2000-08 Honda S2000 SM

INTRODUCTION
- How to Use This Manual

General Information
T h i s m a n u a l is d i v i d e d into m u l t i p l e s e c t i o n s . T h e first p a g e o f
e a c h section is m a r k e d w i t h a b l a c k t a b t h a t lines u p w i t h its
corresponding t h u m b index t a b o n this page a n dt h e back cover. Specifications
Y o u can quickly find t h e first page o f each section w i t h o u t
looking t h r o u g h a full table of contents. T h e s y m b o l s printed at
the t o p corner of each page can also be used as a quick
reference.
Each section includes: Maintenance
1. A table o f c o n t e n t s , o r a n e x p l o d e d v i e w i n d e x s h o w i n g :
• Parts d i s a s s e m b l y s e q u e n c e .
• Bolt t o r q u e s a n d t h r e a d sizes. r \
i „f. ;
• Page references t o descriptions in text.
2. Disassembly/assembly procedures a n d tools.
*Engine Electrical
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Engine Mechanical r , o o o o iTj •
"11
Safety Messages
Y o u r safety, a n d t h e s a f e t y o f o t h e r s , is v e r y i m p o r t a n t . T o h e l p Engine Cooling - 7VCY •
y o u make informed decisions w e have provided safety
messages a n d other safety information t h r o u g h o u t this manual.
O f c o u r s e , it is n o t p r a c t i c a l o r p o s s i b l e t o w a r n y o u a b o u t all t h e
hazards associated with servicing this vehicle. Y o u m u s t use
your o w ngood judgment. Fuel and Emissions :.><. ^ $
Y o u will find i m p o r t a n t safety i n f o r m a t i o n in a variety of f o r m s
including:
• S a f e t y Labels — o n t h e v e h i c l e .
• Safety Messages — p r e c e d e d b y a s a f e t y a l e r t s y m b o l
one of three signal w o r d s , DANGER, W A R N I N G , or CAUTION.
and
*Transaxle
These signal w o r d s m e a n :
'ANGER Y o u W I L L b e K I L L E D o r S E R I O U S L Y H U R T if
^ ^ M P
_ y c u don't follow instructions.
Y o u C A N b e K I L L E D o r S E R I O U S L Y H U R T if
^Steering
you don't follow instructions.
A S AUTION Y o u C A N b e H U R T if y o u d o n ' t f o l l o w
instructions.
Instructions — h o w t o s e r v i c e t h i s v e h i c l e c o r r e c t l y a n d safely.
A l l i n f o r m a t i o n c o n t a i n e d in t h i s m a n u a l is b a s e d o n t h e l a t e s t
product information available at t h e t i m e of printing. W e reserve
t h e right t o m a k e c h a n g e s at a n y t i m e w i t h o u t notice. N o part o f
Brakes
this publication m a y be r e p r o d u c e d , stored in a retrieval s y s t e m ,
or transmitted, in a n y f o r m b y a n y m e a n s , electronic,
(Including VSA)
mechanical, photocopying, recording, or otherwise, without the
prior written permission of the publisher. This includes text,
figures, a n d tables. Body
A s y o u r e a d t h i s m a n u a l , y o u w i l l f i n d i n f o r m a t i o n t h a t is
p r e c e d e d b y a [ NOTICE | s y m b o l . T h e p u r p o s e o f t h i s m e s s a g e i s
to help prevent damage to your vehicle, other property, or the Heating, Ventilation, U
environment.
and Air Conditioning 1 J
F i r s t E d i t i o n 9 / 2 0 0 7 1,968 p a g e s MONDA M O T O R C O . , L T D .
All Rights Reserved
Specifications apply to U S A and Canada
S e r v i c e Publication Office
*Body Electrical
0?
A s s e c t i o n s w i t h * include S R S c o m p o n e n t s ;
special precautions are required w h e n servicing.
^Restraints
2000-08 S-2000
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS)
T h e S2000 SRS Includes a d r i v e r ' s a i r b a g in t h e steering w h e e l h u b , a passenger's airbag in the d a s h b o a r d a b o v e t h e

g l o v e b o x , a n d s e a t b e l t t e n s i o n e r s i n t h e s e a t b e l t r e t r a c t o r s . I n f o r m a t i o n n e c e s s a r y t o s a f e l y s e r v i c e t h e S R S is
included in this Service M a n u a l . Items m a r k e d w i t h an asterisk ( * ) o n the contents page include or are located near
SRS c o m p o n e n t s . Servicing, disassembling, or replacing these items requires special precautions and tools, and
s h o u l d be d o n e b y a n a u t h o r i z e d H o n d a d e a l e r .
• T o a v o i d r e n d e r i n g t h e SRS i n o p e r a t i v e , w h i c h c o u l d lead t o p e r s o n a l i n j u r y o r d e a t h in t h e e v e n t of a s e v e r e f r o n t a l
collision, all SRS service w o r k s h o u l d be d o n e b y an authorized H o n d a dealer.
• I m p r o p e r service procedures, i n c l u d i n g incorrect r e m o v a l a n d installation of t h e SRS, c o u l d lead to personal injury
caused b y unintentional activation of the airbags a n d seat belt tensioners.
• D o n o t b u m p o r i m p a c t t h e S R S u n i t , o r f r o n t i m p a c t s e n s o r s w h e n t h e i g n i t i o n s w i t c h is O N (II), o r f o r a t l e a s t 3
m i n u t e s a f t e r t h e i g n i t i o n s w i t c h is t u r n e d O F F ; o t h e r w i s e , t h e s y s t e m m a y f a i l i n a c o l l i s i o n , o r a i r b a g s m a y d e p l o y .
• SRS electrical c o n n e c t o r s are identified by y e l l o w c o l o r c o d i n g . Related c o m p o n e n t s are located in t h e steering
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e box. Do not use electrical
test e q u i p m e n t on these circuits. "° .
General Information
C h a s s i s and Paint C o d e s
'00 Model 1-2
'01 Model 1-3
'02 Model 1-4
'03 Model 1-5
'04 Model 1-6
'05 Model 1-7
'06 Model 1-8
'07 Model 1-9
'08 Model 1-10
Identification Number Locations 1-11
Danger/Warning/Caution Label Locations .... 1-12
Under-hood Emission Control Label 1-14
Lift and Support Points 1-18
Towing 1-19
Parts Marking 1-21
Service Precaution 1-22
Revised Component T e r m s 1-23

General Information
Chassis and Paint Codes
'00 Model Engine Number
Vehicle Identification Number

F20C1 - 1000001
J H M AP1 1 4 * Y T 000001
c d e 9 h a. Engine T y p e
F 2 0 C 1 : 2.0 L D O H C V T E C S e q u e n t i a l Multiport
a . M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e Fuel-injected engine
J H M : H o n d a M o t o r C o . , Ltd. b. S e r i a l N u m b e r
Honda passenger vehicle 1000001—: U S A models
b. L i n e , B o d y a n d E n g i n e T y p e 1100001—: C a n a d a models
AP1: S2000/F20C1
c. Body T y p e a n d T r a n s m i s s i o n T y p e Transmission Number
1: 2 - d o o r C o n v e r t i b l e / 6 - s p e e d M a n u a l
d. V e h i c l e G r a d e (Series)
4: S 2 0 0 0 SCYM - 1000001
e . C h e c k Digit
f. M o d e l Y e a r
Y:'00
g. F a c t o r y C o d e
T : T o c h i g i F a c t o r y in J a p a n
h. S e r i a l N u m b e r a. T r a n s m i s s i o n T y p e
0 0 0 0 0 1 - . U S A models S C Y M : 6-speed Manual
800001—: Canada models b. S e r i a l N u m b e r
Paint Code
Code Color
NH-547 Berlina Black
NH-565 G r a n d Prix W h i t e
NH-630M S i l v e r s t o n e Metallic
R-510 New Formula Red
COLOR LABEL
V e h i c l e Identification N u m b e r
and Federal Motor Vehicle
Safety S t a n d a r d Certification
Label.
and Canadian Motor Vehicle
Label.
1-2

F20C1 - 1010001
J H M AP1 1 4 * 1 T 000001
a b c d e f g h
a. Engine Type
F20C1: 2.0 L D O H C V T E C S e q u e n t i a l Multiport
Honda p a s s e n g e r vehicle 1010001 - : U S A m o d e l s
b. L i n e , B o d y a n d E n g i n e T y p e 1110001 —: C a n a d a m o d e l s
AP1: S2000/F20C1
c. B o d y T y p e a n d T r a n s m i s s i o n T y p e Transmission Number
d. V e h i c l e G r a d e ( S e r i e s )
4: S 2 0 0 0 SCYM - 1000001
e. C h e c k Digit
1: '01
000001 —: U S A m o d e l s S C Y M : 6-speed Manual
800001 —: C a n a d a m o d e l s b. S e r i a l N u m b e r
Paint Code
Code Color USA Canada

models models
B-66P Montecarlo Blue Pearl O
NH-547 Berlina Black O O
NH-565 G r a n d Prix W h i t e o
NH-630M S i l v e r s t o n e Metallic o o
R-510 New Formula Red o o
Y-52P S p a Y e l l o w Pearl o o
COLOR LABEL
Vehicle Identification N u m b e r
a n d Federal M o t o r Vehicle
Safety Standard Certification
Label,
a n d Canadian M o t o r Vehicle
Safety Standard Certification
Label.
1-3
General Information
Chassis and Paint Codes (cont'd)

F20C1 - 1020001
J H M AP1 1 4 * 2 T 000001
c d e 9 h a. Engine T y p e
Honda passenger vehicle 1020001 - : U S A m o d e l s
b. L i n e , B o d y a n d E n g i n e T y p e 1120001—: C a n a d a models
AP1: S2000/F20C1
c. Body T y p e a n d T r a n s m i s s i o n T y p e Transmission Number
d. Vehicle G r a d e (Series)
4: S 2 0 0 0 SCYM - 2000001
e. C h e c k Digit
2: ' 0 2
000001—: U S A models S C Y M : 6-speed Manual
Paint Code

models models
B-513M S u z u k a B l u e Metallic O O
NH-552M S e b r i n g S i l v e r Metallic o o
NH-565 G r a n d Prix W h i t e o o
Y-52P S p a Y e l l o w Pearl o
COLOR LABEL
Label.
Label.
1-4

F20C1 - 1040001
J H M AP1 1 4 * 3 T 000001
c d e 9 h Engine Type
M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e Fuel-injected engine
J H M : H o n d a M o t o r C o . , Ltd. Serial Number
Honda passenger vehicle 1040001 —: U S A m o d e l s
Line, Body and Engine Type 1130001—: C a n a d a models
AP1: S2000/F20C1
c. B o d y T y p e a n d T r a n s m i s s i o n T y p e Transmission Number
1: 2-door C o n v e r t i b l e / 6 - s p e e d M a n u a l
Vehicle G r a d e (Series)
4: S 2 0 0 0 SCYM -2000001
C h e c k Digit
Model Year
3: '03
Factory C o d e
Serial Number a. Transmission T y p e
000001 - : U S A m o d e l s S C Y M : 6-speed Manual
Paint Code

models models
B-513M S u z u k a B l u e Metallic O
NH-552M S e b r i n g S i l v e r Metallic o o
Y-52P S p a Y e l l o w Pearl o
NH-630M S i l v e r s t o n e Metallic o
COLOR LABEL
Label.
Label.
1-5
General Information

F22C1 - 1000001
JHMAP2 1 4 * 4 T 000001
a. Engine T y p e
c d e g h Fuel-injected engine
b. S e r i a l N u m b e r
a . M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e 1000001-: U S A m o d e l s p r o d u c e d in T o c h i g i
J H M : Honda Motor C o . , Ltd. Factory
Honda passenger vehicle 1100001—: C a n a d a m o d e l s p r o d u c e d in T o c h i g i
b. L i n e , B o d y a n d E n g i n e T y p e Factory
AP2: S2000/F22C1 1007001-: U S A m o d e l s p r o d u c e d in S u z u k a
c. Body T y p e and T r a n s m i s s i o n T y p e Factory
1: 2 - d o o r C o n v e r t i b l e / 6 - s p e e d M a n u a l 1101001-: C a n a d a m o d e l s p r o d u c e d in S u z u k a
Vehicle Grade (Series) Factory
4: S 2 0 0 0
C h e c k Digit Transmission Number
Model Year
4: ' 0 4
Factory Code SCYM -3000001
S : S u z u k a F a c t o r y in J a p a n
Serial Number
000001 —: U S A m o d e l s a. T r a n s m i s s i o n T y p e
800001 —: C a n a d a m o d e l s S C Y M : 6-speed Manual
b. S e r i a l N u m b e r
Paint Code

models models
B-513MY S u z u k a B l u e Metallic O
NH-552M S e b r i n g S i l v e r Metallic o O
o
Y-65P Rio Y e l l o w P e a r l o o
NH-630MX S i l v e r s t o n e Metallic
o
Tochigi model: Suzuka model:
Tochigi model
and Federal Motor Vehicle Safety
S t a n d a r d Certification L a b e l .
and Canadian Motor Vehicle Safety
S t a n d a r d Certification L a b e l .
COLOR LABEL COLOR LABEL
1-6

F22C1 - 1007001
JHMAP2 1 4 * 5 S 000001
i i t)
c d e g h
a. Engine T y p e
M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e Fuel-injected engine
Honda passenger vehicle 1 0 0 2 0 0 1 - -: U S A m o d e l s
Line, Body and Engine Type 1 1 1 0 0 0 1 - -: C a n a d a m o d e l s
AP2: S2000/F22C1
Body Type and Transmission Type Transmission Number
Vehicle G r a d e (Series)
4: S 2 0 0 0 SCYM - 3000001
C h e c k Digit
Model Year
5: ' 0 5
i1 t)
Factory Code
S : S u z u k a F a c t o r y in J a p a n
Serial Number a. T r a n s m i s s i o n T y p e
000001 - : U S A m o d e l s S C Y M : 6-speed Manual
800001—: Canada models b. S e r i a l N u m b e r
Paint Code

models models
o
Y-65P Rio Y e l l o w Pearl o o
NH-630M S i l v e r s t o n e Metallic
o o
COLOR LABEL
Label.
Label.
1-7
General Information

F22C1 - 1040001
JHMAP2 1 4 * 6 S 000001
a
Engine Type
a b c d e f g h
Fuel-injected engine
a . M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e b. S e r i a l N u m b e r
J H M : Honda Motor C o . , Ltd. 1040001 —: U S A m o d e l s
Honda passenger vehicle 1120001 —: C a n a d a m o d e l s
b. L i n e , B o d y a n d E n g i n e T y p e
AP2: S2000/F22C1 Transmission Number
c. B o d y T y p e a n d T r a n s m i s s i o n T y p e
d. V e h i c l e G r a d e ( S e r i e s ) SCYM - 4000001
4: S 2 0 0 0
e. C h e c k Digit
f. M o d e l Y e a r a D
6: '06
g. F a c t o r y C o d e a. T r a n s m i s s i o n T y p e
S : S u z u k a F a c t o r y in J a p a n S C Y M : 6-speed Manual
h. S e r i a l N u m b e r b. S e r i a l N u m b e r
000001 —: U S A m o d e l s
800001—: Canada models Paint Code

models models
B-545P B e r m u d a Blue Pearl
o
NH-547 Berlina Black o O
NH-565 G r a n d Prix W h i t e
o o
NH-676M M o o n R o c k Metallic o
R-510 New Formula Red o
Y-65P Rio Y e l l o w P e a r l o o
COLOR LABEL
Label.
Label.
1-8

F22C1 - 1050001
JHM AP2 1 4 * 7 S 000001

a
a. Engine T y p e
c d e 9 h F 2 2 C 1 : 2.2 L D O H C V T E C S e q u e n t i a l Multiport
M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e b. S e r i a l N u m b e r
J H M : H o n d a Motor C o . , Ltd. 1050001—: U S A m o d e l s
Honda passenger vehicle 1130001—: C a n a d a m o d e l s
Line, Body and Engine Type
Body Type and Transmission Type
Vehicle Grade (Series) SCYM - 4000001
4: S 2 0 0 0
C h e c k Digit
Model Year a D
7:'07
Factory Code a. Transmission T y p e
S : S u z u k a F a c t o r y in J a p a n S C Y M : 6-speed Manual
Serial Number b. S e r i a l N u m b e r
000001 - : U S A m o d e l s
800001—: Canada models Paint Code

models models
B-545P B e r m u d a Blue Pearl O
NH-552M S e b r i n g S i l v e r Metallic O
R-510 New Formula Red o
Y-65P Rio Y e l l o w Pearl o
YR-536P N e w I m o l a O r a n g e Pearl o
COLOR LABEL
Label.
Label.
1-9
General Information

F22C1 - 1060001
JHM AP2 1 2 * 8 S 000001

a
a. Engine T y p e
c d e 9 h F 2 2 C 1 : 2.2 L D O H C V T E C S e q u e n t i a l Multiport
a . M a n u f a c t u r e r , M a k e a n d T y p e of V e h i c l e b. S e r i a l N u m b e r
J H M : Honda Motor C o . , Ltd. 1060001—. U S A models
Honda passenger vehicle 1140001—. C a n a d a models
b. L i n e , B o d y a n d E n g i n e T y p e
c. B o d y T y p e a n d T r a n s m i s s i o n T y p e
d. Vehicle G r a d e (Series) SCYM - 5000001
2:CR
4: S 2 0 0 0
e. C h e c k Digit a D
8: '08 a. T r a n s m i s s i o n T y p e
g Factory Code S C Y M : 6-speed Manual
S : S u z u k a F a c t o r y in J a p a n b. S e r i a l N u m b e r
h. S e r i a l N u m b e r
000001 — U S A m o d e l s Paint Code
800001—: C a n a d a models
Code Color U S A models Canada
S2000 CR models
NH-547 Berlina Black O o O
NH-565 G r a n d Prix W h i t e o o O
NH-745M Chicane Silver o o
Metallic
B-554P A p e x B l u e Pearl o o
Y-65P Rio Y e l l o w Pearl o o o
B-545P L a g u n a B l u e Pearl o
COLOR LABEL
Label.
Label.
CR m o d e l i s s h o w n .
1-10
Identification Number Locations
Transmission Number
(located under transmission)
1-11
General Information
Danger/Warning/Caution Label Locations
Passenger's Compartment:
S R S INFORMATION
USA models
CABLE REEL CAUTION MODULE DANGER
1-12
STEERING
COLUMN NOTICE
AIR CONDITIONING
INFORMATION
General Information
Under-hood Emission Control Label
'mm Models
Emission Group Identification Test Group and Evaporative Family
Test Group:
Example:
VEHICLE EMISSION CONTROL INFORMATION z H N X V 02.0 DYC

THIS VEHICLE CONFORMS TO U.S. EPA NLEV
REGULATIONS APPLICABLE TO 2002 MODEL YEAR
NEW LEV PASSENGER CARS AND CALIFORNIA
REGULATIONS APPLICABLE TO 2002 MODEL YAER
NEW LEV PASSENGER CARS.
a b c d
CATALYST a
TWC/HOZSI2HAIR/SFI/OBO II CERTIFIED
VALVE LASH IN: 0. 23±0. 02 rr
(COLD) EX; 0. 27±0. 02 n a. Model Y e a r
SPARK PLUG GAP GAP: 1.0-1.1 mm
NO OTHER ADJUSTMENTS NEEDED. Y: '00
20VAGFFF 1: ' 0 1
2: ' 0 2
Honda Motor Co. , Ltd. PCX-A02
b. Manufacturer Subcode
HNX: HONDA
'00 M o d e l c. Family Type
THIS VEHICLE C O N F O R M S T O U.S. EPA N L E V V: L D V
REGULATIONS APPLICABLE TO 2000 MODEL YEAR d. - Displacement Group
N E W LEV P A S S E N G E R C A R S A N D C A L I F O R N I A e. Sequence Characters
REGULATIONS APPLICABLE T O 2000 MODEL YEAR
N E W LEV P A S S E N G E R C A R S .
Evaporative Family:
'01 M o d e l
THIS VEHICLE C O N F O R M S T O U.S. EPA N L E V 2 H N X R 0130 AAF
REGULATIONS APPLICABLE T O 2001 M O D E L YEAR
N E W LEV P A S S E N G E R C A R S A N D C A L I F O R N I A
REGULATIONS APPLICABLE T O 2001 MODEL YEAR
a b c d e
C A N A D I A N TSEFt 1 a. Model Y e a r
T H I S V E H I C L E C O N F O R M S T O C A N A D I A N TIER 1 Y : '00
S T A N D A R D S FOR 2 0 0 1 M O D E L Y E A R N E W 1: ' 0 1
PASSENGER CARS. 2: '02
b. M a n u f a c t u r e r S u b c o d e
'02 M o d e l HNX: HONDA
T H I S V E H I C L E C O N F O R M S T O U . S . E P A NLEV c. F a m i l y T y p e
R E G U L A T I O N S APPLICABLE T O 2002 M O D E L YEAR R: E V A P / O R V R
N E W LEV P A S S E N G E R C A R S A N D C A L I F O R N I A d. C a n i s t e r W o r k i n g C a p a c i t y G r o u p
REGULATIONS APPLICABLE TO 2002 M O D E L YEAR e. S e q u e n c e C h a r a c t e r s
1-14
m Model
Emission Group Identification - Test Group and Evaporative Family
Example: Test Group:
3 H N X V 02.0 RJC
VEHICLE EMISSION CONTROL I N F O R M A T I O N
THIS VEHICLE CONFORMS TO U.S. EPA NLEV
REGULATIONS APPLICABLE TO 2003 MODEL YEAR
MEW LEV PASSENGER CARS AND CALIFORNIA
REGULATIONS APPLICABLE TO 2003 MODEL VAER
NEW LEV PASSENGER CARS.
a b c d
3HNXV02. ORJC
CATALYST 3HNXR0130AAA
2.0L
TWC/H02S12I/AIR/SFI/0BD CERTIFIED
a . ModeS Y e a r
VALVE LASH IN: 0. 23±0. 02 mm
{COLD) EX: 0. 27±0. 02 mm 3: '03
NO OTHER ADJUSTMENTS NEEDED b. M a n u f a c t u r e r S u b c o d e
(H)
HNX: HONDA
c. F a m i l y T y p e
Honda Motor Co. , Ltd.PCX ao3 V: LDV
d. D i s p l a c e m e n t G r o u p
e. S e q u e n c e C h a r a c t e r s
THIS VEHICLE C O N F O R M S T O U.S. EPA NLEV
N E W LEV P A S S E N G E R C A R S A N D C A L I F O R N I A Evaporative Family:
N E W LEV P A S S E N G E R C A R S . 3 HNX R 0130 AAA
a b c d e
a. Model Y e a r
3:'03
HNX: HONDA
c. Family T y p e
R: E V A P / O R V R
d. C a n i s t e r Working C a p a c i t y G r o u p
General Information
Under-hood Emission Control Label (cont'd)
'04-05 Models
5 H N X V 02.2 DJE
VEHICLE EMISSION CONTROL INFORMATION
THIS VEHICLE CONFORMS TO U.S. EPA INTERIM
NON-TIER 2 BIN 9 REGULATIONS APPLICABLE TO
2004 MODEL YEAR NEW PASSENGER CARS AND
CALIFORNIA REGULATIONS APPLICABLE TO 2004
MODEL YAER NEW LEV I LEV PASSENGER CARS. a b c d e
4HNXV02. 2PJE
CATALYST 4HNXR0130AAA
2.2L
TWC, HQ2SI2), AIR, SFI OBD II CERTIFIED
a. Model Y e a r
mm
4: ' 0 4
NO OTHER ADJUSTMENTS NEEDED. 5:'05
(H) OJ1AG22F b. M a n u f a c t u r e r S u b c o d e
Honda Motor Co.

CEE> HNX: HONDA
Ltd. P Z X A 0
° c. Family T y p e
V: LDV
'04 Model e. S e q u e n c e C h a r a c t e r s
THIS VEHICLE C O N F O R M S T O U.S. EPA INTERIM P J E : '04 m o d e l
NON-TIER 2 BIN 9 R E G U L A T I O N S APPLICABLE T O DJE: '05 m o d e l
2004 MODEL YEAR N E W PASSENGER CARS A N D
M O D E L Y E A R N E W LEV I LEV P A S S E N G E R C A R S . Evaporative Family:
'05 Model 5 H N X R 0130 AAA

T H I S V E H I C L E C O N F O R M S T O U . S . EPA I N T E R I M
NON-TIER 2 BIN 9 R E G U L A T I O N S APPLICABLE T O
2005 MODEL YEAR N E W PASSENGER CARS A N D
a b C d
M O D E L Y E A R N E W L E V I LEV P A S S E N G E R C A R S .
a. Model Year
4: ' 0 4
5: ' 0 5
HNX: HONDA
R: E V A P / O R V R
d. C a n i s t e r Working Capacity G r o u p
1-16
'06-08 Models
'§6-07 Models
8 H N X V 02.2 AKC
VEHICLE E M I S S I O N CONTROL I N F O R M A T I O N
THIS VEHICLE CONFORMS TO U.S. EPA
TIER 2 BIN 5 REGULATIONS APPLICABLE TO
2006 MODEL YEAR NEW PASSENGER CARS AND
a b cd
MODEL YAER NEW LEV II LEV PASSENGER CARS.
CATALYST a. M o d e l Y e a r
TWC, A/F SENSOR, HQ2S, SFI OBD tl CERTIFIED
VALVE LASH
6: ' 0 6
EXHAUST EMISSIONS STANDARDS
(COLD!
7:'07
NO OTHER ADJUSTMENTS NEEDED 8: ' 0 8
( F T ) HNX: HONDA
HONDA MOTOR CO. , LTD.
V: LDV
'08 M o d e l
f VEHICLE EMISSION CONTROL INFORMATION! Evaporative Family:

CONFORMS TO REGULATIONS : 2008MY
U.S. EPA : T2B5 LDV OBD : CA OBD 11 FUEL : GASOLINE 3 HNX R 0102 B B A
ARB : LEV 11 LEV PC OBD : CA OBD 11 FUEL : GASOLINE
TWC, A/F SENSOR, H02S, SFI

a b Cd
8HNXV02. 2AKC
8HNXR0102BBA
HONDA MOTOR CO. , LTD. 2.2L a. Model Y e a r
6: ' 0 6
7: ' 0 7
8: ' 0 8
'06 M o d e l b. M a n u f a c t u r e r S u b c o d e
T H I S V E H I C L E C O N F O R M S T O U.S. E P A TIER 2 B I N 5 HNX: HONDA
REGULATIONS APPLICABLE TO 2006 M O D E L YEAR c. F a m i l y T y p e
N E W PASSENGER CARS A N D CALIFORNIA R: E V A P / O R V R
REGULATIONS APPLICABLE TO 2006 M O D E L YEAR d. C a n i s t e r W o r k i n g C a p a c i t y G r o u p
N E W LEV II LEV P A S S E N G E R C A R S . e. S e q u e n c e C h a r a c t e r s
BBB: '06 m o d e l
'07 M o d e l BBY: '07 m o d e l
T H I S V E H I C L E C O N F O R M S T O U.S. E P A TIER 2 B I N 5 BBA: '08 m o d e l
R E G U L A T I O N S APPLICABLE T O 2007 M O D E L YEAR
N E W PASSENGER CARS A N D CALIFORNIA
R E G U L A T I O N S APPLICABLE T O 2007 M O D E L YEAR
N E W LEV II LEV P A S S E N G E R C A R S .
General Information
Lift a n d S u p p o r t P o i n t s
N O T E : If y o u a r e g o i n g t o r e m o v e h e a v y c o m p o n e n t s Floor Jack
s u c h as s u s p e n s i o n o r t h e f u e l t a n k f r o m t h e rear o f t h e
v e h i c l e , f i r s t s u p p o r t t h e f r o n t o f t h e v e h i c l e w i t h tall 1. W h e n lifting t h e f r o n t of t h e v e h i c l e , set t h e p a r k i n g
s a f e t y s t a n d s . W h e n s u b s t a n t i a l w e i g h t is r e m o v e d brake. W h e n lifting t h e rear of the vehicle, put t h e
f r o m the rear of the vehicle, t h e center of g r a v i t y can shift lever in reverse.
c h a n g e , c a u s i n g t h e v e h i c l e t o t i p f o r w a r d o n t h e lift.
2. Block t h e w h e e l s t h a t are n o t b e i n g lifted.
Vehicle Lift
3. P o s i t i o n t h e f l o o r j a c k u n d e r t h e f r o n t j a c k i n g
1 . P o s i t i o n t h e lift b l o c k s (A) u n d e r t h e v e h i c l e ' s f r o n t b r a c k e t (A) o r t h e r e a r d i f f e r e n t i a l c a r r i e r (B). C e n t e r
s u p p o r t p o i n t s (B) a n d r e a r s u p p o r t p o i n t s (C). t h e j a c k i n g b r a c k e t o n t h e j a c k l i f t p l a t f o r m (C), a n d
jack up the vehicle high enough to fit the safety
s t a n d s u n d e r it.
'00-05 models '06-08 models

A
'00-05 m o d e l s '06-08 models

2. Raise t h e lift a f e w i n c h e s , a n d rock t h e v e h i c l e
g e n t l y t o b e s u r e it is f i r m l y s u p p o r t e d .
3. R a i s e t h e l i f t t o i t s f u l l h e i g h t , a n d i n s p e c t t h e
v e h i c l e s u p p o r t p o i n t s (B a n d C) f o r s o l i d c o n t a c t
w i t h t h e lift b l o c k s .
Safetf Stands
To s u p p o r t the vehicle on safety stands, use the s a m e

s u p p o r t p o i n t s (B a n d C) as f o r a v e h i c l e l i f t . A l w a y s u s e With a rubber pad or shop towel.
safety stands w h e n w o r k i n g on or under a n y vehicle
t h a t is s u p p o r t e d o n l y b y a j a c k . 4. P o s i t i o n t h e s a f e t y s t a n d s u n d e r t h e s u p p o r t p o i n t s ,
a n d a d j u s t t h e m s o t h e v e h i c l e is l e v e l .
5. L o w e r t h e v e h i c l e o n t o t h e s t a n d s .
1-18
Towing
If t h e v e h i c l e n e e d s to b e t o w e d , call a p r o f e s s i o n a l Rear:
t o w i n g s e r v i c e . N e v e r t o w the v e h i c l e b e h i n d a n o t h e r
'04-08 m o d e l s '00-03 m o d e l s
v e h i c l e w i t h a rope or c h a i n . It is v e r y d a n g e r o u s .
INOTICE1
• T h i s v e h i c l e c a n o n l y be t r a n s p o r t e d o n a flat-bed.
• T r y i n g to lift or t o w the v e h i c l e b y t h e b u m p e r s
will c a u s e s e r i o u s d a m a g e . T h e b u m p e r s a r e not
d e s i g n e d to s u p p o r t t h e v e h i c l e ' s w e i g h t .
F l a t - b e d E q u i p m e n t — T h e o p e r a t o r l o a d s the v e h i c l e
o n t h e b a c k of a truck. T h i s i s t h e o n l y r e c o m m e n d e d
w a y of t r a n s p o r t i n g t h e v e h i c l e .
T o a c c o m m o d a t e flat-bed e q u i p m e n t , t h e v e h i c l e is
e q u i p p e d w i t h t o w i n g hook (A), front tie d o w n s l o t s (B),
a n d r e a r tie d o w n hook s l o t s (C).
T h e t o w i n g hook c a n b e u s e d w i t h a w i n c h to pull t h e
v e h i c l e onto t h e truck, a n d the tie d o w n hook s l o t s c a n
b e u s e d to s e c u r e the v e h i c l e to the truck.
N O T E : T h e tie d o w n h o o k s l o t s u s e r u b b e r p l u g s (D) to
cover the openings.
Front:
'04-08 m o d e l s '00-03 m o d e l s
(cont'd)
1-19
General Information
Towing (cont'd)
Towing Hook Installation W h e e l Lift E q u i p m e n t — T h e t o w truck u s e s t w o

pivoting a r m s that g o u n d e r t h e tires (front or rear) a n d
T h e d e t a c h a b l e t o w i n g h o o k is o n l y for t o w i n g a v e r y lift t h e m off the g r o u n d . T h e o t h e r t w o w h e e l s r e m a i n
s h o r t d i s t a n c e , s u c h a s f r e e i n g t h e c a r . T h e hook o n t h e g r o u n d . N e v e r t o w t h e v e h i c l e w i t h w h e e l lift
m o u n t s to t h e a n c h o r in t h e front a n d r e a r b u m p e r . equipment.
1MOTICE1 S l i n g - t y p e E q u i p m e n t — T h e t o w truck u s e s metal

• T o a v o i d d a m a g e to t h e v e h i c l e , u s e t h e t o w i n g c a b l e s with hooks on the ends. T h e s e hooks go around
h o o k for straight flat g r o u n d t o w i n g o n l y . D o not p a r t s of t h e f r a m e or s u s p e n s i o n , a n d t h e c a b l e s lift that
tow on an angle. e n d of t h e v e h i c l e off t h e g r o u n d . T h e v e h i c l e ' s
• T h e t o w hook s h o u l d not b e u s e d to t o w t h e s u s p e n s i o n a n d b o d y c a n b e s e r i o u s l y d a m a g e d if t h i s
v e h i c l e onto a f l a t - b e d . D o not u s e it a s a tie m e t h o d of t o w i n g is a t t e m p t e d . T h i s m e t h o d of t o w i n g
down. the vehicle is unacceptable.
1. R e m o v e the c o v e r (A) f r o m t h e b u m p e r . T h e o n l y r e c o m m e n d e d w a y of t o w i n g the v e h i c l e is o n

a flat-bed truck.
'04-08 m o d e l s '00-03 m o d e l s
INOTICEI
T o a v o i d d a m a g e to t h e v e h i c l e , u s e t h e t o w i n g
h o o k for straight flat g r o u n d t o w i n g o n l y . Do not
t o w at a n a n g l e . T h e t o w i n g hook s h o u l d not be
u s e d to t o w t h e v e h i c l e onto a flat-bed. Do not u s e
it a s a tie d o w n .
2. R e m o v e t h e t o w i n g h o o k , hook e x t e n s i o n , a n d
w h e e l w r e n c h f r o m t h e tool c a s e in t h e trunk.
3. U s i n g t h e w h e e l w r e n c h , f a s t e n the e x t e n s i o n (B)
into t h e bolt hole in t h e b u m p e r .
4. S c r e w t h e t o w i n g h o o k (A) into the e x t e n s i o n , a n d

tighten it s e c u r e l y b y h a n d .
'04-08 m o d e l s '00-03 m o d e l s
1-20
Parts Marking
T o deter v e h i c l e theft, certain m a j o r c o m p o n e n t s are m a r k e d w i t h t h e v e h i c l e i d e n t i f i c a t i o n n u m b e r (VIN). Original

parts have self-adhesive labels. R e p l a c e m e n t b o d y parts have generic self-adhesive labels. These labels s h o u l d not be
r e m o v e d . T h e original engine or t r a n s m i s s i o n VIN plates are not transferable t o t h e r e p l a c e m e n t e n g i n e or
transmission.
N O T E : Be c a r e f u l n o t t o d a m a g e t h e p a r t s m a r k i n g l a b e l s d u r i n g b o d y r e p a i r . M a s k t h e l a b e l s b e f o r e r e p a i r i n g t h e p a r t .
1-21
General Information
Service Precaution
Adhesive Wheel Balance Weight
T h e w h e e l s o n t h i s m o d e l a r e not d e s i g n e d to m o u n t t h e b a l a n c e w e i g h t o n the outer s i d e of the w h e e l . I n s t e a d , m o u n t

the s e l f - a d h e s i v e b a l a n c e w e i g h t o n the i n n e r s i d e of t h e w h e e l s . Note the f o l l o w i n g s e r v i c e tips a n d install the
weights securely.
• U s e o n l y s e l f - a d h e s i v e w h e e l b a l a n c e w e i g h t s to b a l a n c e the w h e e l s o n t h e c a r .
• T h e w h e e l s a n d w e i g h t m u s t be 41 T (5 ' C ) or a b o v e d u r i n g installation.
• Do not d a m a g e t h e w h e e l w h e n r e m o v i n g the b a l a n c e w e i g h t .
• After r e m o v i n g t h e b a l a n c e w e i g h t , r e m o v e t h e a d h e s i v e r e s i d u e f r o m t h e w h e e l u s i n g a d e g r e a s i n g c l e a n i n g a g e n t .
• R e m o v e a n y d u s t a n d f o r e i g n m a t e r i a l f r o m the i n s i d e s u r f a c e of t h e w h e e l .
• C l e a n the i n s i d e s u r f a c e of t h e w h e e l w i t h IPA ( i s o p r o p y l a l c o h o l ) o r brake c l e a n e r . Let the s u r f a c e d r y t h o r o u g h l y
before a p p l y i n g t h e n e w b a l a n c e w e i g h t .
• P e e l off the b a c k i n g f r o m the b a l a n c e w e i g h t w i t h c a r e ; d o not t o u c h the a d h e s i v e s u r f a c e . P l a c e t h e b a l a n c e w e i g h t
o n the w h e e l l e n g t h w i s e to t h e w h e e l .
• P r e s s t h e entire s u r f a c e of the b a l a n c e w e i g h t w i t h 11.0 to 15.4 Ibf (5 to 7 kg) of f o r c e s o t h e b a l a n c e w e i g h t ' s t a p e
a d h e r e s to the w h e e l s e c u r e l y .
• R o c k t h e b a l a n c e w e i g h t lightly a n d m a k e s u r e that it is p r o p e r l y s e c u r e d to t h e w h e e l .
• D o not p l a c e o n e b a l a n c e w e i g h t o n t o p of a n o t h e r .
• If y o u c a n n o t m e a s u r e the a m o u n t of w e i g h t at the a d h e s i o n position w i t h the w h e e l b a l a n c e m a c h i n e , take the
a m o u n t of u n b a l a n c e at the outer r i m a n d c a l c u l a t e t h e a m o u n t of w e i g h t u s i n g the c o n v e r s i o n factor b e l o w .
S e l e c t t h e b a l a n c e w e i g h t that is t h e c l o s e s t to the c a l c u l a t i o n .
C o n v e r s i o n factor for the a d h e s i o n p o s i t i o n : Front w h e e l : 2.9
R e a r w h e e l : 2.5
Example:
If the u n b a l a n c e at the front rim is 15 g , it is c a l c u l a t e d a s 15 x 2.9 = 43.5 g.
T h e r e f o r e , the u n b a l a n c e is 43.5 g.
There must be clearance. BALANCE WEIGHT
1-22
Revised Component T e r m s
Beginning w i t h '01 m o d e l , the f o l l o w i n g c o m p o n e n t t e r m s have been c h a n g e d to c o n f o r m w i t h t h e standards in SAE

d o c u m e n t J 1 9 3 0 . If y o u f i n d a t e r m o r a b b r e v i a t i o n i n a n ' 0 1 o r l a t e r m a n u a l t h a t is u n f a m i l i a r t o y o u , c h e c k t h i s list. If a
t e r m is n o t l i s t e d b e l o w , it d i d n o t c h a n g e .
'00 and Earlier Models ^ '01 or Later Models

Description Honda Abbreviations Description N e w Abbreviations
S A E recommendation
Brake S w i t c h Brake Pedal Position S w i t c h BPP S w i t c h
Clutch Switch Clutch Pedal Position S w i t c h
Distributor Ignition Rotor Dl R o t o r Distributor Rotor
Function Sensor- Engine Speed Fluctuation CKP Sensor
Sensor
Evaporative Emission Control EVAP Control Canister Evaporative Emission EVAP Canister
Canister Canister
Evaporative Emission Control EVAP Control Canister Evaporative Emission EVAP Canister Vent
Canister Vent S h u t Valve Vent Shut Valve Canister Vent Shut Valve Shut Valve
Evaporative Emission Purge EVAP Purge Control Evaporative Emission EVAP Canister Purge
Control Solenoid Valve Solenoid Valve Canister Purge Valve Valve
Exhaust Gas Recirculation EGR V a l v e Lift S e n s o r Exhaust Gas Recirculation EGR V a l v e P o s i t i o n
Valve Lift S e n s o r Valve Position Sensor Sensor
Exhaust Gas Recirculation EGR C o n t r o l S o l e n o i d Exhaust Gas Recirculation EGR V a l v e V a c u u m
Control Solenoid Valve Valve Valve Vacuum Control Control Solenoid Valve
Solenoid Valve
Exhaust Gas Recirculation EGR V a c u u m C o n t r o l Exhaust Gas Recirculation EGR V a l v e V a c u u m
Vacuum Control Valve Valve Valve Vacuum Control Control Solenoid Valve
Solenoid Valve
Radiator Fan C o n t r o l M o d u l e Fan Control M o d u l e
Fuel T a n k E v a p o r a t i v e Fuel Tank V a p o r / L i q u i d
Emission Valve Separation Valve
ORVR V e n t S h u t V a l v e Fuel T a n k V a p o r Control
Valve
ORVR V a p o r R e c i r c u l a t i o n Fuel Tank V a p o r Recirculation
Tube Tube
First I d l e T h e r m o V a l v e Idle A i r C o n t r o l T h e r m a l IAC T h e r m a l V a l v e
Valve
Fuel I n j e c t o r Injector
Fuel I n j e c t i o n A i r C o n t r o l FIA C o n t r o l V a l v e Intake Air Bypass Control
Valve Valve
Fuel I n j e c t i o n A i r C o n t r o l FIA C o n t r o l S o l e n o i d Intake A i r Bypass Control
Solenoid Valve Valve Thermal Valve
Intake A i r B y p a s s Check V a l v e IAB Check Valve Intake M a n i f o l d Runner IMRC V a c u u m Check
Control V a c u u m Check Valve Valve
Intake M a n i f o l d Runner IMRC Actuator
Control Actuator
Intake M a n i f o l d Runner IMRC Actuator W i r e
Control Actuator Wire
Intake A i r B y p a s s C o n t r o l IAB C o n t r o l D i a p h r a g m Intake M a n i f o l d Runner IMRC D i a p h r a g m
Diaphragm Control Actuator Diaphragm
Intake M a n i f o l d Runner IMRC M o d u l e
1Control Module
(cont'd)
1-23
General Information
Revised Component Terms (cont'd)
'00 and Earlier Models '01 or Later Vlodels

Description Honda Abbreviations Description N e w Abbreviations
S A E recommendation
Intake A i r B y p a s s C o n t r o l IAB Control S o l e n o i d Intake M a n i f o l d R u n n e r IMRC Solenoid Valve
Solenoid Valve Valve Control S o l e n o i d Valve
Intake A i r B y p a s s V a c u u m IAB V a c u u m Tank Intake M a n i f o l d R u n n e r IMRC Vacuum
Tank Control V a c u u m Reservoir
Intake A i r B y p a s s V a l v e B o d y IAB Valve Body Intake M a n i f o l d R u n n e r IMRC Valve
Assembly Assembly Control V a l v e
Breather C h a m b e r Oil/Air Separator
Fuel Pressure Regulator Pressure Regulator V a c u u m
Control Solenoid V a l v e Control S o l e n o i d Valve
Air Control Valve C h e c k Valve S e c o n d a r y A i r Injection Air Control V a c u u m
Control V a c u u m C h e c k Valve Check Valve
Air Control Valve V a c u u m S e c o n d a r y A i r Injection Air Control V a c u u m
Tank Control V a c u u m Reservoir Reservoir
Air Control Solenoid V a l v e S e c o n d a r y A i r Injection Air Control Valve
Control V a c u u m Control V a c u u m Control
Solenoid Valve Solenoid Valve
Air P u m p S e c o n d a r y A i r Injection P u m p Air Pump
Air Control Valve S e c o n d a r y A i r Injection P u m p Air Control Valve
Control V a l v e
Air P u m p Electrical Current S e c o n d a r y A i r Injection P u m p Air P u m p Electrical
Sensor Electrical Current S e n s o r Current Sensor
Shift/Clutch Pressure Control Shift S o l e n o i d a n d A u t o m a t i c S S and A / T Clutch
Solenoid Valve Set Transaxle Clutch Pressure Pressure Control
Control Solenoid Valve S e t Solenoid Valve Set
Shift C o n t r o l S o l e n o i d V a l v e Shift S o l e n o i d a n d T o r q u e S S and T C C Solenoid
Set Converter Clutch Solenoid Valve Set
Valve Set
Shift/Lock-up Clutch Control Shift S o l e n o i d and T o r q u e S S and T C C Solenoid
Solenoid Valve A s s y Converter Clutch Solenoid Valve
Valve
Shift Control S o l e n o i d V a l v e Shift Solenoid V a l v e A S S Valve A
A
Shift C o n t r o l S o l e n o i d V a l v e Shift S o l e n o i d V a l v e B S S Valve B
B
Throttle V a l v e Control Throttle A c t u a t o r
Module
Lock-up Clutch Control Torque Converter Clutch T C C Solenoid and A/T
Solenoid Valve Set Solenoid and Automatic Clutch Pressure Control
Transaxle Clutch Pressure Solenoid Valve Set
Control S o l e n o i d Valve S e t
Lock-up Clutch Control Torque Converter Clutch T C C Solenoid Valve
Solenoid Valve Solenoid Valve
Automatic T r a n s a x l e Position A / T G e a r Position Transmission Range Switch TR Switch
Switch Switch
Variable Valve Timing and V T E C Pressure Switch Variable Valve Timing and V T E C Oil P r e s s u r e
V a l v e Lift E l e c t r o n i c C o n t r o l V a l v e Lift E l e c t r o n i c C o n t r o l Switch
Pressure Switch Pressure Switch
1-24
specs
Specifications
Standards and Service Limits

Engine Electrical 2-2
Engine Assembly 2-2
Cylinder Head 2-3
Engine Block 2-4
Engine Lubrication 2-4
Cooling System 2-5
Fuel and Emissions 2-5
Clutch 2-5
Manual Transmission 2-6
Rear Differential . 2-8
Steering 2-8
Suspension 2-8
Brakes 2-9
Air Conditioning 2-9
Design Specifications
Dimensions 2-10
Weight 2-10
Engine 2-10
Starter 2-10
Clutch 2-10
Rear Differential 2-10
Steering 2-11
Suspension 2-11
Tires 2-11
Wheel Alignment 2-11
Brakes 2-11
Air Conditioning 2-11
Electrical Ratings 2-12
Body Specifications 2-13
Engine Electrical
Item Measurement Qualification S t a n d a r d or N e w | Service Limit
Ignition coil R a t e d voltage 12V
Firing order 1—3-4-2
S p a r k plug Type NGK: PFR7G-1 I S
DENSO:PK22PR-L11S
Gap 1 . 0 - 1 . 1 m m ( 0 . 0 3 9 - 0 . 0 4 3 in.) |
Ignition timing A t idle In neutral 5±2°BTDC
c h e c k the red mark
Drive belt Tension Auto-tensioner
Alternator Output A t 13.5 V a n d 105 A
normal engine
temperature
B r u s h length 10.5 m m (0.41 in.) | 1.5 m m (0.06 in.)
Starter Output '00-03 m o d e l s 1.0 kW
'04-08 m o d e l s 1.1 kW
C o m m u t a t o r m i c a depth 0 . 4 - 0 . 5 m m ( 0 . 0 1 6 - 0 . 0 2 0 in.) 0.15 m m (0.006 in.)
C o m m u t a t o r runout 0.02 m m (0.001 in.) m a x . 0.05 m m (0.002 in.)
C o m m u t a t o r O.D. 2 8 . 0 - 2 8 . 1 m m ( 1 . 1 0 2 - 1 . 1 0 6 in.) 27.5 m m (1.083 in.)
B r u s h length 1 5 . 8 - 1 6 . 2 m m ( 0 . 6 2 - 0 . 6 4 in.) 11.0 m m (0.43 in.)
B r u s h s p r i n g t e n s i o n (new) 1 5 . 7 - 1 7 . 7 N ( 1 . 6 0 - 1 . 8 0 kgf, 3 . 5 3 - 3 . 9 7 Ibf)
Engine Assembly
Item Measurement Qualification S t a n d a r d or N e w
Compression Pressure Nominal 2
1,570 kPa (16.0 k g f / c m , 2 2 8 psi)
C h e c k the e n g i n e with the starter Minimum 2
930 kPa (9.5 k g f / c m , 1 3 5 psi)
cranking Maximum 2
200 kPa (2.0 k g f / c m , 2 8 psi)
variation
2-2
specs
Cylinder Head
Item Measurement Qualification S t a n d a r d or N e w Service Limit
Head Warpage 0.05 m m (0.002 in.)
Height 1 0 4 . 9 5 - 1 0 5 . 0 5 m m ( 4 . 1 3 2 - 4 . 1 3 6 in.)
Camshaft E n d play 0 . 0 5 - 0 . 1 5 m m (0.002—0.006 in.) 0.30 m m (0.012 in.)
Camshaft-to-holder oil c l e a r a n c e 0 . 0 6 0 - 0 . 0 9 9 m m ( 0 . 0 0 2 - 0 . 0 0 4 in.) 0.15 m m (0.006 in.)
Total runout 0.03 m m (0.001 in.) m a x . 0.04 m m (0.002 in.)
C a m lobe height ('00-03 m o d e l s ) Intake, primary 33.677 m m (1.326 in.)
Intake, m i d 36.533 m m (1.438 in.)
Intake, s e c o n d a r y 33.961 m m (1.337 in.)
E x h a u s t , primary 33.716 m m (1.327 in.)
Exhaust, mid 35.928 m m (1.414 in.)
Exhaust, secondary 33.994 m m (1.338 in.)
C a m lobe height ('04-08 m o d e l s ) Intake, primary 33.961 m m (1.337 in.)
Intake, m i d 36.421 m m (1.434 in.)
Intake, s e c o n d a r y 33.961 m m (1.337 in.)
E x h a u s t , primary 33.716 m m (1.327 in.)
Exhaust, mid 35.660 m m (1.404 in.)
Exhaust, secondary 33.716 m m (1.327 in.)
Valve C l e a r a n c e (cold) Intake 0 . 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.)
Exhaust 0 . 2 5 - 0 . 2 9 m m ( 0 . 0 1 0 - 0 . 0 1 1 in.)
S t e m O.D. Intake 5 . 4 8 - 5 . 4 9 m m ( 0 . 2 1 5 7 - 0 . 2 1 6 2 in.) 5.45 m m (0.215 in.)
Exhaust 5 . 4 5 - 5 . 4 6 m m ( 0 . 2 1 4 6 - 0 . 2 1 5 0 in.) 5.42 m m (0.213 in.)
Stem-to-guide c l e a r a n c e Intake 0 . 0 2 - 0 . 0 5 m m ( 0 . 0 0 1 - 0 . 0 0 2 in.) 0.08 m m (0.003 in.)
Exhaust 0 . 0 5 - 0 . 0 8 m m (0.002—0.003 in.) 0.11 m m (0.004 in.)
V a l v e seat Width Intake 1 . 0 5 - 1 . 3 5 m m (0.041—0.053 in.) 1.80 m m (0.071 in.)
Exhaust 1 . 2 5 - 1 . 5 5 m m (0.049—0.061 in.) 2.00 m m (0.079 in.)
S t e m installed height Intake 44.1—44.4 m m (1.736—1.748 in.) 44.7 m m (1.760 in.)
Exhaust 4 4 . 2 - 4 4 . 5 m m (1.740—1.752 in.) 44.8 m m (1.764 in.)
V a l v e spring F r e e length Intake 49.77 m m (1.959 in.)
('00-03 m o d e l s )
Intake 49.76 m m (1.959 in.)
('04-08 m o d e l s )
Exhaust 50.39 m m (1.984 in.)
V a l v e guide I.D. Intake 5 . 5 1 0 - 5 . 5 3 0 m m ( 0 . 2 1 6 9 - 0 . 2 1 7 7 in.) 5.55 m m (0.219 in.)
Exhaust 5 . 5 1 0 - 5 . 5 3 0 m m ( 0 . 2 1 6 9 - 0 . 2 1 7 7 in.) 5.55 m m (0.219 in.)
Installed height Intake 1 5 . 2 - 1 6 . 2 m m ( 0 . 5 9 8 - 0 . 6 3 8 in.)
Exhaust 1 6 . 0 - 1 7 . 0 m m ( 0 . 6 3 0 - 0 . 6 6 9 in.)
Rocker a r m Arm-to-shaft c l e a r a n c e Intake 0 . 0 2 1 - 0 . 0 4 1 m m ( 0 . 0 0 0 8 - 0 . 0 0 1 6 in.) 0.07 m m (0.003 in.)
Exhaust 0 . 0 2 1 - 0 . 0 4 1 m m ( 0 . 0 0 0 8 - 0 . 0 0 1 6 in.) 0.07 m m (0.003 in.)
2-3
Engine Block
Block W a r p a g e of deck 0.07 m m (0.003 in.) m a x . 0.10 m m (0.004 in.)
B o r e diameter Aorl 8 7 . 0 1 0 - 8 7 . 0 2 0 m m ( 3 . 4 2 5 6 - 3 . 4 2 6 0 in.) 87.070 m m (3.4279 in.)
Borll 8 7 . 0 0 0 - 8 7 . 0 1 0 m m ( 3 . 4 2 5 2 - 3 . 4 2 5 6 in.) 87.070 m m (3.4279 in.)
B o r e taper 0.05 m m (0.002 in.)
R e b o r i n g limit 0.25 m m (0.01 in.)
Piston Skirt No letter 8 6 . 9 9 3 - 8 7 . 0 0 6 m m ( 3 . 4 2 4 9 - 3 . 4 2 5 4 in.) 86.980 m m (3.4244 in.)
Letter B 8 6 . 9 8 3 - 8 6 . 9 9 6 m m ( 3 . 4 2 4 5 - 3 . 4 2 5 0 in.) 86.970 m m (3.4240 in.)
C l e a r a n c e in cylinder 0 . 0 0 4 - 0 . 0 2 7 m m ( 0 . 0 0 0 2 - 0 . 0 0 1 1 in.) 0.04 m m (0.002 in.)
Ring groove width Top 1 . 2 3 5 - 1 . 2 6 5 m m ( 0 . 0 4 8 6 - 0 . 0 4 9 8 in.) 1.285 m m (0.0506 in.)
Second 1 . 2 3 0 - 1 . 2 4 5 m m ( 0 . 0 4 8 4 - 0 . 0 4 9 0 in.) 1.265 m m (0.0498 in.)
Oil 2 . 0 0 5 - 2 . 0 2 5 m m ( 0 . 0 7 8 9 - 0 . 0 7 9 7 in.) 2.05 m m (0.081 in.)
Piston ring Ring-to-groove c l e a r a n c e Top 0 . 0 4 5 - 0 . 0 9 0 m m ( 0 . 0 0 1 8 - 0 . 0 0 3 5 in.) 0.135 m m (0.005 in.)
Second 0 . 0 4 0 - 0 . 0 7 0 m m ( 0 . 0 0 1 6 - 0 . 0 0 2 8 in.) 0.13 m m (0.005 in.)
Ring end gap Top 0 . 2 5 - 0 . 3 5 m m ( 0 . 0 1 0 - 0 . 0 1 4 in.) 0.60 m m (0.024 in.)
Second 0 . 6 0 - 0 . 7 5 m m ( 0 . 0 2 4 - 0 . 0 3 0 in.) 0.90 m m (0.035 in.)
Oil 0.20—0.70 m m ( 0 . 0 0 8 - 0 . 0 2 8 in.) 0.80 m m (0.031 in.)
Piston pin O.D. 2 2 . 9 6 1 - 2 2 . 9 6 5 m m ( 0 . 9 0 4 0 - 0 . 9 0 4 1 in.) 22.953 m m (0.9037 in.)
Pin-to-piston c l e a r a n c e - 0 . 0 0 2 0 to + 0 . 0 0 5 0 m m 0.010 m m (0.0004 in.)
(—0.00008 to + 0 . 0 0 0 2 0 in.)
C o n n e c t i n g rod Pin-to-rod c l e a r a n c e 0 . 0 1 8 - 0 . 0 3 5 m m ( 0 . 0 0 0 7 - 0 . 0 0 1 4 in.) 0.04 m m (0.0016 in.)
S m a l l - e n d bore d i a m e t e r 2 2 . 9 8 3 - 2 2 . 9 9 6 m m ( 0 . 9 0 4 8 - 0 . 9 0 5 3 in.)
L a r g e - e n d bore d i a m e t e r (Normal) 51.0 m m (2.01 in.)
E n d play installed o n crankshaft 0.15—0.30 m m ( 0 . 0 0 6 - 0 . 0 1 2 in.) 0.40 m m (0.016 in.)
Crankshaft Main journal diameter 5 4 . 9 7 6 - 5 5 . 0 0 0 m m ( 2 . 1 6 4 4 - 2 . 1 6 5 4 in.)
R o d journal d i a m e t e r 4 7 . 9 7 6 - 4 8 . 0 0 0 m m ( 1 . 8 8 8 8 - 1 . 8 8 9 8 in.)
R o d / m a i n j o u r n a l taper 0.005 m m (0.0002 in.) m a x . 0.006 m m (0.0002 in.)
R o d / m a i n j o u r n a l out-of-round 0.004 m m (0.0002 in.) m a x . 0.006 m m (0.0002 in.)
E n d play 0.10—0.35 m m ( 0 . 0 0 4 - 0 . 0 1 4 in.) 0.45 m m (0.018 in.)
Runout 0.02 m m (0.0008 in.) m a x . 0.04 m m (0.0016 in.)
Crankshaft M a i n bearing-to-journal oil c l e a r a n c e 0 . 0 1 7 - 0 . 0 4 1 m m ( 0 . 0 0 0 7 - 0 . 0 0 1 6 in.) 0.050 m m (0.0020 in.)
bearing R o d bearing c l e a r a n c e 0 . 0 3 0 - 0 . 0 5 4 m m ( 0 . 0 0 1 2 - 0 . 0 0 2 1 in.) 0.060 m m (0.0024 in.)
Engine Lubrication
Item Measurement Qualification S t a n d a r d or N e w | Service Limit
E n g i n e oil Capacity Engine overhaul 5.6L(5.9USqt)
Oil c h a n g e 4.8 L (5.1 U S q t )
including filter
Oil c h a n g e 4.5 L (4.8 U S qt)
w i t h o u t filter
Oil p u m p Inner-to-outer rotor c l e a r a n c e 0.02—0.14 m m (0.001—0.006 in.) 0.20 m m (0.008 in.)
P u m p housing-to-outer rotor c l e a r a n c e 0 . 1 5 - 0 . 2 1 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.) 0.23 m m (0.009 in.)
P u m p housing-to-outer rotor axial 0 . 0 2 - 0 . 0 7 m m ( 0 . 0 0 1 - 0 . 0 0 3 in.) 0.12 m m (0.005 in.)
clearance
Oil p r e s s u r e with oil t e m p e r a t u r e at A t idle 2
250 kPa (2.5 k g f / c m , 3 6 psi)
1 7 6 ° F ( 8 0 *€) A t 3,000 r p m 2
590 kPa (6.0 k g f / c m , 8 5 psi)
2-4
specs
Cooling S y s t e m
Radiator Coolant capacities (including e n g i n e , E n g i n e overhaul 7.6 L (2.01 U S gal)
heater, h o s e s , a n d reservoir) Coolant c h a n g e 6.5 L (1.72 U S gal)
U s e Honda L o n g Life Antifreeze/
Coolant T y p e 2
C o o l a n t reservoir Coolant capacity 0.6 L (0.16 U S gal)
2
Radiator c a p Opening pressure 9 3 - 1 2 3 kPa (0.95—1.25 k g f / c m , 1 4 - 1 8 psi)
Thermostat O p e n i n g temperature B e g i n s to o p e n 1 6 9 - 1 7 6 °F ( 7 6 - 8 0 ' C )
Fully open 194^(90^)
V a l v e lift at fully o p e n 10.0 m m (0.39 in.) m i n .
Radiator fan S w i t c h i n g temperature Turns ON 1 9 6 - 2 0 3 °F (91 - 9 5 °C)
s w i t c h ('00-05 Turns OFF Subtract 5—15 °F (3 —8 °C) from actual O N temperature
models)
Fuel and E m i s s i o n s
2
Fuel p r e s s u r e P r e s s u r e with regulator v a c u u m h o s e '00-05 m o d e l s 3 2 0 - 3 7 0 kPa ( 3 . 3 - 3 . 8 k g f / c m , 4 7 - 5 4 psi)
2
regulator disconnected '06-08 m o d e l s 3 8 0 - 4 3 0 kPa ( 3 . 9 - 4 . 4 k g f / c m , 5 5 - 6 3 psi)
Fuel tank Capacity 50 L (13.2 U S gal)
E n g i n e idle Idle s p e e d without load In neutral 8 0 0 ± 5 0 rpm
('00-05 m o d e l s )
In neutral 9 0 0 ± 5 0 rpm
('06-08 models)
Idle s p e e d with high electrical load In neutral 9 0 0 ± 5 0 rpm
( A / C switch O N , temperature s e t to
m a x c o o l , blower fan o n High, rear
w i n d o w defogger O N (if applicable),
a n d head lights on high b e a m )
Clutch
Clutch pedal Height f r o m the floor 189 m m (7.44 in.)
Stroke 1 1 5 - 1 2 5 m m (4.53—4.92 in.)
Play 9 - 1 7 m m ( 0 . 4 - 0 . 7 in.)
Flywheel Runout on clutch mating surface 0.05 m m (0.002 in.) m a x . 0.15 m m (0.006 in.)
Clutch d i s c Rivet head depth 1 . 2 - 1 . 7 m m ( 0 . 0 4 7 - 0 . 0 6 7 in.) 0.2 m m (0.008 in.)
Thickness 8 . 2 - 8 . 9 m m ( 0 . 3 2 - 0 . 3 5 in.) 6.0 m m (0.24 in.)
P r e s s u r e plate Warpage 0.03 m m (0.001 in.) m a x . 0.15 m m (0.006 in.)
Height-variation of d i a p h r a g m spring 0.4 m m (0.016 in.) m a x . 0.6 m m (0.024 in.)
fingers m e a s u r e d with dial indicator
2-5
Manual Transmission
Item Measurement Qualification S t a n d a r d or N e w | S e r v i c e Limit
Manual Capacity Fluid c h a n g e 1.48 L (1.56 U S qt)
transmission U s e Honda MTF Overhaul 1.62 L (1.71 U S qt)
fluid
Mainshaft E n d play 0 . 1 4 - 0 . 2 1 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.) Adjust
D i a m e t e r of t r a n s m i s s i o n fear c o v e r 2 7 . 9 8 7 - 2 8 . 0 0 0 m m ( 1 . 1 0 1 8 - 1 . 1 0 2 4 in.) 27.94 m m (1.100 in.)
s i d e ball b e a r i n g contact area
D i a m e t e r of 4th/5th g e a r s contact a r e a 3 4 . 9 8 7 - 3 5 . 0 0 0 m m ( 1 . 3 7 7 4 - 1 . 3 7 8 0 in.) 34.94 m m (1.376 in.)
D i a m e t e r of 6th g e a r contact a r e a 3 8 . 9 8 4 - 3 9 . 0 0 0 m m (1.5348—1.5354 in.) 38.94 m m (1.533 in.)
D i a m e t e r of clutch h o u s i n g ball 2 8 . 0 0 2 - 2 8 . 0 1 5 m m ( 1 . 1 0 2 4 - 1 . 1 0 3 0 in.) 27.95 m m (1.100 in.)
bearing contact a r e a
Mainshaft 3rd i.D. 4 0 . 0 0 9 - 4 0 . 0 2 5 m m ( 1 . 5 7 5 2 - 1 . 5 7 5 8 in.)
gear Thickness 3 5 . 0 9 - 3 5 . 1 7 m m ( 1 . 3 8 1 - 1 . 3 8 5 in.) 34.97 m m (1.377 in.)
E n d play 0 . 0 6 - 0 . 1 9 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.) 0.3 m m (0.012 in.)
Mainshaft 3rd I.D. 2 8 . 0 0 2 - 2 8 . 0 1 2 m m ( 1 . 1 0 2 4 - 1 . 1 0 2 8 in.)
g e a r distance O.D. 34.989—35.000 m m ( 1 . 3 7 7 5 - 1 . 3 7 8 0 in.)
collar Length 3 5 . 2 3 - 3 5 . 2 8 m m (1.387—1.389 in.)
Mainshaft 4th I.D. 4 7 . 0 0 9 - 4 7 . 0 2 5 m m ( 1 . 8 5 0 7 - 1 . 8 5 1 4 in.)
a n d 5th g e a r Thickness 31.89—31.97 m m ( 1 . 2 5 6 - 1 . 2 5 9 in.) 31.77 m m (1.251 in.)
a n d 5th g e a r O.D. 4 1 . 9 8 9 - 4 2 . 0 0 0 m m ( 1 . 6 5 3 1 - 1 . 6 5 3 5 in.)
distance collar Length 32.03—32.08 m m (1.261—1.263 in.)
gear Thickness 28.89—28.97 m m ( 1 . 1 3 7 - 1 . 1 4 1 in.) 28.77 m m (1.133 in.)
Countershaft D i a m e t e r of rear c o v e r side needle 3 0 . 0 2 0 - 3 0 . 0 2 9 m m ( 1 . 1 8 1 9 - 1 . 1 8 2 2 in.) 29.97 m m (1.180 in.)
D i a m e t e r of t r a n s m i s s i o n h o u s i n g s i d e 34.002—34.018 m m ( 1 . 3 3 8 7 - 1 . 3 3 9 3 in.) 33.95 m m (1.337 in.)
n e e d l e bearing contact a r e a
D i a m e t e r of 2 n d g e a r contact a r e a 4 3 . 9 8 4 - 4 4 . 0 0 0 m m (1.7317—1.7323 in.) 43.93 m m (1.730 in.)
D i a m e t e r of clutch h o u s i n g side ball 2 8 . 0 0 2 - 2 8 . 0 1 5 m m ( 1 . 1 0 2 4 - 1 . 1 0 3 0 in.) 27.95 m m (1.100 in.)
Countershaft 1st I.D. 57.010—57.029 m m ( 2 . 2 4 4 5 - 2 . 2 4 5 2 in.)
gear Thickness '00-03 m o d e l s 3 1 . 1 8 - 3 1 . 2 6 m m ( 1 . 2 2 8 - 1 . 2 3 1 in.) 31.06 m m (1.223 in.)
'04-08 m o d e l s 2 7 . 8 8 - 2 7 . 9 6 m m ( 1 . 0 9 8 - 1 . 1 0 1 in.) 27.76 m m (1.093 in.)
E n d play '00-03 m o d e l s 0 . 0 4 - 0 . 2 2 m m ( 0 . 0 0 2 - 0 . 0 0 9 in.) 0.3 m m (0.012 in.)
'04-08 m o d e l s 0 . 0 4 - 0 , 1 7 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.)
Countershaft 1st O.D. 5 0 . 9 8 7 - 5 1 . 0 0 0 m m ( 2 . 0 0 7 4 - 2 . 0 0 7 9 in.)
g e a r distance Length 2 8 . 0 3 - 2 8 . 0 8 m m ( 1 . 1 0 4 - 1 . 1 0 6 in.)
collar
Countershaft 2 n d I.D. 4 3 . 9 8 4 - 4 4 . 0 0 0 m m ( 1 . 7 3 1 7 - 1 . 7 3 2 3 in.)
gear Thickness 3 2 . 8 8 - 3 2 . 9 6 m m ( 1 . 2 9 4 - 1 . 2 9 8 in.) 32.76 m m (1.290 in.)
Countershaft I.D. 5 0 . 0 0 9 - 5 0 . 0 2 5 m m ( 1 . 9 6 8 9 - 1 . 9 6 9 5 in.)
reverse gear Thickness 26.38—26.46 m m ( 1 . 0 3 9 - 1 . 0 4 2 in.) 26.26 m m (1.034 in.)
Countershaft O.D. 37.989—38.000 m m (1.4956—1.4961 in.)
reverse gear Length 25.53—25.58 m m (1.005—1.007 in.)
distance collar
2-6
specs
Item Measurement Qualification S t a n d a r d or N e w S e r v i c e Limit

