Honda civic 2003.pdf

INTRODUCTION
Safety
Yoursafety,
andthe satetyof others,isvery important.
To help
you makeinformeddecisions,
we haveprovidedsafety
messages,
andothersafetyinformation
throughoutthis manual.
Of course,
it is not practical
or possible
to warn you aboutallthe
hazards
associated
with servicing
thisvehicle.
You must use
your own goodjudgment.
You will find impoftantsafetyinformationin a varietyof forms
including:
. SatetyLabels
- on the vehicle.
. Satetv Messages precededby a salety alert symbol A and
oneof threesignalwords,DANGEF,
WARNING,
or CAUTION.
Thesesignalwordsmean:
tmEnEErily;,:
H,lli":5*i5"?;r
sE
R
IousLY
H
uBrir
E$EEEE ys,:
f#,ff ,:hl:3,:JjERrousLY
HURT
ir
tlGtltT]llilll YoucAN b€HUBT
if voudon'tfollow
. lnstructions
- howto service
thisvehicle
correctlv
andsafelv.
All information
contained
in this manualis basedon the latest
productinformation
available
at thetime of printing.
We reserve
the rightto makechanges
at anytimewithoutnotice.No partof
this Oublication
maVbe reDrodLrced,
or storedin a retrieval
system,or transmitted,
in anyform by any means,electronic,
mechanical,
photocopying,
recording,
or otherwise,
withoutthe
priorwrittenpermission
o{the publisher.
Thisincludes
text,
figures,
andtables-
As vou readthis manual,vou will tind information
thatis
preceded
by a @ symbol.The purposeof this message
is
to helppreventdamageto your vehicle,
other property,
or the
environment,
*Body z-tl!
^ t l
FirstEdition
8/20021,168
pages HONDA
MOTOR
CO..LTD.
All RightsReserved ServicePublication
Office
Specifications
applyto U.S.A.
andCanada
As seclion3with *inclode SRScomoonentsi
special precautionsare required when servicing.
How to Use This Manual -
Thismanualis dividedinto23sections.
Thefirstpageof each
seclionis markedwith a blacktabthat linesup with its
corresponding
thumb indextab on this pageandthe backcover.
Youcanquicklyfindthefirstpageof eachsectionwithout
lookingthrougha full tableof contents.
Thesymbolsprintedat
thetop cornerof eachpagecanalsobe usedas a quick
re{erence
system.
Eachsectionincludes:
1. A tableof contents,
or an exploded
view indexshowingl
. Partsdisassembly
sequence.
. Bolttorquesandthreadsizes.
. Pagereferences
to descriptions
in text.
Disassembly/assembly
procedures
andtools.
Inspefiron.
Testing/troubleshootin
g.
Repair.
Adjustments.
2.
3.
4.
5.
6.
Specifications 1)ll:{l+'
Maintenance
Emissions
*Restraints

)
General
Information
Ghassis
andPaintCodes
-2002
Model .................
1-2
Chassis
andPaintCodes
-2003
Model .................
1-3
ldentification
NumberLocations........
1-4
Warning/Caution
LabelLocations......1-5
Under-hood
Emission
ControlLabel........... .... 1-7
LiftandSupport
Points.........,....,.......,.
1-8
Towing ......1-9
PaftsMarkingLocations......................
1-10

GeneralInformation
Chassis
andPaintCodes- 2OO2
Model
Vehicle
ldentffi
cationNumber
S H H E P 3
3 5 ' 2 U 3 0 0 0 0 1
[[tttrtF
c d e f g h
a. Manufacturer, Make and Type of Vehicle
SHH; HONDAOFTHE
U.K.MFG.,LTD.U.K.
HONDAPassenger
vehicle
b. Line,Bodyand EngineType
EP3: CIVIC/K20A3
c. Body Type and Transmission Type
3: 2-doorHatchbacUs-speed
Manual
d. VehicleGradelSeries)
5:Si {U.S.}
5;SiR(Canada)
6: Si with sideairbagsystem(U,S.)
6: SiRwith sideairbagsystem(Canada)
e. CheckDigit
l. ModelYear
2i 2002
g. Factory Code
U: Hondaof U.K.Manufacturing
in Swindon,
England
h. SerialNumber
U.S,:
300001
-
1 -
V€hicle ldentification Numbo.
and FederalMotor Vehicle
Safety Standard Certification/
Color Label.
1-2
I
1700001
K2OA3
a
a. EngineType
K20A3: 2.00 DOHCVTECSequentialMultiport
Fuel-injected
engine
b. Serial Number
Engine
Number
Transmission
Number
PaintCode
Code Color u.s. Canada
B-92P Niqhthawk
Black
Pearl
NH-578 TaffetaWhite
NH-623M SatinSilverlvletallic
R-81 MilanoRed
Y-62P EuroYeliowPearl
NBH3
I
a
Transmission
Type
NRH3;s-sDeed
Manual
1000001
t
0

Chassis
andPaintCodes- 2003Model
Vehicle
ldentif
icationNumber
S H H E P 3
3 5 * 3 U 4 0 0 0 0 1
[--t-rlF
c d e f g h
G.
d.
Manufacturer, Make and Type of Vehicle
SHH: HONDAOFTHE
U.K.MFG.,
LTD.U.K.
HONDAPassenger
vehicle
Line.Bodyand EngineType
EP3: CIVIC/K20A3
Body Type and TransmissionType
3: 2-doorHatchbacldS-speed
Manual
Vehicle Grade (Series)
5:Si (U.S.)
5:SiR(Canada)
6: Si with sideairbagsystem(U.S.)
6: SiRwith sideairbagsystem(Canada)
CheckDigir
Model Year
3: 2003
Factory Code
U: Hondaof U.K.Manufacturing
in Swindon,
England
SerialNumber
U.S.:400001
f.
:700001
Vehicleldentification
Number
and FederalMotor Vehicle
Saletv Standard Certification/
ColorLabel.
)_.
2700001
K2OA3
I
a
a. EngineType
K20A3: 2.00 DOHCVTECSequentialMultiport
Fuel-injected
engine
b. SerialNumber
EngineNumber
Transmission
Number
NRH3
I
a
Transmission
Type
NRH3:5-speed
Manual
Serial
Number
- 2000001
PaintCode
Code Color U,S. Canada
B-92P Niohthawk
Black
Pearl
B-520P VividBluePearl
NH-578 Taffeta White
NH-623M SatinSilverN4etallic
R-81 MilanoRed
Y-62P EuroYellow Pearl
1-3

General
Information
ldentificationNumberLocations
Vehicle ldentification
Number{vlN}
Vehicle ldentificalion
Numbe.lvlN)
1-4
(
I
0
EngineNumber
t)

!
..r'
, I O warning/cautionLabelLocations
NOTE:
FRONT
PASSENGER
AIRBAG
WARNING
TAG
(CHILD
SEAT)
isinstalled
onthegloveboxontheU.S.
mooet.
Passenger's
Compartment:
SRSINFORMATION
U.S.
model
SRSWARNING
INFORMATION
FRONTPASSENGER
MODULEDANGER
MONITOR
NOTICE
SIDEAIRBAGCAUTION
Locatedon driver's
ano passen9er
s
doorjamb(notshown)
SIDEMODULE
DANGER
,/
FRONT
SEATBELT
TENSIONER
CAUTION
Steering Wheel:
DRIVER
MODULE
DANGER
CABLEREEL
CAUTION
(cont'd)
1-5

General
Information
Warning/Caution
LabelLocations(cont'dl
SRS
WARNING
LABEL
SERVICE
INFORMATIONLABEL
(Undor-hoodEmission Control
Informationlab€l)and ENGINE
COOLANTINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION
1-6
t
TIREINFORMATION
c

Under-hood
Emission
ControlLabel
Emission
Groupldentif
ication
Example:
2002model
THIS
VEHICLE
CONFORMS
TOU.S.
EPA
TIER
2 BIN5
ANDNLEVLEVREGULATIONS
APPLICABLE
TO2002
MODEL
YEAR
NEWPASSENGER
CARS
AND
CALIFORNIA
REGULATIONS
APPLICABLE
TO2OO2
MODEL
YEAR
NEWLEVIiLEVPASSENGER
CARS.
Example:
2003model
THISVEHICLE
CONFORMS
TOU.S.EPATIER2 BIN5
ANDNLEVLEVREGULATIONS
APPLICABLE
TO2O03
MODEL
YEAR
NEWPASSENGER
CARS
AND
CALIFORNIA
REGULATIONS
APPLICABLE
TO2OO3
MODEL
YEAR
NEWLEVIILEVPASSENGER
CARS,
rH/ @
Engine
andEvaporative
Families:
EngineFamily:
ModelYear
2:2002
3:2003
Manulacturer
Subcode
HNX:
HONDA
Family
Type
V:LDV
Displacement
Sequence
Characters
VBP:
2002
XKC:
2003
Evaporative Family:
2 HNX R OO99 AAH
t[-l=[
a b c d
ModelYear
2t 2002
3: 2003
Manufacturer Subcode
HNX:HONDA
Family Type
R:EVAP/ORVR
Canister Work Capacity
SequenceCharactets
AAH:2002
AAA: 2003
2 HNXV O2.O VBP
rr-tt--[
t t l
a b c d e
c.
d.
e.
c.
d.
e.
1-7

General
Information
Lift andSupportPoints
NOTE:If you are goingto removeheavycomponents
suchassuspensionor the fueltankfrom the rearof the
vehicle,firstsupportthefront ofthe vehiclewith tall
safetystands.When substantialweightis removed
from the rearof the vehicle,the centerof gravitycan
changeand causethe vehicleto tip forwardon the hoist.
FrameHoist
1. Positionthe hoistlift blocks(A),or safetystands,
underthe vehicle'sfront supportpoints(B)and rear
supportpoints(C).
2. Raisethe hoista few inches,and rockthe vehicle
gentlyto be sureit is firmly supported.
3. Raisethe hoistto full height,and inspectthelift
pointsfor solidcontactwith the lift blocks.
Safety Stands
To supportthe vehicleon safetystands.usethe same
suppon points(Band C)asfor a frame hoist,Always
usesatetystandswhen workingon or underany
vehiclethat is supportedonly by a jack.
1-8
FloorJack
1. Setthe parkingbrake.
2. Blockthe wheelsthatare not beinglifted.
3. When liftingthe rearof the vehicle.put the
gearshiftIeverin reverse.
4. Positionthe floor jackunderthe front jacking
bracket(A)or rearjackingbracket(B),centerthe
jackingbracketin thejacklift ptatform(C),andjack
up the vehiclehighenoughto fit the safetystands
underit.
c
Positionthe safetystandsunderthesupportpoints
and adjustthem sothe vehiclewill tevet.
Lowerthe vehicleontothe stands.
0
J t

Towing
lf the vehicleneedsto betowed,calla professional
towing service.Nevertow the vehiclebehindanother
vehiclewith just a ropeor chain.lt is very dangerous.
Emergency
Towing
Therearethreepopular
methods
of towinga vehicle.
Flat-bedEquipment The operatorloadsthe vehicle
on the backof a truck.This is the bestway of
transportingthe vehicle.
To accommodate
flat-bedequipment.the vehicleis
equippedwith towing hooks(A)andtie down hooks{B).
Thetowing hookcan be usedwith a winchto pullthe
vehicleontothe truck,andthe tie down hooksslotscan
be usedto securethe vehicleto truck.
1-9
WheelLift Equipment Thetow truck usestwo
pivotingarmsthat go underthe tires (frontor rear)and
liftsthem off the ground.The othertwo wheelsremain
on the ground.This is an acceptable
way of towingthe
vehicle.
Sling-typeEquipment Thetow truckusesmetal
cables
with hookson theends.
Thesehooksgo around
partsof the frameor suspensionandthe cablesliftthat
endof thevehicle
offtheground.
Thevehicle's
suspension
andbodycanbe seriously
damaged
ifthis
methodof towing is attemPted.
lf the vehiclecannotbetransportedby flat-bed,it
shouldbetowed with the front wheelsoff the ground lf
dueto damage,the vehiclemust betowed with the
front wheelson the ground,do the following:
. Release
the parkingbrake.
. shiftthetransmission
in Neutral.
It is bestto tow the vehicleno fartherthan 50 miles(80
km),and keepthe speedbelow35 mph (55km/h).
. lmproper
towingpreparation
will damage
the
transmission.
Followthe aboveprocedureexactly.lf
you cannotshiftthe transmission,
the vehiclemust
betransDorted
on a flat-bed.
. Tryingto lift or tow the vehicleby the bumperswill
causeserious
damage,
Thebumpers
arenot
designedto supportthe vehicle'sweight.

GeneralInformation
PartsMarking
To detervehicletheft,certainmajorcomponentsare markedwith the vehicleidentification
number(VlN).Original
partshaveself-adhesive
labels.Replacement
body partshavegenericself-adhesive
labels.The originalengrneor
transmissionVIN plateistransferredlo a replacement
engineor transmissionand attachedwith break-offbolts.
NOTE:Becarefulnotto damagethe partsmarkinglabelsduring body repair.Maskthe labelsbeforerepairingthe part.
r a
1-10

ne
Item Measurement Oualification Standard or New Service Limit
lgnition
coil Rated voltage
Firingorder
12V
1 3 - 4 2
NGK:
tZFB6K11
DENSO:
SKJ20DR-M11
1.0 1.1mm(0.039
0.043
in.) 1.3mm(O.OS1
in.)
Spark
plug Type
Gap
lgnitiontiming At idle (checkrhe in neutral:
8t2' ETDC
at650150rpm
Alternator Output At 13.5
V and
normalengine
temperature
80A
2.2 3.0A
Coillrotor)resistance At 68.F(20'C)
5|lp flng u.u. 14.4
mm {0_57
in.) 14.0
mm (0.55
in.)
Brushlength 10.5
mm (0.41
in.l 1.5mm {0.06
in.)
Brushspring
tension 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs)
Starter Output
Commutator
micadepth 0.50 0.80mm (0.020-0.031
in.) 0.20mm 1O.OO8
in.)
Commutator
tunout o:BlalqryL4i) max o.o5
mm(0.002
in.)
Commutator
O.D. 28.0
mm (1.10
in.) 27.0
mm (1.06
in.)
Brushlength 14.0 14.5
mm {0.55 0.57in.) 9.0mm {0.35
in.)
(
I
Standards
andService
Limits
EnqineElectrical
E
e _
.l
nqtne
Item Measurement Oualification Standard or New Service Limit
Compression Pressure
checkat 250rpm with wide
openthroftle.(SeeDesignSpecsfor
rato,
Minimum 930kPa(9.5
kgflcmr,
135psi)
Maximum
vanatton
200kPa{2.0kgf/cm',28
psi)
2-2

