor connector, then removethe knock sensor.

2. 2. Install the knock sensor.

7-26

Engine Machanical - Engine Lubrication


Engine Lubrication

Special Tools 8-2Component Location Index 8-3Oil Pressure Switch Test 8-4Oil Pressure Test 8-4Engine Oil Replacement 8-5Engine Oil Filter Replacement 8-6Oil Pump Overhaul 8-9Oil/Air Separator Installation 8-12Oil Pressure Switch Replacement 8-12



Engine LubricationSpecial Tools


123456

07HAA-PJ7010007406-003000007506-300000007746-001040007749-001000007912-6110001

Oil Filter WrenchOil Pressure Gauge AttachmentOil Pressure GaugeDriver Attachment, 52 x 55 mmHandle DriverOil Filter Wrench

111111

8-2



Engine LubricationComponent Location Index

1. DOWEL PIN2. O-RING3. OIL PRESSURE SWITCH

Circuit Diagram, page 22-88Switch Test, page 8-4Oil Pressure Test, page 8-4Replacement, page 8-12

4. OIL FILTERReplacement, page 8-6

5. OIL/AIR SEPARATORInstallation, page 8-12

6. BREATHING PORT COVER7. WASHER8. DRAIN BOLT9. OIL PAN

Installation, page 7-2410. BAFFLE PLATE11. OIL SCREEN12. GASKET13. OIL PUMP

Overhaul, page 8-9

8-3



Engine LubricationOil Pressure Switch Test

8-4 Oil Pressure Test

1. 1. Remove the YEL/RED wire (A) from the engine oilpressure switch (B).

2. 2. Check for continuity between the positive terminal(C) and the engine (ground). There should becontinuity with the engine stopped. There should beno continuity with the engine running.

3. If the switch fails to operate, check the engine oillevel. If the engine oil level is OK, check the engineoil pressure. If the oil pressure is OK, replace the oilpressure switch.

Special Tools RequiredOil pressure gauge attachment, 07406-0030000Oil pressure Gauge, 07506-3000000

If the oil pressure warning light stays on with the enginerunning, check the engine oil level. If the oil level is correct.1. 1. Connect a tachometer.

2. Remove the engine oil pressure switch and installthe special tools.

2. 3. Start the engine. Shut it off immediately if the gaugeregisters no oil pressure. Repair the problem beforecontinuing.

4. Allow the engine to reach operating temperature (fancomes on at least twice). The pressure should be:

Engine Oil Temperature: 80° C (176° F)Engine Oil Pressure:At Idle: 70 kPa (0.7 kgf/cm2, 10 psi

minimum)

At 3,000 rpm(min-1):

340 kPa (3.5 kgf/cm2, 50 psiminimum)

3. 4. If oil pressure is NOT within specifications, inspectthe oil pump (see step 7 on page 8-10).



Engine LubricationEngine Oil Replacement

1. 1. Warm up the engine.2. 2. Remove the drain bolt (A) and drain the engine oil.

D15Y4, D17A2 (KU, KQ models), D17A5 (KNmodel) engines:

Except D15Y4, D17A2 (KU, KQ models), D17A5(KN model) engines:

3. 3. Reinstall the drain bolt with a new washer (B).

1. 4. Refill with the recommended oil (see page 3-2).CapacityD15Y4, D17A2 (KU, KQ models), D17A5 (KNmodel) engines:

3.3 l (3.5 US qt, 2.9 Imp qt) at oil change3.5 l (3.7 US qt, 3.1 Imp qt) at oil changeincluding filter4.2 l (4.4 US qt, 3.7 Imp qt) after engineoverhaul

Except D15Y4, D17A2 (KU, KQ models), D17A5(KN model) engines:

3.0 l (3.2 US qt, 2.6 Imp qt) at oil change3.2 l (3.4 US qt, 2.8 Imp qt) at oil changeincluding filter4.2 l (4.4 US qt, 3.7 Imp qt) after engineoverhaul

2. 5. Run the engine for more than 3 minutes then checkfor oil leakage.

8-5



Engine LubricationEngine Oil Filter Replacement

Special Tools RequiredOil filter wrench, 07HAA-PJ70100Oil filter wrench, 07912-6110001

Engine Oil Filter Replacement (oil filter type A)1. 1. Remove the oil filter with the special oil filter wrench.

2. Inspect the threads (A) and rubber seal (B) on the new filter.Wipe off the seat on the engine block, then apply a light coatof oil to the filter rubber seal. Use only filters with a built-inbypass system.

2. 3. Install the oil filter by hand.4. After the rubber seal seats, tighten the oil filter clockwise with

the special tool.Tighten: 3/4 turn clockwiseTightening torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)

1. 5. If 4 numbers or marks (1 to 4 or to )are printed around the outside of

the filter, use the following procedure totighten the filter.

Spin the filter until its seal lightly seatsagainst the block and note which numberor mark is at the bottom.Tighten the filter by turning it clockwise 3numbers or marks from the one younoted. For example, if number 2 is at thebottom when the seal is seated, tightenthe filter until the number 1 comes aroundthe bottom.

2. 6. After installation, fill the engine with oil up tothe specified level, run the engine for morethan 3 minutes, then check for oil leakage.

8-6



Engine LubricationEngine Oil Filter Replacement (cont'd)

Engine Oil Filter Replacement (oil filter type B)1. 1. Remove the oil filter with the special oil filter wrench.

2. Inspect the threads (A) and rubber seal (B) on the newfilter. Wipe off the seat on the engine block, then apply alight coat of oil to the filter rubber seal. Use only filters witha built-in bypass system.

2. 3. Install the oil filter by hand.4. After the rubber seal seats, tighten the oil filter clockwise

with the special tool.Tighten: 7/8 turn clockwiseTightening torque: 22 Nm (2.2 kgf/m, 16

lbf/ft)

1. 5. If 8 numbers or marks (1 to 8) are printedaround the outside of the filter, use the followingprocedure to tighten the filter.

Spin the filter until its seal lightly seatsagainst the block and note which number isat the bottom.Tighten the filter by turning it clockwise 7numbers from the one you noted. Forexample, if number 2 is at the bottom whenthe seal is seated, tighten the filter until thenumber 1 comes around the bottom.

2. 6. After installation, fill the engine with oil up tothe specified level, run the engine for more than3 minutes, then check for oil leakage.

8-7



Engine LubricationEngine Oil Filter Replacement (cont'd)

Engine Oil Filter Replacement (oil filter type C)1. 1. Remove the oil filter with the commercially available oil filter

wrench (LABINAL-Purflux 76).2. Inspect the threads (A) and rubber seal (B) on the new filter.

Wipe off the seat on the engine block, then apply a light coat ofoil to the filter rubber seal. Use only filters with a built-in bypasssystem.

2. 3. Install the oil filter by hand.4. After the rubber seal seats, tighten the oil filter clockwise with

the commercially available oil filter wrench (LABINAL-Purflux 76)Tighten: 3/4 turn clockwiseTightening torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)

1. 5. If 4 numbers or marks (1 to 4) are printedaround the outside of the filter, use thefollowing procedure to tighten the filter.

Spin the filter until its seal lightly seatsagainst the block and note whichnumber is at the bottom.Tighten the filter by turning it clockwise3 numbers from the one you noted. Forexample, if number 2 is at the bottomwhen the seal is seated, tighten the filteruntil the number 4 comes around thebottom.

2. 6. After installation, fill the engine with oil upto the specified level, run the engine formore than 3 minutes, then check for oilleakage.

8-8



Engine LubricationOil Pump Overhaul

Exploded View1. DOWEL PIN2. INNER ROTOR3. PUMP COVER4. OUTER ROTOR5. O-RING

Replace6. PUMP HOUSING

Apply liquid gasket to matingsurface of the cylinder blockwhen installing

7. RELIEF VALVEValve must slide freely inhousing bore.Replace if scored.

8. SEALING BOLT39 Nm (4.0 kgf/m, 29 lbf/ft)

9. SPRING10. OIL SEAL

Replace

8-9



Engine LubricationOil Pump Overhaul (cont'd)

Special Tools RequiredDriver, 07749-0010000Driver Attachment, 52 x 55 mm, 07746-0010400

NOTE: Refer to the exploded view as needed during thisprocedure.Removal1. 1. Drain the engine oil.

2. Remove the timing belt (see page 6-18).3. Remove the oil pan.4. Remove the oil screen (A).

2. 5. Remove the mounting bolts and the oil pumpassembly (B).

6. Remove the screws from the pump housing,then separate the housing and cover.

Inspection1. 7. Check the inner-to-outer rotor radial clearance between the

inner rotor (A) and outer rotor (B). If the inner-to-outer rotorradial clearance exceeds the service limit, replace the oilpump assembly.

Inner Rotor-to-Outer Rotor Radial ClearanceStandard (New): 0.02 - 0.07 mm (0.001 -

0.003 in.)Service Limit 0.15 mm (0.006 in.)

2. 8. Check the housing-to-rotor axial clearance between therotor (A) and pump housing (B). If the housing-to-rotoraxial clearance exceeds the service limit, replace the oilpump assembly.

Housing-to-Rotor Axial ClearanceStandard (New): 0.02 - 0.07 mm (0.001 -

0.003 in.)Service Limit 0.15 mm (0.006 in.)

8-10



Engine LubricationOil Pump Overhaul (cont'd)

1. 9. Check the housing-to-outer rotor radial clearancebetween the outer rotor (A) and pump housing (B). Ifthe housing-to-outer rotor radial clearance exceedsthe service limit, replace the oil pump assembly.

Housing-to-Outer Rotor Radial ClearanceStandard(New):

0.10 - 0.18 mm (0.004 - 0.007in.)

Service Limit 0.20 mm (0.008 in.)

2. 10. Inspect both rotors and the pump housing for scoringor other damage. Replace parts if necessary.

11. Remove the old oil seal from the pump.12. Gently tap in the new oil seal until the special tool

bottoms on the pump.

3. 13. Apply liquid thread lock to the pump housing screws.

Installation1. 14. Reassemble the oil pump.

15. Check that the oil pump turns freely.16. Clean and dry the oil pump mating surface.17. Install the oil pump (A).

a. Apply liquid gasket, Part No. 08C70-K0234M, 08C70-K0334M or 08C70-X0331S, evenly to the block matingsurface of the oil pump and to the inner threads of thebolt holes.

b. Grease the lips of the oil seal and apply oil to the newO-ring (B).

c. Install dowel pins (C), then align the inner rotor with thecrankshaft and install the oil pump.

d. Clean the excess grease off the crankshaft and balancershaft and check the seal for distortion.

2. 18. Install the oil screen (D) with a new gasket (E).19. Install the oil pan (see page 7-24).

8-11



Engine LubricationOil/Air Separator Installation

Oil Pressure Switch Replacement

1. 1. Clean and dry the oil/air separator mating surfaces.2. 2. Apply liquid gasket, Part No 08C70-K0234M, 08C70-

K0334M or 08C70-X0331S, evenly to the blockmating surface of the oil/air separator and to theinner threads of the bolt holes.

3. 3. Install the oil/air separator.

1. 1. Disconnect the oil pressure switch connector, thenremove the oil pressure switch.

2. 2. Apply liquid gasket to the oil pressure switch threads,then install the oil pressure switch.

8-12

Engine Mechanical - Intake Manifold and Exhaust System


Intake Manifold and Exhaust System

Intake Manifold Removal and Installation 9-2Exhaust Manifold Removal and Installation 9-3Exhaust Pipe and Muffler Replacement 9-5



Intake Manifold and Exhaust SystemIntake Manifold Removal and Installation

NOTE: Use a new O-rings and gasket when reassembling.

1. O-RINGReplace.

2. MANIFOLD ABSOLUTEPRESSURE (MAP) SENSOR

3. THROTTLE BODY4. O-RING

Replace.5. INJECTOR BASE STIFFENER6. GASKET

Replace.7. INJECTOR BASE8. INTAKE MANIFOLD BRACKET9. O-RINGS

Replace.10. INTAKE MANIFOLD

Replace if cracked or if matingsurfaces are damaged.

9-2



Intake Manifold and Exhaust SystemExhaust Manifold Removal and Installation

NOTE: Use a new gaskets and self-locking nuts when reassembling.D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:

1. 8 x 1.25 mm31 Nm (3.2 kgf/m, 23 lbf/ft)Replace.

2. COVER3. EXHAUST MANIFOLD4. GASKET

Replace.5. 8 x 1.25 mm

31 Nm (3.2 kgf/m, 23 lbf/ft)Replace.

6. SECONDARY HEATEDOXYGEN SENSOR(SECONDARY HO2S)(D15Y6, D17Z2 engines)44 Nm (4.5 kgf/m, 33 lbf/ft)

7. EXHAUST MANIFOLDBRACKET

8. THREE WAY CATALYTICCONVERTER


10. PRIMARY HEATED OXYGENSENSOR (PRIMARY HO2S)44 Nm (4.5 kgf/m, 33 lbf/ft)

11. COVER

9-3



Intake Manifold and Exhaust SystemExhaust Manifold Removal and Installation(cont'd)

NOTE: Use a new gasket when reassembling.Except D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:

1. COVER2. GASKET

Replace.3. EXHAUST MANIFOLD4. 8 x 1.25 mm

31 Nm (3.2 kgf/m, 23 lbf/ft)Replace.


9-4



Intake Manifold and Exhaust SystemExhaust Pipe and Muffler Replacement

NOTE: Use a new gaskets when reassembling.D15Y5, D15Y6, D17A1, D17Z1, D17Z2 engines:

1. GASKETReplace.

2. MUFFLER3. 8 x 1.25 mm

22 Nm (2.2 kgf/m, 16 lbf/ft)Replace.Tighten the bolts in steps,alternating side-to-side

4. HEATSHIELD5. EXHAUST PIPE B6. 8 x 1.25 mm


7. GASKETReplace.

9-5



Intake Manifold and Exhaust SystemExhaust Pipe and Muffler Replacement(cont'd)

NOTE: Use new gaskets and self-locking nuts when reassembling.D14Z5, D15Y2, D15Y4, D16W7, D16W8, D17Z1, D17Z3, D17A2 engines:

1. GASKETReplace.


22 Nm (2.2 kgf/m, 16 lbf/ft)Replace.Tighten the bolts in steps, alternatingside-to-side

4. HEATSHIELD5. 6 x 1.0 mm

98 Nm (1.0 kgf/m, 7.2 ibf/ft)6. EXHAUST PIPE B7. GASKET

Replace.8. THREE WAY CATALYTIC

CONVERTER9. PRIMARY HEATED OXYGEN

SENSOR (PRIMARY HO2S)(D14Z5, D15Y2, D15Y4, D16W7,D16W8, D17Z3, D17A2 engines)44 Nm (4.5 kgf/m, 33 lbf/ft)

10. 8 x 1.25 mm22 Nm (2.2 kgf/m, 16 lbf/ft)Replace.Tighten the bolts in steps, alternatingside-to-side

11. EXHAUST PIPE A12. GASKET

Replace.13. SECONDARY HEATED OXYGEN

SENSOR (SECONDARY HO2S)(D14Z5, D15Y4, D16W7, D17Z3,D17A2 engines)44 Nm (4.5 kgf/m, 33 lbf/ft)

14. SELF-LOCKING NUT10 x 1.25 mm33 N (3.4 kgf/m, 25 lbf/ft)Replace.

9-6



Intake Manifold and Exhaust SystemExhaust Pipe and Muffler Replacement(cont'd)

NOTE: Use new gaskets and self-locking nuts when reassembling.D15Y3, D16V2, D17A5 engines:

1. GASKETReplace.



4. HEATSHIELD5. EXHAUST PIPE B6. GASKET

Replace.7. EXHAUST PIPE A8. 8 x 1.25 mm


9. GASKETReplace.

10. SELF-LOCKING NUT10 x 1.25 mm33 N (3.4 kgf/m, 25 lbf/ft)Replace.

9-7

Engine Cooling - Engine Cooling


Engine CoolingCooling System

Component Location Index 10-2Radiator Cap Test 10-5Radiator Test 10-5Fan Motor Test 10-6Thermostat Test 10-6Water Pump Inspection 10-7Water Pump Replacement 10-7Coolant Check 10-8Coolant Replacement 10-8Thermostat Replacement 10-10Radiator and Fan Replacement 10-11ECT Sensor Replacement 10-12

Fan Controls

Component Location Index 10-13Symptom Troubleshooting Index 10-14Circuit Diagram 10-15Radiator Fan Circuit Troubleshooting 10-16Radiator Fan Switch Circuit Troubleshooting (Open) 10-18Radiator Fan Switch Circuit Troubleshooting (Short) 10-18Radiator Fan Switch Test 10-19Radiator Fan Switch Replacement 10-19

Engine Cooling - Cooling System


Cooling SystemComponent Location Index

DENSO:1. A/C CONDENSER FAN

ASSEMBLYReplacement, page 10-11Fan Motor Test, page 10-6

2. O-RING3. UPPER RADIATOR HOSE4. RADIATOR CAP5. RADIATOR

Replacement, page 10-116. COOLANT RESERVOIR7. LOWER RADIATOR HOSE8. ATF COOLER HOSES9. DRAIN PLUG

10. RADIATOR FANReplacement, page 10-11

11. RADIATOR FAN SHROUDReplacement, page 10-11

12. RADIATOR FAN MOTORTest, page 10-6Replacement, page 10-11

TOYO RADIATOR:1. A/C CONDENSER FAN

ASSEMBLYReplacement, page 10-11Fan Motor Test, page 10-6

2. O-RING3. UPPER RADIATOR HOSE4. RADIATOR CAP5. RADIATOR

Replacement, page 10-116. COOLANT RESERVOIR7. LOWER RADIATOR HOSE8. ATF COOLER HOSES9. DRAIN PLUG

10. RADIATOR FANReplacement, page 10-11

11. RADIATOR FAN MOTORTest, page 10-6Replacement, page 10-11

12. RADIATOR FAN SHROUDReplacement, page 10-11

10-2



Cooling SystemComponent Location Index (cont'd)

RHD models:1. WATER BYPASS HOSE2. WATER PASSAGE3. CONNECTING PIPE4. HEATER HOSES5. HEATER VALVE

LHD models:1. WATER BYPASS HOSE2. WATER PASSAGE3. CONNECTING PIPE4. HEATER VALVE5. HEATER HOSES

10-3



Cooling SystemComponent Location Index (cont'd)

1. O-RING2. GASKET3. EXHAUST GAS RECIRCULATION (EGR)

VALVE(D14Z5, D15Y4, D16W7, S17A2 (KQ, KUmodels) engines)

4. ENGINE COOLANT TEMPERATURE(ECT) SENSOR

5. O-RING6. RADIATOR FAN SWITCH7. O-RING8. WATER PASSAGE9. O-RING

10. CONNECTING PIPE11. CONNECTING PIPE12. O-RING13. WATER PUMP

Inspection, page 10-7Replacement, page 10-7

10-4



Cooling SystemRadiator Cap Test

Radiator Test

1. 1. Remove the radiator cap (A), wet its seal with enginecoolant, then install it on the pressure tester (B)(commercially available). Use a small adapter H-901122-09 (C) (commercially available) to install theradiator cap.