Secondary Diameter of ball bearing contact 31.002—31.013 m m ( 1 . 2 2 0 6 - 1 . 2 2 1 0 in.) 30.95 m m (1.219 in.)
shaft area
Diameter of propeller shaft side 41.002—41.018 m m ( 1 . 6 1 4 3 - 1 . 6 1 4 9 in.) 40.95 m m (1.612 in.)
tapered roller bearing contact
area
Diameter of t r a n s m i s s i o n 3 5 . 0 0 9 - 3 5 . 0 2 5 m m ( 1 . 3 7 8 3 - 1 . 3 7 9 0 in.) 38.94 m m
h o u s i n g side tapered roller (1.5333 in.)
Starting torque (preload) 1 . 8 6 - 2 . 8 4 N-m Adjust
( 1 9 . 0 - 2 9 . 0 kgf-cm, 1 6 . 5 - 2 5 . 2 Ibf-in.)
Shift fork Finger thickness 1-2 shift fork 7 . 4 - 7 . 6 m m ( 0 . 2 9 - 0 . 3 0 in.)
3-4 shift fork 6.2—6.4 m m (0.24—0.25 in.)
5-6 shift fork 6 . 2 - 6 . 4 m m ( 0 . 2 4 - 0 . 2 5 in.)
R e v e r s e shift fork 6 . 2 - 6 . 4 m m ( 0 . 2 4 - 0 . 2 5 in.)
Fork-to-synchro s l e e v e 0 . 3 5 - 0 . 6 5 m m ( 0 . 0 1 4 - 0 . 0 2 6 in.) 1.00 m m (0.039 in.)
clearance
Groove T o 1-2 shift lever 1 7 . 2 - 1 7 . 4 m m ( 0 . 6 7 7 - 0 . 6 8 5 in.) 17.1 m m (0.673 in.)
T o shift a r m A 1 7 . 2 - 1 7 . 4 m m ( 0 . 6 7 7 - 0 . 6 8 5 in.) 17.1 m m (0.673 in.)
Shift a r m A I.D. 1 6 . 0 0 0 - 1 6 . 0 2 7 m m ( 0 . 6 2 9 9 - 0 . 6 3 1 0 in.)
Finger width 1 6 . 8 - 1 7 . 0 m m ( 0 . 6 6 1 - 0 . 6 6 9 in.) 16.7 m m (0.657 in.)
Shift a r m A-to-shift forks 0 . 2 - 0 . 6 m m ( 0 . 0 0 8 - 0 . 0 2 4 in.) 0.7 m m (0.028 in.)
1-2 shift lever Fingerwidth 1 7 . 0 - 1 7 . 2 m m ( 0 . 6 6 9 - 0 . 6 7 7 in.) 16.9 m m (0.665 in.)
Lever-to-shift forks a n d p i e c e s 0—0.4 m m (0—0.016 in.) 0.5 m m (0.020 in.)
clearance
1-2 shift piece Groove T o shift a r m A 1 7 . 2 - 1 7 . 4 m m ( 0 . 6 7 7 - 0 . 6 8 5 in.) 17.1 m m (0.673 in.)
3-4 shift piece Groove T o shift a r m A 1 7 . 2 - 1 7 . 4 m m ( 0 . 6 7 7 - 0 . 6 8 5 in.) 17.1 m m (0.673 in.)
R e v e r s e shift Groove T o 1-2 shift a r m A 1 7 . 2 - 1 7 . 4 m m ( 0 . 6 7 7 - 0 . 6 8 5 in.) 17.1 m m (0.673 in.)
piece T o shift a r m A 17.2—17.4 m m (0.677—0.685 in.) 17.1 m m (0.673 in.)
S y n c h r o ring Ring-to-gear c l e a r a n c e 5th, 6th gear 0 . 7 5 - 1 . 0 0 m m ( 0 . 0 3 0 - 0 . 0 3 9 in.) 0.4 m m (0.016 in.)
(ring p u s h e d against gear) ('00-03 models)
3rd, 4th, 5th, 6th gear 0 . 8 5 - 1 . 1 0 m m ( 0 . 0 3 3 - 0 . 0 4 3 in.) 0.4 m m (0.016 in.)
('04-08 models)
R e v e r s e gear 0 . 8 5 - 1 . 1 0 m m ( 0 . 0 3 3 - 0 . 0 4 3 in.) 0.4 m m (0.016 in.)
Double c o n e Outer s y n c h r o ring-to-synchro 1st, 2nd gear 0 . 7 0 - 1 . 0 9 m m ( 0 . 0 2 8 - 0 . 0 4 3 in.) 0.3 m m (0.012 in.)
synchro c o n e c l e a r a n c e (ring p u s h e d ('00-03 models)
against gear) 1st, 2 n d gear 0 . 5 8 - 1 . 0 9 m m ( 0 . 0 2 3 - 0 . 0 4 3 in.) 0.3 m m (0.012 in.)
('04-08 models)
3 r d , 4th gear 0 . 9 0 - 1 . 3 9 m m ( 0 . 0 3 5 - 0 . 0 5 5 in.) 0.3 m m (0.012 in.)
('00-03 models)
S y n c h r o cone-to-gear c l e a r a n c e 1st, 3 r d , 4th gear 0 . 5 0 - 1 . 0 4 m m ( 0 . 0 2 0 - 0 . 0 4 1 in.) 0.3 m m (0.012 in.)
(ring p u s h e d against gear) ('00-03 m o d e l s )
1st gear ('04-08 m o d e l s ) 0 . 3 3 - 1 . 0 4 m m ( 0 . 0 1 3 - 0 . 0 4 1 in.) 0.3 m m (0.012 in.)
2nd g e a r ('00-03 m o d e l s ) 0 . 6 5 - 1 . 7 8 m m ( 0 . 0 2 6 - 0 . 0 7 0 in.) 0.3 m m (0.012 in.)
2nd gear ('04-08 m o d e l s ) 0 . 3 3 - 1 . 0 4 m m ( 0 . 0 1 3 - 0 . 0 4 1 in.) 0.3 m m (0.012 in.)
Outer s y n c h r o ring-to-gear 1st, 3 r d , 4th gear 0 . 9 5 - 1 . 6 8 m m ( 0 . 0 3 7 - 0 . 0 6 6 in.) 0.6 m m (0.024 in.)
c l e a r a n c e (ring p u s h e d against ('00-03 models)
gear) 1st gear ('04-08 m o d e l s ) 0 . 9 5 - 1 . 3 5 m m ( 0 . 0 3 7 - 0 . 0 5 3 in.) 0.6 m m (0.024 in.)
2nd gear ('00-03 m o d e l s ) 0 . 7 0 - 1 . 8 2 m m ( 0 . 0 2 8 - 0 . 0 7 2 in.) 0.6 m m (0.024 in.)
2 n d gear ('04-08 m o d e l s ) 0 . 9 5 - 1 . 3 5 m m ( 0 . 0 3 7 - 0 . 0 5 3 in.) 0.6 m m (0.024 in.)
Oil p u m p Inner rotor-to-outer rotor radial 0.14 m m (0.006 in.) max. 0.20 m m (0.008 in.)
clearance
Rotor-to-transmission h o u s i n g Radial c l e a r a n c e 0.1—0.2 m m ( 0 . 0 0 4 - 0 . 0 0 8 in.) 0.22 m m (0.009 in.)
clearance Axial clearance 0 . 0 3 - 0 . 0 7 m m ( 0 . 0 0 1 - 0 . 0 0 3 in.) Adjust
2-7
Rear Differential
R e a r differential Capacity Oil c h a n g e 0.74 L (0.78 U S qt)
fluid U s e Hypoid G e a r Oil G L 5 or G L 6 Overhaul 0.77 L (0.81 U S qt)
Drive pinion Starting torque (preload) Additional v a l u e 0 . 8 8 - 1 . 3 7 N-m Adjust
(Add additional v a l u e to actual starting ( 9 . 0 - 1 4 . 0 kgf-cm, 7.81 - 1 2 . 1 5 Ibf-in.)
torque m e a s u r e m e n t )
Ring gear B a c k l a s h to drive pinion 0 . 0 9 - 0 . 1 1 m m (0.0035—0.0043 in.) Adjust
Differential Total starting torque M e a s u r e d with p u s h / 1 4 - 3 0 N ( 1 . 4 - 3 . 1 kgf, 3 . 1 - 6 . 8 Ibf) Adjust
pull g a u g e
Steering
Steering w h e e l Rotational play m e a s u r e d at outside 0—10 m m (0—0.39 in.)
e d g e with e n g i n e running
Initial turning load m e a s u r e d at 3 4 N (3.5 kgf, 7.7 Ibf)
outside e d g e with e n g i n e r u n n i n g
Gearbox A n g l e of rack g u i d e s c r e w l o o s e n e d 10°to20°
f r o m locked position
Suspension
Wheel alignment Camber Front at inspection -0°30'±30'
Front at a d j u s t m e n t -0°30'±10'
R e a r at inspection —1 ° 3 0 ' ± 3 0 '
R e a r at a d j u s t m e n t -1°30'±10'
Caster F r o n t at i n s p e c t i o n 6° 00'±15'
Front at a d j u s t m e n t 6°00'±15'
Total toe-in ('00-03 m o d e l s ) Front 0 ± 2 m m ( 0 + 0 . 0 8 in.)
Rear 6 . 0 ± 2 m m ( 0 . 2 4 + 0 . 0 8 in.)
Total toe-in ('04-08 m o d e l s ) Front 0 ± 2 m m ( 0 ± 0 . 0 8 in.)
R e a r (except C R ) 3.6±2mm(0.14±0.08in.)
R e a r (CR) 5 . 5 ± 2 m m ( 0 . 2 2 ± 0 . 0 8 in.)
Front w h e e l turning angle Inward 34°00'±2°
O u t w a r d (reference) 29°00'
Wheel Runout Axial 0—0.7 m m (0—0.03 in.) 2.0 m m (0.08 in.)
Radial 0—0.7 m m (0—0.03 in.) 1.5 m m (0.06 in.)
W h e e l bearing E n d play Front 0—0.05 m m (0—0.002 in.)
Rear 0—0.05 m m (0—0.002 in.)
2-8
specs
Brakes
Parking brake Distance traveled w h e n lever pulled 9 to 13 clicks
with 196 N (20 kgf, 44 Ibf) of force
Brake pedal Pedal height (carpet m o v e aside) 179 m m (7 1/16 in.)
Free play 1 - 5 m m (1/16—3/16 in.)
Master cylinder Piston-to-push rod c l e a r a n c e 0—0.4 m m (0—0.02 in.)
Brake d i s c Thickness Front 2 4 . 9 ^ 2 5 . 1 m m ( 0 . 9 8 - 0 . 9 9 in.) 23.0 m m (0.91 in.)
Rear 11.9—12.1 m m (0.469—0.476 in.) 10.0 m m (0.39 in.)
Runout Front a n d rear 0.04 m m (0.0016 in.)
Parallelism Front a n d rear 0.015 m m (0.0006 in.)
max.
Brake p a d Thickness Front 9.5—10.5 m m (0.37—0.41 in.) 1.6 m m (0.06 in.)
Rear 8.9—9.1 m m (0.35—0.36 in.) 1.6 m m (0.06 in.)
Mr Conditioning
Refrigerant Type H F C - 1 3 4 a (R-134a)
Capacity of s y s t e m 6 0 0 - 6 5 0 g ( 2 1 . 2 - 2 2 . 9 oz)
Refrigerant oil Type S P - 1 0 (P/N 38897-P13-A01AH or 38899-P13-A01)
C a p a c i t y of c o m p o n e n t s Condenser 25mL(5/6floz)
Evaporator 40mL(1 1/3floz)
E a c h line a n d 10mL(1/3fl-oz)
hose
Receiver 10mL(1/3fl-oz)
Compressor 1 3 0 - 1 5 0 m L (4 1 / 3 - 5 f l o z )
Compressor Field coil r e s i s t a n c e A t 68 °F (20 °C)
3 . 0 5 - 3 . 3 5 £2
Pulley-to-pressure plate c l e a r a n c e 0 . 3 5 - 0 . 6 5 m m ( 0 . 0 1 4 - 0 . 0 2 6 in.)
2-9
Item Measurement Qualification Specification
DIMENSIONS Overall length '00-07 m o d e l s 4,112 m m (162.2 in.)
'08 m o d e l 4,135 m m (162.8 in.)
Overall w i d t h 1,750 m m (68.9 in.)
Overall height 1,270 m m (50.0 in.)
Wheel base 2,400 m m (94.5 in.)
Track Front 1,470 m m (57.9 in.)
R e a r ('00-07 m o d e l s ) 1,508 m m (59.4 in.)
R e a r ('08 model) 1,510 m m (59.4 in.)
Ground clearance 130 m m (5.1 in.)
S e a t i n g capacity T w o (2)
WEIGHT G r o s s V e h i c l e W e i g h t Rating '00-03 m o d e l s 1,535 kg (3,385 lbs)
(GVWR) '04-08 m o d e l s 1,550 kg (3,418 lbs)
ENGINE Type W a t e r - c o o l e d , 4-stroke D O H C V T E C gasoline engine
Cylinder arrangement Inline 4-cylinder, longitudinal
B o r e a n d stroke '00-03 m o d e l s 87.0 x 84.0 m m (3.43 x 3.31 in.)
'04-08 m o d e l s 87.0 x 90.7 m m (3.43 x 3.57 in.)
3
Displacement '00-03 m o d e l s 1,997 c m (121.9 c u in.)
3
'04-08 m o d e l s 2,157 c m (131.6 c u in.)
C o m p r e s s i o n ratio 11.1
V a l v e train C h a i n driven, D O H C V T E C 4 v a l v e s per cylinder
Lubrication s y s t e m F o r c e d , w e t s u m p , with trochoid p u m p
Oil p u m p d i s p l a c e m e n t At 6,000 r p m 58.4 L (61.7 U S q t V m i n u t e
Water pump displacement A t 6,000 r p m 172 L (182 U S qt)/minute
Fuel required P r e m i u m U N L E A D E D g a s o l i n e with 91 P u m p O c t a n e
N u m b e r or higher
STARTER Type G e a r reduction
N o r m a l output '00-03 m o d e l s 1.0 kW
'04-08 m o d e l s 1.1 k W
N o m i n a l voltage 12V
Hour rating 30 s e c o n d s
Direction of rotation C l o c k w i s e a s v i e w e d f r o m drive e n d
CLUTCH Type Single plate dry, d i a p h r a g m spring
2
Clutch friction material s u r f a c e 188 c m (29 s q in.)
area
MANUAL Type Synchronized 6-speed forward, 1 reverse
TRANSMISSION P r i m a r y reduction '00-03 m o d e l s Direct 1:1
'04-08 m o d e l s 1.208
G e a r ratio 1st 3.133
2nd 2.045
3rd 1.481
4th 1.161
5th ('00-03 m o d e l s ) 0.979
5th ('04-08 m o d e l s ) 0.943
6th ('00-03 m o d e l s ) 0.810
6th ('04-08 m o d e l s ) 0.763
Reverse 2.800
S e c o n d a r y reduction gear Type S i n g l e helical gear
G e a r ratio 1.160
('00-03 m o d e l s )
G e a r ratio 1.208
('04-08 m o d e l s )
REAR Final reduction g e a r Type S p i r a l bevel gear
DIFFERENTIAL G e a r ratio 4.100
2-10
specs

STEERING Type R a c k a n d pinion w i t h electrical p o w e r - a s s i s t
Overall ratio 13.9
T u r n s , lock-to-lock 2.4
S t e e r i n g w h e e l diameter 360 m m (14.1 in.)
SUSPENSION Type Front Independent d o u b l e w i s h b o n e , coil spring with stabilizer
Rear Independent d o u b l e w i s h b o n e , coil spring with stabilizer
Shock absorber Front a n d rear T e l e s c o p i c , hydraulic, nitrogen gas-filled
TIRES S i z e of front and rear tires Front 205/55R16 8 9 W
{'00-03 m o d e l s ) Rear 225/50R16 9 2 W
S i z e of front and rear tires Front 215/45R17 9 7 W
('04-07 m o d e l s ) Rear 245/40R17 9 1 W
S i z e of front and rear tires Front 215/45R17 9 7 W
('08 m o d e l s ) Rear (except C R ) 245/40R17 9 1 W
Rear (CR) 255/40R17 9 4 W
S i z e of s p a r e tire Except CR T125/70D16 96W
WHEEL Camber Front -0°30'

ALIGNMENT Rear -1 °30'
Caster Front 6°00'
Total toe-in ('00-03 m o d e l s ) Front 0 m m (0 in.)
Rear 6.0 m m (0.24 in.)
Total toe-in ('04-08 m o d e l s ) Front 0 m m (0 in.)
Rear (except C R ) 3.6 m m (0.14 in.)
Rear (CR) 5.5 m m (0.22 in.)
BRAKES T y p e of service brake Front P o w e r - a s s i s t e d self-adjusting ventilated disc
Rear P o w e r - a s s i s t e d self-adjusting solid disc
T y p e of parking brake M e c h a n i c a l actuating, rear w h e e l s
2
Pad friction surface area Front 42.2 c m (6.5 s q in.) x 2
2
Rear 27.9 c m (4.3 s q in.) x 2
AIR Compressor Type/Manufacturer Scroll
CONDITIONING N u m b e r of c y l i n d e r s
Capacity 85.7 m L (5.23 c u in.)/rev.
Maximum speed 12,000 rpm
Lubricant capacity 130 m L (4 1/3fl-oz)
Lubricant type SP-10
Condenser Type Corrugated fin
Evaporator Type Corrugated fin
Blower Type S i r o c c o fan
Motor input 220W/12V
S p e e d control 7-speed m a n u a l A / C
3
M a x i m u m capacity 430 m ( 15,200 c u ft)/h
T e m p e r a t u r e control Air-mix type
Refrigerant Type H F C - 1 3 4 a (R-134a)
Quantity 6 0 0 - 6 5 0 g ( 2 1 . 2 - 2 2 . 9 oz)
(cont'd)
2-11
ELECTRICAL Battery 12 V - 4 5 A h / 2 0 HR (12 V - 3 6 A h / 5 HR)
RATINGS Fuses Main under-hood fuse/relay 100 A , 40 A 30 A , 20 A , 15 A , 10 A
f
box
Auxiliary u n d e r - h o o d f u s e 70A,60A,20A
box
U n d e r - d a s h f u s e / r e l a y box 20 A 15 A , 10 A , 7.5 A
f
Light b u l b s Headlight high b e a m 12V-55W(H1)

Headlight l o w b e a m (HID) 12V-35W(D2S)
Front turn signal lights 12V-21W
Front parking lights 12V-5W
('00-03 m o d e l s )
Front parking/side marker 12 V - 5 W (Amber)
lights ('04-08 m o d e l s )
R e a r turn signal lights 12V-21 W
R e a r s i d e m a r k e r lights 12V-5W
('00-03 m o d e l s )
R e a r s i d e m a r k e r lights LED
('04-08 m o d e l s )
S i d e turn s i g n a l lights 12V-5W
Brake/taillights 12V-21/5W
('00-03 m o d e l s )
Brake/taillights LED
('04-08 m o d e l s )
High m o u n t brake light LED
Back-up lights 12V-21 W
L i c e n s e plate light 12V-5W
T r u n k light 12V-5W
Ceiling light/Spotlights 12V-5W
G a u g e lights 12 V - 3 W , 2 W
Indicator lights 1 2 V - 1.12W, 1.4W
Panel a n d pilot lights 12 V - 0.56 W , 0.84 W , 0.91 W , L E D
W a s h e r reservoir Capacity ( U S A models) 2.5 L (2.6 U S qt)
Capacity (Canada models) 6.0 L (6.3 U S qt)
2-12
specs
Body Specifications
'00-07 M o d e l s
(cont'd)
2-13
Body Specifications (cont'd)
'08 Model
CR model is shown.
2-14
Maintenance
Lubricants and Fluids

Maintenance Schedule
Listed by Distance/Time
for Normal Conditions
'00 Model
for Severe Conditions
'00 Model
'01-03 Models
'01-03 Models
'04-05 Models
'04-05 Models
Maintenance Minder
General Information
'06-08 Models
Maintenance Main items
'06-08 Models
Maintenance Sub Items
'06-08 Models
Lubricants and Fluids
F o r the d e t a i l s of lubrication points a n d t y p e of l u b r i c a n t s to b e a p p l i e d , refer to t h e illustrated i n d e x a n d v a r i o u s w o r k

p r o c e d u r e s ( s u c h a s A s s e m b l y / R e a s s e m b l y , R e p l a c e m e n t , O v e r h a u l , Installation, etc.) c o n t a i n e d in e a c h s e c t i o n .
Application L u b r i c a n t or F l u i d
A Engine H o n d a M o t o r Oil ( A m e r i c a n H o n d a P/N 0 8 7 9 8 - 9 0 1 5 ,
H o n d a C a n a d a P/N C A 6 6 8 0 6 ) . 1 0 W - 3 0 is t h e p r e f e r r e d
m o t e r oil for o p t i m u m fuel e c o n o m y a n d y e a r r o u n d
protection. L o o k for t h e API Certification s e a l . M a k e
s u r e it s a y s " F o r G a s o l i n e E n g i n e s . "
B Manual transmission H o n d a M a n u a l T r a n s m i s s i o n F l u i d ( M T F ) : P/N
08798-9031
A l w a y s u s e H o n d a M T F . U s i n g m o t o r oil c a n c a u s e
stiffer shifting b e c a u s e it d o e s not c o n t a i n the p r o p e r
additives.
C B r a k e line ( i n c l u d e s A B S / V S A l i n e s ) H o n d a D O T 3 B r a k e F l u i d : P/N 0 8 7 9 8 - 9 0 0 8
D Clutch s y s t e m A l w a y s use Honda D O T 3 Brake Fluid. Using a non-
H o n d a b r a k e fluid c a n c a u s e c o r r o s i o n a n d d e c r e a s e t h e
life of t h e s y s t e m .
E R e l e a s e fork S u p e r High T e m p U r e a G r e a s e
F S h i f t l e v e r pivot : P/N 0 8 7 9 8 - 9 0 0 2
G Slave cylinder pushrod
H Throttle c a b l e e n d (Throttle link) Multipurpose grease
('00-05 m o d e l s )
1 B r a k e m a s t e r c y l i n d e r c l e v i s pin
J Battery t e r m i n a l s
K F u e l fill d o o r
L H o o d h i n g e s a n d h o o d latch
M Trunk hinges
N Door hinges: upper and lower
O Door checker
P C a l i p e r p i s t o n boot a n d s e a l , c a l i p e r p i n s a n d H o n d a S i l i c o n e G r e a s e : P/N 0 8 C 3 0 - B 0 2 3 4 M
boots
Q Air conditioning c o m p r e s s o r C o m p r e s s o r oil: S P - 1 0
(P/N 3 8 8 9 7 - P 1 3 - A 0 1 A H or 3 8 8 9 9 - P 1 3 - A 0 1 )
for refrigerant H F C - 1 3 4 a (R-134a)
R R e a r differential H y p o i d G e a r Oil
API c l a s s i f i c a t i o n : G L 5 or G L 6 ,
V i s c o s i t y : S A E 90
S Cooling s y s t e m H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2:
P/N O L 9 9 9 - 9 0 0 1
3-2
3-3
Listed by Distance/Time for Normal Conditions
'00 Model
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s t h e m i n i m u m
r e q u i r e d m a i n t e n a n c e . If the v e h i c l e is n o r m a l l y d r i v e n in C a n a d a , u s e the M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.
Distance Time Maintenance Items

7,500 m i l e s 12,000 k m D o i t e m s in A .
15,000 m i l e s 24,000 km 1 year D o i t e m s in A a n d B.
22,500 miles 36,000 km Do i t e m s in A .
30,000 miles 48,000 km 2 years D o i t e m s in A , B , a n d C .
45,000 miles 72,000 km 3 years Do i t e m s in A , B, a n d D.
3 years R e p l a c e b r a k e fluid ( s e e p a g e 19-9).
U s e Honda D O T 3 Brake Fluid.
60,000 miles 96,000 km 4 years D o i t e m s in A , B, a n d C .
67,500 miles 108,000 k m Do i t e m s in A .
75,000 miles 120,000 k m 5 years Do i t e m s in A , B , a n d D.
82,500 miles 132,000 k m D o i t e m s in A .
90,000 miles 144,000 k m 6 years D o i t e m s in A , B , C , a n d E .
105,000 m i i e s 168,000 k m 7 years I n s p e c t idle s p e e d ( s e e p a g e 11-140).
Idle s p e e d : 8 0 0 ± 5 0 r p m in neutral.
D o i t e m s in A , B , D, a n d F.
120,000 m i l e s 192,000 k m 8 years D o i t e m s in A , B , a n d C .
3-4
D o t h e i t e m s in p a r t s A , B, C , D, E , a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.
Part Maintenance Items
A R e p l a c e e n g i n e oil ( s e e p a g e 8-6) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
E n g i n e oil c a p a c i t y w i t h o u t oil filter: 4.5 L (4.8 U S qt)
C h e c k tire inflation a n d c o n d i t i o n e v e r y 7,500 m i l e s (12,000 k m ) .
B R e p l a c e e n g i n e oil filter ( s e e p a g e 8-7) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
E n g i n e oil c a p a c i t y with oil filter: 4.8 L (5.1 U S qt)
C h e c k front a n d rear b r a k e s ( s e e p a g e 19-3) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
• C h e c k p a d s a n d d i s c s for w e a r ( t h i c k n e s s ) , d a m a g e , a n d c r a c k s .
• C h e c k c a l i p e r s for d a m a g e , l e a k s , a n d t i g h t n e s s of m o u n t i n g bolts.
C h e c k parking brake a d j u s t m e n t ( s e e p a g e 19-7) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k t h e n u m b e r of c l i c k s (9 to 13) w h e n t h e parking l e v e r is p u l l e d up with 196 N (20 kgf, 44 Ibf) of
force.
I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d b o o t s ( s e e p a g e 17-5) e v e r y 15,000 m i l e s (24,000 km) or
1 year.
• C h e c k rack g r e a s e a n d s t e e r i n g linkage.
• C h e c k b o o t s for d a m a g e a n d leaking g r e a s e .
I n s p e c t s u s p e n s i o n c o m p o n e n t s ( s e e p a g e 18-3) e v e r y 15,000 m i l e s (24,000 k m ) or 1 y e a r .
• C h e c k bolts for t i g h t n e s s .
• C h e c k c o n d i t i o n of ball joint boots for deterioration a n d d a m a g e .
I n s p e c t d r i v e s h a f t b o o t s ( s e e p a g e 16-4) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k boots for c r a c k s a n d boot b a n d s for t i g h t n e s s .
I n s p e c t b r a k e h o s e s a n d l i n e s i n c l u d i n g A B S l i n e s ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) or 1
year.
C h e c k t h e m a s t e r c y l i n d e r , proportioning control v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
I n s p e c t all fluid l e v e l s , c o n d i t i o n of f l u i d s , a n d c h e c k for l e a k s e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
• E n g i n e c o o l a n t ( s e e p a g e 10-9)
• M a n u a l t r a n s m i s s i o n fluid ( M T F ) ( s e e p a g e 13-3)
• B r a k e fluid (see p a g e 19-9)
• C l u t c h fluid ( s e e s t e p 1 o n p a g e 12-6)
• R e a r differential fluid ( s e e p a g e 15-7)
• W i n d s h i e l d w a s h e r fluid ( s e e p a g e 22-184)
I n s p e c t c o o l i n g s y s t e m h o s e s a n d c o n n e c t i o n s ( s e e p a g e 10-2) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
• C h e c k for d a m a g e , l e a k s , a n d deterioration.
• C h e c k for p r o p e r f a n o p e r a t i o n .
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-5) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k catalytic c o n v e r t e r heat s h i e l d , e x h a u s t pipe, a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel lines* ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150) e v e r y 15,000 m i l e s (24,000 km)
or 1 y e a r .
C h e c k for l o o s e c o n n e c t i o n s , c r a c k s , a n d d e t e r i o r a t i o n ; retighten l o o s e c o n n e c t i o n s a n d r e p l a c e
d a m a g e d parts.
N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o t h e m a i n t e n a n c e i t e m s m a r k e d w i t h a n a s t e r i s k ( * ) will
not v o i d t h e c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e be d o n e at
t h e r e c o m m e n d e d intervals to e n s u r e long-term reliability.
(cont'd)
3-5
Listed by Distance/Time for Normal Conditions (conf d)
'00 Model
S e r v i c e at t h e i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s the m i n i m u m
r e q u i r e d m a i n t e n a n c e . If t h e v e h i c l e i s n o r m a l l y d r i v e n in C a n a d a , u s e t h e M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.
D o t h e i t e m s in p a r t s A , B , C , D, E , a n d F a s r e q u i r e d for the m i l e a g e / t i m e interval listed.

C R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-169) e v e r y 30,000 m i l e s (48,000 k m ) .
I n s p e c t d r i v e belt ( s e e p a g e 4-42) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
L o o k for c r a c k s a n d d a m a g e , t h e n c h e c k t h e p o s i t i o n of the d r i v e belt a u t o - t e n s i o n e r indicator.
R e p l a c e d u s t a n d p o l l e n filter ( s e e p a g e 21-27) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
• If t h e v e h i c l e i s p r i m a r i l y d r i v e n in a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in t h e air,
r e p l a c e t w i c e a s often (at t h e 15,000 m i l e s (24,000 km) or 1 y e a r interval).
• R e p l a c e it w h e n e v e r a i r f l o w f r o m t h e h e a t i n g a n d air c o n d i t i o n i n g s y s t e m is l e s s t h a n n o r m a l .
R e p l a c e r e a r differential fluid ( s e e p a g e 15-7) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
C a p a c i t y : 0.74 L (0.78 U S qt); u s e H y p o i d G e a r Oil G L 5 or G L 6 .
D R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9) at 45,000 m i l e s (72,000 km) or 3 y e a r s , t h e n e v e r y 30,000 m i l e s
(48,000 km) or 2 y e a r s .
C a p a c i t y : 6.5 L (1.72 U S gal); u s e H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2.
E R e p l a c e m a n u a l t r a n s m i s s i o n fluid ( s e e p a g e 13-3) e v e r y 90,000 m i l e s (144,000 km) or 6 y e a r s .
C a p a c i t y : 1.48 L (1.56 U S qt); u s e H o n d a M T F .
F R e p l a c e s p a r k p l u g s ( s e e p a g e 4-28) e v e r y 105,000 m i l e s (168,000 km) or 7 y e a r s .
U s e P F R 7 G - 1 I S ( N G K ) or P K 2 2 P R - L 1 1 S ( D E N S O ) .
I n s p e c t v a l v e c l e a r a n c e (cold) ( s e e p a g e 6-10) e v e r y 105,000 m i l e s (168,000 km) or 7 y e a r s .
• Intake: 0 . 2 1 — 0 . 2 5 m m (0.008—0.010 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
3-6
Listed by Distance/Time for Severe Conditions
'00 Model
S e r v i c e at the indicated d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e this s c h e d u l e if t h e v e h i c l e is d r i v e n M A I N L Y in
C a n a d a or in a n y of the f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e the N o r m a l
Conditions schedule.
S e v e r e Driving C o n d i t i o n s
• L e s s than 5 m i l e s (8 km) per trip or, in freezing t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) p e r trip
• In e x t r e m e l y hot w e a t h e r (over 9 0 °F/32 °C)
• E x t e n s i v e idling or long p e r i o d s of s t o p - a n d - g o d r i v i n g , s u c h a s a taxi or a c o m m e r c i a l d e l i v e r y v e h i c l e
• Driving o n m o u n t a i n o u s r o a d s
• O n m u d d y , d u s t y , or d e - i c e d r o a d s

3,750 m i l e s 6,000 km D o item in A .
7,500 m i l e s 12,000 k m D o i t e m s in A a n d B.
11,250 m i l e s 18,000 k m D o item in A .
15,000 m i l e s 24,000 k m 1 year D o i t e m s in A , B , a n d C .
22,500 m i l e s 36,000 km Do i t e m s in A a n d B.
26,250 m i l e s 42,000 k m Do item in A .
30,000 m i l e s 48,000 k m 2 years Do i t e m s in A , B , C , a n d D.
33,750 m i l e s 54,000 k m Do item in A .
37,500 m i l e s 60,000 k m Do i t e m s in A a n d B.
41,250 m i l e s 66,000 km Do item in A .
45,000 m i l e s 72,000 km 3 years Do i t e m s in A , B, C , a n d E .
3 years R e p l a c e brake fluid ( s e e p a g e 19-9).
48,750 miles 78,000 km D o item in A .
52,500 miles 84,000 km D o i t e m s in A a n d B.
60,000 miles 96,000 km 4 years D o i t e m s in A , B, C , a n d D.
(cont'd)
3-7
Listed by Distance/Time for Severe Conditions (cont'd)
'00 Model
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e this s c h e d u l e if the v e h i c l e is d r i v e n M A I N L Y in
S e v e r e Driving Conditions
• L e s s t h a n 5 m i l e s (8 km) per trip or, in f r e e z i n g t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) p e r trip
• In e x t r e m e l y hot w e a t h e r (over 90 °F/32 °C)

63,750 miles 102,000 km D o i t e m in A .
67,500 miles 108,000 km Do i t e m s in A a n d B.
71,250 miles 114,000 km Do i t e m in A .
75,000 miles 120,000 km 5 years Do i t e m s in A , B , C , a n d E .
82,500 miles 132,000 k m D o i t e m s in A a n d B.
86,250 miles 138,000 k m D o i t e m in A .
90,000 miles 144,000 k m 6 years D o i t e m s in A , B, C , a n d D.
93,750 miles 150,000 k m D o i t e m in A .
101,250 m i l e s 162,000 k m D o i t e m in A .
105,000 m i l e s 168,000 k m 7 years D o i t e m s in A , B , C , E , a n d F.
I n s p e c t idle s p e e d ( s e e p a g e 11-140).
108,750 miles 175,000 k m D o item in A .
3-8
Do t h e i t e m s in parts A , B, C D, E a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.
y r

A R e p l a c e e n g i n e oil ( s e e p a g e 8-6) a n d oil filter ( s e e p a g e 8-7) e v e r y 3,750 m i l e s (6,000 km) or 6 m o n t h s .
B C h e c k tire inflation a n d c o n d i t i o n e v e r y 7,500 m i l e s (12,000 k m ) .
C h e c k front a n d r e a r b r a k e s ( s e e p a g e 19-3) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d b o o t s ( s e e p a g e 17-5) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
I n s p e c t s u s p e n s i o n c o m p o n e n t s ( s e e p a g e 18-3) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
I n s p e c t d r i v e s h a f t b o o t s ( s e e p a g e 16-4) e v e r y 7,500 m i l e s (12,000 k m ) or 1 y e a r .
C h e c k b o o t s for c r a c k s a n d boot b a n d s for t i g h t n e s s .
C I n s p e c t b r a k e h o s e s a n d l i n e s i n c l u d i n g A B S l i n e s ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) or 1
year.
C h e c k t h e m a s t e r c y l i n d e r , proportioning c o n t r o l v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
C h e c k t h e n u m b e r of c l i c k s (9 to 13) w h e n the p a r k i n g l e v e r is p u l l e d up with 196 N (20 kgf, 44 Ibf) of
force.
R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-169) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
R e p l a c e rear differential fluid ( s e e p a g e 15-7) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
L u b r i c a t e all h i n g e s , l o c k s , a n d l a t c h e s with M u l t i p u r p o s e G r e a s e .
C h e c k all lights ( s e e p a g e 22-110).
C h e c k f u n c t i o n of all interior a n d exterior lights, a n d t h e position of t h e h e a d l i g h t s .
• B r a k e fluid ( s e e p a g e 19-9)
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-5) e v e r y 15,000 m i l e s (24,000 k m ) or 1 y e a r .
C h e c k c a t a l y t i c c o n v e r t e r heat s h i e l d , e x h a u s t p i p e , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel l i n e s * ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150). e v e r y 15,000 m i l e s (24,000 km)
or 1 year.
Inspect vehicle underbody.
C h e c k t h e paint for d a m a g e , s c r a t c h e s , s t o n e c h i p p i n g , a n d d e n t s .
the r e c o m m e n d e d i n t e r v a l s to e n s u r e long-term reliability.
(cont'd)
3-9
'00 Model
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e this s c h e d u l e if t h e v e h i c l e is d r i v e n M A I N L Y in
C a n a d a o r in a n y of t h e f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e the N o r m a l
• L e s s t h a n 5 m i l e s (8 km) p e r trip or, in f r e e z i n g t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) per trip
• In e x t r e m e l y hot w e a t h e r ( o v e r 90 °F/32 °C)
D o t h e i t e m s in p a r t s A , B, C , D, E , a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.

D I n s p e c t d r i v e belt ( s e e p a g e 4-42) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
L o o k for c r a c k s a n d d a m a g e , t h e n c h e c k t h e p o s i t i o n of t h e d r i v e belt a u t o - t e n s i o n e r indicator.
• If t h e v e h i c l e is p r i m a r i l y d r i v e n in u r b a n a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in
t h e air, r e p l a c e e v e r y 15,000 m i l e s (24,000 k m ) .
R e p l a c e m a n u a l t r a n s m i s s i o n fluid ( s e e p a g e 13-3) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
E R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9) at 4 5 , 0 0 0 m i l e s (72,000 km) or 3 y e a r s , t h e n e v e r y 30,000 m i l e s
(48,000 km) or 2 y e a r s .
U s e P F R 7 G - 1 1 S ( N G K ) or P K 2 2 P R - L 1 1 S ( D E N S O ) .
• Intake: 0 . 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
3-10
'01-03 Models
S e r v i c e at the indicated d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s t h e m i n i m u m
r e q u i r e d m a i n t e n a n c e . If the v e h i c l e is n o r m a l l y d r i v e n in C a n a d a , u s e t h e M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.

7,500 m i l e s 12,000 k m Do items in A.
15,000 m i l e s 24,000 k m 1 year Do items in A a n d B.
22,500 miles 36,000 km Do items in A.
30,000 miles 48,000 k m 2 years Do items in A , B, a n d C .
45,000 m i l e s 72,000 km 3 years Do i t e m s in A a n d B.
52,500 miles 84,000 km D o i t e m s in A .
60,000 miles 96,000 km 4 years Do i t e m s in A , B, a n d C .
75,000 miles 120,000 k m 5 years Do i t e m s in A a n d B.
90,000 miles 144,000 k m 6 years Do i t e m s in A , B , a n d C .
Use Honda D O T 3 Brake Fluid.
105,000 m i l e s 168,000 k m 7 years I n s p e c t idle s p e e d ( s e e p a g e 11-140).
D o i t e m s in A , B, a n d D.
120,000 m i l e s 192,000 k m 8 years Do i t e m s in A , B, C , a n d E .
120,000 m i l e s 192,000 k m 10 y e a r s Do i t e m in F.
(cont'd)
3-11
Listed by Distance/Time for Normal Conditions (cont'd)
'01-03 Models
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s t h e m i n i m u m
r e q u i r e d m a i n t e n a n c e . If the v e h i c l e is n o r m a l l y d r i v e n in C a n a d a , u s e the M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.
Do t h e i t e m s in parts A , B, C , D, E , a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.

C h e c k tire inflation a n d c o n d i t i o n e v e r y 7,500 m i l e s (12,000 k m ) .
E n g i n e oil c a p a c i t y w i t h oil filter: 4.8 L (5.1 U S qt)
C h e c k front a n d r e a r b r a k e s ( s e e p a g e 19-3) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k parking b r a k e a d j u s t m e n t ( s e e p a g e 19-7) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k t h e n u m b e r of c l i c k s (9 to 13) w h e n t h e parking l e v e r is pulled up with 196 N (20 kgf, 44 Ibf) of
force.
1 year.
• C h e c k b o o t s for d a m a g e a n d l e a k i n g g r e a s e .
I n s p e c t s u s p e n s i o n c o m p o n e n t s ( s e e p a g e 18-3) e v e r y 15,000 m i l e s (24,000 km) o r 1 y e a r .
• C h e c k c o n d i t i o n of ball joint b o o t s for d e t e r i o r a t i o n and damage.
I n s p e c t b r a k e h o s e s a n d l i n e s i n c l u d i n g A B S l i n e s ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) or 1
year.
C h e c k t h e m a s t e r c y l i n d e r , p r o p o r t i o n i n g control v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
• C h e c k for d a m a g e , l e a k s , a n d d e t e r i o r a t i o n .
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-5) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k c a t a l y t i c c o n v e r t e r h e a t s h i e l d , e x h a u s t p i p e , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel l i n e s * ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150) e v e r y 15,000 m i l e s (24,000 km)
or 1 y e a r .
N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o the m a i n t e n a n c e i t e m s m a r k e d with a n a s t e r i s k ( * ) will
t h e r e c o m m e n d e d i n t e r v a l s to e n s u r e l o n g - t e r m reliability.
3-12
D o t h e i t e m s in parts A , B , C , D, E , a n d F a s r e q u i r e d for the m i l e a g e / t i m e interval l i s t e d .
C R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-169) e v e r y 3 0 , 0 0 0 m i l e s (48,000 k m ) .
I n s p e c t drive belt ( s e e p a g e 4-42) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
L o o k for c r a c k s a n d d a m a g e , t h e n c h e c k the position of t h e d r i v e belt a u t o - t e n s i o n e r indicator.
R e p l a c e d u s t a n d p o l l e n filter ( s e e p a g e 21-27) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
• If t h e v e h i c l e is p r i m a r i l y d r i v e n in a r e a s that h a v e h i g h c o n c e n t r a t i o n s of d u s t , p o l l e n , o r s o o t in the air,
r e p l a c e t w i c e a s often (at the 15,000 m i l e s (24,000 k m ) o r 1 y e a r interval).
• R e p l a c e it w h e n e v e r a i r f l o w f r o m t h e heating a n d air c o n d i t i o n i n g s y s t e m is l e s s t h a n n o r m a l .
R e p l a c e rear differential fluid ( s e e p a g e 15-7) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
D R e p l a c e s p a r k p l u g s ( s e e p a g e 4-28) e v e r y 105,000 m i l e s (168,000 km) o r 7 y e a r s .
• Intake: 0 . 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
E R e p l a c e m a n u a l t r a n s m i s s i o n fluid ( s e e p a g e 13-3) e v e r y 120,000 m i l e s (192,000 km) o r 8 y e a r s .
F R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9) at 120,000 m i l e s (192,000 km) or 10 y e a r s , t h e n e v e r y
60,000 m i l e s (96,000 k m ) or 5 y e a r s .
C a p a c i t y : 6.5 L (1.72 U S g a l ) ; u s e H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2.
3-13
'01-03 Models
S e r v i c e at the indicated d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e this s c h e d u l e if the v e h i c l e is d r i v e n M A I N L Y in
C a n a d a o r in a n y of t h e f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e the N o r m a l
• L e s s t h a n 5 m i l e s (8 km) per trip or, in freezing t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) per trip
• In e x t r e m e l y hot w e a t h e r (over 9 0 °F/32 *€)
• E x t e n s i v e idling or l o n g p e r i o d s of s t o p - a n d - g o d r i v i n g , s u c h a s a taxi or a c o m m e r c i a l d e l i v e r y v e h i c l e

7,500 m i l e s 12,000 k m Do i t e m s in A a n d B.
11,250 m i l e s 18,000 k m Do i t e m in A .
15,000 m i l e s 24,000 km 1 year Do i t e m s in A , B , a n d C .
18,750 m i l e s 30,000 km Do i t e m in A .
30,000 miles 48,000 km 2 years Do i t e m s in A , B, C , a n d D.
37,500 miles 60,000 km Do i t e m s in A a n d R.
45,000 m i l e s 72,000 km 3 years D o i t e m s in A , B , a n d C .
48,750 m i l e s 78,000 km D o i t e m in A .
52,500 m i l e s 84,000 km D o i t e m s in A a n d B.
60,000 miles 96,000 km 4 years D o i t e m s in A , B , C , D, a n d E .
3-14
63,750 miles 102,000 k m Do item in A .
67,500 miles 108,000 k m Do i t e m s in A a n d B.
75,000 miles 120,000 k m 5 years Do i t e m s in A , B, a n d C .
90,000 m i l e s 144,000 k m 6 years D o i t e m s in A , B , C , a n d D.
105,000 m i l e s 168,000 km 7 years D o i t e m s in A , B , C , a n d F .
Idle s p e e d : 8 0 0 ± 5 0 r p m in n e u t r a l .
120,000 m i l e s 192,000 km 8 years D p i t e m s in A , B , C , D, E , a n d G .
(cont'd)
3-15
'01-03 Models
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e t h i s s c h e d u l e if the v e h i c l e is d r i v e n M A I N L Y in
C a n a d a or in a n y of t h e f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e the N o r m a l
• L e s s t h a n 5 m i l e s (8 km) per trip or, in f r e e z i n g t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) per trip
• In e x t r e m e l y hot w e a t h e r ( o v e r 9 0 °F/32 °C)
• E x t e n s i v e idling o r long p e r i o d s of s t o p - a n d - g o d r i v i n g , s u c h a s a taxi or a c o m m e r c i a l d e l i v e r y v e h i c l e
• Driving on mountainous roads
D o t h e i t e m s in p a r t s A , B, C , D, E , F , a n d G a s r e q u i r e d for the m i l e a g e / t i m e interval listed.

A R e p l a c e e n g i n e oil ( s e e p a g e 8-6) a n d oil filter ( s e e p a g e 8-7) e v e r y 3,750 m i l e s (6,000 km) or 6 m o n t h s .
B C h e c k tire inflation a n d c o n d i t i o n e v e r y 7,500 m i l e s (12,000 km).
C h e c k front a n d rear b r a k e s ( s e e p a g e 19-3) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
• C h e c k c a l i p e r s for d a m a g e , l e a k s , a n d t i g h t n e s s of m o u n t bolts.
I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d b o o t s ( s e e p a g e 17-5) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
• C h e c k c o n d i t i o n of ball joint b o o t s for deterioration a n d d a m a g e .
3-16
D o t h e i t e m s in parts A , B, C , D, E , F , a n d G a s r e q u i r e d for t h e m i i e a g e / t i m e interval listed.
C I n s p e c t brake h o s e s a n d l i n e s i n c l u d i n g A B S l i n e s ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) o r 1
year.
C h e c k t h e m a s t e r c y l i n d e r , proportioning control v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
C h e c k the n u m b e r of c l i c k s (9 to 13) w h e n the parking l e v e r is p u l l e d up with 196 N (20 kgf, 44 Ibf) of
force.
L u b r i c a t e all h i n g e s , l o c k s , a n d l a t c h e s with M u l t i p u r p o s e G r e a s e .
C h e c k all lights ( s e e p a g e 22-110).
C h e c k f u n c t i o n of all interior a n d exterior lights, a n d t h e p o s i t i o n of t h e h e a d l i g h t s .
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-5) e v e r y 15,000 m i l e s (24,000 km) o r 1 y e a r .
C h e c k c a t a l y t i c c o n v e r t e r heat s h i e l d , e x h a u s t p i p e , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel l i n e s * ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150) e v e r y 15,000 m i l e s (24,000 km)
or 1 y e a r .
C h e c k t h e paint for d a m a g e , s c r a t c h e s , s t o n e c h i p p i n g , a n d d e n t s .
D I n s p e c t d r i v e belt ( s e e p a g e 4-42) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
L o o k for c r a c k s a n d d a m a g e , t h e n c h e c k t h e position of the d r i v e belt a u t o - t e n s i o n e r indicator.
R e p l a c e d u s t a n d pollen filter ( s e e p a g e 21-27) e v e r y 30,000 m i l e s (48,000 km) o r 2 y e a r s .
• If the v e h i c l e is primarily d r i v e n in a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in t h e air,
r e p l a c e e v e r y 15,000 m i l e s (24,000 km).
• R e p l a c e it w h e n e v e r a i r f l o w f r o m t h e heating a n d air c o n d i t i o n i n g s y s t e m is l e s s t h a n n o r m a l .
• Intake: 0 . 2 1 — 0 . 2 5 m m (0.008—0.010 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
G R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9) at 120,000 m i l e s (192,000 km) or 10 y e a r s , t h e n e v e r y
60,000 m i l e s (96,000 km) or 5 y e a r s .
N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o the m a i n t e n a n c e i t e m s m a r k e d with a n a s t e r i s k ( * ) will
not v o i d t h e c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e b e d o n e at
the r e c o m m e n d e d i n t e r v a l s to e n s u r e l o n g - t e r m reliability.
3-17
'04-05 Models
S e r v i c e at the i n d i c a t e d d i s t a n c e o r t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s t h e m i n i m u m
r e q u i r e d m a i n t e n a n c e . If t h e v e h i c l e i s n o r m a l l y d r i v e n in C a n a d a , u s e the M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.

15,000 m i l e s 24,000 km 1 year D o i t e m s in A a n d B.
30,000 miles 48,000 km 2 years D o i t e m s in A , B , a n d C .
45,000 miles 72,000 km 3 years D o i t e m s in A a n d B.
60,000 miles 96,000 km 4 years Do items in A , B, and C .
67,500 miles 108,000 k m Do items in A.
75,000 miles 120,000 k m 5 years " Do items in A a n d B.
82,500 miles 132,000 k m Do items in A.
90,000 miles 144,000 k m 6 years D o i t e m s in A , B , a n d C .
105,000 m i l e s 168,000 k m 7 years I n s p e c t idle s p e e d ( s e e p a g e 11-140).
D o i t e m s in A , B, a n d D.
120,000 m i l e s 192,000 k m 8 years D o i t e m in E .
120,000 m i l e s 192,000 k m 8 years D o i t e m s in A , B , C , a n d F.
127,500 m i l e s 204,000 km D o i t e m s in A .
135,000 m i l e s 216,000 km 11 y e a r s D o i t e m s in A a n d B.
142,500 m i l e s 228,000 km D o i t e m s in A .
150,000 m i l e s 240,000 km 12 y e a r s D o i t e m s in A , B, a n d C .
12 y e a r s R e p l a c e b r a k e fluid ( s e e p a g e 19-9).
3-18
D o t h e i t e m s in parts A , B, C , D, E , a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.
C h e c k tire inflation a n d c o n d i t i o n , e v e r y 7,500 m i l e s (12,000 k m ) .
C h e c k front a n d rear b r a k e s ( s e e p a g e 19-3) e v e r y 15,000 m i l e s (24,000 km) o r 1 y e a r .
C h e c k the n u m b e r of c l i c k s (9 to 13) w h e n t h e parking l e v e r is p u l l e d up w i t h 196 N (20 kgf, 44 Ibf) of
force.
1 year.
Inspect brake h o s e s a n d l i n e s i n c l u d i n g A B S l i n e s ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) or 1
year.
C h e c k the m a s t e r c y l i n d e r , proportioning control v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
• Brake fluid ( s e e p a g e 19-9)
Inspect e x h a u s t s y s t e m * ( s e e p a g e 9-6) e v e r y 15,000 m i l e s (24,000 km) or 1 y e a r .
C h e c k catalytic c o n v e r t e r heat s h i e l d , e x h a u s t p i p e , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
Inspect fuel l i n e s * ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150) e v e r y 15,000 m i l e s (24,000 km)
or 1 y e a r .
N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o t h e m a i n t e n a n c e i t e m s m a r k e d with a n a s t e r i s k ( * ) will
not v o i d the c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e be d o n e at
t h e r e c o m m e n d e d intervals to e n s u r e l o n g - t e r m reliability.
(cont'd)
3-19
Listed by Distance/Time for Normal Conditions (cont'd)
'04-05 Models
S e r v i c e at the i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. T h i s M a i n t e n a n c e S c h e d u l e o u t l i n e s the m i n i m u m
r e q u i r e d m a i n t e n a n c e . If t h e v e h i c l e is n o r m a l l y d r i v e n in C a n a d a , u s e the M a i n t e n a n c e S c h e d u l e for S e v e r e
Conditions.
Do t h e i t e m s in p a r t s A , B , C , D, E , a n d F a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.

C R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-169) e v e r y 30,000 m i l e s (48,000 k m ) .
I n s p e c t d r i v e belt ( s e e p a g e 4-42) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
R e p l a c e d u s t a n d p o l l e n filter ( s e e p a g e 21-27) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
• If t h e v e h i c l e is p r i m a r i l y d r i v e n in a r e a s that h a v e h i g h c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in t h e air,
r e p l a c e t w i c e a s often (at t h e 15,000 m i l e s (24,000 km) or 1 y e a r interval).
R e p l a c e r e a r differential fluid ( s e e p a g e 15-7) e v e r y 30,000 m i l e s (48,000 km) or 2 y e a r s .
D R e p l a c e s p a r k p l u g s ( s e e p a g e 4-28) e v e r y 105,000 m i l e s (168,000 k m ) or 7 y e a r s .
• Intake: 0 . 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
F R e p l a c e e n g i n e c o o l a n t (see p a g e 1 0 9 ) a t 120,000 m i l e s (192,000 km) or 10 y e a r s , t h e n e v e r y
6 0 , 0 0 0 m i l e s (96,000 km) or 5 y e a r s .
3-20
'04-05 Models
S e r v i c e at t h e indicated d i s t a n c e o r t i m e , w h i c h e v e r c o m e s first. U s e this s c h e d u l e if t h e v e h i c l e is d r i v e n M A I N L Y in
• L e s s t h a n 5 m i l e s (8 km) per trip or, in freezing t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) per trip
• In e x t r e m e l y hot w e a t h e r (over 9 0 °F/32 °C)

15,000 m i l e s 24,000 km 1 year D o i t e m s in A , B, a n d C .
30,000 m i l e s 48,000 km 2 years Do i t e m s in A , B, C , a n d D.
45,000 m i l e s 72,000 km 3 years D o i t e m s in A , B , a n d C .
52,500 miles 84,000 k m Do i t e m s in A a n d B.
60,000 miles 96,000 k m 4 years Do i t e m s in A , B, C , D, a n d E .
(cont'd)
3-21
'04-05 Models
S e r v i c e at t h e i n d i c a t e d d i s t a n c e o r t i m e , w h i c h e v e r c o m e s first. U s e t h i s s c h e d u l e if t h e v e h i c l e i s d r i v e n M A I N L Y in
C a n a d a or in a n y of t h e f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e the N o r m a l
• L e s s t h a n 5 m i l e s (8 k m ) p e r trip or, in f r e e z i n g t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) p e r trip
• E x t e n s i v e idling o r l o n g p e r i o d s of s t o p - a n d - g o d r i v i n g , s u c h a s a taxi o r a c o m m e r c i a l d e l i v e r y v e h i c l e
• O n m u d d y , dusty, or de-iced roads

75,000 miles 120,000 k m 5 years D o i t e m s in A , B, a n d C .
97,500 miles 156,000 km D o i t e m s in A a n d B.
105,000 m i l e s 168,000 km 7 years D o i t e m s in A , B, C , a n d F.
108,750 m i l e s 174,000 km D o i t e m in A .
120,000 m i l e s 192,000 k m 8 years D o i t e m s in A , B, C , D, a n d E .
120,000 miles 192,000 km 10 y e a r s Do item in G .
123,750 miles 198,000 km Do item in A .
131,250 miles 210,000 km Do item in A .
135,000 miles 216,000 km 11 y e a r s Do i t e m s in A , B , a n d C .
150,000 m i l e s 240,000 km 12 y e a r s D o i t e m s in A , B , C , a n d D.
12 y e a r s R e p l a c e b r a k e fluid ( s e e p a g e 19-9).
3-22
D o t h e i t e m s in parts A , B, C , D, E , F, a n d G a s required for the m i l e a g e / t i m e interval listed.
A R e p l a c e e n g i n e oil ( s e e p a g e 8-6) a n d oil filter ( s e e p a g e 8-7) e v e r y 3,750 m i l e s (6,000 k m ) or 6 m o n t h s .
B C h e c k tire inflation a n d c o n d i t i o n , e v e r y 7,500 m i l e s (12,000 k m ) .
C h e c k front a n d rear b r a k e s ( s e e p a g e 19-3) e v e r y 7 , 5 0 0 m i l e s (12,000 km) or 1 y e a r .
I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d boots ( s e e p a g e 17-5) e v e r y 7,500 m i l e s (12,000 km) or 1 y e a r .
• C h e c k fluid line for d a m a g e or l e a k s .
• C h e c k boots for d a m a g e a n d l e a k i n g g r e a s e .
• C h e c k condition of ball joint b o o t s for deterioration a n d d a m a g e .
C h e c k boots for c r a c k s a n d boot b a n d s for t i g h t n e s s .
C I n s p e c t brake h o s e s a n d lines i n c l u d i n g A B S lines ( s e e p a g e 19-28) e v e r y 15,000 m i l e s (24,000 km) o r 1
year.
C h e c k the m a s t e r c y l i n d e r , proportioning control v a l v e , a n d A B S m o d u l a t o r - c o n t r o l unit for d a m a g e
and leakage.
C h e c k t h e n u m b e r of clicks (9 to 13) w h e n the p a r k i n g l e v e r is p u l l e d up with 196 N (20 kgf, 44 Ibf) of
force.
U s e n o r m a l s c h e d u l e e x c e p t in d u s t y c o n d i t i o n .
L u b r i c a t e ail h i n g e s , l o c k s , a n d l a t c h e s with M u l t i p u r p o s e G r e a s e .
C h e c k all lights a n d c o n t r o l s ( s e e p a g e 22-110).
C h e c k function of all interior a n d exterior lights, a n d t h e position of t h e h e a d l i g h t s .
• C l u t c h fluid ( s e e s t e p 1 on p a g e 12-6)
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-6) e v e r y 15,000 m i l e s (24,000 k m ) or 1 y e a r .
C h e c k catalytic c o n v e r t e r heat s h i e l d , e x h a u s t p i p e , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel lines ( s e e p a g e 11-148) a n d c o n n e c t i o n s * ( s e e p a g e 11-150) e v e r y 15,000 m i l e s (24,000 km)
or 1 y e a r .
C h e c k the paint for d a m a g e , s c r a t c h e s , s t o n e c h i p p i n g , a n d d e n t s .
not v o i d the c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e be d o n e at
t h e r e c o m m e n d e d intervals to e n s u r e long-term reliability.
(cont'd)
3-23
'04-05 Models
S e r v i c e at t h e i n d i c a t e d d i s t a n c e or t i m e , w h i c h e v e r c o m e s first. U s e t h i s s c h e d u l e if t h e v e h i c l e is d r i v e n M A I N L Y in
C a n a d a or in a n y of t h e f o l l o w i n g c o n d i t i o n s . If o n l y O C C A S I O N A L L Y d r i v e n in t h e s e c o n d i t i o n s , u s e t h e N o r m a l
• L e s s t h a n 5 m i l e s (8 km) p e r trip or, in f r e e z i n g t e m p e r a t u r e s , l e s s t h a n 10 m i l e s (16 km) p e r trip
D o t h e i t e m s in p a r t s A , B, C , D, E , F, a n d G a s r e q u i r e d for t h e m i l e a g e / t i m e interval listed.

D I n s p e c t d r i v e belt ( s e e p a g e 4-42) e v e r y 3 0 , 0 0 0 m i l e s (48,000 km) or 2 y e a r s .
• If the v e h i c l e is p r i m a r i l y d r i v e n in a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in t h e air,
r e p l a c e e v e r y 15,000 m i l e s (24,000 k m ) .
Use PFR7G-11S (NGK) or PK22PR-L11S (DENSO).
• Intake: 0.21— 0.25 m m ( 0 . 0 0 8 — 0 . 0 1 0 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
G R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9) at 120,000 m i l e s (192,000 km) or 10 y e a r s , t h e n e v e r y
6 0 , 0 0 0 m i l e s (96,000 km) o r 5 y e a r s .
Capacity*. 6.5 L (1.72 U S g a l ) ; u s e H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2.
3-24
Maintenance Minder
General Information
Maintenance Display
'06-08 M o d e l s
T h e m a i n t e n a n c e m i n d e r is a n important f e a t u r e of the i n f o r m a t i o n d i s p l a y . B a s e d o n e n g i n e a n d t r a n s m i s s i o n
o p e r a t i n g c o n d i t i o n s , t h e S 2 0 0 0 ' s o n b o a r d c o m p u t e r ( E C M ) c a l c u l a t e s t h e r e m a i n i n g e n g i n e oil a n d m a n u a l
t r a n s m i s s i o n fluid life. T h e s y s t e m a l s o d i s p l a y s t h e r e m a i n i n g e n g i n e oil life a l o n g w i t h t h e c o d e for o t h e r s c h e d u l e d
maintenance items needing service.
'06-07 M o d e l s :
MAINTENANCE MINDER INDICATOR INFORMATION DISPLAY TRIP B U T T O N
08 Model:
MAINTENANCE INFORMATION TRIP B U T T O N

MINDER DISPLAY
INDICATOR
(cont'd)
3-25
Maintenance Minder
G e n e r a l I n f o r m a t i o n (cont'd)
Service information W h e n t h e ignition s w i t c h is in t h e O N (II) p o s i t i o n ,

a n d t h e r e m a i n i n g e n g i n e oil life is 1 % to 5 % , t h e
1. T h e r e m a i n i n g e n g i n e oil life (A) is s h o w n a s a m e s s a g e " S E R V I C E " (A) is d i s p l a y e d a l o n g with
percentage on the information display. e n g i n e oil life a n d t h e s a m e m a i n t e n a n c e item
T o s e e t h e c u r r e n t e n g i n e oil life, t u r n t h e ignition code(s).
s w i t c h to t h e O N (II) p o s i t i o n , t h e n p u s h a n d r e l e a s e
t h e trip button r e p e a t e d l y until t h e e n g i n e oil life
displays.
SERVICE
OILLIFE^
OILLIFE%
on
OLI
W h e n t h e ignition s w i t c h is in the O N (II) p o s i t i o n ,

a n d t h e r e m a i n i n g e n g i n e oil life is 0 % , t h e e n g i n e
oil life indicator (A) blinks.
W h e n t h e ignition s w i t c h is in t h e O N (II) p o s i t i o n , P r e s s i n g t h e trip button c a n c e l s t h e d i s p l a y , but t h e
a n d t h e r e m a i n i n g e n g i n e oil life is 6 % to 15 % , the m a i n t e n a n c e m i n d e r indicator s t a y s o n .
r e m a i n i n g e n g i n e oil life (A) a n d o t h e r s c h e d u l e d
m a i n t e n a n c e item(s) needing s e r v i c e are d i s p l a y e d .
T h e m a i n t e n a n c e m i n d e r i n d i c a t o r (B) a l s o c o m e s
o n w h e n t h e e n g i n e oil life is 15 % or l e s s .
T o c a n c e l the display a n d the indicator, p r e s s the
SERVICE
trip button. OILLIFE%
• Complete list of m a i n t e n a n c e m a i n i t e m s (C)
(see page 3-28).
n
u
• Complete list of m a i n t e n a n c e s u b i t e m s (D)
(see page 3-29).
OILLIFE%
A
B
1 3 3 1 J C C
l £ 3 IZIQ (5 f
U L
c
—r B
3-26
5. If t h e indicated m a i n t e n a n c e is not d o n e , the e n g i n e Resetting the Maintenance Information
oil life indicator s h o w s a n e g a t i v e m i l e a g e , for Display
e x a m p l e " — 1 0 , " o n the d i s p l a y .
If t h e n e g a t i v e m i l e a g e is b e t w e e n 0 a n d — 9 , the NOTE:
indicator is d i s p l a y e d for o n l y a f e w s e c o n d s w h e n • T h e v e h i c l e m u s t be s t o p p e d to r e s e t t h e d i s p l a y .
t h e ignition s w i t c h is t u r n e d to the O N (II) position. • If a r e q u i r e d s e r v i c e is d o n e a n d the d i s p l a y is not
T h e n e g a t i v e m i l e a g e r e m a i n s d i s p l a y e d after the r e s e t , or if t h e m a i n t e n a n c e d i s p l a y is r e s e t without
v e h i c l e is d r i v e n m o r e t h a n 10 m i l e s (for U S A d o i n g t h e s e r v i c e , t h e s y s t e m will not s h o w the
m o d e l s ) or 10 k m (for C a n a d a m o d e l s ) after 0 % oil p r o p e r m a i n t e n a n c e t i m i n g . T h i s c a n l e a d to s e r i o u s
life is r e a c h e d . m e c h a n i c a l p r o b l e m s b e c a u s e t h e r e will be no
T h i s m e a n s t h e i n d i c a t e d m a i n t e n a n c e item(s) a c c u r a t e r e c o r d of w h e n t h e r e q u i r e d m a i n t e n a n c e is
s h o u l d h a v e b e e n d o n e m o r e t h a n 10 m i l e s (or needed.
10 km) a g o . • T h e e n g i n e oil life a n d m a i n t e n a n c e i t e m ( s ) c a n be
reset independently only with the H D S .
1. T u r n t h e ignition s w i t c h to the O N (II) p o s i t i o n .
2. P r e s s r e l e a s e t h e trip button r e p e a t e d l y until the

SERVICE
e n g i n e oil life indicator is d i s p l a y e d .
3. P r e s s a n d hold t h e trip button for a b o u t 10 s e c o n d s .