L
v
l o
2-3
a ead
o
nderH
Item Measur6ment Oualification Standard or New Service Limit
Head Warpage 0.05mm {0.002
in.)
Height
'103.95104.05
mm
(4.093 4.096
in.)
Camshaft Endplay 0.05 0.20mm (0.002 0.008
in.) 0.4mm (0.02
in.)
Camshaftto holderoil clearance N o . l j o u r n a l 0.030 0.069
mm
{0.001 0.003
in.)
0.15
mm{0.006
in.)
N o . 2 , 3 ,4 , 5
journals
0.060 0.099
mm
(0.002-0.004
in.)
0.15mm (0.006
in.)
Totalrunout 0.03mrn(0.001
in.)max. 0.04mm {0.002
in.)
Cam lobe height Intake,
primary 33.925
mm (1.3356
in.)
Intake, 29.638
mm (l.1668
in.)
Exhaust 34.092
mm (1.3422
in.)
clearance
(cold) lntake 0.21 0.2smm 10.0080.010
in.)
Exhaust 0.28 0.32mm (0.011 0.013
in.)
StemO.D- lnlaKe 5.475 5.485
mm 10.21560.2159
in.) 5.445
mm (0.214
in.)
Exhaust 5.450 5.460
mm (0.21460.2150
in ) 5.42
mm(0.213
in.)
Stem-to-gLride
clearance lntake 0.030 0.055
mm (0.00120.0022in.| 0.08mm (0.003
in.)
Exhaust 0.055 0.080
mm (0.00220.0031
in ) 0.11mm (0.004
in.)
lntake 1.25 1.55
mm (0.049 0.061
in.) 2.00mm {0.079
in.)
Exhaust 1.25 1.55
mm (0.049 0.061
in.) 2.00mm {0.079
in.)
steminstalled
height lntake 40.8-41.0
mm (1.6061.614in.)
Exhaust 54.6 54.8
mm (2.1502.157
in.)
Valve
springs Free
length lntake 47.61
mm (1.874
in.)
Exhaust 49.64
mm (1.954
in.)
Valveguides LD. Intake 5.515 5.530
mm
|.0.21710.2117
4n.1
5.55mm (0.219
in.)
Exhaust 5.515 5.530
mm
0.21110.2177
in.l
5.55
mm{0.219
in.)
Installedheight lntaKe 15.2"16.2
mm (0.5980.638in.)
Exhaust 15.5 16.5
mm (0.610 0.650
in.)
Rocker
arms Arm-to-shaft
clearance lntaKe 0.025 0.052
mm
(0.00'10
0.0020
in.)
0.08mm (0.003
in.)
Exhaust 0.018 0.056
mm
(0.00070.0022
in.)
0.08mm (0.003
in.)

nqtne
Item Measurement Oualification Standardor New ServiceLimir
Block
Piston
I Warpage
of deck 0.07mm (0.003
in.)max. foro.. (ulur^^-"1
tsore
diameter A o r i
B o r l l
(3.38583.3862
in.)
85.980 85.990
mm (3.38503.3854
in.)
l-il?0 €s.980r"i33846
86.010 86.020
mm
(3.3862 3.3866in.)
86.000 86.010
mm
86.070
mm (3.3886
in.)
86.070
mm (3.3886
in.)
0 . 0 5m m ( 0 . 0 0 2
I n . J
85.920
mm (3.3827
in.)
0.25
mm (00l in.)
85.930
mm (3.383'l
in.)
Reboringlrmit
SkirtO.D.
at 11mm (0.4in.)from
bottomof skirt
F"
btt"'"' A
LetterB
0.020 0.040
mm (00008 0.0016
in.) 0.05mm {0.002
in.)
Top 1.220 1.230
mm (0.04810.0484
in.) 1.25
mm 10.049
rn)
Second 1 . 2 2 0 1 . 2 3 0
m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25
mm 10.049
in.)
Piston
ring
lFis,.€-"'"
",";"*
L-
Ringendgap
o.D.
i 2.005 2.025
mm (0.07890.0797
in.)
fo.o:s o.oto.rn
lo.oora
o.ooza
i.'.f
EO3t 0056
rn. {OJ01r
OOO2
i")
?.09rrl9.091lt
)
0.13mm (0.005
in )
0.13
mm(0.005
in.)
Second
(FEDEHAL
I4OGUL)
Top
0.025 0.060
mm (0.00100.0024
in.) 0.13mm (0.005
in )
0.20 0.35mm (0.008 0.014
in.) 0.60mm (0.024
in.)
Second 0.40 0.55mm {0.016 0.022
in.) 0.70mm (0.028
in.)
OiI(REKEN)
21.961 21.965
mm {0.86460.8648
in.)
0.25 0.65mm (0.010 0.026
in.)
0 20 0.70mm i0.008 0.028
in.)
0.75mm (0.030
in.)
OiI(FEDERAL
I4OG
UL)
0.80mm 10.031
in.)
Piston
pin
21.953mm l0 8643in
Pin'to-piston
clearance 0.005-*0.002
mm( 0.00020
+
0.00008
in.)
0.005
mm (0.0002
in.)
Connecting
rod Pin to-rod clearance 0.005 0.015
mm (0.00020.0006
in.) 0.02mm lO0OO8
in I
Small end bore diameler 21.970 21.976
mm (0.86500.8652
in.)
Large-endbore diameter(Normal) 48.0
mm (1.89
in.)
Endplayinslalled
oncrankshaft 0.15 0.30mm (0.006 0.012
in.) 0.40
mm (0.016
in.)
Crankshaft Main journal diameter
Rodjournal diameter
No.l journal
No.2 journal
No.4journal
No.5journal
No.3 journal
s4.e84 s5.008
mm (2.1648=16illl
54.97655.000
mm (2.1644
2-1654in)
44.976 45.000mm (1.1707 1.1717in.l
Rod/main 0.005
mm 10.0002
in.)max. 0.010
mm (0.0004
in.)
Rod/main
iournal
outof,round 0.005
mm (0.0002
in.)max. 0.010
mm (0.0004
in.)
Endplay 0.10 0.35mm (0.004 0.0'14
in.) 0.45
mm10.018
in.)
Runout
. . - ' . : - - ' +
0.03mm (0.0012
in.)max. 0.04mm {0.0016
in.)
Deaflngs
Marnoear,n9-toJournat
ottctearance No.l journal
No.2journal
No.4journal
N o . 5
No.3 journa/
0.017 0.041
mm (0.00070.0016
in.)
q0rr034, -rn {O'o010
0-o01r|"tl
0.050
mm (0.0020
in.)
0.055
mm (0.0022
in.)
Bodbearing
clearance 0.021 0.049
mm (0.00080.0019
in.) 0.060
mm (0.0024
in.)
StandardsandServiceLimits
Enqine
Block
_ f
c _
2-4
-

L
v
2-5
o i Lubrication
a
a
nqlne
|tem Measurement Oualificalion Standerdor New ServiceLimil
Engine
oil Capacity 5.30 (5.6USqt)forengine
overhaul
4.20 (4.4USqt)foroilchange,
including
filter
4.00(4.2USqt)foroilchange,
withoutfilter
Oilpump lnner-to
outerrotorclearance 0.02 0.16mm {0.001 0.006
in.) 0.20mm (0.008
in.)
Pumphousing
to outerrotor
clearance
0-15 0.21mm {0.006-0.008
in.) 0.23mm (0.009
in.)
Pumphousing-to-rotor
axial
clearance
0.02 0.07mm (0.001 0.003
in.) 0.12mm (0.005
in.)
Balancer
shafts,
journal
diameter No.1journal,
front
shaft
19.938 19.950
mm 10.78500.7854
in.) 19.92
mm (0.784
in.)
No 1 journal,rearshaft 23.938 23.950
mm (0.94240.9429
in.) 23.92
mm (0.942
in.)
No.2 journal,
frontand
rearshaft
32.949 32.961
mm 11.29121.2911
in.l 32.93
mm (1.296
in.)
Ealancer
shafts,
journal
taper 0.005
rnm(0.0002
in.)max.
Balancer
shafts,
endplay Front 0.070 0.135
mm (0.00280.0053
in.) 0.15mm (0.006
in.)
Rear 0.070 0.135
mm (0.00280.0053
in.) 0.15mm (0.006
in.)
Balancer
shatts,shaft-to'bear;ng
clearance
No.1iournal,
front
shaft
0.050 0.082
mm (0.00200.0032
in.) 0.10
mm(0.004
in.)
No. 1 Journal,rearshaft 0.050 0.082
mm (0.00200.0032
in.) 0.10mm (0.004
in.i
No. 2 journal,front and
rear shafl
0.060-0.120
mm (0.00240.0047
in.) 0.15mm (0.006
in.)
Balancer
shaftbearings,
LD. No.1journal,
front
shaft
No.1iournal,
rearshaft
20.000 20.020
mm (0.18140.7442
in.l
Z+.OOO
ZI.OZO
m- tOSa+e-
OSa57
ir'.)
20.03
mm (0.789
in.)
24.03
mm (0.946
in.)
No.2 journal,
frontand
rearshaft
33.021 33.069
mm (1.3000 1.3019
in.) 33.09
mm {1.303
in.)
Reliefvalve,oil pressurewith oil
temperatureat 176'F(80"C)
At idle 70 kPa(0.7kq?cm , 10 psr)min.
At3,000
rpm 300kPa{3.1
ksf/cm',44
psi)min.
Standardor New ServiceLimit
6.7L (7.1
US
Coolant
capacity
{includes
engine,
heater,
hoses,
andreservoir)
0.53L (0.56
US
93 123kPa(0.95 1.25
kqtcm, 14 18psi)
't69 176'F
(76 80'C)
Thermostat OPeningtemPerature
8.0mm {0.31
in.)min.
TurnsOFF Subtract
5 15'F(3 8"C)from
actual
ON

Item Measulement Oualification Standardor New ServiceLimit
Fuelpressure
regulator
Pressure
with fuelpressure
gauge
connected
320-370kPa13.3-'3.8
kgtcm',47 52psi)
Fueltank Capacity 504 (13.2
USgali
Engine
idle ldlespeed
withheadlights
andradiator
fanoff
Neutral 750 50rpm
Fastidle Neutral 1,600150
rpm
FuelandEmissions f
.
r a
Clutch
Item Mea3urem€nl Oualification Slandardor New ServiceLimit
Clutch
pedal Height
fromthefloor 193mm (7.60
in.)
Stroke 130 140
mm15.1 5.5in.)
10 16mm (0.39 0.63in.)
Disengagementheightfrom the floor 1'15
mm (4.53
in.)
min.
Bunout
onclutch
matingsurface 0.05mm 10.002
in.)max. 0.15mm (0.006
in.)
Clutch
disc Bivetheaddepth 1.65 2.25mm (0.065 0.089
in.) 0.7mm {0.03
in.)
Ihickness 8.3 8.9mm (0.33 0.35in.) 6.0mm (0.24
in.)
Pressure
plate Warpage 0.03mm (0.001
in.)max. 0.15
mm(0.001
in.)
Heightof diaphragm spring fingers Measured
with
specialtool
and
feeler
gauge
0.6mm (0.02
in.)max. 0.8mm (0-03
in.)
2-6
< c

L
v
2-7
O E
a
o
nualTransmission
andM/T Differential
Item M€asurement Oualification Standardor New Se.viceLimit
Transmission
fluid
Capacity Forfluidchange:
1.50 (1.6USqt)
Foroverhaul:
1.7
011.8
USqt)
Mainshaft Endplav 0.1
'l -0.17mm(0.0040.007in.) Adiust
Diameter
of bushing
surface 20.80 20.85
mm {0.819 0.821
in.) 20.75
mm 10.817
in.)
Diameterof distancecollar 31.984-32.000
mm (1.2594 1.2598
in.) 3'1.93
mm (1.257
in.)
Diameter
of ballbearing
contact
area
(clutch
housing
side)
27.97727s90
mm1.1015
- 1.1020
in.) 27.92
mm (1.099
in.)
Diameter
of needle
bearing
contact
area
38.984 39.000
mm (1.5348'1.5354
in.) 38.93
mm (1.533
4n.)
Diameter
of ballbearing
contact
area
(transmission
housing
side)
27.987 28.000
mm (1.10'191.1024
in.) 27.93
mm{1.100
in.)
Runout 0.02mm (0.001
in.)max. 0.05mm (0.002
in.)
Mainshaft
3rd,
4thandsth
gears
t.D. 44.009 44.025
mm 11.73261.7333
in.) 44.08
mm (1.735
in.)
Endplay 0.06 0.16mm {0.002 0.006;n.) 0.25
mm (0.010
in.)
Thickness 23.92 23.97
mm (0.94'10.944
in.) 23.80
mm (0.937
in.)
Countershaft Diameterof needlebearingcontact
area(clutch
housing
side)
35.000-35.015
mm (1.3780'1.3785
in.) 34.95
mm (1.376
in.)
Diameter
of distance
collarcontact
alea
39.937 39950mm (1.5723 1.512ain.| 39.88
mm (1.570
in.)
Diameterof ball bearingcontactarea
(transmissionhousingside)
30.020-30.033
mm (1.1819-
1.1824
in.) 29.97
mm (1.180
in.)
Runout 0.02mm {0.001
in.)max. 0.05mm (0.002
in.)
35mm shim-to'bearing
innerrace
clearance
0.04 0.10mm (0.00160.0039
in.) Adjust
Countershaft LD. 52.010 52.029
mm (2.0476-2.0484
in.i 52.08
mm (2.050
in.)
End play 0.06 0.16mm (0.002 0.006
in.) 0.25
mm10.010
in.)
$m 10.902
-0.904in.) 22.87
mm (0.900
in.)
Countershaft
2ndgear
t.D. 52.010 52.029
mm (2.04762.0484
in.) 52.08
mm {2.050
in.}
Endplay 0.06 0.16mm (0.002 0.006
in.) 0.25mm 10.010
4n.)
mtn1.099 1.101
in.) 27.87
mm 11.097
in.)
Countershaft
'lst gear
distance
collar
LD. 39.95 39.96
mm (1.572a1.5132
in.) 39.97
mm (1.574
in.)
o.D. 46.989-47.000
mm (1.8499-
1.8504
in.) 46.94
mm (l.848in.)
Length 23.03 23.08
mm (0.907-0.909
in.i
Countersha{l
2ndgear
distance
coliar
l.D. 39.95 39.96
mm {1.5728'-
1.5732
in.l 39.97
mm (1.574
in.)
o.o. 46.989 47.000
mm (1.8499 1.8504
in.) 46.94
mm (1.848
in.)
Length 28.03 28.08
mm (l.104 1.106in.)

anuatIransm cont'
Item Measutemenl Oualification Standardor New ServiccLimit
Nlainshaft
4th
and5thgears
distance
collar
LD. 32.00-32.01
mm (1.2598 1.2602
in.) 32.02
mm (1.261
in.)
o.D. 38.989 39.000
mm (1.5350 1.5354
in.) 38.94
mm (1.533
in.)
Length 51.95 52.05
mm (2.045 2.049
in.)
B 24.03 24.08
mm (0.946-0.947
in.)
MBSdistance LD. 28.00 28.01mm
(1.102 1.103
in.) 28.02
mm(1.103
in.)
Len9th 23.95 24.05
mm (0.943 0.947
in.)
Reverse
idler
gear
t.D. 20.016 20.043
mm (0.78800.7891
in.) 20.90
mm (0.832
in.)
Gear lo reversegear shaficlearance 0.036 0.08a
mm (0.00140.0033
in.) 0.16
mm{0.006
in.)
Synchro
ring Bingto'gearclearance Ringpushed
against
gear
0.70 1.49
mm (0.028 0 059in ) 0.4mm (0.016
4n.)
Triple
cone Outer
synchro
ring-to
synchro
cone
clearance
Ringpushed
against
qear
0.70- '1.19
mm {0.028 0.047
in.) 0.3mm (0.012
in.)
Synchro
cone-to-gear
clearance Ringpushed
against
gear
0.50 1.04
mm (0.020 0.041
in.) 0.3mm (0.012
in.)
Outersynchro
ring-to-gear
cone
clearance
Ringpushed
against
gear
0.95 1.68
mm (0.037 0.066
in.) 0.6mm (0.024
in.)
Shiftfork Finger
thickness 7.4 7.6mm 10.29 0.30in.)
Forkto-synchro
sleeve
clearance 0.35 0.65mm (0.014 0.026
in.i 1.0mm (0.039
in.)
Reverse
shift
fork
Finger
thinkness 13.4 13.7
mm (0.527 0.539
in.)
Fork-to-reverse
idlergear clearance 0.20 0.59mm (0.007 0.024
in.) 1.3mm (0.051
in.)
Shiftarm t.D. 13.973 '14.000
mm (0.55010.5512
in.)
Shift fork diameterat conlactarea 16.9 '17.0
mm (0.665 0.669
in.)
Shift arm'to-shiftleverclearance 0.2 0.5mm (0.008 0.020
in.) 0.62
mm (0.024
in.)
Select
lever Finger
width 14.85 '14.95
mm (0.585 0.589
in.)
Shiftlever Shaft
-to-select
leverclearance 0.05 0.25mm (0.002 0.010
in.) 0.50mm (0.020
in.)
Groove{toselectlever) 15.00 15.10
mm {0.591 0.594
in.)
Shaftto shiftarmclearance 0.013 0.07mm (0.00050.003
in.) 0.1mm {0.004
in.)
Mfi
differential
carrier
Pinionshaftcontactareal.D. 18.010 18.028
mm (0.70910.7098
in.)
Carrier-to-pinion
shaftclearance 0.027 0.057
mm (0.00110.0022
in.) 0.1mm (0.004
in.l
Driveshaft
contactareaLD. 28.025 28.045
mm (1.1033 1.1041
in.)
Mfi
differential
pinionqear
Backlash 0.05 0.15mm {0.002 0.006
in.)
t.D. 18.04218.066
mm (0.71030.7113in.)
Piniongearto pinion shaftclearance 0.059 0.095
mm (0.00230.0037
in.) 0.15mm (0.006
in.)
80mm shim 80mm shimto-bearing
outerrace
clearance
intransmission
housing
0 0.10mm (0 0.0039
in.) Adjust
ManualTransmission
andDifferential
?
L O
2-8
-

Y
2-9
o
o
a
0 10mm (0 0.39in.)
Rotational
olavmeasured
at outside
29N (3.0
kgf.6.6lbs)
Starting
loadmeasured
at outside
Angle of rackguide screw loosened
n
Item Measurement Oualitication Standardor New ServiceLimit
Wheelalignment
Camber Front 0'00' 45'
Rear 0'45'- 45
Caster Front 1"33' 11"
TotalToe lrytt
Rear
0-3 mm(0::0.12
in.)
lN2 ' , mm (0.08"' ,, in.)
Frontwheel
turningangle lnsidewheel 37'40'-2'
Outside
wheel 29'50'(Reference)
Aluminum
wheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08
in.)
R a d i a l 0 - 0.7mm (0 0.03in.) l.5mm{0.06in.)
Wheelbearing Endplay Front 0 0.05mm (0 0.002
in.)
Rear 0 0.05mm (0 0.002
in.)