2. 2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25kgf/cm2, 14 - 18 psi).

3. Check for a drop in pressure.4. If the pressure drops, replace the cap.

1. 1. Wait until the engine is cool, then carefully removethe radiator cap and fill the radiator with enginecoolant to the top of the filler neck.

2. 2. Attach the pressure tester (A) (commerciallyavailable) to the radiator. Use a small adapter H-901122-09 (B) (commercially available) to attach thepressure tester.

3. 3. Apply a pressure of 93 - 123 kPa (0.95 - 1.25kgf/cm2, 14 - 18 psi).

4. Inspect for engine coolant leaks and a drop inpressure.

5. Remove the tester and reinstall the radiator cap.6. Check for engine oil in the coolant and/or coolant in

the engine oil.

10-5



Cooling SystemFan Motor Test

Thermostat Test

1. 1. Disconnect the 2P connectors from the radiator fanmotor and condenser fan motor.

Terminal side of male terminals

2. 2. Test the motor by connecting battery power to the Bterminal and ground to the A terminal.

3. If the motor fails to run or does not run smoothly,replace it.

Replace the thermostat if it is open at room temperature.To test a closed thermostat:1. 1. Suspend the thermostat (A) in a container of water.

Do not let the thermometer (B) touch the bottom of thehot container.

2. 2. Heat the water and check the temperature with athermometer. Check the temperature at which thethermostat first opens and at which it is fully open.

3. Measure the lift height of the thermostat when it isfully open.

STANDARD THERMOSTATLift height: above 8.0 mm (0.31

in.)Starts opening: 76 - 80oC (169 –

176oF)Fully open: 90oC (194oF)

10-6



Cooling SystemWater Pump Inspection

Water Pump Replacement

1. 1. Remove the timing belt (see page 6-18).2. 2. Turn the water pump pulley counter-clockwise. Check

that it turns freely.3. Check for signs of seal leakage. A small amount of

''weeping'' from the bleed hole (A) is normal.

1. 1. Remove the timing belt (see page 6-18).2. 2. Remove the water pump (A) by removing four bolts.

3. 3. Inspect and clean the O-ring groove and matingsurface with the cylinder block.

4. Install the water pump with a new O-ring (B) in thereverse order of removal.

5. Clean up any spilled engine coolant.

10-7



Cooling SystemCoolant Check

Coolant Replacement

1. 1. Look at the coolant level in the coolant reservoir.Make sure it is between the MAX (A) and MIN mark(B).

2. 2. If the coolant level in the coolant reservoir is at orbelow the MIN mark, add coolant to bring it up to theMAX mark and inspect the cooling system for leaks.

1. 1. Start the engine. Set the heater temperature controldial to maximum heat, then turn off the ignitionswitch. Make sure the engine and radiator are cool tothe touch.


3. Remove the battery.4. Remove the radiator cap.5. Loosen the drain plug (A) and drain the coolant.

10-8



Cooling SystemCoolant Replacement (cont'd)

1. 6. Remove the drain bolt (A) from the rear of thecylinder block.

2. 7. After the coolant has drained, apply liquid gasket tothe drain bolt threads, then reinstall the bolt with anew washer and tighten it securely.

8. Tighten the radiator drain plug securely.9. Remove, drain and reinstall the reservoir. Fill the

tank to the MAX mark (A) with genuine Honda AllSeason Antifreeze/Coolant Type 2.

1. 10. Pour genuine Honda All Season Antifreeze/CoolantType 2 into the radiator up to the base of the fillerneck.

NOTE:Always use genuine Honda All SeasonAntifreeze/Coolant Type 2. Using a non-Hondacoolant can result in corrosion, causing thecooling system to malfunction or fail.Genuine Honda All Season Antifreeze/CoolantType 2 is a mixture of 50% antifreeze and 50%water. Pre-mixing is not required.

Engine Coolant Refill Capacity [including thereservoir capacity of 0.4 l (0.4 US qt, 0.4 lmp qt)]:M/T: 4.0 l (4.2 US qt, 3.5 lmp

qt)

A/T, HONDA MULTIMATIC:

3.9 l (4.1 US qt, 3.4 lmpqt)

2. 11. Install the radiator cap loosely.12. Install the battery.13. Start the engine and let it run until it warms up (the

radiator fan comes on at least twice).14. Turn off the engine. Check the level in the radiator

and add genuine Honda All SeasonAntifreeze/Coolant Type 2 if needed.

15. Put the radiator cap on tightly, then run the engineagain and check for leaks.


10-9


file:///C|/...U3%20EU5%20EU6%20EU7%20EU8%20EU9%20%20ES1%20ES4%20ES5%20ES8%20EM2/2/EngCivic/CivHtml/10-10.htm[8/25/2012 6:43:26 PM]

Cooling SystemThermostat Replacement

1. WATER PASSAGE2. PIN3. RUBBER SEAL

Replace.4. THERMOSTAT COVER5. THERMOSTAT

Install with pin up.

10-10



Cooling SystemRadiator and Fan Replacement

1. 1. Drain engine coolant.2. Remove the front bumper (see page 20-104).3. Remove the hood latch (see page 20-106).4. Remove the upper and lower radiator hoses and ATF cooler hoses.

1. A/C CONDENSER FANASSEMBLY

2. O-RINGReplace.

3. UPPER RADIATOR HOSE4. RADIATOR CAP5. UPPER BRACKET AND

CUSHION6. RADIATOR7. COOLANT RESERVOIR8. LOWER RADIATOR HOSE9. CONDENSER BRACKET

10. LOWER CUSHION11. FAN MOTOR

CONNECTORS12. ATF COOLER HOSES13. DRAIN PLUG14. RADIATOR FAN

ASSEMBLY

5. Disconnect the fan motor connectors and compressor clutch connector.6. Remove the radiator upper brackets, then pull up the radiator.7. Remove the fan shroud assemblies and other parts from the radiator.8. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely.9. Fill the radiator with engine coolant and bleed the air.

10-11



Cooling SystemECT Sensor Replacement

1. 1. Remove the resonator.2. 2. Disconnect the ECT sensor connector, then remove

the ECT sensor (A).

3. 3. Install the ECT sensor using a new O-ring (B).4. Install the resonator.

10-12

Engine Cooling - Fan Controls


Fan ControlsComponent Location Index

1. RADIATOR FAN RELAYTest, page 22-80

2. UNDER-HOOD FUSE/RELAY BOX3. CONDENSER FAN RELAY

Test, page 22-804. RADIATOR FAN SWITCH

Test, page 10-9Replacement, page 10-195. CONDENSER FAN ASSEMBLY

Motor Test, page 10-66. RADIATOR FAN ASSEMBLY

Motor Test, page 10-6

10-13



Fan ControlsSymptom Troubleshooting Index

Before performing any troubleshooting procedures check:FusesGroundsCleanliness and tightness of all connectors

SYMPTOM PROCEDURERadiator fan does not run at all Radiator Fan Circuit Troubleshooting (see page 10-16).Radiator fan does not runs for engine cooling, but it runswith A/C on

Radiator Fan Switch Circuit Troubleshooting (Open) (see page 10-18).

Radiator fan runs with ignition switch ON (II), A/C off andengine temperature below 93oC (199oF)

Radiator Fan Switch Circuit Troubleshooting (Short) (see page 10-18).

10-14



Fan ControlsCircuit Diagram

10-15



Fan ControlsRadiator Fan Circuit Troubleshooting

1. 1. Check the No. 4 (20A) fuse in the under-hoodfuse/relay box and the No. 14 (10A) fuse in thedriver's under-dash fuse/relay box.

Is the fuse (s) OK?YES - Go to step 2.NO - Replace the fuse (s) and recheck.

2. 2. Remove the radiator fan relay from the under-hoodfuse/relay box and test it (see page 22-80).

Is the relay OK?YES - Go to step 3.NO - Replace the radiator fan relay.

3. 3. Measure the voltage between the No. 1 terminal ofthe radiator fan relay 4P socket and body ground.RADIATOR FAN RELAY 4P SOCKET

Terminal side of female terminalsIs there battery voltage?YES - Go to step 4.NO - Replace the under-hood fuse/relay box.

1. 4. Connect the No. 1 and No. 2 terminals of theradiator fan relay 4P socket with a jumper wire.RADIATOR FAN RELAY 4P SOCKET

Terminal side of female terminalsDoes the radiator fan run?YES - Go to step 5.NO - Go to step 6.

2. 5. Disconnect the jumper, and turn the ignition switchON (II). Check for voltage between the No. 3terminal of the radiator fan relay 4P socket and bodyground.RADIATOR FAN RELAY 4P SOCKET

Terminal side of female terminalsIs there battery voltage?YES - Go to step 9.NO - Check for an open in the wire between the under-hood fuse/relay box and under-dash fuse/relay box.

10-16



Fan ControlsRadiator Fan Circuit Troubleshooting (cont'd)

1. 6. Disconnect the radiator fan motor 2P connector.2. 7. Check for continuity between the No. 2 terminal of

the radiator fan relay 4P socket and the No. 2terminal of the radiator fan motor 2P connector.RADIATOR FAN RELAY 4P SOCKET

Terminal side of female terminals

Wire side of female terminalsRADIATOR FAN MOTOR 2P CONNECTOR

Is there continuity?YES - Go to step 8.NO - Repair open in the wire between the under-hoodfuse/relay box and the radiator fan motor 2P connectorterminal No. 2.

3. 8. Check for continuity between the No. 1 terminal ofthe radiator fan motor 2P connector and bodyground.

RADIATOR FAN MOTOR 2P CONNECTOR

Wire side of female terminalsIs there continuity?YES - Replace the radiator fan motor. NO - Check for an open in the wire between radiator fanmotor 2P connector terminal No. 1 and body ground. If thewire is OK, check for a poor ground at G201.

1. 9. Reinstall the radiator fan relay.2. 10. Disconnect the radiator fan switch 2P connector.

jumper terminals No. 1 and No. 2 to see if fan runs.Does the radiator fan run?YES - Replace the radiator fan switch. NO - Go to step 11.

3. 11. Remove the jumper wire, and measure the voltagebetween the No. 2 terminal of the radiator fan switchconnector and body ground.

RADIATOR FAN SWITCH 2P CONNECTOR

Wire side of female terminalsIs there battery voltage?YES - Check for an open in the wire between radiator fanswitch 2P connector terminal No. 1 and body ground. If thewire is OK, check for a poor ground at G101. NO - Repair open in the wire between the radiator fanswitch terminal No. 2 and the under-hood fuse/relay box.

10-17



Fan ControlsRadiator Fan Switch Circuit Troubleshooting (Open)

Radiator Fan Switch Circuit Troubleshooting (Short)

1. 1. Disconnect the radiator fan switch 2P connector.2. 2. Turn the ignition switch ON (II).

3. Measure voltage between the No. 2 terminal of theradiator fan switch 2P connector and body ground.


Wire side of female terminalsIs there battery voltage?YES - Go to step 4.NO - Repair open in the wire between the radiator fanswitch 2P connector terminal No. 2 and under-hoodfuse/relay box.

3. 4. Turn the ignition switch OFF and check for continuitybetween the No. 1 terminal of the radiator fan switch2P connector and body ground.


Wire side of female terminalsIs there continuity?YES - Replace the radiator fan switch. NO - Check for an open in the wire between the radiatorfan switch 2P connector terminal No. 1 and body ground. Ifthe wire is OK, check for a poor ground at G101.

1. 1. Remove the radiator fan relay from the under-hoodfuse/relay box and test it (see page 22-80).

Is the relay OK?YES - Go to step 2.NO - Replace the radiator fan relay.

2. 2. Remove the radiator fan switch and test it (see page10-19).

Is the radiator fan switch OK?YES - Go to step 3.NO - Replace the radiator fan switch.

3. 3. Disconnect ECM/PCM connector B (24P) and under-hood fuse relay box 14P connector.

4. Check for continuity between the No. 2 terminal ofthe radiator fan switch 2P connector and bodyground.


Wire side of female terminalsIs there continuity?YES - Repair short in the wire between the radiator fanswitch 2P connector terminal No. 2 and under-hoodfuse/relay box. NO - Replace the under-hood fuse/relay box.

10-18



Fan ControlsRadiator Fan Switch Test

Radiator Fan Switch Replacement

NOTE: Bleed air from the cooling system after installing theradiator fan switch (see page 10-8).1. 1. Remove the radiator fan switch from the thermostat

cover (see page 10-19).2. Suspend the radiator fan switch (A) in a container of

water as shown.

2. 3. Heat the water and check the temperature with athermometer. Do not let the thermometer (B) touchthe bottom of the hot container.

4. Measure the continuity between the A terminal (C)and B terminal (D) according to the table.

1. 1. Disconnect the radiator fan switch connector, thenremove the radiator fan switch (A).

2. 2. Install the radiator fan switch using a new O-ring (B).

10-19

Fuel and Emissions - Fuel and Emissions


Fuel and Emissions

4-door (KB, KE, KG, TR models) 11-14-door (except KB, KE, KG, TR models) 11-1655-door (KE model) 11-3095-door (except KE model) 11-465

4-door


4-door(KB, KE, KG, TR models)

Fuel and Emissions Systems

Special Tools 11-2General Troubleshooting Information 11-3DTC Troubleshooting Index 11-7Symptom Troubleshooting Index 11-10System Descriptions 11-11

PGM-FI System

Component Location Index 11-56DTC Troubleshooting 11-59MIL Circuit Troubleshooting 11-100VTEC Solenoid Valve Test 11-112Injector Replacement 11-113Primary HO2S Replacement 11-115Secondary HO2S Replacement 11-115

Idle Control System

Component Location Index 11-116DTC Troubleshooting 11-117A/C Signal Circuit Troubleshooting 11-119Alternator FR Signal Circuit Troubleshooting 11-120EPS Signal Circuit Troubleshooting 11-122Brake Pedal Position Switch Signal Circuit Troubleshooting 11-123Idle Speed Inspection 11-125

Fuel Supply System

Component Location Index 11-126Fuel Pump Circuit Troubleshooting 11-127Fuel Pressure Relieving 11-130Fuel Pressure Test 11-131Fuel Lines Inspection 11-132Fuel Tube/Quick-Connect Fittings Precautions 11-134Fuel Tube/Quick-Connect Fittings Removal 11-135Fuel Tube/Quick-Connect Fittings Installation 11-136Fuel Pressure Regulator Replacement 11-138Fuel Filter Replacement 11-138Fuel Pump/Fuel Gauge Sending Unit Replacement 11-139Fuel Tank Replacement 11-140Fuel Gauge Sending Unit Test 11-141Low Fuel Indicator Light Test 11-143

Intake Air System

Component Location Index 11-144Throttle Body Test 11-145Air Cleaner Replacement 11-146

4-door


Air Cleaner Element Replacement 11-147Resonator Replacement 11-148Throttle Cable Adjustment 11-149Throttle Cable Removal/Installation 11-150Throttle Body Removal/Installation 11-151Throttle Body Disassembly/Reassembly 11-152

Catalytic Converter System

DTC Troubleshooting 11-153Tailpipe Emission Test 11-153

EGR System

DTC Troubleshooting 11-154

PCV System

PCV Valve Inspection and Test 11-159

EVAP System

Component Location Index 11-160DTC Troubleshooting 11-161EVAP Control System Troubleshooting 11-163EVAP Two Way Valve Test 11-164

Fuel and Emissions - Fuel and Emissions Systems


Fuel and Emissions SystemsSpecial Tools


(1)(2)(3)(4)(5)(6)(7)

07LAA-PT5010107NAJ-P07010007WAA-001010007ZAJ-S5A010007ZAJ-S5A020007406-007000107406-0040002

O2 Sensor Socket WrenchOil Pressure Gauge AttachmentAdjustable Ring WrenchFuel Pressure Gauge SetHose, Oil PressureLow Pressure GaugeFuel Pressure Gauge

1111111

11-2



Fuel and Emissions SystemsGeneral Troubleshooting Information

Intermittent FailuresThe term ''intermittent failure'' means a system may have hada failure, but it checks OK now. If the Malfunction IndicatorLamp (MIL) on the dash does not come on, check for poorconnections or loose wires at all connectors related to thecircuit that you are troubleshooting.Opens and Shorts''Open'' and ''Short'' are common electrical terms. An open is abreak in a wire or at a connection. A short is an accidentalconnection of a wire to ground or to another wire. In simpleelectronics, this usually means something will not work at all. Incomplex electronics (like ECM's/PCM's) this can sometimesmean something works, but not the way it is supposed to.How to Use the PGM Tester or a Scan ToolIf the MIL (Malfunction Indicator Lamp) has comeon1. 1. Start the engine and check the MIL.

1. 2. If the MIL stays on, connect the Honda PGM Tester(A) or a scan tool to the Data Link Connector (DLC)(B) located under the driver's side of the dashboard.

*: The illustration shows LHD model.2. 3. Turn the ignition switch ON (II).

4. Check the Diagnostic Trouble Code (DTC) and noteit. Also check the freeze frame data. Refer to theDTC Troubleshooting Index and begin theappropriate troubleshooting procedure.

NOTE:Freeze frame data indicates the engine conditionswhen the first malfunction, misfire or fuel trimmalfunction was detected.The scan tool and the Honda PGM Tester can readthe DTC, freeze frame data, current data, and otherEngine Control Module (ECM)/Powertrain ControlModule (PCM) data.For specific operations, refer to the user's manualthat came with the scan tool or Honda PGM Tester.

If the MIL did not come onIf the MIL did not come on but there is a driveability problem,refer to the Symptom Troubleshooting Index in this section.If you cannot duplicate the DTCSome of the troubleshooting in this section requires you toreset the ECM/PCM and try to duplicate the DTC. If theproblem is intermittent and you cannot duplicate the code, donot continue through the procedure. To do so will only result inconfusion and, possibly, a needlessly replaced ECM/PCM.

11-3



Fuel and Emissions SystemsGeneral Troubleshooting Information (cont'd)

How to Reset the ECM/PCMYou can reset the ECM/PCM in either of 2 ways:

Use the scan tool or Honda PGM Tester to clear theECM's/PCM's memory. See the scan tool or Honda PGM Tester user'smanuals for specific instructions.Turn the ignition switch OFF, and remove the No. 6ECU (ECM/PCM) (15A) fuse (A) from the under-hoodfuse/relay box (B) for 10 seconds.

How to End a Troubleshooting Session (requiredafter any troubleshooting)1. 1. Reset the ECM/PCM as described above.

2. Turn the ignition switch OFF.3. Disconnect the scan tool or Honda PGM Tester from

the DLC.NOTE: The ECM/PCM is part of the immobiliser system. Ifyou replace the ECM/PCM, it will have a differentimmobiliser code. In order for the engine to start, you mustrewrite the immobiliser code with the Honda PGM Tester.

How to Remove the ECM/PCM for TestingIf the inspection for a trouble code requires voltage orresistance checks at the ECM/PCM connectors, remove theECM/PCM and test it:1. 1. Remove the passenger's dashboard lower cover (see

page 20-78), the passenger's kick panel (see page20-64), and the glove box (see page 20-79).

2. Remove the bolt. Cut the plastic cross brace in theglove box opening with diagonal cutters in the areashown, and discard it.