T h e e n g i n e oil life indicator a n d t h e m a i n t e n a n c e
item c o d e ( s ) will blink.
N O T E : If y o u a r e resetting t h e d i s p l a y w h e n the
e n g i n e oil life is m o r e t h a n 15 % , m a k e s u r e a n y
m a i n t e n a n c e item(s) requiring s e r v i c e a r e d o n e
b e f o r e resetting t h e d i s p l a y .
4. P r e s s a n d hold t h e trip button for a n o t h e r

5 s e c o n d s . T h e m a i n t e n a n c e item c o d s ( s ) will
d i s a p p e a r , a n d the e n g i n e oil life will r e s e t to " 1 0 0 " .
OILLIFEX
inn
IUU
3-27
Maintenance Minder
Maintenance Main Items
'06-08 Models
If m e s s a g e , " S E R V I C E " d o e s not a p p e a r m o r e t h a n 12 m o n t h s after t h e d i s p l a y is r e s e t , c h a n g e t h e e n g i n e oil e v e r y

year.
NOTE:
• R e p l a c e t h e b r a k e fluid e v e r y 3 y e a r s ( i n d e p e n d e n t of t h e m a i n t e n a n c e m e s s a g e s in t h e information d i s p l a y ) .
• I n s p e c t idle s p e e d e v e r y 160,000 m i l e s (256,000 k m ) .
• A d j u s t the v a l v e s d u r i n g s e r v i c e s A , B, 1 , 2 or 3 if o n l y t h e y a r e n o i s y .
Symbol Maintenance Main Items

A R e p l a c e e n g i n e oil ( s e e p a g e 8-6).
B R e p l a c e e n g i n e oil filter ( s e e p a g e 8-7).
C h e c k front a n d r e a r b r a k e s ( s e e p a g e 19-3).
C h e c k p a r k i n g b r a k e a d j u s t m e n t ( s e e p a g e 19-7).
C h e c k t h e n u m b e r of c l i c k s (9 to 13) w h e n t h e parking brake l e v e r is p u l l e d w i t h 196 N (20 kgf, 44 Ibf)
of f o r c e .
I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d g e a r b o x b o o t s ( s e e p a g e 17-5).
• C h e c k rack g r e a s e a n d s t e e r i n g l i n k a g e .
i n s p e c t s u s p e n s i o n c o m p o n e n t s ( s e e p a g e 18-3).
• C h e c k c o n d i t i o n of ball joint b o o t s for deterioration a n d d a m a g e .
I n s p e c t d r i v e s h a f t b o o t s ( s e e p a g e 16-4).
I n s p e c t b r a k e h o s e s a n d l i n e s i n c l u d i n g V S A l i n e s ( s e e p a g e 19-28).
C h e c k t h e m a s t e r c y l i n d e r a n d V S A m o d u l a t o r - c o n t r o l unit for d a m a g e a n d l e a k a g e .
I n s p e c t all fluid l e v e l s , c o n d i t i o n of f l u i d s , a n d c h e c k for l e a k s .
I n s p e c t e x h a u s t s y s t e m * ( s e e p a g e 9-6).
C h e c k c a t a l y t i c c o n v e r t e r h e a t s h i e l d s , e x h a u s t p i p e s , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s .
I n s p e c t fuel l i n e s * ( s e e p a g e 11-478) a n d c o n n e c t i o n s * ( s e e p a g e 11-480).
C h e c k e x p i r a t i o n date o n the bottle f o r t h e t e m p o r a r y tire r e p a i r kit (CR m o d e l o n l y ) .
N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o t h e m a i n t e n a n c e i t e m s m a r k e d with a n a s t e r i s k ( * ) will
not v o i d t h e c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e s be d o n e at
the r e c o m m e n d e d i n t e r v a l , to e n s u r e l o n g - t e r m reliability.
3-28
Maintenance Sub Items
'06-08 Models
Number Maintenance S u b Items

1 C h e c k tire inflation a n d c o n d i t i o n .
2 R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-505).
If t h e v e h i c l e is p r i m a r i l y d r i v e n in d u s t y c o n d i t i o n s , r e p l a c e e v e r y 15,000 m i l e s (24,000 k m ) .
R e p l a c e d u s t a n d p o l l e n filter ( s e e p a g e 21-27).
• If t h e v e h i c l e is d r i v e n p r i m a r i l y in u r b a n a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t
in t h e air, r e p l a c e e v e r y 15,000 m i l e s (24,000 k m ) .
• R e p l a c e the filter w h e n e v e r a i r f l o w f r o m t h e h e a t i n g a n d air c o n d i t i o n i n g s y s t e m is l e s s t h a n n o r m a l .
I n s p e c t drive belt ( s e e p a g e 4-42).
L o o k for c r a c k s a n d d a m a g e , t h e n c h e c k t h e p o s i t i o n of t h e drive belt a u t o - t e n s i o n e r indicator.
3 R e p l a c e m a n u a l t r a n s m i s s i o n fluid ( s e e p a g e 13-3).
C a p a c i t y : 1.48 L (1.56 U S qt), u s e H o n d a M T F .
4 R e p l a c e s p a r k p l u g s ( s e e p a g e 4-28).
I n s p e c t v a l v e c l e a r a n c e (cold) ( s e e p a g e 6-10).
• Intake: 0.21—0.25 m m (0.008—0.010 in.)
• E x h a u s t : 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
5 R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-9).
6 R e p l a c e rear differential fluid ( s e e p a g e 15-7).
• Driving m o u n t a i n o u s a r e a s r e s u l t s in a h i g h e r level of m e c h a n i c a l ( s h e a r ) s t r e s s to fluid. T h i s
r e q u i r e s differential fluid c h a n g e s m o r e f r e q u e n t l y t h a n r e c o m m e n d e d by t h e m a i n t e n a n c e m i n d e r . If
t h e v e h i c l e is r e g u l a r l y d r i v e n u n d e r t h e s e c o n d i t i o n s , h a v e the differential fluid c h a n g e d at e v e r y
15,000 m i l e s (24,000 k m ) .
• C a p a c i t y : 0.74 L (0.78 U S qt) u s e H y p o i d G e a r Oil G L 5 or G L 6 .
3-29
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If engine electrical maintenance is required)
T h e S 2 0 0 0 S R S i n c l u d e s a d r i v e r ' s a i r b a g in the s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in the d a s h b o a r d a b o v e t h e

g l o v e b o x , a n d s e a t belt t e n s i o n e r s in t h e s e a t belt r e t r a c t o r s . I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e the S R S is
i n c l u d e d in t h i s S e r v i c e M a n u a l . I t e m s m a r k e d w i t h a n a s t e r i s k ( * ) o n the c o n t e n t s p a g e i n c l u d e or a r e l o c a t e d n e a r
S R S c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , or r e p l a c i n g t h e s e i t e m s r e q u i r e s s p e c i a l p r e c a u t i o n s a n d t o o l s , a n d
• T o a v o i d r e n d e r i n g t h e S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury or d e a t h in the e v e n t of a s e v e r e frontal

c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d be d o n e b y a n a u t h o r i z e d H o n d a d e a l e r .
• I m p r o p e r s e r v i c e p r o c e d u r e s , i n c l u d i n g i n c o r r e c t r e m o v a l a n d installation of the S R S , c o u l d l e a d to p e r s o n a l injury
c a u s e d b y u n i n t e n t i o n a l activation of t h e a i r b a g s a n d s e a t belt t e n s i o n e r s .
• D o not b u m p or i m p a c t the S R S unit, o r front i m p a c t s e n s o r s w h e n t h e ignition s w i t c h is O N (II), or for at l e a s t 3
m i n u t e s after t h e ignition s w i t c h is t u r n e d O F F ; o t h e r w i s e , t h e s y s t e m m a y fail in a c o l l i s i o n , or a i r b a g s m a y d e p l o y .
• S R S e l e c t r i c a l c o n n e c t o r s a r e identified b y y e l l o w c o l o r c o d i n g . R e l a t e d c o m p o n e n t s a r e l o c a t e d in t h e s t e e r i n g
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e box. D o not u s e electrical
test e q u i p m e n t on t h e s e circuits.
Engine Electrical
Engine Electrical
Special Tools 4-2 Drive Belt Auto-tensioner
Replacement 4-44
Starting System Tensioner Pulley
Component Location Index .... 4-3 Replacement 4-44
Symptom Troubleshooting Alternator Removal and
Index 4-4 Installation 4-45
Circuit Diagram 4-5 Alternator Overhaul 4-47
Starter System Circuit
Troubleshooting . 4-7 Cruise Control
Clutch Interlock Switch Test ...4-9 Component Location Index .... 4-53
Starter Solenoid Test 4-9 Symptom Troubleshooting
Starter Performance Test 4-10 Index 4-54
Starter Removal and Circuit Diagram 4-58
Installation 4-11 * Cruise Control Unit Input
Starter Overhaul 4-15 Test 4-61
Cruise Control Input Test 4-63
Ignition System Cruise Control Main Switch
Component Location Index .... 4-21 Test 4-65
Circuit Diagram 4-22 Cruise Control Main Switch/
Ignition Timing Inspection 4-24 Indicator/Illumination
Ignition Coil Removal/ Test 4-66
Installation 4-25 Cruise Control Main Switch/
Ignition Coil Relay Circuit Indicator Bulb
Troubleshooting 4-26 Replacement 4-66
Spark Plug Inspection 4-28 Cruise Control Set/decel,
Resume/accel Switch
Charging System Test/Replacement 4-67
Component Location Index .... 4-29 Cruise Control Set/decel,
Symptom Troubleshooting Resume/accel, Cancel
Index 4-30 Switch Test/Replacement .... 4-67
Circuit Diagram 4-31 Cruise Control Actuator
Charging System Indicator Test 4-68
Circuit Troubleshooting 4-34 Cruise Control Actuator
Alternator and Regulator Replacement 4-69
Alternator Control Cable Replacement 4-70
Drive Belt Inspection 4-42 Cable Adjustment 4-71
Drive Belt Replacement 4-42 Clutch Pedal Position Switch
Drive Belt Auto-tensioner Test 4-72
Inspection 4-43
Engine Electrical
Special Tools
Ref. N o . Tool Number Description Qty

© 07746-0010300 A t t a c h m e n t 42 x 47 m m 1
® 07749-0010000 H a n d l e Driver 1
4-2
Starting System
Component Location Index
ENGINE START SWITCH
4-3
Starting System
Symptom Troubleshooting Index
Symptom Diagnostic procedure A l s o c h e c k for

E n g i n e d o e s not start 1. C h e c k for l o o s e battery t e r m i n a l s or c o n n e c t i o n s . P o o r g r o u n d at G401
( d o e s not c r a n k ) 2. T e s t t h e battery for a l o w c h a r g e ( s e e p a g e 22-47).
3. C h e c k the starter ( s e e p a g e 4-7).
4. C h e c k the starter c u t r e l a y ( s e e p a g e 22-48).
5. C h e c k the c l u t c h interlock s w i t c h ( s e e p a g e 4-9).
6. C h e c k the ignition s w i t c h or w i r e ( s e e p a g e 22-51).
7. C h e c k the e n g i n e start s w i t c h .
E n g i n e c r a n k s , but d o e s 1. C h e c k for P G M - F I D T C s .
not start 2. C h e c k t h e fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-145)
• '06-08 m o d e l s ( s e e p a g e 11-477)
3. C h e c k for a p l u g g e d or d a m a g e d fuel line:
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-148)
• '06-08 m o d e l s ( s e e p a g e 11-478)
4. C h e c k for a p l u g g e d fuel filter:
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-154)
• '06-08 m o d e l s ( s e e p a g e 11-486)
5. C h e c k t h e throttle b o d y :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-163)
• '06-08 m o d e l s ( s e e p a g e 11-498)
6. C h e c k for l o w e n g i n e c o m p r e s s i o n ( s e e p a g e 6-7).
7. C h e c k for a d a m a g e d or b r o k e n c a m c h a i n .
E n g i n e is h a r d to start 1. C h e c k for P G M - F I D T C s .
2. C h e c k t h e fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-145)
• '06-08 m o d e l s ( s e e p a g e 11-477)
3. C h e c k for a p l u g g e d or d a m a g e d fuel line:
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-148)
• '06-08 m o d e l s ( s e e p a g e 11-478)
4. C h e c k for a p l u g g e d fuel filter:
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-154)
• '06-08 m o d e l s ( s e e p a g e 11-486)
Engine cranks slowly 1. C h e c k for l o o s e battery t e r m i n a l s or c o n n e c t i o n s .
2. T e s t t h e battery for a l o w c h a r g e ( s e e p a g e 22-47).
3. C h e c k t h e starter for b i n d i n g ( s e e p a g e 4-7).
4. C h e c k for e x c e s s i v e d r a g in t h e e n g i n e .
4-4
[ ENGINE [
Circuit Diagram
'00-05 m o d e l s
•1: '00-03 models

*2: '04-05 models
IGNITION SWITCH
MAIN UNDER-HOOD FUSE/RELAY BOX
ACC HOT in ACC (I)
No. 41 (100 A) No. 42 (40 A) and ON (II)
ACC
-BLK "
0 - IG1-A
WHT IG1-B
IG2-A IG2 HOT in ON (II)
1
WHT/BUK*
WHT*
BAT-B
ACC
IG2-B
ORN BLK/WHT
STARTER
CUT RELAY
• BLK/WHT
BLK/V
No. 21
PGM-FI (7.5 A)
15tRTH BLU/WHT
MAIN
RELAY
A LTBLU
o \ CLUTCH
INTERLOCK
SWITCH
BLU/ORN BLK
ECM (
A24
STS
>
G401 G501
4-
Starting System
Circuit Diagram (cont'd)
'06-08 m o d e l s
IGNITION SWITCH
MAIN UNDER-H00D FUSE/RELAY BOX
No. 41 (100 A) No. 42 (40 A) BAT-A IG1-A IG1 HOT in ON (II)

•O IG2 HOT in ON {II}
1 BLK/YEL
ORN
B4
AUXIUARY
UNDER-HOOD
FUSE BOX UNDER-DASH
STARTER ' No. 3 FUSE/RELAY BOX
CUT RELAY , (7.5 A)
BLK/WHT
12 ENGINE START SWITCH
BLU/WHT
• BLK/WHT-
LTBLU
CLUTCH
2 INTERLOCK
SWITCH
(Closed: Clutch
pedal pressed)
1
BLK
G401 G501
4-6
[ ENGINE §
Starter System Circuit Troubleshooting
NOTE: 7. W i t h the c l u t c h p e d a l p r e s s e d , p r e s s the e n g i n e

• A i r t e m p e r a t u r e m u s t be b e t w e e n 59 a n d 100 °F (15 start s w i t c h .
a n d 3 8 °C) d u r i n g t h i s p r o c e d u r e .
• ' 0 0 - 0 5 m o d e l s : After the i n s p e c t i o n , y o u m u s t r e s e t Does the starter crank the engine normally?
t h e e n g i n e control m o d u l e ( E C M ) u s i n g the H o n d a
D i a g n o s t i c S y s t e m ( H D S ) ( s e e p a g e 11-4), to c l e a r a n y Y E S — T h e s t a r t i n g s y s t e m is O K . •
d i a g n o s t i c trouble c o d e ( D T C s ) .
• ' 0 6 - 0 8 m o d e l s : After the i n s p e c t i o n , y o u m u s t r e s e t N O — G o to s t e p 8.
the E C M u s i n g the H D S ( s e e p a g e 11-214). O t h e r w i s e ,
the E C M c o n t i n u e s to stop t h e fuel injectors. 8. C h e c k t h e battery c o n d i t i o n . C h e c k the electrical
• T h e battery m u s t be in g o o d c o n d i t i o n a n d fully c o n n e c t i o n s at t h e battery, t h e n e g a t i v e battery
charged. c a b l e to t h e b o d y , the e n g i n e g r o u n d c a b l e s , a n d
t h e starter for l o o s e n e s s a n d c o r r o s i o n . T h e n try
R e c o m m e n d e d Procedure: c r a n k i n g the e n g i n e a g a i n .
• U s e a starter s y s t e m tester. Does the starter crank the engine?

• C o n n e c t a n d o p e r a t e the e q u i p m e n t in a c c o r d a n c e
w i t h the m a n u f a c t u r e r ' s i n s t r u c t i o n s . Y E S — R e p a i r i n g the loose connection corrected the
p r o b l e m . T h e starting s y s t e m is O K . G o to s t e p 11.
1. Hook up the f o l l o w i n g equipment:
N O — B a s e d o n t h e f o l l o w i n g s y m p t o m s , take t h e
• Ammeter, 0—400 A appropriate action:
• V o l t m e t e r , 0 — 2 0 V ( a c c u r a t e w i t h i n 0.1 V)
• If the starter will not c r a n k the e n g i n e at a l l , g o to
V r
s t e p 9.
• If the starter c r a n k s the e n g i n e erratically o r too
s l o w l y , g o to s t e p 10.
oA o Vo • If the starter d o e s not d i s e n g a g e f r o m the
f l y w h e e l ring g e a r w h e n y o u r e l e a s e the e n g i n e
start s w i t c h , c h e c k the f o l l o w i n g : •
- Solenoid plunger and switch malfunction
- Dirty d r i v e g e a r or d a m a g e d o v e r r u n n i n g
clutch
'00-05 m o d e l s : R e m o v e the N o . 2 (15 A ) f u s e f r o m

the u n d e r - d a s h f u s e / r e l a y box.
3. '06-08 m o d e l s : C o n n e c t the H D S to the data link

c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e 11-213).
4. T u r n the ignition s w i t c h to O N (II).
5. '06-08 m o d e l s : M a k e s u r e t h e H D S c o m m u n i c a t e s
w i t h the v e h i c l e a n d E C M . If it d o e s n ' t
c o m m u n i c a t e , t r o u b l e s h o o t t h e D L C circuit
( s e e p a g e 11-367).
6. '06-08 m o d e l s : S e l e c t P G M - F I , I N S P E C T I O N , t h e n
A L L I N J E C T O R S O F F on the H D S .
(cont'd)
4-7
Starting System
Starter System Circuit Troubleshooting (cont'd)

M a k e s u r e the t r a n s m i s s i o n is in neutral, t h e n 10. W h i l e c r a n k i n g the e n g i n e , c h e c k the c r a n k i n g
d i s c o n n e c t t h e B L K / W H T w i r e (A) f r o m t h e s t a r t e r voltage and current draw.
solenoid S terminal. Connect a jumper wire from
t h e battery p o s i t i v e t e r m i n a l to the s o l e n o i d S Is the cranking voltage greater than or equal to
terminal. 8.7 V and the current draw less than or equal to
380 A ('00-05 models) or 230 A ('06-08 models)?
Y E S — G o t o s t e p 11.
N O — R e p l a c e the starter ( s e e p a g e 4-11), or r e m o v e

a n d d i s a s s e m b l e it, a n d c h e c k for t h e s e
problems: •
• O p e n circuit in starter a r m a t u r e c o m m u t a t o r
segments
• D r a g in the starter a r m a t u r e
• Shorted armature winding
• E x c e s s i v e d r a g in the e n g i n e
• E x c e s s i v e l y w o r n starter b r u s h e s
• O p e n circuit in the starter b r u s h e s
Does the starter crank the engine normally? • Dirty or d a m a g e d helical s p l i n e or d r i v e g e a r
• F a u l t y d r i v e g e a r clutch
Y E S — C h e c k the f o l l o w i n g i t e m s in the o r d e r listed
until y o u find t h e o p e n circuit: • 11. R e m o v e the starter, a n d i n s p e c t its d r i v e g e a r a n d
the f l y w h e e l ring gear for d a m a g e . Replace any
• T h e B L K / W H T w i r e a n d c o n n e c t o r s b e t w e e n the d a m a g e d parts.
starter c u t r e l a y a n d the starter.
• T h e O R N wire and connectors between the 12. ' 0 0 - 0 5 m o d e l s : R e i n s t a l l the N o . 2 (15 A ) f u s e in the
ignition s w i t c h a n d the s t a r t e r cut relay. u n d e r - d a s h f u s e / r e l a y box.
• T h e L T B L U wire and connectors between the
starter c u t r e l a y a n d the c l u t c h interlock s w i t c h . 13. ' 0 0 - 0 5 m o d e l s : S e l e c t E C M r e s e t o n the H D S
• T h e B L K / W H T w i r e b e t w e e n the u n d e r - d a s h f u s e / ( s e e p a g e 11-4).
r e l a y b o x a n d the e n g i n e start s w i t c h .
• No. 3 f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x . 14. ' 0 6 - 0 8 m o d e l s : S e l e c t E C M r e s e t ( s e e p a g e 11-214)
• T h e ignition s w i t c h ( s e e p a g e 22-51). to c a n c e l the A L L I N J E C T O R S O F F o n the H D S .
• T h e e n g i n e start s w i t c h .
• T h e c l u t c h interlock s w i t c h ( s e e p a g e 4-9). 15. D o the E C M idle learn p r o c e d u r e :
• T h e starter c u t r e l a y ( s e e p a g e 22-48).
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-140)
N O — R e p l a c e t h e starter ( s e e p a g e 4-11), or r e p a i r • ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-462)
the starter ( s e e p a g e 4-15).
4-8
Clutch Interlock Switch Test Starter Solenoid Test
1. D i s c o n n e c t the c o n n e c t o r f r o m t h e c l u t c h interlock 1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e

s w i t c h , t h e n r e m o v e the c l u t c h interlock s w i t c h . a u d i o s y s t e m , t h e n write d o w n the a u d i o p r e s e t s .
2. D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery.
3. D i s c o n n e c t t h e starter c a b l e (A), B L K / W H T w i r e (B),

a n d m o t o r c a b l e (C).
M B S
2. C h e c k t h e clutch interlock s w i t c h c o n n e c t o r
t e r m i n a l s for continuity. T h e r e s h o u l d be no
continuity b e t w e e n t h e t e r m i n a l s with t h e button
(A) r e l e a s e d , a n d t h e r e s h o u l d be c o n t i n u i t y with
t h e button p r e s s e d .
CLUTCH INTERLOCK SWITCH CONNECTOR

4. C h e c k t h e hold-in coil for continuity b e t w e e n t h e
S terminal a n d the armature housing (ground).
T h e r e s h o u l d be continuity.
1 2
• If t h e r e is continuity, g o to s t e p 5.
• If t h e r e is no continuity, r e p l a c e the s o l e n o i d .
T e r m i n a l s i d e of m a l e t e r m i n a l s
5. C h e c k t h e pull-in coil for c o n t i n u i t y b e t w e e n t h e
S t e r m i n a l a n d the M t e r m i n a l . T h e r e s h o u l d b e
continuity.
• If t h e r e is continuity, t h e s o l e n o i d is O K .
• If t h e r e is no continuity, r e p l a c e the s o l e n o i d .
6. C o n n e c t t h e starter c a b l e , B L K / W H T w i r e , a n d
A
motor c a b l e .
3. If t h e c l u t c h interlock s w i t c h is faulty, r e p l a c e it. 7. C o n n e c t t h e n e g a t i v e c a b l e to the battery.
4. Install t h e clutch interlock s w i t c h , a n d a d j u s t it 8. '00-05 m o d e l s : Do the e n g i n e control m o d u l e ( E C M )

( s e e p a g e 12-7). idle l e a r n p r o c e d u r e ( s e e p a g e 11-140).
9. E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m , t h e n
enter t h e a u d i o p r e s e t s . S e t t h e clock.
4-9
Starting System
Starter Performance Test

1. D i s c o n n e c t t h e w i r e s f r o m t h e S t e r m i n a l a n d t h e 5. D i s c o n n e c t t h e battery f r o m the starter b o d y . If t h e
M terminal. pinion retracts i m m e d i a t e l y , it is w o r k i n g properly.
2. M a k e a c o n n e c t i o n f o r t h i s t e s t u s i n g t h e t h i c k e s t
(gauge) wire possible (preferably the s a m e g a u g e
a s u s e d on the vehicle).
N O T E : T o a v o i d d a m a g i n g t h e starter, n e v e r l e a v e
the battery c o n n e c t e d for m o r e t h a n 10 s e c o n d s .
3. C o n n e c t t h e battery a s s h o w n . M a k e s u r e y o u
d i s c o n n e c t t h e starter m o t o r w i r e f r o m t h e s o l e n o i d .
If t h e starter p i n i o n m o v e s out, it i s w o r k i n g
properly.
6. C l a m p t h e starter f i r m l y in a v i s e .
7. C o n n e c t t h e starter to the battery a s s h o w n , a n d

c o n f i r m that t h e m o t o r s t a r t s rotating.
4. D i s c o n n e c t the battery f r o m t h e M t e r m i n a l . If t h e
p i n i o n d o e s not retract, the hold-in coil of t h e
s o l e n o i d is w o r k i n g p r o p e r l y .
8. If t h e electric c u r r e n t m e e t s t h e s p e c i f i c a t i o n w h e n
t h e battery v o l t a g e is at 11.5 V , the starter is
working properly.
Specification
'00-03 m o d e l s : 1.0 k W 9 0 A or l e s s
'04-08 m o d e l s : 1.1 k W (Electric current)
4-10
• ENGINE!
Starter Removal and Installation
Removal 5. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t t h e air control s o l e n o i d

v a l v e c o n n e c t o r (A) a n d v a c u u m h o s e s ( B ) , r e m o v e
1. M a k e s u r e y o u h a v e the anti-theft c o d e for the t h e h a r n e s s c l a m p s ( C ) , t h e n r e m o v e t h e intake air
a u d i o s y s t e m , t h e n w r i t e d o w n the a u d i o p r e s e t s . c l e a n e r h o u s i n g (D).
2. D i s c o n n e c t the n e g a t i v e c a b l e f r o m the battery.
3. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t the air h o s e (A) a n d

b r e a t h e r pipe (B), t h e n r e m o v e the air c l e a n e r
h o u s i n g c o v e r (C) a n d air c l e a n e r a s s e m b l y (D).
6. ' 0 6 - 0 8 m o d e l s : R e m o v e the I A T s e n s o r h a r n e s s
c l a m p s (A), t h e n r e m o v e the intake air c l e a n e r
h o u s i n g (B).
4. ' 0 6 - 0 8 m o d e l s : D i s c o n n e c t the intake air

t e m p e r a t u r e (IAT) s e n s o r c o n n e c t o r (A) a n d
b r e a t h e r pipe (B), r e m o v e the m a n i f o l d a b s o l u t e
p r e s s u r e (MAP) s e n s o r h a r n e s s (C) f r o m the holder,
t h e n r e m o v e the air c l e a n e r h o u s i n g c o v e r (D) a n d
air c l e a n e r a s s e m b l y (E).
7. R e m o v e the d r i v e belt ( s e e p a g e 4-42).
(cont'd)
4-11
Starting System
Starter Removal and Installation (co :'d)
8. D i s c o n n e c t t h e 4 P c o n n e c t o r (A) f r o m t h e a l t e r n a t o r 10. D i s c o n n e c t t h e starter c a b l e f r o m the B t e r m i n a l o n
(B), a n d d i s c o n n e c t t h e B L K w i r e f r o m t h e t h e starter s o l e n o i d (A), t h e n d i s c o n n e c t t h e
alternator B t e r m i n a l ( C ) . B L K / W H T w i r e f r o m t h e S t e r m i n a l (C).
C C B
9. R e m o v e t h e m o u n t i n g b o l t s , t h e n r e m o v e t h e
alternator. 11. R e m o v e t h e t w o bolts s e c u r i n g t h e starter, t h e n
r e m o v e t h e starter.
4-12
• ENGINE •
Installation 3. C o n n e c t t h e 4 P c o n n e c t o r (A) to t h e alternator a n d

B L K w i r e to t h e alternator B t e r m i n a l ( B ) .
1. Install the starter, t h e n c o n n e c t t h e starter c a b l e to
t h e B t e r m i n a l o n t h e starter s o l e n o i d (A) a n d t h e
B L K / W H T w i r e to S t e r m i n a l ( C ) . M a k e s u r e t h e
c r i m p e d s i d e of t h e starter c a b l e ring t e r m i n a l f a c e s
a w a y f r o m t h e s t a r t e r w h e n y o u c o n n e c t it.
10x1.25 mm
4 4 N - m (4.5 k g f - m ,
3 3 Ibf ft)
4. Install t h e d r i v e belt ( s e e p a g e 4-42).
5. ' 0 0 - 0 5 m o d e l s : Install t h e intake a i r c l e a n e r h o u s i n g

(A), t h e n install the h a r n e s s c l a m p s ( B ) , c o n n e c t a i r
8x1.25 mm * 1 0 x 1.25 m m c o n t r o l s o l e n o i d v a l v e c o n n e c t o r (C) a n d v a c u u m
9 N - m (0.9 k g f - m , 7 I b f f t ) 4 4 N - m (4.5 k g f - m , h o s e s (D).
33 Ibfft)
2. Install the alternator.
10 x 1.25 m m
4 4 N - m (4.5 k g f - m , 3 3 Ibf ft)
" 1 0 x 1.25 m m
4 4 N - m (4.5 k g f - m , 3 3 I b f f t )
(cont'd)
4-13
Starting System
Starter Removal and Installation (cont'd)
6. ' 0 6 - 0 8 m o d e l s : Install t h e intake air c l e a n e r h o u s i n g 8. ' 0 6 - 0 8 m o d e l s : Install t h e air c l e a n e r a s s e m b l y (A)

(A), t h e n install t h e I A T s e n s o r h a r n e s s c l a m p s (B). a n d air c l e a n e r h o u s i n g c o v e r ( B ) , t h e n install the
M A P s e n s o r h a r n e s s (C) to the h o l d e r , c o n n e c t the
air h o s e (C) a n d b r e a t h e r pipe (D). 9. C o n n e c t t h e n e g a t i v e c a b l e to the battery.
10. S t a r t t h e e n g i n e to m a k e s u r e the starter w o r k s

properly.
11. ' 0 0 - 0 5 m o d e l s : Do t h e e n g i n e control m o d u l e ( E C M )

idle l e a r n p r o c e d u r e ( s e e p a g e 11-140).
12. E n t e r t h e anti-theft c o d e for the a u d i o s y s t e m , t h e n

enter the audio presets. S e t the clock.
C D
4-14
Starter Overhaul
Disassembly/Reassembly
8 x 1.25 m m
8 x 1.25 m m 9 N - m (0.9 k g f - m , 6.5 Ibf ft)
(cont'd)
4-15
Starting System
Starter Overhaul (cont'd)
1. R e m o v e t h e s t a r t e r ( s e e p a g e 4-11). 5. C h e c k the c o m m u t a t o r d i a m e t e r . If the d i a m e t e r is
b e l o w t h e s e r v i c e limit, r e p l a c e t h e a r m a t u r e .
2. D i s a s s e m b l e t h e starter.
Commutator Diameter
Armature Inspection and Test S t a n d a r d ( N e w ) : 2 8 . 0 - 2 8 . 1 m m ( 1 . 1 0 2 - 1 . 1 0 6 in.)
S e r v i c e Limit: 2 7 . 5 m m (1.083 in.)
3. I n s p e c t t h e a r m a t u r e for w e a r or d a m a g e d u e to
c o n t a c t w i t h t h e p e r m a n e n t m a g n e t . If t h e r e i s w e a r
or d a m a g e , replace the armature.
6. M e a s u r e the c o m m u t a t o r runout.
• If the c o m m u t a t o r r u n o u t is w i t h i n t h e s e r v i c e
4. C h e c k the c o m m u t a t o r (A) s u r f a c e . If t h e s u r f a c e is limit, c h e c k t h e c o m m u t a t o r for c a r b o n d u s t or
dirty o r burnt, r e s u r f a c e it w i t h a n e m e r y cloth o r a b r a s s chips between the s e g m e n t s .
lathe to t h e s p e c i f i c a t i o n s in s t e p 5 o r r e c o n d i t i o n it • If the c o m m u t a t o r r u n o u t is not w i t h i n t h e s e r v i c e
w i t h # 5 0 0 o r # 6 0 0 s a n d p a p e r (B). limit, r e p l a c e t h e a r m a t u r e .
Commutator Runout
S t a n d a r d ( N e w ) : 0.02 m m (0.001 in.) m a x .
S e r v i c e Limit: 0.05 m m (0.002 in.)
4-16
[ ENGINE |
7. C h e c k the m i c a d e p t h (A). If t h e m i c a is t o o high ( B ) , P l a c e t h e a r m a t u r e (A) o n a n a r m a t u r e t e s t e r (B).

cut the m i c a w i t h a h a c k s a w b l a d e to the p r o p e r Hold a h a c k s a w b l a d e (C) o n t h e a r m a t u r e c o r e .
d e p t h . C u t a w a y all t h e m i c a (C) b e t w e e n t h e If t h e b l a d e is attracted to t h e c o r e o r v i b r a t e s w h i l e
c o m m u t a t o r s e g m e n t s . T h e u n d e r c u t s h o u l d not b e the c o r e is t u r n e d , t h e a r m a t u r e is s h o r t e d . R e p l a c e
too s h a l l o w , too n a r r o w , o r V - s h a p e d (D). the a r m a t u r e .
Commutator Mica Depth

S t a n d a r d ( N e w ) : 0 . 4 — 0 . 5 m m ( 0 . 0 1 6 — 0 . 0 2 0 in.)
Service Limit: 0.15 m m (0.006 in.)
10. U s e a n o h m m e t e r to c h e c k for continuity b e t w e e n

8. C h e c k for continuity b e t w e e n the s e g m e n t s of t h e the c o m m u t a t o r (A) a n d t h e a r m a t u r e coil c o r e (B),
c o m m u t a t o r . If t h e r e is a n o p e n circuit b e t w e e n a n y a n d b e t w e e n the c o m m u t a t o r a n d the a r m a t u r e
segments, replace the armature. s h a f t (C). If t h e r e is continuity, r e p l a c e t h e a r m a t u r e .
(cont'd)
4-17
Starting System
Starter Brush Inspection S t a r t e r B r u s h Holder T e s t
11. M e a s u r e t h e b r u s h length. If it is not w i t h i n t h e 14. C h e c k for continuity b e t w e e n the ( + ) b r u s h h o l d e r

s e r v i c e limit, r e p l a c e the b r u s h h o l d e r a s s e m b l y . (A) a n d (—) b r u s h holder (B). If there is continuity,
r e p l a c e t h e b r u s h holder a s s e m b l y .
Brush Length
S t a n d a r d ( N e w ) : 1 5 . 8 - 1 6 . 2 m m ( 0 . 6 2 - 0 . 6 4 in.)
15. Insert the b r u s h (A) into the b r u s h holder, a n d bring

t h e b r u s h into c o n t a c t w i t h t h e c o m m u t a t o r , t h e n
attach a s p r i n g s c a l e (B) to t h e s p r i n g (C). M e a s u r e
Starter Field Winding Test t h e s p r i n g t e n s i o n at the m o m e n t the s p r i n g lifts off
the b r u s h . If t h e s p r i n g t e n s i o n is not to
12. C h e c k for c o n t i n u i t y b e t w e e n t h e b r u s h e s (A). If s p e c i f i c a t i o n , r e p l a c e the s p r i n g .
t h e r e is n o continuity, r e p l a c e t h e a r m a t u r e
h o u s i n g (B). Spring Tension:
1 5 . 7 - 1 7 . 7 N ( 1 . 6 - 1 . 8 kgf, 3 . 5 3 - 3 . 9 7 Ibf)
A
13. C h e c k for continuity b e t w e e n e a c h b r u s h (A) a n d

t h e a r m a t u r e h o u s i n g (B). If t h e r e i s continuity,
replace the armature housing.
4-18
[ ENGINE [
16. P r y b a c k e a c h b r u s h s p r i n g w i t h a s c r e w d r i v e r , t h e n 18. Install t h e starter e n d c o v e r (A) to retain t h e b r u s h

position the b r u s h a b o u t h a l f w a y out of its holder, h o l d e r (B).
a n d r e l e a s e t h e s p r i n g to h o l d it t h e r e .
5x1.0 mm
5.9 N m (0.6 k g f m , 4 . 3 Ibf ft)
17. Install t h e a r m a t u r e in t h e h o u s i n g , a n d install the

b r u s h holder. N e x t , pry b a c k e a c h b r u s h s p r i n g 4 x 0.7 m m
1.5 N m
a g a i n , a n d p u s h the b r u s h d o w n until it s e a t s (0.15 kgf m ,
a g a i n s t the c o m m u t a t o r , t h e n r e l e a s e t h e s p r i n g 1.1 Ibf ft)
a g a i n s t the e n d of t h e b r u s h .
N O T E : T o s e a t the n e w b r u s h e s , s l i p a strip of # 5 0 0
or # 6 0 0 s a n d p a p e r , w i t h t h e grit s i d e u p , b e t w e e n
the commutator and e a c h b r u s h , and smoothly
rotate t h e a r m a t u r e . T h e c o n t a c t s u r f a c e of the
b r u s h e s will be s a n d e d to the s a m e c o n t o u r a s t h e
commutator.
(cont'd)
4-19
Starting System
Overrunning Clutch Inspection
19. S l i d e the o v e r r u n n i n g c l u t c h a l o n g the shaft.

R e p l a c e it if it d o e s not s l i d e s m o o t h l y .
20. Hold t h e p l a n e t a r y g e a r s h a f t (A), a n d t u r n the

o v e r r u n n i n g c l u t c h a s s e m b l y (B) both w a y s . If it
d o e s not lock in either d i r e c t i o n or it l o c k s in both
d i r e c t i o n s , r e p l a c e it.
2 1 . If the starter d r i v e g e a r (C) is w o r n or d a m a g e d ,

r e p l a c e the o v e r r u n n i n g c l u t c h a s s e m b l y ; the g e a r
is not a v a i l a b l e s e p a r a t e l y . C h e c k the c o n d i t i o n of
the f l y w h e e l ring g e a r if t h e starter d r i v e g e a r teeth
are d a m a g e d .
2 2 . R e a s s e m b l e t h e starter in r e v e r s e o r d e r of
disassembly.
4-20
Ignition System
IGNITION COIL RELAY

('06-08 models)
4-21
Ignition System
Circuit Diagram
'00-05 m o d e l s
MAIN UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH
No. 41 (100 A) No. 42 (40 A)

-—"Crvjo cr\j>—
IG1 HOT in ON (II)
UNDER-DASH
No. 4 FUSE/RELAY
(15 A) BOX
BLK/YEL
IGPLS4 IGPLS3 IGPLS2 IGPLS1

C12
WHT/GRN
ICM ICM
BLK/YEL
ICM
I ICM
LK/YEL
IGNITION
COILS
No. 3
BLK BLK BLK
SPARK
PLUGS
G101
ICM: Ignition Control Module
4-22
[ ENGINE |
'06-08 models
UNDER-DASH
MAIN UNDER-HOOD FUSE/RELAY BOX FUSE/RELAY BOX
No. 41 (100 A) No. 59 (20 A) No.16(15A)
©- -YEL- -BLK/YEL-
ECM
IGPLS4 IGPLS3 IGPLS2 IGPLS1
WHT/GRN WHT BLK/YEL
_J
BLK/YEL BLK/YEL BLK/YEL BLK/YEL
1CM ICM ICM
IGNITION
COILS
No. 2
SPARK
PLUGS
G101
ICM: Ignition Control Module
4-23
Ignition System
Ignition Timing Inspection

1. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e 8. A i m the light t o w a r d the pointer (A). C h e c k the
data link c o n n e c t o r ( D L C ) , ' 0 0 - 0 5 m o d e l s ( s e e s t e p 2 ignition t i m i n g u n d e r a no l o a d c o n d i t i o n
o n p a g e 11-3), ' 0 6 - 0 8 m o d e l s ( s e e s t e p 2 o n p a g e ( h e a d l i g h t s , b l o w e r f a n , a n d air c o n d i t i o n e r a r e
11-213), a n d c h e c k for D T C s . If a D T C is p r e s e n t , t u r n e d off).
diagnose and repair the c a u s e before inspecting
the ignition t i m i n g . Ignition T i m i n g :
5 ± 2 ° B T D C ( R E D m a r k (B)) a t idle in n e u t r a l
3. '06-08 m o d e l s : M a k e s u r e t h e H D S c o m m u n i c a t e s
w i t h the v e h i c l e a n d t h e e n g i n e c o n t r o l m o d u l e
( E C M ) . If it d o e s n ' t c o m m u n i c a t e , t r o u b l e s h o o t t h e
D L C circuit ( s e e p a g e 11-367).
4. S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at
3,000 r p m w i t h n o l o a d (in neutral) until t h e radiator
f a n c o m e s o n , t h e n let it idle.
5. C h e c k t h e idle s p e e d :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-140)
• '06-08 m o d e l s ( s e e p a g e 11-461) B
6. J u m p t h e S C S line w i t h t h e H D S . 9. If the ignition t i m i n g differs f r o m t h e s p e c i f i c a t i o n ,

c h e c k the c a m t i m i n g . If t h e c a m t i m i n g is O K ,
7. F r e e the s e r v i c e l o o p (A) f r o m t h e e n g i n e w i r e u p d a t e t h e E C M if it d o e s not h a v e t h e latest
h a r n e s s , t h e n c o n n e c t t h e t i m i n g light to t h e s e r v i c e s o f t w a r e '06-08 m o d e l s ( s e e p a g e 11-216), or
loop. substitute a known-good E C M , '00-05 m o d e l s
( s e e p a g e 11-5), '06-08 m o d e l s ( s e e p a g e 11-217),
t h e n r e c h e c k . If t h e s y s t e m w o r k s p r o p e r l y , a n d the
E C M w a s s u b s t i t u t e d , r e p l a c e t h e original E C M ,
' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-115), '06-08 m o d e l s
( s e e p a g e 11-389).
10. T u r n t h e ignition s w i t c h to L O C K (0).
11. D i s c o n n e c t t h e H D S a n d t h e t i m i n g light.
12. S e c u r e t h e s e r v i c e loop to t h e e n g i n e w i r e h a r n e s s
with wire ties.
4-24
Ignition Coil Removal/Installation
1. R e m o v e t h e ignition coil c o v e r (A). 3. Install t h e ignition c o i l s in t h e r e v e r s e o r d e r of

removal.
N O T E : T h e ignition c o i l s for '06-08 m o d e l s a r e

different f r o m f o r m e r m o d e l s . Do not install t h e
ignition c o i l s f r o m o t h e r m o d e l y e a r s , b e c a u s e t h e y
m a y b e d a m a g e d . T o differentiate b e t w e e n t h e t w o
t y p e s of ignition c o i l s , t h e ignition c o i l s for '06-08
m o d e l s h a v e t h e r i b s (A) o n t h e coil h e a d a n d
s u p p l i e r ' s p a r t s n u m b e r (B).
TT
2. D i s c o n n e c t t h e ignition coil c o n n e c t o r s , t h e n
r e m o v e t h e ignition c o i l s (B).
4-25
Ignition System
Ignition Coil Relay Circuit Troubleshooting
'06-08models 4. C h e c k for continuity b e t w e e n e a c h ignition coil

r e l a y 4 P s o c k e t t e r m i n a l No. 2 a n d ignition coil 3 P
1. C h e c k t h e N o . 1 6 ( 1 5 A ) f u s e in the u n d e r - d a s h f u s e / c o n n e c t o r t e r m i n a l N o . 3.
relay box.
IGNITION C O I L R E L A Y 4P S O C K E T
Is the fuse OK?

1
T e r m i n a l side of
female terminals 2
Y E S — R e i n s t a l l t h e f u s e , t h e n g o to s t e p 2.
4 3
N O — R e p l a c e the f u s e . If t h e f u s e c o n t i n u e s to b l o w ,
locate a n d repair the s h o r t in the circuit b e t w e e n
the u n d e r - d a s h f u s e / r e l a y b o x a n d ignition c o i l s . •
W i r e s i d e of
2. R e m o v e t h e ignition coil r e l a y , a n d t e s t it ( s e e p a g e female terminals
22-48).
Is the relay OK ? IGNITION COIL 3P C O N N E C T O R
Y E S — G o to s t e p 3. Is there continuity ?
N O — R e p l a c e the ignition coil relay. • Y E S — G o to s t e p 5.
3. M e a s u r e t h e v o l t a g e b e t w e e n ignition coil r e l a y 4 P N O — R e p a i r o p e n in the w i r e b e t w e e n ignition coil

s o c k e t t e r m i n a l No. 1 a n d b o d y g r o u n d , t h e n r e l a y 4 P s o c k e t t e r m i n a l No. 2 a n d the ignition coil
terminal No. 4 and body ground. 3 P c o n n e c t o r t e r m i n a l N o . 3. •
5. C h e c k for continuity b e t w e e n e a c h ignition coil 3 P

IGNITION COIL R E L A Y 4P S O C K E T
connector terminal No. 2 and the body ground.
1
IGNITION C O I L 3P C O N N E C T O R
2
4 3
T e r m i n a l s i d e of f e m a l e t e r m i n a l s
Is there battery voltage? W i r e s i d e of f e m a l e t e r m i n a l s
Y E S — G o to s t e p 4.
Is there continuity?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e u n d e r -
d a s h f u s e / r e l a y b o x a n d the ignition c o i l r e l a y 4 P Y E S — G o to s t e p 6.
socket. •
N O — R e p a i r o p e n in the w i r e b e t w e e n ignition coil
3 P c o n n e c t o r t e r m i n a l No. 2 a n d the b o d y
ground. •
4-26
• ENGINE •
6. C o n n e c t the H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e 13. C h e c k for continuity b e t w e e n ignition coil relay 4 P

d a t a link c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e s o c k e t t e r m i n a l No. 3 a n d E C M c o n n e c t o r t e r m i n a l
11-213). E7.
IGNITION COIL R E L A Y 4P S O C K E T
1
8. M a k e s u r e the H D S c o m m u n i c a t e s w i t h t h e v e h i c l e
T e r m i n a l s i d e of 2
a n d t h e e n g i n e c o n t r o l m o d u l e ( E C M ) . If it d o e s n ' t
female terminals
4 3
( s e e p a g e 11-367).
9. J u m p the S C S line w i t h the H D S .
N O T E : T h i s s t e p m u s t be d o n e to protect the E C M
from damage.
1 3 4 5 ' 1 8 | 9

/ 11 12 13 14 15 16 17 18 19 20 21
11. D i s c o n n e c t E C M c o n n e c t o r E (31P).
22
/ 24 25
/ 27 28 29 30
/
E C M CONNECTOR E(31P)
12. C h e c k for continuity b e t w e e n ignition coil r e l a y 4 P W i r e s i d e of f e m a l e t e r m i n a l s

socket terminal No. 3 and body ground.
IGNITION C O I L R E L A Y 4P S O C K E T
Y E S — T h e s y s t e m is O K at t h i s t i m e . C h e c k for
l o o s e or p o o r c o n n e c t i o n s at the ignition coil relay
andtheECM(E7).B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n ignition coil
r e l a y 4 P s o c k e t t e r m i n a l N o . 3 a n d the E C M (E7). •
Y E S — R e p a i r s h o r t to g r o u n d in the w i r e b e t w e e n
the ignition coil r e l a y 4 P s o c k e t t e r m i n a l No. 3 a n d
the E C M ( E 7 ) . H
N O — G o to s t e p 13.
4-27
Ignition System
Spark Plug Inspection

1. R e m o v e the s p a r k p l u g s a n d i n s p e c t the e l e c t r o d e s 3. D o not a d j u s t the g a p of p l a t i n u m tip p l u g s (A);
a n d c e r a m i c insulator. r e p l a c e t h e s p a r k p l u g if the g a p is out of
specification.
• B u r n e d or w o r n e l e c t r o d e s m a y be c a u s e d by:
- A d v a n c e d ignition t i m i n g Electrode G a p
- L o o s e s p a r k plug S t a n d a r d ( N e w ) : 1 . 0 - 1 . 1 m m ( 0 . 0 3 9 - 0 . 0 4 3 in.)
- P l u g heat r a n g e t o o hot
- Insufficient c o o l i n g
• F o u l e d p l u g s m a y be c a u s e d by:
- R e t a r d e d ignition t i m i n g
- Oil in c o m b u s t i o n c h a m b e r
- Incorrect s p a r k plug g a p
- P l u g heat r a n g e too c o l d
- E x c e s s i v e idling/low s p e e d running
- C l o g g e d air c l e a n e r e l e m e n t
- D e t e r i o r a t e d ignition c o i l s
W o r n or deformed
electrodes
Improper gap
• Oil-fouling
• Carbon deposits
Cracked center
electrode insulator 4. R e p l a c e the plug at the s p e c i f i e d interval, or if the
Damaged
gasket c e n t e r e l e c t r o d e is r o u n d e d (A). U s e o n l y the s p a r k
p l u g s listed.
Spark Plugs
NGK: PFR7G-11S
Cracked
insulator
DENSO: PK22PR-L11S
If t h e s p a r k plug e l e c t r o d e is dirty or c o n t a m i n a t e d ,
c l e a n the e l e c t r o d e w i t h a p l u g c l e a n e r .
NOTE:
• D o not u s e a w i r e b r u s h or s c r a p e t h e i r i d i u m
e l e c t r o d e s i n c e t h i s w i l l d a m a g e the e l e c t r o d e .
• W h e n using a s a n d blaster spark plug cleaner, do A p p l y a s m a l l a m o u n t of anti-seize c o m p o u n d to
not c l e a n for m o r e t h a n 20 s e c o n d s to a v o i d the plug t h r e a d s , a n d s c r e w the p l u g s into the
d a m a g i n g the e l e c t r o d e . c y l i n d e r h e a d , finger-tight. T o r q u e t h e m to 25 N-m
(2.5 kgf-m, 18 Ibf-ft).
4-28
Charging System
CHARGING S Y S T E M INDICATOR
(In t h e g a u g e a s s e m b l y )
4-29
Charging System
'00-05 m o d e l s
Charging system T r o u b l e s h o o t t h e c h a r g i n g s y s t e m indicator circuit
indicator d o e s not c o m e ( s e e p a g e 4-34).
o n w i t h t h e ignition
s w i t c h to O N (II)
Charging system 1. T r o u b l e s h o o t the c h a r g i n g s y s t e m indicator circuit
indicator s t a y s o n ( s e e p a g e 4-34).
2. C h e c k for a b r o k e n d r i v e belt ( s e e p a g e 4-42).
3. C h e c k t h e d r i v e belt a u t o - t e n s i o n e r ( s e e p a g e 4-43).
Battery d i s c h a r g e d 1. C h e c k for a p o o r c o n n e c t i o n a n d for o p e n or s h o r t e d
w i r e ( s ) in c h a r g i n g s y s t e m .
2. C h e c k for a n y e l e c t r i c a l e q u i p m e n t (including O E M
o p t i o n s ) that u s e p a r a s i t i c e l e c t r i c a l c u r r e n t d r a w w h e n
t h e ignition s w i t c h is in L O C K (0).
5. T r o u b l e s h o o t t h e alternator a n d regulator circuit
( s e e p a g e 4-38).
6. C h e c k for a p o o r c o n n e c t i o n at t h e battery t e r m i n a l .
7. T e s t t h e battery ( s e e p a g e 22-47).
Battery o v e r c h a r g e d 1. T r o u b l e s h o o t t h e alternator a n d regulator circuit
( s e e p a g e 4-38).
'06-08 m o d e l s
Charging system T r o u b l e s h o o t t h e c h a r g i n g s y s t e m indicator circuit
indicator d o e s not c o m e ( s e e p a g e 4-36).
o n w i t h t h e ignition
s w i t c h to O N (II)
Charging system 1. C h e c k for P G M - F I D T C s ( s e e p a g e 11-213).
indicator s t a y s on 2. T r o u b l e s h o o t t h e c h a r g i n g s y s t e m indicator circuit
( s e e p a g e 4-36).
Battery d i s c h a r g e d 1. C h e c k for a n y e l e c t r i c a l e q u i p m e n t (including O E M
o p t i o n s ) that u s e p a r a s i t i c e l e c t r i c a l c u r r e n t d r a w w h e n
t h e ignition s w i t c h is in L O C K (0).
4. T r o u b l e s h o o t the alternator a n d regulator circuit
( s e e p a g e 4-38).
5. C h e c k for a p o o r c o n n e c t i o n at t h e battery t e r m i n a l .
Battery o v e r c h a r g e d 1. T r o u b l e s h o o t the alternator a n d regulator circuit
( s e e p a g e 4-38).
4-30
Circuit Diagram
'00-03 m o d e l s

Charging System
'04-05 m o d e l s

BATTERY
©-
4-32
'06-08 m o d e l s

BATTERY
No. 41 (100 A)
JCL
G202
ALTF
B13
BLK WHT/RED WHT/BLU WHT/GRN BLK YEL
ALTERNATOR 4 2 1
VOLTAGE REGULATOR
-<W> 1
RECTIFIER
Charging System
Charging System Indicator Circuit Troubleshooting
'00-05 models 9. C o n n e c t the alternator 4 P c o n n e c t o r t e r m i n a l N o . 3

to b o d y g r o u n d w i t h a j u m p e r w i r e . T u r n the
1. T u r n the ignition s w i t c h to O N (II). ignition s w i t c h to O N (II).
Does the charging system indicator come on? A L T E R N A T O R 4P C O N N E C T O R
1
2 W i r e s i d e of
I J
female terminals
2. S t a r t the e n g i n e . 3 4
Does the charging system indicator go off? L (WHT/BLU)

JUMPER WIRE
Y E S — C h a r g i n g s y s t e m indicator circuit is O K . G o
to the alternator a n d regulator circuit
t r o u b l e s h o o t i n g ( s e e p a g e 4-38). •
N O — G o to s t e p 3. Does the charging system indicator come on?
3. T u r n the ignition s w i t c h to L O C K (0). Y E S — G o t o s t e p 11.
4. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r f r o m t h e N O — G o to s t e p 10.
alternator.
Does the charging system indicator come on?
Y E S — R e p a i r s h o r t to g r o u n d in t h e w i r e b e t w e e n
t h e g a u g e a s s e m b l y a n d alternator. •
7. C h e c k t h e N o . 6 (15 A ) f u s e ('00-03 m o d e l s ) or N o . 5
(7.5 A ) f u s e ('04-05 m o d e l s ) in t h e u n d e r - d a s h f u s e /
relay box.
Is the fuse OK?
N O — R e p l a c e the fuse, then r e c h e c k . H
8. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r f r o m the
alternator.
4-34
[ ENGINE |
10. C h e c k for c o n t i n u i t y b e t w e e n t h e alternator 4 P 11. M e a s u r e t h e v o l t a g e b e t w e e n t h e alternator 4 P

c o n n e c t o r t e r m i n a l No. 3 a n d g a u g e a s s e m b l y c o n n e c t o r t e r m i n a l No. 1 a n d b o d y g r o u n d w i t h t h e
c o n n e c t o r t e r m i n a l D11 ('00-03 m o d e l s ) or B 2 6 ignition s w i t c h to O N (II).
('04-05 m o d e l s ) .
A L T E R N A T O R 4P C O N N E C T O R
'00-03 m o d e l s
G A U G E A S S E M B L Y C O N N E C T O R D (16P)
IG ( B L K / Y E L )
W i r e s i d e of
female terminals
L (WHT/BLU) Is there battery voltage?
Y E S — C h a r g i n g s y s t e m i n d i c a t o r circuit is O K . G o
W i r e s i d e of f e m a l e t e r m i n a l s to alternator a n d r e g u l a t o r c i r c u i t
troubleshooting. •
'04-05 m o d e l s
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e u n d e r -
><
G A U G E A S S E M B L Y C O N N E C T O R B (30P)
d a s h f u s e / r e l a y b o x a n d alternator. •
/ 2 3 4 5 6 7 8 9 10
/
12 13
/
15 16 17 18 19 20 21
ALTL (WHT/BLU)
24
/
26 27 28 29 30
p I 3
2
4
(WHT/BLU)
I J
W i r e s i d e of f e m a l e t e r m i n a l s
Y E S — C h e c k f o r a b l o w n c h a r g i n g s y s t e m indicator
bulb. If the b u l b is O K , c h e c k t h e g a u g e a s s e m b l y
( c h a r g i n g s y s t e m indicator) p o w e r s u p p l y circuit. •
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e
alternator a n d g a u g e a s s e m b l y . *
4-35
Charging System
Charging System Indicator Circuit Troubleshooting (cont'd)
'06-08 models 7. T u r n t h e ignition s w i t c h to L O C K (0).
1. T u r n t h e ignition s w i t c h to O N (II). 8. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e
d a t a link c o n n e c t e r ( D L C ) ( s e e s t e p 2 o n p a g e
Does the charging system indicator come on? 11-213).
Y E S — G o to s t e p 2 . 9. T u r n t h e ignition s w i t c h to O N (II).
N O — G o to s t e p 15. 10. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e v e h i c l e
a n d t h e e n g i n e c o n t r o l m o d u l e ( E C M ) . If it d o e s n ' t
2 . Shift to n e u t r a l , a n d start t h e e n g i n e . Hold t h e c o m m u n i c a t e , t r o u b l e s h o o t t h e D L C circuit
e n g i n e s p e e d at 2,000 r p m for 1 m i n u t e . ( s e e p a g e 11-367).
Does the charging system indicator go off? 11. J u m p the S C S line w i t h t h e H D S .
Y E S — C h a r g i n g s y s t e m i n d i c a t o r circuit is O K . G o N O T E : T h i s s t e p m u s t be d o n e to protect t h e E C M
to the alternator a n d r e g u l a t o r circuit from damage.
13. D i s c o n n e c t E C M c o n n e c t o r B (24P).
3. D o t h e g a u g e a s s e m b l y s e l f - d i a g n o s t i c f u n c t i o n
p r o c e d u r e ( s e e p a g e 22-60). 14. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
terminal B10 and body ground.
Does the charging system indicator flash?
E C M C O N N E C T O R B (24P)
N O — R e p l a c e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89). /I 2 I 3 ] 4 ["5
8 11 // 13
Hi°l i l K
17[l8ll9| l20|211/1/1/
ALTL (WHT/BLU)
5. D i s c o n n e c t t h e a l t e r n a t o r 4 P c o n n e c t o r .
6. T u r n t h e ignition s w i t c h to O N (II).
Does the charging system indicator go off? W i r e s i d e of f e m a l e t e r m i n a l s
Y E S — R e p l a c e t h e a l t e r n a t o r ( s e e p a g e 4-45) o r
repair t h e alternator ( s e e p a g e 4-47). • Is there continuity?
N O — G o to s t e p 7. Y E S — R e p a i r s h o r t to g r o u n d in t h e w i r e b e t w e e n
t h e alternator a n d t h e E C M ( B 1 0 ) . »
N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest
s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e
symptom/indication g o e s a w a y with a known-good
E C M , r e p l a c e t h e original E C M ( s e e p a g e 11-389). •
4-36
[ ENGINE |
15. D o the g a u g e a s s e m b l y s e l f - d i a g n o s t i c f u n c t i o n 20. T u r n the ignition s w i t c h to L O C K (0).

p r o c e d u r e ( s e e p a g e 22-60).
2 1 . C o n n e c t the H D S to t h e D L C ( s e e s t e p 2 o n p a g e
Does the charging system indicator flash? 11-213).
Y E S — G o to s t e p 16. 2 2 . T u r n the ignition s w i t c h to O N (II).
N O — R e p l a c e the g a u g e a s s e m b l y ( s e e p a g e 22-89). 2 3 . M a k e s u r e the H D S c o m m u n i c a t e s with the v e h i c l e

• a n d the E C M . If it d o e s n ' t c o m m u n i c a t e ,
t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
16. T u r n the ignition s w i t c h to L O C K (0).
17. D i s c o n n e c t the alternator 4 P c o n n e c t o r .
N O T E : T h i s s t e p m u s t be d o n e to protect t h e E C M
18. C o n n e c t alternator 4P c o n n e c t o r t e r m i n a l N o . 3 a n d from damage.
body ground with a j u m p e r wire.
2 5 . T u r n the ignition s w i t c h to L O C K (0).
2 6 . D i s c o n n e c t E C M c o n n e c t o r B (24P).
41
2 7 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r
2
I J
t e r m i n a l B 1 0 a n d alternator 4 P c o n n e c t o r t e r m i n a l
L (WHT/BLU)
6 No. 3.
JUMPER W i r e s i d e of f e m a l e t e r m i n a l s
WIRE
W i r e s i d e of f e m a l e terminals
ALTL (WHT/BLU)
2
1
Does the charging system indicator come on?
I 3 4
J
Y E S — R e p l a c e the alternator ( s e e p a g e 4-45) or A L T E R N A T O R 4P C O N N E C T O R
repair t h e alternator ( s e e p a g e 4-47). • W i r e s i d e of f e m a l e t e r m i n a l s
N O — R e m o v e the j u m p e r w i r e , t h e n g o to s t e p 20. Is there continuity?
Y E S — U p d a t e the E C M if it d o e s not h a v e t h e latest

g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If the
s y m p t o m / i n d i c a t i o n g o e s a w a y with a k n o w n - g o o d
E C M , r e p l a c e the original E C M ( s e e p a g e 11-389). •
N O — R e p a i r o p e n in the w i r e b e t w e e n the
alternator a n d the E C M ( B 1 0 ) . B
4-37
Charging System
Alternator and Regulator Circuit Troubleshooting
1. M a k e s u r e the battery c o n n e c t i o n s a r e g o o d , a n d 9. R a i s e the e n g i n e s p e e d to 2,000 r p m , a n d hold it
that the battery is sufficiently c h a r g e d ( s e e p a g e there.
22-47).
Is the voltage less than 13.5 V?
2 . C o n n e c t a V A T - 4 0 (or e q u i v a l e n t t e s t e r ) , a n d turn
the s e l e c t o r s w i t c h to p o s i t i o n 1 (starting). Y E S — G o to alternator control circuit
LOAD ADJUSTER FULL FIELD T E S T E R
( C A R B O N PILE) LEAD (BLU)
/
VOLTMETER
NEGATIVE
L E A D (BLK) 10. A p p l y a l o a d w i t h t h e V A T - 4 0 until t h e battery
voltage drops within 12—13.5 V.
VOLTMETER
VOLT
POSITIVE
SELECTOR
LEAD (RED) Is the amperage 87.5 A or more?
Y E S — T h e c h a r g i n g s y s t e m is O K . B
N O T E : If the c h a r g i n g s y s t e m indicator is still o n ,

NEGATIVE TESTER r e p l a c e t h e alternator ( s e e p a g e 4-45).
C A B L E (BLK)
POSITIVE T E S T E R N O — R e p l a c e t h e alternator ( s e e p a g e 4-45) or
C A B L E (RED)
repair t h e alternator ( s e e p a g e 4-47). •
INDUCTIVE
INDUCTIVE PICKUP (GRN)
PICKUP
B TERMINAL
3. Shift to n e u t r a l , a n d start t h e e n g i n e . H o l d t h e
e n g i n e s p e e d at 3,000 r p m , w i t h n o l o a d until t h e
radiator f a n c o m e s o n , t h e n let it idle.
4. R a i s e t h e e n g i n e s p e e d to 2,000 r p m , a n d h o l d it
there.
Is the voltage over 15.1 V?
Y E S — R e p l a c e the alternator o r t h e r e a r h o u s i n g
assembly.•
5. R e l e a s e t h e a c c e l e r a t o r p e d a l , a n d let t h e e n g i n e
idle.
6. T u r n off all t h e a c c e s s o r i e s . S e l e c t t h e c h a r g i n g t e s t
o n the t e s t e r .
7. R e m o v e t h e inductive p i c k u p , a n d z e r o t h e
ammeter.
8. P l a c e the i n d u c t i v e p i c k u p o v e r t h e B t e r m i n a l w i r e
of the alternator s o the a r r o w p o i n t s a w a y f r o m t h e
alternator.
4-38
n
J ENGINE |
Alternator Control Circuit Troubleshooting
'00-05 models 7. C h e c k f o r c o n t i n u i t y b e t w e e n t h e E C M c o n n e c t o r
terminal C 2 and body ground.
1. C h e c k for p r o p e r o p e r a t i o n of t h e e l e c t r i c a l l o a d
detector ( E L D ) b y c h e c k i n g for a D T C . If a D T C is
E C M C O N N E C T O R C (31P)
p r e s e n t , d i a g n o s e a n d repair t h e c a u s e before
c o n t i n u i n g w i t h t h i s test.
ALTC
N O T E : T h e E L D D T C d o e s not t u r n o n t h e MIL. (WHT/GRN)
2. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r f r o m t h e
alternator.
1 2
/
4 5
/
8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
/ 24 25 26 27 28 29 30 /
3. S t a r t t h e e n g i n e , a n d turn o n t h e h e a d l i g h t s to high
beam.
4. M e a s u r e t h e v o l t a g e b e t w e e n t h e alternator 4 P
c o n n e c t o r t e r m i n a l No. 2 a n d t h e p o s i t i v e t e r m i n a l
of t h e battery. Is there continuity?
Y E S — R e p a i r s h o r t to g r o u n d in t h e w i r e b e t w e e n
BATTERY (J)
t h e alternator a n d t h e E C M ( C 2 ) . B
N O — C h e c k for l o o s e or p o o r c o n n e c t i o n s at E C M
c o n n e c t o r C . If t h e c o n n e c t i o n is O K , s u b s t i t u t e a
k n o w n - g o o d E C M ( s e e p a g e 11-5), t h e n r e c h e c k . If
the symptom/indication g o e s a w a y with a known-
C (WHT/GRN)
g o o d E C M , r e p l a c e t h e original E C M ( s e e p a g e
11-115KB
ALTERNATOR W i r e s i d e of
4P C O N N E C T O R female terminals 8. T u r n off t h e h e a d l i g h t s , a n d turn the ignition s w i t c h
to L O C K (0).
9. D i s c o n n e c t E C M c o n n e c t o r C (31P).
Is there less than 1 V?
N O — G o t o s t e p 5.
5. T u r n off the h e a d l i g h t s , a n d turn t h e ignition s w i t c h

to L O C K (0).
6. D i s c o n n e c t e n g i n e control m o d u l e ( E C M )
c o n n e c t o r C (31P).
(cont'd)
4-39
Charging System
Alternator Control Circuit Troubleshooting (cont'd)

10. C h e c k for continuity b e t w e e n t h e E C M c o n n e c t o r '06-08 models
t e r m i n a l C 2 a n d alternator 4P c o n n e c t o r t e r m i n a l
No. 2. 1. C h e c k for p r o p e r o p e r a t i o n of the electrical load
detector ( E L D ) b y c h e c k i n g for a D T C . If a D T C is
p r e s e n t , d i a g n o s e a n d repair t h e c a u s e before
c o n t i n u i n g w i t h t h i s test.
p . N O T E : T h e E L D D T C d o e s not turn o n T h e MIL.
2. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r f r o m the
alternator.
3. S t a r t the e n g i n e , a n d turn o n the h e a d l i g h t s to high

ALTC beam.
(WHT/GRN)
10
4. M e a s u r e the v o l t a g e b e t w e e n the alternator 4 P
12 13 14 15 16 17 18 19 20 22
c o n n e c t o r t e r m i n a l N o . 2 a n d the p o s i t i v e t e r m i n a l
24 25 26 27 28 29 30
of the battery.
Is there
continuity?
BATTERY
©
Y E S — R e p l a c e the alternator ( s e e p a g e 4-45) or
r e p a i r the alternator ( s e e p a g e 4-47). •
C (WHT/GRN)
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e
alternator a n d the E C M ( C 2 ) . B
ALTERNATOR W i r e s i d e of
4P C O N N E C T O R female terminals
Is there less than 1 V?
5. T u r n off the h e a d l i g h t s , a n d turn the ignition s w i t c h

to L O C K (0).
6. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e
data link c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e
11-213).
4-40
+
ENGINE
7. T u r n the ignition s w i t c h to O N (II). 16. M a k e s u r e the H D S c o m m u n i c a t e s with the v e h i c l e

a n d t h e E C M . If it d o e s n ' t c o m m u n i c a t e ,
8. M a k e s u r e t h e H D S c o m m u n i c a t e s with t h e v e h i c l e t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
a n d the e n g i n e control m o d u l e ( E C M ) . If it d o e s n ' t
c o m m u n i c a t e , t r o u b l e s h o o t t h e D L C circuit 17. J u m p the S C S line w i t h t h e H D S .
( s e e p a g e 11-367).
N O T E : T h i s s t e p m u s t be d o n e to protect t h e E C M
9. J u m p the S C S line w i t h t h e H D S . from damage.
N O T E : T h i s s t e p m u s t be d o n e to protect the E C M 18. T u r n the ignition s w i t c h to L O C K (0).

from damage.
19. D i s c o n n e c t t h e E C M c o n n e c t o r B (24P).
20. C h e c k for c o n t i n u i t y b e t w e e n t h e E C M c o n n e c t o r
11. D i s c o n n e c t t h e E C M c o n n e c t o r B (24P). t e r m i n a l B 1 8 a n d alternator 4 P c o n n e c t o r t e r m i n a l
No. 2.
12. C h e c k for continuity b e t w e e n the E C M c o n n e c t o r
E C M C O N N E C T O R B (24P) / •— 2 4 5 6 /
/
8 103 11 13 / ///
17 18 19 20 21 ///
/ 2 3 4 5 6 I ALTC (WHT/GRN)
8
/ 10 11
/ / /
13
@
17 18 19
ALTC
20 21
(WHT/GRN)
/// C (WHT/GRN)
Y E S — R e p a i r s h o r t to g r o u n d in the w i r e b e t w e e n
t h e alternator a n d the E C M ( B 1 8 ) . B Y E S — R e p l a c e t h e alternator ( s e e p a g e 4-45) or
repair the alternator ( s e e p a g e 4-47). •
N O — U p d a t e the E C M if it d o e s not h a v e t h e latest
s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n - N O — R e p a i r o p e n in the w i r e b e t w e e n t h e
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e alternator a n d E C M (B18).H
E C M , r e p l a c e the original E C M ( s e e p a g e 11-389). •
13. T u r n off the h e a d l i g h t s , a n d turn the ignition s w i t c h

to L O C K (0).
14. C o n n e c t the H D S to the D L C ( s e e s t e p 2 o n p a g e

11-213).
4-41
Charging System
Drive Belt Inspection Drive Belt Replacement
1. I n s p e c t t h e belt for c r a c k s o r d a m a g e . If t h e belt is Special Tools Required
c r a c k e d o r d a m a g e d , r e p l a c e it. Belt t e n s i o n r e l e a s e tool S n a p - o n Y A 9 3 1 7 o r e q u i v a l e n t ,
commercially available
2 . C h e c k that t h e indicator (A) o n t h e a u t o - t e n s i o n e r
h o u s i n g i s not b e y o n d t h e e d g e of the i n d i c a t o r rib 1. M o v e t h e a u t o - t e n s i o n e r (A) to r e l i e v e t e n s i o n f r o m
(B) o n t h e t e n s i o n e r b a s e . If it is b e y o n d t h e e d g e of t h e d r i v e belt ( B ) , a n d r e m o v e the d r i v e belt.
t h e indicator rib, r e p l a c e t h e d r i v e belt ( s e e p a g e
4-42).
2 . Install the n e w belt in t h e r e v e r s e o r d e r of r e m o v a l .
N O T E : F o r belt routing, s e e t h e c h a r g i n g s y s t e m
c o m p o n e n t location i n d e x ( s e e p a g e 4-29).
4-42
Drive Belt Auto-tensioner Inspection
Special Tools Required 5. M o v e t h e a u t o - t e n s i o n e r w i t h i n its limit u s i n g the