Item M€asurement Oualification Standardor New ServiceLimit
Parking
brake
lever
Distance
traveled
whenleverpulled
with 196N (20kgf,44lbs)ol force
7 8 clicks
Brake
pedal Pedal
height
(carpet
removed) 1 8 4m m ( 74 / 1 6i n . )
Freeplay 0.4 3.0mm (0016 0 '118
in.)
Master
cylinder Piston-to-pushrod
clearance 0 0.4mm (0 0.02in.)
Erake
disc Thickness Front 21.0
mm (0.83
in.) 19.00
mm (0.75
in.)
Rear 9.0mm {0.35
in.) 8-0mm (0.31
in.i
Runout Front 0.10mm (0.004
in.)
Rear 0.10mm (0.004
in.)
Parallelism Frontandrear 0.015
mm (0.0006
in.)
Brake
pads Thickness Front 10.0
mm (0.39
in.) 1.6
mm (0.06
in.)
llear 9.0mm {0.35
in.) 1.6
mm (0.06
in.)
Brakes
a
e -
AirGonditionin
Item Moasurement Oualilication Standard or New Service Limit
Refrige.ant Tvpe HFC134
a (B-134
a)
Capacity
of system 500 550g 117.6 19.4
oz)
Refrigerant
oil Type SP1O
(P/N
38897-P13-A01AH
or38899-P13-A01
)
Capacity
ofcomponents Condenser 25 m0,15/6fl ozl
Evaporator 45mA111/2fl ozt
Eachlineand
hose
10m0(1/3
fl or)
Compressor 130 150
m014
1/3 5floz)
Compressor Startercoil resistance At 68"F(20"C) 3.05 3.350
Pulley-to-pressure
plate
clearance 0.35 0.6mm (0.014 0.024
in.)
Drivebelt Autotensioner
lneeds
noadjustment)
2-10
q

L
v
2-11
Design
Specifications
O
o
o
|tem Measurement Oualification Specilication
DIMENSIONS Overalllength 4,210
mm{165.8
in.)
Overallwidth 1,695
mm 166.7
in.)
O v e r a l l h e i g h t 1,440
mm (56.7
in.)
2,570
mm (101.2
in.)
Track rront 1,470
mm (57.9
in.)
Rear '1,470
mm (57.9
in.i
Ground
clearance 152mm (5.98
in.)
Seatingcapacity four{4)
wEtGt-iT
{u.s.A.) GrossVehicleWeight Rating
(GVWR)
3,660
rbs
WEIGHT
(CANADA)
Gross
Vehicle
WeightRating
{GVWR)
1,660
kg
ENGINE Tvpe Watercooled.
4 stroke
DOHC
V-ECengin(
Cylinder
arrangement Inline
4'cylinder,
transverse
Boreandstroke 86x 86mm (3.39
x 3.39in.)
Displacement 1,998
cm'(122
cuin.)
Compression
ratio 9.8
Valve
train Chain
drive.DOHC
VTEC
4valves
percylinder
Lubrication
system Forced,
wetsump,
withtrochoid
pumP
Oilpumpdisplacement At 6,000
engine
rpm
54.30 (57.4
USqo/minute
Waterpumpdisplacement At 3,400
engine 820 (87USqt)/minute
F!elrequired UNLEADED
gasoline
with86pumpoctane
number
or higher
STARTER Tvpe Gearreduction
Normaloutput
Nominalvoltage 12V
Hourrating 30seconds
Direction
of rotation Clockwiseas vieweclfrom gear end
CLUTCH Clutchtvpe Sinqle platedry, diaphragmspring
Clutch
friction
material
surface
area 174
cm'{26.97
sqin.)
I,1AN
UAL
TRANSMISSION
Tvpe Svnchronized,
s-speed
forward,1reverse
Primarv
reduction Direct
1:1
Gearratio lst 3.062
2nd 1.769
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Finalreduction Type Sinole
helicalgear
Gearratio 4.164

cont'
Item Measuremeni Oualification Specilication
STEERING Type Electric,
Powerassisted
rackandpinion
Overall
ratio 15.1
Turns,lock
to-lock
Steering
wheeldiameter 360mm (14.2
in)
SUSPENSION Type Independentsrrul with stabiliTer.
coil spring
Rear Doublewishbone
Shock
absorber Front Telescopic,
hydraulic.
nitrogen
gas-frlled
Rear Telescopic,
hydraulic,
nitrogen
gas,filled
WHEEL
ALIGNMENT
Camber Front 0"00'
Bear 0.45'
Caster Front 1'33'
Totaltoe Front 0 mm (0in.)
Rear I n2 m m ( 1 / 1 6
i n . )
BRAKES Typeof servicebrake Front Powerassistedself-adjusling
ventilateddisc
Bear Power-assisted
self-adjusting
soliddisc
Typeof parkingbrake Mechanical
actuating,
rearwheels
Padfrictionsurfacearea Front 45cm'(7.0
sqin.)x2
Rear 28cm'(4.3
sqin.)
x 2
TIRES Sizeoffrontandreartires Pl95/60
81588V
Sizeo{sparetire T125r0D1595M
AIR
CONDITIONING
Compressor Type Scroll
Numberof
cylinders
Capacity 85.7m015.23
cuin.)/rev.
Maximumspeed 12,000
rpm
Lubricantcapacity 130m0{41/3floz)
Lubricanttype SP-10
(P/N
38897'P13-A01AH
or38899-P13
A01)
Condenser Type Corrugated
fin
Evaporator Tvpe Corrugated
fin
Blower Type Siroccofan
Motortype 220Wl12 V
Speed control 4 Speeo
Maximum capacity 480m"116.900
cuft)/h
Temperaturecontrol Airmixtype
Compressor
clutch Tvpe Dry,single
plate,
poly-V
beltdrive
Electricalpower
cons!mptron
at
68"F(20.C)
42W maximum
at 12V
Refrigerant Type HFC134a
(R-134a)
Capacity 500 550g (17.6 19.4
oz)
DesignSpecifications
C
a
L
2-12
../a

t
v
2-13
o
o
a
Item Measurement Oualilication Specitication
ELECTRICAL
RATINGS
Battery 12V 36AH/5
hours
Starter 12V-.1.1
kW,1.2
kW
Alternator 12V 95A,90A
Fuses Under-hood
fuse 80A,60A, 50A,40A,30A,20A, 15A, 10A,7.5A
Under'dash
Iuse 304,20a, 15A,10A,7.5
A
Lightbulbs Headlight
high
beam
'12
v.' 60w
Headlight
low
beam
1 2 V 5 5 W
Frontturn
signal
liqhts
12V 21W
Front parlinq lights 1 2 V 5 W
Bear
turnsignal
lights
12V" 21W
FronVrear
side
marker
lights
1 2 V 5 W
Brale/taillighls 12V 21/5W
High moLrntbrake
light
1 2 V 5 W
Backuplights 12V 21W
License
platelight 1 2 V 5 W
Ceiling
light '12
v'.8 w
Cargoarea light 1 2 V 5 W
Spotlights 1 2 V 5 W
Gaugelights
Indicatorlights LED
Sideturnsignal
light
1 2 V 5 W

BodySpecifications
Unit:mm {in.)
1.555{61.6)
1,i140
(56.71
2-14

I
t
. 4
Maintenance
Lubricants
andFluids
Maintenance
Schedule
for Normal
Conditions
Listedby Distance/Time
Maintenance
Schedule
for Severe
Gonditions
Maintenance
Schedule
Listed
by Maintenance
ltemfor Normal
Conditions ...................
3-8
Listedby Maintenance
ltemfor Severe
Conditions ...................3-9

Lubricants
andFluids
Fordetailsof lubricationpointsandtype of lubricants
to be applied,referto the illustratedindexandvariouswork
ures{such
asAssem overhaul.
lnstallation.
etc.)
contained
in eachsection.
NO. LUBBICATION
POINTS LUBBICANT
1 Engine HondaMotor Oil (P/N08798-9023).
The oil container
must disolavthe APICenification
sealshownbelow.
Makesureit says"ForGasoline
Engines."
SAE
Viscositv:Seechartbelow.
2 Transmission Honda
MTF*'(P/N
08798-9016)
3 Brakesvstem(includes
ABS line) HondaDOT3 BrakeFluid*'(P/N08798-9008)
4 Clutchline
5
6
Release
fork(manual
transmissionl
Throftlecableend (throttleIink)
SuperHighTempUreaGrease
{P/N08798-9002)
7
I
Shiftand selectcableends(manual
transmission)
Throttlecableend (dashboard
lower panelhole)
Silicone
grease
9
1 0
1 1
1 '
1 4
1 6
1 7
Brakeboosterclevis
CIutchboosterclevis
Shift leverpivot
Pedallinkage
Batteryterminals
Fuelfilldoor
Hoodhingesandhoodlatch
Hatchhinges
Doorhinoes,
uoDer
andlower
Multi-purpose
grease
1 8 Caliperpistonboot,caliperpinsand boots HondaCaliDer
Grease(P/N08C30-80234lvl)
1 9 Airconditioning
compressor Compressoroil:
SP-10
(P/N38897-P13-A01AH
or
38899-P'13-A01)
Forrefriqerant;
HFC'134
a (R-134
a)
I
Recommond6dEngineOil
Engine
oilviscosily
for ambenttemperalure
fanges
-30 -20 -10 0 t0 20
* 1 :
"2:
Always useHondaManualTransmission
Fluid(MTF).Usingmotor oii cancausestiffershiftingbecauseit does
not containthe Drooeradditives.
AlwaysuseHondaDOT3 BrakeFluid.Usinga non-Hondabrakefluid cancausecorrosionanddecrease
the lifeof
the system.
3-2

Maintenance
Schedule
for NormalConditions
Thistwo pagel/lanitenance
Schedule
outlines
theminimunrequired
maintenance.
Service
attheindicated
distance
ortime,whichever
comes
first.usethelvlaintenance
Schedule
forSevere
conditions
ifthevehicle
meets
anyofthequalifiers
intheSevere
Conditions
schedule
or ifthe
vehicle
isnormally
driven
in Canada.
Inspect
valveclearance.
(cold)
(see
page6-321r
Intake:
0.21-0.25mm (0.008 0.010
in.)Exhaust:
0.28 0.32mm (0.011 0.013
in.)
Replace
spark
plugs.UseIZFR6K'11
(NGK)
orSKJ20DR-M11
(DENSO).
1.0 1.1mm
! Do itemsin A,B,alqq.,
120,000
mi/ 192,000
km/6 years
I Replace
transmission
fluid.UseHonda
MTF(see
page13-3).
/ / Y vcdrs
120,000
mil 192,000
Beplace
coolant
(see
page106).Capacity:
5.00 (5.3USqt).UseHonda
AllSeason
Antifreeze/Coolant
Type2.
According
to state
andlederal
regulations,
tailure
to dothemaintenance
itemsmarked
withanasterisk
{*)willnotvoidthecustomer's
emissions
warranties,
However,
Honda
recommends
thatallmaintenance
services
bedoneattherecommended
interval
to ensure
long-term
reliability.
I
3-4

Dotheitemsin partsA,B,C,D,andEasrequired
formileage/time
interval
listed.
A
Replace
engine
oillseepage8-5i. Capacity
withoutlilterchange:
4.0S(4.2USqt,3.5lmpqt)
Rotate
tires.
Follow
thepattern
shownintheOwner's
Manual Checktire
information
andcondition.
B
Replace
engine
oilfilterlseepage8-6). Capacity
withfilterchange:
4.20
(4.4USqt,3.7lmpqt)
Inspect
frontandrearbrakes
(see
page193i.
. Check
padsanddjscs
forwear(thickness),
damage,
andcracks.
' Check
calipers
tordamage,
leaks,
andtjghtness
ot mountbolts.
Check
parking
brake
adjustment.
ShouldbeIullyapplied
within7 to I clicks.
Inspect
tie rodends,
steering
gearbox,
andboots{seepage175).
. Check
rack
grease
andsteering
linkage.
. Check
bootsfordamage
andleaking
grease
. Chack
fluidline{ordamage
andleaks.
lnspectsuspension
components.
. Chock
boltsfor tightness.
. Check
condition
of balliointboots
lor deterioration
anddamage.
Inspect
driveshaftboots.Checkbootsfor cracksandbootbandsfor tightness(seepage16-3).
Insp€ct
brake
hoses
andlines{including
ABS). Checkthe
mastercylinder,
proponioning
control
valve,
andABSmodulator{or
damage
andleakage.
Check
allfluidlevels
andcondition
ottluids;
check
forleaks.
lf necessary,
addMTFlseepage13'3),
engioe
coolant,
brake
fluid,and
L
windshield
washer
fluid.
lnspectexhaust
system*.
Check
catalytic
converter
heatshield,
exhaust
pipeandmufflerfordamage,leaks,
andtightness
{soepage9,8).
lnspect
{uellinesandconnections*.
Check
for loose
connections,
cracks
anddeterioration;
retighten
loose
connoctions
andreplace
damaged
parts(s€epage11146).
InsDect
andadiust
drivebelt.
. Lookforcracks
anddamage,
andinspect
autotensioner
(needs
noadjustment).
Replace
thedustandpollen
lilter(see
page2139).
. Replacethe
dustandpollen
filterwhenever
airflowlromtheheating
andcooling
system
islessthan
normal.
Replace
aircleaner
element
every30,000
miles(48,000
km)(independent
of time).
l
D
E
i I Replace
brake
fluidevery3 years(independent
oI mileage).
According
to state
andfederal
regulations,
failure
to dothemaintenance
itemsmarked
withasterisk(
* ) willnotvoidcustomer's
emissions
warranties.
However,
Honda
recommends
thatallmaintsnance
service
interval
to ensure
longtermreliability.
Y
3-5