2. 3. Remove the relays (A), then remove the bolts andthe glove box frame (B).

11-4




1. 4. Remove the grey 20P ECM/PCM wire harnessconnector from the ECM/PCM mounting bracket.Remove the ECM/PCM mounting bolt (A) and thebracket.

*: The illustration shows LHD model.2. 5. Remove the nuts, then remove the ECM/PCM (B).

How to Troubleshoot Circuits at the ECM/PCM1. 1. Gently slide the sharp tester probe (A) into the

connector from wire side until it touches the end ofthe wire terminal.

*: The illustration shows LHD model.2. 2. If you cannot get to the wire side of the connector or

the wire side is sealed (A), disconnect the connectorand probe the terminals (B) from the terminal side.Do not force the probe into the connector.

Do not puncture the insulation on a wire. Punctures cancause poor or intermittent electrical connections.

11-5




How to Substitute the ECM/PCM1. 1. Remove the ECM/PCM from the vehicle.

2. Install a known-good ECM/PCM in the vehicle.3. Rewrite the immobiliser code with the ECM/PCM

replacement procedure on the Honda PGM Tester. Itallows you to start the engine.

4. After completing your tests, reinstall the originalECM/PCM and rewrite the immobiliser code with theECM/PCM replacement procedure on the HondaPGM Tester again.

11-6



Fuel and Emissions SystemsDTC Troubleshooting Index

Scan tool DTC Honda DTC Detection Item Page

DTC TemporaryDTC

DTC (MILIndication*)

TemporaryDTC

P0107 - 3-1 (3) - Manifold Absolute Pressure (MAP) Sensor CircuitLow Voltage

(seepage 11-59)

P0108 - 3-2 (3) - Manifold Absolute Pressure (MAP) Sensor CircuitHigh Voltage

(seepage 11-60)

P0112 - 10-1 (10) - Intake Air Temperature (IAT) Sensor Circuit LowVoltage

(seepage 11-61)

P0113 - 10-2 (10) - Intake Air Temperature (IAT) Sensor Circuit HighVoltage

(seepage 11-62)

P0117 - 6-1 (6) - Engine Coolant Temperature (ECT) Sensor CircuitLow Voltage

(seepage 11-63)

P0118 - 6-2 (6) - Engine Coolant Temperature (ECT) Sensor CircuitHigh Voltage

(seepage 11-64)

P0122 - 7-1 (7) - Throttle Position (TP) Sensor Circuit Low Voltage (seepage 11-65)

P0123 - 7-2 (7) - Throttle Position (TP) Sensor Circuit High Voltage (seepage 11-67)

P0131 - 1-1 (1) - Primary Heated Oxygen Sensor (Primary HO2S)(Sensor 1) Circuit Low Voltage

(seepage 11-68)

P0132 - 1-2 (1) - Primary Heated Oxygen Sensor (Primary HO2S)(Sensor 1) Circuit High Voltage

(seepage 11-69)

P0133 P0133 61-1 (61) T61-1 Primary Heated Oxygen Sensor (Primary HO2S)(Sensor 1) Slow Response

(seepage 11-70)

P0135 - 41-2 (41) - Primary Heated Oxygen Sensor (Primary HO2S)(Sensor 1) Heater Circuit Malfunction

(seepage 11-71)

P0137 P0137 63-1 (63) T61-1 Secondary Heated Oxygen Sensor (SecondaryHO2S) (Sensor 2) Circuit Low Voltage

(seepage 11-73)

P0138 P0138 63-2 (63) T63-2 Secondary Heated Oxygen Sensor (SecondaryHO2S) (Sensor 2) Circuit High Voltage

(seepage 11-74)

P0139 P0139 63-3 (63) T63-3 Secondary Heated Oxygen Sensor (Secondary (see

11-7



Fuel and Emissions SystemsDTC Troubleshooting Index (cont'd)


DTC TemporaryDTC


TemporaryDTC

P0301 P0301 71-1(71) T71-1 No. 1 Cylinder Misfire (see page 11-80)




P0325 - 23-1 (23) - Knock Sensor Circuit Malfunction (see page 11-85)

P0335 - 4-1 (4) - Crankshaft Position (CKP) Sensor No Signal (see page 11-88)

P0336 - 4-2 (4) - Crankshaft Position (CKP) Sensor IntermittentInterruption

(see page 11-88)

P0401 P0401 80-1 (80) T80-1 Exhaust Gas Recirculation (EGR) InsufficientFlow

(see page 11-154)

P0420 P0420 67-1 (67) T67-1 Catalyst System Efficiency Below Threshold (see page 11-153)

P0443 - 92-4 (92) - Evaporative Emission (EVAP) Canister PurgeValve Circuit Malfunction

(see page 11-161)

P0500*3 - 17-1 (17) - Vehicle Speed Sensor (VSS) Circuit Malfunction (see page 11-90)

P0501*2 - 17-2*2 - Vehicle Speed Sensor (VSS)Range/Performance

(see page 11-90)

P0563 - 34-2 (34) - Engine Control Module (ECM)/PowertrainControl Module (PCM) Power Source CircuitUnexpected Voltage

(see page 11-91)

P0600 - 39-1 (39) - Serial Communication Link Malfunction Refer to the Multiplex ControlSystem Troubleshooting (seepage 22-273).

P07xx***2

70-2 (70)*2 - Automatic Transaxle System Malfunction*2 Refer to the AutomaticTransmission DTCTroubleshooting Index

P1107 - 13-1 (13) - Barometric Pressure (BARO) Sensor CircuitLow Voltage

(see page 11-93)

P1108 - 13-2 (13) - Barometric Pressure (BARO) Sensor CircuitHigh Voltage

(see page 11-93)

P1259*1 - 22-4 (22)*1 - VTEC System Malfunction*1 (see page 11-94)

P1324 - 23-2 (23) - Knock Sensor Power Source Circuit LowVoltage

(see page 11-87)

*: These DTCs will be indicated by the blinking of the MIL when SCS short connector is connected.

**: The D indicator light and the MIL may come on simultaneously.

*1: D16W7, D16V1 engines

*2: A/T

11-8



Fuel and Emissions SystemsDTC Troubleshooting Index (cont'd)


DTC TemporaryDTC


TemporaryDTC

P1361 - 8-2 (8) - Top Dead Centre (TDC) Sensor IntermittentInterruption

(see page 11-98)

P1362 - 8-1 (8) - Top Dead Centre (TDC) Sensor No Signal (see page 11-98)

P1491 P1491 12-3 (12) T12-3 Exhaust Gas Recirculation (EGR) ValveInsufficient Lift

(see page 11-154)

P1498 - 12-2 (12) - Exhaust Gas Recirculation (EGR) Valve PositionSensor Circuit High Voltage

(see page 11-158)

P1519 - 14-3 (14) - Idle Air Control (IAC) Valve Circuit Malfunction (see page 11-117)

P1607 - 0-2 - Engine Control Module (ECM)/PowertrainControl Module (PCM) Internal CircuitMalfunction

(see page 11-99)

P17xx***2

- 70-3 (70)*2 - Automatic Transaxle System Malfunction*2 Refer to the AutomaticTransmission DTCTroubleshooting Index

*: These DTCs will be indicated by the blinking of the MIL when SCS short connector isconnected.

**: The D indicator light and the MIL may come on simultaneously.*1: D16W7, D16V1 engines*2: A/T*3: M/T

11-9



Fuel and Emissions SystemsSymptom Troubleshooting Index

When the vehicle has one of these symptoms, check the Diagnostic Trouble Code (DTC) with the scan tool. If there is no DTC, dothe diagnostic procedure for the symptom, in the sequence listed, until you find the cause.

Symptom Diagnostic procedure Also check for

Engine will not start (MIL works OK, noDTCs set)

1. Test the battery (see page 22-79).

2. Test the starter (see page 4-8).3. Troubleshoot the fuel pump

circuit (see page 11-127).

Low compressionIntake air leaksLocked up engineSlipped/ broken timing beltContaminated fuel

Engine will not start (MIL comes on andstays on, or never comes on at all, noDTCs set)

Troubleshoot the MIL circuit (see page 11-100).

Engine will not start (immobiliserindicator light comes on)

Troubleshoot the immobiliser system (seepage 22-245).

Hard starting (MIL works OK, no DTCsset)

1. Test the battery (see page 22-79).

2. Check the fuel pressure (seepage 11-131).

Low compressionIntake air leaksContaminated fuel

Cold fast idle too low (MIL works OK, noDTCs set)

Check the idle speed (see page 11-125).

Cold fast idle too high (MIL works OK,no DTCs set)

1. Check the idle speed (see page11-125).

2. Inspect/adjust the throttle cable(see page 11-149).

3. Inspect and test the throttle body(see page 11-145).

Idle speed fluctuates (MIL works OK, noDTCs set)

1. Check the idle speed (see page11-125).



Intake air leaks

After warming up idle speed is belowspecifications with no load (MIL worksOK, no DTCs set)

1. Troubleshoot the ALT FR signalcircuit (see page 11-120).


Vacuum hose clogged/cracked/poorconnection

After warming up idle speed is abovespecifications with no load (MIL worksOK, no DTCs set)

Troubleshoot the ALT FR signal circuit (seepage 11-120).

Low power (MIL works OK, no DTCsset)




Low compression

Engine stalls (MIL works OK, no DTCsset)


2. Check the idle speed (see page

Intake air leaksFaulty harness and sensorconnections

11-10



Fuel and Emissions SystemsSystem Descriptions

Electronic Control SystemThe functions of the fuel and emission control systems are managed by the Engine Control Module (ECM) on vehicles with manualtransmissions or the Powertrain Control Module (PCM) on vehicles with automatic transmissions.Fail-safe FunctionWhen an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed valuefor that sensor that allows the engine to continue to run.Back-up FunctionWhen an abnormality occurs in the ECM/PCM, the injectors are controlled by a back-up circuit independent of the system to permitminimal driving.Self-diagnosisWhen an abnormality occurs in the signal from a sensor, the ECM/PCM supplies ground for the Malfunction Indicator Lamp (MIL)and stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is first turned on, the ECM/PCM suppliesground for the MIL for 2 seconds to check the MIL bulb condition.Two Driving Cycle Detection MethodTo prevent false indications, the ''two driving cycle detection method'' is used for some self-diagnostic functions. When anabnormality occurs, the ECM/PCM stores it in its memory. When the same abnormality recurs after the ignition switch is turnedOFF and ON (II) again, the ECM/PCM informs the driver by turning on the MIL.

11-11



Fuel and Emissions SystemsSystem Descriptions (cont'd)

ECM/PCM DataYou can retrieve data from the ECM/PCM by connecting the scan tool or the Honda PGM Tester to the Data Link Connector (DLC).The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond thatrecommended by SAE so that this data may help you find the causes of intermittent problems.NOTE:

The ''operating values'' listed are approximate and may vary depending on the environment and the individual vehicle.Unless noted otherwise, ''at idle speed'' means idling with the engine completely warmed up, A/T in Park or neutral, M/Tin neutral position, and the A/C and all accessories turned off.Data Description Operating

ValueFreezeData

Diagnostic TroubleCode (DTC)

If the ECM/PCM detects a problem, it will store it as a code consisting of oneletter and four numbers. Depending on the problem, an SAE-defined code(P0xxx) or a Honda-defined code (P1xxx) will be output to the tester.

If no problemis detected,there is nooutput.

YES

Engine Speed The ECM/PCM computes engine speed from the signals sent from theCrankshaft Position (CKP) sensor. This data is used for determining the timeand amount of injected fuel.

Nearly thesame astachometerindicationAt idlespeed:650+50 rpm(min-1)

YES

Vehicle Speed The ECM/PCM converts pulse signals from Vehicle Speed Sensor (VSS). Nearly thesame asspeedometerindication

YES

Manifold AbsolutePressure (MAP)

The absolute pressure caused in the intake manifold by engine load andspeed.

With enginestopped:Nearly thesame asatmosphericpressureAt idlespeed: about20-34 kPa(150-260mmHg, 6-10in.Hg), 0.7-1.1 V

YES

Engine CoolantTemperature (ECT)

The ECT sensor converts coolant temperature into voltage and signals theECM/PCM. The sensor is a thermistor whose internal resistance changes withcoolant temperature. The ECM/PCM uses the voltage signals from the ECTsensor to determine the amount of injected fuel.

With coldengine:Same asambienttemperatureand IATWith enginewarmed up:about 80-100°C (176-212°F), 0.5-0.8 V

YES

11-12




ECM/PCM Data (cont'd)Data Description Operating

ValueFreezeData

Fuel SystemStatus

Fuel system status is indicated as ''open'' or ''closed''.Closed: Based on the HO2S output, the ECM/PCM determines the air/fuel ratio andcontrols the amount of injected fuel.Open: ignoring HO2S output, the ECM/PCM refers to signals from the Throttle Position(TP), Manifold Absolute Pressure (MAP), Intake Air Temperature (IAT), BarometricPressure (BARO) and Engine Coolant Temperature (ECT)) sensors to control the amountof injected fuel.

At idlespeed:closed

YES

Short TermFuel Trim

The air/fuel ratio correction coefficient for correcting the amount of injected fuel when theFuel System Status is ''closed. ''When the ratio is leaner than the stoichiometric ratio, theECM/PCM increases short term fuel trim gradually, and the amount of injected fuelincreases. The air/fuel ratio gradually gets richer, causing a lower oxygen content in theexhaust gas. Consequently, the short term fuel trim is lowered, and the ECM/PCM reducesthe amount of injected fuel.This cycle keeps the air/fuel ratio close to the stoichiometric ratio when in closed loopstatus.

0.6-1.5 YES

Long TermFuel Trim

Long term fuel trim is computed from short term fuel trim and indicates changes occurringin the fuel supply system over a long period.If long term fuel trim is higher than 1.00, the amount of injected fuel must be increased. If itis lower than 1.00, the amount of injected fuel must be reduced.

0.8-1.2 YES

Intake AirTemperature(IAT)

The IAT sensor converts intake air temperature into voltage and signals the ECM/PCM.When intake air temperature is low, the internal resistance of the sensor increases, andthe voltage signal is higher.

With coldengine:Same asambienttemperatureand ECT

YES

ThrottlePosition

Based on the accelerator pedal position, the opening angle of the throttle valve isindicated.

At idlespeed:about 10 %

YES

IgnitionTiming

Ignition timing is the ignition advance angle set by the ECM/PCM. The ECM/PCM matchesignition timing to the driving conditions.

At idlespeed:8°+2°BTDC whenthe SCSshortconnector isconnected

NO

11-13




ECM/PCM Inputs and Outputs at Connector A (31P)

Wire side of female terminalsNOTE: Standard battery voltage is 12 V.

Terminalnumber

Wirecolour

Terminal name Description Signal

1 BLK/WHT PO2SHTC (PRIMARY HEATEDOXYGEN SENSOR (PRIMARY HO2S)HEATER CONTROL)

Drives primaryHO2S heater

With ignition switch ON (II): batteryvoltageWith fully warmed up engine running:duty controlled

2 YEL/BLK IGP2 (POWER SOURCE) Power source forthe ECM/PCMcircuit

With the ignition switch ON (II): batteryvoltageWith the ignition switch OFF: about 0 V

3 YEL/BLK IGP1 (POWER SOURCE) Power source forthe ECM/PCMcircuit

With the ignition switch ON (II): batteryvoltageWith the ignition switch OFF: about 0 V

4 BLK PG2 (POWER GROUND) Ground for theECM/PCM circuit

Less than 1.0 V at all times

5 BLK PG1 (POWER GROUND) Ground for theECM/PCM circuit


6 WHT PHO2S (PRIMARY HEATED OXYGENSENSOR (PRIMARY HO2S), SENSOR1)

Detects primaryHO2S sensor(sensor 1) signal

With throttle fully opened from idle withfully warmed up engine: about 0.6 VWith throttle quickly closed: below 0.4 V

7 BLU CKP (CRANKSHAFT POSITION (CKP)SENSOR)

Detects CKP sensorsignal

With engine running: pulses

8 YEL VCCR (SENSOR VOLTAGE RETURN) Detects sensorvoltage

With ignition switch ON (II): about 5 VWith the ignition switch OFF: about 0 V

9 RED/BLU KS (KNOCK SENSOR) Detects knocksensor signal

With engine knocking: pulsesWith ignition switch ON (II): about 5 V

10 GRN/YEL SG2 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times

11 GRN/WHT SG1 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times

12 BLK/RED IACV (IDLE AIR CONTROL (IAC)VALVE)

Drives IAC valve With engine running: duty controlledWith ignition switch ON (II): about 5 V

13 WHT/BLK EGRP (EXHAUST GASRECIRCULATION (EGR) VALVEPOSITION SENSOR)

Detects EGR valveposition sensorsignal

With engine running: 1.2 V-2.0 V(depending on EGR valve lift)

15 RED/BLK

11-14




ECM/PCM Inputs and Outputs at Connector A (31P)


Terminal number Wire colour Terminal name Description Signal

19 GRN/RED

MAP (MANIFOLDABSOLUTEPRESSURE (MAP)SENSOR)

Detects MAP sensorsignal

With ignition switch ON (II): about 3 VAt idle: about 1.0 V (depending onengine speed)

20 YEL/BLU VCC2 (SENSORVOLTAGE)

Provides sensorvoltage

With ignition switch ON (II): about 5 VWith ignition switch OFF: about 0 V

21 YEL/RED VCC1 (SENSORVOLTAGE)

Provides sensorvoltage

With ignition switch ON (II): about 5 VWith ignition switch OFF: about 0 V

23 BRN/YEL LG2 (LOGIC GROUND)Ground for theECM/PCM circuit


24 BRN/YEL LG1 (LOGIC GROUND)Ground for theECM/PCM circuit


26 GRNTDC (TOP DEADCENTRE (TDC)SENSOR)

Detects TDC sensor With engine running: pulses

27 BRNIGPLS4 (No. 4IGNITION COILPULSE)

Drives No. 4 ignitioncoil

With ignition switch ON (II): about 0 VWith engine running: pulses

28 WHT/BLUIGPLS3 (No. 3IGNITION COILPULSE)


29 BLU/REDIGPLS2 (No. 2IGNITION COILPULSE)


30 YEL/GRNIGPLS1 (No. 1IGNITION COILPULSE)


*1: D16W7, D16V1 engines*2: A/T

11-15




ECM/PCM Inputs and Outputs at Connector B (24P)


Terminalnumber

Wirecolour


2 YEL INJ4 (No. 4 INJECTOR) Drives No. 4 injector With ignition switch ON (II): batteryvoltageAt idle: duty controlled

3 BLU INJ3 (No. 3 INJECTOR) Drives No. 3 injector

4 RED INJ2 (No. 2 INJECTOR) Drives No. 2 injector

5 BRN INJ1 (No. 1 INJECTOR) Drives No. 1 injector

6 GRN FANC (RADIATOR FAN CONTROL) Drives radiator fanrelay

With radiator fan running: about 0 VWith radiator fan stopped: batteryvoltage

7*2 RED/BLK LSA + (A/T PRESSURE CONTROLSOLENOID VALVE A + SIDE

Drives A/T pressurecontrol solenoid valveA

With the ignition switch ON (II): dutycontrolled

8 RED/WHT ECT (ENGINE COOLANTTEMPERATURE (ECT) SENSOR)

Detects ECT sensorsignal

With the ignition switch ON (II): about0.1-4.8 V(depending on engine coolanttemperature)