Belt t e n s i o n r e l e a s e tool S n a p - o n Y A 9 3 1 7 or e q u i v a l e n t , belt t e n s i o n r e l e a s e tool in the d i r e c t i o n s h o w n ,
c o m m e r c i a l l y available c h e c k that the t e n s i o n e r m o v e s s m o o t h l y a n d
w i t h o u t a n y a b n o r m a l n o i s e . If the t e n s i o n e r d o e s
1. T u r n the ignition s w i t c h to O N (II), a n d m a k e s u r e not m o v e s m o o t h l y , or y o u h e a r a b n o r m a l n o i s e ,
t h e A / C s w i t c h is O F F . T u r n the ignition s w i t c h to replace the auto-tensioner.
L O C K (0).
2. C h e c k the position of t h e a u t o - t e n s i o n e r i n d i c a t o r ' s

p o i n t e r (A). Start t h e e n g i n e , t h e n c h e c k the
p o s i t i o n a g a i n w i t h t h e e n g i n e idling. If the position
of t h e indicator m o v e s or f l u c t u a t e s v e r y m u c h ,
r e p l a c e the a u t o - t e n s i o n e r ( s e e p a g e 4-44).
6. A t t a c h a t o r q u e w r e n c h (A) to the p u l l e y bolt. A l i g n

t h e indicator o n the a u t o - t e n s i o n e r h o u s i n g w i t h
t h e e d g e of the indicator rib o n the t e n s i o n e r b a s e
b y u s i n g t h e t o r q u e w r e n c h , a n d m e a s u r e the
t o r q u e . If the t o r q u e v a l v e is out of s p e c i f i c a t i o n ,
r e p l a c e the a u t o - t e n s i o n e r .
3. C h e c k for a b n o r m a l n o i s e f r o m t h e t e n s i o n e r pulley. Auto-tensioner Spring Torque:

If y o u h e a r a b n o r m a l n o i s e , r e m o v e t h e auto- 2 6 . 2 N-m (2.67 kgf-m, 19.3 Ibf ft)
t e n s i o n e r , a n d r e p l a c e t h e t e n s i o n e r pulley.
4. T u r n off the e n g i n e . M o v e the a u t o - t e n s i o n e r (A) in

t h e direction s h o w n w i t h t h e belt t e n s i o n r e l e a s e
tool (B) to relieve t e n s i o n f r o m the d r i v e belt (C),
t h e n r e m o v e the belt.
4-43
Charging System
Drive Belt Auto-tensioner Tensioner Pulley Replacement
Replacement
1. R e m o v e t h e a u t o - t e n s i o n e r ( s e e p a g e 4-44).
1. R e m o v e t h e d r i v e belt ( s e e p a g e 4-42). 2 . S e c u r e t h e a u t o - t e n s i o n e r in a b e n c h v i s e w i t h soft

j a w s . T o prevent d a m a g e to the tensioner, a l w a y s
2. R e m o v e the auto-tensioner. u s e soft j a w s o r e q u i v a l e n t m a t e r i a l s b e t w e e n t h e
tensioner and the vise.
8x1.25 mm
2 2 N-m (2.2 kgf-m, 16 I b f f t )
8x1.25 mm
3. R e m o v e t h e p u l l e y bolt (left-hand t h r e a d s ) , a n d
2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
r e m o v e t h e t e n s i o n e r pulley.
3. Install t h e p a r t s in t h e r e v e r s e o r d e r of r e m o v a l .
42 N-m
( 4 . 3 k g f m , 3 1 Ibfft)
4. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l .
4-44
Alternator Removal and Installation
Removal 5. R e m o v e the m o u n t i n g b o l t s , t h e n r e m o v e t h e
alternator.
1. M a k e s u r e y o u h a v e the anti-theft c o d e for the
a u d i o s y s t e m , t h e n write d o w n the a u d i o p r e s e t s .
2. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery.
3. R e m o v e t h e d r i v e belt ( s e e p a g e 4-42).
4. D i s c o n n e c t the 4 P c o n n e c t o r (A) f r o m t h e alternator

(B) a n d the B L K w i r e f r o m the a l t e r n a t o r B t e r m i n a l
(C) .
(cont'd)
4-45
Charging System
Alternator Removal and Installation (cont'd)
Installation 3. Install t h e drive belt ( s e e p a g e 4-42).
1. Install t h e alternator. 4. C o n n e c t t h e n e g a t i v e c a b l e to t h e battery.
10x1.25 m m
4 4 N - m (4.5 k g f - m , 3 3 Ibf ft)
5. '00-05 m o d e l s : D o t h e e n g i n e control m o d u l e ( E C M )
10 x 1.25 m m
4 4 N - m (4.5 k g f - m , 3 3 Ibf ft)
2. C o n n e c t t h e 4 P c o n n e c t o r (A) to t h e a l t e r n a t o r (B)
a n d t h e B L K w i r e to t h e alternator B t e r m i n a l (C).
4-46
Alternator Overhaul
Exploded View
ROTOR
END COVER INSULATOR
(cont'd)
4-47
Charging System
Alternator Overhaul (cont'd)
Special Tools Required 5. R e m o v e t h e w a s h e r nut (A) a n d t e r m i n a l i n s u l a t o r

• Handle Driver 07749-0010000 (B) f r o m t h e B t e r m i n a l , t h e n r e m o v e the e n d c o v e r
• A t t a c h m e n t , 42 x 47 m m 0 7 7 4 6 - 0 0 1 0 3 0 0 (C) a n d b r u s h h o l d e r i n s u l a t o r (D).
N O T E : R e f e r to t h e E x p l o d e d V i e w a s n e e d e d d u r i n g
this procedure.
Alternator Disassembly
1. T e s t t h e a l t e r n a t o r a n d regulator b e f o r e y o u
r e m o v e t h e m ( s e e p a g e 4-38).
2. R e m o v e t h e a l t e r n a t o r ( s e e p a g e 4-45).
D
3. If t h e front b e a r i n g n e e d s r e p l a c i n g , r e m o v e t h e
p u l l e y locknut w i t h a 10 m m w r e n c h (A) a n d a
2 2 m m w r e n c h (B). If n e c e s s a r y , u s e a n i m p a c t
wrench.
6. R e m o v e t h e b r u s h h o l d e r .
4. R e m o v e t h e t h r e e f l a n g e n u t s (A) a n d t h e s c r e w (B)
f r o m t h e alternator, t h e n r e m o v e t h e t e r m i n a l plate
(C).
4-48
(cont'd)
4-49
Charging System
11. If y o u a r e not r e p l a c i n g the front b e a r i n g a n d / o r t h e 14. W i t h a h a m m e r a n d c o m m e r c i a l l y a v a i l a b l e t o o l s

r e a r b e a r i n g , g o to s t e p 18. R e m o v e t h e rotor f r o m s h o w n , install a n e w rear b e a r i n g o n t h e rotor shaft.
the stator drive-end housing.
12. I n s p e c t t h e rotor s h a f t for s c o r i n g , a n d i n s p e c t t h e 15. R e m o v e t h e front b e a r i n g retainer plate.

b e a r i n g j o u r n a l s u r f a c e in t h e stator h o u s i n g for
seizure marks.
• If e i t h e r t h e rotor or stator h o u s i n g i s d a m a g e d ,
r e p l a c e t h e alternator.
• If both t h e rotor a n d the stator h o u s i n g a r e O K ,
g o to s t e p 13.
13. R e m o v e t h e rear b e a r i n g u s i n g a p u l l e r a s s h o w n .
4-50
[ ENGINE [
16. S u p p o r t t h e stator h o u s i n g in a v i s e , a n d d r i v e out Rectifier T e s t

t h e front b e a r i n g w i t h a b r a s s drift (A) a n d h a m m e r .
18. C h e c k for continuity in e a c h d i r e c t i o n , b e t w e e n t h e
B terminal a n d P terminals, a n d between the E
t e r m i n a l a n d P t e r m i n a l s of e a c h d i o d e pair.
A l l d i o d e s s h o u l d h a v e continuity in o n l y o n e
d i r e c t i o n . B e c a u s e t h e rectifier d i o d e s a r e d e s i g n e d
to a l l o w c u r r e n t to p a s s in o n e d i r e c t i o n , a n d t h e
rectifier is m a d e up of eight d i o d e s (four p a i r s ) , y o u
m u s t t e s t e a c h d i o d e in both d i r e c t i o n s for
continuity with an o h m m e t e r t h a t h a s diode
c h e c k i n g capability: a total of 16 c h e c k s .
• If a n y d i o d e is faulty, r e p l a c e the rectifier

a s s e m b l y . ( D i o d e s a r e not a v a i l a b l e s e p a r a t e l y . )
• If all t h e d i o d e s a r e O K , g o to s t e p 19.
17. Install a n e w front b e a r i n g in t h e stator h o u s i n g

w i t h a h a m m e r , t h e h a n d l e driver, a n d a t t a c h m e n t .
07749-0010000
07746-0010300
(cont'd)
4-51
Charging System
Alternator Brush Inspection Stator Test
19. M e a s u r e t h e length of both b r u s h e s (A) w i t h a 2 2 . C h e c k for c o n t i n u i t y b e t w e e n e a c h pair of l e a d s (A).

v e r n i e r c a l i p e r (B).
• If t h e r e is no c o n t i n u i t y , g o to s t e p 2 3 .
• If either b r u s h is s h o r t e r t h a n t h e s e r v i c e limit, • If t h e r e is no continuity, r e p l a c e t h e alternator.
replace the brush a s s e m b l y .
A
• If b r u s h length is O K , g o to s t e p 2 0 .
Alternator Brush Length:

S t a n d a r d ( N e w ) : 10.5 m m (0.41 in.)
2 3 . C h e c k for continuity b e t w e e n e a c h l e a d a n d t h e coil

c o r e (B).
• If t h e r e is no c o n t i n u i t y , g o to s t e p 24.
B
• If t h e r e is c o n t i n u i t y , r e p l a c e t h e alternator.
Rotor Slip Ring T e s t Alternator Reassembly
2 0 . C h e c k for continuity b e t w e e n t h e s l i p r i n g s (A). 24. R e a s s e m b l e the alternator in t h e r e v e r s e o r d e r of

d i s a s s e m b l y , a n d note t h e s e i t e m s :
• If t h e r e is c o n t i n u i t y , g o to s t e p 2 1 .
• If t h e r e is no c o n t i n u i t y , r e p l a c e t h e alternator. • B e c a r e f u l not to get a n y g r e a s e o r oil o n t h e s l i p
rings.
C
• If y o u r e m o v e d t h e p u l l e y , tighten its locknut to
111 N-m (11.3 kgf-m, 81.7 Ibfft) w h e n y o u
reinstall it.
2 1 . T h e n c h e c k for c o n t i n u i t y b e t w e e n e a c h s l i p ring
a n d t h e rotor (B) a n d t h e rotor s h a f t ( C ) .
• If t h e r e is n o c o n t i n u i t y , g o to s t e p 2 2 .
• If t h e r e is c o n t i n u i t y , r e p l a c e t h e alternator.
4-52
Cruise Control
CRUISE CONTROL UNIT CLUTCH PEDAL POSITION SWITCH

('00-05 m o d e l s ) T e s t , p a g e 4-72
I n p u t T e s t , p a g e 4-61 A d j u s t m e n t , p a g e 12-7
CRUISE CONTROL ACTUATOR ACTUATOR CABLE

('00-05 m o d e l s ) ('00-05 m o d e l s )
Test, p a g e 4-68 A d j u s t m e n t , p a g e 4-71
R e p l a c e m e n t , p a g e 4-69 R e p l a c e m e n t , p a g e 4-70
4-53
Cruise Control
'00-05 m o d e l s
C r u i s e control c a n n o t be s e t 1. C h e c k horn operation. • B l o w n N o . 6 (15 A )
2. '00-03 m o d e l s : C h e c k cruise control s e t / d e c e l , f u s e in t h e u n d e r -
r e s u m e / a c c e l s w i t c h ( s e e p a g e 4-67). dash fuse/relay
3. ' 0 4 - 0 5 m o d e l s : C h e c k c r u i s e control s e t / d e c e l , box
r e s u m e / a c c e l , c a n c e l s w i t c h ( s e e p a g e 4-67). • B l o w n No. 47
4. T e s t t h e b r a k e p e d a l position s w i t c h ( s e e p a g e ('00-01 m o d e l s :
22-144) a n d c h e c k its a d j u s t m e n t ( s e e p a g e 19-6). 10 A ,
5. T e s t c l u t c h p e d a l p o s i t i o n s w i t c h ( s e e p a g e 4-72) a n d '02-05 m o d e l s :
c h e c k its a d j u s t m e n t ( s e e p a g e 12-7). 15 A ) f u s e in t h e
6. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61). main under-hood
fuse/relay box
• Poor ground: G 3 0 1 ,
G401,G402
• O p e n circuit, l o o s e
or d i s c o n n e c t e d
terminals: B L K / Y E L ,
L T G R N , LT GRN/
RED, GRY, ORN,
WHT/BLK
C r u i s e control c a n b e s e t , but 1. ' 0 0 - 0 3 m o d e l s : C h e c k d i m m i n g circuit in g a u g e • Poor ground: G501
t h e c r u i s e control i n d i c a t o r a s s e m b l y ( s e e p a g e 22-63). • O p e n circuit, l o o s e
d o e s not c o m e o n 2. ' 0 4 - 0 5 m o d e l s : C h e c k d i m m i n g c i r c u i t in g a u g e or d i s c o n n e c t e d
a s s e m b l y ( s e e p a g e 22-68). terminals: B L U /
3. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61). YEL
C r u i s e s p e e d is n o t i c e a b l y 1. C h e c k v e h i c l e s p e e d s e n s o r ( V S S ) ( s e e p a g e 22-94).
h i g h e r or l o w e r t h a n w h a t 2. C h e c k c r u i s e control a c t u a t o r ( s e e p a g e 4-68), a n d
w a s set c a b l e a d j u s t m e n t ( s e e p a g e 4-71).
3. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
E x c e s s i v e o v e r s h o o t i n g or 1. C h e c k v e h i c l e s p e e d s e n s o r ( V S S ) ( s e e p a g e 22-94).
u n d e r s h o o t i n g w h e n trying to 2. C h e c k c r u i s e control actuator ( s e e p a g e 4-68), a n d
set speed c a b l e a d j u s t m e n t ( s e e p a g e 4-71).
3. D o t h e c r u i s e control unit input test ( s e e p a g e 4-61).
S p e e d f l u c t u a t e s o n a flat 1. C h e c k v e h i c l e s p e e d s e n s o r ( V S S ) ( s e e p a g e 22-94).
road with the cruise control 2. C h e c k c r u i s e control a c t u a t o r a n d c a b l e a d j u s t m e n t
set ( s e e p a g e 4-68).
3. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
V e h i c l e d o e s not d e c e l e r a t e 1. ' 0 0 - 0 3 m o d e l s : C h e c k c r u i s e control s e t / d e c e l , O p e n circuit, l o o s e or
or a c c e l e r a t e a c c o r d i n g l y r e s u m e / a c c e l s w i t c h ( s e e p a g e 4-67). disconnected
w h e n the s e t / d e c e l or 2. '04-05 m o d e l s : C h e c k cruise control s e t / d e c e l , terminals:
r e s u m e / a c c e l s w i t c h is r e s u m e / a c c e l , c a n c e l s w i t c h ( s e e p a g e 4-67). LT GRN/RED,
pressed 3. Do t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61). LT GRN/BLK
4-54
S e t s p e e d d o e s not c a n c e l 1. T e s t the brake pedal position s w i t c h (see page S h o r t to p o w e r in t h e
w h e n the brake p e d a l is 22-144) a n d c h e c k its a d j u s t m e n t ( s e e p a g e 19-6). GRYwire
pressed 2. Do t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
S e t s p e e d d o e s not c a n c e l 1. T e s t c l u t c h p e d a l position s w i t c h ( s e e p a g e 4-72) a n d S h o r t to g r o u n d in
( e n g i n e r p m s t a y s high) w h e n c h e c k its a d j u s t m e n t ( s e e p a g e 12-7). the P N K w i r e
t h e c l u t c h p e d a l is p r e s s e d 2. Do t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
S e t s p e e d d o e s not c a n c e l 1. C h e c k c r u i s e control m a i n s w i t c h ( s e e p a g e 4-65). S h o r t to p o w e r in t h e
w h e n the c r u i s e control m a i n 2. Do t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61). LT G R N wire
s w i t c h is t u r n e d off
S e t s p e e d d o e s not c a n c e l 1. C h e c k c r u i s e control s e t / d e c e l , r e s u m e / a c c e l , c a n c e l O p e n circuit, l o o s e or
w h e n the c a n c e l s w i t c h is s w i t c h ( s e e p a g e 4-67). disconnected
p r e s s e d ('04-05 m o d e l s ) 2. Do t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61). terminals: L T G R N /
RED, LT GRN/BLK
S e t s p e e d will not r e s u m e 1. T e s t t h e b r a k e pedal p o s i t i o n s w i t c h ( s e e p a g e • F a u l t y brake p e d a l
w h e n the r e s u m e / a c c e l 22-144) a n d c h e c k its a d j u s t m e n t . position switch
s w i t c h is p r e s s e d (with the 2. '00-03 m o d e l s : C h e c k c r u i s e control set/decel, • O p e n circuit, l o o s e
c r u i s e control m a i n s w i t c h r e s u m e / a c c e l s w i t c h ( s e e p a g e 4-67). or d i s c o n n e c t e d
turned on, and set speed '04-05 m o d e l s : C h e c k c r u i s e c o n t r o l s e t / d e c e l , terminals: L T G R N /
t e m p o r a r i l y c a n c e l e d by r e s u m e / a c c e l , c a n c e l s w i t c h ( s e e p a g e 4-67). BLK
p r e s s i n g t h e b r a k e pedal) 3. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
S e t s p e e d will not r e s u m e 1. T e s t c l u t c h p e d a l position s w i t c h ( s e e p a g e 4-72) a n d • F a u l t y clutch p e d a l
w h e n the r e s u m e / a q c e l c h e c k its a d j u s t m e n t ( s e e p a g e 12-7). position s w i t c h
s w i t c h is p r e s s e d (with the 2. '00-03 m o d e l s : C h e c k c r u i s e control s e t / d e c e l , • O p e n circuit, l o o s e
c r u i s e control m a i n s w i t c h r e s u m e / a c c e l s w i t c h ( s e e p a g e 4-67). or d i s c o n n e c t e d
turned on, and set speed '04-05 m o d e l s : C h e c k c r u i s e control set/decel, terminals: L T G R N /
temporarily canceled by r e s u m e / a c c e l , c a n c e l s w i t c h ( s e e p a g e 4-67). BLK
p r e s s i n g t h e c l u t c h pedal) 3. D o t h e c r u i s e control unit input t e s t ( s e e p a g e 4-61).
4-55
Cruise Control
Symptom Troubleshooting Index (cont'd)
'06-08 m o d e l s
C r u i s e control c a n n o t b e 1. C h e c k for P G M - F I D T C s . Poor ground G501
set 2. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63).
3. Do the cruise control s e t / d e c e l , r e s u m e / a c c e l , cancel
s w i t c h t e s t ( s e e p a g e 4-67).
C r u i s e control c a n b e s e t , 1. C h e c k for P G M - F I D T C s . Faulty gauge a s s e m b l y
but t h e c r u i s e c o n t r o l 2. Do the gauge a s s e m b l y self-diagnostic function
indicator d o e s not c o m e p r o c e d u r e ( s e e p a g e 22-60).
on 3. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63).
T e s t t h e c r u i s e control i n d i c a t o r s i g n a l input.
V e h i c l e d o e s not 1. C h e c k for P G M - F I D T C s . O p e n circuit, l o o s e or
d e c e l e r a t e or a c c e l e r a t e 2. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63). disconnected
accordingly w h e n the set/ T e s t t h e c r u i s e control s e t / d e c e l a n d r e s u m e / a c c e l terminals: L T G R N / R E D
d e c e l or r e s u m e / a c c e l switch signal inputs. orLTGRN/BLKwire
s w i t c h is p r e s s e d 3. Do the cruise control s e t / d e c e l , r e s u m e / a c c e l , cancel
S e t s p e e d d o e s not 1. C h e c k for P G M - F I D T C s . • S h o r t to p o w e r in the
cancel w h e n the brake 2. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63). GRYwire
p e d a l is p r e s s e d T e s t t h e b r a k e p e d a l p o s i t i o n s w i t c h s i g n a l input. • F a u l t y brake p e d a l
3. D o t h e b r a k e p e d a l p o s i t i o n s w i t c h test ( s e e p a g e position s w i t c h
22-144).
S e t s p e e d d o e s not 1. C h e c k for P G M - F I D T C s . • S h o r t to g r o u n d in
cancel (engine rpm stays 2. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63). the PNK wire
high) w h e n t h e c l u t c h T e s t t h e c l u t c h p e d a l p o s i t i o n s w i t c h s i g n a l input. • Faulty clutch pedal
p e d a l is p r e s s e d 3. D o t h e c l u t c h p e d a l p o s i t i o n s w i t c h t e s t ( s e e p a g e 4-72). position s w i t c h
S e t s p e e d d o e s not 1. C h e c k for P G M - F I D T C s . S h o r t to p o w e r in t h e
cancel w h e n the c r u i s e 2. D o t h e c r u i s e c o n t r o l input t e s t ( s e e p a g e 4-63). LT G R N wire
control m a i n switch is T e s t t h e c r u i s e c o n t r o l m a i n s w i t c h s i g n a l input.
t u r n e d off 3. D o t h e c r u i s e control s e t / d e c e l , r e s u m e / a c c e l , c a n c e l
S e t s p e e d d o e s not 1. C h e c k for P G M - F I D T C s . O p e n circuit, l o o s e or
c a n c e l w h e n the c a n c e l 2. D o t h e c r u i s e control input t e s t ( s e e p a g e 4-63). disconnected
s w i t c h is p r e s s e d T e s t t h e c r u i s e control c a n c e l s w i t c h s i g n a l input. terminals: L T G R N / R E D
3. D o t h e c r u i s e control s e t / d e c e l , r e s u m e / a c c e l , c a n c e l orLTGRN/BLKwire
4-56
S e t s p e e d w i l l not 1. C h e c k for P G M - F I D T C s . • O p e n circuit, l o o s e o r
r e s u m e w h e n the 2. C h e c k the brake pedal position s w i t c h adjustment disconnected
r e s u m e / a c c e l s w i t c h is ( s e e p a g e 19-6). terminals:
p r e s s e d (with t h e c r u i s e 3. D o t h e c r u i s e control input t e s t ( s e e p a g e 4-63). L T G R N / B L K wire
control m a i n s w i t c h T e s t t h e c r u i s e control r e s u m e / a c c e l s w i t c h s i g n a l input. • F a u l t y brake p e d a l
turned o n , a n d set s p e e d T e s t t h e b r a k e p e d a l p o s i t i o n s w i t c h s i g n a l input. position s w i t c h
t e m p o r a r i l y c a n c e l e d by 4. D o t h e c r u i s e control s e t / d e c e l , r e s u m e / a c c e l , c a n c e l
p r e s s i n g t h e b r a k e pedal) s w i t c h t e s t ( s e e p a g e 4-67).
S e t s p e e d w i l l not 1. C h e c k for P G M - F I D T C s . • O p e n circuit, l o o s e o r
r e s u m e w h e n the 2. C h e c k the clutch pedal position s w i t c h adjustment disconnected
r e s u m e / a c c e l s w i t c h is ( s e e p a g e 12-7). terminals:
p r e s s e d (with the c r u i s e 3. D o t h e c r u i s e control input t e s t ( s e e p a g e 4-63). L T G R N / B L K wire
control m a i n s w i t c h T e s t t h e c r u i s e control r e s u m e / a c c e l s w i t c h s i g n a l input. • Faulty clutch pedal
turned o n , a n d set s p e e d T e s t t h e c l u t c h p e d a l p o s i t i o n s w i t c h s i g n a l input. position switch
t e m p o r a r i l y c a n c e l e d by 4. D o t h e c r u i s e control s e t / d e c e l , r e s u m e / a c c e l , c a n c e l
p r e s s i n g t h e c l u t c h pedal) s w i t c h t e s t ( s e e p a g e 4-67).
4-57
Cruise Control
Circuit Diagram
'00-03 m o d e l s
No. 47 (10 A) :'00-01 models

UNDER-DASH
No. 47 (15 A) :'02-03 models
No. 23 (10 A)
- RED/BLK
LIGHTING
IGNITION SWITCH SWITCH
No. 6 (15 A)
— C T V j D —
IG1 HOT in ON (II)

and START (Mi
". No. 47*
- C T N J O -
DASH LIGHTS
BRIGHTNESS
CONTROLLER
(In the gauge
4>
ILLUMINATION
LIGHT
CRUISE CONTROL MAIN SWITCH G501
IG BRAKESW BRAKE SW MAINSW

(CRUISE)
CRUISE CONTROL UNIT
MOTOR MOTOR ACTUATOR

RESUME SW SETSW OPEN CLOSE CLUTCH CRUISE IND SPEEDOMETER CLUTCH SW GND
ORN LTGRN/BLK LTGRN/RED BRN BRN/BLK BRN/WHT BLU/YEL WHT BLK
CLUTCH
•CABLE BRN =jr\ PEDAL
BRN/BLK BRN/WHT BLU/YEL WHT/B
REEL sy POSITION
SWITCH
GAUGE GAUGE
ASSEMBLY ASSEMBLY
CRUISE SPEEDOMETER
CONTROL SIGNAL
INDICATOR
LIGHT
J! MAGNETIC
ACCEL pj DECEL * CLUTCH
SOLENOID
T
CRUISE CONTROL CRUISE CONTROL ACTUATOR
SET/DECEL, RSUME/ACCEL SWITCH
_Q_
G301 G401 G402
4-58
• ENGINE!
'04-05 m o d e l s
UNDER-DASH
IG BRAKESW BRAKE SW MAINSW

(CRUISE)
CRUISE CONTROL UNIT
MOTOR MOTOR ACTUATOR

RESUME SW SETSW OPEN CLOSE CLUTCH CRUISE IND SPEEDC METER CLUTCH SW 6ND
4-59
Cruise Control
'06-08 m o d e l s
TAILLIGHT
RELAY
y
BLK/YEL RED BLK
CRUISE CONTROL
6 MAIN SWITCH
INDICATOR
LIGHT
ILLMINATION
UGHT
LTGRN BLK
A.
LTGRN UNDER-DASH
FUSE/RELAY BOX
No. 5 (7.5 A) FUSE
BRAKE PEDAL \7
POSITION
GAUGE
SWITCH A19
A 9
ASSEMBLY
DIMMING CIRCUIT
THROTTLE BODY THROTTLE ACTUATOR CONTROL MODULE
4-60
Cruise Control Unit Input Test
'00-05 models
S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a , r e v i e w the S R S c o m p o n e n t l o c a t i o n s , ' 0 0 - 0 5 m o d e l s ( s e e p a g e 2 3 - 1 1 ) , '06-08

m o d e l s ( s e e p a g e 2 3 - 1 2 ) , p r e c a u t i o n s , a n d p r o c e d u r e s ( s e e p a g e 2 3 - 1 3 ) , before p e r f o r m i n g r e p a i r s or s e r v i c e .
1. R e m o v e the knee b o l s t e r u n d e r t h e s t e e r i n g c o l u m n .
2. D i s c o n n e c t t h e 14P c o n n e c t o r f r o m t h e c r u i s e control unit.
3. I n s p e c t the c o n n e c t o r a n d c o n n e c t o r t e r m i n a l s to b e s u r e t h e y a r e m a k i n g g o o d c o n t a c t .
4. If t h e t e r m i n a l s a r e bent, l o o s e , o r c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
5. D o t h e f o l l o w i n g input test, at t h e 14P c o n n e c t o r .
• If a test i n d i c a t e s a p r o b l e m , find a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k the s y s t e m .

• If all the t e s t s p r o v e O K , c h e c k t h e c r u i s e control a c t u a t o r o p e r a t i o n , a n d a d j u s t t h e a c t u a t o r c a b l e .
CRUISE CONTROL UNIT CONNECTOR (14P)
1 2 3 4 5 6 7
/ 9 10 11 12 13 14
Wire side of female terminals
Cavity Wire color Test condition Test: Desired result P o s s i b l e c a u s e if r e s u l t i s n o t

obtained
1 BRN/WHT C o n n e c t to t e r m i n a l 4 The magnetic clutch should • F a u l t y actuator
( B L K / Y E L ) with a click a n d t h e output link s h o u l d • Poor ground (G301)
jumper wire, and be l o c k e d . • A n o p e n in t h e w i r e
turn ignition s w i t c h
to O N (II)
2 GRY Ignition s w i t c h to C h e c k for v o l t a g e to g r o u n d : • F a u l t y brake s w i t c h
O N (II), c r u i s e control T h e r e s h o u l d be 0 V w i t h t h e • F a u l t y c r u i s e control m a i n
main switch O N , and brake p e d a l p r e s s e d , a n d t h e r e switch
brake p e d a l p r e s s e d , s h o u l d b e battery v o l t a g e w i t h • A n o p e n in t h e w i r e
then released the brake pedal r e l e a s e d . • B l o w n No. 6 (15 A ) f u s e in the
under-dash fuse/relay box
3 BLK U n d e r all c o n d i t i o n s C h e c k for continuity to g r o u n d : • P o o r g r o u n d (G402)
T h e r e s h o u l d be continuity. • A n o p e n in t h e w i r e
4 BLK/YEL Ignition s w i t c h to C h e c k for v o l t a g e to g r o u n d : • B l o w n No. 6 (15 A ) f u s e in the
O N (II) T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
• A n o p e n in t h e w i r e
5 WHT/BLK W i t h brake p e d a l C h e c k for v o l t a g e to g r o u n d : • B l o w n No. 47 (10 A ) [No. 47
pressed and released T h e r e s h o u l d be battery v o l t a g e (15 A ) ] f u s e in t h e m a i n
w i t h t h e brake p e d a l p r e s s e d , u n d e r - h o o d f u s e / r e l a y box
a n d t h e r e s h o u l d b e 0 V w i t h the • F a u l t y brake s w i t c h
brake p e d a l r e l e a s e d . • A n o p e n in t h e w i r e
[] :'02-05 models
(cont'd)
4-61
Cruise Control
Cruise Control Unit Input Test (cont'd)
Cavity Wire color T e s t condition Test: Desired result P o s s i b l e c a u s e if r e s u l t i s n o t

obtained
6 LT G R N / Ignition s w i t c h to C h e c k for v o l t a g e to g r o u n d : • B l o w n No. 47 (10 A ) [ N o . 47
RED O N (II), c r u i s e c o n t r o l T h e r e s h o u l d b e battery v o l t a g e . (15 A>] f u s e in t h e m a i n
main switch turned W h e n t e s t i n g t e r m i n a l N o . 6, under-hood fuse/relay box
on, and set/decel t h e r e s h o u l d be n o v o l t a g e o n • Faulty horn relay
switch pushed t e r m i n a l N o . 7. • F a u l t y '00-03 m o d e l s : c r u i s e
7 LTGRN/ Ignition s w i t c h to W h e n t e s t i n g t e r m i n a l No. 7, control s e t / d e c e l , r e s u m e /
BLK O N (II), c r u i s e c o n t r o l t h e r e s h o u l d be no v o l t a g e o n accel switch, '04-05 models:
main switch turned t e r m i n a l N o . 6. c r u i s e control s e t / d e c e l ,
on, and resume/accel resume/accel, cancel switch
switch pushed • F a u l t y c a b l e reel
9 BRN C o n n e c t the B R N C h e c k t h e a c t u a t o r motor: Y o u • F a u l t y actuator
t e r m i n a l to t e r m i n a l s h o u l d be a b l e to h e a r it r u n . • Poor ground (G402)
11 BRN/BLK 4 ( B L K / Y E L ) with a • A n o p e n in t h e w i r e
jumper wire.
C o n n e c t the B R N /
B L K t e r m i n a l to b o d y
ground. Turn the
ignition s w i t c h to
O N (II)
10 BLU/YEL Ignition s w i t c h to C r u i s e indicator light s h o u l d • B l o w n No. 5 (7.5 A ) f u s e in t h e
O N (II), attach to come on. under-dash fuse/relay box
ground • B l o w n c r u i s e control indicator
• F a u l t y c r u i s e control indicator
circuit in g a u g e a s s e m b l y
12 WHT/BLK R a i s e t h e r e a r of C h e c k v o l t a g e b e t w e e n N o . 12 • Faulty vehicle s p e e d s e n s o r
v e h i c l e , a n d shift to ( + ) a n d N o . 3 (—) t e r m i n a l s : • F a u l t y s p e e d o m e t e r circuit in
N e u t r a l . Ignition T h e r e s h o u l d be 0 V a n d a b o u t the gauge a s s e m b l y
s w i t c h to O N (II), 5 V or battery v o l t a g e • A n o p e n in t h e w i r e
c r u i s e control m a i n alternately.
switch turned o n ,
a n d rotate o n e r e a r
w h e e l while holding
t h e other
13 LTGRN Ignition s w i t c h to C h e c k for v o l t a g e to g r o u n d : • B l o w n N o . 6 (15 A ) f u s e in the
O N (II) a n d c r u i s e T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
control main s w i t c h • F a u l t y c r u i s e control m a i n
turned on switch
14 PNK Clutch pedal pressed C h e c k for continuity to g r o u n d : • Faulty clutch switch
and released T h e r e s h o u l d be no continuity • Misadjusted clutch pedal
with the clutch pedal p r e s s e d , position s w i t c h installation
a n d t h e r e s h o u l d be continuity • Poor ground (G401)
w i t h the c l u t c h p e d a l r e l e a s e d . • A n o p e n in t h e w i r e
[] : '02-05 m o d e l s
6. If a n y t e s t i n d i c a t e s a p r o b l e m , find a n d c o r r e c t the c a u s e , t h e n r e c h e c k the s y s t e m . If all the input t e s t s p r o v e O K ,

t h e c o n t r o l unit m a y b e faulty. S u b s t i t u t e a k n o w n - g o o d c r u i s e control unit, a n d r e s e t . If t h e s y s t e m w o r k s
p r o p e r l y , r e p l a c e t h e c r u i s e c o n t ro l unit.
4-62
Cruise Control Input Test
'06-08 models
1. C o n n e c t the H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e data link c o n n e c t o r ( D L C ) .
3. M a k e s u r e t h e H D S c o m m u n c a t e s w i t h the v e h i c l e a n d t h e e n g i n e c o n t r o l m o d u l e ( E C M ) . If it d o e s n ' t ,
c o m m u n i c a t e t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
4. G o to P G M - F I , a n d c h e c k for D T C s .
5. D o t h e f o l l o w i n g t e s t s w h i l e m o n i t o r i n g p a r a m e t e r s in t h e P G M - F I D A T A L I S T w i t h the H D S .
N O T E : Intermittent f a i l u r e s a r e often c a u s e d b y l o o s e circuit c o n n e c t i o n s . W h i l e m o n i t o r i n g c r u i s e control i n p u t s ,

flex their c i r c u i t s , a n d note if a n y of t h e test r e s u l t s c h a n g e .
Signal to be tested Test condition Parameter: Desired result Possible cause if result is not obtained
Brake switch Brake pedal p r e s s e d , CRUISE BRAKE S W • F a u l t y brake p e d a l position s w i t c h
signal then released with s h o u l d indicate O F F • B l o w n No. 6 (15 A ) f u s e in t h e
cruise control main w h e n the b r a k e p e d a l is under-dash fuse/relay box
switch turned on pressed and ON w h e n • A n o p e n in t h e w i r e b e t w e e n t h e E C M
t h e brake p e d a l i s a n d the brake p e d a l position s w i t c h
released. • A w i r e s h o r t e d to g r o u n d b e t w e e n t h e
E C M a n d the brake p e d a l position s w i t c h
Clutch pedal Clutch pedal p r e s s e d , SHIFT/CLUTCH S W • F a u l t y c l u t c h p e d a l position s w i t c h
position then released s h o u l d indicate O F F • A n o p e n in the w i r e b e t w e e n t h e E C M
switch signal w h e n the clutch pedal a n d the c l u t c h p e d a l position s w i t c h
is p r e s s e d a n d O N • A w i r e s h o r t e d to g r o u n d b e t w e e n t h e
w h e n the c l u t c h p e d a l E C M a n d the c l u t c h p e d a l position
is r e l e a s e d . switch
• Poor ground G401
C r u i s e control Cruise control main CRUISE MASTER • F a u l t y c r u i s e control m a i n s w i t c h
main switch s w i t c h o n a n d off (MAIN)SW should • B l o w n No. 6 (15A) f u s e in t h e u n d e r -
signal indicate O N w h e n t h e d a s h fuse/relay box
c r u i s e control m a i n • A n o p e n in t h e w i r e b e t w e e n t h e E C M
s w i t c h is t u r n e d o n a n d a n d the c r u i s e control m a i n s w i t c h
O F F w h e n the c r u i s e • A w i r e s h o r t e d to g r o u n d b e t w e e n the
control m a i n s w i t c h is E C M a n d the c r u i s e control m a i n s w i t c h
t u r n e d off.
Set switch Set/decel switch CRUISE S E T S W • F a u l t y c r u i s e control s e t / d e c e l , r e s u m e /
signal pressed and released s h o u l d indicate O N accel, cancel switch
w h e n the set/decel • A n o p e n in the w i r e b e t w e e n t h e E C M
s w i t c h is p r e s s e d a n d a n d the c r u i s e control s e t / d e c e l , r e s u m e /
O F F w h e n the s e t / d e c e l accel, cancel switch
s w i t c h is r e l e a s e d . • A w i r e s h o r t e d to g r o u n d b e t w e e n the
E C M a n d the c r u i s e control s e t / d e c e l ,
resume/accel, cancel switch
(cont'd)
4-63
Cruise Control
Cruise Control Input Test (cont'd)
Signal to be tested Test condition Parameter: Desired result Possible cause if result is not obtained
Resume Resume/accel switch CRUISE RESUME SW • F a u l t y c r u i s e control s e t / d e c e l , r e s u m e /
switch signal pressed and released s h o u l d indicate O N accel, cancel switch
w h e n the r e s u m e / a c c e l • A n o p e n in the w i r e b e t w e e n the E C M
s w i t c h is p r e s s e d a n d a n d the c r u i s e control s e t / d e c e l , r e s u m e /
O F F w h e n the r e s u m e / accel, cancel switch
a c c e l s w i t c h is r e l e a s e d . • A w i r e s h o r t e d to g r o u n d b e t w e e n the
E C M a n d the c r u i s e control s e t / d e c e l ,
resume/accel, cancel switch
Cancel switch Cancel switch CRUISE CANCEL SW • F a u l t y c r u i s e control s e t / d e c e l , r e s u m e /
signal pressed and released s h o u l d indicate O N accel, cancel switch
w h e n the c a n c e l s w i t c h
is p r e s s e d a n d O F F
w h e n the c a n c e l s w i t c h
is r e l e a s e d .
4-64
Cruise Control Main Switch Test
1. C a r e f u l l y pry t h e c r u i s e control m a i n s w i t c h out of 3. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 2 a n d N o . 3

the i n s t r u m e n t p a n e l , t h e n d i s c o n n e c t t h e t e r m i n a l s . T h e r e s h o u l d b e continuity.
connector f r o m the switch.
4. If a failure o c c u r s b e t w e e n t e r m i n a l s No. 6 a n d
N o . 1, r e p l a c e the c r u i s e c o n t r o l m a i n s w i t c h .
5. If a failure o c c u r s b e t w e e n t e r m i n a l s No. 6 a n d
N o . 5, a n d b e t w e e n t h e N o . 2 a n d N o . 3 , c h e c k t h e
cruise control main switch indicator and
i l l u m i n a t i o n ( s e e p a g e 4-66).
2. C h e c k for continuity b e t w e e n t e r m i n a l s N o . 6 a n d
No. 1, a n d b e t w e e n t e r m i n a l s No. 6 a n d N o . 5 o n
t h e s w i t c h . T h e r e s h o u l d b e continuity w h e n t h e
s w i t c h is p r e s s e d , a n d n o continuity w h e n t h e
switch is p r e s s e d again.
CRUISE CONTROL MAIN

SWITCH CONNECTOR
1 2 3
/ 5 6 -
4-65
Cruise Control
Cruise Control Main Switch/ Cruise Control Main Switch/
Indicator/Illumination Test Indicator Bulb Replacement
1. T u r n the ignition s w i t c h to O N (II). T u r n the lighting 1. C a r e f u l l y pry the c r u i s e control m a i n s w i t c h (A) out
s w i t c h a n d t h e c r u i s e control m a i n s w i t c h (A) O N . of the i n s t r u m e n t p a n e l , t h e n d i s c o n n e c t the
c o n n e c t o r f r o m the s w i t c h .
2. C h e c k that the i l l u m i n a t i o n indicator (B) a n d t h e

indicator light (C) in the c r u i s e c o n t r o l m a i n s w i t c h 2. R e p l a c e the indicator bulb (B) or the s w i t c h , a s
come on. needed.
3. If the indicator d o e s not c o m e o n , r e m o v e t h e

s w i t c h , a n d r e p l a c e the bulb.
4. If the indicator d o e s not c o m e o n after the b u l b h a s

b e e n r e p l a c e d , r e p l a c e the c r u i s e control m a i n
switch.
4-66
Cruise Control Set/decel, Resume/ Cruise Control Set/decel, Resume/
accel Switch Test/Replacement accel, Cancel Switch Test/
Replacement
'00-03 models
'04-08 models
1. R e m o v e t h e t w o s c r e w s s e c u r i n g the c r u i s e control
set/decel, r e s u m e / a c c e l s w i t c h , then remove the 1. R e m o v e the t w o s c r e w s s e c u r i n g t h e c r u i s e control
switch. set/decel, r e s u m e / a c c e l , cancel switch, then
r e m o v e the s w i t c h .
CRUISE CONTROL
SET/DECEL, RESUME/ACCEL
SWITCH CONNECTOR CRUISE CONTROL SET/DECEL,
RESUME/ACCEL, CANCEL
SWITCH CONNECTOR
1 2 3 4 5
CO
1 2 4
T e r m i n a l s i d e of m a l e terminals
T e r m i n a l s i d e of m a l e terminals
2. D i s c o n n e c t the c o n n e c t o r f r o m the s w i t c h .
2. D i s c o n n e c t t h e c o n n e c t o r f r o m the s w i t c h .
3. C h e c k for continuity b e t w e e n t h e t e r m i n a l s in the
s w i t c h position a c c o r d i n g to the table. T h e r e s h o u l d 3. C h e c k for c o n t i n u i t y b e t w e e n the t e r m i n a l s in the
be continuity w h i l e p r e s s i n g the s w i t c h d o w n , a n d s w i t c h position a c c o r d i n g to t h e t a b l e . T h e r e s h o u l d
no c o n t i n u i t y w h e n the s w i t c h is r e l e a s e d . be c o n t i n u i t y w h i l e p r e s s i n g the s w i t c h d o w n , a n d
no c o n t i n u i t y w h e n the s w i t c h is r e l e a s e d .
\ Terminal
1 3 5
Position \ \ Terminal
1 2 3
o —o
Position \
Set/decel
(PRESSED) Set/decel o. r\
vJ
O —o
Resume/accel (PRESSED)
(PRESSED) Resume/accel
(PRESSED)
O— —o
r\
—o
4. If either s w i t c h is faulty, r e p l a c e the s w i t c h Cancel (PRESSED)
assembly.
5. If the s w i t c h is O K , but s w i t c h failure h a s o c c u r r e d 4. If either s w i t c h is faulty, r e p l a c e t h e s w i t c h

o n the c r u i s e control unit input test, c h e c k a n d assembly.
repair the w i r e h a r n e s s o n t h e s w i t c h circuit.
5. If the s w i t c h is O K , but s w i t c h f a i l u r e h a s o c c u r r e d
o n the c r u i s e control unit input test ('04-05 m o d e l s )
or c r u i s e control input test ('06-08 m o d e l s ) , c h e c k
a n d repair t h e w i r e h a r n e s s o n the s w i t c h circuit.
4-67
Cruise Control
Cruise Control Actuator Test
'00-05 models 6. W i t h p o w e r a n d g r o u n d still c o n n e c t e d a s in s t e p 3,

c o n n e c t battery p o w e r to t h e N o . 4 t e r m i n a l a n d
1. D i s c o n n e c t t h e 4 P c o n n e c t o r f r o m t h e c r u i s e g r o u n d to N o . 3 t e r m i n a l , a n d c h e c k that t h e output
control a c t u a t o r . linkage s t a r t s to t u r n f r o m t h e fully c l o s e d position
a n d s t o p s at t h e fully o p e n e d position b y t h e m o t o r
in t h e actuator.
7. R e v e r s e p o w e r a n d g r o u n d at c o n n e c t o r t e r m i n a l s ,
N o . 4 a n d N o . 3, a n d c h e c k that t h e output linkage
r e v e r s e s a n d s t o p s at t h e fully c l o s e d p o s i t i o n .
TRAVEL
2. R e m o v e the actuator cover.
3 . C o n n e c t battery p o w e r to t h e N o . 2 t e r m i n a l of t h e 8. If t h e output linkage m o v e s s l u g g i s h l y , or t h e m o t o r

4 P c o n n e c t o r , a n d c o n n e c t g r o u n d to t h e N o . 1 d o e s not o p e r a t e p r o p e r l y , r e p l a c e the c r u i s e
terminal. control actuator a s s e m b l y .
4. C h e c k t h e m a g n e t i c c l u t c h for p r o p e r e n g a g e m e n t .
Y o u s h o u l d h e a r a c l i c k i n g s o u n d a n d t h e output
linkage s h o u l d b e l o c k e d .
5. If t h e output l i n k a g e i s not l o c k e d , r e p l a c e t h e
cruise control actuator a s s e m b l y .
4-68
ENGINE
Cruise Control Actuator Replacement
'00-05 models 3. R e m o v e t h e c r u i s e c o n t r o l a c t u a t o r a s s e m b l y .
6x1.0 mm
1. R e m o v e t h e actuator c o v e r , a n d d i s c o n n e c t the 4 P
9 . 8 N m (1.0 k g f - m , 7 . 2 I b f f t )
c o n n e c t o r f r o m the c r u i s e control actuator.
2. D i s c o n n e c t the actuator c a b l e e n d (A) f r o m t h e

output linkage (B), a n d r e m o v e t h e c a b l e (C) f r o m
t h e c r u i s e control actuator. 4. R e p l a c e the a c t u a t o r , a n d install the n e w c r u i s e
control a c t u a t o r in t h e r e v e r s e o r d e r of r e m o v a l .
5. A d j u s t t h e a c t u a t o r c a b l e o n t h e c r u i s e c o n t r o l
actuator s i d e ( s e e p a g e 4-71).
4-69
Cruise Control
Cruise Control Actuator Cable Replacement
'00-05 models 3. R e m o v e the a c c e l e r a t o r p e d a l a s s e m b l y .
1. R e m o v e the a c t u a t o r c o v e r , a n d d i s c o n n e c t t h e 4 P
c o n n e c t o r f r o m the c r u i s e control actuator.
4. D i s c o n n e c t the actuator c a b l e e n d (A) f r o m the a r m

(B) o n t h e a c c e l e r a t o r p e d a l a s s e m b l y (C).
2. D i s c o n n e c t the a c t u a t o r c a b l e e n d (A), a n d r e m o v e
the c a b l e (B) f r o m t h e c r u i s e control actuator.
5. R e p l a c e the actuator c a b l e , a n d install the n e w

c a b l e in the r e v e r s e o r d e r of r e m o v a l .
6. A d j u s t the actuator c a b l e o n the c r u i s e control

a c t u a t o r s i d e ( s e e p a g e 4-71).
4-70
[ ENGINE §
Cruise Control Actuator Cable Adjustment
'00-05 models 5. T u r n t h e a d j u s t i n g nut (A) until it is 9 m m (0.35 in.)

a w a y f r o m t h e a c t u a t o r c a b l e bracket w h e n t h e
1. H o l d the c a b l e s h e a t h , r e m o v i n g all s l a c k f r o m the throttle linkage s t a r t s o p e n .
throttle c a b l e .
9 m m (0.35 in.)
2. T u r n the a d j u s t i n g nut (A) until it i s 3 m m (1/8 in.)
a w a y f r o m t h e throttle c a b l e b r a c k e t .
3 m m ( 1 / 8 in.)
6. Pull t h e c a b l e s o t h e a d j u s t i n g nut (A) t o u c h e s the

9.8 N m d . O k g f m , b r a c k e t , a n d tighten t h e locknut (B).
7.2 Ibf ft)
3. T i g h t e n the locknut (B). T h e throttle c a b l e deflection

s h o u l d n o w b e 4 — 6 m m (0.16—0.24 in.).
4. R e m o v e t h e a c t u a t o r c o v e r , t h e n d i s c o n n e c t the
a c t u a t o r c a b l e e n d f r o m the c r u i s e control actuator.
7. M a k e s u r e t h e throttle linkage starts to o p e n w h e n

the a c t u a t o r c a b l e is p u l l e d 9 m m (0.35 in.) f r o m the
starting point by rotating t h e actuator linkage.
4-71
Cruise Control
Clutch Pedal Position Switch Test
1. D i s c o n n e c t t h e c o n n e c t o r f r o m the c l u t c h p e d a l
position s w i t c h , then r e m o v e the switch.
2. C h e c k for continuity b e t w e e n the c l u t c h p e d a l

position s w i t c h connector terminals. T h e r e s h o u l d
b e no c o n t i n u i t y b e t w e e n t h e t e r m i n a l s w i t h the
button (A) r e l e a s e d , a n d t h e r e s h o u l d be c o n t i n u i t y
w i t h the button p r e s s e d .
CLUTCH PEDAL POSITION SWITCH CONNECTOR
1 2
3. If t h e c l u t c h p e d a l position s w i t c h is faulty, r e p l a c e
it.
4. Install t h e c l u t c h p e d a l p o s i t i o n s w i t c h , a n d a d j u s t it
( s e e p a g e 12-7).
4-72
Engine Mechanical
Engine A s s e m b l y
Special Tools 5-2
Engine Removal 5-3
Engine Installation 5-9
Engine Mount Replacement 5-16
Cylinder Head 6-1
Engine Block 7-1
Engine Lubrication 8-1
Intake Manifold and E x h a u s t S y s t e m 9-1

Engine Assembly
Special Tools

© 07AAK-SNAA120 Universal Eyelet 2
5-2
Engine Removal
Special Tools Required 10. D i s c o n n e c t t h e e n g i n e control m o d u l e ( E C M )

Universal eyelet 0 7 A A K - S N A A 1 2 0 c o n n e c t o r s (A) f r o m t h e E C M .
NOTE: '00-05 m o d e l s
• U s e f e n d e r c o v e r s to a v o i d d a m a g i n g painted
surfaces.
• T o avoid d a m a g i n g the w i r e s and terminals, unplug
t h e w i r i n g c o n n e c t o r s c a r e f u l l y w h i l e holding t h e
c o n n e c t o r portion.
• M a r k all w i r i n g a n d h o s e s to a v o i d m i s c o n n e c t i o n .
A l s o , be s u r e that t h e y d o not c o n t a c t other w i r i n g or
h o s e s , o r interfere w i t h other p a r t s .
1. R e m o v e t h e h o o d s u p p o r t rod f r o m t h e d r i v e r ' s
s i d e of the c a r , t h e n u s e it a s s h o w n to fix the h o o d
in a vertical p o s i t i o n .
'06-08 m o d e l s
2. M a k e s u r e y o u h a v e the anti-theft c o d e for t h e

a u d i o s y s t e m , t h e n write d o w n t h e a u d i o p r e s e t s .
3. R e l i e v e the fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-145)
• '06-08 m o d e l s ( s e e p a g e 11-474)
4. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery,
t h e n d i s c o n n e c t t h e positive c a b l e .
5. R e m o v e t h e battery.
11. D i s c o n n e c t t h e d a s h b o a r d w i r e h a r n e s s A
6. R a i s e the v e h i c l e o n t h e lift. c o n n e c t o r ( s ) (B).
7. D r a i n t h e e n g i n e oil ( s e e p a g e 8-6).
8. R e m o v e the t r a n s m i s s i o n ( s e e p a g e 13-6).
9. L o w e r the v e h i c l e o n the lift.
(cont'd)
5-3
Engine Assembly
E n g i n e R e m o v a l (cont'd)
12. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e v a c u u m tank. 14. R e m o v e the f o u r bolts (A) s e c u r i n g the electrical

p o w e r s t e e r i n g ( E P S ) control unit (B).
13. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e throttle c a b l e (A) b y

l o o s e n i n g t h e locknut (B), t h e n s l i p p i n g t h e c a b l e
e n d o u t of t h e a c c e l e r a t o r l i n k a g e . T a k e c a r e not to
b e n d t h e c a b l e w h e n r e m o v i n g it. A l w a y s r e p l a c e
any kinked cable with a n e w one. 15. R e m o v e t h e battery c a b l e (A) f r o m the m a i n
under-hood fuse/relay box, then r e m o v e the
h a r n e s s c l a m p s (B).
5-4
16. R e m o v e the battery c a b l e (A) f r o m the a u x i l i a r y 18. R e m o v e t h e radiator c a p .
u n d e r - h o o d f u s e b o x , a n d r e m o v e the g r o u n d c a b l e
(B) a n d h a r n e s s c l a m p s (C). 19. R a i s e the v e h i c l e o n the lift.
'00-05 m o d e l s 20. L o o s e t h e d r a i n plug in t h e radiator, a n d d r a i n the

e n g i n e c o o l a n t ( s e e p a g e 10-9).
2 1 . R e m o v e t h e e n g i n e s t o p b r a c k e t c u s h i o n (A), t h e n
r e m o v e t h e e n g i n e s t o p b r a c k e t (B).
2 2 . L o w e r the v e h i c l e o n t h e lift.
17. R e m o v e the g r o m m e t (D) f r o m the b u l k h e a d , t h e n

pull out the E C M c o n n e c t o r s .
(cont'd)
5-5
Engine Assembly
2 3 . R e m o v e t h e h e a t e r h o s e s (A) a n d t h e l o w e r radiator 2 5 . ' 0 0 - 0 5 m o d e l s : R e m o v e t h e fuel f e e d h o s e (A), fuel

h o s e (B). return h o s e (B) a n d brake b o o s t e r v a c u u m h o s e (C).
' 0 0 - 0 3 models
A B
' 0 4 - 0 5 models
24. R e m o v e t h e u p p e r radiator h o s e .
A B
5-6
(cont'd)
5-7
Engine Assembly
2 9 . A t t a c h t h e c h a i n hoist to the e n g i n e a s s h o w n . 3 0 . R e m o v e the s u p p o r t nut f r o m the left s i d e e n g i n e

T a k e c a r e not to d a m a g e t h e r o c k e r a r m oil c o n t r o l m o u n t bracket.
solenoid ( V T E C solenoid valve) and wire harness.
3 1 . R e m o v e the s u p p o r t nut (A) a n d f o u r m o u n t i n g

bolts (B), t h e n r e m o v e the right s i d e e n g i n e m o u n t
b r a c k e t (C).
07 A A K - S N A A 1 2 0
3 2 . C h e c k that the e n g i n e is c o m p l e t e l y f r e e of v a c u u m
h o s e s , fuel a n d c o o l a n t h o s e s , a n d electrical w i r i n g .
3 3 . S l o w l y r a i s e the e n g i n e a b o u t 150 m m (6 in.).

C h e c k o n c e a g a i n that all h o s e s a n d w i r e s a r e
d i s c o n n e c t e d f r o m the e n g i n e .
3 4 . R a i s e the e n g i n e all t h e w a y , a n d r e m o v e it f r o m
the v e h i c l e .
5-8
E n g i n e Installation
Special Tools Required

Universal eyelet 07AAK-SNAA120
1. Install t h e a c c e s s o r y b r a c k e t s , a n d t i g h t e n t h e i r bolts to t h e s p e c i f i e d t o r q u e .
(2.2 kgf-m, 1 6 I b f f t )
(cont'd)
5-9
Engine Assembly
E n g i n e I n s t a l l a t i o n (cont'd)
2 . Install t h e e n g i n e into p o s i t i o n in t h e v e h i c l e . 5. C o n n e c t t h e e v a p o r a t i v e e m i s s i o n ( E V A P ) c a n i s t e r
hose.
N O T E : R e i n s t a l l t h e m o u n t i n g bolts a n d s u p p o r t
n u t s in t h e s e q u e n c e g i v e n . F a i l u r e to f o l l o w t h i s '00-05 m o d e l s
sequence m a y c a u s e excessive noise and vibration,
a n d r e d u c e b u s h i n g life.
3. Install t h e right s i d e e n g i n e m o u n t b r a c k e t , t h e n
t i g h t e n t h e bolts a n d nut in t h e n u m b e r e d s e q u e n c e
shown.
3 8 N-m
(3.9 kgf-m, 2 8 I b f f t )
Yellow bolts
4. T i g h t e n t h e s u p p o r t nut o n t h e left s i d e e n g i n e
m o u n t bracket.
5-10
(cont'd)
5-11
Engine Assembly
E n g i n e I n s t a l l a t i o n (cont'd)
9. Install t h e u p p e r radiator h o s e . 11. R a i s e t h e v e h i c l e o n t h e lift.
12. Install t h e e n g i n e s t o p b r a c k e t ( A ) , t h e n install t h e

engine stop bracket c u s h i o n (B).
10. Install t h e h e a t e r h o s e s (A) a n d t h e l o w e r radiator

h o s e (B).
8 x 1.25 m m
22 N m
(2.2 k g f m , 1 6 Ibf ft)
13. L o w e r t h e v e h i c l e o n t h e lift.
5-12
14. P u s h t h e e n g i n e control m o d u l e ( E C M ) c o n n e c t o r s 16. Install t h e h a r n e s s c l a m p s (A), t h e n install t h e
t h r o u g h t h e b u l k h e a d , t h e n install t h e g r o m m e t (A). battery c a b l e (B) o n t h e m a i n u n d e r - h o o d f u s e / r e l a y
box.
'00-05 models
6x1.0 mm
17. Install t h e e l e c t r i c a l p o w e r s t e e r i n g ( E P S ) control

unit.
D C D
6x1.0 mm
1 2 N m (1.2 kgf m , 8.7 Ibf ft)
15. Install t h e battery c a b l e (B) o n t h e a u x i l i a r y u n d e r -
h o o d f u s e / r e l a y box. Install the g r o u n d c a b l e (C)
a n d h a r n e s s c l a m p s (D).
(cont'd)
5-13
Engine Assembly
E n g i n e Installation (cont'd)
18. ' 0 0 - 0 5 m o d e l s : Install the v a c u u m tank. 2 0 . C o n n e c t t h e E C M c o n n e c t o r s (A) a n d d a s h b o a r d

w i r e h a r n e s s A c o n n e c t o r s (B).
'00-05 m o d e l s
19. ' 0 0 - 0 5 m o d e l s : Install the throttle c a b l e ( s e e p a g e

11-167), t h e n a d j u s t the c a b l e ( s e e p a g e 11-168).
'06-08 m o d e l s
5-14
2 1 . Install t h e t r a n s m i s s i o n ( s e e p a g e 13-67).
2 2 . Install t h e battery.
23. C l e a n the battery p o s t s a n d c a b l e t e r m i n a l s , t h e n

a s s e m b l e t h e m a n d a p p l y g r e a s e to p r e v e n t
corrosion.
24. I n s p e c t for fuel l e a k s . T u r n t h e ignition s w i t c h to

O N (II) (do not o p e r a t e the starter) s o that t h e fuel
p u m p r u n s for a b o u t 2 s e c o n d s a n d p r e s s u r i z e s t h e
fuel line. R e p e a t t h i s o p e r a t i o n t h r e e t i m e s , t h e n
c h e c k for fuel l e a k a g e at a n y point in t h e fuel line.
25. Refill t h e e n g i n e w i t h e n g i n e oil ( s e e p a g e 8-6).
26. Refill t h e radiator w i t h e n g i n e c o o l a n t , a n d b l e e d

air f r o m the c o o l i n g s y s t e m w i t h t h e h e a t e r v a l v e
o p e n ( s e e s t e p 8 o n p a g e 10-9).
27. C h e c k that t h e t r a n s m i s s i o n shifts into g e a r

smoothly.
28. D o t h e E C M r e s e t p r o c e d u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-4)
• '06-08 m o d e l s ( s e e p a g e 11-214)
29. D o the E C M idle l e a r n p r o c e d u r e :
• '00-05 m o d e l s ( s e e p a g e 11-140)
• '06-08 m o d e l s ( s e e p a g e 11-462)
30. '06-08 m o d e l s : D o t h e c r a n k s h a f t p o s i t i o n ( C K P )
pattern c l e a r / C K P pattern l e a r n p r o c e d u r e
( s e e p a g e 11-214).
3 1 . I n s p e c t the idle s p e e d :
• '00-05 m o d e l s ( s e e p a g e 11-140)
• '06-08 m o d e l s ( s e e p a g e 11-461)
3 2 . I n s p e c t the ignition t i m i n g ( s e e p a g e 4-24).
3 3 . E n t e r the anti-theft c o d e for the a u d i o s y s t e m , t h e n

e n t e r t h e a u d i o p r e s e t s . S e t the c l o c k .
Engine Assembly
Engine Mount Replacement
1. T u r n the s t e e r i n g w h e e l to the s t r a i g h t - a h e a d 4. L o o s e n the left s i d e e n g i n e m o u n t s u p p o r t nuts.

p o s i t i o n , t h e n r e m o v e t h e key f r o m t h e ignition
s w i t c h to lock t h e s t e e r i n g c o l u m n . M a k e a
r e f e r e n c e m a r k (A) a c r o s s the s t e e r i n g joint ( B ) .
B A
2. L o o s e n t h e u p p e r s t e e r i n g joint bolt (C), a n d

r e m o v e the l o w e r s t e e r i n g joint bolt (D). D i s c o n n e c t
the s t e e r i n g joint f r o m the g e a r b o x .
3. R e m o v e the g r o u n d c a b l e (A) o n t h e r e a r e n d of t h e
e n g i n e block.
5-16
6. A t t a c h t h e c h a i n hoist t o t h e e n g i n e a s s h o w n . T a k e 9. R e m o v e the t w o front s u b f r a m e c e n t e r m o u n t i n g
c a r e not to d a m a g e the r o c k e r a r m oil c o n t r o l bolts (A).
solenoid (VTEC solenoid valve) and wire harness.
B
14x1.5 mm
1 1 6 N m ( 1 1 . 8 kgf m , 8 5 . 3 Ibf ft)
59 N-m
(6.0 k g f m , 4 3 I b f f t )
Replace.
10. L o o s e n t h e f o u r front s u b f r a m e m o u n t i n g bolts (B)

7 5 m m (3.0 in.) a s s h o w n , a n d l o w e r t h e front
subframe.
07 A A K - S N A A 1 2 0
11. R e m o v e t h e e n g i n e m o u n t s .
7. R a i s e t h e v e h i c l e o n the lift.
12. Put both s i d e e n g i n e m o u n t s into p o s i t i o n .
8. R e m o v e t h e s i x n u t s f r o m both s i d e e n g i n e m o u n t s .
13. T i g h t e n t h e f o u r front s u b f r a m e m o u n t i n g bolts.
N O T E : Lift t h e front s u b f r a m e a f e w i n c h e s at a t i m e
s o that the u p p e r bolt of t h e e n g i n e m o u n t c a n be
put in t h e bolt h o l e of t h e e n g i n e m o u n t bracket.
14. Install the t w o front s u b f r a m e c e n t e r m o u n t i n g

bolts.
(cont'd)
5-17
Engine Assembly
E n g i n e M o u n t R e p l a c e m e n t (cont'd)
15. L o o s e l y tighten t h e left s i d e e n g i n e m o u n t s u p p o r t 19. L o o s e n t h e l o w e r s u p p o r t n u t s (C) (D).

nuts.
2 0 . T i g h t e n t h e left s i d e l o w e r s u p p o r t nuts to the
16. L o o s e l y tighten t h e right s i d e e n g i n e m o u n t specified torque.
support nuts.
2 1 . T i g h t e n t h e right s i d e l o w e r s u p p o r t nuts to the
17. R e m o v e t h e c h a i n hoist a n d u n i v e r s a l e y e l e t s . specified torque.
18. T i g h t e n t h e u p p e r s u p p o r t nut (A) (B) to t h e 2 2 . Install t h e g r o u n d c a b l e .

specified torque.
Leftside
12x1.25 m m
5 4 N m (5.5 k g f - m , 4 0 I b f f t )
BK 1.0 mm
12 N - m (1.2 k g f - m , 8.7 I b f f t )
23. C o n n e c t t h e s t e e r i n g joint (A) by a l i g n i n g t h e

r e f e r e n c e m a r k s (B) a n d tighten t h e bolt (C) to
specified torque.
1 2 x 1.25 m m
5 4 N - m (5.5 k g f - m , 4 0 Ibf ft) U S A models thru VIN JHMAP114*YT008411
Canada models thru VIN JHMAP114*YT800750
Right s i d e T o r q u e : 2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
U S A models from VIN JHMAP114*YT008412

B Canada models from VIN JHMAP114*YT800751
1 2 x 1.25 m m T o r q u e : 2 9 N - m (3.0 k g f - m , 2 2 I b f f t )
54 N-m
; (5.5 k g f - m , 4 0 Ibf-ft)
1 2 x 1.25 m m
5 4 N - m (5.5 k g f - m , 4 0 I b f f t )
5-18
2 4 . R e m o v e t h e s t e e r i n g w h e e l ( s e e p a g e 17-6).
2 5 . C e n t e r t h e c a b l e r e e l , a n d reinstall t h e s t e e r i n g
w h e e l ( s e e p a g e 17-8).
2 6 . C h e c k t h e front w h e e l a l i g n m e n t ( s e e p a g e 18-7).
Engine Mechanical
Cylinder Head
Special Tools . 6-2
Component Location Index 6-3
Engine Compression Inspection 6-7
VTEC Rocker Arm Test 6-8
Valve Clearance Adjustment 6-10
Crankshaft Pulley Removal and Installation 6-12
Cam Chain Removal 6-13
Cam Chain Installation 6-15
Chain Case Oil Seal Installation 6-18
CKP Pulse Plate Replacement 6-19
Cylinder Head Cover Removal 6-21
Cylinder Head Cover Installation 6-22
Cylinder Head Removal 6-25
CMP Pulse Plate A Replacement 6-33
CMP Pulse Plate B Replacement 6-33
CMP Pulse Plate Replacement 6-34
Camshaft Gear Removal 6-34
Cylinder Head Inspection for Warpage 6-35
Rocker Arm Assembly Removal 6-35
Rocker Arm and Shaft Disassembly/Reassembly 6-36
Rocker Arm and Shaft Inspection 6-37
Camshaft Inspection 6-39
Valve, Spring, and Valve Seal Removal 6-41
Valve Inspection 6-42
Valve Stem-to-Guide Clearance Inspection 6-43
Valve Guide Replacement 6-43
Valve Seat Reconditioning 6-45
Valve, Spring, and Valve Seal Installation 6-47
Rocker Arm Assembly Installation 6-48
Camshaft Gear Installation 6-49
Cylinder Head Installation 6-49
Cylinder Head
Special Tools

© 07AAJ-PNAA101 Air Pressure Regulator 1
® 07HAH-PJ7A100 V a l v e G u i d e R e a m e r , 5.5 m m 1
® 07JAA-001020A S o c k e t , 19 m m 1
® 07JAB-001020B Holder Handle 1
® 07LAK-PR3A101 G a u g e Joint Adapter 1
® 07NAB-001040A H o l d e r A t t a c h m e n t , 50 m m 1
® 07PAD-0010000 S t e m S e a l Driver 1
• ® 07ZAJ-PNAA101 V T E C Air Adapter

® 07ZAJ-PNAA300 Air Joint Adapter 1
® 07742-0010100 V a l v e G u i d e D r i v e r , 5.5 m m 1
® 07746-0010400 A t t a c h m e n t , 52 x 5 5 m m 1
@ 07749-0010000 Handle Driver 1
® 07757-PJ1010A Valve Spring C o m p r e s s o r Attachment 1
) B
® ® (D ©
© ® ® ®
6-2
C o m p o n e n t L o c a t i o n Index
'00-05 m o d e l s
C A M S H A F T P O S I T I O N (CMP) S E N S O R A
( T O P D E A D C E N T E R ( T D C ) S E N S O R 1)
C A M S H A F T POSITION (CMP) S E N S O R B
( T O P D E A D C E N T E R ( T D C ) S E N S O R 2)
CAMSHAFT HOLDERS
WASHERS
RUBBER SEALS
CYLINDER HEAD
COVER
Removal,
p a g e 6-21
Installation,
p a g e 6-22
CMP PULSE PLATES