Maintenance
Schedule
for SevereConditions
Service
attheindicated
distance
ortime,whichever
comes
first.Usethisschedule
ifthevehicle
isdrivenMAINLY
inCanada
or inanyof the
tollowing
conditions;
il onlyOCCASIONALLY
driven
inthese
conditions,
usetheNormal
Conditions
schedule
(seepage3-4).
SevereDrivingConditions
. Driving
less
than5 miles{8km)pertripor,infreezing
temperatures,
drivingless
than10miles(16km)pertrip
. Driving
inextremely
hot(over
90"F/32"C)
conditions
. Extensive
idl;ng
or longperiods
of stopandgodriving,
suchasa taxior a commercial
delivery
vehicle.
. Trailer
towing,driving
witha car-top
carrier,
ordrivinginmountainous
conditions.
. Driving
onmuddy,
dusty,
or de'iced
roads
Replacetransmissionfluid.Use HondaMTF {seepage 13 3).
Inspect
valveclearance.
(cold)
(seepage6 32):lntake:
0.21 0.25mm (0.008 0.010
in.)Exhaust:
0.28 0.32mm (0.011 0.013
in.)
Replace
sparkplugs.Use
IZFR6K
11(NGK)or SKJ20DR'M
11{DENSO)
km/ 6 years
Replace
transmissionfluid. Use Honda MTF (seepage 13 3).
mil 192,000
km/10years,
thenevery60,000
mi/96,000
km/5 years
Replace
coolant(seepage10-6).
Capacity:
5.0015.3
USqt)UseHonda
AllSeason
Antifreeze/coo
lantType2.
3-6

L
A
I
Dotheitemsin parts
A, B,C,D,E,F,andG asrequired
for mileage/time
interval
listed.
Feplace
engine
oil(seepageS5). Capacity
withoutlilter
change:4.0
q (4.2USqt,3.5lmpqt)
Replace
engjne
oilfilter(seepageI 6). Capacity
withfilterchange:
4.2014.4
USqt,3.7lmpqt)
Insoect
frontandrearbrakes,
. Check
padsanddiscsforwearlthickness),
damage,
andcracks.
. Check
calipers
fordamage,
leaks,
andtightness
of mountbolts.
Lubricate
doorlocks,
latches
andhinges
withHonda
whitelithiumgrease.
Rotate
tires,ifthevehicle
hasbeendriven
thedistance
listed.
Follow
thepattern
shownintheOwner's
Manual-Check
tireinflaronaoo
condition,
Inspecttie
rodends,
steering
gearbox,
andboots(seepage17,5).
. Check
rackgrease
andsteering
linkage.
. Check
bootsfordamage
andleaking
grease.
. Checklluid
linefordamage
andleaks.
Inspect
suspensron
components
. Check
boltsfortightness.
. Check
condition
of balljointbootsfordeterioration
anddamage.
Inspect
driveshaft
boots.
Check
bootsforcracks
andbootbands
fortightness
(seepage16-3).
Check
parking
brake
adjustment.
Should
befullyapplied
within7 to 9 clicks.
Insp€ct
brake
hoses
andlioes.
(including
ABS). Check
themaster
cylinder,
proportioning
control
valve,
andABSmodulator
fordamage
andleakage
(seepage19-24).
Check
allfluidlevels
andcondition
otlluids;check
forleaks.
lf necessary,
addMTF(see
page133),engine
coolant,
brake
fluid,and
windshield
washer
fluid.
Inspect
exhaust
system*.
Check
catalytic
converter
heatshield,
exhaust
pipeandmuffler
fordamage,
leaks,
andtightness
(see
page9 8).
Inspect
fuellines
andconnections*.
Check
forlooseconnections,
cracks
anddeterioration;
retighten
loose
connections
andreplace
damaged
pans(seo
page11'146).
Check
alllights.
Checkfunction
otallinterior
andexterior
lights,
andtheposition
oftheheadlights
(seepage22-68).
Inspect
thev€hicle
underbody.
Check
thepaintfordamage,
scratches,
stonechippin0,
anddents.
L
D
E
F
H
InsDect
andadiustdrivebelt.
. Looktorcracks
anddamage,
andinspect
autotensioner
{needs
noadjustment).
Reolace
dustandoollen
filter.
Replace
aircleaner
element
every15,000
miles124,000
km)industvcondition
{independent
ol timeiotherwise
useNormal
Conditions
scredule
(seepage11-162).
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace
brake
fluidevery3 years(independent
oJmileagei.
Replacethe
dustandpollen
Iilterevery15,000
milesifvehicle
isdrivenmostlywhere
airhashighconcentration
olsootfromindustryand
dieselpowered
vehiclesj
alsoreplace
thedustandpollen
filteranytime
aarflow
isless
thanussal(seepags21-39).
Accordingto stateand federalregulations,
failureto do the maintenanceitems markedwith asterisk(*) will not void customer'semissions
warranties.However,Hondarecommendsthat all maintenanceservicesbe done at the recommendedintervalto ensurelong-termreliability,
3-7

Maintenance
Schedule
Service
attheindicated
distance
ortime,
whichever
comes
first.
milesx 1,000 t0 20 30 40 50 70 80 90 100 110 r20
km x 1,000 16 32 48 64 80 96 112 128 144 160 192
months 12 24 3 48 60 12
Replace
engine
oil o o o o a o o a a o O a
Rotatetires
{Checktire intlationand conditionat leastonce per month)
Replace
engine
oilfilter o o a a a a
Inspect
frontandrearbrakes
Checkparkingbrakeadjustment
Visually
inspect
thefollowing
items:
. Tie-rod
ends,steering
gearbox
andboots
. Suspension
components
. Driveshaft
boots
. Brake
hoses
andlines(including
ABSi
. Allfluidlevels
andcondition
of{luids
. Exhaust
system*
. Fuellinesandconnections*
Inspect
andadjust
drivebelt a a a a
Replace
dustandpollen
filter
Reolace
transmission
fluid
Servicethefollowingitemsat the recommended
intervals
a
Replaceair cleanerelement Every
30,000
miles
(48,000
km)
Replace
sparkplugs Every
110,000
miles
(176,000
Lm)
Inspect
valveclearance Inspect
every
110,000
miles
{176,000
km),
otherwise
adiusl
only
ifnoisy.
Inspectidlespeed* Every
160.000
mres1256,000
km)
or8years
Replaceenginecoolant At120,000
miles
(192,000
km)
or10years,
then
every
60,000
miles
(96,000
km)
or5
Replace
brake
fluid Every
3years
ltem for NormalConditions
Follow
theNormalSchedule
ifthesevere
driving
conditions
specified
inthelMaintenance
Schedule
for Severe
Conditions
onthenextpagedo
notapply,
andif onlyOCCASIONALLY
drivenin severe
driving
conditions.
Follow
theSevere
Conditions
schedule
ifthevehicle
isdrivenMAINLY
in Canada.
* : According
to state
andlederal
regulations,
failure
to dothemaintenance
itemsmarked
withasterisk
(*)willnotvoidcustomer's
emissions
warranties.
However,
Honda
recommends
thatallmaintenance
service
interval
to ensure
long-term
reliability-
c
3-8

ltem for SevereConditions
Usethisschedule
ifthevehicle
isdrivenMAINLY
inCanada
or in anvof thefollowina
conditions.
NOTE:
itonlyOCCASIONALLY
driveninthese
conditions,
usetheNormal
Conditions
schedute.
SovereDrivingConditions
. Driving
less
than5 miles(8km)pertripor,inlreezing
temperatures,
drivingless
than
. Driving
inextremely
hotover90"F132
'C)conditions.
10miles(16km)pertrip.
. Extensive
idling,
or longperiods
ot stop-and-go-driving,
suchasataxiora commercial
delivery
vehicle.
. Trailer
towing,driving
withacartopcarrier,
or drivingin mountainous
conditions.
. Driving
onmuddy,
dusty,
orde icedroads.
Service
attheindicated
distance
ortime,
whichever
comes
first.
milesx 1,000 10 20 30 40 50 60 70 80 90 100 110 120
km x 1,000 16 48 64 80 96 112 128 144 160 176 192
months 12 24 36 48 60 72
Replace
engine
oil Replace
every
5,000
miies
18,000
km)or
6months
Rotate
tires
{Checktire
intlation
andcondition
atleastonce
permonthi
a o a a o a a o a a a o
Replaceengineoil fiher
Inspect
frontandrearbrakes
Lubricateall locks,hinges,and latches
Visually
inspect
thefollowing
items:
. Tierodends,
steering
gearbox
andboots
. Suspension
components
' Driveshaft
boots
Checlparking
braleadjuslment a a O a o a
Visually
inspect
thefollowing
items:
. Brake
hoses
andlines
{including
ABSi
. Allfluidlevels
andcondition
oflluids
. Exhaust
system*
. Fuellines
andconnections*
. Lights
andcontrols,
vehicle
underbody
Inspect
andadjust
drivebeh o a o a
Replacedust and pollenfilter"o't'
Replace
transmission
lluid a a
Service
the followingitemsatthe recommended
interuals
Replace
aircleaner
element Every
15,000
miies
(24,000
km)industy
conditions,
otheMise
usenormal
schedule.
Replace
spark
plugs Every
110,000
miles
(176,000
km)
Inspect
valveclearance Inspect
every
110,000
miles
(176,000
km),
otheMise
adiust
only
ifnoisy.
Inspectidlespeed' Every
160,000
miles
(256,000
km)or8
vears
Replace
engine
coolant At120,000
miles
(192,000
km)
of10years,lhen
every
60,000
miles
(96,000
km)or
5
Replace
brake
fluid Every
3years
* : Accordingto stateand federalregulations,
failureto do the maintenanceitems markedwith asterisk1*)will not void customer'semissions
warranties.However,Honda recommendsthat all maintenanceservicebe done at the recommendedintervalto ensurelong{erm reliabilitv.
NOTE1:Replacethe dust and pollenfilter at 15,000miles/24,000
km if the vehicleis driven mostly in urban areasthat havehigh concentrations
of soot in the air from industrvand diesel-Dowered
vehicles.
t ,
3-9

.
EngineElectrical
Engine
Electrical
SpecialTools
StartingSystem
Comoonent
Location
Index...............
Circuit
Diagram
Starter
Circu
it Troubleshooting
ClutchInterlock
SwitchTest
Starter
Solenoid
Test ..............
StarterPerformance
Test
Starter
Reolacement
...............
Starter
Overhaul
.......................
lgnitionSystem
Component
Location
Index...............
Circuit
Diagram
lgnition
TimingInspection
lgnition
CoilRemoval/1nsta11ation
.......................
Spark
PlugInspection
ChargingSystem
Component
Location
Index..................................
4-2O
Circuit
Diagram ...........................
4-21
Charging
Circuit
Troubleshooting
.......................
4-22
Drive
BeltInspection ...................
4-26
Drive
BeftReplacement ..............
4-26
Drive
BeftAuto-tensioner
Inspection
..................
4-27
Drive
Beft
Auto-tensioner
Replacement
..............
4-28
Alternator
Reolacement .............
4-29
Alternator
Overhaul................ ....4-30
CruiseControl
Component
Location
Index..................................
4-36
Circuit
Diagram ...........................
4-37
Symptom
Troubleshooting
Index .......................
4-38
Cruise
Control
UnitlnDut
Test .............................
4-40
MainSwitch
TesVReolacement
...........................
4-42
SeVResume/Cancel
SwitchTesVReplacement
.. 4-42
Cruise
Control
Actuator
Test ......4-43
Cruise
Control
Actuator/Cable
Replacement
......4-44
Actuator
Cable
Adjustment
..................................
4-45
Clutch
Pedal
Position
Switch
Test .......................
4-45
4-2
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-15
4-16
4-17
4-18
4-19
- +
ENGINE

EngineElectrical
SpecialTools
I
Number Tool Number Description otv
o
@
07746-0010400
07749-0010000
Attachment,52x 55 mm
Driver
1
1
C
4-2
( a

-
StartingSystem
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
CLUTCH INTERLOCK
SWITCH
Test,page4-6
STARTER
StanerCircuitTroubleshoot,ng,
page4 5
SolenoidTest,page4-7
Performance
Test,page4-8
Replacement,
page4-9
Overhaul,page4 '10
- l - -
a r ] ] ] l l
- i
I
- .
- _ -
r t _ . 1
_-- _. /
I t t i :
: - l t . i t i t -
! t : ! | -
- ! t
STARTER
CUTRELAY
Test,
page
22-51
r ' l
' l I
r , l ,
, . /
/
'....",r.v
:,...)
/'
t l
4-3

StartingSystem
CircuitDiagram
-
ilo.20lOA) :USA
motkl
No.2!l50A) :C.nid. model
UiIOEN
H@D
fUSE/REI.IY
BOX
UNDEiOASTI
FUST/ifLAY
80x
Y.
STHOT
inSTA8T
illl
cLuTot
[{Tr8LocK
swtlcH
4-4
a

StarterCircuitTroubleshooting
NOTE:
. Airtemperaturemust be between59'and 100'F(15'
and38'C)duringthis procedure.
. Afterthistest,or any subsequent
repair,resetthe
enginecontrolemodule(ECM)
to clearany diagnostlc
troublecodes(DTCS)
{seepage11-4).
. The batterymust be in goodconditionandfully
charged.
. lf you disconnect
the baftery,do the ECMidle learn
procedure
(seepage11-139).
Recommended
Procedure:
. Usea startersystemtester.
. Connectandoperatethe equipmentin accordance
with the manufacturer'sinstructions.
Alternate Procedure
1. Hookup the followingequipment:
. Ammeter,0 400A
. Voltmeter,0 20V (accurate
within 0.1volt)
. Tachometer,0 1200rpm
2. Removethe No. 17(15A)fusefrom the under-dash
fuse/relaybox.
With the clutchpedalpressed,
turn the ignition
switchto start(lll).
Did thestartercrank theenginenormally?
YES-The startingsystemis OK.I
NO-Go to step4.
3.
L
4-5
4. Checkthe batterycondition.Checkelectrical
connections
at the battery,the negativebaftery
cableto body,the enginegroundcablesandthe
starterfor looseness
andcorrosion.Thentry
startingthe engineagain.
Did the statter crank the engine?
YES Repairing
the looseconnectionfixedthe
problem.The startingsystemis now OK.!
NO lf starterwill
notcranktheengine
atall,goto
step5. lf it cranksthe engineerraticallyor too
slowly,go to step7. lf it won't disengage
from the
flywheelring gearwhen you releasethe key,check
for the followinguntilyou find the cause.
. Solenoidplungerand switchmalfunction
. Dirtydrivegearor damagedoverrunningclutch
5. Makesurethe transmissionis in neutral,then
disconnect
the startersubharness
1Pconnector(A)
from the enginewire harness
'lP
connector(B).
Connecta jumperwire from the batterypositive
terminalto the startersubharness
'l
Pconnector.
Did thestarter crank theengine?
YES-Go to step6.
NO Checkthe BLK,ANHT
wire betweenthe starter
subharness
1Pconnectorandthe starter.lf wire is
OK,removethe starter,and repairor replaceas
necessary.
(cont'd)