9*1 BLU/BLK VTPSW (VTEC OIL PRESSURESWITCH)

Detects VTEC oilpressure switch signal

At idle: about 0 V

10 WHT/BLU ALTL (ALTERNATOR L SIGNAL) Detects alternator Lsignal

With ignition switch ON (II): about 0 VWith engine running: battery voltage

13 WHT/RED ALTF (ALTERNATOR FR SIGNAL) Detects alternator FRsignal

With engine running: 0 V-5 V(depending on electrical load)

14 BLU/RED EGR (EXHAUST GASRECIRCULATION (EGR) VALVE)

Drives EGR valve With EGR operating: duty controlledWith EGR not operating: about 0 V

15*1 GRN/YEL VTS (VTEC SOLENOID VALVE) Drives VTEC solenoidvalve

At idle: about 0 V

16*2 BLK/RED LSB + (A/T PRESSURE CONTROLSOLENOID VALVE B + SIDE

Drives A/T pressurecontrol solenoid valveB

With the ignition switch ON (II): dutycontrolled

17 RED/YEL IAT (INTAKE AIR TEMPERATURE(IAT) SENSOR)

Detects IAT sensorsignal

With ignition switch ON (II): about 0.1V-4.8 V

11-16




PCM Inputs and Outputs at Connector C (22P)


Terminalnumber

Wirecolour


1*2 WHT/BLK LSA- (A/T PRESSURE CONTROLSOLENOID VALVE A-SIDE

Ground for A/T pressurecontrol solenoid valve A

2*2 YEL/BLU LC (TORQUE CONVERTERCLUTCH SOLENOID VALVE)

Drives torque converter clutchsolenoid valve

With lock-up ON: battery voltageWith lock-up OFF: about 0 V

4*2 GRN/WHT SHB (SHIFT SOLENOID VALVE B) Drives shift solenoid valve B With engine running in 1st, 2ndgears: battery voltageWith engine running in 3rd, 4thgears: about 0 V

6*2 BLU/BLK SHA (SHIFT SOLENOID VALVE A) Drives shift solenoid valve A With engine running in 2nd, 3rdgears: battery voltageWith engine running in 1st, 4thgears: about 0 V

7*2 WHT/RED NM (MAINSHAFT SPEEDSENSOR)

Detects mainshaft speedsensor signals

With engine running: pulses

8*2 BRN/WHT LSB- (A/T PRESSURE CONTROLSOLENOID VALVE B-SIDE

Ground for A/T pressurecontrol solenoid valve B

9*2 RED ATPD3 (TRANSMISSION RANGESWITCH D3 POSITION)

Detects transmission rangeswitch D3 position signal

In D3 position: about 0 VIn any other position: about 5 V orbattery voltage

10*2 WHT ATPR (TRANSMISSION RANGESWITCH R POSITION)

Detects transmission rangeswitch R position signal

In R position: about 0 VIn any other position: about 5 V orbattery voltage

11*2 BLU ATP2 (TRANSMISSION RANGESWITCH 2 POSITION)

Detects transmission rangeswitch 2 position signal

In 2nd position: about 0 VIn any other position: about 5 V orbattery voltage

12*2 BLU/WHT ATPNP (TRANSMISSION RANGESWITCH NEUTRAL/PARKPOSITION)

Detects transmission rangeswitch Neutral/Park positionsignal

In Park or neutral: about 0 VIn any other position: about 5 V orbattery voltage

14*2 GRN NCSG (COUNTERSHAFT SPEEDSENSOR GROUND)

Ground for countershaftspeed sensor

11-17




ECM/PCM Inputs and Outputs at Connector E (31P)


Terminalnumber

Wirecolour


1 GRN/YEL IMO FPR (IMMOBILIZER FUEL PUMPRELAY)

Drives PGM-FI main relay2

0 V for 2 seconds after turningignition switch ON (II), thenbattery voltage

2 WHT/RED SHO2S (SECONDARY HEATEDOXYGEN SENSOR (SECONDARYHO2S), SENSOR 2)

Detects secondary HO2S(sensor 2) signal

With throttle fully opened fromidle with fully warmed upengine: above 0.6 VWith throttle quickly closed:below 0.4 V

3 BRN/YEL LG3 (LOGIC GROUND) Ground for the ECM/PCMcontrol circuit


4 PNK SG3 (SENSOR GROUND) Sensor ground Less than 1.0 V at all times

6 BLK/WHT SO2SHTC (SECONDARY HEATEDOXYGEN SENSOR (SECONDARY HO2S)HEATER CONTROL)

Drives secondary HO2Sheater

With ignition switch ON (II):battery voltageWith fully warmed up enginerunning: duty controlled

7 RED/YEL MRLY (PGM-FI MAIN RELAY) Drives PGM-FI main relay1 Power source for theDTC memory

With ignition switch ON (II):about 0 VWith ignition switch OFF:battery voltage

9 YEL/BLK IG1 (IGNITION SIGNAL) Detects ignition signal With ignition switch ON (II):battery voltageWith ignition switch OFF: about0 V

16 LTGRN/BLK

EPSLD (ELECTRICAL POWERSTEERING LOAD DETECT)

Detects power steeringload signal

At idle with steering wheel instraight ahead position: about 0VAt idle with steering wheel atfull lock: battery voltagemomentarily

18 RED ACC (A/C CLUTCH RELAY) Drives A/C clutch relay With compressor ON: about 0 VWith compressor OFF: batteryvoltage

22 WHT/BLK BKSW (BRAKE PEDAL POSITION Detects brake pedal With brake pedal released:

11-18




Vacuum Hose Routing1. To EVAPORATIVE EMISSION

(EVAP) CANISTER2. EVAPORATIVE EMISSION (EVAP)

CANISTER PURGE VALVE3. FRONT OF VEHICLE

11-19




Vacuum Distribution

(1) PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S)(SENSOR 1)

(13) FUEL PRESSURE REGULATOR

(14) FUEL PUMP

(2) SECONDARY HEATED OXYGEN SENSOR (SECONDARYHO2S) (SENSOR 2)

(15) FUEL TANK

(16) AIR CLEANER

(3) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (17) RESONATOR

(4) ENGINE COOLANT TEMPERATURE (ECT) SENSOR (18) EXHAUST GAS RECIRCULATION (EGR) VALVE andPOSITION SENSOR

(5) INTAKE AIR TEMPERATURE (IAT) SENSOR

(6) CRANKSHAFT POSITION (CKP) SENSOR (19) POSITIVE CRANKCASE VENTILATION (PCV) VALVE

(7) KNOCK SENSOR (20) THREE WAY CATALYTIC CONVERTER

(8) IDLE AIR CONTROL (IAC) VALVE (21) EVAPORATIVE EMISSION (EVAP) CANISTER

(9) THROTTLE BODY (22) EVAPORATIVE EMISSION (EVAP) CANISTER PURGEVALVE

(10) INJECTOR

11-20




PGM-FI SystemThe Programmed Fuel Injection (PGM-FI) system is asequential multiport fuel injection system.Air Conditioning (A/C) Compressor Clutch RelayWhen the ECM/PCM receives a demand for cooling from theA/C system, it delays the compressor from being energised,and enriches the mixture to assure smooth transition to the A/Cmode.Alternator ControlThe alternator signals the Engine Control Module(ECM)/Powertrain Control Module (PCM) during charging.Barometric Pressure (BARO) SensorThe BARO sensor is inside the ECM/PCM. It convertsatmospheric pressure into a voltage signal that modifies thebasic duration of the fuel injection discharge.Crankshaft Position (CKP) SensorThe CKP sensor detects engine speed and determines ignitiontiming and timing for fuel injection of each cylinder.

1. 1. MAGNET

Engine Coolant Temperature (ECT) SensorThe ECT sensor is a temperature dependent resistor(thermistor). The resistor of the thermistor decreases as theengine coolant temperature increases.

1. 1. THERMISTOR

Ignition Timing ControlThe ECM/PCM contains the memory for basic ignition timing atvarious engine speeds and manifold absolute pressure. It alsoadjusts the timing according to engine coolant temperature.Injector Timing and DurationThe ECM/PCM contains the memory for basic dischargeduration at various engine speeds and manifold pressures. Thebasic discharge duration, after being read out from thememory, is further modified by signals sent from varioussensors to obtain the final discharge duration.By monitoring long term fuel trim, the ECM/PCM detects longterm malfunctions in the fuel system, and will set a DiagnosticTrouble Code (DTC).Intake Air Temperature (IAT) SensorThe IAT sensor is a temperature dependent resistor(thermistor). The resistance of the thermistor decreases as theintake air temperature increases.

2. 1. THERMISTOR

11-21




Knock SensorThe knock control system adjusts the ignition timing tominimise knock.

1. 1. WEIGHT2. PIEZO ELEMENT

Manifold Absolute Pressure (MAP) SensorThe MAP sensor converts manifold absolute pressure intoelectrical signals to the ECM/PCM.

2. 1. SENSOR UNIT

Primary Heated Oxygen Sensor (Primary HO2S)The primary HO2S detects the oxygen content in the exhaustgas and sends signals to the ECM/PCM which varies theduration of fuel injection accordingly. To stabilise its output, thesensor has an internal heater. The primary HO2S is installed inthe exhaust manifold. By controlling the air fuel ratio withprimary HO2S and secondary HO2S, the deterioration of theprimary HO2S can be evaluated by its feedback period. Whenthe feedback period exceeds a certain value during stabledriving conditions, the sensor is considered deteriorated andthe ECM/PCM sets a DTC.

1. 1. ZIRCONIA ELEMENT2. SENSOR TERMINALS3. HEATER TERMINALS4. HEATER

Secondary Heated Oxygen Sensor (SecondaryHO2S)The secondary HO2S detects the oxygen content in theexhaust gas downstream of the Three Way Catalytic Converter(TWC) and sends signals to the ECM/PCM which varies theduration of fuel injection accordingly. To stabilise its output, thesensor has an internal heater. The secondary HO2S isinstalled in the TWC.

2. 1. ZIRCONIA ELEMENT2. SENSOR TERMINALS3. HEATER TERMINALS4. HEATER

Starting ControlWhen the engine is started, the ECM/PCM provides a richmixture by increasing injector duration.

11-22




Throttle Position (TP) SensorThe TP sensor is a potentiometer connected to the throttlevalve shaft. As the throttle position changes, the sensor variesthe signal voltage to the ECM/PCM. The TP sensor is notreplaceable apart from the throttle body.

1. 1. ELEMENT2. BRUSH HOLDER3. BRUSH

Top Dead Centre (TDC) SensorThe TDC sensor detects the position of the No. 1 cylinder as areference for sequential fuel injection to each cylinder.

2. 1. MAGNET

Vehicle Speed Sensor (VSS)The VSS is driven by the differential. It generates a pulsedsignal from an input of 5 volts. The number of pulses perminute increases/decreases with the speed of the vehicle.

Idle Control SystemWhen the engine is cold, the A/C compressor is on, thetransmission is in gear, the brake pedal is pressed, the powersteering load is high, or the alternator is charging, theECM/PCM controls current to the Idle Air Control (IAC) valve tomaintain the correct idle speed. Refer to the System Diagramto see the functional layout of the system.Brake Pedal Position SwitchThe brake pedal position switch signals the ECM/PCM whenthe brake pedal is pressed.Electrical Power Steering (EPS) SignalThe EPS signals the ECM/PCM when the power steering loadis high.Idle Air Control (IAC) ValveTo maintain the proper idle speed, the IAC valve changes theamount of air bypassing the throttle body in response to anelectrical signal from the ECM/PCM.

1. 1. VALVE2. From AIR CLEANER3. To INTAKE MANIFOLD

11-23




Fuel Supply SystemFuel Cut-off ControlDuring deceleration with the throttle valve closed, current to theinjectors is cut off to improve fuel economy at speeds over 850rpm (min-1). Fuel cut-off action also occurs when enginespeed exceeds 6,400 rpm (min-1) (D14Z5, D14Z6 engines),6,500 rpm (min-1) (D16W7, D16V1 engines), regardless of theposition of the throttle valve, to protect the engine from over-revving. With A/T model, when the vehicle is stopped, the PCMcuts the fuel at engine speeds over 5,000 rpm (min-1).Fuel Pump ControlWhen the ignition is turned on, the ECM/PCM grounds thePGM-FI main relay which feeds current to the fuel pump for 2seconds to pressurise the fuel system. With the engine running,the ECM/PCM grounds the PGM-FI main relay and feedscurrent to the fuel pump. When the engine is not running andthe ignition is on, the ECM/PCM cuts ground to the PGM-FImain relay which cuts current to the fuel pump.PGM-FI Main Relay 1 and 2The PGM-FI relay consists of two separate relays. The PGM-FI main relay 1 is energised whenever the ignition switch isON (II) which supplies battery voltage to the ECM/PCM, powerto the injectors, and power for the PGM-FI main relay 2. ThePGM-FI main relay 2 is energised to supply power to the fuelpump for 2 seconds when the ignition switch is turned ON (II),and when the engine is running.

Intake Air SystemRefer to the System Diagram to see the functional layout of thesystem.Throttle BodyThe throttle body is a single-barrel down draft type. The sideportion of the IAC valve is heated by engine coolant from thecylinder head.

1. 1. TP SENSOR2. IAC VALVE

11-24




Catalytic Converter SystemThree Way Catalytic Converter (TWC)The TWC converts hydrocarbons (HC), carbon monoxide (CO),and oxides of nitrogen (NOx) in the exhaust gas to carbondioxide (CO2), dinitrogen (N2), and water vapour.

1. 1. HOUSING2. FRONT OF VEHICLE3. THREE WAY CATALYSTS

Exhaust Gas Recirculation (EGR) SystemRefer to the System Diagram to see the functional layout of thesystem.EGR ValveThe EGR valve is designed to lower peak combustiontemperatures and reduce oxides of nitrogen emissions (NOx)by recirculating exhaust gas through the intake manifold andinto the combustion chambers.Positive Crankcase Ventilation (PCV) SystemThe PCV valve prevents blow-by gasses from escaping intothe atmosphere by venting them into the intake manifold.

1. 1. PCV HOSE2. BREATHER PIPE3. INTAKE MANIFOLD4. PCV VALVE5. BLOW BY VAPOUR6. FRESH AIR

11-25




Evaporative Emission (EVAP) Control SystemRefer to the System Diagram to see the functional layout of thesystem.EVAP CanisterThe EVAP canister temporarily stores fuel vapour from the fueltank until it can be purged back into the engine and burned(refer to the System Diagram to see the functional layout of thesystem).EVAP Canister Purge ValveWhen the engine coolant temperature is below 70°C (158°F),the ECM/PCM turns off the EVAP canister purge valve whichcuts vacuum to the EVAP canister.

11-26




Idle Control System DiagramThe idle speed of the engine is controlled by the Idle Air Control (IAC) valve:

After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idlespeed.When the engine coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount ofbypassed air is thus controlled in relation to engine coolant temperature.

Intake Air System DiagramThis system supplies air for engine needs. A resonator in the intake air pipe provides additional silencing as air is drawn into thesystem.

11-27




Exhaust Gas Recirculation (EGR) System DiagramThe EGR system reduces oxides of nitrogen (NOx) emissions by recirculating exhaust gas through the EGR valve and the intakemanifold into the combustion chambers. The ECM/PCM memory includes the ideal EGR valve position for varying operatingconditions.The EGR valve position sensor detects the amount of EGR valve lift and sends it to the ECM/PCM. The ECM/PCM then comparesit with the ideal lift in its memory (based on signals sent from other sensors). If there is any difference between the two, theECM/PCM cuts current to the EGR valve.

11-28




Evaporative Emission (EVAP) Control DiagramThe EVAP controls minimise the amount of fuel vapour escaping to the atmosphere. Vapour from the fuel tank is temporarily storedin the EVAP canister until it can be purged from the EVAP canister into the engine and burned.

The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold.The purging vacuum is controlled by the EVAP canister purge valve, which is open whenever engine coolant temperature isabove 70°C (158°F).

When vapour pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens andregulates the flow of fuel vapour to the EVAP canister.

11-29




ECM/PCM Circuit Diagram

11-30




11-31




ECM/PCM Circuit Diagram (cont'd)

11-32




11-33





11-34




11-35





11-36




11-37





11-38




1. FLOOR WIRE HARNESS

NOTE Connector with male terminals (double outline): View from terminalsideConnector with female terminals (single outline): View from wire sideO: Related to ECM/PCM control.

11-39




ECM/PCM Circuit Diagram (cont'd)LHD model:

1. ENGINE COMPARTMENTWIRE HARNESS

2. ENGINE WIRE HARNESS

*1: D16W7, D16V1 engines*2: A/T

11-40




11-41






11-42




11-43





1. DASHBOARD WIRE HARNESSA

2. DASHBOARD WIRE HARNESSB

3. ENGINE COMPARTMENT WIREHARNESS

4. ECM/PCM WIRE HARNESS

11-44




11-45





1. DASHBOARD WIREHARNESS

2. ENGINE WIRE HARNESS3. ECM/PCM WIRE

HARNESS4. FLOOR WIRE HARNESS5. ENGINE COMPARTMENT

WIRE HARNESS A

11-46




11-47




ECM/PCM Circuit Diagram (cont'd)RHD model:

1. ENGINE COMPARTMENTWIRE HARNESS


*1: D16W7 engine*2: A/T

11-48




11-49






11-50




11-51





1. DASHBOARD WIREHARNESS A

2. ECM/PCM WIRE HARNESS3. ENGINE COMPARTMENT

WIRE HARNESS4. DASHBOARD WIRE

HARNESS B

11-52




11-53





1. ENGINE WIREHARNESS

2. DASHBOARD WIREHARNESS A

3. FLOOR WIREHARNESS

4. ECM/PCM WIREHARNESS

11-54




11-55



11-125).3. Troubleshoot the brake pedal

position switch signal circuit (seepage 11-123).

Fuel and Emissions - PGM-FI System


PGM-FI SystemComponent Location Index

1. THROTTLE POSITION (TP) SENSORTroubleshooting, page 11-65

2. INTAKE AIR TEMPERATURE (IAT)SENSORTroubleshooting, page 11-61

3. MANIFOLD ABSOLUTE PRESSURE(MAP) SENSORTroubleshooting, page 11-59

4. TOP DEAD CENTRE (TDC) SENSORTroubleshooting, page 11-98

5. CRANKSHAFT POSITION (CKP)SENSORTroubleshooting, page 11-88

6. KNOCK SENSORTroubleshooting, page 11-85

7. ENGINE COOLANT TEMPERATURE(ECT) SENSORTroubleshooting, page 11-63

8. PRIMARY HEATED OXYGEN SENSOR(PRIMARY HO2S) (SENSOR 1)Troubleshooting, page 11-68Replacement, page 11-115

9. SECONDARY HEATED OXYGENSENSOR (SECONDARY HO2S)(SENSOR 2)Troubleshooting, page 11-73Replacement, page 11-115

11-56



PGM-FI SystemComponent Location Index (cont'd)

1. INJECTORSReplacement, page 11-113

11-57



PGM-FI SystemComponent Location Index (cont'd)

1. DATA LINK CONNECTOR (DLC)General Troubleshooting Information,page 11-3

*: The illustration shows LHD model.