Replacement, HEAD COVER GASKET
p a g e 6-33
RUBBER SEALS
INTAKE C A M S H A F T G E A R
R e m o v a l , p a g e 6-34
ROCKER ARM I n s t a l l a t i o n , p a g e 6-49
ASSEMBLY
V T E C Rocker A r m Test,
p a g e 6-8 EXHAUST CAMSHAFT GEAR
Rocker A r m A s s e m b l y
R e m o v a l , p a g e 6-35
Rocker A r m and Shaft
Disassembly/Reassembly EXHAUST CAMSHAFT
p a g e 6-36 I n s p e c t i o n , p a g e 6-39
Rocker A r m and Shaft
I n s p e c t i o n , p a g e 6-37
Rocker A r m A s s e m b l y
I n s t a l l a t i o n , p a g e 6-48
(cont'd)
6-3
Cylinder Head
C o m p o n e n t L o c a t i o n I n d e x (cont'd)
'06-08 m o d e l s
C A M S H A F T POSITION (CMP) S E N S O R
CAMSHAFT HOLDERS
WASHERS
RUBBER SEALS
CYLINDER HEAD COVER

Removal, page 6-21
Installation, page 6-22
CMP PULSE PLATES

Replacement, HEAD COVER GASKET
page 6-34
RUBBER SEALS
ROCKER ARM
INTAKE CAMSHAFT G E A R
ASSEMBLY
V T E C Rocker Arm Test, Removal, page 6-34
page 6-8 Installation, page 6-49
Rocker Arm Assembly Removal
page 6-35
EXHAUST CAMSHAFT GEAR
Rocker Arm and Shaft
Disassembly/Reassembly
page 6-36
Rocker Arm and Shaft EXHAUST CAMSHAFT
Inspection, Inspection, page 6-39
page 6-37
Rocker Arm Assembly
Installation,
page 6-48
EXHAUST VALVE GUIDE
Inspection, p a g e 6-43
R e p l a c e m e n t , p a g e 6-43
CYLINDER HEAD BOLTS
LOST MOTION A S S E M B L Y
INTAKE V A L V E SPRING
VALVE COTTERS
INTAKE V A L V E S E A L
SPRING RETAINER
INTAKE V A L V E GUIDE
EXHAUST VALVE SPRING Inspection, p a g e 6-43
IDLER G E A R COLLAR
EXHAUST VALVESEAL
IDLER G E A R
VALVE SPRINGSEAT CAM CHAIN SPROCKET
CYLINDER HEAD
R O C K E R A R M OIL
CONTROL SOLENOID
(VTEC SOLENOID VALVE)
FILTER WASHER
R O C K E R A R M OIL
CONTROL SOLENOID
ASSEMBLY
EXHAUST VALVE
R e m o v a l , p a g e 6-41
CYLINDER HEAD i n s t a l l a t i o n , p a g e 6-47
GASKET
INTAKE V A L V E
R e m o v a l , p a g e 6-41
(cont'd)
6-5
Cylinder Head
C o m p o n e n t L o c a t i o n I n d e x (cont'd)
CHAIN C A S E OIL S E A L
6-6
E n g i n e C o m p r e s s i o n Inspection
NOTE: 11. O p e n the throttle fully, t h e n c r a n k t h e e n g i n e w i t h

• ' 0 0 - 0 5 m o d e l s : A f t e r the I n s p e c t i o n , y o u m u s t r e s e t t h e starter m o t o r a n d m e a s u r e t h e c o m p r e s s i o n .
t h e e n g i n e control m o d u l e ( E C M ) u s i n g the H o n d a
D i a g n o s t i c S y s t e m ( H D S ) ( s e e p a g e 11-3), to c l e a r a n y Compression Pressure:
diagnostic trouble c o d e s (DTCs). A b o v e 9 3 0 k P a (9.5 k g f / c m , 1 3 5 p s i )
• ' 0 6 - 0 8 m o d e l s : After the i n s p e c t i o n , y o u m u s t r e s e t
t h e E C M u s i n g the H D S ( s e e p a g e 11-214). O t h e r w i s e , 12. M e a s u r e t h e c o m p r e s s i o n o n t h e r e m a i n i n g
t h e E C M c o n t i n u e s to s t o p the fuel injectors. cylinders.
1. W a r m up t h e e n g i n e to n o r m a l operating M a x i m u m Variation:
t e m p e r a t u r e (cooling fan c o m e s on). W i t h i n 2 0 0 k P a (2.0 k g f / c m , 2 8 p s i )
2. '00-05 m o d e l s : R e m o v e the N o . 2 (15 A ) f u s e f r o m 13. If the c o m p r e s s i o n is not w i t h i n s p e c i f i c a t i o n s ,

the under-dash fuse/relay box. c h e c k t h e f o l l o w i n g i t e m s , t h e n r e m e a s u r e the
compression.
3. ' 0 6 - 0 8 m o d e l s : C o n n e c t t h e H D S to the data link
c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e 11-213). • Damaged or w o r n valves and seats
• Damaged cylinder head gasket
4. T u r n the ignition s w i t c h to O N (II). • Damaged or w o r n piston r i n g s
• Damaged or w o r n piston a n d c y l i n d e r bore
5. ' 0 6 - 0 8 m o d e l s : M a k e s u r e t h e H D S c o m m u n i c a t e s
w i t h the v e h i c l e a n d the E C M . If it d o e s n ' t 14. ' 0 0 - 0 5 m o d e l s : R e i n s t a l l the N o . 2 (15 A ) f u s e in t h e
c o m m u n i c a t e , t r o u b l e s h o o t t h e D L C circuit under-dash fuse/relay box.
( s e e p a g e 11-367).
15. ' 0 0 - 0 5 m o d e l s : S e l e c t E C M r e s e t o n the H D S
6. '06-08 m o d e l s : S e l e c t P G M - F I , I N S P E C T I O N , t h e n ( s e e p a g e 11-4).
A L L I N J E C T O R S O F F o n the H D S .
16. ' 0 6 - 0 8 m o d e l s : S e l e c t E C M r e s e t ( s e e p a g e 11-214)
7. T u r n the ignition s w i t c h to L O C K (0). to c a n c e l the A L L I N J E C T O R O F F o n the H D S .
8. R e m o v e t h e f o u r ignition c o i l s ( s e e p a g e 4-25). 17. D o the E C M idle learn p r o c e d u r e :
9. R e m o v e the four s p a r k p l u g s . • ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-140)

• ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-462)
10. A t t a c h the c o m p r e s s i o n g a u g e to the s p a r k plug
hole.
6-7
Cylinder Head
VTEC Rocker Arm Test
Special Tools Required 6. C h e c k that t h e air p r e s s u r e o n t h e s h o p air

•Air pressure regulator07AAJ-PNAA101 c o m p r e s s o r g a u g e indicator is o v e r 400 kPa
• G a u g e joint a d a p t e r 0 7 L A K - P R 3 A 1 0 1 2
(4 k g f / c m , 57 p s i ) .
• V T E C air a d a p t e r (2) 0 7 Z A J - P N A A 1 0 0
• A i r joint a d a p t e r 0 7 Z A J - P N A A 3 0 0 7. I n s p e c t t h e v a l v e c l e a r a n c e ( s e e p a g e 6-10).
1. Start t h e e n g i n e a n d let it r u n for 5 m i n u t e s , t h e n 8. R e m o v e t h e N o . 3 a n d No. 4 c a m s h a f t h o l d e r bolts,

t u r n t h e ignition s w i t c h to L O C K (0). a n d install the V T E C air a d a p t e r s (A) finger-tight.
E
2 . R e m o v e t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21).
07AAJ-PNAA101
\ D
3. S e t the N o . 1 p i s t o n at top d e a d c e n t e r ( T D C ) ( s e e V 07ZAJ-PNAA300
s t e p 2 o n p a g e 6-10).
4. M o v e t h e s e c o n d a r y r o c k e r a r m (A) for N o . 1
cylinder. T h e s e c o n d a r y rocker a r m should m o v e
i n d e p e n d e n t l y of t h e m i d r o c k e r a r m (B).
• If the s e c o n d a r y rocker a r m m o v e s
i n d e p e n d e n t l y of the m i d r o c k e r a r m , g o to
s t e p 5.
• If the s e c o n d a r y rocker a r m d o e s not m o v e ,
r e m o v e t h e m i d , p r i m a r y , a n d s e c o n d a r y rocker
a r m s a s a n a s s e m b l y , a n d c h e c k that t h e p i s t o n s
in t h e m i d a n d p r i m a r y r o c k e r a r m s m o v e
s m o o t h l y . If a n y rocker a r m n e e d s r e p l a c i n g ,
r e p l a c e t h e m i d , p r i m a r y , a n d s e c o n d a r y rocker
arms as an assembly.
9. Install the g a u g e j o i n t a d a p t e r (B) to the i n s p e c t i o n

hole(C).
10. C o n n e c t t h e air joint a d a p t e r (D) to the V T E C air

adapters.
11. C o n n e c t t h e air p r e s s u r e regulator (E) to the air

joint a d a p t e r .
5. R e p e a t s t e p 4 o n t h e r e m a i n i n g rocker a r m s w i t h
e a c h p i s t o n at T D C . W h e n all t h e s e c o n d a r y rocker
a r m s p a s s t h e t e s t , g o to s t e p 6.
6-8
12. L o o s e n the v a l v e o n the regulator, t h e n a p p l y the
s p e c i f i e d air p r e s s u r e .
Specified Air Pressure:

2
2 9 0 k P a (3.0 k g f / c m , 4 2 psi)
N O T E : If t h e rocker a r m piston d o e s not m o v e after

a p p l y i n g air p r e s s u r e , m o v e the p r i m a r y a n d
s e c o n d a r y r o c k e r a r m s up a n d d o w n m a n u a l l y b y
rotating the c r a n k s h a f t c l o c k w i s e .
13. W i t h t h e s p e c i f i e d air p r e s s u r e a p p l i e d a n d t h e
piston at T D C , m o v e the s e c o n d a r y rocker a r m (A).
T h e m i d r o c k e r a r m (B), the p r i m a r y r o c k e r a r m ( C ) ,
a n d s e c o n d a r y rocker a r m s h o u l d m o v e t o g e t h e r .
• If the t h r e e rocker a r m s m o v e t o g e t h e r , g o to
s t e p 14.
• If the t h r e e rocker a r m s d o not m o v e t o g e t h e r ,
r e m o v e t h e m i d , p r i m a r y , a n d s e c o n d a r y rocker
a r m s a n a s s e m b l y , a n d c h e c k that t h e p i s t o n s in
the m i d a n d p r i m a r y rocker a r m s m o v e s m o o t h l y .
If r o c k e r a r m n e e d s r e p l a c i n g , r e p l a c e t h e m i d ,
p r i m a r y , a n d s e c o n d a r y rocker a r m s a s a n
assembly.
14. R e p e a t s t e p 13 o n the r e m a i n i n g rocker a r m s w i t h

e a c h p i s t o n at T D C . W h e n all the rocker a r m s p a s s
the t e s t , g o to s t e p 15.
15. R e m o v e t h e s p e c i a l t o o l s .
16. T i g h t e n t h e c a m s h a f t holder bolts to 22 N-m

(2.2 kgf-m, 16 Ibf-ft).
17. Install t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).

Cylinder Head
Valve Clearance Adjustment
N O T E : Adjust the v a l v e s only w h e n the cylinder head 4. Insert t h e f e e l e r g a u g e (A) b e t w e e n t h e a d j u s t i n g
t e m p e r a t u r e i s l e s s t h a n 100 °F (38 °C). s c r e w a n d t h e e n d of the v a l v e s t e m a n d s l i d e it
b a c k a n d forth; y o u s h o u l d feel a slight a m o u n t of
1. R e m o v e t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21). drag.
2. S e t the No. 1 piston at top d e a d c e n t e r ( T D C ) . T h e

T D C m a r k s (A) o n the c a m c h a i n s p r o c k e t s h o u l d
align w i t h t h e c y l i n d e r h e a d s u r f a c e .
5. If y o u feel too m u c h or too little d r a g , l o o s e n the

locknut (A), a n d turn the a d j u s t i n g s c r e w (B) until
the d r a g o n t h e f e e l e r g a u g e is c o r r e c t .
3. S e l e c t t h e c o r r e c t t h i c k n e s s f e e l e r g a u g e for t h e
v a l v e s y o u ' r e g o i n g to c h e c k .
Intake: 0 . 2 1 — 0.25 m m ( 0 . 0 0 8 — 0 . 0 1 0 in.)

Exhaust: 0 . 2 5 — 0 . 2 9 m m (0.010—0.011 in.)
Adjusting S c r e w Location:
INTAKE
No. 4 No. 3 No. 2 No. 1
2 0 N - m (2.0 k g f - m , 14 I b f f t )
6. T i g h t e n the locknut a n d r e c h e c k the c l e a r a n c e .

R e p e a t the a d j u s t m e n t , if n e c e s s a r y .
No. 4 No. 3 No. 2 No. 1
EXHAUST
6-10
7. Rotate the c r a n k s h a f t 180 ° c l o c k w i s e ( c a m s h a f t 11. Rotate the c r a n k s h a f t 180 ° c l o c k w i s e ( c a m s h a f t
g e a r s turn 9 0 °). g e a r s t u r n 9 0 °).
8. C h e c k a n d , if n e c e s s a r y , a d j u s t t h e v a l v e c l e a r a n c e 12. C h e c k a n d , if n e c e s s a r y , a d j u s t the v a l v e c l e a r a n c e
o n No. 3 c y l i n d e r . on No. 2 cylinder.
9. Rotate t h e c r a n k s h a f t 180 ° c l o c k w i s e ( c a m s h a f t 13. Install the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).

g e a r s turn 9 0 °).
10. C h e c k a n d , if n e c e s s a r y , a d j u s t the v a l v e c l e a r a n c e
on No. 4 cylinder.
6-11
Cylinder Head
Crankshaft Pulley Removal and Installation
Special Tools Required Installation
• S o c k e t , 19 m m 0 7 J A A - 0 0 1 0 2 0 A
o r a c o m m e r c i a l l y a v a i l a b l e 19 m m s o c k e t 1. C l e a n the bolt (A), w a s h e r (B), p u l l e y (C), a n d
• Holder handle 0 7 J A B - 0 0 1 0 2 0 B c r a n k s h a f t (D). L u b r i c a t e w i t h n e w e n g i n e oil a s
• Holder attachment, 50 m m 07NAB-001040A shown.
O: C l e a n
Removal # : Lubricate w i t h n e w engine oil
1. H o l d t h e p u l l e y With h o l d e r h a n d l e (A) a n d h o l d e r
a t t a c h m e n t (B).
07NAB-001040A
07JAA-001020A /
:r omilium
5-T
oooo oooo^-\
(or c o m m e r c i a l l y
available) rr u o**«« pooo OOOOCL-/
•i
• L.
2. Install the c r a n k s h a f t pulley, a n d tighten t h e bolt to

2 6 0 N-m (26.5 kgf-m, 192 Ibf-ft). D o not u s e a n
impact wrench.
-1 Hold the pulley w i t h t h e h o l d e r h a n d l e (A) a n d

h o l d e r a t t a c h m e n t (B).
-2 T i g h t e n the bolt w i t h a t o r q u e w r e n c h a n d
h e a v y duty 19 m m s o c k e t (C).
2 . R e m o v e t h e bolt w i t h a h e a v y duty 19 m m s o c k e t
(C) a n d b r e a k e r bar. 07NAB-001040A
07JAA-001020A
(or c o m m e r c i a l l y
available)
6-12
Cam Chain Removal
NOTE: 9. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e v a c u u m tank.

• U s e f e n d e r c o v e r s to a v o i d d a m a g i n g painted
surfaces.
• T o avoid d a m a g i n g the w i r e s a n d terminals, unplug
the w i r i n g c o n n e c t o r s c a r e f u l l y w h i l e h o l d i n g t h e
• T o a v o i d d a m a g i n g the c y l i n d e r h e a d , w a i t until t h e
e n g i n e c o o l a n t t e m p e r a t u r e d r o p s b e l o w 100 °F
(38 °C) b e f o r e l o o s e n i n g t h e c y l i n d e r h e a d bolts.
A l s o , b e s u r e that t h e y d o not c o n t a c t other w i r i n g o r
h o s e s , or interfere w i t h o t h e r p a r t s .
• K e e p the c a m c h a i n a w a y f r o m m a g n e t i c field.
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for the

2. R e l i e v e t h e fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11 -145)
10. R e m o v e t h e w a t e r b y p a s s h o s e (A), t h e n r e m o v e
• '06-08 m o d e l s ( s e e p a g e 11-474) t h e t h r e e bolts (B) s e c u r i n g t h e w a t e r b y p a s s t u b e
(C).
C
4. D r a i n t h e e n g i n e c o o l a n t ( s e e p a g e 10-9).
5. D r a i n t h e e n g i n e oil ( s e e p a g e 8-6).
6. L o o s e n t h e w a t e r p u m p p u l l e y bolts.
8. R e m o v e t h e c y l i n d e r h e a d ( s e e p a g e 6-25).
B A B
(cont'd)
6-13
Cylinder Head
Cam Chain Removal (cont'd)
11. R e m o v e the w a t e r p u m p pulley. 15. R e m o v e the oil p a n ( s e e p a g e 7-10).
16. R e m o v e the c r a n k s h a f t p u l l e y ( s e e p a g e 6-12).
17. R e m o v e t h e c r a n k s h a f t p o s i t i o n ( C K P ) s e n s o r .
18. R e m o v e t h e c h a i n c a s e .
12. R e m o v e the a u t o - t e n s i o n e r ( s e e p a g e 4-44).
13. R e m o v e t h e alternator ( s e e p a g e 4-45).
14. R e m o v e the idler p u l l e y (A), t h e n r e m o v e the idler 19. R e m o v e t h e C K P p u l s e plate ( s e e p a g e 6-19).

p u l l e y b a s e (B).
20. R e m o v e t h e oil p u m p c h a i n g u i d e .
21. R e m o v e the c a m chain.
6-14
Cam Chain Installation
N O T E : K e e p the c a m c h a i n a w a y f r o m m a g n e t i c field. 3. Install t h e oil p u m p c h a i n g u i d e .
1. S e t the c r a n k s h a f t s p r o c k e t s o that the No. 1 p i s t o n

is at top d e a d c e n t e r (TDG). A l i g n the key (A) o n t h e
s p r o c k e t a n d c r a n k s h a f t w i t h t h e pointer (B) o n t h e
e n g i n e block.
4. Install t h e C K P p u l s e plate ( s e e p a g e 6-19).
5. C h e c k t h e c h a i n c a s e oil s e a l for d a m a g e . If t h e oil

s e a l is d a m a g e d , r e p l a c e t h e c h a i n c a s e oil s e a l
( s e e p a g e 6-18).
2. Install t h e c a m c h a i n w i t h t h e c o l o r e d p i e c e (A)
a l i g n e d w i t h t h e p u n c h m a r k (B) o n t h e c r a n k s h a f t 6. R e m o v e a n y o l d liquid g a s k e t f r o m the c h a i n c a s e
sprocket. m a t i n g s u r f a c e s , bolts, a n d bolt h o l e s .
7. C l e a n a n d dry t h e c h a i n c a s e m a t i n g s u r f a c e s .
8. A p p l y liquid g a s k e t , P/N 0 8 7 1 7 - 0 0 0 4 , 0 8 7 1 8 - 0 0 0 1 ,
0 8 7 1 8 - 0 0 0 3 , o r 0 8 7 1 8 - 0 0 0 9 , e v e n l y to the e n g i n e
block m a t i n g s u r f a c e of the c h a i n c a s e .
N O T E : D o not install t h e p a r t s if 5 m i n u t e s or m o r e
h a v e e l a p s e d s i n c e a p p l y i n g liquid g a s k e t . I n s t e a d ,
r e a p p l y liquid g a s k e t after r e m o v i n g the old
residue.
A p p l y liquid gasket
along the broken line.
(cont'd)
6-15
Cylinder Head
Cam Chain installation (cont'd)
9. Install t h e d o w e l p i n s (A) a n d c h a i n c a s e (B) u s i n g a 14. Install t h e alternator ( s e e p a g e 4-46).

n e w O-ring (C).
15. Install t h e a u t o - t e n s i o n e r ( s e e p a g e 4-44).
16. Install t h e w a t e r p u m p p u l l e y .
i z iM-m
(1.2 k g f m , 8.7 I b f f t )
10. Install t h e c r a n k s h a f t p o s i t i o n ( C K P ) s e n s o r .
11. Install t h e c r a n k s h a f t p u l l e y ( s e e p a g e 6-12). 17, I n s t a l l t h e w a t e r b y p a s s h o s e (A), a n d tighten t h e

t h r e e bolts (B) s e c u r i n g t h e w a t e r b y p a s s t u b e .
12. Install t h e oil p a n ( s e e p a g e 7-25).
13. Install t h e idler p u l l e y b a s e (A), t h e n install t h e idler

pulley (B).
B A B
6x1.0 mm 6x1.0 mm
12 N m 12 N-m
(1.2 k g f m , 8.7 I b f f t ) (1.2 k g f m , 8.7 I b f f t )
6-16
18. Install t h e c y l i n d e r h e a d ( s e e p a g e 6-49) u s i n g t h e 2 1 . After i n s t a l l a t i o n , c h e c k that all t u b e s , h o s e s , a n d
f o l l o w i n g p r o c e s s by installing t h e c a m c h a i n c o n n e c t o r s a r e installed c o r r e c t l y .
sprocket a s s e m b l y .
2 2 . After a s s e m b l y , w a i t at l e a s t 3 0 m i n u t e s b e f o r e
-1 M a k e s u r e the c r a n k s h a f t p u l l e y is at T D C . filling t h e e n g i n e with oil.
-2 P l a c e t h e idler g e a r / c a m c h a i n s p r o c k e t
a s s e m b l y a n d idler g e a r c o l l a r into t h e c y l i n d e r 2 3 . C o n n e c t t h e n e g a t i v e c a b l e to t h e battery.
head.
-3 Install t h e c a m c h a i n o n t h e s p r o c k e t w i t h t h e 24. I n s p e c t for fuel l e a k s . T u r n t h e ignition s w i t c h to
o n e p u n c h m a r k (A) a l i g n e d w i t h the c e n t e r of O N (II) (do not o p e r a t e t h e starter) s o that the fuel
t h e t w o c o l o r e d p i e c e s (B). p u m p r u n s for a b o u t 2 s e c o n d s a n d p r e s s u r i z e s t h e
-4 Fit the c a m c h a i n s p r o c k e t a s s e m b l y into t h e fuel line. R e p e a t t h i s o p e r a t i o n t h r e e t i m e s , t h e n
cylinder head. c h e c k for fuel l e a k a g e at a n y point in the fuel line.
-5 T u r n the c a m c h a i n s p r o c k e t a s s e m b l y
c o u n t e r c l o c k w i s e to r e l i e v e c a m c h a i n f r e e p l a y , 2 5 . Refill the e n g i n e with e n g i n e oil ( s e e p a g e 8-6).
a n d c h e c k the a l i g n m e n t of t h e T D C m a r k (C)
o n the c a m c h a i n s p r o c k e t w i t h the c y l i n d e r 26. Refill the radiator with e n g i n e c o o l a n t , a n d b l e e d
h e a d s u r f a c e . If the c a m c h a i n s p r o c k e t is not air f r o m t h e c o o l i n g s y s t e m w i t h t h e h e a t e r v a l v e
p o s i t i o n e d at T D C , r e m o v e t h e a s s e m b l y f r o m o p e n ( s e e s t e p 7 o n p a g e 10-9).
the c y l i n d e r h e a d a n d r e p o s i t i o n t h e c a m c h a i n
to bring t h e c a m c h a i n s p r o c k e t to T D C . 2 7 . '00-05 m o d e l s : D o the e n g i n e control m o d u l e ( E C M )
2 8 . '06-08 m o d e l s : Do the C K P pattern c l e a r / C K P

pattern l e a r n p r o c e d u r e ( s e e p a g e 11-214).
29. I n s p e c t t h e idle s p e e d :
• '00-05 m o d e l s ( s e e p a g e 11-140)
• '06-08 m o d e l s ( s e e p a g e 11-461)
30. I n s p e c t t h e ignition t i m i n g ( s e e p a g e 4-24).

c
3 1 . E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m , t h e n
19. Install t h e d r i v e belt ( s e e p a g e 4-42). enter the a u d i o p r e s e t s . S e t t h e c l o c k .
20. Install t h e v a c u u m tank.
6-17
Cylinder Head
Chain Case Oil Seal Installation
• A t t a c h m e n t , 52 x 5 5 m m 0 7 7 4 6 - 0 0 1 0 4 0 0
• Handle driver 07749-0010000
1. U s e t h e h a n d l e d r i v e r a n d a t t a c h m e n t to d r i v e a
n e w oil s e a l s q u a r e l y into t h e c h a i n c a s e to t h e
s p e c i f i e d i n s t a l l e d height.
07749-0010000
07746-0010400
2. M e a s u r e t h e d i s t a n c e b e t w e e n t h e c h a i n c a s e
s u r f a c e (A) a n d t h e oil s e a l (B).
Oil S e a l Installed Height:

3 4 . 0 - 3 4 . 7 m m ( 1 . 3 4 - 1 . 3 7 in.)
^P3 f 34.0-34.7 mm
1
1 ( 1 . 3 4 — 1 . 3 7 in.)
6-18
CKP Pulse Plate Replacement
NOTE: 15. R e m o v e t h e oil p a n ( s e e p a g e 7-10).
• U s e f e n d e r c o v e r s to a v o i d d a m a g i n g p a i n t e d
surfaces. 16. R e m o v e t h e c r a n k s h a f t p u l l e y ( s e e p a g e 6-12).
• T o avoid damaging the w i r e s and terminals, unplug
the w i r i n g c o n n e c t o r s c a r e f u l l y w h i l e h o l d i n g the 17. R e m o v e t h e c r a n k s h a f t p o s i t i o n ( C K P ) s e n s o r .
• T o a v o i d d a m a g i n g t h e c y l i n d e r h e a d , w a i t until the 18. R e m o v e t h e c h a i n c a s e .
(38 °C) before l o o s e n i n g t h e c y l i n d e r h e a d bolts. 19. R e m o v e t h e C K P p u l s e plate.
• Mark all w i r i n g a n d h o s e s to a v o i d m i s c o n n e c t i o n .
A l s o , b e s u r e that t h e y d o not c o n t a c t o t h e r w i r i n g or
h o s e s , or interfere w i t h o t h e r parts.
• Keep the c a m chain a w a y from magnetic fields.
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for the

audio s y s t e m , then write d o w n the audio presets.
2. R e l i e v e the fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-145)
• '06-08 m o d e l s ( s e e p a g e 11-474)
3. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery.
5. D r a i n t h e e n g i n e oil ( s e e p a g e 8-6). 2 0 . Install t h e C K P p u l s e plate.
6. L o o s e n the w a t e r p u m p pulley bolts. 2 1 . C h e c k t h e c h a i n c a s e oil s e a l for d a m a g e . If t h e oil

s e a l is d a m a g e d , r e p l a c e t h e c h a i n c a s e oil s e a l
7. R e m o v e t h e d r i v e belt ( s e e p a g e 4-42). ( s e e p a g e 6-18).
8. R e m o v e the c y l i n d e r h e a d ( s e e p a g e 6-25). 2 2 . R e m o v e a n y old liquid g a s k e t f r o m the c h a i n c a s e

9. ' 0 0 - 0 5 m o d e l s : R e m o v e the v a c u u m tank ( s e e s t e p m a t i n g s u r f a c e s , bolt, a n d bolt h o l e s .
9 o n p a g e 6-13).
2 3 . C l e a n a n d d r y the c h a i n c a s e m a t i n g s u r f a c e s .
10. R e m o v e the w a t e r b y p a s s h o s e , t h e n r e m o v e t h e
t h r e e bolts s e c u r i n g t h e w a t e r b y p a s s t u b e ( s e e 2 4 . A p p l y liquid g a s k e t , P/N 0 8 7 1 7 - 0 0 0 4 , 0 8 7 1 8 - 0 0 0 1 ,
s t e p 10 on p a g e 6-13). 0 8 7 1 8 - 0 0 0 3 , or 0 8 7 1 8 - 0 0 0 9 , e v e n l y to t h e c y l i n d e r
b l o c k m a t i n g s u r f a c e of the c h a i n c a s e ( s e e p a g e
11. R e m o v e the w a t e r p u m p pulley ( s e e s t e p 11 o n 6-15).
p a g e 6-14).
N O T E : D o not install t h e parts if 5 m i n u t e s or m o r e
12. R e m o v e t h e a u t o - t e n s i o n e r ( s e e p a g e 4-44). h a v e e l a p s e d s i n c e a p p l y i n g liquid g a s k e t . I n s t e a d ,
r e a p p l y liquid g a s k e t after r e m o v i n g t h e old
13. R e m o v e the alternator ( s e e p a g e 4-45). residue.
14. R e m o v e the idler pulley, t h e n r e m o v e t h e idler

p u l l e y b a s e ( s e e s t e p 14 o n p a g e 6-14).
(cont'd)
6-19
Cylinder Head
CKP Pulse Plate Replacement (cont'd)
2 5 . Install t h e d o w e l p i n s a n d c h a i n c a s e u s i n g a n e w 44. ' 0 6 - 0 8 m o d e l s : D o the C K P pattern c l e a r / C K P

O-ring ( s e e s t e p 9 o n p a g e 6-16). pattern l e a r n p r o c e d u r e ( s e e p a g e 11-214).
26. Install the c r a n k s h a f t p u l l e y ( s e e p a g e 6-12). 4 5 . I n s p e c t t h e idle s p e e d :
2 7 . Install t h e C K P s e n s o r . • '00-05 m o d e l s ( s e e p a g e 11-140)

• '06-08 m o d e l s ( s e e p a g e 11-461)
28. Install t h e oil p a n ( s e e p a g e 7-25).
4 6 . I n s p e c t t h e ignition t i m i n g ( s e e p a g e 4-24).
29. Install t h e idler p u l l e y b a s e , t h e n install t h e idler
pulley ( s e e s t e p 13 o n p a g e 6-16). 4 7 . E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m , t h e n
30. Install t h e alternator ( s e e p a g e 4-46).
3 1 . Install t h e a u t o - t e n s i o n e r ( s e e p a g e 4-44).
3 2 . Install t h e w a t e r p u m p p u l l e y ( s e e s t e p 16 o n p a g e
6-16).
3 3 . Install t h e w a t e r b y p a s s h o s e , a n d tighten t h e t h r e e
bolts s e c u r i n g t h e w a t e r b y p a s s t u b e ( s e e s t e p 17
o n p a g e 6-16).
34. Install t h e c y l i n d e r h e a d ( s e e p a g e 6-49).
3 5 . Install t h e d r i v e belt ( s e e p a g e 4-42).
36. Install t h e v a c u u m tank ( s e e s t e p 2 0 o n p a g e 6-17).
3 7 . After installation, c h e c k that all t u b e s , h o s e , a n d

connectors are installed correctly.
3 8 . After a s s e m b l y , w a i t at l e a s t 3 0 m i n u t e s before
filling t h e e n g i n e w i t h oil ( s e e p a g e 8-6).
3 9 . C o n n e c t t h e n e g a t i v e c a b l e to t h e battery.

O N (II) (do not o p e r a t e t h e starter) s o that t h e fuel
p u m p r u n s for a b o u t 2 s e c o n d s a n d p r e s s u r i z e s t h e
41. Refill t h e e n g i n e w i t h e n g i n e oil ( s e e p a g e 8-6).

air f r o m t h e c o o l i n g s y s t e m w i t h t h e h e a t e r v a l v e
43. ' 0 0 - 0 5 m o d e l s : D o t h e e n g i n e c o n t r o l m o d u l e ( E C M )
6-20
Cylinder Head Cover Removal
1. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t the c a m s h a f t position 3. R e m o v e t h e dipstick (A), p o s i t i v e c r a n k c a s e

( C M P ) s e n s o r A (top d e a d c e n t e r ( T D C ) s e n s o r 1) ventilation ( P C V ) h o s e (B), a n d b r e a t h e r h o s e (C).
c o n n e c t o r a n d C M P s e n s o r B ( T D C s e n s o r 2)
connector. '00-03 m o d e l s
(cont'd)
6-21
Cylinder Head
Cylinder Head Cover Removal Cylinder Head Cover Installation
(cont'd)
1. T h o r o u g h l y c l e a n the h e a d c o v e r g a s k e t a n d the
groove.
4. R e m o v e the h a r n e s s c l a m p s (A).
2. Install t h e h e a d c o v e r g a s k e t in the g r o o v e of the
cylinder head cover.
3. S e t the s p a r k plug s e a l (A) o n the s p a r k plug t u b e .

Install t h e c y l i n d e r h e a d c o v e r (B) o n the c y l i n d e r
head.
NOTE:
• T a k e c a r e not to d a m a g e t h e s p a r k plug s e a l s
w h e n installing the c y l i n d e r h e a d c o v e r .
• V i s u a l l y i n s p e c t t h e s p a r k p l u g s e a l s for d a m a g e .
5. R e m o v e t h e ignition coil ( s e e p a g e 4-25).
6. R e m o v e the c y l i n d e r h e a d c o v e r .
6-22
4. I n s p e c t the c y l i n d e r h e a d c o v e r w a s h e r s . R e p l a c e 9. Install t h e ignition c o i l ( s e e p a g e 4-25).
a n y w a s h e r s a n d r u b b e r s e a l s that a r e d a m a g e d o r
deteriorated. 10. Install t h e h a r n e s s c l a m p s (A).
5. C l e a n the w a s h e r m a t i n g s u r f a c e s of the c y l i n d e r
head cover.
6. Install the h e a d c o v e r w a s h e r s (A).
7. M a k e s u r e t h e r u b b e r s e a l s (B) a r e s e c u r e l y s e a t e d
o n the c y l i n d e r h e a d c o v e r .
8. T i g h t e n the bolts in t h r e e s t e p s . In the final s t e p ,

tighten all bolts, in s e q u e n c e , to 12 N«m (1.2 kgf-m,
8.7 Ibfft).
(cont'd)
6-23
Cylinder Head
Cylinder Head Cover Installation (cont'd)
11. Install the positive c r a n k c a s e v e n t i l a t i o n ( P C V ) 12. ' 0 0 - 0 5 m o d e l s : C o n n e c t t h e c a m s h a f t position

h o s e (A) a n d b r e a t h e r h o s e (B), t h e n i n s e r t the ( C M P ) s e n s o r A (top d e a d c e n t e r ( T D C ) s e n s o r 1)
dipstick (C). c o n n e c t o r a n d C M P s e n s o r B ( T D C s e n s o r 2)
connector.
'00-03 m o d e l s
6-24
Cylinder Head Removal
NOTE: 6. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t t h e air h o s e (A) a n d
• U s e f e n d e r c o v e r s to a v o i d d a m a g i n g p a i n t e d b r e a t h e r pipe (B), t h e n r e m o v e t h e air c l e a n e r
surfaces. h o u s i n g c o v e r (C) a n d air c l e a n e r a s s e m b l y (D).
• T o a v o i d d a m a g i n g the w i r e s a n d t e r m i n a l s , u n p l u g
t h e w i r i n g c o n n e c t o r s c a r e f u l l y w h i l e h o l d i n g the
• T o a v o i d d a m a g i n g the c y l i n d e r h e a d , w a i t until the
(38 °C) b e f o r e l o o s e n i n g t h e c y l i n d e r h e a d bolts.
A l s o , be s u r e that t h e y d o not c o n t a c t other w i r i n g or
h o s e s , or interfere with other parts.
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e
2. R e l i e v e t h e fuel p r e s s u r e :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-145)
• '06-08 m o d e l s ( s e e p a g e 11-474)
A B
3. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery. 7. '06-08 m o d e l s : D i s c o n n e c t t h e intake air

t e m p e r a t u r e (IAT) s e n s o r c o n n e c t o r (A) a n d
4. D r a i n t h e e n g i n e c o o l a n t ( s e e p a g e 10-9). b r e a t h e r pipe (B), r e m o v e t h e m a n i f o l d a b s o l u t e
p r e s s u r e ( M A P ) s e n s o r h a r n e s s (C) f r o m the h o l d e r ,
5. D r a i n t h e e n g i n e oil ( s e e p a g e 8-6). t h e n r e m o v e the air c l e a n e r h o u s i n g c o v e r (D) a n d
air c l e a n e r a s s e m b l y ( E ) .
A B
(cont'd)
6-25
Cylinder Head
Cylinder Head Removal (cont'd)
8. '00-05 m o d e l s : D i s c o n n e c t the air control s o l e n o i d 12. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e fuel f e e d h o s e (A), fuel

v a l v e c o n n e c t o r (A) a n d v a c u u m h o s e s ( B ) , r e m o v e return h o s e (B), a n d brake b o o s t e r v a c u u m h o s e
t h e h a r n e s s c l a m p s ( C ) , t h e n r e m o v e the intake air (C).
c l e a n e r h o u s i n g (D).
11. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e throttle c a b l e ( s e e s t e p

13 o n p a g e 5-4).
6-26
(cont'd)
6-27
Cylinder Head
16. '00-05 m o d e l s : R e m o v e t h e bolt (A) s e c u r i n g the 18. R e m o v e the w a t e r outlet c o v e r .

intake m a n i f o l d bracket, a n d r e m o v e t h e air h o s e
(B).
19. R e m o v e the f o l l o w i n g e n g i n e w i r e h a r n e s s c o n n e c t o r s
a n d w i r e h a r n e s s c l a m p s f r o m the c y l i n d e r h e a d a n d
intake m a n i f o l d :
17. '06-08 m o d e l s : R e m o v e t h e bolt (A) s e c u r i n g the
intake m a n i f o l d bracket. • F o u r fuel injector c o n n e c t o r s
• Intake air t e m p e r a t u r e (IAT) s e n s o r c o n n e c t o r
('00-05 m o d e l s )
• Idle air control (IAC) v a l v e c o n n e c t o r
('00-05 m o d e l s )
• Throttle position (TP) s e n s o r c o n n e c t o r ('00-05
models)
• Throttle b o d y c o n n e c t o r ('06-08 m o d e l s )
• M a n i f o l d a b s o l u t e p r e s s u r e (MAP) s e n s o r
connector
• Primary heated oxygen s e n s o r (primary H 0 2 S )
c o n n e c t o r ('00-05 m o d e l s )
• A / F s e n s o r c o n n e c t o r ('06-08 m o d e l s )
• Engine coolant temperature (ECT) s e n s o r
A
• Engine coolant temperature (ECT) s e n s o r 1
• R o c k e r a r m oil control s o l e n o i d ( V T E C s o l e n o i d
valve) connector
• R o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil
pressure switch) connector
• C r a n k s h a f t position ( C K P ) s e n s o r c o n n e c t o r
6-28
2 0 . ' 0 0 - 0 5 m o d e l s : R e m o v e t w o bolts (A) s e c u r i n g t h e 2 2 . R e m o v e the f o u r bolts s e c u r i n g t h e e x h a u s t
intake m a n i f o l d bracket, a n d r e m o v e the w a t e r manifold cover.
b y p a s s h o s e (B).
(cont'd)
6-29
Cylinder Head
C y l i n d e r H e a d R e m o v a l (cont'd)
24. R e m o v e t h e e x h a u s t m a n i f o l d c o v e r , t h e n r e m o v e 28. S e t the N o . 1 p i s t o n at top d e a d c e n t e r ( T D C ) . T h e

t h e e x h a u s t m a n i f o l d b r a c k e t (A) a n d the e x h a u s t T D C m a r k s (A) o n t h e c a m c h a i n s p r o c k e t s h o u l d
m a n i f o l d (B). a l i g n w i t h the c y l i n d e r h e a d s u r f a c e .
25. '00-05 m o d e l s : R e m o v e the injectors (see page

11-112).
2 9 . R e m o v e the e n d c o v e r (A) a n d nozzle (B) f r o m t h e
26. R e m o v e t h e intake m a n i f o l d s t a y (A) a n d the intake c a m chain auto-tensioner.
m a n i f o l d (B).
A B
27. R e m o v e t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21).
6-30
30. T h r e a d a nut (A) o n t o a 5 x 0.8 m m bolt that is at 33. L o o s e n the rocker a r m a d j u s t i n g s c r e w s (A).
l e a s t 40 m m l o n g ( B ) , t h e n t h r e a d the bolt into the
A
m a i n t e n a n c e h o l e in the c a m c h a i n a u t o - t e n s i o n e r .
34. R e m o v e the c a m s h a f t h o l d e r s a n d c a m s h a f t s . T o
p r e v e n t d a m a g i n g the c a m s h a f t s , l o o s e n the
3 1 . T u r n the bolt c l o c k w i s e to c o m p r e s s the c a m c h a i n c a m s h a f t h o l d e r bolts in s e q u e n c e t w o t u r n s at a
a u t o - t e n s i o n e r , a n d lock the bolt w i t h the nut. t i m e , in a c r i s s c r o s s pattern.
3 2 . R e m o v e the c a m c h a i n a u t o - t e n s i o n e r . 35. Insert t h e bolts (A) into t h e rocker shaft holder, t h e n

r e m o v e t h e rocker a r m a s s e m b l y (B).
(cont'd)
6-31
Cylinder Head

36. R e m o v e the idler g e a r / c a m c h a i n s p r o c k e t
a s s e m b l y , idler g e a r c o l l a r , a n d w a s h e r .
3 7 . R e m o v e the c y l i n d e r h e a d bolts. T o p r e v e n t
w a r p a g e , l o o s e n t h e bolts in s e q u e n c e 1/3 t u r n at a
t i m e ; r e p e a t the s e q u e n c e until all t h e bolts a r e
loose.
<D ©
® ®
38. R e m o v e t h e c y l i n d e r h e a d .
6-32
CMP Pulse Plate A Replacement CMP Pulse Plate B Replacement
1. R e m o v e the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21). 1. R e m o v e t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21).
2. Hold the intake c a m s h a f t w i t h a n o p e n - e n d w r e n c h , 2. Hold t h e e x h a u s t c a m s h a f t w i t h a n o p e n - e n d

t h e n l o o s e n t h e bolt. w r e n c h , t h e n l o o s e n the bolt.
N O T E : T h i s bolt h a s left h a n d t h r e a d s . N O T E : T h i s bolt h a s left h a n d t h r e a d s .
3. R e m o v e the c a m s h a f t position ( C M P ) p u l s e plate A . 3. R e m o v e t h e c a m s h a f t position ( C M P ) p u l s e plate B.
4. C l e a n the bolt, t h e n a p p l y n e w e n g i n e oil to t h e 4. C l e a n t h e bolt, t h e n a p p l y n e w e n g i n e oil to the

threads. threads.
5. A l i g n the C M P p u l s e plate A g r o o v e w i t h the pin o n 5. A l i g n the C M P p u l s e plate B g r o o v e w i t h the pin o n

the c a m s h a f t e n d , t h e n install the C M P p u l s e plate t h e c a m s h a f t e n d , t h e n install t h e C M P p u l s e plate
A. B.
6. Install the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22). 6. Install the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).
6-33
Cylinder Head
CMP Pulse Plate Replacement Camshaft Gear Removal
'06-08 models 1. R e m o v e the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21).
1. R e m o v e t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21). 2. L o o s e n the r o c k e r a r m a d j u s t i n g s c r e w s ( s e e s t e p 2
o n p a g e 6-35).
2. H o l d t h e c a m s h a f t w i t h a n o p e n - e n d w r e n c h , t h e n
l o o s e n t h e bolt. 3. R e m o v e the c a m s h a f t h o l d e r s a n d c a m s h a f t s . T o
N O T E : T h i s bolt h a s left h a n d t h r e a d s . c a m s h a f t h o l d e r bolts in s e q u e n c e t w o t u r n s at a
t i m e , in a c r i s s c r o s s pattern.
4. H o l d t h e c a m s h a f t w i t h a n o p e n - e n d w r e n c h , t h e n
l o o s e n the c a m s h a f t g e a r m o u n t i n g nut.
3. R e m o v e the c a m s h a f t p o s i t i o n ( C M P ) p u l s e plate.
5. R e m o v e the c a m s h a f t g e a r .
N O T E : T h e e x h a u s t c a m s h a f t g e a r h a s a g r o o v e (A)
in t h e f a c e . T h e intake c a m s h a f t g e a r d o e s not h a v e a
groove.
4. C l e a n t h e bolt, t h e n a p p l y n e w e n g i n e oil to t h e
threads.
5. L o c a t e t h e position m a r k to t h e o u t s i d e a n d a l i g n
the C M P p u l s e plate g r o o v e w i t h t h e pin o n the
c a m s h a f t e n d , t h e n install t h e C M P p u l s e plate.
6. Install t h e c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).
6-34
Cylinder Head Inspection for Rocker Arm Assembly Removal
Warpage
1. R e m o v e the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-21).
1. R e m o v e the c y l i n d e r h e a d ( s e e p a g e 6-25). 2. L o o s e n the r o c k e r a r m a d j u s t i n g s c r e w s (A).
2. I n s p e c t the c a m s h a f t ( s e e p a g e 6-39).
3. C h e c k the c y l i n d e r h e a d for w a r p a g e . M e a s u r e
a l o n g the e d g e s , a n d t h r e e w a y s a c r o s s t h e center.
• If w a r p a g e is l e s s t h a n 0.05 m m (0.002 in.)

c y l i n d e r h e a d r e s u r f a c i n g is not r e q u i r e d .
• If w a r p a g e is b e t w e e n 0.05 m m (0.002 in.) a n d
0.2 m m (0.008 in.), r e s u r f a c e the c y l i n d e r h e a d .
• M a x i m u m r e s u r f a c e limit is 0.2 m m (0.008 in.)
b a s e d o n a height of 105 m m (4.13 in.).
Cylinder Head Height

Standard (New): 104.95—105.05 m m
( 4 . 1 3 2 - 4 . 1 3 6 in.) 3. R e m o v e t h e c a m s h a f t h o l d e r s a n d c a m s h a f t s . T o
PRECISION STRAIGHT EDGE
c a m s h a f t h o l d e r bolts in s e q u e n c e t w o t u r n s at a
t i m e , in a c r i s s c r o s s pattern.
4. Insert t h e bolts (A) into t h e r o c k e r shaft h o l d e r , t h e n

r e m o v e t h e rocker a r m a s s e m b l y (B).
6-35
Cylinder Head
Rocker Arm and Shaft Disassembly/Reassembly
NOTE:
• Identify parts a s t h e y a r e r e m o v e d to e n s u r e reinstallation in their original l o c a t i o n s .
• I n s p e c t rocker s h a f t s a n d r o c k e r a r m s ( s e e p a g e 6-37).
• If r e u s e d , t h e r o c k e r a r m s m u s t be i n s t a l l e d in t h e s a m e p o s i t i o n .
• Prior to r e a s s e m b l i n g , c l e a n all the parts in s o l v e n t , d r y t h e m , a n d a p p l y n e w e n g i n e oil to a n y c o n t a c t points.
• B u n d l e the r o c k e r a r m s w i t h r u b b e r b a n d s to k e e p t h e m t o g e t h e r a s a s e t .
• W h e n r e p l a c i n g the V T E C r o c k e r a r m a s s e m b l y , r e m o v e t h e f a s t e n i n g h a r d w a r e f r o m the n e w V T E C rocker a r m
assembly.
INTAKE ROCKER SHAFT
INTAKE ROCKER
ARM ASSEMBLY
EXHAUST ROCKER SHAFT
6-36
Rocker Arm and Shaft Inspection
1. R e m o v e the rocker a r m a s s e m b l y ( s e e p a g e 6-35). 5. M e a s u r e t h e i n s i d e d i a m e t e r of the r o c k e r a r m , a n d

c h e c k it for a n out-of-round c o n d i t i o n .
2. D i s a s s e m b l e the r o c k e r a r m a s s e m b l y ( s e e p a g e
6-36). Rocker Arm-to-Shaft Clearance:
S t a n d a r d ( N e w ) : 0.021 —0.041 m m
3. M e a s u r e the d i a m e t e r of t h e shaft at t h e first rocker ( 0 . 0 0 0 8 - 0 . 0 0 1 6 in.)
location. Service Limit: 0.07 m m (0.003 in.)
6. R e p e a t for all rocker a r m s a n d both s h a f t s . If the

c l e a r a n c e is o v e r the limit, r e p l a c e t h e r o c k e r s h a f t
4. Z e r o t h e g a u g e (A) to the shaft d i a m e t e r . a n d all o v e r - t o l e r a n c e r o c k e r a r m s . If a n y r o c k e r
a r m n e e d s r e p l a c e m e n t , r e p l a c e all t h r e e r o c k e r
a r m s in that s e t ( p r i m a r y , m i d , a n d s e c o n d a r y ) .
(cont'd)
6-37
Cylinder Head
Rocker Arm and Shaft Inspection (cont'd)
7. I n s p e c t the r o c k e r a r m p i s t o n s (A). P u s h e a c h
piston m a n u a l l y . If it d o e s not m o v e s m o o t h l y ,
r e p l a c e the rocker a r m a s s e m b l y .
NOTE:
• W h e n r e a s s e m b l i n g the p r i m a r y rocker a r m (B),
carefully a p p l y air p r e s s u r e to its oil p a s s a g e .
• A p p l y n e w e n g i n e oil to the r o c k e r a r m p i s t o n s
when reassembling.
8. R e a s s e m b l e t h e rocker a r m a s s e m b l y ( s e e p a g e
6-36).
9. Install the r o c k e r a r m a s s e m b l y ( s e e p a g e 6-48).
6-38
Camshaft Inspection
N O T E : D o not rotate the c a m s h a f t d u r i n g i n s p e c t i o n . 5. Z e r o the dial indicator a g a i n s t t h e e n d of t h e
c a m s h a f t , t h e n p u s h the c a m s h a f t b a c k a n d forth
1. R e m o v e the rocker a r m a s s e m b l y ( s e e p a g e 6-35). a n d r e a d t h e e n d play. If t h e e n d p l a y is b e y o n d t h e
s e r v i c e limit, r e p l a c e the c y l i n d e r h e a d a n d r e c h e c k .
2. D i s a s s e m b l e the rocker a r m a s s e m b l y ( s e e p a g e If it is still b e y o n d the s e r v i c e limit, r e p l a c e t h e
6-36). camshaft.
3. Put the rocker shaft h o l d e r s , c a m s h a f t s , a n d the C a m s h a f t E n d Play

c a m s h a f t h o l d e r s o n the c y l i n d e r h e a d , t h e n tighten Standard (New): 0.05—0.15 m m
t h e bolts to the s p e c i f i e d t o r q u e . ( 0 . 0 0 2 - 0 . 0 0 6 in.)
N O T E : A p p l y n e w e n g i n e oil to t h e bolt t h r e a d s .
Specified Torque
8x1.25 mm:
2 2 N-m (2.2 kgf m , 16 Ibf ft)
® <8> • ® ® ® ® ®(0> ® ®
6. R e m o v e the c a m s h a f t h o l d e r s a n d the rocker shaft

h o l d e r s f r o m the c y l i n d e r h e a d .
" ® ® (ID® ® ® ® ® (ID® 7. Lift t h e c a m s h a f t s out of the c y l i n d e r h e a d , w i p e

t h e m c l e a n , t h e n i n s p e c t the lift r a m p s . R e p l a c e the
4. S e a t the c a m s h a f t s by p u s h i n g t h e m t o w a r d the c a m s h a f t if a n y l o b e s a r e pitted, s c o r e d , or
rear e n d of the c y l i n d e r h e a d . excessively worn.
(cont'd)
6-39
Cylinder Head
Camshaft Inspection (cont'd)
8. C l e a n the c a m s h a f t j o u r n a l s u r f a c e s in the c y l i n d e r 11. C h e c k t h e total runout w i t h the c a m s h a f t s u p p o r t e d

h e a d , t h e n s e t t h e c a m s h a f t s b a c k in p l a c e . P l a c e a on V-blocks.
p l a s t i g a g e strip a c r o s s e a c h j o u r n a l .
• If t h e total runout of t h e c a m s h a f t is w i t h i n t h e
9. Install the c a m s h a f t h o l d e r s , t h e n tighten t h e bolts s e r v i c e limit, r e p l a c e t h e c y l i n d e r h e a d .
to t h e s p e c i f i e d t o r q u e a s s h o w n in s t e p 3. • If the total runout is b e y o n d the s e r v i c e limit,
replace the camshaft and recheck the camshaft-
10. R e m o v e t h e c a m s h a f t h o l d e r s . M e a s u r e t h e w i d e s t t o - h o l d e r oil c l e a r a n c e . If the oil c l e a r a n c e is still
part of p l a s t i g a g e o n e a c h j o u r n a l . out of t o l e r a n c e , r e p l a c e t h e c y l i n d e r h e a d .
• If t h e c a m s h a f t - t o - h o l d e r c l e a r a n c e is w i t h i n Camshaft Total Runout

limits, g o to s t e p 12. S t a n d a r d ( N e w ) : 0.03 m m (0.001 in.) m a x .
• If t h e c a m s h a f t - t o - h o l d e r c l e a r a n c e is b e y o n d t h e S e r v i c e Limit: 0.04 m m (0.002 in.)
s e r v i c e limit a n d t h e c a m s h a f t h a s b e e n r e p l a c e d ,
replace the cylinder head.
• If t h e c a m s h a f t - t o - h o l d e r c l e a r a n c e is b e y o n d t h e
s e r v i c e limit a n d t h e c a m s h a f t h a s not b e e n
r e p l a c e d , g o to s t e p 11.
Camshaft-to-Holder Oil Clearance

S t a n d a r d (New): 0.060—0.099 m m
( 0 . 0 0 2 - 0 . 0 0 4 in.)
6-40
Valve, Spring, and Valve Seal
Removal
12. M e a s u r e c a m lobe height.
C a m Lobe Height S t a n d a r d (New): Special Tools Required

Valve spring c o m p r e s s o r attachment 07757-PJ1010A
'00-03 m o d e l s
INTAKE EXHAUST Identify t h e v a l v e s a n d v a l v e s p r i n g s a s t h e y a r e
PRIMARY 33.677 m m 33.716 m m r e m o v e d s o that e a c h item c a n be reinstalled in its
(1.326 in.) (1.327 in.) original p o s i t i o n .
MID 36.533 mm 35.928 mm
(1.438 in.) (1.414 in.) 1. R e m o v e the c y l i n d e r h e a d ( s e e p a g e 6-25).
SECONDARY 33.961 mm 33.994 mm
(1.337 in.) (1.338 in.) 2. U s i n g a n a p p r o p r i a t e - s i z e d s o c k e t (A) a n d plastic
m a l l e t (B), lightly t a p the s p r i n g retainer to l o o s e n
'04-08 m o d e l s the v a l v e c o t t e r s .
INTAKE EXHAUST
PRIMARY 33.961 mm 33.716 m m
(1.337 in.) (1.327 in.)
MID 36.421 mm 35.660 mm
(1.434 in.) (1.404 in.)
SECONDARY 33.961 mm 33.716 mm
(1.337 in.) (1.327 in.)
PRI: P R I M A R Y MID: MID SEC: SECONDARY

C/C: CAM CHAIN
INTAKE EXHAUST
PRI MID SEC SEC MID PRI
3. Install the v a l v e s p r i n g c o m p r e s s o r . C o m p r e s s the

s p r i n g a n d r e m o v e the v a l v e cotters.
C/C C/C
07757-PJ1010A
I n s p e c t t h i s a r e a for w e a r .
4. R e m o v e t h e v a l v e s p r i n g c o m p r e s s o r , t h e n r e m o v e
the s p r i n g retainer a n d v a l v e s p r i n g .
(cont'd)
6-41
Cylinder Head
Valve, Spring, and Valve Seal Valve Inspection
Removal (cont'd)
1. R e m o v e t h e v a l v e s ( s e e p a g e 6-41).
5. Install t h e v a l v e g u i d e s e a l r e m o v e r . 2. M e a s u r e t h e v a l v e in t h e s e a r e a s .
Intake V a l v e Dimensions
A S t a n d a r d (New): 35.90—36.10 m m
( 1 . 4 1 3 - 1 . 4 2 1 in.)
B S t a n d a r d (New): 108.85—109.15 m m
( 4 . 2 8 5 - 4 . 2 9 7 in.)
C S t a n d a r d (New): 5.48—5.49 m m
( 0 . 2 1 5 7 - 0 . 2 1 6 1 in.)
C Service Limit: 5.45 m m (0.215 in.)
D S t a n d a r d (New): 0.55—0.85 m m
( 0 . 0 2 2 - 0 . 0 3 3 in.)
D Service Limit: 0.40 m m (0.016 in.)
Exhaust Valve Dimensions

A S t a n d a r d (New): 30.90—31.10 m m
( 1 . 2 1 7 - 1 . 2 2 4 in.)
6. R e m o v e t h e v a l v e s e a l . B S t a n d a r d (New): 107.60—107.90 m m
( 4 . 2 3 6 - 4 . 2 4 8 in.)
C S t a n d a r d (New): 5.45—5.46 m m
( 0 . 2 1 4 6 - 0 . 2 1 5 0 in.)
C Service Limit: 5.42 m m (0.213 in.)
D S t a n d a r d (New): 0.85—1.15 m m
( 0 . 0 3 3 - 0 . 0 4 5 in.)
D Service Limit: 0.70 m m (0.028 in.)
7. R e m o v e t h e v a l v e s p r i n g s e a t a n d v a l v e .
6-42
Valve Stem-to-Guide Clearance Valve Guide Replacement
Inspection
• V a l v e g u i d e d r i v e r , 5.5 m m 0 7 7 4 2 - 0 0 1 0 1 0 0
1. R e m o v e t h e v a l v e s ( s e e p a g e 6-41). • V a l v e g u i d e r e a m e r , 5.5 m m 0 7 H A H - P J 7 A 1 0 0
2. S l i d e t h e v a l v e out of its g u i d e a b o u t 10 m m 1. I n s p e c t v a l v e s t e m - t o - g u i d e c l e a r a n c e ( s e e p a g e
(0.39 in.), t h e n m e a s u r e t h e g u i d e - t o - s t e m 6-43).
c l e a r a n c e w i t h a dial indicator w h i l e r o c k i n g the
s t e m in the direction of n o r m a l t h r u s t ( w o b b l e 2. A s illustrated, u s e a c o m m e r c i a l l y a v a i l a b l e air-
method). i m p a c t v a l v e g u i d e d r i v e r (A) m o d i f i e d to fit t h e
d i a m e t e r of t h e v a l v e g u i d e s . In m o s t c a s e s , t h e
• If the m e a s u r e m e n t e x c e e d s the s e r v i c e limit, s a m e p r o c e d u r e c a n be d o n e u s i n g t h e s p e c i a l tool
r e c h e c k it u s i n g a n e w v a l v e . and a conventional hammer.
• If the m e a s u r e m e n t is n o w within the s e r v i c e
limit, r e a s s e m b l e u s i n g a n e w v a l v e .
• If the m e a s u r e m e n t w i t h a n e w v a l v e still
e x c e e d s the s e r v i c e limit, g o to s t e p 3. 5.3 m m
Intake V a l v e S t e m - t o - G u i d e C l e a r a n c e / (0.21 in.)
S t a n d a r d (New): 0.04—0.10 m m
( 0 . 0 0 2 - 0 . 0 0 4 in.)
3C
87 m m _ 57 m m
S e r v i c e Limit: 0.16 m m (0.006 in.) ( 3 . 4 3 in.) " (2.24 in.)
10.8 m m
Exhaust Valve Stem-to-Guide Clearance ( 0 . 4 2 in.)
S t a n d a r d (New): 0.10—0.16 m m
( 0 . 0 0 4 - 0 . 0 0 6 in.)
S e l e c t t h e p r o p e r r e p l a c e m e n t g u i d e s , a n d chill
t h e m in the f r e e z e r s e c t i o n of a refrigerator for
about a n hour.
U s e a hot plate or o v e n to e v e n l y heat the c y l i n d e r

h e a d to 3 0 0 °F (150 °C). Monitor t h e t e m p e r a t u r e
w i t h a c o o k i n g t h e r m o m e t e r . Do not get t h e h e a d
hotter t h a n 3 0 0 °F (150 °C); e x c e s s i v e heat m a y
loosen the valve seats.
3. S u b t r a c t the O.D. of the v a l v e s t e m , m e a s u r e d w i t h
a m i c r o m e t e r , f r o m t h e I.D. of the v a l v e g u i d e ,
m e a s u r e d with a n i n s i d e m i c r o m e t e r o r ball g a u g e .
T a k e the m e a s u r e m e n t s in t h r e e p l a c e s a l o n g the
v a l v e s t e m a n d t h r e e p l a c e s i n s i d e the v a l v e g u i d e .
T h e difference b e t w e e n the largest g u i d e
m e a s u r e m e n t a n d the s m a l l e s t s t e m m e a s u r e m e n t
s h o u l d not e x c e e d the s e r v i c e limit.
Intake V a l v e S t e m - t o - G u i d e C l e a r a n c e
S t a n d a r d (New): 0.02—0.05 m m
( 0 . 0 0 1 - 0 . 0 0 2 in.)
Exhaust Valve Stem-to-Guide Clearance

S t a n d a r d (New): 0.05—0.08 m m
( 0 . 0 0 2 - 0 . 0 0 3 in.)
(cont'd)
6-43
Cylinder Head
Valve Guide Replacement (cont'd)
5. W o r k i n g f r o m t h e c a m s h a f t s i d e , u s e t h e d r i v e r a n d 9. A p p l y a thin c o a t of n e w e n g i n e oil to t h e o u t s i d e of
a n air h a m m e r to d r i v e the g u i d e a b o u t 2 m m t h e n e w v a l v e g u i d e . Install the g u i d e f r o m the
(0.1 in.) t o w a r d s t h e c o m b u s t i o n c h a m b e r . T h i s will c a m s h a f t s i d e of the h e a d ; u s e t h e v a l v e g u i d e
k n o c k off s o m e of t h e c a r b o n a n d m a k e r e m o v a l d r i v e r to d r i v e the g u i d e to the s p e c i f i e d i n s t a l l e d
e a s i e r . Hold t h e air h a m m e r directly in line w i t h the height (A) of t h e g u i d e (B). If y o u h a v e all 16 g u i d e s
v a l v e g u i d e to p r e v e n t d a m a g i n g t h e d r i v e r . W e a r to d o , y o u m a y h a v e to r e h e a t the h e a d .
s a f e t y g o g g l e s or a f a c e s h i e l d .
V a l v e G u i d e Installed Height
6. T u r n t h e h e a d o v e r a n d d r i v e t h e g u i d e out t o w a r d Intake: 1 5 . 2 - 1 6 . 2 m m ( 0 . 5 9 8 - 0 . 6 3 8 in.)
the c a m s h a f t s i d e of t h e h e a d . Exhaust: 1 6 . 0 — 1 7 . 0 m m (0.630—0.669 in.)
7. If a v a l v e g u i d e w o n ' t m o v e , drill it out w i t h a 8 m m

(5/16 in.) bit, t h e n try a g a i n . Drill g u i d e s o n l y in
extreme c a s e s ; y o u could d a m a g e the cylinder
h e a d if t h e g u i d e b r e a k s .
8. T a k e out t h e n e w g u i d e ( s ) f r o m t h e f r e e z e r , o n e at a
time, a s you need them.
6-44
Valve Seat Reconditioning
10. C o a t both r e a m e r a n d v a l v e g u i d e with cutting oil. 1. I n s p e c t v a l v e s t e m - t o - g u i d e c l e a r a n c e ( s e e p a g e

6-43). If t h e v a l v e g u i d e s a r e w o r n , r e p l a c e t h e m
11. Rotate the r e a m e r c l o c k w i s e t h e full length of t h e ( s e e p a g e 6-43) b e f o r e cutting the v a l v e s e a t s .
valve guide bore.
2. R e n e w t h e v a l v e s e a t s in t h e c y l i n d e r h e a d u s i n g a
v a l v e s e a t cutter.
07HAH-PJ7A100
12. C o n t i n u e to rotate t h e r e a m e r c l o c k w i s e w h i l e
d r a w i n g it f r o m t h e b o r e .
13. T h o r o u g h l y w a s h t h e g u i d e in d e t e r g e n t a n d w a t e r Carefully cut a 45 °seat, removing only e n o u g h

to r e m o v e a n y cutting r e s i d u e . m a t e r i a l to e n s u r e a s m o o t h a n d c o n c e n t r i c s e a t .
14. C h e c k t h e c l e a r a n c e s w i t h a v a l v e ( s e e p a g e 6-43). B e v e l t h e u p p e r e d g e of t h e s e a t w i t h t h e 3 2 ° cutter

V e r i f y that a v a l v e s l i d e s in t h e intake a n d e x h a u s t a n d t h e l o w e r e d g e of t h e s e a t w i t h t h e 6 0 ° c u t t e r .
valve guides without sticking. C h e c k t h e w i d t h of t h e s e a t a n d a d j u s t a c c o r d i n g l y .
15. I n s p e c t the v a l v e s e a t i n g , if n e c e s s a r y r e n e w t h e
v a l v e s e a t u s i n g a v a l v e s e a t cutter ( s e e p a g e 6-45).
M a k e o n e m o r e v e r y light p a s s w i t h t h e 4 5 ° cutter
to r e m o v e a n y p o s s i b l e b u r r s c a u s e d b y t h e other
cutters.
Valve Seat Width

Intake:
S t a n d a r d ( N e w ) 1 . 0 5 - 1 . 3 5 m m ( 0 . 0 4 1 - 0 . 0 5 3 in.)
Exhaust:
S t a n d a r d ( N e w ) 1 . 2 5 - 1 . 5 5 m m ( 0 . 0 4 9 - 0 . 0 6 1 in.)
(cont'd)
6-45
Cylinder Head
Valve Seat Reconditioning (cont'd)
6. After r e s u r f a c i n g t h e s e a t , i n s p e c t for e v e n v a l v e 8. Insert the intake a n d e x h a u s t v a l v e s in the h e a d a n d
s e a t i n g . A p p l y P r u s s i a n B l u e c o m p o u n d (A) to t h e m e a s u r e v a l v e s t e m installed height (A).
v a l v e f a c e . Insert the v a l v e in its original location in
t h e h e a d , t h e n lift it a n d s n a p it c l o s e d a g a i n s t t h e Intake V a l v e S t e m Installed Height
seat several times. Standard (New): 44.1—44.4 m m
( 1 . 7 3 6 - 1 . 7 4 8 in.)
E x h a u s t V a l v e S t e m Installed Height
Standard (New): 44.2—44.5 m m
( 1 . 7 4 0 - 1 . 7 5 2 in.)
S e r v i c e Limit: 4 4 . 8 m m (1.764 in.)
7. T h e a c t u a l v a l v e s e a t i n g s u r f a c e (B), a s s h o w n b y
the blue c o m p o u n d , s h o u l d be c e n t e r e d o n t h e s e a t .
• If it is too high ( c l o s e r to the v a l v e s t e m ) , y o u

m u s t m a k e a s e c o n d c u t w i t h t h e 60 ° cutter to
m o v e it d o w n , t h e n o n e m o r e c u t w i t h the 4 5 °
cutter to r e s t o r e s e a t w i d t h .
• If it is too l o w ( c l o s e to the v a l v e e d g e ) , y o u m u s t
m a k e a s e c o n d cut w i t h t h e 3 2 ° cutter to m o v e it
u p , t h e n m a k e o n e m o r e cut w i t h t h e 45 ° cutter 9. If v a l v e s t e m i n s t a l l e d height is o v e r t h e s e r v i c e
to restore s e a t w i d t h . limit, r e p l a c e the v a l v e a n d r e c h e c k . If it is still o v e r
the s e r v i c e limit, r e p l a c e the c y l i n d e r h e a d ; the
N O T E : T h e final cut s h o u l d a l w a y s be m a d e w i t h v a l v e s e a t in t h e h e a d is too d e e p .
the 4 5 ° cutter.
6-46
Valve, Spring, and Valve Seal Installation
Special Tools Required 5. Install the v a l v e s p r i n g a n d s p r i n g retainer. P l a c e