StartingSystem
StarterCircuitTroubleshooting
(cont'dl
6. Checkthe followingitemsin the orderlisteduntil
you find the opencircuit.
. Checkthe BLIVWHT
wire andconnectors
betweenthe under-dash
fuse/relaybox andthe
ignitionswitch,and betweenthe under-dash
fuse/relaybox andthe starter.
. Checkthe ignitionswitch{seepage22-53).
. Checkthe clutchinterlockswitchand connector.
. Checkthe startercut relay(seepage22-51).
. CheckLT GRNwire betweenthe startercut relayl
under-dash
fuse/relaybox andthe clutch
interlockswitch.
. Checkthe BLKwire betweenthe clutchinterlock
switchand G501.
7, Checkthe crankingvoltageand currentdraw.
ls ctanking voltagegreatet thanor equalto 8.7 V
and current draw lessthanor equalto 230 A?
YES-Go to step8.
NO Replace
the starter.or removeand
disassemble
it,and checktheseitemsuntilyou find
thecause.
. Starterarmaturedragging
. Shortedarmature winding
. Excessive
dragin engine
8. Check
theengine
speedwhilecranking
theengine.
ls the engine speed above 100tpm?
YES Goto step9.
NO-Replace the starter,or removeand
disassemble
it,and checkfor the following until
youfindthecause.
. Excessively
worn starterbrushes
. Opencircuitin commutatorbrushes
. Opencircuitin starterarmaturecommutator
segments
. Dirtyor damaged
helical
splines
or drivegear
. Faultydrive gearclutch
9. Removethe starter,and inspectits drivegearand
the flywheelringgearfor damage.Replace
any
damaged
pans.I
4-6
ClutchInterlockSwitchTest
1. Disconnect
theclutch
interlock
switch
2Pconnector.
2. Removethe clutchinterlockswitch(A).
Checkfor continuitybetweenthe terminals
accordingto the table.
. lf the continuityis not asspecified,replacethe
clutchinterlockswitch.
. lf OK,installclutchinterlockswitchandadjust
the pedalheight(seepage12-4l..
Terminal
Cl","f ri"t.tf ."tS""*Jrl
2
PRESSED o-- - --o
RELEASED

et
StarterSolenoidTest
1. Disconnect
theS andlvlconnectors
fromthestarter
solenoid.
2. Checkthe hold-incoilfor continuitybetweenthe S
terminalandthe armaturehousing(ground).There
shouldbe continuity.
. lf thereis continuity,goto step3.
. lf there is no continuity,replacethe solenoid,
3. Checkthe pull-incoilfor continuitybetwee
n the S
terminal
andM terminal.
Thereshouldbe
continuity,
. lf thereis continuity,the solenoidis OK.
. lf thereis no continuity,replacethe solenoid,
4-7

StartingSystem
StarterPerformance
Test
1 , Disconnect
the wires from the S terminalandthe M
termrnal.
Makea connectionas describedbelow usingas
heavya wire as possible(preterably
equivalentto
the wire usedfor the vehicle).
To avoiddamaging
the starter,neverleavethe batteryconnected
for
more than 10seconds,
Connectthe batteryas shown.Besureto
disconnect
the startermotor wire from the solenoid.
lf the starterpinionmovesout, it is working
propefly.
Disconnect
the batteryfrom the M terminal.lf the
piniondoesnot retract,the hold-incoil of the
solenoidis working properly.
4-8
L
5. Disconnect
the batteryfrom the starterbody.lfthe
pinionretractsimmediately,it is working properly.
Clampthe starterfirmly in a vise.
Connect
the starterto the batteryas describedin
the diagrambelow,and confirmthatthe motor
startsand keepsrotating.
6.
7 .
lf the eiectriccurrentand motor speedmeetthe
specifications
when the batteryvoltageis at 11.5V,
the staneris working properly,
Specifications:
1.1kw 90 A or less(Electric
current),
ot more

StarterReplacement
1. Makesureyou havethe anti-theft
codefor the radio.
thenwrite down the frequencies
for the radio's
presetbuttons.
2. Disconnect
the negativecablefrom the batteryfirst,
then disconnect
the positivecable.
3. Disconnect
the knocksensorconnector.
4. Removethe bolt(A)securingthe harnessbracket,
then removethe intakemanifoldbracket(B).
A
6 x 1 , 0 m m
12N.m {1.2kgf.m,
8.7tbt.ft)
8 x 1.25
mm
22N,m12.2
kgt.m,
16rbf.ftl
L 't2.
4-9
5. Disconnect
the startercable(A)from the B terminal
on the solenoid,then disconnect
the BLK,/WHT
wire
{B)fromtheSterminal.
10x 1.25
mm
44N.m{a.5
kgf.m,33lblft)
8 x 1.25mm
9 N m
10.9
kgf.m,7 lbl ft)
7 .
9.
'10.
1 1 .
2
S'-12x12smm
6 i l N m
{6.5kgl m,47lbfft)
Removethe two boltsholdingthe starter,then
removethe starter.
lnstallthe starterin the reverseorderof removal.
Makesurethe crimpedsideof the ringterminal(A)
is facingout.
Connectthe positivecableand negativecableto
the batterY.
Startthe engineto makesurethe starteroperates
propeny.
Enterthe anti-theftcodefor the radio,then enter
the customer'sradiostationpresets.
Setthe clock.
Performthe enginecontrolmodule(EcM)idlelearn
procedure(seepage1
'1-
139).
I

StartingSystem
StarterOverhaul
Disassembly/Reassembly
f
@
@
,--
----_2<-
; ,/ 1(-
rw.h
:!@a- @-A
q -zhsc6
b-.- ,"
OVERRUNNING
CLUTCHASSEMBLY
G SOLENOID
LEVER
o*"lu*.
V*rN*
#. A*@
c^)* -#""Jli[X:""
S#o
7:-o
a<-4t^ fr/ / ffiA
-v
9:-/ ffitr
,.. D lW
ENDCOVER t/
'!4/
STARTERSOLENOID
4-10
BRUSHHOLDER
r

?.-
Armature Inspection and Test
1. Removethe starter(seepage4-9).
2. Disassemble
thestarter
asshownatthe beginning
of this procedure.
3. Inspectthe armaturefor wear or damagefrom
contactwith the permanentmagnet.lf thereis wear
or damage,replacethe armature.
Checkthe commutator(A)surface.lf the surfaceis
dirty or burnt,resurface
with emeryclothor a lathe
within the specifications
in step5, or recondition
with # 500or # 600sandpaper(B).
6.
5. Checkthe commutatordiameter.lf the diameteris
belowthe servicelimit,replacethe armature.
Commutator Diameter
Standard(Newl:28.0mm (1.10in.l
ServiceLimit: 27.0mm (1.06in.)
Measurethe commutator(A)runout.
. lf the commutatorrunoutis within the service
limit,checkthe commutatorfor carbondustor
brasschipsbetweenthe segments.
. lf the commutatorrunoutis not within the service
limit,reolacethe armature.
Commutator Runout
StandardlNew):0.02mm 10.001
in.)max.
ServiceLimit: 0.05mm (0.002
in.)
(cont'd)
4-11

StartingSystem
StarterOverhaul(cont'dl
7. Checkthe micadepth(A).lf the micais too high {B),
undercutthe micawith a hacksawbladeto the
properdepth.Cutawayallthe mica(C)between
the commutatorsegments.
The undercutshould
not betoo shallow,too narrow,or V-shaped(D).
Commutator Mica Depth
Standard(New):0.50-0.80 mm {0.020-0.031in.)
Checkfor continuitybetweenthe segmentsof the
commutator.lf an opencircuitexistsbetweenany
segments,replacethe armature.
M
4-12

9. Placethe armature(A)on an armaturetester(B).
Holda hacksawblade(C)on the armaturecore.lf
the bladeis attracted
to the coreor vibrateswhile
thecoreisturned,
thearmature
isshoned.Replace
thearmature.
Checkwith an ohmmeterthat no continuityexists
betweenthe commutator(A)and armaturecoll
core(B),and betweenthe commutatorand
armatureshaft(C).lf continuityexists,replacethe
armature.
10,

Starter Brush Inspection
11. lvleasure
the brushlength.lf it is notwithin the
servicelimit,replacethe brushholderassembly.
Brush Length
Standard{New):14.0-14.5 mm (0.55-0.57in.)
Service Limit: 9.0 mm {0.35in.)
Starter Field Winding Test
12. Checkfor continuitybetweenthe brushes(A).lf
thereis no continuity.replacethe armature
housing
(B).
Checkfor continuitybetweeneachbrush(A)and
the armaturehousing(B).li thereis continuity,
replacethe armaturehousing.
13.
Starter Brush Holder Test
14, Checkthatthereis no continuitybetweenthe (+ )
brushholder{A)and( ) brushholder(B}.lfthere
is continuity,replacethe brushholderassembly.
Brush Spring Inspection
15. Insenthe brush(A)intothe brushholder,and bring
the brushintocontactwith the commutator,then
attacha springscale(B)to the spring(C).Measure
the springtensionat the momentthe springliftsoff
the brush.lf the springtensionis notwithin
specification,
replacethe spring.
SpringTension: 13.7-17.7 N {1.40-1.80 kgf,
3.09 3.97lbf)
(cont'd)
4-13

StartingSystem
StarterOverhaul(cont'dl
PlanetaryGear Inspection
16. Check
the planetary
gears(A)andringgear{B).
Replace
them if they areworn or damaged.
OverrunningCluichInspection
17. Slidethe overrunningclutchalongthe shaft.
Replaceit if it doesnot slidesmoothly.
18. Rotatethe overrunningclutch(A)bothways.
Doesit lockin one directionand rotatesmoothlyin
reverse?
lf it doesnot lockin eitherdirectionor it
locksin both directions,replaceit.
lf the starterdrive gear(B)isworn or damaged,
replacethe overrunningclutchassembly;
the gear
is not availableseparately.
Checkthe conditionof the flywheelring gear.
Replaceit if the starterdrivegearteethare
oamageo.
19.
4-14
i.-
Starter Reassembly
20, Prybackeachbrushspringwith a screwdriver,
then
positionthe brushabouthalfwayout of its holder,
andrelease
thespringto holditthere.
NOTE:To seatthe new brushes.slipa stripof #5OO
or # 600sandpaper.
with the grit sideout,be&veen
the commutatorandeachbrush,and smoothly
rotatethe armature.The contactsurfaceof the
brusheswill be sandedto the samecontourasthe
commutator.
21 lnstallthe
armature
in thehousing,
andinstallthe
brushholder.Next,pry backeachbrushspring
again,
andpushthebrushdownuntilit seats
againstthe commutator,then release
the spring
againstthe end of the brush.
s
Installthe starterendcoverto retainthe brush
holder.

lgnitionSystem
SPARK
PLUG
Inspection,
page
4-'19 IGNITION
COIL
lgnition
Timing
Inspection,
page
4-17
Removal/lnstallation,
page
4-18
4-15

lgnitionSystem
Gircuit
Diagram
'No.20lOA)
:USAmo&l
No.A
l50A):Cmrda
model
(
UNDEB
HOOD
FUST/8TIAY
M)(
lG1tioT in0N{ll)
rd SIARIilll)
4-16

lgnitionTimingInspection
1 .
4.
5.
Connectthe HondaPGMTesterto the datalink
connector(DTC),
andcheckfor DTC'S.
lf a DTCis
present,diagnoseand repairthe causebefore
inspecting
theignition
timing.
Startthe engine.Holdthe engineat 3,000rpm with
no load (in Neutral)untilthe radiatorfan comeson,
then let it idle.
Check
the idlespeed(seepage11-138).
Followthe tester'spromptsin the "SCS" menu
{seethe testeroperator'smanual),
Connectthe timing lightto the serviceloop.
o
6. Pointthe lighttowardthe pointer(A)on the cam
chaincase.
Check
the ignition
timingunderno load
conditions:headlights,
blowerfan. rearwindow
defogger,and air conditionerare not operaling.lf
the ignitiontiming differsfrom the specification,
andthereare no enginecontrolmodule{ECM)DTcs,
replace
theECM(seepage11-4)
lgnitionTiming:
8"+2" BTDC{REDmark {B))duringidlingin neutral
A
7. Turnthe ignitionswitchOFF.
Disconnectthe
HondaPGMTester
andthetiming
light.
4-17

lgnitionSystem
lgnitionCoilRemoval/lnstallation
1. Removethe ignitioncoilcover(A),then removethe
ignition
coils(B).
6 x 1 . 0 m m
2. Installtheignitioncoilsin the reverseorderof
removal.
9.8N.m (1.0kgf.m,7.2lbfftl
4-18
---
a

SparkPlugInspection
1 . Inspectthe electrodes
andceramicinsulator.
Burned or worn electrodes may be causedby:
. Advancedignitiontiming
. Loosesparkplug
. Plugheatrangetoo hot
.Insufficientcooling
Fouledplug may be causedby:
. Retardedignitiontiming
. Oilin combustion
chamber
. Incorrect
sparkplug gap
. Plugheatrangetoo cold
. Excessive
idling/lowspeedrunning
. Clogged
aircleaner
element
. Deteriorated
ignitioncoils
Wornor deformed
electrodes
Do not adjustthe gap of iridiumtip plugs(A);
replacethe sparkplug if the gap is out of
specification.
ElectrodeGap:
Standard(New): 1.0 1.1mm
{0.039-0.0€ in.)
ServiceLimit: 1.3mm {0.051in.l
f .lmproper
gap
I J.Oil-touling
r- 1 . Cs6on deposits
' I . Cracked
center
electrode
insulator
L
3. Replace
the plugatthe specifiedinterval,or if the
centerelectrodeis rounded{A).UseonlVthe spark
plugslistedbelow.
SparkPlugs: lZFR6Kl1(NGK)
SKJ2ODR-M11
(DENSO)
Apply a smallquantityof anti-seize
compoundto
the plugthreads,and screwthe plugsintothe
cylinderheadfinger-tight.
Thentorquethem to
18N m (1.8kgf.m,13lbfft).
4.
4-19

Gharging
System
CHARGING
SYSTEM
INDICATOR
(lnthe gaugeassembly)
q * o
DRIVE
BELT
Inspection,
page4 26
Replacement,
page4 26
BATTERY
Test,
page22-50
ALTEBNATOR
Troubleshooting,
page4-22
Replacement,
page4-29
Overhaul,
page4-30
4-20

L
CircuitDiagram
'flo.
{l0Al :uSAhod.l
ilo.20l50Al:C.n.d.mod.l
UNDTR
XOOD
FUSI/RILAY
MX
+--,
Ifmlil*t"t'
T-
+ilt
= l
4-21

Gharging
System
Charging
CircuitTroubleshooting
lf the chargingsystemindicatordoesnot come on or
doesnot go off,or the batteryis deador low,testthese
itemsin the orderlistedbelow:
Battery(seepage22-50)
Chargingsystemindicator
Alternatorand regulatorcircuit
Alternatorcontrolsystem
Charging
SystemIndicator
Test
1. Turnthe ignition
switchON {ll).
Does the chatging system indicator come on?
YES Goto step2.
NO Goto step3.
2. Startthe engine.
Does the charging system indicator go off?
YES-Charging systemindicatorcircuitis OK.Go
to the Alternatorand Regulator
circuitTest.t
NO-Go to step3.
4. Troubleshoot
the multiplexcontrolsystem(see
page22 172).
ls the multiplex control system OK?
YES Goto step5.
NO Checkthe multiplexcontrolsystemas
indicatedby the diagnostic
troublecode (DTC)(see
step8 on page22-172).1
5. Disconnect
the enginewire harness6Pconnector
from the startersub harness6Pconnector.
4-22
" 4
6. Measurethe voltageat the No.3 terminalof the
engine
wireharness
6Pconnector
withthe ignition
switchON {ll).
ENGINE
WIREHARNESS
6PCONNECTOR
IBLK/YEL}
Wiresideoffemale
terminals
ls therebattery voltage?
YES-Go to step7.
NO-Checkfor a blownNo.4{10A)
fuseinthe
under-dash
fuse/relaybox.lf the fuseis OK,repair
openin the wire betweenthe alternatorandthe
under-dash
fuse/relaybox.I
Turnthe ignitionswitchOFF.
Disconnect
enginecontrolmodule(ECM)connector
B (24P).
Checkcontinuitybetweenthe ECMconnector
terminalB'10
andengine
wire harness
6Pconnector
terminalNo.6.
?
7 .
8.
9.
ACGL
{WHT/BLU)
ENGINE
WIBE
HARNESS
6P
L (WHT/BLUI
Wiresideof femaletermina
s
ls therecontinuity?
YES Goto step10.
NO-Repair open in the wire betweenthe
alternator
andthe ECN4.I
ECM CONNECTOB A (24P)

'10.
Checkcontinuitybetweenthe ECMconnector
terminal810andbodyground.
ECMCONNECTOR
S I24PI
2 3 t 4t 5 6 7
8 I 10,/1,/ 3 15
1 1 8 ,Nnt,/21 23
ACGL(WHT/BLUI
t1'
Wire sideol femaleterminals
ls there continuity?
YES- Repairshortto ground in the wire between
the ECMandthe enginewire harness6Pconnector.
t
NO-Go to alternatorand regulatortest.
AlternatorandRegulatorCircuitTest
1. Besurethe batteryis sufficientlychargedand in
goodcondition{seepage22-50),
andthe
connections
at the fusebox and alternatorare
cleanandtight.
2. Raisethe hoistto full height.
3. Hookup the ammeter,0 400A, to the starter
subharness.
Lowerthe hoist.
Hookup the voltmeter,0 20V (accurate
within
0 . 1 V ) , t o T 1 0 1 .
(cont'd)
4-23