1. ENGINE CONTROLMODULE/POWERTRAIN CONTROLMODULE (ECM/PCM)General Troubleshooting Information, page11-3Troubleshooting, page 11-99

2. PGM-FI MAIN RELAY 1Troubleshooting, page 11-100

3. INERTIA SWITCHTroubleshooting, page 11-100


11-58



PGM-FI SystemDTC Troubleshooting

DTC P0107: MAP Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the MAP with the scan tool.Is about 101 kPa (760 mmHg, 30 in.Hg) or 2.9 V indicated?

YES - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theMAP sensor and at the ECM/PCM.

NO - Go to step 3.

2. 3. Turn the ignition switch OFF.4. Disconnect the MAP sensor 3P connector.5. Turn the ignition switch ON (II).6. Measure voltage between the MAP sensor 3P

connector terminals No. 1 and No. 3.MAP SENSOR 3P CONNECTOR

Wire side of female terminalsIs there about 5 V?

YES - Go to step 8.

NO - Go to step 7.

3. 7. Measure voltage between ECM/PCM connectorterminals A11 and A21.



Is there about 5 V?

YES - Repair open in the wire between ECM/PCM (A21)and the MAP sensor.

NO - Substitute a known-good ECM/PCM and recheck(see page 11-6). If symptom/indication goes away,replace the original ECM/PCM.

1. 8. Check the MAP with the scan tool.Is 2 kPa (15 mmHg, 0.6 in.Hg) or less or 0 V indicated?

YES - Go to step 9.

NO - Replace the MAP sensor.

2. 9. Turn the ignition switch OFF.10. Disconnect ECM/PCM connector A (31P).11. Check for continuity between the MAP sensor

connector terminal No. 2 and body ground.MAP SENSOR 3P CONNECTOR

Wire side of female terminalsIs there continuity?

YES - Repair short in the wire between the ECM/PCM(A19) and the MAP sensor.


11-59



PGM-FI SystemDTC Troubleshooting (cont'd)

DTC P0108: MAP Sensor Circuit High Voltage1. 1. Start the engine. Hold the engine at 3,000 rpm with

no load (in Park or neutral) until the radiator fancomes on, then let it idle.

2. Check the MAP with the scan tool.Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about2.9 V or higher indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theMAP sensor and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect the MAP sensor 3P connector.5. Connect the MAP sensor 3P connector terminals No.

2 and No. 3 with a jumper wire.MAP SENSOR 3P CONNECTOR

JUMPER WIREWire side of female terminals

3. 6. Turn the ignition switch ON (II).7. Check the MAP with the scan tool.

Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about2.9 V or higher indicated?

YES - Go to step 8.


4. 8. Remove the jumper wire.

1. 9. Measure voltage between the MAP sensor 3Pconnector terminals No. 1 and No. 3.

MAP SENSOR 3P CONNECTOR


YES - Go to step 10.

NO - Repair open in the wire between the ECM/PCM(A11) and the MAP sensor.

2. 10. Turn the ignition switch OFF.11. Connect ECM/PCM connector terminals A11 and

A19 with a jumper wire.ECM/PCM CONNECTOR A (31P)


3. 12. Turn the ignition switch ON (II).13. Check the MAP with the scan tool.

Is about 101 kPa (760 mmHg, 30 in.Hg) or higher, or about2.9 V or higher indicated?

YES - Substitute a known-good ECM/PCM and recheck(see page 11-6). If symptom/indication goes away,replace the original ECM/PCM.

NO - Repair open in the wire between the ECM/PCM(A19) and the MAP sensor.

11-60




DTC P0112: IAT Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the IAT with the scan tool.Is 150°C (302°F) or higher (or H-Limit in Honda mode ofPGM Tester) or 0 V indicated?

YES - Go to step 3.

NO - Go to step 8.

2. 3. Disconnect the IAT sensor 2P connector.4. Check the IAT with the scan tool.

Is 150°C (302°F) or higher (or H-Limit in Honda mode ofPGM Tester) or 0 V indicated?

YES - Go to step 5.

NO - Replace the IAT sensor.

3. 5. Turn the ignition switch OFF.6. Disconnect ECM/PCM connector B (24P).7. Check for continuity between the IAT sensor 2P

connector terminal No. 2 and body ground.IAT SENSOR 2P CONNECTOR


YES - Repair short in the wire between the ECM/PCM(B17) and the IAT sensor.


1. 8. Check the temperature reading on the scan tool.Be aware that if the engine is warm, the reading will behigher than ambient temperature. If the engine is cold, theIAT and ECT will have the same value.Is the correct ambient temperature indicated?

YES - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theIAT sensor and at the ECM/PCM.


11-61




DTC P0113: IAT Sensor Circuit High Voltage1. 1. Turn the ignition switch ON (II).

2. Check the IAT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theIAT sensor and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect the IAT sensor 2P connector.5. Connect the IAT sensor 2P connector terminals No.

1 and No. 2 with a jumper wire.IAT SENSOR 2P CONNECTOR


3. 6. Turn the ignition switch ON (II).

1. 7. Check the IAT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 8.


2. 8. Turn the ignition switch OFF.9. Remove the jumper wire.

10. Connect ECM/PCM connector terminals A10 andB17 with a jumper wire.

ECM/PCM CONNECTORS


3. 11. Turn the ignition switch ON (II).12. Check the IAT with the scan tool.

Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?


NO - Repair open in the wire between the ECM/PCM(A10, B17) and the IAT sensor.

11-62




DTC P0117: ECT Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the ECT with the scan tool.Is 150°C (302°F) or higher (or H-Limit in Honda mode ofPGM Tester) or 0 V indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theECT sensor and at the ECM/PCM.

2. 3. Disconnect the ECT sensor 2P connector.4. Check the ECT with the scan tool.


YES - Go to step 5.

NO - Replace the ECT sensor.

3. 5. Turn the ignition switch OFF.6. Disconnect ECM/PCM connector B (24P).

1. 7. Check for continuity between the ECT sensor 2Pconnector terminal No. 2 and body ground.

ECT SENSOR 2P CONNECTOR


YES - Repair short in the wire between the ECM/PCM(B8) and the ECT sensor.


11-63




DTC P0118: ECT Sensor Circuit High Voltage1. 1. Turn the ignition switch ON (II).

2. Check the ECT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 3.


2. 3. Turn the ignition switch OFF.4. Disconnect the ECT sensor 2P connector.5. Connect the ECT sensor 2P connector terminals No.

1 and No. 2 with a jumper wire.ECT SENSOR 2P CONNECTOR



1. 7. Check the ECT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 8.



10. Connect ECM/PCM connector terminals A10 and B8with a jumper wire.

ECM/PCM CONNECTORS


3. 11. Turn the ignition switch ON (II).12. Check the ECT with the scan tool.



NO - Repair open in the wire between the ECM/PCM(A10, B8) and the ECT sensor.

11-64




DTC P0122: TP Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the throttle position with the scan tool.Is there about 10% or 0.5 V when the throttle is fully closedand about 90% or 4.5 V when the throttle is fully opened?

YES - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at the TPsensor and at the ECM/PCM.

NO - Go to step 3.

2. 8. Turn the ignition switch OFF.9. Disconnect the TP sensor 3P connector.

10. Turn the ignition switch ON (II).11. Measure voltage between the TP sensor 3P

connector terminals No. 1 and No. 3.TP SENSOR 3P CONNECTOR


YES - Go to step 7.

NO - Go to step 14.

3. 7. Turn the ignition switch OFF.

1. 8. At the sensor side, measure resistance between theTP sensor 3P connector terminals No. 1 and No. 3with the throttle fully closed.

TP SENSOR 3P CONNECTOR

Terminal side of male terminalsIs there about 0.5-0.9 k ohms?

YES - Go to step 9.

NO - Replace the throttle body.

2. 9. Measure resistance between the TP sensor 3Pconnector terminals No. 1 and No. 2 with the throttlefully closed.


Terminal side of male terminalsIs there about 4.5k ohms?



10. Disconnect ECM/PCM connector A (31P).

11-65




1. 11. At the wire harness side, check for continuitybetween TP sensor 3P connector terminal No. 2 andbody ground.



YES - Repair short in the wire between the ECM/PCM(A15) and the TP sensor.

NO - Go to step 12.

12. Connect ECM/PCM connector terminal A15 and bodyground with a jumper wire.



1. 13. At the wire harness side, check for continuitybetween TP sensor 3P connector terminals No. 2and body ground.




NO - Repair open in the wire between the ECM/PCM(A15) and the TP sensor.

14. Measure voltage between ECM/PCM connectorterminals A10 and A20.



YES - Repair open in the wire between the ECM/PCM(A20) and the TP sensor.


11-66




DTC P0123: TP Sensor Circuit High Voltage

1. 1. Turn the ignition switch ON (II).2. Check the throttle position with the scan tool.

Is there about 10% or 0.5 V when the throttle is fully closedand about 90% or 4.5 V when the throttle is fully opened?


NO - Go to step 3.

2. 3. Turn the ignition switch OFF.4. Disconnect the TP sensor 3P connector.5. Turn the ignition switch ON (II).6. At the wire harness side, measure voltage between

the TP sensor 3P connector terminals No. 1 and No.3.



YES - Replace the throttle body.

NO - Go to step 7.






11-67




DTC P0131: Primary HO2S (Sensor 1) Circuit LowVoltage1. 1. Reset the ECM/PCM (see page 11-4).

2. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load (in Park or neutral) until the radiatorfan comes on.

3. Check the primary HO2S (Sensor 1) output voltagewith the scan tool during acceleration using wideopen throttle.

Does the voltage stay at 0.5 V or less?

YES - Go to step 4.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theprimary HO2S (Sensor 1) and at the ECM/PCM.

2. 4. Check the fuel pressure (see page 11-131).Is it normal?

YES - Go to step 5.

NO - Repair the fuel supply system.

3. 5. Turn the ignition switch OFF.6. Disconnect the primary HO2S (Sensor 1) 4P

connector.7. Turn the ignition switch ON (II).8. Check the primary HO2S (Sensor 1) output voltage

with the scan tool.Does it stay at 0.5 V or less?

YES - Go to step 9.

NO - Replace the primary HO2S (Sensor 1).


10. Disconnect ECM/PCM connector A (31P).11. Check for continuity between the primary HO2S (Sensor

1) 4P connector terminal No. 2 and body ground.

PRIMARY HO2S (SENSOR 1) 4P CONNECTOR

Terminal side of male terminalsIs there continuity?

YES - Repair short in the wire between the ECM/PCM(A6) and the primary HO2S (Sensor 1).


11-68




DTC P0132: Primary HO2S (Sensor 1) Circuit HighVoltage1. 1. Reset the ECM/PCM (see page 11-4).


3. Check the primary HO2S (Sensor 1) output voltagewith the scan tool.

Does the voltage stay at 0.9 V or more?

YES - Go to step 4.



connector.6. Connect the primary HO2S (Sensor 1) 4P connector

terminals No. 1 and No. 2 with a jumper wire.PRIMARY HO2S (SENSOR 1) 4P CONNECTOR

Terminal side of male terminals3. 7. Turn the ignition switch ON (II).


Is there 0.9 V or more?

YES - Go to step 9.



10. Connect ECM/PCM connector terminals A6 and A10with a jumper wire.



11. Turn the ignition switch ON (II).12. Check the primary HO2S (Sensor 1) output voltage with

the scan tool.



NO - Repair open in the wire between the ECM/PCM(A6, A10) and the primary HO2S (Sensor 1).

11-69




DTC P0117: ECT Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the ECT with the scan tool.Is 150°C (302°F) or higher (or H-Limit in Honda mode ofPGM Tester) or 0 V indicated?

YES - Go to step 3.


2. 3. Disconnect the ECT sensor 2P connector.4. Check the ECT with the scan tool.


YES - Go to step 5.


3. 5. Turn the ignition switch OFF.6. Disconnect ECM/PCM connector B (24P).

1. 7. Check for continuity between the ECT sensor 2Pconnector terminal No. 2 and body ground.

ECT SENSOR 2P CONNECTOR


YES - Repair short in the wire between the ECM/PCM(B8) and the ECT sensor.


11-63




DTC P0118: ECT Sensor Circuit High Voltage1. 1. Turn the ignition switch ON (II).

2. Check the ECT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 3.


2. 3. Turn the ignition switch OFF.4. Disconnect the ECT sensor 2P connector.5. Connect the ECT sensor 2P connector terminals No.

1 and No. 2 with a jumper wire.ECT SENSOR 2P CONNECTOR



1. 7. Check the ECT with the scan tool.Is -20°C (-4°F) or less (or L-Limit in Honda mode of PGMTester) or 5 V indicated?

YES - Go to step 8.



10. Connect ECM/PCM connector terminals A10 and B8with a jumper wire.

ECM/PCM CONNECTORS


3. 11. Turn the ignition switch ON (II).12. Check the ECT with the scan tool.



NO - Repair open in the wire between the ECM/PCM(A10, B8) and the ECT sensor.

11-64




DTC P0122: TP Sensor Circuit Low Voltage1. 1. Turn the ignition switch ON (II).

2. Check the throttle position with the scan tool.Is there about 10% or 0.5 V when the throttle is fully closedand about 90% or 4.5 V when the throttle is fully opened?


NO - Go to step 3.

2. 8. Turn the ignition switch OFF.9. Disconnect the TP sensor 3P connector.

10. Turn the ignition switch ON (II).11. Measure voltage between the TP sensor 3P

connector terminals No. 1 and No. 3.TP SENSOR 3P CONNECTOR


YES - Go to step 7.

NO - Go to step 14.


1. 8. At the sensor side, measure resistance between theTP sensor 3P connector terminals No. 1 and No. 3with the throttle fully closed.


Terminal side of male terminalsIs there about 0.5-0.9 k ohms?

YES - Go to step 9.


2. 9. Measure resistance between the TP sensor 3Pconnector terminals No. 1 and No. 2 with the throttlefully closed.


Terminal side of male terminalsIs there about 4.5k ohms?




11-65




1. 11. At the wire harness side, check for continuitybetween TP sensor 3P connector terminal No. 2 andbody ground.



YES - Repair short in the wire between the ECM/PCM(A15) and the TP sensor.

NO - Go to step 12.

12. Connect ECM/PCM connector terminal A15 and bodyground with a jumper wire.



1. 13. At the wire harness side, check for continuitybetween TP sensor 3P connector terminals No. 2and body ground.




NO - Repair open in the wire between the ECM/PCM(A15) and the TP sensor.






11-66




DTC P0123: TP Sensor Circuit High Voltage

1. 1. Turn the ignition switch ON (II).2. Check the throttle position with the scan tool.

Is there about 10% or 0.5 V when the throttle is fully closedand about 90% or 4.5 V when the throttle is fully opened?


NO - Go to step 3.

2. 3. Turn the ignition switch OFF.4. Disconnect the TP sensor 3P connector.5. Turn the ignition switch ON (II).6. At the wire harness side, measure voltage between

the TP sensor 3P connector terminals No. 1 and No.3.



YES - Replace the throttle body.

NO - Go to step 7.






11-67




DTC P0131: Primary HO2S (Sensor 1) Circuit LowVoltage1. 1. Reset the ECM/PCM (see page 11-4).


3. Check the primary HO2S (Sensor 1) output voltagewith the scan tool during acceleration using wideopen throttle.


YES - Go to step 4.


2. 4. Check the fuel pressure (see page 11-131).Is it normal?

YES - Go to step 5.

NO - Repair the fuel supply system.


connector.7. Turn the ignition switch ON (II).8. Check the primary HO2S (Sensor 1) output voltage

with the scan tool.Does it stay at 0.5 V or less?

YES - Go to step 9.



10. Disconnect ECM/PCM connector A (31P).11. Check for continuity between the primary HO2S (Sensor

1) 4P connector terminal No. 2 and body ground.





11-68




DTC P0132: Primary HO2S (Sensor 1) Circuit HighVoltage1. 1. Reset the ECM/PCM (see page 11-4).




YES - Go to step 4.



connector.6. Connect the primary HO2S (Sensor 1) 4P connector

terminals No. 1 and No. 2 with a jumper wire.PRIMARY HO2S (SENSOR 1) 4P CONNECTOR




YES - Go to step 9.



10. Connect ECM/PCM connector terminals A6 and A10with a jumper wire.



11. Turn the ignition switch ON (II).12. Check the primary HO2S (Sensor 1) output voltage with

the scan tool.



NO - Repair open in the wire between the ECM/PCM(A6, A10) and the primary HO2S (Sensor 1).

11-69




DTC P0133: Primary HO2S (Sensor 1) Slow ResponseNOTE: If DTC P0131, P0132 and/or P0135 are stored at thesame time as DTC P0133, troubleshoot those DTCs first, thenrecheck for DTC P0133.1. 1. Reset the ECM/PCM (see page 11-4).


3. Test-drive under the following conditions:89 km/h (55 mph) steady speedA/T in D position (M/T in 5th gear)Until readiness code or Temporary DTC P0133comes on

2. 4. Check for a Temporary DTC with the scan tool.Is Temporary DTC P0133 indicated?

YES - Replace the primary HO2S (Sensor 1).

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theprimary HO2S (Sensor 1) and the ECM/PCM.

11-70




DTC P0135: Primary HO2S (Sensor 1) Heater CircuitMalfunction1. 1. Reset the ECM/PCM (see page 11-4).

2. Start the engine.Is DTC P0135 indicated?

YES - Go to step 3.



connector.5. At the primary HO2S side, measure resistance

between the primary HO2S (sensor 1) 4P connectorterminals No. 3 and No. 4.


Wire side of female terminalsIs there 10-40 ohms?

YES - Go to step 6.


1. 6. Check for continuity between body ground and theprimary HO2S (Sensor 1) 4P connector terminals No.3 and No. 4 individually.




NO - Go to step 7.

2. 7. Turn the ignition switch ON (II).8. Measure voltage between the primary HO2S (Sensor

1) 4P connector terminal No. 3 and No. 4.PRIMARY HO2S (SENSOR 1) 4P CONNECTOR

Wire side of female terminalsIs there battery voltage?

YES - Go to step 9.

NO - Go to step 12.

3. 9. Turn the ignition switch OFF.10. Disconnect ECM/PCM connector A (31P).

11-71




1. 11. Check for continuity between ECM/PCM connectorterminal A1 and body ground.





12. Measure voltage between the primary HO2S (Sensor 1)4P connector terminal No. 3 (No. 4)* and body ground.


Terminals side of male terminalsIs there battery voltage?


NO - Check the No. 4 ACG (10A) fuse in the under-dashfuse/relay box. If fuse is OK, repair open in the wirebetween the primary HO2S (Sensor 1) and No. 4ACG (10A) fuse.

1. 13. Turn the ignition switch OFF.14. Reconnect the primary HO2S (Sensor 1) 4P

connector.15. Disconnect ECM/PCM connector A (31P).16. Turn the ignition switch ON (II).17. Measure voltage between ECM/PCM connector

terminal A1 and A5.ECM/PCM CONNECTOR A (31P)

Wire side of female terminalsIs there 0.1 V or less?