• S t e m s e a l driver 07PAD-0010000 t h e e n d of the v a l v e s p r i n g w i t h c l o s e l y w o u n d c o i l s
• V a l v e spring compressor attachment 07757-PJ1010A t o w a r d the c y l i n d e r h e a d .
1. C o a t the v a l v e s t e m s w i t h n e w e n g i n e oil. Install 6. Install the v a l v e s p r i n g c o m p r e s s o r . C o m p r e s s t h e

t h e v a l v e s in the v a l v e g u i d e s . s p r i n g a n d install t h e v a l v e c o t t e r s .
07757-PJ1010A
2. C h e c k that t h e v a l v e s m o v e up a n d d o w n s m o o t h l y .
3. Install the s p r i n g s e a t s o n the c y l i n d e r h e a d .
4. Install the n e w v a l v e s e a l s (A) u s i n g the s t e m s e a l

d r i v e r (B).
N O T E : T h e e x h a u s t v a l v e s e a l (C) h a s a black s p r i n g
(D), a n d the intake v a l v e s e a l (E) h a s a w h i t e s p r i n g
(F). T h e y are not i n t e r c h a n g e a b l e .
7. R e m o v e the v a l v e s p r i n g c o m p r e s s o r .
8. Lightly t a p the e n d of e a c h v a l v e s t e m t w o or t h r e e
t i m e s w i t h a p l a s t i c m a l l e t (A) to e n s u r e p r o p e r
s e a t i n g of the v a l v e a n d v a l v e cotters. T a p the v a l v e
s t e m o n l y a l o n g its a x i s s o y o u d o not b e n d the
07PAD-0010000
NOTE: Use 5.5 m m side. stem.
6-47
Cylinder Head
Rocker Arm Assembly Installation
1. M a k e s u r e the c r a n k s h a f t p u l l e y is at t o p d e a d 3. C h e c k the a l i g n m e n t of the T D C m a r k s (A) o n the

c e n t e r ( T D C ) . A l i g n t h e T D C m a r k (A) o n t h e c a m chain sprocket with the cylinder head surface.
c r a n k s h a f t p u l l e y w i t h t h e pointer (B) o n t h e c h a i n
case.
B A
4. A l i g n the T D C m a r k s (B) o n t h e intake c a m s h a f t

g e a r (C) a n d t h e e x h a u s t c a m s h a f t g e a r (D), a n d
install the c a m s h a f t s .
2 . Insert t h e bolts (A) into t h e r o c k e r s h a f t h o l d e r , t h e n
install t h e rocker a r m a s s e m b l y (B). 5. A p p l y n e w e n g i n e oil to t h e bolt t h r e a d s of all t h e
c a m s h a f t h o l d e r bolts.
6. Put the c a m s h a f t h o l d e r s o n t h e c y l i n d e r h e a d , t h e n
tighten all bolts to 2 2 N-m (2.2 kgf-m, 16 Ibf-ft). T o
p r e v e n t d a m a g i n g t h e c a m s h a f t s , tighten the bolts
t w o t u r n s at a t i m e , in t h e s e q u e n c e s h o w n .
® ® ® ® ®® ®® ®®
(§> ® ® ® ® ® ® ® ® ®
7. A d j u s t the v a l v e c l e a r a n c e ( s e e p a g e 6-10).
8. Install the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).
6-48
Camshaft Gear Installation Cylinder Head Installation
1. Install the c a m s h a f t g e a r (A). 1. M e a s u r e t h e d i a m e t e r of e a c h c y l i n d e r h e a d bolt at

point A a n d point B. If either d i a m e t e r is l e s s t h a n
N O T E : T h e e x h a u s t c a m s h a f t g e a r h a s a g r o o v e (B) 11.5 m m (0.45 in.), r e p l a c e t h e c y l i n d e r h e a d bolt.
in the f a c e . T h e intake c a m s h a f t g e a r d o e s not h a v e
5 0 m m (2.0 in.)
a g r o o v e . B e s u r e to install the c o r r e c t c a m s h a f t
gear on each camshafts. 4 5 m m (1.8 in.)
2. A p p l y n e w e n g i n e oil to t h e t h r e a d s of the c a m s h a f t 2. C l e a n a n d dry t h e c y l i n d e r h e a d , e n g i n e block, a n d

g e a r m o u n t i n g nut (C), t h e n install it. chain c a s e mating surfaces.
3. Hold the c a m s h a f t w i t h a n o p e n - e n d w r e n c h , t h e n 3. A p p l y liquid g a s k e t , P/N 0 8 7 1 7 - 0 0 0 4 , 0 8 7 1 8 - 0 0 0 1 ,

tighten the c a m s h a f t g e a r m o u n t i n g nut. 0 8 7 1 8 - 0 0 0 3 , or 0 8 7 1 8 - 0 0 0 9 , to the s h a d e d a r e a s (A)
of the c y l i n d e r h e a d g a s k e t m a t i n g s u r f a c e of t h e
Specified Torque: e n g i n e block a n d c h a i n c a s e .
118 N-m (12.0 kgf-m, 86.8 Ibfft)
N O T E : Do not install the parts if 5 m i n u t e s o r m o r e
r e a p p l y liquid g a s k e t after r e m o v i n g the old
residue.
2J—^QP O
(cont'd)
6-49
Cylinder Head
Cylinder Head Installation (cont'd)
4. Install t h e d o w e l p i n s (A) a n d t h e n e w c y l i n d e r h e a d 6. Install t h e c y l i n d e r h e a d o n t h e e n g i n e block.

g a s k e t (B).
7. A p p l y n e w e n g i n e oil to the t h r e a d s a n d f l a n g e of
all t h e c y l i n d e r h e a d bolts.
8. T i g h t e n the c y l i n d e r h e a d bolts in s e q u e n c e to
2 9 N-m (3.0 kgf-m, 22 Ibfft). U s e a b e a m - t y p e
torque w r e n c h . W h e n using a preset-type torque
w r e n c h , be s u r e to tighten s l o w l y a n d d o not
o v e r t i g h t e n . If a bolt m a k e s a n y n o i s e w h i l e y o u a r e
t o r q u i n g it, l o o s e n t h e bolt a n d retighten it.
A p p l y liquid g a s k e t , P/N 0 8 7 1 7 - 0 0 0 4 , 0 8 7 1 8 - 0 0 0 1 ,
0 8 7 1 8 - 0 0 0 3 , or 0 8 7 1 8 - 0 0 0 9 , to t h e c y l i n d e r h e a d
m a t i n g s u r f a c e of t h e block a n d c h a i n c a s e w i t h i n
5 m m of t h e e d g e of t h e c y l i n d e r h e a d g a s k e t .
N O T E : D o not install t h e p a r t s if 5 m i n u t e s o r m o r e
r e a p p l y liquid g a s k e t after r e m o v i n g t h e o l d FIRST STEP
residue.
0
)^ e)O(5®oO
SECOND STEP
THIRD S T E P
( N e w bolt)
) Q) & o^ c2 ol 9. T i g h t e n all c y l i n d e r h e a d bolts in t w o s t e p s (90 ° per

s t e p ) . If y o u a r e u s i n g a n e w c y l i n d e r h e a d bolt,
tighten the bolt a n extra 9 0 °,
10. T i g h t e n the 8 m m bolts (A) to 22 N-m (2.2 kgf-m,

A p p l y liquid g a s k e t 16 Ibf-ft).
a l o n g t h e broken line.
6-50
11. M a k e s u r e the c r a n k s h a f t pulley is at top d e a d 14. Install t h e c a m c h a i n o n t h e s p r o c k e t , t h e n fit the
c e n t e r ( T D C ) . A l i g n the T D C m a r k (A) o n t h e a s s e m b l y into the c y l i n d e r h e a d .
c r a n k s h a f t pulley w i t h the pointer (B) o n t h e c h a i n
case. 15. T u r n the c a m c h a i n s p r o c k e t a s s e m b l y
c o u n t e r c l o c k w i s e to r e l i e v e c a m c h a i n f r e e p l a y ,
B A a n d c h e c k the a l i g n m e n t of t h e T D C m a r k s (A) o n
the c a m c h a i n s p r o c k e t w i t h the c y l i n d e r h e a d
s u r f a c e . If the c a m c h a i n s p r o c k e t is not p o s i t i o n e d
at T D C , r e m o v e t h e a s s e m b l y f r o m the c y l i n d e r
h e a d a n d r e p o s i t i o n t h e c a m c h a i n to bring the c a m
c h a i n s p r o c k e t to T D C .
12. A s s e m b l e the idler g e a r (A) a n d c a m c h a i n

s p r o c k e t (B) with t h r e e m o u n t i n g bolts (C).
T o r q u e the bolts to 13 N-m (1.3 kgf-m, 9.4 Ibf-ft).
13. P l a c e the idler g e a r / c a m c h a i n s p r o c k e t a s s e m b l y

a n d idler g e a r collar into the c y l i n d e r h e a d .
17. Install t h e w a s h e r (C) o n t h e idler g e a r , a n d tighten

the c e n t e r bolt.
(cont'd)
6-51
Cylinder Head
18. C l a m p t h e c a m c h a i n a u t o - t e n s i o n e r in a s o f t - j a w e d 2 1 . Install the c a m c h a i n a u t o - t e n s i o n e r (A) in the
vise. c y l i n d e r h e a d w i t h n e w O - r i n g s (B).
B
19. T u r n t h e 5 x 0.8 m m bolt (A) c l o c k w i s e to c o m p r e s s
t h e b o t t o m of the a u t o - t e n s i o n e r , t h e n i n s e r t t h e s e t
pin ( B ) , P/N 1 4 5 1 1 - P C X - 0 0 5 .
6x1.0 mm
12 N m
(1.2 k g f - m , 8.7 Ibf ft)
2 2 . R e m o v e the m a i n t e n a n c e bolt (C) f r o m t h e c y l i n d e r

head.
2 3 . R e m o v e the s e t pin (A) f r o m the c a m c h a i n auto-

t e n s i o n e r . R e i n s t a l l the m a i n t e n a n c e bolt (B) w i t h a
n e w w a s h e r (C).
2 9 N-m
(3.0 k g f - m , 2 2 Ibf ft)
6-52
24. Insert t h e bolts (A) into the rocker s h a f t h o l d e r , t h e n 28. Put the c a m s h a f t h o l d e r s o n the c y l i n d e r h e a d , t h e n
install t h e rocker a r m a s s e m b l y (B). tighten all bolts to 22 N-m (2.2 k g f m , 16 Ibf.ft). T o
p r e v e n t d a m a g i n g t h e c a m s h a f t s , t i g h t e n t h e bolts
t w o t u r n s at a t i m e , in t h e s e q u e n c e s h o w n .
® @ ® ® ® ® ®
29. M a k e s u r e the c a m s h a f t g e a r s a r e at T D C .
2 5 . C h e c k the a l i g n m e n t of the T D C m a r k s (A) o n the

c a m c h a i n s p r o c k e t w i t h the c y l i n d e r h e a d s u r f a c e .
30. A d j u s t the v a l v e c l e a r a n c e ( s e e p a g e 6-10).
3 1 . Install the c y l i n d e r h e a d c o v e r ( s e e p a g e 6-22).
26. A l i g n the T D C m a r k s (B) o n the intake c a m s h a f t

g e a r (C) a n d the e x h a u s t c a m s h a f t g e a r (D), a n d
install the c a m s h a f t s .
27. A p p l y n e w e n g i n e oil to the bolt t h r e a d s of all the

c a m s h a f t h o l d e r bolts.
(cont'd)
6-53
Cylinder Head
3 2 . Install the intake m a n i f o l d (A) w i t h a n e w g a s k e t ( B ) , 36. Put t h e e x h a u s t m a n i f o l d c o v e r o n t h e e x h a u s t
t h e n install t h e intake m a n i f o l d s t a y ( C ) . manifold.
B 8x1.25 mm
37. Install t h e h e a t s h i e l d .
2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
10 x 1.25 m m
44 N-m
(4.5 k g f - m , 3 3 I b f f t ) 6x1.0 mm
9.8 N - m (1.0 k g f - m , 7.2 Ibf-ft)
3 3 . ' 0 0 - 0 5 m o d e l s : Install t h e i n j e c t o r s ( s e e p a g e
11-112). 3 8 . T i g h t e n t h e f o u r bolts s e c u r i n g t h e e x h a u s t
manifold cover.
34. Install t h e e x h a u s t m a n i f o l d (A) u s i n g n e w g a s k e t s
8x1.25 mm
(B) a n d n e w s e l f - l o c k i n g n u t s ( C ) .
2 2 N - m (2.2 k g f - m , 1 6 Ibf ft)
10x1.25 mm
44 N-m
(4.5 k g f - m , 3 3 I b f f t )
C
8 x 1.25 m m
31 N - m
8 x 1.25 m m (3.2 k g f - m ,
22 N-m 23 Ibfft)
(2.2 k g f - m , 1 6 I b f f t )
8x1.25 mm
2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
3 5 . Install t h e e x h a u s t m a n i f o l d b r a c k e t (D). M a k e s u r e
the s m o o t h s i d e s of t h e w a s h e r s ( E ) f a c e t h e
e x h a u s t manifold bracket.
6-54
3 9 . ' 0 0 - 0 5 m o d e l s : Install the w a t e r b y p a s s h o s e (A), 41. Install the f o l l o w i n g e n g i n e w i r e h a r n e s s c o n n e c t o r s
a n d tighten t h e t w o bolts (B) s e c u r i n g t h e intake a n d w i r e h a r n e s s c l a m p s to t h e c y l i n d e r h e a d a n d intake
m a n i f o l d bracket. intake m a n i f o l d :
• F o u r fuel injector c o n n e c t o r s
• Intake air t e m p e r a t u r e (IAT) s e n s o r c o n n e c t o r
('00-05 m o d e l s )
• Idle air control (IAC) v a l v e c o n n e c t o r ('00-05
models)
• Throttle position (TP) s e n s o r c o n n e c t o r ('00-05
models)
• Throttle b o d y c o n n e c t o r ('06-08 m o d e l s )
• M a n i f o l d a b s o l u t e p r e s s u r e (MAP) s e n s o r
connector
• Primary heated o x y g e n s e n s o r (primary H 0 2 S )
• A / F s e n s o r c o n n e c t o r ('06-08 m o d e l s )
• Engine coolant temperature (ECT) s e n s o r
• Engine coolant temperature (ECT) s e n s o r 1
• R o c k e r a r m oil control s o l e n o i d ( V T E C s o l e n o i d
(4.5 kgf-m, 33 Ibf ft)
valve) connector
• R o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil
40. ' 0 6 - 0 8 m o d e l s : Install the intake m a n i f o l d bracket pressure switch) connector
(A), t h e n install the e v a p o r a t i v e e m i s s i o n ( E V A P ) • Crankshaft position (CKP) s e n s o r connector
h o s e (B) a n d its bracket ( C ) , install the w i r e h a r n e s s
c l a m p (D) a n d t h e w a t e r b y p a s s h o s e (E). 42. Install t h e w a t e r outlet c o v e r (A) w i t h a n e w O-ring
(cont'd)
6-55
Cylinder Head
4 3 . ' 0 0 - 0 5 m o d e l s : Install t h e air h o s e (A), a n d tighten 45. C o n n e c t the evaporative e m i s s i o n (EVAP) canister
t h e bolt (B) s e c u r i n g t h e intake m a n i f o l d bracket. hose.
'00-05 m o d e l s
44. ' 0 6 - 0 8 m o d e l s : Install t h e bolt (A) s e c u r i n g t h e

intake m a n i f o l d b r a c k e t .
10x1.25 m m
4 4 N m (4.5 k g f - m , 3 3 I b f f t )
6-56
46. '00-05 m o d e l s : Install the brake b o o s t e r v a c u u m 47. '06-08 m o d e l s : C o n n e c t t h e fuel f e e d h o s e (A), t h e n
h o s e (A), fuel return h o s e (B), a n d fuel f e e d h o s e ( C ) , install the q u i c k - c o n n e c t fitting c o v e r (B), a n d install
u s i n g n e w w a s h e r s (D). t h e brake b o o s t e r v a c u u m h o s e (C).
'00-03 m o d e l s
22 N m
(2.2 k g f - m , 1 6 I b f f t )
48. '06-08 m o d e l s : Install t h e intake m a n i f o l d c o v e r .
C B
'04-05 m o d e l s
2 2 N m (2.2kgf-m, 16Ibfft)
49. '00-05 m o d e l s : Install the throttle c a b l e ( s e e p a g e

11-167), t h e n a d j u s t t h e c a b l e ( s e e p a g e 11-168).
50. Install t h e d r i v e belt ( s e e p a g e 4-42).
(cont'd)
6-57
Cylinder Head
Cylinder Head installation (cont'd)
51. ' 0 0 - 0 5 m o d e l s : Install the intake air c l e a n e r h o u s i n g 53. ' 0 0 - 0 5 m o d e l s : Install the air c l e a n e r a s s e m b l y (A)
(A), t h e n install t h e h a r n e s s c l a m p s (B), c o n n e c t a i r a n d air c l e a n e r h o u s i n g c o v e r (B), t h e n c o n n e c t the
control s o l e n o i d v a l v e c o n n e c t o r (C) a n d v a c u u m air h o s e (C) a n d b r e a t h e r pipe (D).
h o s e s (D).
C D
54. ' 0 6 - 0 8 m o d e l s : Install the air c l e a n e r a s s e m b l y (A)

52. ' 0 6 - 0 8 m o d e l s : Install t h e intake air c l e a n e r h o u s i n g a n d air c l e a n e r h o u s i n g c o v e r (B), t h e n install the
(A), t h e n install t h e I A T s e n s o r h a r n e s s c l a m p s (B). M A P s e n s o r h a r n e s s (C) to t h e h o l d e r , c o n n e c t the
I A T s e n s o r c o n n e c t o r (D) a n d b r e a t h e r pipe (E).
6-58
55. After installation, c h e c k that all t u b e s , h o s e s , a n d
connectors are installed correctly.
56. After a s s e m b l y , w a i t at l e a s t 30 m i n u t e s before

filling t h e e n g i n e with oil.
57. C l e a n t h e battery p o s t s a n d c a b l e t e r m i n a l s , t h e n
a s s e m b l e t h e m a n d a p p l y g r e a s e to p r e v e n t
corrosion.

O N (II) (do not o p e r a t e t h e starter) s o that the fuel
p u m p r u n s for a b o u t 2 s e c o n d s a n d p r e s s u r i z e s the
59. Refill the e n g i n e with e n g i n e oil ( s e e p a g e 8-6).

air f r o m the c o o l i n g s y s t e m with the h e a t e r v a l v e
6 1 . '00-05 m o d e l s : Do t h e e n g i n e control m o d u l e ( E C M )
6 2 . '06-08 m o d e l s : Do t h e c r a n k s h a f t position ( C K P ) /
C K P learn p r o c e d u r e ( s e e p a g e 11-214).
6 3 . I n s p e c t the idle s p e e d :
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-140)
• '06-08 m o d e l s ( s e e p a g e 11-461)
64. I n s p e c t the ignition t i m i n g ( s e e p a g e 4-24).
6 5 . E n t e r the anti-theft c o d e for the a u d i o s y s t e m , t h e n

enter t h e a u d i o p r e s e t s . S e t the clock.
Engine Mechanical
Engine Block
Special Tools 7-2
Connecting Rod and Crankshaft End Play
Inspection 7-5
Crankshaft Main Bearing Replacement 7-6
Connecting Rod Bearing Replacement 7-8
Oil Pan Removal 7-10
Crankshaft and Piston Removal 7-10
Crankshaft Inspection 7-12
Block and Piston Inspection 7-13
Cylinder Bore Honing 7-15
Piston, Pin and Connecting Rod Replacement ......... 7-16
r
Piston Ring Replacement .. 7-19

Piston Installation 7-21
Crankshaft Installation 7-23
Oil Pan Installation 7-25
Pulley End Crankshaft Oil Seal
Installation - In Car 7-26
Transmission End Crankshaft Oil Seal
Installation - In Car 7-26
Drain Bolt Installation 7-27
Engine Block
Special Tools
Ref. N o . Tool Number Description Qtv
© 07LAD-PT3010A S e a l Driver 1
® 07749-0010000 Handle Driver 1
® 07948-SB00101 Driver Attachment 1
© (2) (D
7-2
(cont'd)
7-3
Engine Block
Component Location Index (cont'd)
S N A P RING
PISTON RINGS
P I S T O N PIN
D i s a s s e m b l y , p a g e 7-16
PISTON R e a s s e m b l y , s t e p 1 o n p a g e 7-18
R e m o v a l , p a g e 7-10 I n s p e c t i o n , s t e p 1 o n p a g e 7-17
M e a s u r e m e n t , p a g e 7-13
CONNECTING ROD
E n d p l a y , p a g e 7-5
S m a l l e n d m e a s u r e m e n t , s t e p 1 o n p a g e 7-17
ENGINE BLOCK
Inspection, page 7-13
C y l i n d e r bore h o n i n g , p a g e 7-15
CONNECTING ROD BEARINGS
C l e a r a n c e , p a g e 7-8
S e l e c t i o n , s t e p 1 o n p a g e 7-8
CONNECTING ROD
BEARING CAP
CONNECTING ROD BOLT
7-4
Connecting Rod and Crankshaft End Play Inspection
1. R e m o v e t h e oil p u m p (see p a g e 8-11). P u s h the c r a n k s h a f t f i r m l y a w a y f r o m the dial

indicator, a n d zero t h e dial a g a i n s t the e n d of the
2. M e a s u r e t h e c o n n e c t i n g rod e n d p l a y w i t h a f e e l e r c r a n k s h a f t . T h e n pull the c r a n k s h a f t f i r m l y b a c k
g a u g e b e t w e e n the c o n n e c t i n g rod a n d c r a n k s h a f t . t o w a r d t h e indicator; the dial r e a d i n g s h o u l d not
e x c e e d t h e s e r v i c e limit.
C o n n e c t i n g R o d E n d Play
S t a n d a r d (New): 0.15—0.30 m m Crankshaft E n d Play
( 0 . 0 0 6 - 0 . 0 1 2 in.) S t a n d a r d (New): 0.10—0.35 m m
Service Limit: 0.40 m m (0.016 in.) ( 0 . 0 0 4 - 0 . 0 1 4 in.)
If the c o n n e c t i n g rod e n d p l a y is out-of-tolerance,

install a n e w c o n n e c t i n g r o d , a n d r e c h e c k . If it is If the e n d p l a y is e x c e s s i v e , r e p l a c e the t h r u s t
still out-of-tolerance, r e p l a c e the c r a n k s h a f t w a s h e r s a n d r e c h e c k . If it is still out-of-tolerance,
( s e e p a g e 7-10). r e p l a c e the c r a n k s h a f t ( s e e p a g e 7-10).
7-5
Engine Block
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection If t h e p l a s t i g a u g e m e a s u r e s too w i d e or too n a r r o w ,

r e m o v e t h e c r a n k s h a f t , a n d r e m o v e the u p p e r half
1. R e m o v e t h e l o w e r block a n d b e a r i n g h a l v e s of the b e a r i n g . Install a n e w , c o m p l e t e b e a r i n g w i t h
( s e e p a g e 7-10). t h e s a m e c o l o r c o d e ( s ) , a n d r e c h e c k the c l e a r a n c e .
D o not file, s h i m , or s c r a p e the b e a r i n g s or t h e c a p s
2. R e m o v e all of the old liquid g a s k e t f r o m t h e l o w e r to a d j u s t c l e a r a n c e .
block m a t i n g s u r f a c e s , b o l t s , a n d bolt h o l e s .
If t h e p l a s t i g a u g e s h o w s t h e c l e a r a n c e is still
3. C l e a n the l o w e r block m a t i n g s u r f a c e . i n c o r r e c t , try t h e next larger or s m a l l e r b e a r i n g (the
c o l o r listed a b o v e o r b e l o w that o n e ) , a n d c h e c k
4. C l e a n e a c h m a i n j o u r n a l a n d b e a r i n g half w i t h a a g a i n . If t h e p r o p e r c l e a r a n c e c a n n o t be o b t a i n e d
clean shop towel. b y u s i n g t h e a p p r o p r i a t e larger or s m a l l e r b e a r i n g s ,
r e p l a c e the c r a n k s h a f t a n d start o v e r .
5. P l a c e o n e strip of p l a s t i g a u g e a c r o s s e a c h m a i n
journal.
6. R e i n s t a l l the b e a r i n g s a n d l o w e r block, t h e n t o r q u e
t h e bolts to 2 9 N-m (3.0 k g f m , 22 Ibfft) + 6 0 °.
N O T E : D o not rotate the c r a n k s h a f t d u r i n g

inspection.
7. R e m o v e the l o w e r block a n d b e a r i n g s a g a i n , a n d
m e a s u r e the w i d e s t part of t h e p l a s t i g a u g e .
Main Bearing-to-Journal Oil C l e a r a n c e

S t a n d a r d ( N e w ) : 0.017—0.041 m m
( 0 . 0 0 0 7 - 0 . 0 0 1 6 in.)
7-6
Main Bearing Selection Main Journal Code Location
Crankshaft Bore Code Location 2. T h e m a i n j o u r n a l c o d e s a r e s t a m p e d o n t h e N o . 1

web.
1. N u m b e r s or letters or b a r s h a v e b e e n s t a m p e d o n
the e n d of the block a s a c o d e for the s i z e of e a c h of
the five m a i n j o u r n a l b o r e s . Write d o w n the c r a n k
bore c o d e s .
If y o u c a n ' t r e a d t h e c o d e s b e c a u s e of a c c u m u l a t e d
dirt a n d d u s t , d o not s c r u b t h e m w i t h a w i r e b r u s h
or s c r a p e r . C l e a n t h e m o n l y w i t h s o l v e n t or
detergent.
No. 5 J O U R N A L No. 1 J O U R N A L
(FLYWHEEL END) (PULLEY END)
3. U s e t h e c r a n k bore c o d e s a n d c r a n k j o u r n a l c o d e s
to s e l e c t t h e a p p r o p r i a t e r e p l a c e m e n t b e a r i n g s
f r o m the f o l l o w i n g t a b l e .
NOTE:
• C o l o r c o d e is o n t h e e d g e of the b e a r i n g .
• W h e n u s i n g b e a r i n g h a l v e s of different c o l o r s , it
d o e s not matter w h i c h c o l o r is u s e d in t h e top or
bottom.
- • Larger crank bore

Crank
bore 1 or 2 or 3 or 4 or
Main code Aorl B o r II C o r III D o r llll
journal
code - • S m a l l e r bearing (Thicker)
Pink/ Yellow/
1orl Yellow Yellow Green
Green
Yellow/ Green/
2 o r II Yellow Green Green Brown
Yellow/ Green/
3 o r III Green Green Brown
Brown
Green/ Brown/
4 o r llll Green Brown
Brown Black
Green/ Brown/
5 o r Hill Brown Brown Black
Black
Brown/ Black/
6 o r llllll Brown Black
Black Blue
V V
Smaller Smaller
main bearing
journal (Thicker)
7-7
Engine Block
Connecting Rod Bearing Replacement
Connecting Rod Bearing Clearance Connecting Rod Bearing Selection

Inspection
1. I n s p e c t e a c h c o n n e c t i n g rod for c r a c k s a n d heat
1. R e m o v e the c o n n e c t i n g rod c a p a n d b e a r i n g half damage.
( s e e p a g e 7-10).
Connecting R o d Big E n d Bore C o d e Locations
2. C l e a n the c r a n k s h a f t rod j o u r n a l a n d b e a r i n g half
with a clean s h o p towel. 2 . E a c h c o n n e c t i n g rod h a s a t o l e r a n c e r a n g e f r o m 0
to 0.024 m m (0.0009 in.), in 0.006 m m (0.0002 in.)
3. P l a c e a p l a s t i g a u g e a c r o s s t h e r o d j o u r n a l . i n c r e m e n t s , d e p e n d i n g o n the s i z e of its big e n d
b o r e . It's t h e n s t a m p e d w i t h a n u m b e r or bar ( 1 , 2 , 3
4. R e i n s t a l l the b e a r i n g half a n d c a p , a n d t o r q u e the or 4/I, II, III, or Mil) indicating the r a n g e . Y o u m a y
bolt to 2 5 N-m (2.5 kgf-m, 18 Ibf-ft) + 9 0 °. find a n y c o m b i n a t i o n of n u m b e r s or b a r s in a n y
e n g i n e , (half the n u m b e r or bar is s t a m p e d o n the
N O T E : Do not rotate the c r a n k s h a f t d u r i n g b e a r i n g c a p , the other half o n the rod).
inspection.
If y o u c a n ' t r e a d the c o d e b e c a u s e of a n
5. R e m o v e the rod c a p a n d b e a r i n g half, a n d m e a s u r e a c c u m u l a t i o n of oil a n d v a r n i s h , d o not s c r u b it
t h e w i d e s t part of t h e p l a s t i g a u g e . w i t h a w i r e b r u s h or s c r a p e r . C l e a n it o n l y w i t h
s o l v e n t or detergent.
Connecting R o d Bearing-to-Journal Oil C l e a r a n c e
Standard (New): 0.030—0.054 m m
( 0 . 0 0 1 2 - 0 . 0 0 2 1 in.)
6. If t h e p l a s t i g a u g e m e a s u r e s t o o w i d e or too n a r r o w ,
r e m o v e the u p p e r half of the b e a r i n g , install a n e w ,
c o m p l e t e b e a r i n g w i t h the s a m e c o l o r c o d e ( s ) , a n d
r e c h e c k the c l e a r a n c e . D o not file, s h i m , or s c r a p e
the b e a r i n g s or t h e c a p s to a d j u s t c l e a r a n c e .
7. If t h e p l a s t i g a u g e s h o w s the c l e a r a n c e is still
i n c o r r e c t , try the n e x t larger or s m a l l e r b e a r i n g (the
c o l o r listed a b o v e o r b e l o w that o n e ) , a n d c h e c k
c l e a r a n c e a g a i n . If t h e p r o p e r c l e a r a n c e c a n n o t be
o b t a i n e d b y u s i n g t h e a p p r o p r i a t e larger or s m a l l e r
b e a r i n g , r e p l a c e t h e c r a n k s h a f t a n d start o v e r .
7-8
Connecting Rod Journal Code Location 4 . U s e the big e n d b o r e c o d e s a n d r o d j o u r n a l c o d e s
to s e l e c t a p p r o p r i a t e r e p l a c e m e n t b e a r i n g s f r o m
3 . T h e c o n n e c t i n g rod j o u r n a l c o d e s a r e s t a m p e d o n the following table.
the No. 1 w e b .
N O T E : C o l o r c o d e is o n the e d g e of t h e b e a r i n g .
Connecting Rod Journal Code Location
Big end Larger big e n d bore
( L e t t e r s or B a r s ) bore
code 1 orl 2 o r II 3 o r III 4 o r llll
Rod
Journal
code - • S m a l l e r bearing (Thicker)
A or 1 Red Pink Yellow Green
B o r II Pink Yellow Green Brown
C o r III Yellow Green Brown Black
D o r llll Green Brown Black Blue

V V
Smaller Smaller
rod bearing
journal (Thicker)
7-9
Engine Block
Oil Pan Removal Crankshaft and Piston Removal
1. If the e n g i n e is out of the v e h i c l e , g o to s t e p 3. 1. R e m o v e the c a m c h a i n ( s e e p a g e 6-13).
2. D r a i n t h e e n g i n e oil ( s e e p a g e 8-6). 2. R e m o v e the oil p u m p ( s e e s t e p 1 o n p a g e 8-11).
3. R e m o v e the bolt s e c u r i n g the oil p a n , t h e n r e m o v e 3. If y o u c a n feel a ridge of m e t a l or h a r d c a r b o n

t h e oil p a n . a r o u n d the top of a n y c y l i n d e r , r e m o v e it w i t h a
ridge r e a m e r (A). F o l l o w t h e r e a m e r m a n u f a c t u r e r ' s
N O T E : C u t t h e oil p a n s e a l by u s i n g t h e oil s e a l i n s t r u c t i o n s . If t h e ridge is not r e m o v e d , it m a y
cutter w h e n oil p a n d o e s n ' t c o m e off e a s i l y . d a m a g e t h e p i s t o n a s it is p u s h e d out.
4. R e m o v e the 8 m m bolts s e c u r i n g the l o w e r block.
© ®® ® ® . <e> ® ®
® ® ® ® ® ®
7-10
5. R e m o v e the b e a r i n g c a p bolts. T o p r e v e n t w a r p a g e , 8. Lift the c r a n k s h a f t out of the e n g i n e block, b e i n g
l o o s e n the bolts in s e q u e n c e 1/3 turn at a t i m e ; c a r e f u l not to d a m a g e the j o u r n a l s .
repeat the s e q u e n c e until all bolts a r e l o o s e n e d .
9. U s e the w o o d e n h a n d l e of a h a m m e r (A) to d r i v e
6. R e m o v e the l o w e r block a n d b e a r i n g s . K e e p all out the p i s t o n s (B).
b e a r i n g s in order.
10. R e i n s t a l l the c o n n e c t i n g rod b e a r i n g s a n d c a p s

after r e m o v i n g e a c h piston a n d c o n n e c t i n g rod
assembly.
11. T o a v o i d m i x - u p o n r e a s s e m b l y , m a r k e a c h p i s t o n
a n d c o n n e c t i n g rod a s s e m b l y w i t h its c y l i n d e r
7. R e m o v e the rod c a p s a n d b e a r i n g s . K e e p all c a p s number.
a n d b e a r i n g s in order.
N O T E : T h e e x i s t i n g n u m b e r o n the c o n n e c t i n g rod
d o e s not indicate its position in the e n g i n e , it
i n d i c a t e s the rod b o r e s i z e .
7-11
Engine Block
Crankshaft Inspection
Out-of-Round and Taper Straightness
1. R e m o v e the c r a n k s h a f t f r o m the e n g i n e block 6. P l a c e t h e e n g i n e block o n the s u r f a c e plate.

( s e e p a g e 7-10).
7. C l e a n a n d install t h e b e a r i n g s o n t h e N o . 1 a n d
2. C l e a n t h e c r a n k s h a f t oil p a s s a g e s w i t h pipe No. 5 j o u r n a l s of t h e e n g i n e block.
c l e a n e r s or a s u i t a b l e b r u s h .
8. L o w e r t h e c r a n k s h a f t into t h e e n g i n e block.
3. C h e c k the k e y w a y a n d t h r e a d s .
9. M e a s u r e t h e r u n o u t o n all of t h e m a i n j o u r n a l s .
4. M e a s u r e t h e out-of-round at t h e m i d d l e of e a c h rod Rotate t h e c r a n k s h a f t t w o c o m p l e t e r e v o l u t i o n s .
a n d m a i n j o u r n a l in t w o p l a c e s of t h e c r o s s T h e difference between m e a s u r e m e n t s on e a c h
direction. T h e difference between m e a s u r e m e n t s j o u r n a l m u s t not be m o r e t h a n the s e r v i c e limit.
o n e a c h j o u r n a l m u s t not be m o r e t h a n t h e s e r v i c e
limit. Crankshaft Total Indicator Runout
Journal Out-of-Round Service Limit: 0.04 m m (0.0016 in.)
S t a n d a r d ( N e w ) : 0 . 0 0 4 m m (0.0002 in.) m a x .
S e r v i c e Limit: 0 . 0 0 6 m m (0.0002 in.)
TT
5. M e a s u r e t h e t a p e r at the e d g e of e a c h rod a n d m a i n
journal. T h e difference between m e a s u r e m e n t s on
e a c h j o u r n a l m u s t not be m o r e t h a n t h e s e r v i c e
limit.
Journal Taper
S t a n d a r d ( N e w ) : 0 . 0 0 5 m m (0.0002 in.) m a x .
Service Limit: 0 . 0 0 6 m m (0.0002 in.)
7-12
Block and Piston Inspection
1. R e m o v e t h e c r a n k s h a f t a n d p i s t o n s ( s e e p a g e 7-10). 4. R e m o v e all of the old liquid g a s k e t f r o m t h e l o w e r

block m a t i n g s u r f a c e s , b o l t s , a n d bolt h o l e s .
2. C h e c k the piston for distortion or c r a c k s .
5. C l e a n t h e l o w e r block m a t i n g s u r f a c e s .
3. M e a s u r e the p i s t o n d i a m e t e r at a point 16 m m
(0.6 in.) ('00-03 m o d e l s ) , or 10 m m (0.4 in.) ('04-08 6. Put the l o w e r block o n t h e e n g i n e block.
m o d e l s ) f r o m the bottom of the skirt. T h e r e a r e t w o
s t a n d a r d - s i z e p i s t o n s (No Letter or A , a n d B). T h e 7. T i g h t e n t h e b e a r i n g c a p bolts in s e q u e n c e to
letter is s t a m p e d o n the top of the p i s t o n . Letters 29 N-m (3.0 kgf-m, 22 Ibfft).
a r e a l s o s t a m p e d o n the e n g i n e block a s c y l i n d e r
bore sizes.
Piston Diameter
Standard (New):
N o L e t t e r (or A ) : 86.993—87.006 mm
(3.4249-3.4254 in.)
B: 86.983—86.996 mm
(3.4245-3.4250 in.)
Service Limit:
N o L e t t e r (or A ) : 8 6 . 9 8 0 m m (3.4244 in.)
B: 8 6 . 9 7 0 m m (3.4240 in.)
Oversize Piston Diameter

0.25: 8 7 . 2 3 3 - 8 7 . 2 4 6 m m ( 3 . 4 3 4 4 - 3 . 4 3 4 9 in.)
'00-03 m o d e l s :
16 m m (0.6 in.) SKIRT DIAMETER
'04-08 m o d e l s : ® • ® (D
10 m m (0.4 in.)
8. T i g h t e n the b e a r i n g c a p bolts a n additional 6 0 °.
60°
(cont'd)
7-13
Engine Block
Block and Piston Inspection (cont'd)
9. M e a s u r e t h e w e a r a n d t a p e r in direction X a n d Y at 10. S c o r e d or s c r a t c h e d c y l i n d e r b o r e s m u s t be h o n e d .
t h r e e l e v e l s in e a c h c y l i n d e r a s s h o w n . If
m e a s u r e m e n t s in a n y c y l i n d e r a r e b e y o n d t h e 11. C h e c k the top of t h e block for w a r p a g e . M e a s u r e
o v e r s i z e b o r e s e r v i c e limit, r e p l a c e t h e e n g i n e block. a l o n g the e d g e s a n d a c r o s s the c e n t e r a s s h o w n .
If the block is to b e r e b o r e d , refer to s t e p 12 after
reboring. Engine Block Warpage
Cylinder Bore S i z e S e r v i c e Limit: 0.10 m m (0.004 in.)
Standard (New)
A or I: 8 7 . 0 1 0 - 8 7 . 0 2 0 m m ( 3 . 4 2 5 6 - 3 . 4 2 6 0 in.)
B or II: 8 7 . 0 0 0 - 8 7 . 0 1 0 m m ( 3 . 4 2 5 2 - 3 . 4 2 5 6 in.)
Oversize
0.25: 8 7 . 2 5 0 - 8 7 . 2 6 0 m m ( 3 . 4 3 5 0 - 3 . 4 3 5 4 in.)
Reboring Limit: 0.25 m m (0.01 in.) m a x .
Bore Taper
L i m i t : (Difference b e t w e e n first a n d t h i r d
m e a s u r e m e n t ) 0.05 m m (0.002 in.) PRECISION STRAIGHT EDGE
6 m m (0.2 in.)
No. 4 No. 1
7-14
Cylinder Bore Honing
12. C a l c u l a t e t h e difference b e t w e e n t h e c y l i n d e r bore T h e c y l i n d e r l i n e r s a r e m a d e w i t h F R M (fiber r e i n f o r c e d

d i a m e t e r a n d the p i s t o n d i a m e t e r . If t h e c l e a r a n c e m e t a l ) . H o n e the c y l i n d e r s o n l y a s d e s c r i b e d h e r e .
is n e a r or e x c e e d s t h e s e r v i c e limit, i n s p e c t the
p i s t o n a n d e n g i n e block for e x c e s s i v e w e a r . 1. M e a s u r e t h e c y l i n d e r b o r e s ( s e e p a g e 7-13). If the
e n g i n e block is to b e r e u s e d , h o n e t h e c y l i n d e r s
Piston-to-Cylinder Clearance a n d r e m e a s u r e t h e b o r e s . S c o r e d or s c r a t c h e d
S t a n d a r d (New): 0.004—0.027 m m c y l i n d e r b o r e s m u s t be h o n e d .
( 0 . 0 0 0 2 - 0 . 0 0 1 1 in.)
S e r v i c e Limit: 0 . 0 0 4 m m (0.0002 in.) 2 . H o n e the c y l i n d e r s u s i n g the f o l l o w i n g e q u i p m e n t ,
materials and methods:
S E R V I C E LIMIT
0 . 0 4 m m ( 0 . 0 0 2 in.)
• U s e o n l y a rigid h o n e .
• H o n i n g s t o n e s : G C - 6 0 0 - J or f i n e r s t o n e s for
nonferrous metals
2
• P r e s s u r e : 2 0 0 — 3 0 0 k P a ( 2 — 3 k g f / c m , 2 8 — 4 3 psi)
• Honing rpm: 45—50
• H o n i n g t h i c k n e s s : L e s s t h a n 0.02 m m (0.0008 in.)
D o not h o n e m o r e t h a n 2 0 c y c l e s .
• H o n i n g lubricant: Oil t y p e
• H o n i n g pattern: 6 0 d e g r e e c r o s s - h a t c h (A)
• H o n e c l e a n i n g : C l e a n t h e s t o n e s e v e r y five c y c l e s .
W h e n h o n i n g is c o m p l e t e , t h o r o u g h l y c l e a n the
e n g i n e block of all m e t a l p a r t i c l e s . W a s h the
c y l i n d e r b o r e s w i t h hot s o a p y w a t e r , t h e n dry a n d
oil t h e m i m m e d i a t e l y to p r e v e n t r u s t i n g . N e v e r u s e
s o l v e n t , it will o n l y redistribute t h e grit o n the
cylinder walls.
If s c o r i n g or s c r a t c h e s a r e still p r e s e n t in the
c y l i n d e r b o r e s after h o n i n g to t h e s e r v i c e limit,
r e b o r e the c y l i n d e r s . S o m e light v e r t i c a l s c o r i n g
a n d s c r a t c h i n g is a c c e p t a b l e if it is not d e e p e n o u g h
to c a t c h y o u r fingernail a n d if it d o e s not run the full
length of the bore.
7-15
Engine Block
Piston, Pin, and Connecting Rod Replacement
Disassembly 4. Heat t h e p i s t o n a n d c o n n e c t i n g rod a s s e m b l y to

a b o u t 158 °F (70 * € ) , t h e n r e m o v e the piston pin.
1. R e m o v e the piston f r o m t h e e n g i n e block ( s e e p a g e
7-10).
2. A p p l y n e w e n g i n e oil to the p i s t o n pin s n a p

r i n g s (A), a n d turn t h e m in the ring g r o o v e s until
t h e e n d g a p s a r e lined u p w i t h t h e c u t o u t s in t h e
p i s t o n pin b o r e s (B).
N O T E : T a k e c a r e not to d a m a g e the ring g r o o v e s .
3. R e m o v e both s n a p r i n g s ( A ) . S t a r t at t h e cutout in
the p i s t o n pin b o r e . R e m o v e t h e s n a p r i n g s
c a r e f u l l y s o t h e y d o not g o flying or get lost. W e a r
e y e protection.
7-16
Inspection 3 . C h e c k the d i f f e r e n c e b e t w e e n the p i s t o n pin
d i a m e t e r a n d p i s t o n p i n h o l e d i a m e t e r in t h e p i s t o n .
N O T E : I n s p e c t the p i s t o n , piston p i n , a n d c o n n e c t i n g
rod w h e n t h e y a r e at r o o m t e m p e r a t u r e . Piston Pin-to-Piston Clearance
Standard (New): —0.002 to + 0 . 0 0 5 m m
1. M e a s u r e the d i a m e t e r of the p i s t o n pin. ( - 0 . 0 0 0 0 8 t o + 0 . 0 0 0 2 0 in.)
Service Limit: 0 . 0 1 0 m m (0.0004 in.)
P i s t o n Pin D i a m e t e r
S t a n d a r d (New): 22.961—22.965 m m
( 0 . 9 0 4 0 - 0 . 9 0 4 1 in.)
S e r v i c e Limit: 2 2 . 9 5 3 m m (0.9037 in.)
4 . M e a s u r e t h e p i s t o n p i n - t o - c o n n e c t i n g rod c l e a r a n c e .
N O T E : W h e n replacing the connecting rod, also

2 . Z e r o the dial i n d i c a t o r to the piston pin d i a m e t e r . r e p l a c e the p i s t o n pin a s a s e t .
Piston Pin-to-Connecting Rod Clearance

S t a n d a r d (New): 0.018—0.035 m m
( 0 . 0 0 0 7 - 0 . 0 0 1 4 in.)
(cont'd)
7-17
Engine Block
Piston, Pin, and Connecting Rod Replacement (cont'd)
Reassembly 4. Install the p i s t o n pin (A). A s s e m b l e the p i s t o n (B)

a n d c o n n e c t i n g rod (C) w i t h the " I N " m a r k (D) a n d
1. Install a n e w piston pin s n a p ring (A) o n l y o n o n e the r e f e r e n c e m a r k (E) o n the s a m e s i d e .
side.
2. C o a t the piston pin b o r e in t h e piston a n d t h e

c o n n e c t i n g r o d , a n d the p i s t o n pin w i t h n e w e n g i n e
oil.
3. Heat the p i s t o n to a b o u t 158 °F (70
5. Install the r e m a i n i n g n e w s n a p ring (F).
6. T u r n the s n a p r i n g s in the ring g r o o v e s until the

e n d g a p s a r e p o s i t i o n e d at the bottom of the p i s t o n .
7-18
Piston Ring Replacement
1. R e m o v e the p i s t o n f r o m the e n g i n e block ( s e e p a g e 4. U s i n g a p i s t o n , p u s h a n e w ring (A) into the
7-10). c y l i n d e r b o r e 1 5 — 2 0 m m (0.6—0.8 in.) f r o m t h e
bottom.
2. U s i n g a ring e x p a n d e r (A), r e m o v e the old piston
rings (B).
5. M e a s u r e the p i s t o n ring e n d - g a p (B) w i t h a f e e l e r

3. C l e a n all ring g r o o v e s t h o r o u g h l y w i t h a s q u a r e d - gauge:
off b r o k e n ring or ring g r o o v e c l e a n e r w i t h a b l a d e
that fits the piston g r o o v e s . T h e top a n d s e c o n d • If the g a p is too s m a l l , c h e c k to s e e if y o u h a v e
ring g r o o v e s a r e 1.2 m m (0.05 in.) w i d e . T h e oil ring the proper r i n g s for y o u r e n g i n e .
g r o o v e is 2.0 m m (0.08 in.) w i d e . File d o w n a b l a d e • If the g a p is too large, r e c h e c k the c y l i n d e r b o r e
if n e c e s s a r y . Do not u s e a w i r e b r u s h to c l e a n the d i a m e t e r a g a i n s t the w e a r limits ( s e e p a g e 7-13)
ring g r o o v e s , or cut the ring g r o o v e s d e e p e r w i t h If the bore is o v e r the s e r v i c e limit, the e n g i n e
the c l e a n i n g t o o l s . block m u s t be r e b o r e d .
N O T E : If the piston is to be s e p a r a t e d f r o m the Piston Ring E n d - G a p

c o n n e c t i n g r o d , d o not install n e w r i n g s yet. T o p Ring:
S t a n d a r d (New): 0.25—0.35 m m
( 0 . 0 1 0 - 0 . 0 1 4 in.)
S e c o n d Ring:
S t a n d a r d (New): 0.60—0.75 m m
( 0 . 0 2 4 - 0 . 0 3 0 in.)
Oil Ring:
S t a n d a r d (New): 0.20—0.70 m m
( 0 . 0 0 8 - 0 . 0 2 8 in.)
(cont'd)
7-19
Engine Block
Piston Ring Replacement (cont'd)
6 . Install t h e r i n g s a s s h o w n . T h e top ring (A) h a s a R 1 7. Rotate t h e r i n g s in their g r o o v e s to m a k e s u r e t h e y

m a r k a n d t h e s e c o n d ring (B) h a s a R 2 m a r k . T h e d o not b i n d .
m a n u f a c t u r i n g m a r k s (C) m u s t be f a c i n g u p w a r d .
8 . P o s i t i o n t h e ring e n d g a p s a s s h o w n :
About 90 °
P I S T O N PIN
9 . After installing a n e w s e t of r i n g s , m e a s u r e the

ring-to-groove c l e a r a n c e s :
N O T E : After t h e i n s p e c t i o n , m a k e s u r e e a c h ring i s
in p r o p e r position a s s t e p 8 .
T o p Ring Clearance
S t a n d a r d (New): 0.045—0.090 m m
( 0 . 0 0 1 8 - 0 . 0 0 3 5 in.)
Second Ring Clearance

S t a n d a r d (New): 0.040—0.070 m m
( 0 . 0 0 1 6 - 0 . 0 0 2 8 in.)
Piston Ring Dimensions:
I f~ T o p Ring (Standard):
n A : 2 . 8 m m (0.11 in.)
" B : 1.2 m m (0.05 in.)
S e c o n d Ring (Standard):
A : 3 . 2 m m (0.13 in.)
« * B : 1.2 m m (0.05 in.)
7-20
Piston Installation
If the Crankshaft is Already Installed 7. C h e c k t h e c o n n e c t i n g rod b e a r i n g c l e a r a n c e w i t h

p l a s t i g a u g e ( s e e p a g e 7-8).
1. S e t the c r a n k s h a f t to b o t t o m d e a d c e n t e r ( B D C ) for
each cylinder. 8. A p p l y n e w e n g i n e oil to t h e t h r e a d s of t h e
c o n n e c t i n g rod bolts.
2. A p p l y n e w e n g i n e oil to t h e p i s t o n , i n s i d e the ring
c o m p r e s s o r , a n d the c y l i n d e r b o r e . T h e n attach the 9. Install t h e rod c a p s w i t h b e a r i n g s , t h e n tighten the
ring c o m p r e s s o r to the p i s t o n . c o n n e c t i n g rod bolts is s e q u e n c e to 2 5 N-m
(2.5 kgf-m, 18 Ibfft).
3. R e m o v e t h e c o n n e c t i n g rod c a p s , t h e n c h e c k that
the b e a r i n g is s e c u r e l y in p l a c e . 10. T i g h t e n t h e c o n n e c t i n g rod bolts a n a d d i t i o n a l 90 °.
4. Position t h e a r r o w (A) f a c i n g t h e c a m c h a i n s i d e of
the e n g i n e .
5. P o s i t i o n t h e piston in t h e c y l i n d e r , a n d t a p it in
u s i n g t h e w o o d e n h a n d l e of a h a m m e r (A).
M a i n t a i n d o w n w a r d f o r c e o n t h e ring c o m p r e s s o r
(B) to p r e v e n t the rings f r o m e x p a n d i n g before
entering the cylinder bore.
6. S t o p after t h e ring c o m p r e s s o r p o p s f r e e , a n d
c h e c k t h e c o n n e c t i n g rod-to-crank j o u r n a l
a l i g n m e n t before p u s h i n g t h e piston into p l a c e .
(cont'd)
7-21
Engine Block
Piston Installation (cont'd)
If the Crankshaft is Not Installed
1. A p p l y n e w e n g i n e oil to t h e p i s t o n , i n s i d e t h e ring
c o m p r e s s o r , a n d the cylinder bore. T h e n attach the
ring c o m p r e s s o r to t h e p i s t o n .
2 . R e m o v e t h e c o n n e c t i n g rod c a p s , t h e n c h e c k t h a t
t h e b e a r i n g i s s e c u r e l y in p l a c e .
3 . P o s i t i o n t h e a r r o w (A) f a c i n g t h e c a m c h a i n s i d e of
the engine.
4 . P o s i t i o n t h e p i s t o n in t h e c y l i n d e r , a n d t a p it in
u s i n g t h e w o o d e n h a n d l e of a h a m m e r (A).
M a i n t a i n d o w n w a r d f o r c e o n t h e ring c o m p r e s s o r
(B) to p r e v e n t t h e r i n g s f r o m e x p a n d i n g b e f o r e
entering the cylinder bore.
5 . P o s i t i o n all p i s t o n s at t o p d e a d c e n t e r .
7-22
Crankshaft Installation
Special Tools Required 12. T i g h t e n t h e c o n n e c t i n g rod bolts in s e q u e n c e to

• H a n d l e driver 0 7 7 4 9 - 0 0 1 0 0 0 0 2 5 N-m (2.5 k g f - m , 18 Ibfft).
• Driver a t t a c h m e n t 0 7 9 4 8 - S B 0 0 1 0 1
13. T i g h t e n t h e c o n n e c t i n g rod bolts a n a d d i t i o n a l 9 0 °.
1. R e m o v e all of the old liquid g a s k e t f r o m t h e l o w e r
block m a t i n g s u r f a c e s , bolt, a n d bolt h o l e s . 14. A p p l y liquid g a s k e t , P/N 0 8 7 1 7 - 0 0 0 4 , 0 8 7 1 8 - 0 0 0 1 ,
0 8 7 1 8 - 0 0 0 3 , o r 0 8 7 1 8 - 0 0 0 9 , e v e n l y to t h e e n g i n e
2. C l e a n the l o w e r block m a t i n g s u r f a c e s . block m a t i n g s u r f a c e of t h e l o w e r block.
3. C h e c k t h e c o n n e c t i n g rod b e a r i n g c l e a r a n c e w i t h N O T E : D o not install t h e p a r t s if 5 m i n u t e s or m o r e

p l a s t i g a u g e ( s e e p a g e 7-8). h a v e e l a p s e d s i n c e a p p l y i n g liquid g a s k e t . I n s t e a d ,
r e a p p l y liquid g a s k e t after r e m o v i n g old t h e
4. C h e c k t h e m a i n b e a r i n g c l e a r a n c e w i t h p l a s t i g a u g e residue.
( s e e p a g e 7-6).
5. Install t h e b e a r i n g h a l v e s in the e n g i n e block a n d

connecting rods.
6. A p p l y n e w e n g i n e oil to t h e m a i n b e a r i n g s a n d rod
bearings.
7. Hold the c r a n k s h a f t s o rod j o u r n a l No. 2 a n d rod

j o u r n a l No. 3 a r e straight u p , a n d l o w e r t h e
c r a n k s h a f t into t h e e n g i n e block.
8. Install t h e t h r u s t w a s h e r s (A) o n both e d g e s of t h e

No. 4 m a i n b e a r i n g r e c e s s .
A p p l y liquid gasket along

t h e broken line.
9. A p p l y n e w e n g i n e oil to t h e t h r e a d s of t h e
c o n n e c t i n g rod bolts.
10. S e a t t h e rod j o u r n a l s into c o n n e c t i n g rod No. 1 a n d

c o n n e c t i n g rod No. 4. Install t h e c o n n e c t i n g rod
c a p s a n d bolts finger-tight. Install the c a p s s o the
b e a r i n g r e c e s s is o n t h e s a m e s i d e a s t h e r e c e s s in
the r o d .
11. Rotate t h e c r a n k s h a f t c l o c k w i s e , a n d s e a t t h e
j o u r n a l s into c o n n e c t i n g rod No. 2 a n d c o n n e c t i n g
rod N o . 3. Install the c o n n e c t i n g rod c a p s a n d bolts
finger-tight.
(cont'd)
7-23
Engine Block
Crankshaft Installation (cont'd)
15. Put t h e l o w e r block o n t h e e n g i n e block. 18. T i g h t e n t h e 8 m m bolts in s e q u e n c e to 22 N-m

(2.2 kgf-m, 16 Ibf-ft).
16. T i g h t e n t h e b e a r i n g c a p bolts is s e q u e n c e to
® . ® ®
2 9 N-m (3.0 kgf-m, 22 Ibf-ft).
® ® © ® ®
® © ®. ® 19. U s e t h e h a n d l e d r i v e r a n d d r i v e r a t t a c h m e n t to
d r i v e a n e w oil s e a l s q u a r e l y into t h e block to t h e
17. T i g h t e n t h e b e a r i n g c a p bolts a n a d d i t i o n a l 60 °. s p e c i f i e d i n s t a l l e d height.
60°
07749-0010000
07948-SB00101
7-24
Oil Pan Installation
20. M e a s u r e the d i s t a n c e b e t w e e n t h e c r a n k s h a f t (A) 1. R e m o v e a n y o l d liquid g a s k e t f r o m t h e oil p a n
a n d oil s e a l (B). m a t i n g s u r f a c e s , b o l t s , a n d bolt h o l e s .
Oil S e a l Installed Height: 5.5—6.5 mm 2. C l e a n a n d d r y the oil p a n m a t i n g s u r f a c e s .

( 0 . 2 2 - 0 . 2 6 in.)
3. A p p l y liquid g a s k e t , P/N 08717-0004,08718-0001,
5.5—6.5 m m
( 0 . 2 2 - 0 . 2 6 in.)
0 8 7 1 8 - 0 0 0 3 , o r 0 8 7 1 8 - 0 0 0 9 , e v e n l y to t h e e n g i n e
block m a t i n g s u r f a c e of t h e oil p a n . Install t h e oil
pan.
N O T E : D o not install t h e p a r t s if 5 m i n u t e s o r m o r e
r e a p p l y liquid g a s k e t after r e m o v i n g t h e o l d
residue.
2 1 . Install t h e oil p u m p ( s e e s t e p 12 o n p a g e 8-13).
2 2 . Install t h e c a m c h a i n ( s e e p a g e 6-15).
A p p l y liquid g a s k e t
along t h e broken line.
4. T i g h t e n t h e bolts in t h r e e s t e p s . In the final s t e p ,

tighten all b o l t s , in s e q u e n c e , to 12 N-m (1.2 kgf-m,
8.7 Ibfft).
® ® © <D
5. After a s s e m b l y , w a i t at l e a s t 30 m i n u t e s before
filling t h e e n g i n e w i t h oil.
7-25
Engine Block
Pulley End Crankshaft Oil Seal Transmission End Crankshaft Oil
Installation - In Car Seal Installation - In Car
Special Tools Required Special Tools Required

S e a l d r i v e r 0 7 L A D - P T 3 0 1 OA • Handle driver 07749-0010000
• Driver attachment 07948-SB00101
1. C l e a n a n d d r y t h e c r a n k s h a f t oil s e a l h o u s i n g .
1. C l e a n a n d d r y t h e c r a n k s h a f t oil s e a l h o u s i n g .
2. U s i n g t h e s e a l d r i v e r , d r i v e in t h e c r a n k s h a f t oil s e a l
until t h e d r i v e r b o t t o m s a g a i n s t the c h a i n c a s e . 2. U s e t h e h a n d l e d r i v e r a n d d r i v e r a t t a c h m e n t to
d r i v e a n e w oil s e a l s q u a r e l y into t h e b l o c k to t h e
07LAD-PT3010A
s p e c i f i e d i n s t a l l e d height.
3. M e a s u r e t h e d i s t a n c e b e t w e e n t h e c r a n k s h a f t (A)
a n d oil s e a l (B).
Oil S e a l Installed Height: 5.5—6.5 m m

( 0 . 2 2 - 0 . 2 6 in.)
5.5—6.5 m m
( 0 . 2 2 - 0 . 2 6 in.)
7-26
Drain Bolt Installation
N O T E : W h e n installing t h e d r a i n bolt, a l w a y s u s e a n e w
washer.
2 8 x 1.0 m m
8 3 N-m
(8.5 k g f - m , 61 Ibf-ft)
7-27
Engine Mechanical
Engine Lubrication
Special Tools 8-2
Symptom Troubleshooting Index 8-4
Oil Pressure Switch Test 8-5
Oil Pressure Switch Replacement 8-5
Oil Pressure Test 8-6
Engine Oil Replacement 8-6
Engine Oil Filter Replacement 8-7
Oil Cooler Center Bolt/Oil Cooler Replacement 8-8
Oil Jet Replacement 8-9
OilJetInspection 8-9
Oil Pump Overhaul 8-10
Engine Lubrication
Special Tools

® 07912-6110001 Oil Filter W r e n c h 1
8-2
OIL P A N
R e m o v a l , p a g e 7-10
Installation, p a g e 7-25
BAFFLE PLATE
WASHER
DRAIN BOLT
OIL PUMP
O v e r h a u l , p a g e 8-10
OIL J E T
ENGINE OIL C O O L E R
ENGINE OIL COOLER

CENTER BOLT
OIL FILTER
ENGINE OIL P R E S S U R E SWITCH

CHAIN CASE
Circuit Diagram
'00-03 m o d e l s , page 22-63
'04-05 m o d e l s , page 22-68
'06-08 m o d e l s , page 22-73
S w i t c h T e s t , p a g e 8-5
S w i t c h R e p l a c e m e n t , p a g e 8-5
O i l P r e s s u r e T e s t , p a g e 8-6
Engine Lubrication

E x c e s s i v e e n g i n e oil c o n s u m p t i o n 1. V e r i f y t h e e n g i n e oil filler c a p , oil d r a i n bolt, a n d
oil filter a r e tight.
2. C h e c k f o r oil l e a k s .
3. C h e c k f o r w o r n v a l v e g u i d e ( s ) ( s e e p a g e 6-43) or
w o r n v a l v e s t e m s e a l ( s ) ( s e e p a g e 6-43).
4. C h e c k f o r d a m a g e d or w o r n p i s t o n ring(s)
( s e e p a g e 7-19).
5. C h e c k f o r d a m a g e d o r w o r n e n g i n e internal parts
( c y l i n d e r w a l l , p i s t o n s , etc.).
L o w oil p r e s s u r e i n d i c a t o r d o e s not 1. ' 0 6 - 0 8 m o d e l s : D o t h e g a u g e a s s e m b l y self- A n o p e n in the
c o m e o n w i t h t h e ignition s w i t c h d i a g n o s t i c f u n c t i o n ( s e e p a g e 22-60). wire between the
O N (II) 2. T e s t the oil p r e s s u r e s w i t c h ( s e e p a g e 8-5). gauge assembly
a n d t h e oil
pressure switch
L o w oil p r e s s u r e i n d i c a t o r s t a y s o n 1. C h e c k t h e e n g i n e oil l e v e l . A w i r e s h o r t e d to
2. ' 0 6 - 0 8 m o d e l s : D o t h e g a u g e a s s e m b l y self- ground between
d i a g n o s t i c f u n c t i o n ( s e e p a g e 22-60). the gauge
3. T e s t t h e oil p r e s s u r e s w i t c h ( s e e p a g e 8-5). a s s e m b l y and the
4. C h e c k t h e e n g i n e oil p r e s s u r e ( s e e p a g e 8-6). oil p r e s s u r e s w i t c h
5. C h e c k t h e oil filter for c l o g g i n g .
6. C h e c k t h e oil s c r e e n for c l o g g i n g .
7. C h e c k t h e relief v a l v e .
8. C h e c k t h e oil p u m p ( s e e p a g e 8-12).
8-4
Oil Pressure Switch Test Oil Pressure Switch Replacement
1. R e m o v e the w i r e (A) f r o m the e n g i n e oil p r e s s u r e 1. R e m o v e t h e w i r e f r o m t h e oil p r e s s u r e s w i t c h , t h e n

s w i t c h (B). r e m o v e t h e oil p r e s s u r e s w i t c h .
2 . R e m o v e a n y old liquid g a s k e t f r o m the s w i t c h a n d

2 . C h e c k for continuity b e t w e e n the p o s i t i v e t e r m i n a l switch mounting hole.
(C) a n d the e n g i n e (ground). T h e r e s h o u l d be
continuity w i t h the e n g i n e s t o p p e d . T h e r e s h o u l d 3. A p p l y a v e r y s m a l l a m o u n t of liquid g a s k e t to the
be no continuity w i t h t h e e n g i n e r u n n i n g . oil p r e s s u r e s w i t c h t h r e a d s , t h e n install the oil
pressure switch.
3. If the s w i t c h fails to o p e r a t e , c h e c k the e n g i n e oil
l e v e l . If the e n g i n e oil level is O K , c h e c k the e n g i n e N O T E : U s i n g too m u c h liquid g a s k e t m a y c a u s e
oil p r e s s u r e ( s e e p a g e 8-6). liquid g a s k e t to e n t e r t h e oil p a s s a g e or the e n d of
the n e w oil p r e s s u r e s w i t c h .
8-5
Engine Lubrication
Oil Pressure Test Engine Oil Replacement

If t h e oil p r e s s u r e i n d i c a t o r s t a y s o n w i t h t h e e n g i n e 1. W a r m up the e n g i n e .
r u n n i n g , c h e c k the e n g i n e oil l e v e l . If the oil level is
correct: 2. R e m o v e the d r a i n bolt (A), a n d d r a i n the e n g i n e oil.
1. R e m o v e the e n g i n e oil p r e s s u r e s w i t c h , a n d install

a n oil p r e s s u r e g a u g e (A).
3 9 N - m (4.0 kgf m , 2 9 Ibf-ft)

D o not overtighten.
3. R e i n s t a l l the d r a i n bolt w i t h a n e w w a s h e r (B).
4. Refill w i t h the r e c o m m e n d e d oil.

2. Start the e n g i n e . S h u t it off i m m e d i a t e l y if t h e
g a u g e r e g i s t e r s n o oil p r e s s u r e . R e p a i r the p r o b l e m Capacity
before c o n t i n u i n g . At Oil C h a n g e :
4.5 L (4.8 U S qt)
3. A l l o w the e n g i n e to r e a c h o p e r a t i n g t e m p e r a t u r e A t O i l C h a n g e i n c l u d i n g Filter:
(fan c o m e s o n at l e a s t t w i c e ) . T h e p r e s s u r e s h o u l d 4.8 L (5.1 U S qt)
be: After E n g i n e O v e r h a u l :
5.6 L (5.9 U S qt)
E n g i n e O i l T e m p e r a t u r e : 176 ° F ( 8 0 * 0
Engine Oil P r e s s u r e : 5. R u n the e n g i n e for m o r e t h a n 3 m i n u t e s , t h e n c h e c k
2
A t Idle: 2 5 0 k P a (2.5 k g f / c m , 3 6 psi) m i n . for oil l e a k a g e .
2
A t 3,000 r p m : 5 9 0 k P a (6.0 k g f / c m , 8 5 psi) m i n .
4. If oil p r e s s u r e i s out of s p e c i f i c a t i o n s , i n s p e c t t h e s e
items:
• I n s p e c t the oil p r e s s u r e relief v a l v e ( s e e p a g e

8-10).
• C h e c k the oil filter for c l o g g i n g .
• I n s p e c t the oil p u m p ( s e e p a g e 8-12).
8-6
Engine Oil Filter Replacement
M a i n t e n a n c e M i n d e r R e s e t ('06-08 m o d e l s ) Special Tools Required
Oil filter w r e n c h 0 7 9 1 2 - 6 1 1 0 0 0 1
6. C o n n e c t the H o n d a D i a g n o s t i c S y s t e m ( H D S ) to the
d a t a link c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e 1. R e m o v e the oil filter w i t h t h e oil fiIter w r e n c h .
11-213).
2. I n s p e c t the t h r e a d s (A) a n d r u b b e r s e a l (B) o n the
7. T u r n the ignition s w i t c h to O N (II). n e w filter. W i p e off t h e s e a t o n t h e e n g i n e block,
t h e n a p p l y a light c o a t of n e w e n g i n e oil to the filter
8. M a k e s u r e the H D S c o m m u n i c a t e s w i t h t h e v e h i c l e r u b b e r s e a l . U s e o n l y filters w i t h a built-in b y p a s s
a n d t h e e n g i n e control m o d u l e ( E C M ) . If it d o e s n ' t system.
c o m m u n i c a t e , t r o u b l e s h o o t the D L C circuit
( s e e p a g e 11-367).
9. S e l e c t B O D Y E L E C T R I C A L w i t h t h e H D S .
10. S e l e c t A D J U S T M E N T in the G A U G E S M E N U w i t h
the H D S .
11. S e l e c t R E S E T in the M A I N T E N A N C E M I N D E R w i t h
the HDS.
12. S e l e c t R E S E T T I N G T H E E N G I N E O I L L I F E w i t h the
HDS.
N O T E : If y o u c h a n g e d the M T F at t h e s a m e t i m e
w i t h t h e e n g i n e oil, s e l e c t R E S E T T I N G T H E E N G I N E 3. Install t h e oil filter b y h a n d .
O I L L I F E A N D M T F w i t h the H D S i n s t e a d .
4. After the rubber s e a l s e a t s , tighten t h e oil filter
13. R e s e t t h e m a i n t e n a n c e information d i s p l a y c l o c k w i s e w i t h the oil filter w r e n c h .
( s e e p a g e 3-27).
Tighten: 7/8 Turn Clockwise
Tightening Torque: 2 2 N m (2.2 k g f - m , 16 Ibfft)
(cont'd)
8-7
Engine Lubrication
Engine Oil Filter Replacement Oil Cooler Center Bolt/Oil Cooler
(cont'd) Replacement
5. If e i g h t n u m b e r s (1 to 8) are printed a r o u n d t h e 1. R e m o v e t h e oil filter ( s e e p a g e 8-7).

o u t s i d e of t h e filter, u s e the f o l l o w i n g p r o c e d u r e to
t i g h t e n t h e filter. 2. D i s c o n n e c t t h e w a t e r b y p a s s h o s e s .
• S p i n t h e filter o n until its s e a l lightly s e a t s a g a i n s t 3. R e m o v e t h e oil c o o l e r c e n t e r bolt (A) a n d oil c o o l e r

t h e e n g i n e oil c o o l e r , a n d note w h i c h n u m b e r i s (B).
at t h e bottom.
• T i g h t e n t h e filter b y turing it c l o c k w i s e s e v e n
n u m b e r s f r o m t h e o n e y o u n o t e d . F o r e x a m p l e , if
n u m b e r 2 i s at t h e bottom w h e n t h e s e a l i s lightly
s e a t e d , tighten t h e filter until t h e n u m b e r 1
c o m e s a r o u n d t h e bottom.
4. A p p l y n e w e n g i n e oil to n e w O-ring (C).
5. Install t h e oil c o o l e r . T i g h t e n t h e oil c o o l e r c e n t e r

bolt to t h e e n g i n e block.
N u m b e r w h e n rubber N u m b e r after t i g h t e n i n g ,
s e a l is s e a t e d .
6. C o n n e c t t h e w a t e r b y p a s s h o s e s .
7. Install t h e n e w oil filter ( s e e p a g e 8-7).