GhargingSystem
Charging
CircuitTroubleshooting
(cont'd)
6. Startthe engine.Holdthe engineat 3,000rpm with
no load(in Neutral)untilthe radiatorfan comeson,
then let it idle.
7. Raisethe enginespeedto 2,000rpm, and hold it
there.
8. Turnthe headlights(highbeam)on, and measure
voltageat the under-hoodfuse/relayboxterminal.
ls the voltagebetween 13.9and 15.1v?
YES-Go to step9.
NO Repairor replacethe alternatorcomponents
(seepage4-30).1
9. Readthe amperageat
'13.5
V.
NOTE:Adjustthe voltageby turningthe blower
motor,rearwindow defogger,brakelights.etc.ON.
ls theamperage604 ot morc?
YES-Alternator/regulator
operationis OK.I
NO Repairor replacethe alternatorcomponents
(seepage4-30).1
4-24
,
AlternatorControlSystemTest
NOTE:Aftertroubleshooting,
performthe engine
controlmodule(ECM)idlelearnprocedure(seepage
1 1 - 1 3 9 ) .
1. Checkfor properoperationof the electricalload
detector(ELD)by checkingthe malfunction
indicator
lamp(MlL) (seepage1l-3).lf a DTCis
present,diagnoseand repairthe causebefore
continuingwith thistest.
2. Disconnect
the enginewire harness6Pconnector
from the startersub harness6Pconnector.
3. Startthe engine,andturn the headlights(high
beam)ON,
4. Measurevoltagebetweenthe enginewire harness
6PconnectorterminalNo.2 andthe positive
terminalof lhe battery.
C {WHT/GRN)
ENGINE
WIRE
HARNESS
6PCONNECTOR
Wiresideoffemale
terminals
ls there 1 V or less?
YES Goto step8.
NO-Go to step5.
Turntheheadlights
andignition
switchOFF.
Disconnect
ECMconnectorB (24P).
5 .
6.
BATTERY

L
7, Checkfor continuitybetweenECMconnector
terminal818andbodyground.
ECMCONNECTOR
B {24PI
1 2 3 t 4t 5 6 1
8 9 10,/1,/ 3 5
1 1 o nt,/21 23
ACGC
{WHT/GRN}
o
Wire sideot femaleterminals
9.
ls there continuity?
YES-Repair shortto ground in the wire between
the alternatorandthe ECM.I
NO-Check thatthe terminalsarefirmly seatedat
the ECMconnectorB.lf OK,substitutea known-
good ECM,and recheck(seepage11-6).
lf prescribed
voltageis now available.replacethe
original
ECM,I
Turnthe headlights
and ignitionswitchOFF.
Disconnect
ECMconnectorB (24P).
10. Checkfor continuitybetweenECMconnector
terminal818andengine
wire harness
6Pconnector
terminalNo.2.
ACGC
(WHT/GRN)
ECMCONNECTOR
B l2,lPI
1 2 3 1 4 l 5 l l l
6 7
8 9 10 t . ) 1 5
1 1 o n 21 23
o C(WHT/GRN)
2 3
5 6
ENGINE
WIREHARNESS
6PCONNECTOR
Wire sideoI lemaleterminals
ls therc continuity?
YES Repairor replacethe startersubharness
or
the alternator(seepage4-30).I
NO Repairopen in the wire betweenthe
alternator
andtheECM.I
4-25

Charging
System
DriveBeltInspection
Check
thattheauto-tensioner
indicator
(A)iswithinthe
standard
range
(B)asshown.
lf it isoutofthestandard
range,
replace
thedrivebelt(see
page4-26).
4-26
DriveBeltReplacement
1, Movethe auto-tensioner
(A)to relievetensionfrom
the drive belt(B).and removethe drive belt.
2. Installthenew beltin the reverseorderof removal.

DriveBeltAuto-tensioner
Inspection
1 . Checkwhetherthereis a changein the positionof
the auto-tensioner
indicatorbeforestartingthe
engineand afterstartingthe engine.lf thereis a
change
inthe position,
replace
theauto-tensioner.
3.
Check
for abnormal
noisefromthetensioner
pulley.
lf abnormal
noiseis heard,replace
thetensioner
pulley.
Removethe drive belt(seepage4-26).
lMove
the auto-tensioner
within its limit with the
belttensionrelease
tool in the directionshown.
Checkthatthetensionermovessmoothlyand
without anyabnormalnoise.lf the tensionerdoes
not move smoothlyor thereis abnormalnoise,
replacethe auto-tensioner.
7 .
8.
Removethe auto-tensioner
(seepage4-28).
Install
thetensioner
pulley.
Clampthe auto-tensioner
(A)by usingtwo 8 mm
bolts(B)and a vise (C)asshown.Do not clampthe
auto-tensioner
itself.
Setthe torquewrench(D)on the pulleybolt.
Alignthe indicator{E)on the tensionerbasewith
centermark(F)on thetensioner
arm by usingthe
torquewrench,and measurethe torque.lf the
torquevalueis out of specification,
replacethe
auto-tensioner,
NOTE;lf the indicatorexceeds
the centermark,
recheck
the torque.
Auto-tensioner spring torque:
26.5-36.3 N.m 12.7-3.7kg.m, 19.5-26.8lbt.ft)
9 .
4-27

Charging
System
DriveBeltAuto-tensioner
Replacement
1. Removethe drive belt(seepage4'26).
2. Remove
the idlerpulley.
6 x l . 0 m m
9.8N.m
(1,0kgl.m,
7.2 tbf.ft)
d
I
6 x 1 , 0 m m
12N.m
('1.2
kgt.m.8.7lbt.ft)
3. Removethe tensionerpulley.
x 1.25mm
22N.m
{2.2kgt m, 16lbf ft}
4-28
4. Removethe auto-tensioner,
8 x 1.25mm
22 N.m (2.2kgf.m,16lbt.ft)
5. lnstall in the reverse order of removal.
- a

l- AlternatorReplacement
codefor the radio,
for the radio's
presetbuttons,
2. Disconnect
thendisconnect
the positivecable.
3. Removethe front bumper(seepage20-85).
4. Removethe rightsideheadlight(seepage22-79).
5. Removethe reservetankfrom the bracket.
6. Removethe drive belt(seepage4-26).
7. Removethe threeboltssecuringthe alternator.
8 x 1.25mm
22 N.n 12.2kgl.m,
Disconnect
the alternatorconnector(A)and BLK
wire (B)from the alternator.
8 N.m
10.8
kgf.m,6lbf.ft)

6
'I
1.
9 .
1 0 .
13.
14.
Removethe alternator.
Installthealternatorand drive beltin the reverse
orderof removal.
Connectthe positivecableand negativecableto
the battery.
Enterthe anti-theft
codefor the radio,then enter
Setthe clock.
Performthe enginecontrolmodule{ECM)idle learn
procedure
(seepage11-139).
t t .
4-29

ChargingSystem
AlternatorOverhaul
ExplodedView
BEARING
PULLEY
LOCKNUT
-a
TERMINAL
INSULATOR
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
PULLEY
/
/
/@
W|UF.,
.oy."
-
/
REARBEARING /
,/ ./ FRoNr
B
@b.J.y{=RE+LN'"'
I
vVFko"-% /
qtr*njlv
V ( r ) ,
"V
BRUSH 11
BRUSH
HOLOER HOLDER -
TNSULATOR l
VOLTAGE }
-
REGULATOR (-
@*F,
-:
v_re*^i
gP^@'I
*ffilw9
ROTOR
4-30

L
SpecialTools Required
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
NOTE:Referto the ExplodedView as neededduring
this procedure.
1, Testthe alternatorand regulatorbeforeyou
remove them (seepage 4-22l,.
2. Removethe alternator(seepage4-29).
3. lf the front bearingneedsreplacing,removethe
pulleylocknutwith a 10mm wrench(A)anda
22 mm wrench(B).lf necessary,
usean impact
wrencn.
Removethe harnessbracket(A),insulator(B).three
flangenuts(C),andthe screw(D),then removethe
plateterminal(E).
, (( , t tI
; r _l L t
5. Remove
theendcover(A)anddustseal{B).
Removethe brushholder(A),voltageregulator(B),
andthe rubberseal{C}.
6.
L1i.21---^
tqLJ
B-"--|.
(cont'd)
1!q[-dr,:l
4-31

ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier
(A)andfour insulators
(B).
Removethe four flangenuts,then removethe rear
housing
(A)andwasher(B).
o
4-32
f.r,e
9. lfyouarenotreplacing
thefrontbearing
and/or
rearbearing,
goto step
'16.
Remove
therotorfrom
thestator
driveendhousing.
Inspectthe rotorshaftfor scoring,and inspectthe
bearingjournalsurfacein the statorhousingfor
setzure
marks.
. lf eithertherotororstatorhousing
isdamaged,
replacethe alternator,
. lf boththe rotorandthe statorhousingare OK,
go to step11.
'l
1. Remove
the rearbearing
usinga pullerasshown.
10.
"

-
12.Witha hammerandcommercially
available
tools
shown,installa new rearbearingon the rotorshaft.
NOTE:Installthebearingusingthe innerrace.
13. Removethe front bearingretainerplate.
s q
H E
6 e
u s
f-
r-:1
s---'^/
14. Supportthestatorhousingin a vise,and driveout
the front bearingwith a brassdrift and hammer.
15. Witha hammerandthespecialtools,
install
a new
front bearingin the statorhousing.
07749-0010000
07746-0010400
(cont'd
)
4-33

ChargingSystem
AlternatorOverhaul(cont'd)
RectitierTest
16. Checkfor continuityin eachdirection,betweenthe
Bterminaland Pterminals,and betweenthe E
terminal
andPterminals
of eachdiodepair.
All diodesshouldhavecontinuity
in onlyone
direction.Because
the rectifierdiodesaredesigned
to allow currentto passin one direction,andthe
rectifieris madeup of eightdiodes(fourpairs).you
musttesteachdiode in bothdirectionsfor
continuitywith an ohmmeterthat hasdiode
checkingcapability:
a total of 16checks.
. lf any diode is faulty.replacethe rectifier
assembly.{Diodesare not availableseparately.)
' lf allthe diodesareOK,go to step 17.
/--:',t- -L . --
- -o -- l'-=
B P "
P,
P.
P,
P.
4-34
1 9 .
r'a
Alternator Brush Inspection
17. Measure
the lengthof bothbrushes
(A)witha
vernier
caliper
{B).
. lf eitherbrushisshorterthanthe
service
limit,
replace
thebrushassembly.
. lf brushlengthis OK,go to step
'18.
Alternator Brush Length:
Standard(New):10.5mm (0.41in.)
RotorSlip BingTest
18. Checkthatthereis continuitybetweenthe slip rings
{A).
. lf thereis continuity,go to step19.
. lf thereis no continuity,replacethealternator.
Checkthatthere is no continuitybetweeneachslip
ring andthe rotor(B)andthe rotorshaft(C).
. lf thereis no continuity,goto step20.
. lf thereis continuity,replacethe alternator.
"

Stator Test
20. Checkthatthereis continuitybetweeneachpairof
leads(A).
lf thereis continuity,go to step21.
lf there is no continuity,replacethe alternator.
Checkfor no continuitybetweeneachleadandthe
coil core(B).
. lf thereis no continuity,goto step22.
. lfthere is continuity,replacethe alternator.
Assemblethe alternatorin reverseorderof
disassembly,
and notetheseitems:
. Becarefulnotto get any greaseor oil on lhe slip
nngs.
. lf you removedlhe pulley,tightenits locknutto
111N.m(11.3
kgfm,81.7lbf.ft)whenyou
install
it.
2 1 .
22.
'--l-- --i
4-35

GruiseControl
CLUTCH
PEDAL
POSITION
swtTcH
Test,
page
4-45
Clutch
Pedal
Adjustment,
page12-4
t.- _,- _
CRUISE
CONTROL
ACTUATOR
Test,
page
4'43
Replacement,
page4-44
CRUISE
CONTROL
UNIT
lnputTest,
page
4-40
BRAKE
PEDAL
POSITION
SWITCH
Test,page22-84
Pedal
Height
Adjustment,
page'19-6
CRUISE
CONTROL
INDICATOR
(Builtintogaug6assembly)
ACTUATORCABLE
Adjustment,page4-45
- l l
4-36
-a

CircuitDiagram
'
No.aloAl USAnod.l
No.20
itoAl C.md! modrl
UISEF NOOD
fUS'/iILAY IOX
-to ots BU/YIL
lcl H0Tii0llilll
mdSTARTlllll
1 Honilsffroi
CTuICII
PEDAL
P0sm0
swtrct
2 6 1 1 1 3
cnu6EcoNTnoL
uNtT l0
4-37

Cruise
Control
SymptomTroubleshooting
Index
NOTE:
' The numbersin the tableshowthetroubleshootingsequence.
. Beforetroubleshooting.
- checkthe No, 10(7.5A)and No. 4 (10A)fusesin the under-dash
fuse/relaybox.andthe No.7 (15A)fusein the
under-hoodfuse/relaybox,
- checkthatthe horn sounds.
- checkthe tachometerto seeif it works properly.
- checkthe speedometer
lo seeif it worksproperly.
Symptom Diagnostic procedure Also checkfor
Cruisecontrolcannotbe
set
1. Checkmain switch(seepage4-42)
2. CheckSET/RESUME/CANCEL
switch(seepage4-42)
3. Testbrakepedalpositionswitch(seepage22-84)andcheck
its adjustment{seepage19,6)
4. Testclutchpedalpositionswitch(seepage4-45)andcheck
its adjustment(seepage 12-41
5. Checkcruisecontrolunit{seepage4-40}
6. Checkvehiclespeedsensor(VSS)(seepage22-65)
. Poorground:
G501
. Opencircuit,
loose
or
disconnected
term
inals:
LTGRN,
BLI(ORN.
GRY/RED,
BLU.
LTBLU,
BLUAA/HT
Cruisecontrolcanbe set
but indicatorlightdoes
not go on
1. Check
cruise
controlindicator
bulbingauge
assembly
{see
page22-631
2. Check
cruise
controlunit(seepage4-40)
. Poorground:
G501
. Opencircuit,
looseor
disconnected
termrnats:
YEL,BLUA/EL
a r , ' i . a c ^ a a . l i c
noticeably
higheror
lowerthanwhat was set
1. Checkvehiclespeedsensor(VSS){seepage22-65)
Checkcruisecontrolactuator{seepage4-43)
2. Checkcruisecontrolunit (seepage4-40)
Excessive
overshooting
or undershooting
when
tryingto setspeed
1. Checkcruisecontrolactuator(seepage4-43)
Checkcruisecontrolunit (seepage4-40)
3.
Speedfluctuationon a
flat roadwith cruise
controlset
Checkcruisecontrolactuator(seepage4-43)
Vehicledoes not
decelerate
or accelerate
accordingly
when SET/
RESUME/CANCEL
button
is pushed
1. CheckSET/RESU
ME/CANCEL
switch(seepage4-42)
2. Checkcruisecontrolunit{seepage4-40)
Opencircuit,loose
or disconnected
terminals:
GRY/RED,
LTGRN/BLK
Setspeeddoesnot
cancel(enginerpm stays
high)whenclutchpedal
is pushed
1. Testclutchpedalpositionswitch(seepage4-45)andcheck
its adjustment(seepage12-4)
Shortto groundin
theLTBLUwire
Setspeeddoesnot
cancelwhen brakepedal
is pushed
'1.
Testbrakepedalpositionswitch(seepage22-84)andcheck
its adjustment(seepage19-6)
Opencircuit,loose
or disconnected
terminals:
WHT/BLK
4-38
g ,

svmptom Diagnosticprocedure Also checkfor
Setspeeddoesnot
cancelwhen main switch
is oushed
OFF
1. Checkmain switch(seepage4-42)
2. Checkcruisecontrolunit(seepage4-40)
Shortto power in
the LT GRNwire.
Setspeeddoesnot
cancel
whenCANCEL
buttonis pushed
1. CheckSET/RESU
ME/CANCEL
switch(seepage4-42)
Open
circuit,
loose
or disconnected
terminals:
GRYiRED,
LTGRN/BLK
Setspeedwill not
resume
whenRESUME
buttonis pushed(with
main switchon, and set
speedtemporarily
cancelledby pressingthe
brakeDedal)
1. CheckSET/RESU
ME/CANCEL
switch(seepage4-42)
2. Checkcruisecontrolunit{seepage4-40)
Opencircuit,loose
or disconnected
terminals:
LTGRN/BLK
4-39