YES - Repair open in the wire between the ECM/PCM(A1) and the primary HO2S (Sensor 1).


11-72




DTC P0137: Secondary HO2S (Sensor 2) Circuit LowVoltage1. 1. Reset the ECM/PCM (see page 11-4).


3. Check the secondary HO2S (Sensor 2) outputvoltage at 3,000 rpm (min-1) with the scan tool.


YES - Go to step 4.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at thesecondary HO2S (Sensor 2) and at the ECM/PCM.

2. 4. Turn the ignition switch OFF.5. Disconnect the secondary HO2S (Sensor 2) 4P

connector.6. Turn the ignition switch ON (II).7. Check the secondary HO2S (Sensor 2) output

voltage with the scan tool.Does the voltage stay at 0.3 V or less?

YES - Go to step 8.

NO - Replace the secondary HO2S (Sensor 2).

3. 8. Turn the ignition switch OFF.9. Disconnect ECM/PCM connector E (31P).

1. 10. Check for continuity between the secondary HO2S(Sensor 2) 4P connector terminal No. 2 and bodyground.

SECONDARY HO2S (SENSOR 2) 4P CONNECTOR


YES - Repair short in the wire between the ECM/PCM(E2) and the secondary HO2S (Sensor 2).


11-73




DTC P0138: Secondary HO2S (Sensor 2) Circuit HighVoltage1. 1. Reset the ECM/PCM (see page 11-4).


3. Check the secondary HO2S (Sensor 2) outputvoltage at 3,000 rpm (min-1) with the scan tool.


YES - Go to step 4.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at thesecondary HO2S (Sensor 2) and the at ECM/PCM.


connector.6. Connect the secondary HO2S (Sensor 2) 4P

connector terminals No. 1 and No. 2 with a jumperwire.

SECONDARY HO2S (SENSOR 2) 4P CONNECTORJUMPER WIRE


1. 8. Check the secondary HO2S (Sensor 2) outputvoltage with the scan tool.


YES - Go to step 9.


2. 9. Turn the ignition switch OFF.10. Connect ECM/PCM connector terminals E2 and E4

with a jumper wire.ECM/PCM CONNECTOR E (31P)


11. Turn the ignition switch ON (II).12. Check the secondary HO2S (Sensor 2) output voltage

with the scan tool.



NO - Repair open in the wire between the ECM/PCM(E2, E4) and the secondary HO2S (Sensor 2).

11-74




DTC P0139: Secondary HO2S (Sensor 2) SlowResponse1. 1. Reset the ECM/PCM (see page 11-4).


3. Check the secondary HO2S (Sensor 2) outputvoltage at 3,000 rpm with the scan tool.

Does the voltage stay within 0.3-0.8 V for 2 minutes?

YES - Replace the secondary HO2S (Sensor 2).


11-75




DTC P0141: Secondary HO2S (Sensor 2) HeaterCircuit Malfunction1. 1. Reset the ECM/PCM (see page 11-4).

2. Start the engine.Is DTC P0141 indicated?

YES - Go to step 3.



connector.5. At the secondary HO2S (Sensor 2) side, measure

resistance between the HO2S 4P connectorterminals No. 3 and No. 4.


Wire side of female terminalsIs there 10-40 ohms?

YES - Go to step 6.


1. 6. Check continuity between body ground and thesecondary HO2S (Sensor 2) 4P connector terminalsNo. 3 and No. 4 individually.



YES - Replace the secondary HO2S (Sensor 2).

NO - Go to step 7.

2. 7. Turn the ignition switch ON (II).8. Measure voltage between the secondary HO2S 4P

connector terminals No. 3 and No. 4.SECONDARY HO2S (SENSOR 2) 4P CONNECTOR

Terminal side of male terminalsIs there battery voltage?

YES - Go to step 9.

NO - Go to step 12.


11-76




1. 11. Check for continuity between ECM/PCM connectorterminal E6 and body ground.



YES - Repair short in the wire between the ECM/PCM(E6) and the secondary HO2S (Sensor 2).


12. Measure voltage between the secondary HO2S (Sensor2) 4P connector terminal No. 4 and body ground.


Terminal side of male terminalsIs there battery voltage?


NO - Check the No. 4 ACG (10A) fuse in the under-dashfuse/relay box. If the fuse is OK, repair open in thewire between the secondary HO2S (Sensor 2) andNo. 4 ACG (10A) fuse.

1. 13. Turn the ignition switch OFF.14. Reconnect the secondary HO2S (Sensor 2) 4P

connector.15. Disconnect ECM/PCM connector E (31P).16. Turn the ignition switch ON (II).17. Measure voltage between ECM/PCM connector

terminal E6 and A5.ECM/PCM CONNECTORS

Wire side of female terminalsIs there 0.1 V or less?

YES - Repair open in the wire between the ECM/PCM(E6) and the secondary HO2S (Sensor 2).


11-77




DTC P0171: Fuel System Too LeanDTC P0172: Fuel System Too RichNOTE: If some of the DTCs listed below are stored at thesame time as DTC P0171 and/or P0172, troubleshoot thoseDTCs first, then recheck for P0171 and/or P0172.P0107, P0108: Manifold Absolute Pressure (MAP) sensorP0135: Primary Heated Oxygen Sensor (Primary HO2S)(Sensor 1) heaterP0137, P0138: Secondary HO2S (Sensor 2)P0141: Secondary HO2S (Sensor 2) heaterP0401 P1491, P1498: Exhaust Gas Recirculation (EGR)system*P1259: VTEC system**: D16W7, D16V1 engines1. 1. Check the fuel pressure (see page 11-131).

Is fuel pressure OK?

YES - Go to step 2.

NO - Check these items:

If the pressure is too high, replace the fuelpressure regulator (see page 11-138). If the pressure is too low, check the fuel pump,the fuel feed pipe, the fuel filter, and replace thefuel pressure regulator (see page 11-138).

2. 2. Start the engine. Hold the engine at 3,000 rpm withno load (in Park or neutral) until the radiator fancomes on.

3. Check the primary HO2S (Sensor 1) output with thescan tool.

Does it stay at less than 0.3 V or more than 0.6 V?


NO - Go to step 4.


1. 5. With a vacuum pump (A), apply vacuum to theevaporative emission (EVAP) canister purge valve(B) from the intake manifold side.

Does it hold vacuum?

YES - Go to step 6.

NO - Replace the EVAP canister purge valve.

2. 6. Turn the ignition switch ON (II).7. Check the manifold pressure with the scan tool.

Does it indicate atmospheric pressure?

YES - Go to step 8.


3. 8. Start the engine.9. Check the MAP with the scan tool.

Is a MAP of 40.0 kPa (300 mmHg, 12.0 in.Hg) or lessindicated within 1 second after starting the engine?

YES - Check the valve clearances and adjust ifnecessary. If the valve clearances are OK, replacethe injectors.


11-78




DTC P0300: Random misfire and any Combination of the Following:

DTC P0301: No. 1 Cylinder Misfire




NOTE:If the misfiring is frequent enough to trigger detection of increased emissions during two consecutive driving cycles, theMIL will come on, and DTC P0300 (and some combination of P0301 through P0304) will be stored.If the misfiring is frequent enough to damage the catalyst, the MIL will blink whenever the misfiring occurs, and DTCP0300 (and some combination of P0301 through P0304) will be stored. When the misfiring stops, the MIL will remain on.

1. 1. Troubleshoot the following DTCs first if any of them were stored along with the random misfire DTC(s):P0107, P0108: Manifold Absolute Pressure (MAP) sensorP0131, P0132: Primary Heated Oxygen SensorP0171, P0172: Fuel systemP0335, P0336: Crankshaft Position (CKP) sensorP0401, P1491, P1498: Exhaust Gas Recirculation (EGR) system*P0505: Idle control systemP1259: VTEC system*P1361, P1362: Top Dead Centre (TDC) sensorP1519: Idle Air Control (IAC) valve*: D16W7, D16V1 engines

2. 2. Test-drive the vehicle to verify the symptom.3. Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause.

Symptom Procedure(s) Also check for:

Random misfire only at low RPM and under load Check fuel pressure (see page11-131).

Low compression.Low quality fuel.

Random misfire only during acceleration Check fuel pressure (see page11-131).

Malfunction in the VTEC system(D16W7, D16V1 engine) (see page6-9).

Random misfire at high RPM, under load, or underrandom conditions

Check fuel pressure (see page11-131).

Correct valve clearance (see page6-14).

11-79




DTC P0301: No. 1 Cylinder MisfireDTC P0302: No. 2 Cylinder MisfireDTC P0303: No. 3 Cylinder MisfireDTC P0304: No. 4 Cylinder Misfire1. 1. After checking and recording the freeze data, reset

the ECM/PCM (see page 11-4). If there is no freezedata of the misfire, just clear the DTC.

2. Start the engine, and listen for a clicking sound atthe injector at the problem cylinder.

Does it click?

YES - Go to step 3.

NO - Go to step 30.

2. 3. Turn the ignition switch OFF, and reset theECM/PCM.

4. Exchange the ignition coil from the problem cylinderwith one from another cylinder.

5. Test-drive the vehicle several times in the range ofthe freeze data or under various conditions if therewas no freeze data.

6. Check the DTC or the Temporary DTC with the scantool.

Is DTC or Temporary DTC P0301, P0302, P0303 or P0304indicated?

YES - Go to step 7.

NO - Intermittent misfire due to poor contact at theignition coil connector (no misfire at this time).

1. 7. Determine which cylinder(s) had the misfire.Does the misfire occur in the other cylinder whose ignitioncoil was exchanged?

YES - Replace the faulty ignition coil.

NO - Go to step 8.

2. 8. Turn the ignition switch OFF, and reset theECM/PCM.

9. Exchange the spark plug from the problem cylinderwith one from another cylinder.

10. Test-drive the vehicle several times in the range ofthe freeze data or under various conditions if therewas no freeze data.

11. Check the DTC or the Temporary DTC with the scanTool.



NO - Intermittent misfire due to spark plug fouling, etc.(no misfire at this time).

12. Determine which cylinder(s) had the misfire.

Does the misfire occur in the other cylinder whose sparkplug was exchanged?

YES - Replace the faulty spark plug.

NO - Go to step 13.

13. Turn the ignition switch OFF, and reset the ECM/PCM.14. Exchange the injector in the problem cylinder with one

from another cylinder.15. Let the engine idle for 2 minutes.

11-80




1. 16. Test-drive the vehicle several times in the range ofthe freeze data or under various conditions if therewas no freeze data.

17. Check the DTC or the Temporary DTC with the scanTool.



NO - Intermittent misfire due to bad contact at theinjector connector (no misfire at this time).

18. Determine which cylinder (s) had the misfire.

Does the misfire occur in the other cylinder whose injectorwas exchanged?

YES - Replace the faulty injector.

NO - Go to step 19.

19. Turn the ignition switch OFF.20. Disconnect the ignition coil 3P connector from the

problem cylinder.21. Turn the ignition switch ON (II).

1. 22. Measure voltage between the ignition coil 3Pconnector terminal No. 3 and body ground.




NO - Repair open or short in the wire between the No. 1IGN COIL (15A) fuse and the ignition coil.

23. Turn the ignition switch OFF.24. Check for continuity between the ignition coil 3P

connector terminal No. 2 and body ground.




NO - Repair open in the wire between the ignition coiland G101.


11-81




1. 26. Check for continuity between body ground and theappropriate ECM/PCM connector terminal (seetable).



PROBLEMCYLINDER

DTC ECM/PCMTERMINAL

WIRECOLOUR

No. 1 P0301 A30 YEL/GRN

No. 2 P0302 A29 BLU/RED

No. 3 P0303 A28 WHT/BLU

No. 4 P0304 A27 BRN

Is there continuity?

YES - Repair short in the wire between the ECM/PCMand the ignition coil.

NO - Go to step 27.

27. Connect the appropriate ignition coil 3P connectorterminal No. 1 and body ground with a jumper wire (seetable).



PROBLEMCYLINDER

DTC WIRECOLOUR

No. 1 P0301 YEL/GRN

No. 2 P0302 BLU/RED

No. 3 P0303 WHT/BLU

No. 4 P0304 BRN

1. 28. Check for continuity between body ground and theappropriate ECM/PCM connector terminal (seetable).



PROBLEMCYLINDER

DTC ECM/PCMTERMINAL

WIRECOLOUR

No. 1 P0301 A30 YEL/GRN

No. 2 P0302 A29 BLU/RED

No. 3 P0303 A28 WHT/BLU

No. 4 P0304 A27 BRN



NO - Repair open in the wire between the ECM/PCMand the ignition coil.

29. Check the compression.

Is the engine compression OK?


NO - Repair the engine.

30. Disconnect ECM/PCM connector B (24P).31. Turn the ignition switch ON (II).

11-82




1. 32. Measure voltage between body ground and theappropriate ECM/PCM connector terminal (seetable).



PROBLEMCYLINDER

DTC ECM/PCMTERMINAL

WIRECOLOUR

No. 1 P0301 B5 BRN

No. 2 P0302 B4 RED

No. 3 P0303 B3 BLU

No. 4 P0304 B2 YEL

Is there battery voltage?


NO - Go to step 42.

33. Turn the ignition switch OFF, and remove the aircleaner (see page 11-146).

34. Disconnect the injector 2P connector on the problemcylinder.

35. Measure the resistance between the injector 2Pconnector terminals No. 1 and No. 2.

INJECTOR 2P CONNECTOR

Terminal side of male terminalsIs there 10 ohms-13ohms?


NO - Replace the injector (see page 11-113).

1. 36. Exchange the injector in the problem cylinder withone from another cylinder.

37. Install the air cleaner (see page 11-146), and resetthe ECM/PCM.

38. Let the engine idle for 2 minutes.39. Test-drive the vehicle several times in the range of

the freeze data or under various conditions if therewas no freeze data.

40. Check the DTC or the Temporary DTC with a scantool.

Is DTC or Temporary DTC P0301, P0302, P0303, or P0304indicated?


NO - Intermittent misfire due to injector malfunction etc.

41. Determine which cylinder (s) had the misfire.

Does the misfire occur in the other cylinder whose injectorwas exchanged?

YES - Replace the faulty injector.


42. Turn the ignition switch OFF.43. Remove the air cleaner (see page 11-146).44. Disconnect the injector 2P connector on the problem

cylinder.45. Turn the ignition switch ON (II).

11-83




46. Measure voltage between the injector 2P connectorterminal No. 1 and body ground.




NO - Repair open in the wire between the injector andthe PGM-FI main relay.

47. Turn the ignition switch OFF.48. Check for continuity between body ground and the

appropriate ECM/PCM connector terminal (see table).



PROBLEMCYLINDER

DTC ECM/PCMTERMINAL

WIRECOLOUR

No. 1 P0301 B5 BRN

No. 2 P0302 B4 RED

No. 3 P0303 B3 BLU

No. 4 P0304 B2 YEL


YES - Repair short in the wire between the ECM/PCMand the injector.

NO - Go to step 49.

49. Connect the appropriate injector 2P connector terminalNo. 2 to body ground with a jumper wire (see table).



PROBLEMCYLINDER

DTC WIRECOLOUR

No. 1 P0301 BRN

No. 2 P0302 RED

No. 3 P0303 BLU

No. 4 P0304 YEL

50. Check for continuity between body ground and theappropriate ECM/PCM connector terminal (see table).



PROBLEMCYLINDER

DTC ECM/PCMTERMINAL

WIRECOLOUR

No. 1 P0301 B5 BRN

No. 2 P0302 B4 RED

No. 3 P0303 B3 BLU

No. 4 P0304 B2 YEL


YES - Replace the injector, then recheck.

NO - Repair open in the wire between the ECM/PCMand the injector.

11-84




DTC P0325:Knock Sensor Circuit Malfunction

1. 1. Reset the ECM/PCM (see page 11-4).2. Start the engine. Hold the engine at 3,000 rpm (min-

1) with no load (in Park or neutral) until the radiatorfan comes on, then let it idle.

3. Hold the engine at 3,000-4,000 rpm (min-1) for atleast 60 seconds.

Is DTC P0325 indicated?

YES - Go to step 4.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theknock sensor and at the ECM/PCM.

2. 4. Turn the ignition switch OFF.5. Disconnect the knock sensor 3P connector.6. Turn the ignition switch ON (II).7. Measure voltage between knock sensor 3P connector

terminal No. 1 and body ground.KNOCK SENSOR 3P CONNECTOR



NO - Go to step 8.

8. Measure voltage between ECM/PCM connector terminalA9 and body ground.



YES - Repair open in the wire between the ECM/PCM(A9) and knock sensor.

NO - Go to step 9.

1. 9. Turn the ignition switch OFF.10. Disconnect ECM/PCM connector A (31P).11. Check for continuity between ECM/PCM connector

terminal A9 and body ground.ECM/PCM CONNECTOR A (31P)


YES - Repair short in the wire between ECM/PCM (A9)and knock sensor.


11-85




12. Substitute a known-good knock sensor and recheck.



NO - Replace the original knock sensor.

11-86




DTC P1324: Knock Sensor Power Source CircuitLow Voltage1. 1. Reset the ECM/PCM (see page 11-4).

2. Turn the ignition switch ON (II).Is DTC P1324 indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theknock sensor and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect ECM/PCM connector A (31P).5. Check for continuity between ECM/PCM connector

terminals A8 and A20.ECM/PCM CONNECTOR A (31P)



NO - Go to step 6.

3. 6. Disconnect the knock sensor 3P connector.

7. Connect the knock sensor 3P connector terminals No. 2and No. 3 with a jumper wire.

KNOCK SENSOR 3P CONNECTOR


1. 8. Check for continuity between ECM/PCM connectorterminals A8 and A20.



YES - Replace the knock sensor.

NO - Repair open in the wire between theECM/PCM (A8, A20) and the knock sensor.

11-87




DTC P0335: - CKP Sensor No SignalDTC P0336: - CKP Sensor Intermittent Interruption1. 1. Reset the ECM/PCM (see page 11-4).

2. Start the engine.Is DTC P0335 and/or P0336 indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theCKP sensor and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect the CKP sensor 3P connector.5. Turn the ignition switch ON (II).6. Measure voltage between the CKP sensor 3P

connector terminal No. 3 and body ground.CKP SENSOR 3P CONNECTOR


YES - Go to step 7.

NO - Repair open in the wire between the PGM-FI mainrelay 1 and the CKP sensor.

7. Measure voltage between the CKP sensor 3P connectorterminal No. 1 and body ground.

CKP SENSOR 3P CONNECTOR


YES - Go to step 8.

NO - Go to step 10.

1. 8. Measure voltage between the CKP sensor 3Pconnector terminals No. 2 and No. 3.

CKP SENSOR 3P CONNECTOR


YES - Go to step 9.

NO - Repair open in the wire between the CKP sensorand G101.

2. 9. Substitute a known-good CKP sensor and recheck.Is DTC P0335 and/or P0336 indicated?


NO - Replace the original CKP sensor.