Number when 1 2 3 4 5 6 7 8
rubber seal is
seated
N u m b e r after 8 1 2 3 4 5 6 7
tightening
6. After installation, fill t h e e n g i n e w i t h t h e

r e c o m m e n d e d oil up to t h e s p e c i f i e d l e v e l , run t h e
e n g i n e for m o r e t h a n 3 m i n u t e s , t h e n c h e c k for oil
leakage.
8-8
Oil Jet Replacement Oil Jet Inspection
1. R e m o v e the c r a n k s h a f t f r o m the e n g i n e block 1. R e m o v e the oil jet, a n d i n s p e c t it a s f o l l o w s .

( s e e p a g e 7-10).
• M a k e s u r e t h a t a 1.5 m m (0.059 in.) d i a m e t e r drill
2. R e m o v e the oil jet bolt (A) a n d oil jet (B). will g o t h r o u g h t h e nozzle h o l e (A) (1.6 m m
(0.062 in.) d i a m e t e r ) .
• Insert the e n d of a 1.1 m m (0.043 in.) drill into t h e
oil intake (1.2 m m (0.047 in.) d i a m e t e r ) .
• M a k e s u r e t h e c h e c k ball (B) m o v e s s m o o t h l y a n d
h a s a s t r o k e of a p p r o x i m a t e l y 4.0 m m (0.16 in.).
• C h e c k the oil jet o p e r a t i o n w i t h a n air nozzle. It
2
s h o u l d take at l e a s t 200 kPa (2.0 k g f / c m , 2 8 psi)
to u n s e a t t h e c h e c k ball.
N O T E : R e p l a c e t h e oil jet a s s e m b l y if the nozzle is

d a m a g e d or bent.
3. C a r e f u l l y install t h e oil jet a n d tighten the oil jet bolt.
4. Install the c r a n k s h a f t ( s e e p a g e 7-10).
2. T h e m o u n t i n g t o r q u e is critical. B e v e r y p r e c i s e
w h e n installing t h e oil jet.
T o r q u e : 16 N-m (1.6 kgf-m, 12 Ibf-ft)
8-9
Engine Lubrication
Oil Pump Overhaul
Exploded View
PUMP COVER
D O W E L PINS (1.2 k g f - m , 8.7 Ibf-ft)
8-10
(cont'd)
8-11
Engine Lubrication
Oil Pump Overhaul (cont'd)
Inspection 9 . C h e c k t h e h o u s i n g - t o - o u t e r rotor radial c l e a r a n c e
b e t w e e n the outer rotor (A) a n d p u m p h o u s i n g (B).
6 . R e m o v e t h e bolts f r o m t h e p u m p h o u s i n g , t h e n If t h e h o u s i n g - t o - o u t e r rotor radial c l e a r a n c e
separate the p u m p housing a n d the p u m p c o v e r . e x c e e d s the s e r v i c e limit, r e p l a c e t h e oil p u m p
assembly.
7. C h e c k t h e inner-to-outer rotor radial c l e a r a n c e
b e t w e e n t h e i n n e r rotor (A) a n d outer rotor ( B ) . If Housing-to-Outer Rotor Radial Clearance
t h e i n n e r - t o - o u t e r rotor radial c l e a r a n c e e x c e e d s S t a n d a r d ( N e w ) : 0.15—0.21 m m
t h e s e r v i c e limit, r e p l a c e t h e oil p u m p a s s e m b l y . ( 0 . 0 0 6 - 0 . 0 0 8 in.)
Inner Rotor-to-Outer Rotor Radial Clearance
S t a n d a r d (New): 0.02—0.14 m m
( 0 . 0 0 1 - 0 . 0 0 6 in.)
10. I n s p e c t both rotors a n d the p u m p h o u s i n g for

s c o r i n g or o t h e r d a m a g e . R e p l a c e t h e oil p u m p
a s s e m b l y , if n e c e s s a r y .
8 . C h e c k the housing-to-rotor axial c l e a r a n c e between 11. C h e c k that the oil p u m p t u r n s f r e e l y .

t h e rotors (A) a n d p u m p h o u s i n g (B). If t h e h o u s i n g -
to-rotor a x i a l c l e a r a n c e e x c e e d s t h e s e r v i c e limit,
r e p l a c e t h e oil p u m p a s s e m b l y .
Housing-to-Rotor Axial Clearance

S t a n d a r d (New): 0.02—0.07 m m
( 0 . 0 0 1 - 0 . 0 0 3 in.)
8-12
Installation 14. T i g h t e n t h e bolts o n t h e oil p u m p .
8 x 1.25 m m
12. S q u e e z e t h e n e w oil p u m p c h a i n t e n s i o n e r (A), t h e n
22 N m
install t h e s e t clip (B) o n it a s s h o w n . (2.2 k g f - m , 1 6 I b f f t )
N O T E : T h e s e t clip i s s u p p l i e d with t h e oil p u m p 6x1.0 mm

12 N-m
chain tensioner. (1.2 k g f - m ,
8.7 I b f f t )
15. Install t h e baffle plate.

13. Install t h e c r a n k s h a f t s p r o c k e t (A), oil p u m p c h a i n
(B), a n d oil p u m p (C).
6 x 1.0 m m
12 N m
( 1 . 2 k g f m , 8.7 Ibf ft)
(cont'd)
8-13
Engine Lubrication
Oil Pump Overhaul (cont'd)
16. S e t t h e c r a n k s h a f t s p r o c k e t s o t h a t t h e N o . 1 p i s t o n 18. Install t h e oil p u m p c h a i n g u i d e (A) a n d oil p u m p

is at t o p d e a d c e n t e r ( T D C ) . A l i g n t h e k e y (A) o n t h e c h a i n t e n s i o n e r (B) w i t h t h e s e a t clip (C).
s p r o c k e t a n d c r a n k s h a f t w i t h t h e pointer (B) o n t h e
e n g i n e block. 6 x 1.0 m m
12 N-m
(1.2 k g f - m , 8.7 I b f f t )
^ 6 x 1.0 m m
1 2 N - m (1.2 k g f - m , 8.7 Ibf ft)
8x1.25 mm
2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
17. M o v e t h e c a m c h a i n s o that t h e c o l o r e d p i e c e (A)

a l i g n s w i t h t h e p u n c h m a r k (B) o n t h e c r a n k s h a f t 19. R e m o v e t h e s e t c l i p f r o m t h e oil p u m p c h a i n
sprocket. tensioner.
20. Install t h e c a m c h a i n ( s e e p a g e 6-15).
8 -14
Engine Mechanical
Intake Manifold and Exhaust System

Intake Manifold Removal and Installation 9-2
Exhaust Manifold Removal and Installation 9-4
Exhaust Pipe and Muffler Replacement 9-5
Intake Manifold Removal and Installation
'00-05 models
NOTE: U s e n e w O-rings and gaskets w h e n reassembling.
5 x 0.8 m m
6 N-m
(0.6 k g f - m , 4 Ibf-ft) AIR C O N T R O L V A L V E
8 x 1.25 m m 8 x 1.25 m m
22 N-m 22 N-m
(2.2 k g f - m (2.2 k g f - m , 1 6 Ibf-ft)
GASKET ENGINE COOLANT

Replace. T E M P E R A T U R E (ECT)
SENSOR
12 N - m
(1.2 k g f - m , 8.7 Ibf-ft)
O-RING
Replace.
WATER OUTLET
COVER
THROTTLE
BODY
6 x 1.0 m m
12 N - m
(1.2 k g f - m , 8.7 Ibf-ft)
8 x 1.25 m m IDLE AIR C O N T R O L

22 N m (IAC) V A L V E
(2.2 k g f - m , 1 6 Ibf-ft)
^10x1.25 m m
44 N-m
INTAKE MANIFOLD (4.5 k g f - m , 3 3 Ibf-ft)
BRACKETS
10 x 1.25 m m
44 N-m
(4.5 k g f - m , 3 3 Ibf-ft)
9-2
'06-08 models
N O T E : U s e n e w O-rings and gaskets w h e n reassembling.
MANIFOLD ABSOLUTE INTAKE MANIFOLD

P R E S S U R E (MAP) R e p l a c e if c r a c k e d o r
SENSOR if t h e m a t i n g s u r f a c e i s
damaged.
8 x 1.25 m m ENGINE COOLANT

22 N m T E M P E R A T U R E (ECT)
(2.2 k g f - m , 16 I b f f t ) SENSOR 1
12 N m
(1.2 k g f - m , 8.7 I b f f t )
GASKET
Replace.
INTAKE MANIFOLD
BRACKET
BLEED BOLT
9.8 N - m
(1.0 k g f - m , 7.2 I b f f t )
10 x 1.25 m m
44 N m
(4.5 k g f - m , 3 3 I b f f t )
8 x 1.25 m m
22 N m 6x1.0 mm
(2.2 k g f - m , 1 6 I b f f t ) 12 N - m
(1.2 k g f - m , 8.7 I b f f t )
THROTTLE BODY WATER OUTLET COVER
INTAKE MANIFOLD
BRACKET
9-
Exhaust Manifold Removal and Installation
N O T E : U s e n e w g a s k e t s a n d s e l f - l o c k i n g nuts w h e n r e a s s e m b l i n g .
CYLINDER HEAD
SIDE COVER
COVER
GASKET
Replace.
8 x 1.25 m m
22 N m
(2.2 k g f m , 1 6 I b f f t )
6x1.0 mm
12 N - m
(1.2 k g f - m , 8.7 I b f f t ) 6 x 1.0 m m
14 N - m
(1.4 k g f m , 10 I b f ft)
COVER
COVER
8x1.25 mm
22 N-m
(2.2 k g f - m , 1 6 I b f f t )
GASKET
Replace.
PRIMARY HEATED SELF-LOCKING NUT

OXYGEN SENSOR 8x1.25 mm
(PRIMARY H 0 2 S ) 31 N - m (3.2 k g f - m , 2 3 I b f f t )
('00-05 m o d e l s ) Replace.
4 4 N m (4.5 k g f m , 3 3 I b f f t )
AIR F U E L RATIO ( A / F ) EXHAUST MANIFOLD
S E N S O R ('06-08 m o d e l s )
4 4 N - m (4.5 k g f - m , 3 3 I b f f t )
EXHAUST MANIFOLD
1 0 x 1.25 m m BRACKET
44 N-m
(4.5 k g f - m , 3 3 I b f f t )
WASHERS
Make sure the smooth side
f a c e s the bracket.
9-4
Exhaust Pipe and Muffler Replacement
'00-03 models
N O T E : U s e n e w gaskets and self-locking nuts w h e n r e a s s e m b l i n g .
MUFFLER
6x1.0 mm
12 N m (1.2 k g f m , 8.7 Ibf-ft)
9-5
Exhaust Pipe and Muffler Replacement (cont'd)
'04-08 models
N O T E : U s e n e w g a s k e t s a n d s e l f - l o c k i n g nuts w h e n r e a s s e m b l i n g .
12 N m
(1.2 k g f m , 8.7 Ibf-ft)
9-6
Engine Cooling
Cooling System
Radiator Cap Test 10-6
Radiator Test 10-6
Fan Motor Test 10-7
Thermostat Test - 10-7
Water Pump Inspection 10-8
Water Pump Replacement 10-8
Coolant Replacement 10-9
Thermostat Replacement .. - 10-11
Radiator and Fan Replacement 10-12
Fan Controls
Circuit Diagram 10-16
Radiator Fan Circuit Troubleshooting 10-18
Radiator Fan Switch Circuit
Troubleshooting (Open) 10-22
Radiator Fan Switch Circuit
Troubleshooting (Short) 10-23
Radiator Fan Switch Test - 10-23
Radiator Fan Switch Replacement 10-24
Cooling System
S E N S O R 2 ('06-08 m o d e l s ) / / \ RADIATOR FAN SHROUD

/ / \ R e p l a c e m e n t , p a g e 10-12
LOWER RADIATOR HOSE A / C CONDENSER FAN SHROUD

RADIATOR FAN
10-2
'00-05 m o d e l s
IDLE AIR C O N T R O L
(IAC) V A L V E
(cont'd)
10-3
Cooling System
'06-08 m o d e l s
HEATER VALVE
10-4
ENGINE COOLANT TEMPERATURE
( E C T ) S E N S O R ('00-05 m o d e l s )
( E C T ) S E N S O R 1 ('06-08 m o d e l s )
WATER PUMP PULLEY
10-5
Cooling System
Radiator Cap Test Radiator Test
1. R e m o v e t h e radiator c a p (A), w e t its s e a l w i t h 1. W a i t until t h e e n g i n e is c o o l , t h e n c a r e f u l l y r e m o v e
e n g i n e c o o l a n t , t h e n install it o n t h e c o m m e r c i a l l y t h e radiator c a p a n d fill the radiator w i t h e n g i n e
a v a i l a b l e p r e s s u r e t e s t e r (B). c o o l a n t to the top of the filler neck.
2 . A t t a c h the c o m m e r c i a l l y a v a i l a b l e p r e s s u r e tester
(A) to t h e radiator a n d a p p l y a p r e s s u r e of 9 3 —
2
123 kPa ( 0 . 9 5 - 1 . 2 5 k g f / c m , 1 4 - 1 8 p s i ) .
2. A p p l y a p r e s s u r e of 9 3 — 1 2 3 k P a (0.95—
2
1.25 k g f / c m , 1 4 - 1 8 p s i ) .
3. C h e c k for a d r o p in p r e s s u r e .
4. If t h e p r e s s u r e d r o p s / r e p l a c e t h e c a p . 3. I n s p e c t for e n g i n e c o o l a n t l e a k s a n d a d r o p in
pressure.
4. R e m o v e t h e tester a n d reinstall the radiator c a p .
10-6
Fan Motor Test Thermostat Test
1. D i s c o n n e c t t h e 2 P c o n n e c t o r s f r o m the radiator f a n R e p l a c e t h e t h e r m o s t a t if it is o p e n at r o o m
m o t o r (A) a n d A / C c o n d e n s e r f a n m o t o r (B). temperature.
3 . If either m o t o r fails to run o r d o e s not run s m o o t h l y ,

r e p l a c e it ( s e e p a g e 1 0 - 1 2 ) . 2 . Heat the water a n d check the temperature with the
t h e r m o m e t e r . C h e c k the t e m p e r a t u r e w h e n t h e
t h e r m o s t a t first o p e n s , t h e n c h e c k t h e t e m p e r a t u r e
w h e n t h e t h e r m o s t a t is fully o p e n .
3 . M e a s u r e the lift height of t h e t h e r m o s t a t w h e n it is

fully o p e n .
Standard Thermostat
Lift H e i g h t : A b o v e 10.0 m m (0.39 in.)
S t a r t s O p e n i n g : 1 6 9 - 1 7 6 °F (76 - 8 0 °C)
Fully O p e n : 1941= ( 9 0 * 0
10-7
Cooling System
Water Pump Inspection Water Pump Replacement
1. L o o s e n t h e w a t e r p u m p p u l l e y bolts. 1. D r a i n t h e e n g i n e c o o l a n t ( s e e p a g e 10-9).
2. R e m o v e t h e d r i v e belt ( s e e p a g e 4-42). 2. L o o s e n t h e w a t e r p u m p p u l l e y b o l t s .
3. R e m o v e t h e w a t e r p u m p pulley. 3. R e m o v e t h e d r i v e belt ( s e e p a g e 4-42).
4. R e m o v e t h e w a t e r p u m p p u l l e y .
5. R e m o v e t h e s i x bolts t h e n r e m o v e t h e w a t e r p u m p
(A).
4. T u r n the w a t e r p u m p p u l l e y c o u n t e r c l o c k w i s e , a n d
m a k e s u r e it t u r n s f r e e l y . If it d o e s n ' t , r e p l a c e t h e
w a t e r p u m p ( s e e p a g e 10-8).
10x1.25 mm
N O T E : W h e n y o u c h e c k t h e w a t e r p u m p pulley, y o u 4 4 N - m (4.5 k g f - m , 3 3 I b f f t )
m a y s e e a s m a l l a m o u n t of " w e e p i n g " f r o m the
b l e e d h o l e s (A). T h i s is n o r m a l . 6. C l e a n a n d i n s p e c t t h e O - r i n g g r o o v e a n d t h e m a t i n g
s u r f a c e w i t h the t h e r m o s t a t h o u s i n g .
7. Install the w a t e r p u m p w i t h a n e w O - r i n g (B) in t h e

r e v e r s e o r d e r of r e m o v a l .
8. Refill the radiator w i t h e n g i n e c o o l a n t , t h e n b l e e d

t h e air f r o m t h e c o o l i n g s y s t e m ( s e e s t e p 7 o n p a g e
10-9).
9. C l e a n up a n y s p i l l e d e n g i n e c o o l a n t .
10-8
Coolant Replacement
1. S t a r t the e n g i n e . S e t t h e heater t e m p e r a t u r e control 5. After t h e c o o l a n t h a s d r a i n e d , a p p l y liquid g a s k e t ,
dial to m a x i m u m heat, t h e n turn t h e ignition s w i t c h P/N 0 8 7 1 8 - 0 0 0 9 , to t h e d r a i n bolt t h r e a d s , t h e n
to L O C K (0). M a k e s u r e the e n g i n e a n d radiator a r e reinstall t h e bolt w i t h a n e w w a s h e r a n d tighten it
c o o l to the t o u c h . securely.
2. R e m o v e t h e r a d i a t o r c a p . 6. T i g h t e n the radiator d r a i n p l u g s e c u r e l y .
3. L o o s e n t h e d r a i n plug (A), a n d d r a i n t h e c o o l a n t . 7. R e m o v e , d r a i n , a n d reinstall t h e c o o l a n t r e s e r v o i r .

Fill the c o o l a n t r e s e r v o i r to t h e M A X m a r k w i t h
H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2
(P/NOL999-9001).
8. R e m o v e t h e b l e e d c a p (A) f r o m t h e h e a t e r b y p a s s
tube.
4. R e m o v e t h e d r a i n bolt (A) f r o m the right s i d e of the

e n g i n e block.
(cont'd)
10-9
Cooling System
Coolant Replacement (cont'd)
9. L o o s e n t h e air b l e e d bolt (A) in t h e intake m a n i f o l d , 10. T i g h t e n t h e air b l e e d bolt a s s o o n a s c o o l a n t starts
t h e n p o u r H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e to run out in a s t e a d y s t r e a m .
2 into t h e radiator to t h e b o t t o m of t h e filler n e c k .
D o not let c o o l a n t s p i l l o n a n y e l e c t r i c a l p a r t s or t h e 11. R e i n s t a l l t h e b l e e d c a p o n t h e h e a t e r b y p a s s t u b e
paint. If a n y c o o l a n t s p i l l s , r i n s e it off i m m e d i a t e l y . a s s o o n a s c o o l a n t s t a r t s to run out in a s t e a d y
stream.
NOTE:
• A l w a y s u s e H o n d a L o n g Life A n t i f r e e z e / C o o l a n t 12. W i t h t h e radiator c a p off, start t h e e n g i n e a n d let it
T y p e 2 (P/N O L 9 9 9 - 9 0 0 T ) . U s i n g a n o n - H o n d a run until w a r m e d up (radiator f a n c o m e s o n at l e a s t
c o o l a n t c a n r e s u l t in c o r r o s i o n , c a u s i n g t h e t w i c e ) . T h e n , if n e c e s s a r y , a d d m o r e H o n d a L o n g
c o o l i n g s y s t e m to m a l f u n c t i o n or f a i l . Life A n t i f r e e z e / C o o l a n t T y p e 2 to bring the level
• H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2 is a b a c k up to t h e bottom of t h e filler n e c k .
m i x t u r e of 50 % antifreeze a n d 50 % w a t e r .
P r e m i x i n g is not r e q u i r e d . 13. Put the radiator c a p o n tightly, t h e n run the e n g i n e
a g a i n a n d c h e c k for l e a k s .
E n g i n e C o o l a n t Refill C a p a c i t i e s
( i n c l u d i n g r e s e r v e t a n k c a p a c i t y of 0.6 L (0.16 U S 14. C l e a n up a n y s p i l l e d e n g i n e c o o l a n t .
gal))
At Coolant Change: 6 . 5 L (1.72 U S gal) M a i n t e n a n c e M i n d e r R e s e t ('06-08 m o d e l s )
After E n g i n e O v e r h a u l : 7.6 L (2.01 U S gal)
15. If t h e m a i n t e n a n c e m i n d e r r e q u i r e d e n g i n e c o o l a n t
A
9 . 8 N - m (1.0 k g f - m , 7 . 2 Ibf-ft)
replacement, reset the maintenance minder
(see p a g e 3-27), a n d t h i s p r o c e d u r e is c o m p l e t e . If
t h e m a i n t e n a n c e m i n d e r did not require e n g i n e
c o o l a n t r e p l a c e m e n t , g o to s t e p 16.
16. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e
data link c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e
11-213).
17. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e v e h i c l e
a n d t h e e n g i n e control m o d u l e ( E C M ) . If it d o e s n ' t
(see p a g e 11-367).
19. S e l e c t B O D Y E L E C T R I C A L w i t h t h e H D S .
2 0 . S e l e c t A D J U S T M E N T in the G A U G E M E N U w i t h
the H D S .
2 1 . S e l e c t R E S E T in t h e M A I N T E N A N C E M I N D E R w i t h
the H D S .
22. S e l e c t M A I N T E N A N C E S U B I T E M 5 R E S E T with the

HDS.
23. Reset the m a i n t e n a n c e information display

(see p a g e 3-27).
10-10
Thermostat Replacement
2. R e m o v e the l o w e r radiator h o s e a n d t h e t h e r m o s t a t c o v e r , t h e n r e m o v e t h e t h e r m o s t a t .
3. Install the t h e r m o s t a t w i t h a n e w r u b b e r s e a l .
4. Install the t h e r m o s t a t c o v e r a n d the l o w e r radiator h o s e .
5. Refill t h e radiator w i t h e n g i n e c o o l a n t , t h e n b l e e d air f r o m t h e c o o l i n g s y s t e m ( s e e s t e p 7 o n p a g e 10-9).
6x1.0 mm
12 N m
(1.2 k g f m , 8.7 I b f f t )
10-11
Cooling System
Radiator and Fan Replacement
1. D r a i n the e n g i n e c o o l a n t ( s e e p a g e 10-9).
2 . R e m o v e t h e u p p e r a n d l o w e r radiator h o s e s .
6x1.0 mm RADIATOR CAP UPPER BRACKETS

12 N m AND CUSHIONS
(1.2 k g f - m , 8.7 I b f f t ) RADIATOR
UPPER RADIATOR HOSE

COOLANT RESERVOIR
FAN MOTOR
CONNECTORS
6 x 1.0 m m
7 N-m
(0.7 kgf m , 5 Ibf ft)
RADIATOR FAN
SHROUD ASSEMBLY
x 1.0 m m
N-m
7 kgfm,5lbfft)
A / C CONDENSER FAN
SHROUD ASSEMBLY
RADIATER FAN SWITCH
CONNECTOR LOWER RADIATOR HOSE
('00-05 m o d e l s )
ENGINE COOLANT RADIATOR FAN SWITCH ENGINE COOLANT TEMPERATURE
T E M P E R A T U R E (ECT) ('00-05 m o d e l s ) ( E C T ) S E N S O R 2 ('06-08 m o d e l s )
SENSOR 2 CONNECTOR 2 4 N-m 12 N m
('06-08 m o d e l s ) (2.4 kgf m , 17 I b f f t ) (1.2 k g f - m , 8.7 I b f f t )
3. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t the f a n m o t o r c o n n e c t o r s a n d radiator fan s w i t c h c o n n e c t o r .
4. ' 0 6 - 0 8 m o d e l s : D i s c o n n e c t the f a n m o t o r c o n n e c t o r s a n d e n g i n e c o o l a n t t e m p e r a t u r e ( E C T ) s e n s o r 2 c o n n e c t o r .
5. R e m o v e the radiator u p p e r b r a c k e t s a n d c u s h i o n s , t h e n pull up t h e radiator.
6. R e m o v e both f a n s h r o u d a s s e m b l i e s a n d o t h e r parts f r o m the radiator.
7. Install the radiator in t h e r e v e r s e o r d e r of r e m o v a l . M a k e s u r e t h e u p p e r a n d l o w e r c u s h i o n s a r e s e t s e c u r e l y .
8. Refill t h e radiator w i t h e n g i n e c o o l a n t , t h e n b l e e d t h e air f r o m the c o o l i n g s y s t e m ( s e e s t e p 7 o n p a g e 10-9).
10-12
Fan Controls
MAIN UNDER-HOOD
FUSE/RELAY BOX
A / C CONDENSER FAN RELAY

Test, page 22-48
RADIATOR FAN R E L A Y
Test, page 22-48
A / C CONDENSER FAN A S S E M B L Y ENGINE COOLANT TEMPERATURE

M o t o r T e s t , p a g e 10-7 ( E C T ) S E N S O R 2 ('06-08 m o d e l s )
10-13
Fan Controls
'00-05 m o d e l s
Engine overheats 1. Check the coolant level.
2. C h e c k f o r a n y e n g i n e c o o l a n t l e a k a g e (from
g a s k e t s , h o s e s , O - r i n g s , etc.).
3. C h e c k for dirt, l e a v e s , or i n s e c t s o n radiator
and A / C condenser.
4. C h e c k for d e t e r i o r a t e d c o o l a n t .
5. C h e c k for d a m a g e d or d e f o r m e d f a n s h r o u d .
6. I n s p e c t t h e f a n m o t o r s ( s e e p a g e 10-7), f a n
r e l a y s ( s e e p a g e 2 2 - 4 8 ) , o r radiator f a n s w i t c h
( s e e p a g e 10-23).
7. C h e c k t h e radiator c a p ( s e e p a g e 10-6).
8. C h e c k t h e t h e r m o s t a t ( s e e p a g e 10-7).
9. I n s p e c t t h e w a t e r p u m p ( s e e p a g e 10-8).
10. C h e c k for p l u g g e d o r d e t e r i o r a t e d radiator
hoses.
11. C h e c k for p i u g g e d h e a t e r c o r e o r h o s e s .
12. C h e c k for a d a m a g e d c y l i n d e r h e a d g a s k e t .
T h e radiator f a n d o e s not run at all R a d i a t o r f a n c i r c u i t t r o u b l e s h o o t i n g ( s e e p a g e 10-18). Cleanliness and
t i g h t n e s s of all
connectors
T h e radiator f a n d o e s not run for R a d i a t o r fan s w i t c h circuit t r o u b l e s h o o t i n g ( O p e n ) Cleanliness and
e n g i n e c o o l i n g , but it r u n s w i t h ( s e e p a g e 10-22). t i g h t n e s s of all
the A / C o n connectors
T h e radiator f a n r u n s w i t h t h e R a d i a t o r f a n s w i t c h circuit t r o u b l e s h o o t i n g (Short) Cleanliness and
ignition s w i t c h O N (II), t h e A / C off, ( s e e p a g e 10-23). t i g h t n e s s of all
and the engine coolant connectors
t e m p e r a t u r e b e l o w 199 °F (93 °C)
T h e A / C c o n d e n s e r f a n d o e s not A / C c o n d e n s e r fan circuit troubleshooting (see page • HVAC DTCs
run at all (but t h e r a d i a t o r f a n r u n s 21-53). ( s e e p a g e 21-5)
w i t h t h e A / C on) * Cleanliness and
connectors
Both t h e radiator f a n a n d t h e A / C Radiator and A / C c o n d e n s e r fan c o m m o n circuit • HVAC DTCs
c o n d e n s e r f a n d o not run w i t h t h e t r o u b l e s h o o t i n g ( s e e p a g e 21-54). ( s e e p a g e 21-5)
A / C o n (but t h e A / C c o m p r e s s o r • Cleanliness and
runs with the A / C on) t i g h t n e s s of all
connectors
10-14
'06-08 m o d e l s
Engine overheats 1. Check the coolant level.
2. C h e c k for a n y e n g i n e c o o l a n t l e a k a g e (from
g a s k e t s , h o s e s , O - r i n g s , etc.).
3. C h e c k for dirt, l e a v e s , or i n s e c t s o n radiator
and A / C condenser.
4. C h e c k for deteriorated c o o l a n t .
5. C h e c k for d a m a g e d or d e f o r m e d f a n s h r o u d .
6. I n s p e c t t h e f a n m o t o r s ( s e e p a g e 10-7) or f a n
r e l a y s ( s e e p a g e 22-48).
7. C h e c k t h e radiator c a p ( s e e p a g e 10-6).
8. C h e c k t h e t h e r m o s t a t ( s e e p a g e 10-7).
9. I n s p e c t t h e w a t e r p u m p ( s e e p a g e 10-8).
10. C h e c k for p l u g g e d or d e t e r i o r a t e d radiator
hoses.
11. C h e c k for p l u g g e d h e a t e r c o r e or h o s e s .
12. C h e c k for a d a m a g e d c y l i n d e r h e a d g a s k e t .
T h e radiator f a n d o e s not run at ail 1. C h e c k for P G M - F I D T C s ( s e e p a g e 11-213). Cleanliness and
2. R a d i a t o r f a n circuit t r o u b l e s h o o t i n g ( s e e p a g e t i g h t n e s s of all
10-20). connectors
T h e radiator f a n d o e s not run for 1. C h e c k for P G M - F I D T C s ( s e e p a g e 11-213). Cleanliness and
e n g i n e c o o l i n g , but it r u n s w i t h 2. R a d i a t o r f a n circuit t r o u b l e s h o o t i n g ( s e e p a g e t i g h t n e s s of all
the A / C on 10-20). connectors
T h e radiator f a n r u n s w i t h the 1. C h e c k for P G M - F I D T C s ( s e e p a g e 11-213). Cleanliness and
ignition s w i t c h O N (II), the A / C off, 2. R a d i a t o r f a n circuit t r o u b l e s h o o t i n g ( s e e p a g e t i g h t n e s s of all
a n d the engine coolant 10-20). connectors
t e m p e r a t u r e b e l o w 199 °F (93 °C)
T h e A / C c o n d e n s e r f a n d o e s not A / C c o n d e n s e r f a n circuit t r o u b l e s h o o t i n g ( s e e p a g e • HVACDTCs
run at all (but t h e radiator f a n r u n s 21-53). ( s e e p a g e 21-5)
w i t h the A / C on) • Cleanliness and
connectors
B o t h the radiator f a n a n d the A / C R a d i a t o r a n d A / C c o n d e n s e r f a n c o m m o n circuit • HVAC DTCs
c o n d e n s e r f a n d o not run w i t h t h e t r o u b l e s h o o t i n g ( s e e p a g e 21-54). ( s e e p a g e 21-5)
A / C o n (but the A / C c o m p r e s s o r • Cleanliness and
r u n s w i t h the A / C on) t i g h t n e s s of all
connectors
10-15
Fan Controls
Circuit Diagram
'00-05 m o d e l s
1 :
ENGINE * '00-03 models
MAIN UNDER-H00D FUSE/RELAY BOX START *2:'04-05 models
IGNITION SWITCH SWITCH
BATTERY
No. 41 (100 A) No. 42 (40 A)
®- —<rvô—
1
— K T V J O —
. WHT*
WHT/BLK
No. 57 (20 A) No. 58 {20 A)
- BLK/YEL
RADIATOR
FAN
RELAY
BLU/BLK GRN BLU/YEL
ECM (
A20
FANC
RADIATOR A/C
RADIATOR FAN CONDENSER
FAN MOTOR SWITCH FAN MOTOR
1 f Closed: Above
199 T (93 "C)
BLK BLK
G201 G301 G201

G301
L.
(With A/C)
10-16
'06-08 m o d e l s
MAIN UNDER-H00D FUSE/RELAY BOX *1:'06>07 models

IGNITION SWITCH •2:'08 model
BATTERY
No. 41 (100 A) No. 42 (40 A) BAT
©- —cr\_o— -WHT | WHT-
1G1-A
WHT/BLK
ACC
IG2-B
M
No. 57 (20 A) BLK RED
1
(30 A)" No.58(20A)
UNDER-DASH
FUSE/RELAYBOX B4
T
-BLK/YEL BLK/YEL — I
3 No. 20
No. 3
A/C £ (7.5A) (7.5 A)
RADIATOR
FAN CONDENSER BLK/YEL
RELAY FAN
RELAY
AIR BLK/WHT
CONDITIONING
SYSTEM
BLU/BLK GRN BLU/YEL a p ENGINE

START
ON \J OFF SWITCH
ECM YEL BLK/RED BLU/WHT

FANC
5V
H52
RELAY
SG3
El E4
LTBLU
BLU GRN
2 CLUTCH
1 INTERLOCK
SWITCH
(Closed: Clutch
RADIATOR , A/C 1 pedal pressed)
M ) CONDENSER
FAN MOTOR
FAN MOTOR
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR2
BLK BLK
1
G201 G201 G401
10-
Fan Controls
Radiator Fan Circuit Troubleshooting
'00-05 models 4. C o n n e c t t h e radiator f a n relay 4 P s o c k e t t e r m i n a l s

No. 1 a n d No. 2 with a jumper wire.
1. C h e c k t h e N o . 57 (20 A ) , No. 41 (100 A ) , a n d N o . 4 2
(40 A ) f u s e s in t h e m a i n u n d e r - h o o d f u s e / r e l a y b o x , R A D I A T O R F A N R E L A Y 4P S O C K E T
a n d t h e N o . 2 0 (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e /
r e l a y box.
Are the fuses OK? 1 JUMPER

WIRE
2
4 3
N O — R e p l a c e the fuse(s) and recheck. •
2. R e m o v e t h e radiator f a n relay f r o m the m a i n u n d e r -

h o o d f u s e / r e l a y b o x , a n d test it ( s e e p a g e 22-48). T e r m i n a l s i d e of f e m a l e t e r m i n a l s
Is the relay OK ?
Does the radiator fan run?
N O — R e p l a c e t h e radiator f a n relay. •
3. M e a s u r e the v o l t a g e b e t w e e n the radiator f a n r e l a y
4P socket terminal No. 1 and body ground. 5. D i s c o n n e c t t h e j u m p e r , a n d turn the ignition s w i t c h
to O N (II). C h e c k for v o l t a g e b e t w e e n the radiator
f a n relay 4 P s o c k e t t e r m i n a l N o . 3 a n d b o d y g r o u n d .
RADIATOR F A N R E L A Y 4P S O C K E T
1
2 .1
2
4 3
4 3
Is there battery voltage?
Y E S — G o to s t e p 4. Is there battery voltage?
N O — R e p l a c e the m a i n under-hood fuse/relay Y E S — G o to s t e p 9.

box.B
N O — R e p a i r o p e n in the w i r e b e t w e e n the m a i n
under-hood fuse/relay box and under-dash fuse/
relay box. •
10-18
6. D i s c o n n e c t the radiator f a n m o t o r 2 P c o n n e c t o r . 9. R e i n s t a l l t h e radiator f a n relay.
7. C h e c k for continuity b e t w e e n t h e radiator f a n relay 10. D i s c o n n e c t t h e radiator f a n s w i t c h 2 P c o n n e c t o r .

4 P s o c k e t t e r m i n a l N o . 2 a n d the radiator f a n motor
2 P c o n n e c t o r t e r m i n a l No. 2. 11. T u r n t h e ignition s w i t c h to L O C K (0). C o n n e c t the
radiator f a n s w i t c h 2 P c o n n e c t o r t e r m i n a l s No. 1
a n d N o . 2 w i t h a j u m p e r w i r e , t h e n t u r n t h e ignition
R A D I A T O R F A N R E L A Y 4P S O C K E T
s w i t c h to O N (II).
RADIATOR FAN SWITCH

1 2P CONNECTOR
female terminals
4 3
BLU/BLK
W i r e s i d e of
female terminals
1 2
RADIATOR FAN MOTOR 2P C O N N E C T O R Wire side of female terminals
Is there continuity? Does the radiator fan run?
Y E S — G o to s t e p 8. Y E S — R e p l a c e the radiator f a n s w i t c h . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e m a i n N O — G o to s t e p 12.
u n d e r - h o o d f u s e / r e l a y box a n d t h e radiator f a n
m o t o r 2 P c o n n e c t o r t e r m i n a l No. 2M 12. T u r n t h e ignition s w i t c h to L O C K (0). R e m o v e the
j u m p e r w i r e , t h e n turn t h e ignition s w i t c h to O N (II).
8. C h e c k for continuity b e t w e e n t h e radiator f a n M e a s u r e t h e v o l t a g e b e t w e e n the radiator f a n
motor 2P connector terminal No. 1 and body s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
ground. ground.
RADIATOR FAN MOTOR 2P C O N N E C T O R RADIATOR FAN SWITCH

2P C O N N E C T O R
BLK
Wire side of
female terminals
W i r e side of f e m a l e terminals Is there battery voltage?
Is there continuity? Y E S — R e p a i r o p e n in the w i r e b e t w e e n radiator f a n

s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 1 a n d b o d y
Y E S — R e p l a c e the radiator f a n motor. • g r o u n d . If t h e w i r e is O K , c h e c k for a p o o r g r o u n d at
G301.B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n radiator f a n
m o t o r 2 P c o n n e c t o r t e r m i n a l No. 1 a n d b o d y N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e radiator
g r o u n d . If t h e w i r e is O K , c h e c k for a p o o r g r o u n d at f a n s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 2 a n d t h e
G201.H main under-hood fuse/relay b o x . B
10-19
Fan Controls
Radiator Fan Circuit Troubleshooting (cont'd)
'06-08 models 5. M e a s u r e t h e v o l t a g e b e t w e e n the radiator f a n r e l a y

4 P s o c k e t t e r m i n a l No. 1 a n d b o d y g r o u n d .
1. C h e c k for the P G M - F I D T C s ( s e e p a g e 11-213).
RADIATOR FAN R E L A Y 4P S O C K E T
Is DTCP2183, P2184, and/or P2185 Indicated?
Y E S — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g , t h e n
recheck. •
\
2
4 3
2. '06-07 m o d e l s : C h e c k the No. 57 (20 A ) ,
N o . 41 (100 A ) , a n d N o . 42 (40 A ) f u s e s in t h e m a i n
u n d e r - h o o d f u s e / r e l a y b o x , a n d t h e N o . 2 0 (7.5 A )
f u s e in t h e u n d e r - d a s h f u s e / r e l a y box. T e r m i n a l s i d e of f e m a l e t e r m i n a l s
3. ' 0 8 m o d e l : C h e c k t h e No. 57 (30 A ) , N o . 41 (100 A ) ,

a n d N o . 42 (40 A ) f u s e s in t h e m a i n u n d e r - h o o d Is there battery voltage?
f u s e / r e l a y b o x , a n d the N o . 2 0 (7.5 A ) f u s e in t h e
under-dash fuse/relay box. Y E S — G o to s t e p 6.
Are the fuses OK ? N O — R e p l a c e the main under-hood fuse/relay

box.1
6. C o n n e c t t h e radiator fan r e l a y 4 P s o c k e t t e r m i n a l s
N O — R e p l a c e the fuse(s) a n d recheck. • No. 1 and No. 2 with a jumper wire.
4. R e m o v e the radiator fan r e l a y f r o m t h e m a i n u n d e r -

h o o d f u s e / r e l a y b o x , a n d t e s t it ( s e e p a g e 22-48).
Is the relay OK?

1 JUMPER
WIRE
Y E S — G o to s t e p 5. 2
N O — R e p l a c e t h e radiator f a n relay. • 4 3
Does the radiator fan run?
10-20
7. D i s c o n n e c t the j u m p e r , a n d t u r n t h e ignition s w i t c h 10. C h e c k for c o n t i n u i t y b e t w e e n t h e radiator f a n
to O N (II). C h e c k for v o l t a g e b e t w e e n the radiator motor 2P connector terminal No. 1 a n d body
f a n relay 4 P s o c k e t t e r m i n a l N o . 3 a n d b o d y g r o u n d . ground.
RADIATOR FAN MOTOR 2P C O N N E C T O R

BLK
Is there battery voltage? Is there continuity?
Y E S — G o to s t e p 11. Y E S — R e p l a c e t h e radiator f a n m o t o r . !
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the m a i n N O — R e p a i r o p e n in t h e w i r e b e t w e e n radiator f a n
under-hood fuse/relay box and under-dash fuse/ motor 2P connector terminal No. 1 a n d body
r e l a y box. • g r o u n d . If t h e w i r e is O K , c h e c k for a p o o r g r o u n d at
G201.B
8. D i s c o n n e c t the radiator f a n m o t o r 2 P c o n n e c t o r .
9. C h e c k for continuity b e t w e e n t h e radiator f a n r e l a y

4 P s o c k e t t e r m i n a l N o . 2 a n d t h e radiator f a n m o t o r
2 P c o n n e c t o r t e r m i n a l No. 2.
1
female terminals
4 3 i BLU/BLK
W i r e s i d e of
female terminals
RADIATOR FAN MOTOR 2P CONNECTOR
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the m a i n
u n d e r - h o o d f u s e / r e l a y b o x a n d t h e radiator f a n
m o t o r 2 P c o n n e c t o r t e r m i n a l N o . 2.M
(cont'd)
10-21
Fan Controls
Radiator Fan Circuit Radiator Fan Switch Circuit
Troubleshooting (cont'd) Troubleshooting (Open)
11. C h e c k for c o n t i n u i t y b e t w e e n t h e radiator f a n r e l a y '00-05 models

4P socket terminal No. 4 a n d the engine control
module (ECM) connector terminal E12. 1. D i s c o n n e c t t h e radiator f a n s w i t c h 2 P c o n n e c t o r .
T e r m i n a l s i d e of
3. M e a s u r e the v o l t a g e b e t w e e n t h e radiator f a n
female terminals switch 2P connector terminal No. 2 and body
ground.
RADIATOR FAN SWITCH

2P CONNECTOR
W i r e s i d e of
female terminals
/1 3 4 5 7 8 9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
E C M C O N N E C T O R E (31P)
/ Wire side of
female terminals
Y E S — U p d a t e t h e E C M if it d o e s not h a v e t h e latest Is there battery voltage?

s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k it. If t h e Y E S — G o to s t e p 4.
E C M , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-389). • N O — R e p a i r o p e n in the w i r e b e t w e e n the radiator
fan switch 2P connector terminal No. 2 a n d main
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M under-hood fuse/relay box. •
connector terminal E 1 2 and the main under-hood
fuse/relay box. • 4. T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k for
continuity b e t w e e n t h e radiator f a n s w i t c h 2 P
connector terminal No. 1 and body ground.
RADIATOR FAN SWITCH

2 P CONNECTOR
BLK
Wire side of
female terminals
Y E S — R e p l a c e t h e radiator f a n s w i t c h . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e radiator
f a n s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 1 a n d b o d y
g r o u n d . If t h e w i r e is O K , c h e c k for a p o o r g r o u n d at
G301.B
10-22
Radiator Fan Switch Circuit Radiator Fan Switch Test
Troubleshooting (Short)
'00-05 models
'00-05 models 1. R e m o v e t h e radiator f a n s w i t c h f r o m t h e radiator

( s e e p a g e 10-24).
1. R e m o v e the radiator f a n relay f r o m the m a i n under-
h o o d f u s e / r e l a y b o x , a n d test it ( s e e p a g e 22-48). 2. S u s p e n d t h e radiator f a n s w i t c h (A) in a c o n t a i n e r
of w a t e r a s s h o w n .
Is the relay OK?
Y E S — G o to s t e p 2. B
N O — R e p l a c e t h e radiator f a n relay. •
2. R e m o v e t h e radiator f a n s w i t c h ( s e e p a g e 10-24),
a n d t e s t it ( s e e p a g e 10-23).
Is the radiator fan switch OK?
N O — R e p l a c e the radiator f a n s w i t c h ( s e e p a g e
10-24).B
3. D i s c o n n e c t e n g i n e control m o d u l e ( E C M ) c o n n e c t o r
A (32P) a n d t h e u n d e r - h o o d f u s e / r e l a y b o x 16P 3. Heat t h e w a t e r a n d c h e c k t h e t e m p e r a t u r e w i t h a
connector. t h e r m o m e t e r . Do not let t h e t h e r m o m e t e r (B) t o u c h
the b o t t o m of t h e hot c o n t a i n e r .
4. C h e c k f o r continuity b e t w e e n t h e radiator f a n
s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y 4. M e a s u r e t h e continuity b e t w e e n t e r m i n a l No. 1 a n d
ground. t e r m i n a l N o . 2 a c c o r d i n g to t h e t a b l e .
\ Terminal
RADIATOR FAN SWITCH 1 2
2P C O N N E C T O R Operation Temperature \
1 9 6 - 2 0 3 °F
ON
( 9 1 - 9 5 °C)
O -o
SWITCH 5 - 1 5 ° F ( 3 - 8 < € ) lower
OFF than the temperature
w h e n it g o e s o n
5. R e p l a c e if n e c e s s a r y , a n d install t h e radiator f a n
s w i t c h ( s e e p a g e 10-24).
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the radiator

f a n s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 2 a n d m a i n
under-hood fuse/relay box.H
N O — R e p l a c e the main under-hood fuse/relay

box.H
10-23
Fan Controls
Radiator Fan Switch Replacement
'00-05 models
2. D i s c o n n e c t t h e radiator f a n s w i t c h c o n n e c t o r , t h e n
r e m o v e t h e radiator f a n s w i t c h (A).
3. Install t h e radiator f a n s w i t c h w i t h a n e w O - r i n g (B).
4. Refill t h e radiator w i t h e n g i n e c o o l a n t , t h e n b l e e d
t h e air f r o m t h e c o o l i n g s y s t e m ( s e e s t e p 7 o n p a g e
10-9).
10-24
Fuel and Emissions
'00-05 Models 11-1

'06-08 Models 11-211
I
'00-05 Models
Fuel and Emissions Systems Fuel Pressure Regulator R e p l a c e m e n t ......... 11-154
Special Tools 11-2 Fuel Filter Replacement 11-154
General Troubleshooting Information .. 11-3 Fuel Pump/Fuel G a u g e S e n d i n g Unit
D T C Troubleshooting Index 11-6 Replacement 11-155
S y m p t o m Troubleshooting Index 11-10 Fuel Tank Replacement 11-156
S y s t e m Description 11-12 Fuel G a u g e S e n d i n g Unit T e s t 11-160
H o w to Set R e a d i n e s s C o d e s 11-40 L o w Fuel Indicator T e s t 11-161
PGM-FI System Intake Air System

Component Location Index 11-43 Component Location Index 11-162
D T C Troubleshooting 11-45 Throttle Body T e s t 11-163
MIL Circuit Troubleshooting 11-106 Throttle Position S e n s o r Signal
D L C Circuit Troubleshooting 11-110 Inspection 11-164
Injector Replacement 11-112 Throttle Body Removal/Installation 11-165
Primary H 0 2 S Replacement 11-114 Throttle Body D i s a s s e m b l y / R e a s s e m b l y 11-166
S e c o n d a r y H 0 2 S Replacement 11-114 Throttle Cable Removal/Installation 11-167
E C M Replacement 11-115 Throttle Cable Adjustment 11-168
Air Cleaner Element
VTEC Inspection/Replacement 11-169
D T C Troubleshooting 11-117 Catalytic Converter System
Rocker A r m Oil Control Solenoid D T C Troubleshooting 11-170
( V T E C Solenoid Valve) Inspection 11-126
PCV System
Idle Control System D T C Troubleshooting 11-171
Component Location Index 11-127 PCV Valve Inspection 11-171
D T C Troubleshooting 11-128 PCV Valve Replacement 11-172
A / C Signal Circuit Troubleshooting 11-133
Alternator FR Signal Circuit EVAP System
Troubleshooting 11-135 C o m p o n e n t Location Index 11-173
Starter Switch Signal Circuit D T C Troubleshooting 11-174
Troubleshooting . 11-136 E V A P T w o W a y Valve T e s t 11-194
Electrical Power Steering (EPS) Fuel Tank Vapor Control Valve Test 11-195
Signal Circuit Troubleshooting 11-137 Fuel Tank Vapor Control Valve
Brake Pedal Position Switch Signal Circuit Replacement 11-196
Troubleshooting 11-139
Idle S p e e d Inspection 11-140 Pulsed Secondary Air Injection System
E C M Idle Learn Procedure 11-140 Component Location Index 11-197
D T C Troubleshooting 11-198
Fuel Supply System Air Pump/Air P u m p Relay
Component Location Index 11-141 Removal/Installation 11-208
PGM-FI Main Relay Circuit Air P u m p Relay T e s t 11-209
Troubleshooting 11-142 Air P u m p Electrical Current S e n s o r
Fuel Pressure Relieving 11-145 Removal/Installation 11-209
Fuel Pressure T e s t 11-145
FuelPumpTest 11-147
Fuel Line Inspection 11-148
Fuel Line/Quick-Connect Fitting
Precautions 11-150
Fuel Line/Quick-Connect Fitting R e m o v a l .... 11-150
Installation 11-151
Fuel and Emissions Systems
Special Tools

© 07JAZ-001000B V a c u u m / P r e s s u r e G a u g e , 0 — 4 in.Hg 1
® 07SAZ-001000A Backprobe Set 2
07VAJ-0040100 Fuel Pressure G a u g e Attachment 1
® 07406-004000B Fuel Pressure G a u g e 1
® 07NAJ-P07010A Pressure Gauge Adapter 1
®-i 07406-0020201 A/T Pressure Hose 1
®-2 07406-0070301 A/T L o w Pressure Gauge W/Panel 1
®-3 07MAJ-PY4011A A / T P r e s s u r e H o s e , 2,210 m m 1
®-4 07MAJ-PY40120 A / T Pressure Hose, Adapter 1
® <D (D-i,(D-2,(D-3,©-4
11-2
General Troubleshooting Information
Intermittent Failures '02-05 m o d e l s
T h e t e r m "intermittent f a i l u r e " m e a n s a s y s t e m m a y
h a v e h a d a failure, but it c h e c k s O K n o w . If t h e
m a l f u n c t i o n indicator l a m p (MIL) o n the d a s h d o e s not
c o m e o n , c h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
at all c o n n e c t o r s related to the circuit that y o u a r e
t r o u b l e s h o o t i n g . T h e M I L m a y be t u r n e d off by t h e E C M
if t h e p r o b l e m that originally c a u s e d the M I L to b e
i l l u m i n a t e d is a n intermittent o n e .
Service Information
P e r i o d i c a l l y , n e w E C M s o f t w a r e or n e w s e r v i c e
procedures m a y become available. A l w a y s check
o n l i n e for t h e latest s o f t w a r e or s e r v i c e i n f o r m a t i o n
related to t h e D T C s or s y m p t o m s y o u a r e
troubleshooting. 3. T u r n the ignition s w i t c h O N (II).
Opens and Shorts 4. M a k e s u r e t h e H D S or a n O B D II s c a n tool

c o m m u n i c a t e s w i t h t h e E C M a n d other v e h i c l e
" O p e n " a n d " S h o r t " a r e c o m m o n electrical t e r m s . A n s y s t e m s . If it d o e s n ' t , g o to t h e D L C circuit
o p e n is a b r e a k in a w i r e or at a c o n n e c t i o n . A s h o r t is t r o u b l e s h o o t i n g ( s e e p a g e 11-110).
a n a c c i d e n t a l c o n n e c t i o n of a w i r e to g r o u n d or to
a n o t h e r w i r e . In s i m p l e e l e c t r o n i c s , t h i s u s u a l l y m e a n s 5. C h e c k t h e d i a g n o s t i c t r o u b l e c o d e ( D T C ) a n d note it.
s o m e t h i n g w o n ' t w o r k at all. W i t h c o m p l e x e l e c t r o n i c s A l s o c h e c k t h e f r e e z e d a t a . R e f e r to t h e i n d i c a t e d
(such a s E C M s ) , this c a n s o m e t i m e s m e a n something D T C s troubleshooting, a n d begin the appropriate
w o r k s , but not t h e w a y it's s u p p o s e d to. troubleshooting procedure.
How to Use the Honda Diagnostic System NOTE:

(HDS) or a Scan Tool • Freeze data indicates the engine conditions w h e n
t h e first m a l f u n c t i o n , m i s f i r e or fuel t r i m
If t h e M I L ( m a l f u n c t i o n i n d i c a t o r l a m p ) h a s c o m e o n malfunction w a s detected.
• T h e s c a n tool a n d the H D S c a n r e a d the D T C ,
1. S t a r t t h e e n g i n e , a n d c h e c k t h e MIL. f r e e z e d a t a , c u r r e n t d a t a , a n d other e n g i n e
control m o d u l e ( E C M ) d a t a .
2. If the M I L s t a y s o n , c o n n e c t the H D S or a n O B D II • F o r s p e c i f i c o p e r a t i o n s , refer to the u s e r ' s
s c a n tool to the data link c o n n e c t o r ( D L C ) (A). m a n u a l that c a m e w i t h a s c a n tool or H D S .
F o r '00-01 m o d e l s , t h e D L C is l o c a t e d u n d e r t h e
p a s s e n g e r ' s s i d e of t h e d a s h b o a r d . 6. If no D T C s a r e f o u n d , g o to M I L t r o u b l e s h o o t i n g
F o r '02-05 m o d e l s , t h e D L C is located b e h i n d the ( s e e p a g e 11-106).
d r i v e r ' s s i d e of the front c o n s o l e .
If t h e M I L d i d n o t c o m e o n
'00-01 m o d e l s If t h e M I L did not c o m e o n but t h e r e is a driveablity
problem, do the s y m p t o m troubleshooting.
If y o u c a n ' t d u p l i c a t e t h e D T C
S o m e of t h e t r o u b l e s h o o t i n g r e q u i r e s y o u to r e s e t t h e
E C M a n d try to d u p l i c a t e the D T C . If the p r o b l e m is
intermittent a n d y o u c a n ' t d u p l i c a t e the D T C , d o not
c o n t i n u e t h r o u g h t h e p r o c e d u r e . T o d o s o will o n l y
r e s u l t in c o n f u s i o n a n d p o s s i b l y , a n e e d l e s s l y r e p l a c e d
ECM.
(cont'd)
11-3
General Troubleshooting Information (cont'd)
How to Reset the ECM How to Troubleshoot Circuits at the ECM
Y o u c a n r e s e t the E C M in either of t w o w a y s : Special Tools Required

• Digital m u l t i m e t e r K S - A H M - 3 2 - 0 0 3 (1) or a
N O T E : After resetting the E C M , d o the E C M idle l e a r n c o m m e r c i a l l y a v a i l a b l e digital m u l t i m e t e r
p r o c e d u r e ( s e e p a g e 11-140). • B a c k p r o b e s e t 0 7 S A Z - 0 0 1 0 0 0 A (2)
Reset the ECM with an OBD II Scan Tool or 1. C o n n e c t t h e b a c k p r o b e a d a p t e r s (A) to t h e s t a c k i n g

the HDS patch c o r d s (B), a n d c o n n e c t the c o r d s to a
multimeter (C).
1. T u r n the ignition s w i t c h O N (II). D o not start t h e
engine.
2. U s e a n O B D II s c a n tool or H D S to c l e a r the D T C .
N O T E : F o r t h e s p e c i f i c o p e r a t i o n s , refer to the u s e r ' s

m a n u a l that c a m e w i t h a s c a n tool or H D S .
Reset the ECM by Removing the Fuse
1. T u r n the ignition s w i t c h O F F .
2 . R e m o v e the N o . 2 5 B A C K U P (7.5 A ) f u s e (A) f r o m

the u n d e r - d a s h f u s e / r e l a y b o x (B) for 60 s e c o n d s .
2. U s i n g the w i r e i n s u l a t i o n a s a g u i d e for the
c o n t o u r e d tip of the b a c k p r o b e a d a p t e r , gently s l i d e
t h e tip into t h e c o n n e c t o r f r o m the w i r e s i d e until it
t o u c h e s the e n d of the w i r e t e r m i n a l .
3. If y o u c a n n o t get to the w i r e s i d e of the c o n n e c t o r

or the w i r e s i d e is s e a l e d (A), d i s c o n n e c t the
c o n n e c t o r a n d t o u c h the t e s t e r probe (B) to
t e r m i n a l s (C) f r o m the t e r m i n a l s i d e . D o not f o r c e
the p r o b e into the c o n n e c t o r .
INOTICEl
D o not p u n c t u r e t h e i n s u l a t i o n o n a w i r e .
How to End a Troubleshooting Session P u n c t u r e s c a n c a u s e p o o r or intermittent
(required after any troubleshooting) electrical c o n n e c t i o n s .
1. R e s e t the E C M w i t h the H D S or O B D II s c a n t o o l .
A B
2 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140).
4. D i s c o n n e c t a n O B D II s c a n tool o r H D S f r o m the
data link c o n n e c t o r ( D L C ) .
N O T E : T h e E C M is part of t h e i m m o b i l i z e r s y s t e m .
If y o u r e p l a c e t h e E C M , it will h a v e a different
C
i m m o b i l i z e r c o d e . In o r d e r for t h e e n g i n e to start,
y o u m u s t rewrite the i m m o b i l i z e r c o d e w i t h t h e
HDS.
11-4
How to Substitute the ECM for Testing
Purposes
U s e t h i s p r o c e d u r e if y o u n e e d a k n o w n - g o o d E C M to
test a v e h i c l e . It a l l o w s y o u to s w a p a n E C M f r o m a
" d o n o r " v e h i c l e w i t h o u t h a v i n g to p r o g r a m it to the test
v e h i c l e ' s ignition key.
1. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery o n
the t e s t v e h i c l e .
2. C u t a t e m p o r a r y ignition k e y for the t e s t v e h i c l e

w i t h a n o n - i m m o b i l i z e r k e y blank.
3 . R e m o v e the E C M f r o m t h e test v e h i c l e .
4 . W r i t e the t e s t v e h i c l e ' s V I N o n t h e E C M y o u j u s t
r e m o v e d to a v o i d c o n f u s i n g it w i t h t h e d o n o r
vehicle's E C M .
5 . D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery o n
the donor vehicle.
6 . R e m o v e the k n o w n - g o o d E C M f r o m t h e d o n o r
v e h i c l e , a n d install it in t h e test v e h i c l e .
7 . T a p e the d o n o r v e h i c l e ' s ignition k e y h e a d - t o - h e a d

to t h e t e s t v e h i c l e ' s t e m p o r a r y k e y (A). T h e E C M
w i l l r e c o g n i z e the c o d e f r o m t h e d o n o r v e h i c l e ' s
key '(B) a n d a l l o w y o u to start the e n g i n e w i t h the
t e m p o r a r y key.
8 . After c o m p l e t i n g y o u r t e s t s , reinstall both E C M s ,

a n d d e s t r o y the t e m p o r a r y key.
9 . R e c o n n e c t the n e g a t i v e c a b l e to t h e battery.
DTC Troubleshooting Index

DTC T w o Drive Cycle Detection h e m Note
(MIL indication* ) 1
Detection
P 0 1 0 7 (3) Manifold Absolute Pressure (MAP) S e n s o r Circuit L o w ( s e e p a g e 11-45)
Voltage
P0108(3) M a n i f o l d A b s o l u t e P r e s s u r e ( M A P ) S e n s o r C i r c u i t High ( s e e p a g e 11-47)
Voltage
P0112(10) Intake A i r T e m p e r a t u r e (IAT) S e n s o r C i r c u i t L o w V o l t a g e ( s e e p a g e 11-49)
P0113(10) Intake A i r T e m p e r a t u r e (IAT) S e n s o r C i r c u i t High V o l t a g e ( s e e p a g e 11-50)
P0116(86) P0116 Engine Coolant Temperature (ECT) S e n s o r Circuit R a n g e / ( s e e p a g e 11-52)
Performance Problem
P0117(6) Engine Coolant Temperature (ECT) S e n s o r Circuit L o w ( s e e p a g e 11-52)
Voltage
P0118(6) E n g i n e C o o l a n t T e m p e r a t u r e ( E C T ) S e n s o r C i r c u i t High ( s e e p a g e 11-54)
Voltage
P 0 1 2 2 (7) T h r o t t l e P o s i t i o n (TP) S e n s o r C i r c u i t L o w V o l t a g e ( s e e p a g e 11-56)
P 0 1 2 3 (7) T h r o t t l e P o s i t i o n (TP) S e n s o r C i r c u i t High V o l t a g e ( s e e p a g e 11-58)
P0125 (86)* 4
P0125 Engine Coolant Temperature (ECT) S e n s o r Malfunction/ ( s e e p a g e 11-59)
Slow Response
P0128 (87)* 2
P0128 Cooling S y s t e m Malfunction ( s e e p a g e 11-59)
3
P0131 or Primary Heated O x y g e n S e n s o r (Primary H 0 2 S ) ( s e e p a g e 11-61)
( S e n s o r 1) C i r c u i t L o w V o l t a g e
P0131 ( I ) * 4
Primary Heated O x y g e n S e n s o r (Primary H 0 2 S ) ( s e e p a g e 11-62)
P0132(1)* 3
(Sensor 1) C i r c u i t High V o l t a g e
P0132(ir 4
(Sensor 1) C i r c u i t High V o l t a g e
P 0 1 3 3 (61) P0133 Primary Heated O x y g e n S e n s o r (Primary H 0 2 S ) ( s e e p a g e 11-66)
( S e n s o r 1) C i r c u i t S l o w R e s p o n s e
P0134(ir 6
( S e n s o r 1) H e a t e r S y s t e m M a l f u n c t i o n
P0134 0 ) * 7
( S e n s o r 1) H e a t e r S y s t e m M a l f u n c t i o n
P 0 1 3 5 (41) Primary Heated O x y g e n S e n s o r (Primary H 0 2 S ) ( s e e p a g e 11-70)
( S e n s o r 1) H e a t e r C i r c u i t M a l f u n c t i o n
P 0 1 3 7 (63) P0136* 5
S e c o n d a r y Heated O x y g e n S e n s o r (Secondary H 0 2 S ) ( s e e p a g e 11-73)
*7
* 1: T h e s e D T C s a r e i n d i c a t e d b y a blinking M I L w h e n t h e S C S line is j u m p e d w i t h t h e H D S .
* 2: ' 0 2 - 0 5 m o d e l s
* 3: ' 0 0 - 0 3 m o d e l s
* 4: ' 0 4 - 0 5 m o d e l s
* 5: ' 0 0 - 0 4 m o d e l s
* 6: ' 0 4 m o d e l
* 7: ' 0 5 m o d e l
11-6
DTC T w o Drive Cycle Detection Item Note
Detection
P0138(63)/ 5
P0136 S e c o n d a r y Heated O x y g e n S e n s o r ( S e c o n d a r y H02S) ( s e e p a g e 11.-74)
( S e n s o r 2) Circuit High V o l t a g e
P0138 (63)* 7
S e c o n d a r y Heated O x y g e n S e n s o r ( S e c o n d a r y H02S) ( s e e p a g e 11-75)
( S e n s o r 2) C i r c u i t High V o l t a g e
P0139 (63)* 5
P0139 S e c o n d a r y Heated O x y g e n S e n s o r ( S e c o n d a r y H02S) ( s e e p a g e 11-77)
( S e n s o r 2) C i r c u i t S l o w R e s p o n s e
P0141 (65) S e c o n d a r y Heated O x y g e n S e n s o r (Secondary H02S) ( s e e p a g e 11-70)
( S e n s o r 2) Heater C i r c u i t M a l f u n c t i o n
5
P0171(45) P0170* Fuel S y s t e m T o o Lean ( s e e p a g e 11-78)
7
P0171*
5
P 0 1 7 2 (45) P0170* Fuel S y s t e m T o o Rich ( s e e p a g e 11-78)
7
P0172*
5
P0300 a n y P1399* R a n d o m Misfire D e t e c t e d ( s e e p a g e 11-79)
combination P0300* 7
of the
following
P0301 (71)
P0302(72)
P 0 3 0 3 (73)
P 0 3 0 4 (74)
P030K71) P1399* 5
N o . 1 C y l i n d e r Misfire D e t e c t e d ( s e e p a g e 11-80)
7
P030V
P 0 3 0 2 (72) P1399/ ?
N o . 2 C y l i n d e r Misfire D e t e c t e d ( s e e p a g e 11-80)
7
P0302*
CO CO
CO CO
O CO
P 0 3 0 3 (73) N o . 3 C y l i n d e r Misfire D e t e c t e d ( s e e p a g e 11-80)
5
P 0 3 0 4 (74) P1399* N o . 4 C y l i n d e r Misfire D e t e c t e d ( s e e p a g e 11-80)
7
P0304*
P 0 3 2 5 (23) Knock S e n s o r Circuit Malfunction ( s e e p a g e 11-85)
P 0 3 3 5 (4) Crankshaft Position (CKP) S e n s o r No Signal ( s e e p a g e 11-86)
P0336(4)* 3
C r a n k s h a f t P o s i t i o n ( C K P ) S e n s o r C i r c u i t Intermittent ( s e e p a g e 11-86)
Interruption
P0339(4)* 4
C r a n k s h a f t P o s i t i o n ( C K P ) S e n s o r C i r c u i t Intermittent ( s e e p a g e 11-86)
Interruption
P0340 (8)* 4
C a m s h a f t Position (CMP) S e n s o r A No Signal ( s e e p a g e 11-88)
P0344 (8)* 4
C a m s h a f t P o s i t i o n ( C M P ) S e n s o r A C i r c u i t Intermittent ( s e e p a g e 11-88)
Interruption
P 0 3 6 5 (58) C a m s h a f t Position (CMP) S e n s o r B No Signal ( s e e p a g e 11-89)
P0369 (58)* 4
C a m s h a f t P o s i t i o n ( C M P ) S e n s o r B C i r c u i t Intermittent ( s e e p a g e 11-89)
Interruption
* 1: T h e s e D T C s a r e indicated by a blinking M I L w h e n t h e S C S line is j u m p e d w i t h t h e H D S .
* 3: ' 0 0 - 0 3 m o d e l s
* 4: ' 0 4 - 0 5 m o d e l s
* 5: '00-04 m o d e l s
* 7: ' 0 5 m o d e l
(cont'd)
11-7
DTC Troubleshooting Index (cont'd)
Detection
P0410(60) P0410 Air P u m p Circuit Malfunction (see page 11-198)
P0411 (60) P0411 S e c o n d a r y A i r Injection S y s t e m I n c o r r e c t F l o w (see page 11-202)
P 0 4 2 0 (67) P0420 Catalyst S y s t e m Efficiency Below Threshold (see page 11-170)
P0451 (91) P0451 Fuel T a n k Pressure (FTP) S e n s o r Circuit Range/ (see page 11-174)
Performance Problem
P 0 4 5 2 (91) P0450* 5
Fuel T a n k Pressure (FTP) S e n s o r Circuit L o w Voltage ( s e e p a g e 11-175)
7
P0452*
P 0 4 5 3 (91) P0450* 5
F u e l T a n k P r e s s u r e ( F T P ) S e n s o r C i r c u i t High V o l t a g e (see p a g e 11-177)
7
P0453*
P0497 (90) P0497 Evaporative E m i s s i o n (EVAP) S y s t e m L o w Purge F l o w ( s e e p a g e 11-179)
Detected
P 0 5 0 0 (17) Vehicle S p e e d S e n s o r ( V S S ) Circuit Malfunction (see page 11-91)
P0505(14)* 3
Idle C o n t r o l S y s t e m M a l f u n c t i o n (see page 11-128)
P0506(14)* 4
P0506 Idle A i r C o n t r o l S y s t e m R P M L o w e r T h a n E x p e c t e d (see page 11-129)
P0507 0 4 ) * 4
P0507 Idle A i r C o n t r o l S y s t e m R P M H i g h e r T h a n E x p e c t e d (see page 11-130)
P0511 ( 1 4 ) * 4
Idle A i r C o n t r o l (IAC) V a l v e C i r c u i t M a l f u n c t i o n (see page 11-131)
P0607(-r4 E n g i n e C o n t r o l M o d u l e ( E C M ) Internal C i r c u i t Malfunction (see page 11-93)
P0630(139)* 4
V I N Not P r o g r a m m e d o r M i s m a t c h (see page 11-94)
P1106(13K 3
P1106 Barometric Pressure (BARO) Sensor Range/Performance (see page 11-95)
Problem
P1107(13)* 3
Barometric Pressure ( B A R O ) S e n s o r Circuit L o w Voltage ( s e e p a g e 11-95)
P1108 0 3 ) * 3
B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r C i r c u i t High V o l t a g e (see p a g e 11-95)
P1109 0 3 ) * 4
B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r C i r c u i t O u t of R a n g e ( s e e p a g e 11-96)
High
P1121 (7) P1121 Throttle P o s i t i o n (TP) S e n s o r S i g n a l L o w e r T h a n E x p e c t e d ( s e e p a g e 11-97)
P 1 1 2 2 (7) P1122 Throttle P o s i t i o n (TP) S e n s o r S i g n a l H i g h e r T h a n ( s e e p a g e 11-97)
Expected
P 1 1 2 8 (5) P1128 Manifold Absolute Pressure (MAP) S e n s o r Signal L o w e r ( s e e p a g e 11-98)
Than Expected
P 1 1 2 9 (5) P1129 Manifold Absolute Pressure (MAP) S e n s o r Signal Higher ( s e e p a g e 11-98)
Than Expected
* 1: T h e s e D T C s a r e i n d i c a t e d by a blinking M I L w h e n t h e S C S line is j u m p e d w i t h t h e H D S .
* 3: ' 0 0 - 0 3 m o d e l s
* 4: ' 0 4 - 0 5 m o d e l s
* 5: ' 0 0 - 0 4 m o d e l s
* 7 : ' 0 5 model
11-8
1
(MIL indication* ) Detection
P1259 ( 2 2 ) * 3
P1257 V T E C S y s t e m Malfunction ( s e e p a g e 11-117)
P1297 (20) E l e c t r i c a l L o a d Detector ( E L D ) C i r c u i t L o w V o l t a g e ( s e e p a g e 11-99)
P1298 (20) E l e c t r i c a l L o a d Detector ( E L D ) C i r c u i t High V o l t a g e ( s e e p a g e 11-100)
P1361 ( 8 ) * 3
C a m s h a f t Position ( C M P ) S e n s o r A (Top D e a d C e n t e r ( s e e p a g e 11-88)
( T D C ) S e n s o r ) Circuit Intermittent Interruption
P1362(8)* 3
C a m s h a f t Position ( C M P ) S e n s o r A (Top D e a d C e n t e r ( s e e p a g e 11-88)
(TDC) S e n s o r ) No S i g n a l
3
P1366 (58) * C a m s h a f t Position ( C M P ) S e n s o r B (Top D e a d C e n t e r ( s e e p a g e 11-89)
( T D C ) S e n s o r ) Circuit Intermittent Interruption
3
P1367 ( 5 8 ) * C a m s h a f t Position ( C M P ) S e n s o r B (Top D e a d C e n t e r ( s e e p a g e 11-89)
(TDC) S e n s o r ) No Signal
P1410(60r 3
P1410 A i r P u m p Malfunction (see page 11-204)
P I 415 (83) Air P u m p Electrical Current S e n s o r Circuit L o w Voltage (see page 11-205)
P1416(83) A i r P u m p E l e c t r i c a l C u r r e n t S e n s o r C i r c u i t High V o l t a g e (see page 11-207)
P1456 (90) P1456 Evaporative E m i s s i o n s (EVAP) Control S y s t e m Leakage (see page 11-183)
(Fuel T a n k S y s t e m )
P I 457 (90) P1457 Evaporative E m i s s i o n s (EVAP) Control S y s t e m Leakage ( s e e p a g e 11-188)
(EVAP Canister System)
3
P1519(14)* Idle A i r C o n t r o l (IAC) V a l v e C i r c u i t M a l f u n c t i o n ( s e e p a g e 11-131)
3
P1607 ( - - ) * E n g i n e C o n t r o l M o d u l e ( E C M ) Internal C i r c u i t M a l f u n c t i o n ( s e e p a g e 11-93)
6
P2195(1)* Primary Heated O x y g e n S e n s o r (Primary H 0 2 S ) ( s e e p a g e 11-102)
7
P2227(13)* 4
P2227 Barometric Pressure (BARO) S e n s o r Range/Performance ( s e e p a g e 11-95)
Problem
4
P2228(13)* Barometric Pressure (BARO) S e n s o r Circuit L o w Voltage ( s e e p a g e 11-95)
4
P2229(13)* B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r C i r c u i t High V o l t a g e ( s e e p a g e 11-95)
4
P2270 ( 6 3 ) * S e c o n d a r y Heated O x y g e n S e n s o r (Secondary H 0 2 S ) ( s e e p a g e 11-104)
7
P2270* ( S e n s o r 2) C i r c u i t S i g n a l S t u c k L e a n
4 *6
P2271 ( 6 3 ) * S e c o n d a r y Heated O x y g e n S e n s o r (Secondary H 0 2 S ) ( s e e p a g e 11-105)
7
P2271* ( S e n s o r 2) C i r c u i t S i g n a l S t u c k R i c h
4
P2279(109)* P2279 Intake A i r S y s t e m L e a k D e t e c t e d ( s e e p a g e 11-171)
4
( S e n s o r 1) C i r c u i t High V o l t a g e
P2445 (60)* 4
P2445 Air P u m p Malfunction ( s e e p a g e 11-204)
4
P2646 (22)* R o c k e r A r m Oil P r e s s u r e S w i t c h ( V T E C Oil P r e s s u r e ( s e e p a g e 11-121)
Switch) Circuit L o w Voltage
4
P2647 ( 2 2 ) * R o c k e r A r m Oil P r e s s u r e S w i t c h ( V T E C Oil P r e s s u r e ( s e e p a g e 11-124)
S w i t c h ) C i r c u i t High V o l t a g e
* 1: T h e s e D T C s a r e i n d i c a t e d b y a blinking M I L w h e n t h e S C S line is j u m p e d w i t h t h e H D S .
* 3: '00-03 m o d e l s
* 4: '04-05 m o d e l s
* 6: ' 0 4 m o d e l
* 7: ' 0 5 m o d e l
11-9

T h e s e s y m p t o m s D O N O T trigger d i a g n o s t i c t r o u b l e c o d e s ( D T C s ) or c a u s e t h e m a l f u n c t i o n indicator l a m p (MIL) to
c o m e o n . If t h e M I L is r e p o r t e d o n , c h e c k for D T C s . If t h e v e h i c l e h a s o n e of t h e s e s y m p t o m s , d o the d i a g n o s t i c
p r o c e d u r e for it, in the s e q u e n c e l i s t e d , until y o u find t h e c a u s e .