Cruise
Gontrol
CruiseControlUnit InputTest
SRScomponentsare locatedin this area.ReviewtheSRScomponentlocations(seepage23-'13)
and precautions
and
procedures
(seepage23-14)in the SRSsectionbeforeperformingrepairsor service.
1. Disconnect
the 14Pconnectorfrom the controlunit.
2. Inspectthe connectorand socketterminalsto be surethey areall makinggood contact.
. lf the terminalsare bent,loose,orcorroded,repairthemas necessary,
and recheckthesystem.
. lf the terminalslookOK,go to step3.
Wiresideof
femaleterminals
3. With the 14Pconnectordisconnected,
maketheseinDuttests.
Cavity Wire Test condition Test:Desired
result Possiblecause
ifresuh
isnotobtained
BRN/WHT Connectbattery
power
Checkthe operationof the
magneticclutch:Clutch
shouldclickandoutputlink
shouldbe locked.
' Faultyactuator
. Poorground(G301)
. An open in the wire
. Shon to ground(arcswhen
Doweris connected)
2 BLU lgnitionswitchON
(ll),main swltchON
and brakepedal
pressed,
then
reteaseo
Checkfor voltageto ground;
Thereshouldbe 0 V with lhe
pedalpressedand battery
voltagewith the pedal
released.
. Faultybrakepedalposition
switch
. An openin thewire
. Openin cruisecontrolmain
swrtcn
. BlownNo.4 (10A)fusein the
under/dash
fuse/relavbox
3 BLK Underallconditions Checkfor continuityto
grouno:
Thereshouldbecontinuitv
. Poorground(G501)
. An openin the wire
BLIVORN lgnition
switchON
flr)
Checkfor voltageto ground:
Thereshouldbe battery
vottaqe.
BlownNo.4 (10A)fuseinthe
under-dash
fuse/relay
box
An oDenin the wire
5 WHT/BLK Brakepedalpressed,
then released
voltagewith the pedal
pressed,and 0 V with the
pedalreleased.
BlownNo.7 {15A) fuseinthe
under-hoodfuse/relaybox
Faultybrakepedalposition
SWIICN
An oDeninthewire
4-40

Cavity Wire Test condition Test:Desired
result Possible
cause
il result
isnotobtained
6 GRYiRED Setbuttonpushed Checkfor voltageto ground:
voltage,
Whentesting
terminalNo.6,
thereshouldbe no voltageon
terminalNo.7.
under-hoodfuse/relaybox
Faultyhorn relay
Faultysevresume/cancel
swrtch
Faultycablereel
An openin the wire
Shon to ground(hornsounds
when buttonis pressed)
7 LTGRN/
BLK
Resume
button
pusneo
voltage.
Whentesting
terminalNo.7,
thereshouldbe no voltageon
terminalNo.6.
BRN Connectbattery
powerto the BRN
terminalandground
to the BRNIVEL
termrnal
Checkthe operationof the
actuatormotor:You should
be ableto hearthe motor.
. Faultyactuator
. An openin the wire
1 1 BRNI/EL
1 0 BLUIVE
L lgnitionswitchON
0r)
Attachto groundi
Cruise
indicator
lightin the
gaugeassembly
shouldcome
on.
Blown No. 10(7.5A) fusein
the under-dash
fuse/relaybox
Blowncruiseindicatorbulfl
Faulty
gaugeassembly
An openin the wire
12 BLU/VVHT lgnitionswitchON
(ll)and main switch
ON; raisethe front of
the vehicle,and
rotateonewheel
slowlywhileholding
the otherwheel
Checkfor voltagebetween
thEBLU/VVHT
(+) ANdBLK
( )terminals:
T h e r e s h o u l d b e 05 V o r
more repeatedly.
Faulty
VSS
Anopeninthewire
Shortto ground
1 3 LTGRN lgnition
switchoN
{ll)andmainswitch
ON
Check
forvoltage
to ground:
There
shouldbebattery
voltage.
under-dash
fuse/relaybox
Faultymain switch
An oDenin the wire
1 4 LTBLU Clutchpedal
reteaseo
Checkfor continuityto
grouno:
Thereshouldbecontinuity.
NOTE:There
shouldbe no
continuitywhen the clutch
oedalis Dressed.
Faultyclutchpedalposition
swtlcn
Poorground(G501)
Incorrect
clutchswitch
adjustment
An open in the wire
lf anytestindicatesa problem,find and correctthe cause,then recheck
the system.lf all the inputtestsproveOK,
the cruisecontrolunit may be faulty.Substitutea known-goodcruisecontrolunitand retest.lf the systemworks
properly,replacethe cruisecontrolunit.
4-41

CruiseControl
1 .
MainSwitchTest/Replacement
Removethe driver'sdashboardlowercover(see
page20-59).
Release
the clipsof the main switchand pushthe
main switch1A)out of the panel,then disconnect
the 5Pconnector(B)from the main switch.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.lf the
continuityis not as specified,replaceillumination
bulbs(C)or the switch.
-------11v1
Position
1 4
OFF (9 @
ON o @ o J o
4-42
r--
Set/Resume/Cancel
SwitchTest/
Replacement
1. Removethe two screws.then removethe switch.
Checkfor continuitybetweentheterminalsin each
switchpositionaccordingto the table.
. lfthere is continuity,and it matchesthe table,but
switchfailureoccurredon the cruisecontrolunit
inputtest,checkand repairthe switchcircult.
. lf thereis no continuityin one or both positions,
replacethe switch.
Terminal
;"itl*
' 2
sET(ONt CF --o
RESUME
ION) o --o
CANCEL
{ON}
o

CruiseControlActuatorTest
1. Disconnect
the 4Pconnector(A)from the cruise
controlactuator(B).
Removethe cover(A),andcheckthe outputlinkage
(B)for smoothmovement.
2.
,to
5.
Connectbatterypowerto the No, 2 terminaland
groundto theNo.1 terminal.
Check
for a clicking
soundfromthe magnetic
clutch.
The outputlinkageshouldbe locked.
lf the outputlinkageis not locked,replacethe
cruisecontrolactuatorassembly,
6. Checkthe operationof the actuatormotor in each
outputlinkagepositionaccordingto the table.You
shouldbe ableto hearthe motor.
Battery
power
Dolarities
Outputlinkageposition
FULt
CLOSE
MIDDLE
PO$TION
FUtL
OPEN
N o , 4
Terminal
No.3
Terminal
The
motor
runs.
The
motor
runs.
The
motor
stoDs,
N o . 3
Terminal
No.4
Terminal
The
motor
sIoos.
The
motor
runs.
The
motor
runs.
1 . lf the actuatormotor doesnot operateasspecified,
replacethe cruisecontrolactuatorassembly,
OUTPUTLINKAGE
FULLCLOSE
4-43

Cruise
Control
CruiseControlActuator/Cable
Replacement
1 . Fullyopenthe cruisecontrollinkby hand,then
removethe cruisecontrolcable{A)from link.
Loosenthe locknut(B),and removethe cablefrom
the bracket.
Disconnect
the 4Pconnector,and removethe three
boltssecuringthe cruisecontrolactuator.
2.
6 x 1 , 0 m m
12N.m (1.2kgf.m,8.7lbf.ft)
4-44
rla
3. Removethe actuatorcover(A),then removethe
actuatorcable(B)from the cruisecontrolactuator.
Installin the reverseorderof removal,and adjust
the free playat the throttlelinkageafterconnecting
the actuatorcable.
4.

ActuatorCableAdiustment
1. Checkthatthe actuatorcable{A)movessmoothly
with no bindingor sticking.
2. Startthe engine.
3. Measurethe amountof movementof the output
linkage(B)untilthe enginespeedstartsto increase.
At first,the outputlinkageshouldbe locatedat the
fully closedposition(C).Thefree play (D)shouldbe
3.7510.5mm (0.1510.02
in,).
4. lf the free play is notwithin specs,loosenthe
locknut(E).andturn the adjustingnut (F)untilthe
free playis asspecified,
then retightenthe locknut
ClutchPedalPositionSwitchTest
1. Disconnect
the 2Pconnectorfrom the clutchpedal
positionswitch(A),
CLUTCH
PEOAL
POSITION
SWITCH
2PCONNECTOR
Terminalside
of
maleterminals
Removethe clutchpedalpositionswitch.
Checkfor continuitybetweenthe terminals
accordingto the table.
. lf the continuityis not asspecified,replacethe
clutchpedalpositionswitch.
. lf OK,installtheclutch pedalpositionswitchand
adjustthe pedalheight(seepage12-4).
Terminal
Cl"t"h P"d"l I
PositionSwitch
1 2
PRESSED
RELEASED o o
4-45

Engine
Assembly
I
Engine
Removal
FrontsubframeadapterEOS02C00001
1
NOTE:
. Usefendercoversto avoiddamagingpainted
surfaces.
. To avoiddamage,unplugthe wiring connectors
carefullywhile holdingthe connectorportion.
. Markall wiring and hosesto avoidmisconnection.
Also,be surethatthey do not contactotherwiring or
hoses,or interferewith otherparts.
1. Securethe hoodin the wide openposition(support
rod in the lowerhole).
codefor the radio,
for the radio's
presetbuttons.
3. Disconnect
then disconnect
the positivecable.
4. Removethe battery.
5. Removethe intakemanifoldcover.
II
5-2
,
6. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),removethe breatherhose(B)and
vacuumhose(C),
thenremove
theaircleaner
housingcover/intake
air ductassemblv(D).
A C
7. Removethe air cleanerhousing.

8. Removethe intakeair duct.
9. Removethe batterycables{A)fromthe under-hood
fuse/relaybox.then removethe harnessclamp(B)
andgroundcable(C).
10. Fullvooenthe throttlelinkandcruisecontrollink
by hand,then removethe throttlecable(A)and
cruisecontrol
cable(B)fromthelinks.Loosen
the
locknuts{C),and removethe cablesfrom the
bracket.
11. Relievefuel
pressure
(seepage11-144).
1 2 .R e m o v e
t h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) .
13. Removethe evaporative
emission(EVAP)
canister
hose{A)and brakeboostervacuumhose(B).
(cont'd)
5-3

Engine
Assembly
EngineRemoval(cont'dl
14. Remove
theclutchslavecylinder
{A)andclutchline
bracketmountingbolt (B).
15. Removethe shiftcable(A)and selectcable(B).
5-4
..4,
16. Disconnect
the enginecontrolmodule(ECM)
connectors(A)and mainwire harnessconnector
(B).
Removethe harnessclamps(A)and grommet(B),
thenpulltheengine
wireharness
throughthe
bulkhead.
't7.
l,

18.
19.
Removethe drivebelt(seepage4-26).
Remove
thelvC linemountingbolt.
20. Removethe radiatorcap.
21. Raise
thehoistto full height.
22. Removethe fronttires/wheels.
23. Removethe splashshield.
o@
24. Loosen
thedrainplugin theradiatorto
drainthe
enginecoolant(seepage10-6).
25. Drainthetransmission
fluid(seepage13'3).
26. Drainthe engineoil {seepage8-5).
27. Disconnect
thestabilizer
links(seepage18-18).
28. Disconnect
the suspension
lowerarm balljoints
(seestep3 on page18-19).
29. Removethe driveshafts
{seepage16-3).
Coatall
precision
finished
surfaces
withcleanengine
oil.
Tie plasticbagsoverthe driveshaftends.
30. Disconnect
the airfuel ratio{4,/F)
sensorconnector
(A)and secondaryheatedoxygensensor
(secondary
HO2S)connector(B),then removethe
threeway catalyticconverter{TWC)assembly{C).
31. Remove
thelowerhose.
(cont'd)
5-5

Engine
Assembly
Engine
Removal
(cont'd)
32. Lower
thehoist.
33. Remove
theupperhose(A)andheater
hoses
(B).
34. Bemovethe radiator(seepage10-10).
35. Attachthe chainhoistto the engineasshown.
5-6
36. Remove
thetransmission
mountbracket
support
boltandnuts.
37. Remove
theupperbracket
mounting
boltandnut.
(.g
a

39.
Makesurethe hoistbrackets
are positioned
properly.Raisethe hoistto full height.
Removethe rearmount mountingbolts.
40. Remove
thefrontmountbracket
mountinq
bolt.
41. Attach
thesubframe
adapterto
frontofthe
subframe,
thentighten
theknurled
knob.
Raisethejack.Lineup the slotsin the armswith the
bolt holeson the cornerof the jackbase,then
attachthe adaDter
to the iackbasewith the bolts.
(cont'd)
5-7

Engine
Assembly
Engine
Removal
(cont'd)
43. Usea markerto makealignmentmarkson the
referencelines(A)that alignwith the centersof the
rearsubframe
mountingbolts(B).
, !:_- _l.=
:r -- ---.-','-
-
44. Removethe front subframe(C).
5-8
ffi4
ffit'"
45. Disconnect
the compressorclutchconnector(A),
then removethe Ay'C
compressor(B)without
disconnecting
theA'./C
hoses.
Checkthatthe engine/transmission
is completely
free of vacuumhoses,fuel andcoolanthoses,and
electrical
wiring.
Slowlylowertheengine
about150mm (6in.).
Check
onceagainthatallhosesandwiresare
disconnected
trom the engine/transmission.
Lowerthe engineallthe way. Removethe chain
hoistfrom the engine.
Removethe enginefrom underthe vehicle.
46.
4 7 .
48.
49.

Engine
lnstallation
FrontsubframeadapterEOS02C00001
1
1. lnstalltheaccessory
brackets,
andtightentheir boltsand nutsto the specifiedtorques.
10x 1.25mm
il4 N.m {4.5kgf.m,33lbl.ft)
A/CCOMPRESSOR
BRACKET
10x 1,25mm
44N.m {4.5kgf.m,33lbt.ft)
(cont'dl
ENGINE
MOUNTBRACKET
5-9

Engine
Assembly
Engine
Installation
(cont'd)
Positionlhe engineunderthe vehicle.Attachthe
chainhoistto the engine,then lift the engineinto
position
inthevehicle.
Reinstallthe
mountingbolts/support
nutsin
the sequencegiven.Failureto follow this
sequencemay causeexcessive
noiseand
vibration,and reducebushinglife.
3. Installthe A,/C
compressor(A),andconnectthe
compressorclutchconnector{B).
8 x 1.25
mm
22N.m12.2
kgf m.16lbf.ft)
4. Supportthe subframewith the subframeadapter
anda jack.
6r"
6-_-'-
5-10
- --.'.:
- --=---=-- .-€..'tt-
---:- -
5. Install
thesubframe
(A).
Alignthereference
marks
(B)onthesubframe
withthecenter
ofthebolt
heads,
thentighten
thebolts.
1 4 x 1 . 5m m
1 0 3 N m
{10,5
kgf m.
76 rbt.ftl
Replace.
6. Tightenthe rearmount mountingbolts.
l0x 1.25mm
59 N.m (6.0kgf.m, 4:]lbI.ft)
F
I

7. Looselytightenthe front mount bracketmounting
bolt.
Lowerthe hoist.
Tightenthe upperbracketmountingbolt and nut.
8.
9 .
10. Tightenthe transmissionmount bracketsupport
boltand nuts.
12x 1.25
mm
54N m {5.5kgtm,40lbf.ft}
Raisethe hoistto full height.
Tightenthe front enginemount bracketmounting
bolt.
'l'1.
't2.
12x 1.25rnrn
64N.m{6.5
kgf.m,
47tbt.ftl
13. Lowerthe hoist.
14. Remove
thechainhoistfromtheengine.
'15.
Installthe
radiator
(seepage10-10).
'16.
Raise
the hoistto fullheight.
17. Installa new setringon the end of eachdriveshaft,
then installthe driveshafts.
Makesureeachring
"clicks" into placeinthe differentialand
intermediate
shaft.
(cont'd)
:l
5-11

Engine
Assembly
1 8 .
EngineInstallation{cont'dl
10x 1.25
mm
33N.m{3.i1kgf.m,
25tbt.ftl
1 9 .
20.
Connectthe suspension
lowerarm balljoints(see
step6 on page18-19).
Connectthe stabilizer
links(seepage18-18).
Installthe threeway catalyticconverter(TWC)
assembly(A);usenew gaskets(B)and new self-
lockingnuts{C).