11-88




10. Measure voltage between ECM/PCM connector terminalA7 and body ground.



YES - Repair open in the wire between the ECM/PCM(A7) and the CKP sensor.

NO - Go to step 11.

11. Turn the ignition switch OFF.12. Disconnect ECM/PCM connector A (31P).13. Check for continuity between ECM/PCM connector

terminal A7 and body ground.



YES - Repair short in the wire between the ECM/PCM(A7) and the CKP sensor.


11-89




DTC P0500: VSS Circuit MalfunctionDTC P0501: VSS Range/Performance Problem1. 1. Test-drive the vehicle.

2. Check the vehicle speed with the scan tool.Is the correct speed indicated?

YES - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theVSS and at the ECM.

NO - Go to step 3.

2. 3. Turn the ignition switch OFF.4. Block the rear wheels and set the parking brake.5. Raise the front of the vehicle, and make sure it is

securely supported.6. Turn the ignition switch ON (II).7. Block the right front wheel, and slowly rotate the left

front wheel.8. Measure voltage between ECM/PCM connector

terminals A18 and A24.ECM/PCM CONNECTOR A (31P)

Wire side of female terminalsDoes the voltage pulse between 0 V and 5 V or batteryvoltage?


NO - Go to step 9.

3. 9. Turn the ignition switch OFF.10. Disconnect ECM/PCM connector A (31P).

11. Turn the ignition switch ON (II).

12. Block the right front wheel, and slowly rotate the leftfront wheel.



Wire side of female terminalsDoes the voltage pulse between 0 V and 5 V or batteryvoltage?


NO - Check these items:

A short or an open in the wire between theECM/PCM (A18) and the VSS.If the wire is OK, test the VSS (see page 22-94).

11-90




DTC P0563: ECM/PCM Power Source Circuit UnexpectedVoltage1. 1. Reset the ECM/PCM (see page 11-4).

2. Turn the ignition switch OFF.3. Wait 5 seconds.4. Turn the ignition switch ON (II).


YES - Go to step 5.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theNo. 6 ECU (ECM/PCM) (15 A) fuse in the under-hood fuse/relay box and at the ECM/PCM.

2. 5. Turn the ignition switch OFF.6. Disconnect ECM/PCM connector E (31P).7. Measure voltage between ECM/PCM connector




NO - Go to step 8.

3. 8. Remove the glove box.

9. Remove the PGM-FI main relay 1 (A).

LHD model:

RHD model:

10. Check for continuity between ECM/PCM connectorterminal E7 and body ground.



YES - Repair short in the wire between the ECM/PCM(E7) and the PGM-FI main relay 1.

NO - Replace the PGM-FI main relay 1.

11. Reconnect ECM/PCM connector E (31P).

11-91




12. Measure voltage between ECM/PCM connector terminalE7 and body ground.





13. Disconnect ECM/PCM connector A (31P).14. Measure voltage between body ground and ECM/PCM

connector terminals A3 and A2 individually.





15. Remove the glove box.


LHD model:

RHD model:

11-92




1. 17. Measure voltage between body ground andECM/PCM connector terminals A3 and A2individually.



YES - Repair short to power in the wire between theECM/PCM (A2,A3) and the PGM-FI main relay 1.


DTC P1107: BARO Sensor Circuit Low VoltageDTC P1108: BARO Sensor Circuit High Voltage1. 1. Reset the ECM/PCM (see page 11-4).

2. Turn the ignition switch ON (II).Is DTC P1107 or P1108 indicated?


NO - Intermittent failure, system is OK at this time.

11-93




DTC P1259: VTEC System MalfunctionSpecial Tools Required

Oil pressure gauge attachment 07NAJ-P070100Low pressure gauge 07406-0070001Hose oil pressure 07ZAJ-S5A02001. Reset the ECM/PCM (see page 11-4).2. Check the engine oil level, and refill if necessary.3. Start the engine. Hold the engine at 3.000 rpm

(min-1) with no load (in Park or neutral) until theradiator fan comes on.

4. Road test the vehicle:Accelerate in 1st gear to an engine speed over 4,000 rpm.Hold that engine speed for at least 2 seconds. If DTCP1259 is not repeated during the first road test, repeat thistest 2 more times.Is DTC P1259 indicated?YES- Go to step 5.NO- Intermittent failure, system is OK at this time. Checkfor poor connections or loose wires at the VTEC solenoidvalve and at the ECM/PCM.

1. 5. Turn the ignition switch OFF.6. Remove the resonator (see page 11-148).

1. 7. Disconnect the VTEC oil pressure switch 2Pconnector.

2. 8. Check for continuity on the VTEC oil pressure switchbetween the VTEC oil pressure switch 2P connectorterminals No. 1 and No. 2.

VTEC OIL PRESSURE SWITCH 2P CONNECTOR


YES - Go to step 9.

NO - Replace the VTEC oil pressure switch.

3. 9. Turn the ignition switch ON (II).10. Measure voltage between the VTEC oil pressure

switch 2P connector terminal No. 1 and bodyground.

VTEC OIL PRESSURE SWITCH HARNESS 2PCONNECTOR



NO - Go to step 11.

11-94




1. 11. Measure voltage between ECM/PCM connectorterminal B9 and body ground.



YES - Repair open in the wire between the VTEC oilpressure switch and ECM/PCM (B9).

NO - Go to step 12.

12. Turn the ignition switch OFF.13. Disconnect ECM/PCM connector B (24P).14. Check for continuity between ECM/PCM connector

terminal B9 and body ground.



YES - Repair short in the wire between the VTEC oilpressure switch and the ECM/PCM (B9).


15. Measure voltage between the VTEC oil pressure switch2P connector terminals No. 1 and No. 2.

VTEC OIL PRESSURE SWITCH HARNESS 2PCONNECTOR



NO - Repair open in the wire between the VTECoil pressure switch and G101.

16. Turn the ignition switch OFF.17. Disconnect the VTEC solenoid valve 1P connector.18. Check for resistance between the VTEC solenoid valve

1P connector terminal No. 1 and body ground.

VTEC SOLENOID VALVE 1P CONNECTOR

Terminal side of male terminalIs there 14-30 ohms?


NO - Replace the VTEC solenoid valve.

11-95




1. 19. Remove the VTEC oil pressure switch (A) and installthe special tools as shown, then reinstall the VTECoil pressure switch.

20. Reconnect the VTEC solenoid valve 1P connector andVTEC oil pressure switch 2P connector.

21. Connect a tachometer.22. Start the engine. Hold the engine at 3.000 rpm with no

load (in Park or neutral) until the radiator fan comes on.23. Check oil pressure at engine speeds of 1,000 and 2,000

rpm (min-1). Keep measuring time as short as possiblebecause the engine is running with no load (less than 1minute).

Is pressure below 49 kPa (0.5 kgf/cm2, 7 psi)?


NO - Inspect the VTEC solenoid valve (see page 11-112).


25. Disconnect the VTEC solenoid valve 1P connector.26. Attach the battery positive terminal to the VTEC

solenoid valve terminal.27. Start the engine, and check oil pressure at an engine

speed of 3,000 rpm (min-1).

Is pressure above 390 kPa (4.0 kgf/cm2, 57 psi)?


NO - Inspect the VTEC solenoid valve (see page 11-112).

28. With the battery positive terminal still connected to theVTEC solenoid valve, measure voltage betweenECM/PCM connector terminal B9 and body ground.


Wire side of female terminalsIs there battery voltage above 4,000 rpm?


NO - Replace the VTEC oil pressure switch.

29. Turn the ignition switch OFF.30. Disconnect the battery positive terminal from the VTEC

solenoid valve terminal.

11-96




1. 31. Disconnect ECM/PCM connector B (24P).

32. Check for continuity between ECM/PCM connectorterminal B15 and body ground.



YES - Repair short in the wire between the VTECsolenoid valve and the ECM/PCM (B15).

NO - Go to step 32.

1. 33. Connect the VTEC solenoid valve 1P connectorterminal No. 1 and body ground with a jumper wire.

VTEC SOLENOID VALVE HARNESS 1PCONNECTORS


34. Check for continuity between ECM/PCM connectorterminal B15 and body ground.




NO - Repair short in the wire between the VTECsolenoid valve and the ECM/PCM (B15).

11-97




DTC P1361: TDC Sensor Intermittent InterruptionDTC P1362: TDC Sensor No Signal1. 1. Reset the ECM/PCM (see page 11-4).

2. Start the engine.Is DTC P1361 and/or P1362 indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theTDC sensor and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect the TDC sensor 3P connector.5. Turn the ignition switch ON (II).6. Measure voltage between the TDC sensor 3P

connector terminal No. 3 and body ground.TDC SENSOR 3P CONNECTOR

Wire of female terminalsIs there battery voltage?

YES - Go to step 7.

NO - Repair open in the wire between the PGM-FI mainrelay 1 and the TDC sensor.

1. 7. Measure voltage between the TDC sensor 3Pconnector terminal No. 2 and body ground.

TDC SENSOR 3P CONNECTOR


YES - Go to step 8.

NO - Go to step 10.

2. 8. Measure voltage between the TDC sensor 3Pconnector terminals No. 1 and No. 3.

TDC SENSOR 3P CONNECTOR


YES - Go to step 9.

NO - Repair open in the wire between the TDC sensorand G101.

3. 9. Substitute a known-good TDC sensor and recheck.Is DTC P1361 and/or P1362 indicated?


NO - Replace the original TDC sensor.

11-98




1. 10. Measure voltage between ECM/PCM connectorterminal A26 and body ground.



YES - Repair open in the wire between the ECM/PCM(A26) and TDC sensor.

NO - Go to step 11.

11. Turn the ignition switch OFF.12. Disconnect ECM/PCM connector A (31P).13. Check for continuity between ECM/PCM connector

terminal A26 and body ground.



YES - Repair short in the wire between the ECM/PCM(A26) and the TDC sensor.


DTC P1607: Malfunction in ECM/PCM Internal Circuit1. 1. Reset the ECM/PCM (see page 11-4).

2. Turn the ignition switch ON (II).3. Wait 40 seconds.



NO - Intermittent failure, system is OK at this time.

11-99



PGM-FI SystemMIL Circuit Troubleshooting

1. 1. Turn the ignition switch ON (II) and watch theMalfunction Indicator Lamp (MIL).

Does the MIL come on and stay on?YES- If the MIL always comes on and stays on, go to step70. But if the MIL sometimes works normally, first check forthese problems.

An intermittent short in the wire between theECM/PCM (E29) and the Data Link Connector(DLC).An intermittent short in the wire between theECM/PCM (E31) and the gauge assembly.

NO If the MIL is always off, go to step 2. But if the MILsometimes works normally, first check for these problems.

A loose No. 10 METER (7.5A) fuse in the under-dash fuse/relay box.A loose No. 20 IG (40A) fuse in the under-hoodfuse/relay box.A loose No. 6 ECU (ECM/PCM) (15A) fuse in theunder-hood fuse/relay box.A loose No. 17 FUEL PUMP (15A) fuse in theunder-dash fuse/relay box.A poor connection at ECM/PCM terminal E31.An intermittent open in the GRN/ORN wirebetween the ECM/PCM (E31) and the gaugeassembly.An intermittent short in the wire between theECM/PCM (A21) and the manifold absolutepressure (MAP) sensor.An intermittent short in the wire between theECM/PCM (A20) and the throttle position (TP)sensor, knock sensor, exhaust gas recirculation(EGR) valve position sensor.An intermittent short in the wire between theECM/PCM (A8) and the knock sensor.

2. 2. Turn the ignition switch OFF.3. Press the inertia switch button.4. Turn the ignition switch ON (II).

Does the MIL come on for 2 seconds after the ignitionswitch is turned ON (II)?

YES - Intermittent failure system is OK at this time.

NO - Go to step 5.

1. 5. Turn the ignition switch OFF.2. 6. Disconnect the inertia switch 3P connector.

7. Connect the inertia switch 3P connector terminalsNo. 1 and No. 3 with a jumper wire.INERTIA SWITCH 3P CONNECTOR

Wire side of female terminals3. 8. Turn the ignition switch ON (II).

Does the MIL come on for 2 seconds after the ignitionswitch is turned ON (II)?

YES - Replace the inertia switch.

NO - Go to step 9.

4. 9. Turn the ignition switch OFF.10. Turn the ignition switch ON (II).

Is the low oil pressure light on?


NO - Go to step 11.

11. Inspect the No. 10 METER (7.5 A) fuse in the under-dash fuse/relay box.

Is the fuse OK?


NO - Repair short in the wire between No. 10 METER(7.5A) fuse and the gauge assembly. Also replacethe No. 10 METER (7.5A) fuse.

11-100



PGM-FI SystemMIL Circuit Troubleshooting (cont'd)

1. 12. Inspect the No. 20 IG1 (40A) fuse in the under-hoodfuse/relay box.

Is the fuse OK?

YES - Repair open in the wire between the No. 20 IG1(40A) fuse and the gauge assembly. If the wires areOK, test the ignition switch (see page 22-83).

NO - Repair short in the wire between No. 20 IG1 (40A)fuse and the under-dash fuse/relay box. Alsoreplace the No. 20 IG1 (40A) fuse.

13. Try to start the engine.

Does the engine start?


NO - Go to step 17.

14. Turn the ignition switch OFF.15. Connect ECM/PCM connector terminal E31 and body

ground with a jumper wire.



16. Turn the ignition switch ON (II).

Is the MIL on?


NO - Check for an open in the wire between theECM/PCM (E31) and the gauge assembly. Alsocheck for a blown MIL bulb. If the wires and the bulbare OK, replace the gauge assembly.


18. Inspect the No. 6 ECU (ECM/PCM) (15A) fuse in theunder-hood fuse/relay box.

Is the fuse OK?


NO - Go to step 19.

19. Remove the blown No. 6 ECU (ECM/PCM) (15A) fusein the under-dash fuse/relay box.


LHD model:

RHD model:

11-101




1. 21. Check for continuity between body ground and thePGM-FI main relay 14P connector terminals No. 2and No. 4 individually.


YES - Repair short in the wire between the No. 6 ECU(ECM/PCM) (15A) fuse and the PGM-FI main relay1. Also replace the No. 6 ECU (ECM/PCM) (15A)fuse.

NO - Go to step 22.

22. Disconnect each of the components or the connectorsbelow, one at a time, and check for continuity betweenthe PGM-FI main relay 1 4P connector terminal No. 1and body ground.

PGM-FI main relay 2ECM/PCM connector A (31P)Each injector 2P connectorIdle air control (IAC) valve 3P connectorTop dead centre (TDC) sensor 3P connectorCrankshaft position (CKP) sensor 3P connector




NO - Replace the component that made continuity tobody ground go away when disconnected. If theitem is the ECM/PCM, substitute a known-goodECM/PCM and recheck (see page 11-6). Ifsymptom/indication goes away, replace the originalECM/PCM.Also replace the No. 6 ECU (ECM/PCM) (15 A)fuse.

23. Disconnect the connectors of all these components.

PGM-FI main relay 2ECM/PCM connector A (31P)InjectorsIdle air control (IAC) valveTop dead centre (TDC) sensorCrankshaft position (CKP) sensor

24. Check for continuity between the PGM-FI main relay 14P connector terminal No. 2 and body ground.


YES - Repair short in the wire between the PGM-FI main relay 1 and each item. Also replacethe No. 6 ECU (ECM/PCM) (15A) fuse.

NO - Replace the PGM-FI main relay 1. Alsoreplace the No 6 ECU (ECM/PCM) (15A)fuse.

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1. 25. Inspect the No. 17 FUEL PUMP (15A) fuse in theunder-dash fuse/relay box.

Is the fuse OK?


NO - Go to step 26.

26. Remove the blown No. 17 FUEL PUMP (15A) fuse inthe under-dash fuse/relay box.

27. Disconnect ECM/PCM connector E (31P).28. Check for continuity between ECM/PCM connector

terminal E9 and body ground.




NO - Replace the No. 17 FUEL PUMP (15 A) fuse, andsubstitute a known-good ECM/PCM and recheck(see page 11-6). If symptom/indication goes away,replace the original ECM/PCM.

1. 29. Remove the PGM-FI main relay 2 (A).LHD model:

RHD model:

30. Check for continuity between ECM/PCM connectorterminal E9 and body ground.



YES - Repair short in the wire between the No. 17 FUELPUMP (15A) fuse and the ECM/PCM (E9), or theNo. 17 FUEL PUMP (15 A) fuse and the PGM-FImain relay 2. Also replace the No. 17 FUEL PUMP(15A) fuse.

NO - Go to step 31.

31. Remove the rear seat cushion (see page 20-95).

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1. 32. Remove the access panel from the floor.

33. Disconnect the fuel pump 5P connector.34. Check for continuity between the fuel pump 5P

connector terminal No. 5 and body ground.

FUEL PUMP 5P CONNECTOR


YES - Repair short in the wire between the fuel pumpand the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse.

NO - Go to step 35.

35. Reinstall the PGM-FI main relay 2 (A).

LHD model:

RHD model:

1. 36. Check for continuity between the fuel pump 5Pconnector terminal No. 5 and body ground.



YES - Replace the PGM-FI main relay 2. Also replacethe No. 17 FUEL PUMP (15A) fuse.

NO - Check the fuel pump, and replace it as necessary.Also replace the No. 17 FUEL PUMP (15A) fuse.

37. Disconnect ECM/PCM connector E (31P).38. Turn the ignition switch ON (II).39. Measure voltage between ECM/PCM connector

terminals E9 and body ground.




NO - Repair open in the wire between the No. 17 FUELPUMP (15A) fuse and the ECM/PCM (E9).

11-104





41. Measure voltage between ECM/PCM connector terminalE7 and body ground.




NO - Go to step 42.


LHD model:

RHD model:

1. 43. Measure voltage between the PGM-FI main relay 14P connector terminal No. 4 and body ground.



NO - Repair open in the wire between the No. 6 ECU(ECM/PCM) (15 A) fuse and the PGM-FI main relay1.

44. Check for continuity between the PGM-FI main relay 14P connector terminal No. 3 and ECM/PCM connectorterminal E7.


YES - Test the PGM-FI main relay 1 (see page 22-80). Ifthe relay is OK, substitute a known-good ECM/PCMand recheck (see page 11-6). If symptom/indicationgoes away, replace the original ECM/PCM.

NO - Repair open in the wire between the PGM-FI mainrelay 1 and the ECM/PCM (E7).

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1. 45. Reconnect ECM/PCM connector E (31P).

46. Turn the ignition switch ON (II).47. Measure voltage between body ground and ECM/PCM

connector terminals A2 and A3 individually.




NO - Go to step 48.

48. Turn the ignition switch OFF.49. Remove the PGM-FI main relay 1 (A).

LHD model:

RHD model:


51. Measure voltage between the PGM-FI main relay 1 4Pconnector terminal No. 2 and body ground.



NO - Repair open in the wire between the No. 6 ECU(ECM/PCM) (15A) fuse and the PGM-FI main relay1.

52. Turn the ignition switch OFF.53. Check for continuity between the PGM-FI main relay 1

4P connector terminal No. 1 and ECM/PCM connectorterminals A2 and A3 individually.


YES - Replace the PGM-FI main relay 1.

NO - Repair open in the wire between the PGM-FI mainrelay 1 and the ECM/PCM (A2, A3).

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1. 54. Measure voltage between body ground andECM/PCM connector terminals A4, A5, A23 and A24individually.


Wire side of female terminalsIs there less than 1.0 V?

YES - Repair open in the wire (s) between that had morethan 1.0 V between G101 and the ECM/PCM (A4,A5, A23, A24).

NO - Go to step 55.

55. Measure voltage between body ground and ECM/PCMconnector terminal A21.




NO - Go to step 56.


57. Disconnect the manifold absolute pressure (MAP)sensor 3P connector.

58. Turn the ignition switch ON (II).59. Measure voltage between body ground and ECM/PCM

connector terminal A21.



YES - Replace the MAP sensor.

NO - Go to step 60.

60. Turn the ignition switch OFF.61. Disconnect ECM/PCM connector A (31P).

11-107







YES - Repair short in the wire between the ECM/PCM(A21) and the MAP sensor.


63. Measure voltage between body ground and ECM/PCMconnector terminal A20.




NO - Go to step 64.


65. Disconnect the 3P connector from each of thesesensors, one at a time, and measure voltage betweenbody ground and ECM/PCM connector terminal A20with the ignition switch ON (II).

Exhaust gas recirculation (EGR) valve positionsensorKnock sensorThrottle position (TP) sensorECM/PCM CONNECTOR A (31P)


YES - Replace the sensor that restored about 5 V whendisconnected.

NO - Go to step 66.

66. Turn the ignition switch OFF.67. Disconnect the 3P connectors from the following

sensors.

Exhaust gas recirculation (EGR) valve positionsensorKnock sensorThrottle position (TP) sensor


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YES - Repair short in the wire between the ECM/PCM(A20) and the EGR valve position sensor, knocksensor or TP sensor, or repair short in the wirebetween the ECM/PCM (A8) and the knock sensor.



71. Connect a scan tool/Honda PGM Tester (see page 11-3).

72. Turn the ignition switch ON (II), and read the scantool/Honda PGM Tester.

Does the scan tool/Honda PGM Tester communicate withthe ECM/PCM?


NO - Go to step 73.

73. Turn the ignition switch OFF.74. Disconnect ECM/PCM connector E (31P).75. Check for continuity between body ground and data link

connector (DLC) terminal No. 7.

DATA LINK CONNECTOR (DLC)


YES - Repair short in the wire between the DLC and theECM/PCM (E23). After repairing it, check the DTCwith the scan tool/Honda PGM Tester and go to theDTC Troubleshooting Index.

NO - Go to step 76.

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1. 76. Check for continuity between ECM/PCM connectorterminal E23 and DLC terminal No. 7.

DATA LINK CONNECTOR (DLC)



NO - Repair open in the wire between the DLC and theECM/PCM (E23). After repairing it, check the DTCwith the scan tool/Honda PGM Tester and go to theDTC Troubleshooting Index.

77. Check the scan tool/Honda PGM Tester for DTCs.

Are any DTCs indicated?

YES - Go to the DTC Troubleshooting Index.

NO - Go to step 78.

78. Turn the ignition switch OFF.79. Turn the ignition switch ON (II).

1. 80. Measure voltage between ECM/PCM connectorterminal E29 and body ground.


Wire side of female terminalsIs there about 5 V (or battery voltage)?


NO - Go to step 81.

81. Turn the ignition switch OFF.82. Disconnect ECM/PCM connector E (31P).

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1. 83. Check for continuity between ECM/PCM connectorterminal E29 and body ground.



YES - Repair short in the wire between the service checkconnector and the ECM/PCM (E29).


84. Turn the ignition switch OFF.85. Disconnect ECM/PCM connector E (31P).86. Turn the ignition switch ON (II).

Is the MIL on?

YES - Repair short in the wire between the gaugeassembly and the ECM/PCM (E31). If the wires areOK, replace the gauge assembly.


11-111



PGM-FI SystemVTEC Solenoid Valve Test

1. 1. Remove the resonator (see page 11-148).2. 2. Disconnect the VTEC solenoid valve 1P connector.

3. Measure resistance between the VTEC solenoidvalve connector terminal No. 1 and body ground.

Resistance: 14-30 ohms

3. 4. If the resistance is within specifications, remove theVTEC solenoid valve assembly (A) from the cylinderhead, and check the VTEC solenoid valve filter (B)for clogging. If there is clogging, replace the solenoidvalve filter, the engine oil filter and the engine oil.

1. 5. If the filter is not clogged, push the VTEC solenoidvalve with your finger and check its movement. If theVTEC solenoid valve is normal, check the engine oilpressure.

11-112



PGM-FI SystemInjector Replacement

1. 1. Relieve fuel pressure (see page 11-130).2. Remove the air cleaner (see page 11-146).3. Disconnect the connectors from the injectors (A), the manifold absolute pressure (MAP) sensor (B), the evaporative

emission (EVAP) canister purge valve (C), and the throttle position (TP) sensor (D).

2. 4. Disconnect the quick-connect fittings (E).5. Disconnect the hoses from the fuel rail (F).6. Remove the fuel rail mounting nuts (G) from the fuel rail.7. Remove the injector clip (H) from the injector.8. Remove the injector from the fuel rail.

11-113



PGM-FI SystemInjector Replacement (cont'd)

1. 9. Coat the new O-rings (A) with clean engine oil, and insert the injectors (B) into the fuel rail (C).

2. 10. Install the injector clip (D).11. Coat the injector O-ring (E) with clean engine oil.12. To prevent damage to the O-rings, install the injectors in the fuel rail first, then install them in the injector base.13. Install the fuel rail mounting nuts.14. Connect the connectors on the injectors, the MAP sensor, the EVAP canister purge valve, and the TP sensor.15. Connect the quick-connect fittings.16. Install the air cleaner (see page 11-146).17. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately 2 seconds, the

fuel pressure in the fuel line rises. Repeat this 2 or 3 times, then check for fuel leakage.

11-114

Secondary HO2S Replacement


PGM-FI SystemPrimary HO2S Replacement

Secondary HO2S Replacement

Special Tools RequiredO2 sensor wrench 07LAA-PT501011. 1. Disconnect the primary HO2S 4P connector (A), then

remove the primary HO2S (B).

2. 2. Install the primary HO2S in the reverse order ofremoval.

Special Tools RequiredO2 sensor wrench 07LAA-PT501011. 1. Disconnect the secondary HO2S 4P connector (A),

then remove the secondary HO2S (B).

2. 2. Install the secondary HO2S in the reverse order ofremoval.

11-115

Fuel and Emissions - Idle Control System


Idle Control SystemComponent Location Index

1. IDLE AIR CONTROL (IAC) VALVETroubleshooting, page 11-117

11-116



Idle Control SystemDTC Troubleshooting

DTC P1519: IAC Valve Circuit Malfunction1. 1. Reset the ECM/PCM (see page 11-4).

2. Turn the ignition switch ON (II).Is DTC P1519 indicated?

YES - Go to step 3.

NO - Intermittent failure, system is OK at this time.Check for poor connections or loose wires at theIAC valve and at the ECM/PCM.

2. 3. Turn the ignition switch OFF.4. Disconnect the IAC valve 3P connector.5. Turn the ignition switch ON (II).6. Measure voltage between the IAC valve 3P

connector terminal No. 2 and body ground.IAC VALVE 3P CONNECTOR


YES - Go to step 7.

NO - Repair open in the wire between the IAC valve andthe PGM-FI main relay.


1. 8. Check for continuity between body ground and IACvalve 3P connector terminal No. 1.

IAC VALVE 3P CONNECTOR

Wire side female terminalsIs there continuity?

YES - Go to step 9.

NO - Repair open in the wire between the IAC valve andG101.

2. 9. Disconnect ECM/PCM connector A (31P).10. Check for continuity between body ground and

ECM/PCM connector terminal A12.ECM/PCM CONNECTOR A (31P)


YES - Repair short in the wire between the IAC valve andthe ECM/PCM (A12).

NO - Go to step 11.

11-117



Idle Control SystemDTC Troubleshooting (cont'd)

1. 11. Connect the IAC valve 3P connector terminal No. 3and body ground with a jumper wire.

IAC VALVE 3P CONNECTOR


12. Check for continuity between ECM/PCM connectorterminal A12 and body ground.




NO - Repair open in the wire between the IAC valve andthe ECM/PCM (A12).

13. Reconnect the IAC valve 3P connector.14. Turn the ignition switch ON (II).

1. 15. Measure voltage between body ground andECM/PCM connector terminal A12.




NO - Replace the IAC valve.

11-118



Idle Control SystemA/C Signal Circuit Troubleshooting

1. 1. Turn the ignition switch ON (II).2. 2. Momentarily connect ECM/PCM connector terminals

A24 and E18 with a jumper wire several times.ECM/PCM CONNECTORS A (31P)

Wire side of female terminalsIs there a clicking noise from the A/C compressor clutch?

YES - Go to step 3.

NO - Go to step 6.

3. 3. Start the engine.4. Turn the blower switch ON.5. Turn the A/C switch ON.

Does the A/C operate?

YES - The air conditioning signal is OK.


1. 6. Momentarily connect the under-hood fuse/relay box14P connector terminal No. 10 and body ground witha jumper wire several times.

UNDER-HOOD FUSE/RELAY BOX 14P CONNECTOR

Wire side of female terminalsIs there clicking noise from the A/C compressor clutch?

YES - Repair open in the wire between the ECM/PCM(E18) and the A/C clutch relay.

NO - Check the A/C system for other symptoms.

11-119



Primary Heated OxygenSensor (Primary HO2S)(Sensor 1), SecondaryHeated Oxygen Sensor(Secondary HO2S)(Sensor 2)

The HO2S detects the oxygen content in the exhaust gas and sends voltagesignals to the ECM/PCM. Based on these signals, the ECM/PCM controls theair fuel ratio. When the oxygen content is high (that is, when the ratio is leanerthan the stoichiometric ratio), the voltage signal is lower. When the oxygencontent is low (that is, when the radio is richer than the stoichiometric ratio),the voltage signal is higher.

0.0-1.25 VAt idlespeed: about0.1-0.9 V

NO



Idle Control SystemAlternator FR Signal Circuit Troubleshooting

1. 1. Disconnect the ALT 4P connector.2. 2. Turn the ignition switch ON (II).

3. Measure voltage between ECM/PCM connectorterminals A24 and B13.

ECM/PCM CONNECTORS


YES - Go to step 4.

NO - Go to step 14.

3. 4. Turn the ignition switch OFF.5. Reconnect the ALT 4P connector.6. Start the engine. Hold the engine at 3,000 rpm (min-

1) with no load (in Park or neutral) until the radiatorfan comes on, then let it idle.

7. Measure voltage between ECM/PCM connectorterminals A24 and B13.

Does the voltage decrease when the headlights and rearwindow defogger are turned on?

YES - The ALT FR signal is OK.

NO - Go to step 8.

4. 8. Turn the ignition switch OFF.9. Disconnect the negative cable from the battery.

10. Disconnect ECM/PCM connector B (24P).11. Disconnect the ALT 4P connector.

1. 12. Connect the ALT 4P connector terminal No. 4 andbody ground with a jumper wire.

ALT 4P CONNECTOR


13. Check for continuity between body ground andECM/PCM connector terminal B13.



YES - Test the ALT (see step 1 on page 4-29).

NO - Repair open in the wire between the ECM/PCM(B13) and the ALT.

14. Turn the ignition switch OFF.15. Disconnect the negative cable from the battery.16. Disconnect ECM/PCM connector B (24P).

11-120



Idle Control SystemAlternator FR Signal Circuit Troubleshooting(cont'd)

1. 17. Check for continuity between body ground andECM/PCM connector terminal B13.



YES - Repair short in the wire between the ECM/PCM(B13) and the ALT.


11-121



Idle Control SystemElectrical Power Steering (EPS) Signal CircuitTroubleshooting

1. 1. Turn the ignition switch ON (II).2. 2. Measure voltage between ECM/PCM connector

terminals A24 and E16.ECM/PCM CONNECTORS


YES - Go to step 6.

NO - Go to step 3.

3. 3. Start the engine.4. Turn the steering wheel to the full lock position.5. Measure voltage between ECM/PCM connector

terminals A24 and E16.Is there battery voltage momentarily?

YES - The EPS signal is OK.

NO - Go to step 10.

4. 6. Turn the ignition switch OFF.7. Disconnect the EPS control unit 20P connector.8. Turn the ignition switch ON (II).

1. 9. Measure voltage between the EPS control unitterminal No.17 and body ground.

EPS CONTROL UNIT 20P CONNECTOR


YES - Substitute a known-good EPS control unit andrecheck.

NO - Repair open in the wire between the ECM/PCM(E16) and the EPS control unit.

10. Turn the ignition switch OFF.11. Disconnect the EPS control unit 20P connector.12. Turn the ignition switch ON (II).

11-122

Brake Pedal Position Switch Signal Circuit Troubleshooting


Idle Control SystemElectrical Power Steering (EPS) Signal CircuitTroubleshooting (cont'd)

Brake Pedal Position Switch Signal CircuitTroubleshooting

1. 13. Measure voltage between EPS control unit terminalNo. 17 and the body ground.

EPS CONTROL UNIT 20P CONNECTOR


YES - Substitute a known-good EPS control unit andrecheck.

NO - Go to step 14.

14. Turn the ignition switch OFF.15. Disconnect the ECM/PCM connector E (31P).16. Check for continuity between body ground and

ECM/PCM connector terminal E16.

ECM/PCM CONNECTORS E (31P)


YES - Repair short in the wire between the ECM/PCM(E16) and the EPS control unit.

NO - Substitute a known-good ECM/PCM and recheck(see page 11-6). If prescribed voltage is nowavailable, replace the original ECM.

1. 1. Check the brake lights.Are the brake lights on without pressing the brake pedal?

YES - Inspect the brake pedal position switch (see page19-10).

NO - Go to step 2.

2. 2. Press the brake pedal.Do the brake lights come on?

YES - Go to step 3.

NO - Go to step 4.

3. 3. Measure voltage between ECM/PCM connectorterminals A24 and E22 with the brake pedal pressed.

ECM/PCM CONNECTORS


YES - The brake pedal position switch signal is OK.

NO - Repair open in the wire between the ECM/PCM(E22) and the brake pedal position switch.

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Idle Control SystemBrake Pedal Position Switch Signal CircuitTroubleshooting (cont'd)

1. 4. Inspect the No. 7 HORN, STOP (15A) fuse in theunder-hood fuse/relay box.

Is the fuse OK?

YES - Repair open in the wire between the brakepedal position switch and the No. 7 HORN,STOP (15 A) fuse. Inspect the brake pedalposition switch (see page 19-10).

NO - Repair short in the wire between theECM/PCM (E22) and the No. 7 HORN,STOP (15A) fuse. Replace the No. 7 HORN,STOP (15A) fuse.

11-124



Idle Control SystemIdle Speed Inspection

NOTE:Leave the Idle Air Control (IAC) valve connected.Before checking the idle speed, check these items:

The Malfunction Indicator Lamp (MIL) has not beenreported on.Ignition timingSpark plugsAir cleanerPCV system

2. 1. Disconnect the Evaporative Emission (EVAP)canister purge valve 2P connector.

2. Connect a tachometer (A) to the test tachometerconnector (B).

3. 3. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load (in Park or neutral) until the radiatorfan comes on, then let it idle.

4. Turn the ignition switch OFF.5. Start the engine.Check the idle speed with no-load

conditions: headlights, blower fan, rear defogger,radiator fan, and air conditioner are not operating. Idle speed should be:M/T 650+50 rpm (min-1)A/T 650+50 rpm (min-1)

(in Park or neutral)NOTE:ECM/PCM might control to raise the idle speed 750rpm (min-1) in case of the battery performance,etc. In thiscase, idle speed is OK.Go to step 6.

1. 6. Idle the engine for 1 minute with heater fan switchon HI and air conditioner on, then check the idlespeed.

Idle speed should be:M/T 750+50 rpm (min-1)A/T 750+50 rpm (min-1)

(in Park or neutral)NOTE: If the idle speed in not within specification, seeSymptom Chart.

2. 7. Reconnect the EVAP canister purge valve 2Pconnector.

11-125

Fuel and Emissions - Fuel Supply System


Fuel Supply SystemComponent Location Index

1. FUEL PUMPTroubleshooting, page 11-127Replacement, page 11-139FUEL FILTERReplacement, page 11-138FUEL GAUGE SENDING UNITTest/Replacement, page 11-141FUEL PRESSURE REGULATORReplacement, page 11-138

2. FUEL FILL CAP3. FUEL TANK

Replacement, page 11-1404. FUEL TUBE/QUICK-CONNECT

FITTINGSPrecautions, page 11-134Removal, page 11-135Installation, page 11-136

5. FUEL VAPOUR PIPE6. PGM-FI MAIN RELAY 2

Troubleshooting, page 11-1277. PGM-FI MAIN RELAY 18. FUEL FEED PIPE9. FUEL RAIL


11-126



Fuel Supply SystemFuel Pump Circuit Troubleshooting

If you suspect a problem with the fuel pump, check that thefuel pump actually runs; when it is ON, you will hear somenoise if you listen to the fuel fill port with the fuel fill capremoved. The fuel pump should run for 2 seconds when theignition switch is first turned on. If the fuel pump does notmake noise, check as follows:1. 1. Turn the ignition switch OFF.

2. Remove the glove box (see page 20-79), thenremove the PGM-FI main relay 2 (A).

LHD model:

RHD model:




YES - Go to step 5.

NO - Repair open in the wire between the PGM-FI mainrelay 1 and the PGM-FI main relay 2.



YES - Go to step 6.

NO - Repair open in the wire between the under dashfuse/relay box and PGM-FI main relay 2.


11-127



Fuel Supply SystemFuel Pump Circuit Troubleshooting (cont'd)

1. 8. Check for continuity between the PGM-FI main relay2 4P connector terminal No. 3 and ECM/PCMconnector terminal E1.


YES - Go to step 9.

NO - Repair open in the wire between the PGM-FImain relay 2 and the ECM/PCM (E1).

2. 9. Reinstall the PGM-FI main relay 2.10. Turn the ignition switch ON (II).11. Measure voltage between ECM/PCM connector





12. Turn the ignition switch OFF.13. Reconnect ECM/PCM connector E (31P).

1. 14. Turn the ignition switch ON (II), and measure voltagebetween ECM/PCM connector terminal E1 and bodyground within the first 2 seconds after the ignitionswitch was turned ON (II).




NO - Go to step 15.

15. Turn the ignition switch OFF.16. Remove the rear seat cushion (see page 20-95).17. Remove the access panel from the floor.18. Measure voltage between the fuel pump 5P connector

terminal No. 5 and body ground within the first 2seconds after the ignition switch was turned ON (II).




NO - Go to step 19.

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CIVIC 4/5D MAINTENANCE, REPAIR & CONSTRUCTION 01 · 2020. 4. 30. · MANUAL CIVIC CIVIC 4/5D...

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Transcript of CIVIC 4/5D MAINTENANCE, REPAIR & CONSTRUCTION 01 · 2020. 4. 30. · MANUAL CIVIC CIVIC 4/5D...