D
21.
- d
,ry
6
8x 1.25
mm
22N.m|.2.2kgl
m,
16tbt.ft)
Connect
the air fuel ratio(4,/F)
sensorconnector(D)
andsecondaryheatedoxygensensor(secondary
HO2S)connector(E).
Installthe lower radiatorhose.
5-12
v a
23. Installthe
splash
shield.
24.
25.
26.
Lower
thehoist.
Installthe
drive
belt.
Installthe
A,/C
linemounting
bolt.
6 x '!.0mm
9.8N.m (1.0kgf.m,
7.2 tbt.ftl
.
-t- -- - -- --r

27. lnstalltheupperradiatorhose{A)and heaterhoses
(B).
Push
theengine
control
module
(ECM)
connectors
through
thebulkhead,
theninstallthe
grommet
(A).
29. Installthe
harness
clamps(B).
30. Connectthe ECI4
connectors(A)and mainwire
harnessconnector(B).
Installthe throttlecable(seepage11-164),
then
adjustthe
cable{seepage11-'163).
Installthecruisecontrolcable(seepage4-44),
then
adjustthe cable(seepage4-45),
Installthe brakeboostervacuumhose(A)andthe
evaporative
emission(EVAP)
canisterhose(B).
34. Installthe
fuelline(seepage11-150).
3 1 .
32.
33.
(cont'd)
5-13

Engine
Assembly
Engine
Installation
{cont'dl
Installthe selectcable(A)andshiftcable(B)using
the plasticwashers(C),washers(D),and new cotter
pins(E).
6 x 1 . 0 m m
9.8N.m(1.0
kgf.m,
7.2tbl.ftl
Install
theclutchslavecylinder
(A)andclutchline
bracketmountingbolt (B).
6 x 1 . 0 m m
9.8N.m
{1.0kgf.m,
7.2 tbt.ft)
"-.----->)
"------'6
8 x '1.25
mm
24 N.m (2.4kgl.m,
5-14
37. Installthebatterycables(A)on the under-hood
fuse/relaybox,then installthe harnessclamp(B).
Installthe
groundcable(C).
Installthe
intake
airduct.
6 x 1 . 0 m m
1 2 N m { 1 . 2 k g f . m ,
8.7tbf.ft)
39.
"
-
a
6 x 1 . 0 m m
1 2 N m { 1 . 2 k g t . m ,
8.7rbf.ft)

40. Install
the aircleaner
housinq.
6 x 1 . 0 m m
12N m (1.2kgf.m,8.7lbt.ft)
Install
theaircleaner
housing
cover(A)and
connectthe intakeairtemperature(lAT)sensor
connector(B),
42. Installthe
breather
hose(C)andvacuumhose1D).
41.
43. Installthe
intake
manifold
cover.
6 x 1 . 0 m m
1 2 N m 1 1 . 2 k g f . m .
8.7tbf.ft)
Installthebattery.Cleanthe batterypostsand
cableterminals
withsandpaper,
thenassemble
them and applygreaseto preventcorrosion.
Checkthatthe transmissionshiftsintogear
smoothly.
Inspectfor fuel leaks.
Turnthe ignitionswitchON
(ll){do not operatethe starter)sothat the fuel pump
runsfor about2 secondsand pressurizes
the fuel
line.Repeat
this operationtwo or threetimes,then
checkfor fuel leakageat any point in the fuel line.
Refillthe
engine
withengineoil (seepage8-5).
Refill
thetransmission
withfluid(seepage13-3).
Refillthe radiatorwith enginecoolant,and bleed
airfrom the coolingsystemwith the heatervalve
open(seepage10-6).
Perform
theengine
controlmodule(ECM)
idlelearn
procedure
(seepage11-139).
Inspectthe idlespeed(seepage11-138).
Inspect
the ignition
timing(seepage4-17).
Check
thewheelalignment
{seepage18-4).
Enterthe anti-theft
codefor the radio,then enter
Setthe clock.
Y
E
44.
41.
]tE
46.
48.
49.
52.
53.
54.
50.
5 1 .
55.
5-15

EngineMechanical
Cylinder
Head
Special
Tools
Comoonent
Location
Index
Engine
Compression
Inspection
VTEC
Rocker
ArmTest ........... ............
6-7
VTCActuator
Inspection ....................
6-8
Valve
Clearance
Adjustment .............
6-9
Crankshaft
Pulley
Removal
andInstallation
..............
6-11
CamChain
Removal ...........................
6-12
CamChain
Installation .......................
6-15
Auto-Tensioner
Removal/1nsta11ation
.........................
6-19
Chain
Case
OilSealInstallation ........
6-21
Cyf
inderHead
Cover
Removal ..........
6-22
Cylinder
Head
Removal .....................
6-23
WC Actuator.
Exhaust
Camshaft
Sorocket
Repf
acement .........6-24
Cylinder
Head
Inspection
forWarpage......................
6-25
Rocker
ArmAssembly
Removal.................................
6-26
Rocker
ArmsandShafts
Disassembly/Reassembly ..............
6-27
Rocker
ArmsandShafts
Inspection
............................
6-28
Camshaft
Inspection ..........................
6-29
Valves,
Springs,
andValve
Seals
Removal................
6-31
Valve
Insoection
...................... ...........
6-32
Valve
Stem-to-Guide
Clearance
Insoection
...............
6-32
Valve
Guide
Reolacement .................
6-33
Valve
SeatReconditioning ................
6-35
Valves,
Springs,
andValve
Seals
Installation
............
6-37
Rocker
ArmAssemblv
Installation ....6-38
Cvlinder
Head
Installation
...........................................
6-39
Cylinder
Head
Cover
Installation ......6-41
6-2
6-3
b-t'

Cylinder
Head
a
SpecialTools
I
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OD
Ref.No. Tool Number Description Oty
O OTAAJ.PNAA'IOO
.D OTHAH-PJ7O1OB
o Ioz..rae-oot
ozoa
@ 07JAB-0010204
o 07NAB-0010404
G) 07VAE-001010A
OTZAJ.PNAAlOO
E] OTZAJ-PNAA2OO
O I 07ZAJ-PNAA300
tro 07742-0010100
@ 07746-001o4oo
(D 07749-0010000
Air Pressure
Regulator
ValveGuideReamer,
5.5mm
Socket,19mm
HolderHandle
HolderAttachment,50 mm
ValveSpringCompressor
Attachment
VTECAir Adapter
VTECAlr Stopper
Air Joint Adapter
ValveGuideDriver,5.5
mm
Attachment,52x 55 mm
Driver
1
1
1
1
1
1
2
1
1
6-2

Component
Location
lndex
TENSIONER
ARM
AUTO.TENSIONER
Replacement,
page6-'lI
IGNITION
COIL
COVER
CYLINDER
HEAD
COVER
Removal,
page
6-22
lnstallation,
page
6-41
CAM CHAIN
Bemoval,page6-'12
Installation,
page6-15
frn
|]tJ
,
"p
CAMCHAINGUIDEB
CAMCHAINGUIDEA
VARIABLE
VALVE
TIMING
CONTROL
twc) olLsoLENotD
VALVE
CRANKSHAFT
PULLEY
Replacement,
page6 11
O-RING
(cont'd)
6-3

Cylinder
Head
ComponentLocationIndex(cont'd)
CAMSHAFTPOSITION
ICMP}SENSOR
TOPDEADCENTER
(TDC)
SENSOR
CAMSHAFT
HOLDER
f
fr
T
F]
F
g
Y
R
LI
CAMCHAIN
GUIDE
B
/
EEI
g-----
-"-oowetew
EXHAUSTCAMSHAFT
SPROCKET
Removal,
page6 24
Installation,
page6-25
EXHAUSTCAMSHAFT
ROCKER
ARM
ASSEMBLY
Overhaul,
page6 27
Inspection,
page6-28
6-4

SPRING
RETAINER
EXHAUST
VALVE
SEAL
vALvE / .""or", uo.u,
.
ll"
l* I / uo.ur.r","o
--€.i
d:l.
aFl
T1
l l
l l
H
,p
2bw
9)
*""'RArNERcovER

wcsrRArNER
CYLINDER
HEAD
Removal,page6'23
Inspection,
page6-25
Installation,
page6-39
EXHAUSTVALVE
Removal,
page6-31
Installation,
page6-37
INTAKEVALVE
Removal,page6 31
Installation,
page6 37
CYLINDER
HEAD
GASKET
,H v .-- spntruc
>il( G-r_
l g
| | g -/ TNTAKE
vALVE
II ^-'-- 9E4L
I I U- Replacement,
Page
6-31
H e ,
tl E- _-/ |NTAKE
VALVE
Y I 1.- GUIDE
U Replacement,
page
6-33
i
HEATSHIELD
6-5

Cylinder
Head
EngineCompression
Inspection
1. Warmuptheengine
to normaloperating
temperature(coolingfan comeson).
3. Removethe intakemanifoldcover(seestep 1 on
page6-22).
4, Disconnect
all four injectorconnectors.
5. Startthe engine,and let it run until it stalls.
6. Remove
theiour ignition
coils(seepage4-18).
7. Removethe four sparkplugs.
8. Attachthe compressiongaugeto the sparkplug
note.
6-6
V ,

9.
10.
Openthe throttlefully,then crankthe enginewith
the startermotor and measurethe compression.
Compression Pressure
Above 930 kpa (9.5kgf/cm', 135psi)
Measurethe compressionon the remaining
cylinders,
Maximumvadation
Within 200 kPa (2.0kgf/cm', 28 psi)
lf the compressionis notwithin specifications,
checktheseitems,then remeasure
the
compressron.
. Damagedorworn valvesand seats
. Damagedcylinderheadgasket
. Damagedor worn pistonrings
. Damagedorworn pistonandcylinderbore
1 1 .
-

WECRocker
ArmsTest
. Air pressureregulator07AAJ-PNAA100
. VTECair adaoter07ZAJ-PNAA100
. WEC air stoDoer
07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300
1. Removethe cylinderheadcover(seepage6-22).
2. Setthe No. 1 pistonat top deadcenter(TDC)
(see
step1 on page6-12).
3. Verifythatthe intakeprimaryrockerarm (A)moves
independently
of the intakesecondaryrockerarm
(B).
. lf the intakeprimaryrockerarmdoesnot move,
removethe primaryandsecondaryrockerarms
asan assemblyandcheckthatthe pistonsin the
secondaryand primaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primaryand secondaryrockerarms
asan assemblv,andtest.
. lfthe intakeprimaryrockerarm movesfreely,go
to step 4.
6.
Repeatstep3 on the remainingintakeprimary
rockerarmswith eachpistonat TDC.When allthe
primaryrockerarmspassthetest,go to step5.
Checkthatthe air pressureon the shopair
compressorgaugeindicatesover 400kPa
(4 kgflcm',57 psi).
Inspectthe valveclearance
(seepage6-9).
Removethe sealingbolt(A)from the reliefhole,
and installthe VTECair stopper(B).
7 .
OTAAJ.PNAAlOO
D
OTZAJ-PNAA3OO
Removethe No.2 and No.3 camshaftholderbolts,
and installtheVTECair adapters(C)finger-tight.
Connectthe air joint adapter(D),and air pressure
regulatorwith a 0-100psi gauge(E).
(cont'd)
OTZAJ.PNAAlOO
6-7

CylinderHead
WEC RockerArmsTest(cont'dl
'10.
Loosenthe valveon the regulator,and applythe
specifiedair pressure.
Specified air pressure:
290 kPa 13.0kgt/cm', 42 psi)
NOTE:lf the synchronizing
pistondoesnot move
afterapplyingair pressure;
movethe primaryor
secondaryrockerarm up and down manuallyby
rotatingthe crankshaft
clockwise.
11.Withthespecified
airpressure
applied,
movethe
intake
primaryrocker
arm (A)fortheNo,1cylinder.
The primaryrockerarm and secondaryrockerarm
(B)shouldmovetogether.
lf the intakesecondaryrockerarm doesnot move,
removethe primaryand secondaryrockerarms as
an assembly,and checkthatthe pistonsin the
primaryand secondaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primaryand secondaryrockerarms as
an assembly,andtest.
Removethe specialtools.
Tightenthe camshaftholdermountingboltslo
22N m 12.2
kgf.m,16lbf.ft).
Tighten
thesealing
boltto20 N.m(2.0kgf.m,
14tbf.ft).
Installthe
cylinder
headcover(seepage6-41).
12.
13.
1 4 .
t 5 .
6-8
VTGActuatorInspection
'11.
Removethe cylinderheadcover(seepage6-22lr.
2. Removethe auto-tensioner
(seepage6-19).
3. Loosenthe rockerarm adjustingscrewslseestep2
on page6-26).
4. Removethe camshaftholder(seestep3 on page6-
26t.
5. Removethe intakecamshaft.
6, Checkthat the variablevalvetiming control(VTC)
actuatoris lockedby turningthe VTCactuator
clockwiseandcounterclockwise.
lf the VTCactuator
is not locked,replacethe VTCactuator.
7. Sealtheadvance
holes(A)andretardholes(B)in
the No. 1 camshaftjournalwith tape.
Puncha holethroughthe tapeoverone of the
advanceholes.

9. Apply airto the advanceholeto release
the lock.
Checkthat the VTCactuatormovessmoothly.lf the
VTCactuatordoesnot move smoothly,replacethe
VTCacluator.
10.
ValveGlearance
Adiustment
NOTE:Adjustthe valvesonly when the cylinderhead
temperatureis lessthan 100'F(38'C).
1. Removethe cylinderheadcover(seepage6-22).
2. Setthe No. 1 pistonat top deadcenter(TDC).
The
punchmark(A)on the variablevalvetiming control
(VTC)actuatorandthe punchmark (B)on the
exhaustcamshaftsprocketshouldbe at the top.
Align the TDCmarks(C)on the VTCactuatorand
exhaustcamshaftsprocket.
{cont'd)
6-9

GylinderHead
I
ValveClearance
Adjustment(cont'd)
3. Select
thecorrect
thickness
feelergauge
forthe
valves
you'regoingto check.
Intake: 0.21 0.25mm (0.008-0.010
in.)
Exhaust;0.28 0.32mm (0.011 0.013
in.)
Adiustingscrewlocations:
No. 1
EXHAUST
No.2 No.3 No.4
No. 1 N o . 4
4. Insertthe feelergauge{A)betweenthe adjusting
screw(B)andtheendofthe valvestem,andslideit
backandforth;you shouldfeela slightamountof
drag.
6-10
.
5. lf youfeeltoomuchortoolittledrag,loosenthe
locknut(A),andturn the adjustingscrew{B)until
the dragon the feelergaugeis correct..
Tightenthe locknut,and recheck
the clearance.
Repeatthe adjustmentif necessary
Rotatethe crankshaft180"clockwise(camshaft
pulleyturns90').
7 .
t .
-
8. Checkand,if necessary,
adjustthe valveclearance
on No.3 cylinder.

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