E n g i n e w i l l not start 1. T e s t t h e battery ( s e e p a g e 22-47). • Low compression
(MIL w o r k s O K , no D T C s s e t ) 2. T e s t t h e starter ( s e e p a g e 4-7). • No ignition s p a r k
3. T e s t t h e fuel p u m p ( s e e p a g e 11-147). • Intake air l e a k s
4. T r o u b l e s h o o t t h e P G M - F I m a i n r e l a y circuit ( s e e p a g e • L o c k e d up e n g i n e
11-142). • Broken c a m chain
• C o n t a m i n a t e d fuel
E n g i n e will not start T r o u b l e s h o o t t h e M I L circuit ( s e e p a g e 11-106).
(MIL c o m e s o n a n d s t a y s o n ,
or n e v e r c o m e s o n at a l l , n o
D T C s set)
E n g i n e w i l l not start T r o u b l e s h o o t t h e i m m o b i l i z e r s y s t e m ( s e e p a g e 22-192).
( i m m o b i l i z e r indicator s t a y s
o n or f l a s h e s )
E n g i n e is h a r d to start 1. T e s t t h e battery ( s e e p a g e 22-47). • Low compression
(MIL w o r k s O K , no D T C s s e t ) 2. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-145). • Intake air l e a k s
Cold f a s t idle t o o l o w 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140).
(MIL w o r k s O K , no D T C s set) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11-140).
Cold f a s t idle t o o h i g h 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140). Intake air l e a k s
(MIL w o r k s O K , no D T C s set) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11-140).
3. I n s p e c t / a d j u s t t h e throttle c a b l e ( s e e p a g e 11-168).
4. T e s t t h e throttle b o d y ( s e e p a g e 11-163).
Idle s p e e d f l u c t u a t e s 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140). Incorrect v a l v e
(MIL w o r k s O K , n o D T C s s e t ) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11-140). t i m i n g or c l e a r a n c e
3. I n s p e c t / a d j u s t t h e throttle c a b l e ( s e e p a g e 11-168). adjustment
5. T r o u b l e s h o o t the A / C s i g n a l circuit ( s e e p a g e 11-133).
After w a r m i n g u p , idle s p e e d 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140). • F a u l t y throttle
is b e l o w s p e c i f i c a t i o n w i t h o u t 2. T r o u b l e s h o o t the alternator F R s i g n a l circuit cable
load ( s e e p a g e 11-135). • Incorrect valve
(MIL w o r k s O K , no D T C s set) 3. T r o u b l e s h o o t the electrical p o w e r s t e e r i n g ( E P S ) t i m i n g or c l e a r a n c e
s i g n a l circuit ( s e e p a g e 11-137). adjustment
After w a r m i n g u p , idle s p e e d 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140). Intake air l e a k s
is a b o v e s p e c i f i c a t i o n w i t h o u t 2. T r o u b l e s h o o t t h e alternator F R s i g n a l circuit
load ( s e e p a g e 11-135).
(MIL w o r k s O K , no D T C s set) 3. I n s p e c t t h e T P S e n s o r ( s e e p a g e 11-164).
4. T r o u b l e s h o o t t h e A / C s i g n a l circuit ( s e e p a g e 11-133).
5. T r o u b l e s h o o t the electrical p o w e r s t e e r i n g ( E P S )
s i g n a l circuit ( s e e p a g e 11-137).
11-10
Low power 1. T e s t t h e fuel p r e s s u r e ( s e e p a g e 11-145). • Low compression
(MIL w o r k s O K , n o D T C s s e t ) 2. T e s t the throttle b o d y ( s e e p a g e 11-163). • Incorrect c a m s h a f t
3. I n s p e c t / a d j u s t the throttle c a b l e ( s e e p a g e 11-168). timing
• Incorrect e n g i n e oil
level
Engine stalls 1. Do t h e idle learn p r o c e d u r e ( s e e p a g e 11-140). • Intake a i r l e a k s
(MIL w o r k s O K , no D T C s s e t ) 2. T e s t the fuel p r e s s u r e ( s e e p a g e 11-145). • Faulty h a r n e s s and
3. C h e c k t h e idle s p e e d ( s e e p a g e 11-140). sensor
4. Troubleshoot the brake pedal position switch signal connections
circuit ( s e e p a g e 11-139).
Difficult to refuel 1. T e s t t h e fuel tank v a p o r c o n t r o l v a l v e ( s e e p a g e Malfunctioning g a s
(MIL w o r k s O K , no D T C s s e t ) 11-195). station filling nozzle.
2. I n s p e c t t h e fuel tank s i g n a l t u b e b e t w e e n t h e fuel p i p e
a n d the fuel tank v a p o r c o n t r o l v a l v e .
3. I n s p e c t t h e fuel tank v e n t t u b e b e t w e e n t h e E V A P
c a n i s t e r a n d t h e fuel tank v a p o r control v a l v e .
4. C h e c k t h e E V A P c a n i s t e r .
Fuel overflows during R e p l a c e t h e fuel tank v a p o r c o n t r o l v a l v e ( s e e p a g e Malfunctioning g a s
refueling 11-196). station filling nozzle.
(No D T C s set)
11-11
System Description
Electronic Control System
T h e f u n c t i o n s of t h e fuel a n d e m i s s i o n s c o n t r o l s y s t e m s a r e m a n a g e d by t h e e n g i n e control m o d u l e ( E C M ) .
Fail-safe Function
W h e n a n a b n o r m a l i t y o c c u r s in t h e s i g n a l f r o m a s e n s o r , t h e E C M i g n o r e s t h e s i g n a l a n d a s s u m e s a p r e - p r o g r a m m e d
v a l u e for t h e s e n s o r that a l l o w s t h e e n g i n e to c o n t i n u e to r u n .
Back-up Function
W h e n a n a b n o r m a l i t y o c c u r s in t h e E C M , t h e i n j e c t o r s a r e c o n t r o l l e d b y a b a c k - u p circuit i n d e p e n d e n t of t h e s y s t e m to
permit minimal driving.
Self-diagnosis
W h e n a n a b n o r m a l i t y o c c u r s in t h e s i g n a l f r o m a s e n s o r , t h e E C M s u p p l i e s g r o u n d for t h e m a l f u n c t i o n indicator l a m p
(MIL) a n d s t o r e s t h e d i a g n o s t i c t r o u b l e c o d e ( D T C ) in e r a s a b l e m e m o r y . W h e n t h e ignition is first t u r n e d o n (II), the
E C M s u p p l i e s g r o u n d to t h e M I L f o r 15 to 2 0 s e c o n d s to c h e c k t h e M I L bulb c o n d i t i o n . If all r e a d i n e s s c o d e a r e not s e t ,
t h e M I L will f l a s h five t i m e s . If r e a d i n e s s c o d e a r e s e t to c o m p l e t e , t h e M I L will go out. T h e M I L m a y be t u r n e d off by
t h e E C M if t h e p r o b l e m that o r i g i n a l l y c a u s e d t h e M I L to b e i l l u m i n a t e d is a intermittent o n e .
t w o Driving C y c l e Detection M e t h o d
T o p r e v e n t f a l s e i n d i c a t i o n s , t h e " t w o d r i v i n g c y c l e d e t e c t i o n m e t h o d " is u s e d for s o m e s e l f - d i a g n o s t i c f u n c t i o n s .
W h e n a n a b n o r m a l i t y o c c u r s , t h e E C M s t o r e s it in its m e m o r y . W h e n t h e s a m e a b n o r m a l i t y r e c u r s after t h e ignition
s w i t c h is t u r n e d O F F a n d O N (II) a g a i n , t h e E C M t u r n s o n t h e M I L .
11-12
ECM Data
Y o u c a n retrieve data f r o m t h e E C M by c o n n e c t i n g a n O B D li s c a n tool o r t h e H D S to t h e d a t a link c o n n e c t o r ( D L C ) . T h e

i t e m s listed in the table b e l o w c o n f o r m to S A E r e c o m m e n d e d p r a c t i c e . T h e H D S a l s o r e a d s d a t a b e y o n d that
r e c o m m e n d e d by S A E to help y o u find the c a u s e s of intermittent p r o b l e m s .
NOTE:
T h e " o p e r a t i n g v a l u e s " listed a r e a p p r o x i m a t e a n d m a y v a r y d e p e n d i n g o n t h e e n v i r o n m e n t a n d the i n d i v i d u a l v e h i c l e .
U n l e s s noted o t h e r w i s e , " a t idle s p e e d " m e a n s idling w i t h t h e e n g i n e c o m p l e t e l y w a r m e d u p , in neutral p o s i t i o n , a n d
t h e A / C a n d all a c c e s s o r i e s t u r n e d off.
Data Description Operating Value Freeze

Data
Diagnostic Trouble If the E C M d e t e c t s a p r o b l e m , it w i l l s t o r e it a s a c o d e If no p r o b l e m is d e t e c t e d , YES
C o d e (DTC) c o n s i s t i n g of o n e letter a n d f o u r n u m b e r s . D e p e n d i n g t h e r e is n o output.
o n t h e p r o b l e m , a n S A E - d e f i n e d c o d e (POxxx, P 2 x x x )
or a H o n d a - d e f i n e d c o d e ( P l x x x ) will be output to a
s c a n tool or t h e H D S .
Engine Speed T h e E C M c o m p u t e s e n g i n e s p e e d f r o m the s i g n a l s Nearly the s a m e a s YES
s e n t f r o m the C r a n k s h a f t P o s i t i o n ( C K P ) s e n s o r . T h i s t a c h o m e t e r indication
d a t a is u s e d for d e t e r m i n i n g t h e t i m e a n d a m o u n t of A t idle s p e e d :
injected f u e l . 8 0 0 ± 5 0 rpm
Vehicle S p e e d T h e E C M c o n v e r t s p u l s e s i g n a l s f r o m the V e h i c l e Nearly the s a m e a s YES
S p e e d S e n s o r ( V S S ) into s p e e d d a t a . s p e e d o m e t e r indication
Manifold Absolute T h e a b s o l u t e p r e s s u r e c a u s e d in t h e intake m a n i f o l d With engine stopped: YES
P r e s s u r e (MAP) by engine load and speed. Nearly the s a m e a s
atmospheric pressure
A t idle s p e e d : 2 8 — 4 8 kPa
( 8 . 3 - 1 4 . 2 in.Hg,
2 1 0 - 3 6 0 mmHg)
Engine Coolant T h e E C T s e n s o r c o n v e r t s c o o l a n t t e m p e r a t u r e into With cold engine: S a m e YES
Temperature (ECT) v o l t a g e , a n d s e n d s a v o l t a g e s i g n a l to the E C M . T h e as ambient temperature
s e n s o r is a t h e r m i s t o r w h o s e internal r e s i s t a n c e and IAT
c h a n g e s w i t h c o o l a n t t e m p e r a t u r e . T h e E C M u s e s the W i t h e n g i n e w a r m e d up:
v o l t a g e s i g n a l s f r o m the E C T s e n s o r to d e t e r m i n e t h e a b o u t 1 7 6 - 2 1 2 °F
a m o u n t of i n j e c t e d f u e l . ( 8 0 — 1 0 0 °C)
Primary Heated T h e H 0 2 S d e t e c t s t h e o x y g e n c o n t e n t in the e x h a u s t 0.0-1.4 V NO
Oxygen Sensor g a s a n d s e n d s v o l t a g e s i g n a l s to t h e E C M . B a s e d o n At idle s p e e d :
(Primary H 0 2 S ) t h e s e s i g n a l s , t h e E C M c o n t r o l s t h e air/fuel ratio. about 0.1—0.9 V
( S e n s o r 1), W h e n t h e o x y g e n c o n t e n t is high (that i s , w h e n t h e
S e c o n d a r y Heated ratio is l e a n e r t h a n t h e s t o i c h i o m e t r i c ratio), t h e
Oxygen Sensor v o l t a g e s i g n a l is l o w e r . W h e n t h e o x y g e n c o n t e n t is
(Secondary H02S) l o w (that i s , w h e n t h e ratio is r i c h e r t h a n the
( S e n s o r 2) s t o i c h i o m e t r i c ratio), the v o l t a g e s i g n a l is h i g h e r .
(cont'd)
11-13
System Description (cont'd)
ECM Data (cont'd)
Data Description Operating Value Freeze

Data
Fuel S y s t e m Status F u e l s y s t e m s t a t u s i s i n d i c a t e d a s " o p e n " or " c l o s e d " . A t idle s p e e d : c l o s e d YES
C l o s e d : B a s e d o n t h e H 0 2 S output, t h e E C M
d e t e r m i n e s t h e air/fuel ratio a n d c o n t r o l s t h e a m o u n t
of i n j e c t e d f u e l .
O p e n : Ignoring H 0 2 S output, t h e E C M r e f e r s to
s i g n a l s f r o m t h e throttle p o s i t i o n ( T P ) , m a n i f o l d
a b s o l u t e p r e s s u r e ( M A P ) , intake a i r t e m p e r a t u r e (IAT),
barometric pressure (BARO) and engine coolant
t e m p e r a t u r e ( E C T ) s e n s o r s to c o n t r o l t h e a m o u n t of
injected f u e l .
Short T e r m Fuel T h e air f u e l ratio c o r r e c t i o n c o e f f i c i e n t for c o r r e c t i n g 0.73-1.47 YES
Trim t h e a m o u n t of i n j e c t e d fuel w h e n t h e F u e l S y s t e m
S t a t u s is " c l o s e d " . W h e n t h e ratio is l e a n e r t h a n t h e
s t o i c h i o m e t r i c ratio, t h e E C M i n c r e a s e s h o r t t e r m fuel
t r i m g r a d u a l l y , a n d t h e a m o u n t of i n j e c t e d fuel
i n c r e a s e s . T h e air fuel ratio g r a d u a l l y g e t s r i c h e r ,
c a u s i n g a l o w e r o x y g e n c o n t e n t in t h e e x h a u s t g a s .
C o n s e q u e n t l y , t h e s h o r t t e r m fuel t r i m is l o w e r e d ,
a n d t h e E C M r e d u c e s t h e a m o u n t of injected f u e l .
T h i s c y c l e k e e p s t h e air/fuel ratio c l o s e to the
s t o i c h i o m e t r i c ratio w h e n in c l o s e d loop s t a t u s .
Long T e r m Fuel L o n g t e r m f u e l t r i m is c o m p u t e d f r o m s h o r t t e r m fuel 0.80-1.20 YES
Trim t r i m a n d i n d i c a t e s c h a n g e s o c c u r r i n g in the fuel
supply s y s t e m over a long period.
If long t e r m fuel t r i m is h i g h e r t h a n 1.00, the a m o u n t
of i n j e c t e d f u e l m u s t b e i n c r e a s e d . If it is l o w e r t h a n
1.00, t h e a m o u n t of i n j e c t e d f u e l m u s t be r e d u c e d .
Intake A i r T h e I A T s e n s o r c o n v e r t s intake air t e m p e r a t u r e into With cold engine: YES
T e m p e r a t u r e (IAT) v o l t a g e a n d s i g n a l s t h e E C M . W h e n intake air S a m e a s ambient
t e m p e r a t u r e is l o w , t h e i n t e r n a l r e s i s t a n c e of t h e temperature and E C T
s e n s o r i n c r e a s e s , a n d t h e v o l t a g e s i g n a l is h i g h e r .
Throttle P o s i t i o n B a s e d on the accelerator pedal position, the opening A t idle s p e e d : a b o u t 6 % YES
a n g l e of t h e throttle v a l v e is i n d i c a t e d .
Ignition T i m i n g Ignition t i m i n g is t h e ignition a d v a n c e a n g l e s e t by A t idle s p e e d : NO
t h e E C M . T h e E C M m a t c h e s ignition t i m i n g to t h e 5°±5°BTDCwiththe
driving conditions. S C S s e r v i c e s i g n a l line
j u m p e d with the H D S
Calculated Load C L V is t h e e n g i n e l o a d c a l c u l a t e d f r o m the M A P d a t a . A t idle s p e e d : 2 2 — 4 2 % YES
Value (CLV) At 2,500 r p m w i t h o u t
load: 2 7 - 4 8 %
11-14
E C M Electrical Connections
PGM-FI MAIN RELAY
•ora m •HWV-i LQTO-
\ FUEL
/PUMP
ENGINE
START
SWITCH
6
B9IGP2 PG2 B10
A24STS IMOFLR A15
CMP (TDC)
SENSOR B C30CMP2M INJ2 B3
CMP (TDC) INJ3 B4

SENSOR A INJ4 B5 $ O-^RP-O-
CKP C8CKP+
SENSOR
IACV B23 rf3
DATA
LINK
CONNECTOR
A10SCS
BRAKE PEDAL
POSITION SWITCH
- • T o ECT GAUGE
—•—
KNOCKSENSOR
-^To A/C CLUTCH RELAY
r _^To RADIATOR FAN RELAY,
FANC A20
^ RADIATOR FAN SWITCH
-•To A/C SWITCH
To ELD
To EPS CONTROL UNIT
ALTERNATOR
FUSES:
© N o . 41 B A T T E R Y ( 1 0 0 A ) * A A32 BKSW
( I N o . 5 4 B A C K U P A C C (30 A ) * A
( D N o . 4 7 S T O P (10 A ) * ( 1 5 A ) * A IMOLMP A12
BARO
4 N o . 4 2 I G 1 M A I N (40 A ) * A SENSOR
®No.46ACGS(15A) *A (Built into the IMMOBILIZER
(DNo. 3 2 A I R P U M P (60 A ) * B ECM) INDICATOR
DNo. 2 5 B A C K U P (7.5 A ) * C - • To IMMOBILIZER RECEIVER
DN0.6ACG (15 A ) * C
- • To IMMOBILIZER RECEIVER
D N o . 5 I N S T R U M E N T L I G H T B A C K U P L I G H T (7.5 A ) * C
(§>No. 2 F U E L P U M P S R S (15 A ) * C
1J N o . 4 I G N C O I L ( 1 5 A ) * C TEST
@No. 3 E N G I N E S T A R T (7.5 A ) * C TACHOMETER
( U N o . 2 1 S T A R T E R S I G N A L (7.5 A ) * C To GAUGE ASSEMBLY
* A : in t h e m a i n under-hood f u s e / r e l a y b o x
* B : in t h e auxiliary u n d e r - h o o d f u s e b o x
* C : in t h e u n d e r - d a s h f u s e / r e l a y b o x
* : '00-01 m o d e l s
(cont'd)
11-15
E C M Electrical C o n n e c t i o n s (cont'd)
MAP
SENSOR
To
SPARK
L - ^ - | PLUG
No. 11GNITION COIL
To
" — I SPARK
~1
PLUG
p|
C
I M I i—nnp-i
No. 2 IGNITION COIL
To
SPARK
PLUG
No. 3 IGNITION COIL
To
SPARK
—
i nnp—] P
LUG
No. 4 IGNITION COIL
EVAP CANISTER PURGE VALVE

0 _ ^jv<>—
i
AIR CONTROL VALVE VACUUM CONTROL SOLENOID VALVE

o-^RT^-o
EVAP BYPASS SOLENOID VALVE
O-TflffV-O
EVAP CANISTER VENT SHUT VALVE
Q_r$fl\_o
ROCKER ARM OIL CONTROL SOLENOID (VTEC SOLENOID VALVE)
o-ntfpô
ROCKER ARM OIL PRESSURE SWITCH

(VTEC OIL PRESSURE SWITCH)
AIR PUMP
RELAY
AIR PUMP (Mj
TERMINAL LOCATIONS
ECM A (32P) ECM B (25P) ECMC(31P)
1 2 3 4 / / /
6 9 10 1 2 1 2
/4 5
/ 8 9 10
12 13
/ /15 17 18 19 20 21 24 9 10 11 H Z Z Z 11 12 13 14 15 16 17 18 19 20 21 22
25 26 27 28 29 30 32 20 2122 23
/ 24 25 26 27 28 29 30
/
11-16
ECM Inputs and Outputs at Connector A (32P)
/ /
1 2 3 4 6 9 10
MTF?
TW SAVS 2WBS VSV PCS VSS SCS
12
IMO
LMP
13
IMO
EN /25
15
IMO
FLR
26
/
27
17
ACC
18
MiL
28
19
NEP
29
20
FANC K-UNE
30
21
32
24
STS
IMO EPS
CO LD ACS APR PTANK ELD BKSW
NOTE: S t a n d a r d battery voltage is about 12 V.
Terminal W i r e color Terminal name Description Signal

number
1 YELG
/ RN MT
R T
W S e n d s ECT signal to ECT With ignition s w i t c h ON (If): duty controlled
gauge
2 RED S AVS (AIR C ON T RO LVALVED r i v e s air control v a l v e W i t h ignition s w i t c h ON (II): battery voltage
V ACU UM C ON TRO L v a c u u m control s o l e n o i d With air p u m p w o r k i n g : a b o u t 0 V
S OLEN O D
I VA LV E) valve
3 ORN 2WBS (E V APB YPAS S Drives E V AP bypass solenoid W i t h ignition s w i t c h ON (II): battery voltage
S OLEN O D
I VA LV E) valve
4 LTG R N/ VSV (
E VA PC A N S
ITE RV ENT Drives E V AP canister vent W i t h ignition s w i t c h ON (II): battery voltage
WHT S HUTV A LVE) shut valve
6 RED /
Y EL PCS (
E VA PC A NSITE R PURGEDrives E V AP canister purge With e n g i n e r u n n i n g , e n g i n e c o o l a n t b e l o w 149 °F
V ALVE) valve (65 <C): battery voltage
With e n g i n e running e n g i n e c o o l a n t a b o v e 149 °F
(65 °C): duty controlled
9 BLU7WHT VSS (
V EHI
C L ES PEED S e n d s vehicle speed sensor Depending on vehicle speed: pulses
S ENSOR (VSS) N
IPUT (VSS) input signal
S I
G NAL)
10 BRN SCS (SERV I
C EC HECK Detects service c h e c k With the s e r v i c e c h e c k s i g n a l s h o r t e d with the
S I
G NAL) c o n n e c t o r signal (the s i g n a l HDS: about 0 V
c a u s i n g a DTC indication) With the s e r v i c e c h e c k s i g n a l o p e n e d :
about 5.0 V or battery voltage
12 PNK M
I OL
M P(M
I MOBL
IZ
IER D r i v e s immobilizer indicator With immobilizer indicator t u r n e d ON: about 0 V
N
IDC
IA TOR) W i t h immobilizer indicator t u r n e d OFF:
battery voltage
13 PNK B
/LU M
I O E N( M
I M OB L
IZ
IER S e n d s immobilizer e n a b l e
E NAB L E S I
G NA L) signal
15 GRN Y
/EL M
I O F
L R (M
I M O BL
IZIER FU ELD r i v e s fuel p u m p relay 0 V for 2 s e c o n d s after turning ignition s w i t c h ON
P UMPR EL AY) (II), then battery voltage
17 RED ACC (A/C C L UT
C H R ELAY) D r i v e s A/C clutch relay With c o m p r e s s o r ON: about 0 V
With c o m p r e s s o r OFF: battery voltage
18 GRN O
/RN ML
I (
M ALFUN CTO
I N D r i v e s ML I With ML I turned ON: about 0 V
N
ID C
IA TOR L AM P) W i t h ML
I turned OFF: battery voltage
19 BLU NEP (ENGI
N E S PEEDP ULSE)O u t p u t s engine s p e e d p u l s e With e n g i n e running: p u l s e s
20 GRN F ANC( RAD A
IT
O R FAN D r i v e s radiator fan relay With radiator fan running: about 0 V
C ON TROL) With radiator f a n s t o p p e d : battery voltage
(cont'd)
11-17

1
MTR
2 3 4 6
/ / 9 10
/
TW SAVS 2WBS VSV PCS VSS SCS
12
IMO
IMP
13
IMO
EN
25
IMO
15
IMO
FLR
26
EPS
/ 27
17
ACC
18
MIL
28
19
NEP
29
20
FANC
30
21
K-UNE
32
24
STS
CO LD ACS APR PTANK ELD BKSW
N O T E : S t a n d a r d battery voltage is about 12 V.

number
21 GRY K-LINE S e n d s a n d r e c e i v e s s c a n tool With ignition switch O N (II): battery voltage
signal
24 BLU/ORN S T S (STARTER SWITCH Detects starter s w i t c h signal With starter s w i t c h O N (III): battery voltage
SIGNAL) With starter s w i t c h O F F : about 0 V
25 RED/BLU IMOCO (IMMOBILIZER C O D E ) Detects immobilizer signal
26 BLU/BLK E P S L D (ELECTRICAL P/S Detects P / S load sig n al With steering w h e e l at full lock:
LOAD DETECT) battery voltage m o m e n t a r i l y
With steering w h e e l stationary: about 0 V
27 BLU/RED A C S (A/C S W I T C H S I G N A L ) Detects A / C s w i t c h s i g n a l With A / C s w i t c h O N : about 0 V
With A / C s w i t c h O F F : about 5.0 V
28 BLU A P R (AIR P U M P R E L A Y ) D r i v e s air p u m p relay With ignition s w i t c h O N (II): about 0 V
With air p u m p w o r k i n g : battery voltage
29 LTGRN PTANK (FUEL TANK Detects fuel tank p r e s s u r e With ignition s w i t c h O N (II) a n d fuel fill c a p :
P R E S S U R E (FTP) S E N S O R ) (FTP) s e n s o r signal o p e n e d : about 2.5 V
30 GRN/RED ELD (ELECTRICAL LOAD Detects E L D signal With parking lights turned o n at idle:
DETECTOR) about 2 . 5 - 3 . 5 V
With high b e a m headlights turned o n at idle:
about 1 . 5 - 2 . 5 V
32 WHT/BLK B K S W (BRAKE PEDAL Detects brake pedal position With brake pedal r e l e a s e d : about 0 V
POSITION SWITCH) s w i t c h sig n al With brake pedal p r e s s e d : battery voltage
11-18
ECM Inputs and Outputs at Connector B (25P)

number
1 YEL/BLK IGP1 ( P O W E R S O U R C E ) P o w e r s o u r c e for E C M control With ignition s w i t c h O N (II): battery voltage
circuit W i t h ignition s w i t c h O F F : about 0 V
2 BLK PG1 ( P O W E R G R O U N D ) G r o u n d for E C M control L e s s t h a n 1.0 V at all t i m e s
circuit
3 RED INJ2 (No. 2 I N J E C T O R ) Drives No. 2 injector With ignition s w i t c h O N (II): battery voltage
4 BLU INJ3 (No. 3 I N J E C T O R ) Drives No. 3 injector With e n g i n e running: duty controlled
5 YEL INJ4 (No. 4 I N J E C T O R ) Drives No. 4 injector
9 YEL/BLK IGP2 (POWER SOURCE) P o w e r s o u r c e for E C M control With ignition s w i t c h O N (II): battery voltage
circuit With ignition s w i t c h O F F : about 0 V
10 BLK PG2 (POWER G R O U N D ) G r o u n d for E C M control L e s s than 1.0 V at all t i m e s
circuit
11 BRN INJ1 (No. 1 I N J E C T O R ) Drives No. 1 injector With ignition s w i t c h O N (II): battery voltage
With engine running: duty controlled
12 GRN/YEL V T S (ROCKER A R M OIL Drives rocker a r m oil control With e n g i n e at low r p m : about 0 V
CONTROL SOLENOID (VTEC solenoid ( V T E C s o l e n o i d With e n g i n e at high r p m : battery voltage
SOLENOID VALVE)) valve)
20 BRN/YEL LG1 ( L O G I C G R O U N D ) G r o u n d for E C M control L e s s than 1.0 V at all t i m e s
circuit
21 WHT/RED V B U ( V O L T A G E B A C K UP) P o w e r s o u r c e for E C M control Battery voltage at all t i m e s
circuit
P o w e r s o u r c e for D T C
memory
22 BRN/YEL LG2 (LOGIC GROUND) G r o u n d for E C M control L e s s than 1.0 V at all t i m e s
circuit
23 BLK/RED I A C V (IDLE AIR C O N T R O L Drives I A C v a l v e With engine running: duty controlled
VALVE)
(cont'd)
11-19
ECM Inputs and Outputs at Connector C (31P)
1 2 4 5 7 8 9 10
P02S IGPLS
HTC ALTC 1 ALTF SG1 CKP+ C K P - VTM
11 12 13 14 15 16 17 18 19 20 21 22
S02S IGPLS IGPLS IGPLS
HTC 2 3 4 SH02S PH02S MAP SG2 VCC1 CMP1P CMP1M KS
24 25 26 27 28 29 30
ECS IAT ECT TPS VCC2 CMP2P CMP2M
N O T E : S t a n d a r d battery voltage is a b o u t 12 V.

number
1 BLK/WHT P 0 2 S H T C (PRIMARY H E A T E D D r i v e s p r i m a r y heated o x y g e n With ignition s w i t c h O N (II): battery voltage
O X Y G E N SENSOR HEATER s e n s o r heater With fully w a r m e d up engine running:
CONTROL) duty controlled
2 WHT/GRN ALTC (ALTERNATOR S e n d s alternator control With fully w a r m e d up e n g i n e running: about 8.0 V
CONTROL) signal With engine running at low electrical load:
about 0 V
4 WHT I G P L S 1 (No. 1 IGNITION C O I L Drives No. 1 ignition coil With ignition s w i t c h O N (II): about 0 V
PULSE) With engine running: p u l s e s
5 WHT/RED A L T F ( A L T E R N A T O R FR Detects alternator FR signal With fully w a r m e d up engine running:
SIGNAL) about 0 V—battery voltage
(depending on electrical load)
7 GRN/WHT SG1 (SENSOR GROUND) G r o u n d for M A P s e n s o r L e s s than 1.0 V at all t i m e s
8 BLU C K P + (CKP S E N S O R P + S I D E ) Detects C K P s e n s o r With engine running: p u l s e s
9 WHT C K P - (CKP S E N S O R M - S I D E ) G r o u n d for C K P s e n s o r
10 BLU/BLK V T M (ROCKER A R M OIL Detects rocker a r m oil With engine at low e n g i n e s p e e d : about 0 V
P R E S S U R E S W I T C H (VTEC OIL p r e s s u r e s w i t c h ( V T E C oil With engine at high e n g i n e s p e e d (vehicle
P R E S S U R E SWITCH) SIGNAL) pressure switch) signal running): battery voltage
11 BLK/WHT S02SHTC (SECONDARY Drives s e c o n d a r y heated With ignition s w i t c h O N (II): battery voltage
HEATED O X Y G E N SENSOR o x y g e n s e n s o r heater With fully w a r m e d up engine running:
HEATER CONTROL) duty controlled
12 WHT/GRN I G P L S 2 (No. 2 IGNITION C O I L Drives No. 2 ignition coil With ignition s w i t c h O N (II): about 0 V
PULSE) With engine running: p u l s e s
13 WHT/BLK I G P L S 3 (No. 3 IGNITION C O I L Drives No. 3 ignition coil
PULSE)
14 WHT/BLU I G P L S 4 (No. 4 IGNITION C O I L Drives No. 4 ignition coil
PULSE)
15 WHT/RED SH02S (SECONDARY HEATED Detects s e c o n d a r y heated With throttle fully o p e n e d f r o m idle with fully,
O X Y G E N S E N S O R , S E N S O R 2) oxygen s e n s o r ( s e n s o r 2) w a r m e d up engine: a b o v e 0.6 V
signal With throttle quickly c l o s e d : b e l o w 0.4 V
16 WHT P H 0 2 S (PRIMARY H E A T E D Detects primary heated With throttle fully o p e n e d f r o m idle with fully,
O X Y G E N S E N S O R , S E N S O R 1) oxygen s e n s o r ( s e n s o r 1) w a r m e d up engine: a b o v e 0.6 V
signal With throttle quickly c l o s e d : b e l o w 0.4 V
17 GRN/RED MAP (MANIFOLD A B S O L U T E Detects M A P s e n s o r signal With ignition s w i t c h O N (II): about 3.0 V
PRESSURE SENSOR) At idle: about 1.0 V (depending on engine s p e e d )
18 GRN/YEL SG2 (SENSOR GROUND) Sensor ground L e s s than 1.0 V at all t i m e s .
19 YEL/RED VCC1 (SENSOR V O L T A G E ) P o w e r s o u r c e to M A P s e n s o r With ignition s w i t c h O N (II): about 5.0 V
With ignition s w i t c h O F F : about 0 V
11-20
ECM Inputs and Outputs at Connector C (31P)
1 2 4 5 7 8 9 10
P02S IGPLS
HTC ALTC 1 ALTF SG1 CKP+ C K P - VTM
11 12 13 14 15 16 17 18 19 20 21 22
SQ2S IGPLS IGPLS IGPLS
HTC 2 3 4 SHC2S PH02S MAP SG2 VCC1 CMP1P CMP1M KS
24 25 26 27 28 29 30
ECS IAT ECT TPS VCC2 CMP2P CMP2M
N O T E : S t a n d a r d battery voltage is about 12 V .

number
20 GRN CMP1P (CAMSHAFT POSITION Detects C M P (TDC) s e n s o r A With engine running: p u l s e s
(CMP) S E N S O R (TOP D E A D
C E N T E R (TDC) S E N S O R ) A P
SIDE)
21 RED CMP1M (CAMSHAFT POSITION G r o u n d for C M P (TDC) s e n s o r
(CMP) S E N S O R ( T O P D E A D A
C E N T E R (TDC) S E N S O R ) A M
SIDE)
22 RED/BLU KS (KNOCK S E N S O R ) Detects knock s e n s o r s i g n a l With engine knocking: p u l s e s
24 WHT/BLK E C S (AIR P U M P E L E C T R I C A L Detects air p u m p electrical With ignition s w i t c h O N (II): about 0.5 V
CURRENT SENSOR) current s e n s o r signal With air p u m p working: about 2.0—5.0 V
25 RED/YEL IAT ( I N T A K E AIR Detects IAT s e n s o r s i g n a l With ignition s w i t c h O N (II): about 0.1—4.8 V
TEMPERATURE SENSOR) (depending o n intake air temperature)
26 RED/WHT E C T (ENGINE C O O L A N T Detects E C T s e n s o r s i g n a l With ignition s w i t c h O N (II): about 0.1—4.8 V
TEMPERATURE SENSOR) (depending o n e n g i n e coolant temperature)
27 RED/BLK T P S (THROTTLE POSITION Detects T P s e n s o r signal With throttle fully o p e n : about 4.8 V
SENSOR) With throttle fully c l o s e d : about 0.3 V
28 YEL/BLU VCC2 (SENSOR VOLTAGE) Provides s e n s o r voltage With ignition s w i t c h O N (II): about 5.0 V
With ignition s w i t c h O F F : about 0 V
29 YEL CMP2P (CAMSHAFT POSITION Detects C M P (TDC) s e n s o r B With engine running: p u l s e s
(CMP) S E N S O R (TOP D E A D
C E N T E R (TDC) S E N S O R ) B P
SIDE)
30 BLK CMP2M (CAMSHAFT POSITION G r o u n d for C M P (TDC) s e n s o r
(CMP) S E N S O R ( T O P D E A D B
C E N T E R (TDC) S E N S O R ) B M
SIDE)
(cont'd)
11-21
Vacuum Hose Routing
FUEL
PRESSURE
AIR C O N T R O L V A C U U M R E S E R V O I R
11-22
Vacuum Distribution
® P( SREI MN SAORRY H1)E A T E D O X Y G E N S E N S O R (PRIMARY H 0 2 S ) ® E V A P O R A T I V E E M I S S I O N (EVAP) C A N I S T E R FILTER

20) E V A P O R A T I V E E M I S S I O N ( E V A P ) C A N I S T E R P U R G E
® SECONDARY HEATED OXYGEN SENSOR (SECONDARY VALVE
H 0 2 S ) ( S E N S O R 2) ® EVAPORATIVE E M I S S I O N (EVAP) CANISTER V E N T
® M A N I F O L D A B S O L U T E P R E S S U R E (MAP) S E N S O R SHUT VALVE
•® I N T A K E A I R T E M P E R A T U R E (IAT) S E N S O R 9 EVAPORATIVE E M I S S I O N (EVAP) T W O W A Y V A L V E
® ENGINE C O O L A N T T E M P E R A T U R E (ECT) S E N S O R 23) E V A P O R A T I V E E M I S S I O N ( E V A P ) B Y P A S S S O L E N O I D
® KNOCK SENSOR VALVE
® I D L E A I R C O N T R O L (IAC) V A L V E © F U E L T A N K P R E S S U R E (FTP) S E N S O R
® THROTTLE BODY © FUEL TANK VAPOR CONTROL VALVE
® INJECTOR © FUEL TANK VAPOR RECIRCULATION VALVE
FUEL PRESSURE REGULATOR 2/0 P U R G E J O I N T
© FUEL FILTER © AIR P U M P
FUEL PUMP © AIR C O N T R O L V A L V E V A C U U M C O N T R O L S O L E N O I D
FUELTANK VALVE
FUEL PULSATION DAMPER (§> A I R C O N T R O L V A L V E
POSITIVE C R A N K C A S E V E N T I L A T I O N (PCV) V A L V E © AIR C O N T R O L V A C U U M R E S E R V O I R
THREE WAY CATALYTIC CONVERTER © AIR C O N T R O L V A C U U M C H E C K V A L V E
AIR C L E A N E R
EVAPORATIVE E M I S S I O N (EVAP) CANISTER
(cont'd)
11-23
S y s t e m D e s c r i p t i o n (cont'd)
PGM-FI System Engine Coolant Temperature (ECT) Sensor

T h e E C T s e n s o r is a temperature dependent resistor
T h e p r o g r a m m e d fuel injection ( P G M - F I ) s y s t e m is a (thermistor). T h e r e s i s t a n c e of t h e t h e r m i s t o r d e c r e a s e s
s e q u e n t i a l m u l t i p o r t f u e l injection s y s t e m . a s the e n g i n e c o o l a n t t e m p e r a t u r e i n c r e a s e s .
Alternator Control
T h e alternator s i g n a l s the E C M d u r i n g c h a r g i n g . T h e TERMINAL O-RING
E C M t h e n c o n t r o l s t h e v o l t a g e g e n e r a t e d at t h e
alternator a c c o r d i n g to t h e e l e c t r i c a l load d e t e r m i n e d
b y t h e E L D ( E l e c t r i c a l L o a d Detector) a n d d r i v i n g m o d e .
T h i s r e d u c e s e n g i n e load to i m p r o v e fuel e c o n o m y .
/
A / C Switch
T h e A / C (air c o n d i t i o n i n g ) s w i t c h s i g n a l s t h e E C M L - ^ - l - L-\
U
I
w h e n e v e r t h e r e is a d e m a n d for c o o l i n g .
THERMISTOR
A / C CompressorClutch Relay
W h e n the E C M r e c e i v e s a d e m a n d for c o o l i n g f r o m t h e
A / C s y s t e m , it d e l a y s t h e c o m p r e s s o r f r o m b e i n g
e n e r g i z e d , a n d e n r i c h e s t h e m i x t u r e to a s s u r e s m o o t h I n t a k e A i r T e m p e r a t u r e (IAT) S e n s o r
t r a n s i t i o n to t h e A / C m o d e . T h e I A T s e n s o r is a t e m p e r a t u r e d e p e n d e n t r e s i s t o r
(thermistor). T h e r e s i s t a n c e of the t h e r m i s t o r d e c r e a s e s
Barometric Pressure (BARO) Sensor a s t h e intake air t e m p e r a t u r e i n c r e a s e s .
T h e B A R O s e n s o r is i n s i d e t h e E C M . It c o n v e r t s
a t m o s p h e r i c p r e s s u r e into a v o l t a g e s i g n a l t h a t is u s e d
b y the E C M to m o d i f y t h e b a s i c d u r a t i o n of t h e fuel TERMINAL O-RING
injection d i s c h a r g e .
Crankshaft Position (CKP) S e n s o r

T h e C K P s e n s o r d e t e r m i n e s t i m i n g for injection of e a c h
cylinder and also detects engine speed.
T h e E C M d e t e c t s m i s f i r i n g b y u s i n g the C K P s e n s o r to
m o n i t o r f l u c t u a t i o n s in c r a n k s h a f t s p e e d . It w i l l t h e n s e t
D T C s depending on h o w m u c h misfiring o c c u r s .
THERMISTOR
I I
[[Qui i Tb3£t
CKPSENSOR
11-24
Injector T i m i n g a n d D u r a t i o n Primary and Secondary Heated O x y g e n S e n s o r s
T h e E C M c o n t a i n s t h e m e m o r y for b a s i c d i s c h a r g e (H02S)
duration at v a r i o u s e n g i n e s p e e d s a n d m a n i f o l d T h e heated o x y g e n s e n s o r s detect the oxygen content
p r e s s u r e s . T h e b a s i c d i s c h a r g e d u r a t i o n , after b e i n g in t h e e x h a u s t g a s , t h e n s e n d s a s i g n a l to t h e E C M
r e a d out f r o m t h e m e m o r y , is further m o d i f i e d b y w h i c h v a r i e s t h e d u r a t i o n of injection a c c o r d i n g l y . T o
s i g n a l s s e n t f r o m v a r i o u s s e n s o r s to obtain t h e final stabilize its output, t h e s e n s o r s h a v e a n internal h e a t e r .
discharge duration. T h e p r i m a r y s e n s o r is installed in t h e e x h a u s t p i p e . T h e
B y m o n i t o r i n g long t e r m fuel t r i m , the E C M d e t e c t s long s e c o n d a r y s e n s o r i s installed in t h e T W C .
t e r m m a l f u n c t i o n s in t h e fuel s y s t e m , a n d will s e t a D T C
if the m a l f u n c t i o n o c c u r s d u r i n g t w o c o n s e c u t i v e trips.
SENSOR
ZIRCONIA TERMINALS
Ignition T i m i n g C o n t r o l ELEMENT
T h e E C M c o n t a i n s t h e m e m o r y for b a s i c ignition t i m i n g
at v a r i o u s e n g i n e s p e e d s a n d m a n i f o l d p r e s s u r e s . It
a l s o a d j u s t s t h e t i m i n g a c c o r d i n g to e n g i n e c o o l a n t
temperature.
Knock Sensor
T h e knock control s y s t e m a d j u s t s t h e ignition t i m i n g to
m i n i m i z e knock.
HEATER
TERMINAL HEATER TERMINALS
PIEZO CERAMIC
B y controlling t h e air/fuel ratio w i t h s e n s o r s , t h e

DIAPHRAGM
deterioration of t h e p r i m a r y s e n s o r c a n be e v a l u a t e d by
its f e e d b a c k p e r i o d . W h e n the f e e d b a c k period e x c e e d s
a certain value during stable driving conditions, the
s e n s o r is c o n s i d e r e d deteriorated a n d the E C M s e t s a
DTC.
Starting Control
W h e n t h e e n g i n e is s t a r t e d , the E C M p r o v i d e s a rich
m i x t u r e by i n c r e a s i n g injector d u r a t i o n .
Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r
T h e M A P s e n s o r converts manifold absolute pressure
into electrical s i g n a l s to the E C M .
S E N S O R UNIT
TERMINAL
(cont'd)
11-25
T h r o t t l e P o s i t i o n (TP) S e n s o r Idle Control System

T h e T P s e n s o r is a p o t e n t i o m e t e r c o n n e c t e d to t h e
throttle v a l v e shaft. A s t h e throttle p o s i t i o n c h a n g e s , t h e W h e n the e n g i n e is c o l d , the A / C c o m p r e s s o r is o n , t h e
s e n s o r v a r i e s t h e s i g n a l v o l t a g e to t h e E C M . T h e T P t r a n s m i s s i o n is in g e a r , t h e b r a k e p e d a l is p r e s s e d , t h e
s e n s o r is not r e p l a c e a b l e a p a r t f r o m t h e throttle b o d y . P / S l o a d is h i g h , or the alternator i s c h a r g i n g , t h e E C M
s e n d s s i g n a l s to t h e I A C v a l v e to m a i n t a i n t h e c o r r e c t
BRUSH HOLDER
idle s p e e d . R e f e r to the s y s t e m d i a g r a m to s e e t h e
f u n c t i o n a l l a y o u t of t h e s y s t e m .
Brake Pedal Position S w i t c h

T h e brake p e d a l position s w i t c h s i g n a l s t h e E C M w h e n
t h e brake p e d a l is p r e s s e d .
Electrical P o w e r Steering (EPS) Signal

T h e E P S signals the E C M w h e n the p o w e r steering load
is h i g h .
Engine Start Switch

T h e e n g i n e start s w i t c h s i g n a l s t h e E C M w h e n the
e n g i n e is c r a n k i n g .
C a m s h a f t Position (CMP S e n s o r (Top D e a d C e n t e r Idle A i r C o n t r o l (IAC) V a l v e

(TDC) S e n s o r s ) T o m a i n t a i n t h e p r o p e r idle s p e e d , t h e I A C v a l v e
T h e C M P A / B ( T D C 1 / 2 ) s e n s o r d e t e r m i n e s t h e ignition c h a n g e s t h e a m o u n t of air b y p a s s i n g t h e throttle b o d y
t i m i n g at start u p (cranking) a n d w h e n t h e c r a n k a n g l e in r e s p o n s e to a n e l e c t r i c a l s i g n a l f r o m t h e E C M .
is a b n o r m a l .
VALVE
(TDC) S E N S O R A
(TDC) S E N S O R B
11-26
Fuel Supply System Intake Air System
F u e l Cutoff C o n t r o l R e f e r to t h e s y s t e m d i a g r a m to s e e a f u n c t i o n a l layout
D u r i n g d e c e l e r a t i o n w i t h the throttle v a l v e c l o s e d , of t h e s y s t e m .
c u r r e n t to the i n j e c t o r s is cut off to i m p r o v e fuel
e c o n o m y at s p e e d s o v e r 1,050 r p m . Throttle Body
F u e l cutoff a l s o o c c u r s w h e n e n g i n e s p e e d e x c e e d s T h e throttle b o d y is a s i n g l e - b a r r e l s i d e draft t y p e . T h e
9,000 r p m , r e g a r d l e s s of t h e position of t h e throttle l o w e r portion of t h e throttle v a l v e is h e a t e d b y e n g i n e
v a l v e , to protect t h e e n g i n e f r o m o v e r - r e v v i n g . coolant from the cylinder h e a d .
Fuel Pump Control

W h e n t h e ignition is t u r n e d O N (II), t h e E C M g r o u n d s
the P G M - F I m a i n r e l a y w h i c h f e e d s c u r r e n t to the fuel
p u m p for 2 s e c o n d s to p r e s s u r i z e t h e fuel s y s t e m . W i t h
the engine running, the E C M grounds the PGM-FI main
relay a n d f e e d s c u r r e n t to the fuel p u m p . W h e n t h e
e n g i n e is not r u n n i n g a n d the ignition is O N (II), the
E C M c u t s g r o u n d to t h e P G M - F I m a i n r e l a y w h i c h c u t s
c u r r e n t to the fuel p u m p .
PGM-FI Main Relay

T h e PGM-FI main relay contains two separate relays.
O n e is e n e r g i z e d w h e n e v e r t h e ignition is O N (II), w h i c h
s u p p l i e s battery v o l t a g e to t h e E C M , p o w e r to the
i n j e c t o r s , a n d p o w e r f o r t h e s e c o n d relay. T h e s e c o n d Catalytic Converter System
relay is e n e r g i z e d to s u p p l y p o w e r to the fuel p u m p for
2 s e c o n d s w h e n the ignition s w i t c h is O N (II), a n d w h e n T W C (Three W a y Catalytic Converter)
t h e e n g i n e is r u n n i n g o r c r a n k i n g . T h e T W C converts hydrocarbons (HC), carbon
m o n o x i d e ( C O ) , a n d o x i d e s of nitrogen ( N O x ) in t h e
e x h a u s t g a s to c a r b o n d i o x i d e ( C 0 ) , nitrogen (N ), a n d
2 2
water vapor.
THREE WAY
(cont'd)
11-27
Positive Crankcase Ventilation (PCV) System Evaporative Emission (EVAP) Control

System
T h e P C V valve prevents blow-by g a s e s from escaping
into t h e a t m o s p h e r e b y v e n t i n g t h e m into the intake R e f e r to t h e s y s t e m d i a g r a m to s e e a functional layout
manifold. of the s y s t e m .
BREATHER
E V A P Canister
PIPE
PCV PCV HOSE T h e E V A P c a n i s t e r t e m p o r a r i l y s t o r e s fuel v a p o r f r o m
VALVE t h e fuel tank until it c a n be p u r g e d b a c k into the e n g i n e
and burned.
E V A P Canister Purge Valve

W h e n the e n g i n e c o o l a n t t e m p e r a t u r e is b e l o w 149 °F
(65 °C), the E C M t u r n s off the E V A P c a n i s t e r p u r g e v a l v e
w h i c h c u t s v a c u u m to the E V A P c a n i s t e r .
Fuel T a n k P r e s s u r e (FTP) S e n s o r
T h e F T P s e n s o r c o n v e r t s fuel tank a b s o l u t e p r e s s u r e
into a n electrical input to the E C M .
S E N S O R CHIP
BLOW-BY VAPOR
<=: F R E S H A I R
TERMINAL
E V A P Canister Vent Shut Valve

T h e E V A P c a n i s t e r v e n t s h u t v a l v e is o n the E V A P
canister.
T h e E V A P c a n i s t e r v e n t s h u t v a l v e c o n t r o l s the v e n t i n g
of the E V A P c a n i s t e r .
11-28
Idle Control System Diagram
T h e idle s p e e d of t h e e n g i n e is c o n t r o l l e d b y the idle air control (IAC) v a l v e :
• After the e n g i n e s t a r t s , the I A C v a l v e o p e n s for a certain a m o u n t of t i m e . T h e a m o u n t of a i r is i n c r e a s e d to r a i s e t h e

idle s p e e d .
• W h e n t h e e n g i n e c o o l a n t t e m p e r a t u r e i s l o w , t h e I A C v a l v e is o p e n e d to obtain t h e p r o p e r f a s t idle s p e e d . T h e
a m o u n t of b y p a s s e d a i r is c o n t r o l l e d in relation to e n g i n e c o o l a n t t e m p e r a t u r e .
BLK BLK
1 1
Intake Air System Diagram
T h i s s y s t e m s u p p l i e s a i r for e n g i n e n e e d s . A r e s o n a t o r in t h e air intake d u c t p r o v i d e s a d d i t i o n a l s i l e n c i n g a s air i s
d r a w n into the s y s t e m .
BLK BLK
JL _L
(cont'd)
11-29
Pulsed Secondary Air Injection
T h e p u l s e d s e c o n d a r y air i n j e c t i o n a d v a n c e s t h e a c t i v a t i o n of t h e c a t a l y t i c c o n v e r t e r a n d r e d u c e s t h e h y d r o c a r b o n s
( H Q , c a r b o n m o n o x i d e ( C O ) , a n d o x i d e s of nitrogen ( N O x ) in t h e e x h a u s t g a s .
T h e s y s t e m o p e r a t e s after t h e e n g i n e s t a r t s u n d e r t h e s e c o n d i t i o n s :
• T h e e n g i n e c o o l a n t t e m p e r a t u r e is b e t w e e n 32 °F a n d 158 °F {0°C a n d 7 0 °C).
• T h e difference i s m o r e t h a n 3 6 °F (20 °C) b e t w e e n t h e e n g i n e c o o l a n t t e m p e r a t u r e w h e n the e n g i n e is started a n d
w h e n the e n g i n e w a s s t o p p e d in t h e p r e v i o u s d r i v i n g c y c l e .
AIR C O N T R O L V A C U U M
CHECK VALVE
-AIR CONTROL V A C U U M
RESERVOIR
-AIR CONTROL V A L V E V A C U U M
CONTROL SOLENOID VALVE
No. 6 A C Q
(15 A ) F U S E
AIR P U M P
ELECTRICAL
CURRENT
SENSOR
AIR P U M P
(60 A ) F U S E
AIR P U M P
RELAY
AIR PUMP
W h e n t h e e n g i n e is c o l d a n d first s t a r t e d , t h e air p u m p p u m p s f r e s h air into t h e e x h a u s t ports. T h e a m o u n t of air

e n t e r i n g t h e e x h a u s t is r e g u l a t e d b y a n air control v a l v e w h i c h is c o n t r o l l e d b y t h e E C M . T h e s y s t e m d o e s not w o r k for
m o r e t h a n 60 s e c o n d s at a t i m e . A c t u a l o p e r a t i n g t i m e will v e r y d e p e n d i n g o n t h e difference b e t w e e n e n g i n e c o o l a n t
t e m p e r a t u r e a n d intake a i r t e m p e r a t u r e .
W h e n f r e s h air r e a c t s w i t h a n y u n b u r n e d e x h a u s t g a s e s , t h e e x h a u s t g a s t e m p e r a t u r e s rise. T h i s r i s e in t e m p e r a t u r e
p r o m o t e s f a s t e r w a r m - u p of t h e c a t a l y t i c c o n v e r t e r , r e s u l t i n g in c l e a n e r e m i s s i o n s d u r i n g c o l d start-up.
W h e n t h e air i n d u c t i o n s y s t e m is not o p e r a t i n g , t h e air c o n t r o l s o l e n o i d c l o s e s t h e air control v a l v e to p r e v e n t a n y

e x h a u s t g a s e s f r o m f l o w i n g b a c k into t h e s y s t e m .
11-30
Evaporative Emission (EVAP) Control Diagram
T h e E V A P c o n t r o l s m i n i m i z e t h e a m o u n t of fuel v a p o r e s c a p i n g to t h e a t m o s p h e r e . V a p o r f r o m t h e fuel t a n k is
t e m p o r a r i l y s t o r e d in t h e E V A P c a n i s t e r until it c a n be p u r g e d f r o m the c a n i s t e r into t h e e n g i n e a n d b u r n e d .
• T h e E V A P c a n i s t e r is p u r g e d b y d r a w i n g f r e s h air t h r o u g h it a n d a port o n t h e intake m a n i f o l d . T h e p u r g i n g v a c u u m

is controlled b y t h e E V A P c a n i s t e r p u r g e v a l v e , w h i c h is o p e n w h e n e v e r e n g i n e c o o l a n t t e m p e r a t u r e is a b o v e
149^(65*0.
• W h e n v a p o r p r e s s u r e in t h e fuel tank is h i g h e r t h a n t h e s e t v a l u e of t h e E V A P t w o w a y v a l v e , t h e v a l v e o p e n s a n d
r e g u l a t e s the f l o w of fuel v a p o r to t h e E V A P c a n i s t e r .
• D u r i n g r e f u e l i n g , t h e fuel tank v a p o r control v a l v e o p e n s w i t h t h e p r e s s u r e in t h e fuel tank, a n d f e e d s t h e fuel v a p o r
to t h e E V A P c a n i s t e r .
(cont'd)
11-31
E C M Circuit Diagram
t . -YEL/RED
X MAP
C7
-GRN/RED
-GRN/WHT-
MAP SENSOR
-RED/WHT
-GRN/YEL
ECT SENSOR
-RED/YEL
-GRN/YEL
IATSENSOR
VCC2
-YEL/BLU
C27 -GRN/YEL
-RED/BLK TPSENSOR
--WH*]
PH02S -GRN/YEL
C1 -BLK/YEL
-BLK/WHT
PRIMARY
H02S (SENSOR 1)
-WHT/RED :
SH02S -GRN/YEL
C11 -BLK/YEL
-BLK/WHT
SECONDARY
H02S (SENSOR 2)
IF V
a El
C102
JUNCTION
CONNECTOR
-GRN/YEL
11-32
-YEL/BLU -
A9 C
VSS C -BLU/WHT
M l
BRN/YEL
J C101
VSS
-YEL/BLU -YEL/BLU
A29
-LTGRN — -LTGRN —
-GRN r
FTP SENSOR
AIR PUMP ELECTRICAL

CURRENT SENSOR
C24 C101
WHT/BLK Q-WHT/BLK
ECS
12V
A28
APR
BLK AIR PUMP RELAY
G301
-GRN/YEL -
VTS
ROCKER ARM OIL
CONTROL SOLENOID _
-WHT/GRN -
-WHT/RED -
ALTF
ALTERNATOR
-RED/BLU -
IMOCO
To
IMMOBILIZER
RECEIVER-CONTROL
UNIT
-PNK/BLU -
IMOEN
(cont'd)
11-33
E C M C i r c u i t D i a g r a m (cont'd)
-YEL/BLK
B11 J
-BRN -
INJ1
No. 11NJECTOR
-YEL/BLK
No. 2 INJECTOR
-YEL/BLK
No. 3 INJECTOR
-YEL/BLK
-YEL -
INJ4
No. 4 INJECTOR
-YEL/BLK
-BLK/RED
IACV
da
-YEL/BLK
i - r ®
JUNCTION
CONNECTOR
YEL/BLK
IGP2
L D C1
YEL/BLK
C403
YEL/BLK
A26
-BLU/BLK - • To EPS CONTROL UNIT
11-34
-BLK/YEL
To
IGPLS1
-WHT
I 1—HRP—f
No. 11GNITION C O I L
PARK
PLUG
1 -BLK/YEL
-WHT/GRN
-BLK -
-
ICM
g —
To
I SPARK
T L-rffiY-j PLUG
No. 2 IGNITION C O I L
-BLK/YEL -
To
-WHT/BLK PARK
-BLK t ICM
»—nnn—! P
LUG
1 -BLK/YEL
-WHT/BLU
-
L-yyp-,
To
•SPARK
PLUG
JUNCTION
CONNECTOR
-BLK/YEL -BLK/YEL
-BLK/YEL
• 5 " AIR C O N T R O L
VALVE VACUUM CONTROL
SOLENOID VALVE
-BLK/YEL
PCS
-RED/YEL - -RED/YEL 3
EVAP CANISTER
PURGE VALVE
-BLK/YEL
-ORN-
EVAP BYPASS
SOLENOID VALVE
-BLK/YEL
- LT G R N / W H T - L T GRN/WHT
C301 EVAP
CANISTER V E N T
SHUT VALVE
(cont'd)
11-35
IMOLMP
WHT/RED — ® — '
IMMOBILIZEF
-GRN/ORN -
[IT INDICATOR
MIL - ® - |
To
A1 „COOLANT
-YEL/GRN TEMPERATURE
GAUGE
To
-BLU - •-TACHOMETER
NEP
GAUGE ASSEMBLY
-TEST
-BLU TACHOMETER
"CONNECTOR
C20
CMP1P
C21 3 CMP (TDC)
SENSORA
CMP2P
C30
CMP2M
3 CMP (TDC)
SENSOR B
-BRN/YEL -BLK -
T
3
-BLU ~ -BLU
CKP+ CKP
C9 SENSOR
-WHT- -WHT-
CKP-
0 0
11-36
ROCKER ARM OIL
PRESSURE SWITCH
(VTEC OIL PRESSURE SWITCH)
-BLK- 1
B2
PG1
-BLK-
JUNCTION
CONNECTOR
r
-C404 r-CIOI
I BLK 1 I BLK -
G101
m
C101
•-BRN/YEL Ij BRN -
A10
SCS DATA LINK
-GRY CONNECTOR
A21 -WHT/GRN —
-BLK -
r
G401
(cont'd)
1.1.-37
E C M Circuit D i a g r a m (cont'd)
-GRN/YEL -
7 IMOFLR
IP
-BLU/ORN
FUSES
A: No. 21 STARTER SIGNAL (7.5 A)
B: No. 2 FUEL PUMP SRS (15 A)
C. No.6ACG(15 A)
D: No. 5 INSTRUMENT LIGHT
BACK UP LIGHT (7.5 A)
E: No. 4IGNCOIL (15 A)
*: '00-01 models
11-38
®
X ACS
-BLU/RED
To A/C
PRESSURE SWITCH
C101 | C403
-WHT/RED • -WHT/RED |J- -WHT/RED
VBU
-YEL —
UNDER-DASH
FUSE/RELAY BOX
-WHT/BLK -
BKSW
-WHT/GRN
BRAKE PEDAL
POSITION SWITCH
CONNECTOR B
C201 G
-WHT/GRN
H
-o—*-o-
CONNECTOR C
-WHT -WHT £ -o->-o-
CONNECTOR A
3 L -WHT/GRN - -WHT/GRN £
J
-BLK/YEL -BLK/YEL
C204 - i
QRN/RED - -GRN/RED -
-BLK si!
CONNECTOR D To RADIATOR
A20 FAN SWITCH,
IT FANC CONDENSER
FAN RELAY
To RADIATOR
FAN SWITCH
To A/C
-CLUTCH
IT- RELAY
MAIN UNDER-HOOD
FUSE/RELAY BOX
BATTERY
FUSES
F: No. 25 B A C K U P (7.5 A)
G : No. 47 S T O P (10 A ) * (15 A )
H: No. 54 B A C K U P A C C (30 A ) G1
I: N o . 4 2 I G 1 M A I N (40 A)
J: No. 46ACGS (15 A) CONNECTOR A ~~
K: No. 41 B A T T E R Y (100 A) -WHT [J —
L: No. 32 AIR P U M P (60 A )
*: '00-01 models
AUXILIARY UNDER-HOOD
FUSE BOX
11
How to Set Readiness Codes
Malfunction Indicator Lamp (MIL) Indication Enable Criteria

(In relation to Readiness Codes)
• E C T S E N S O R at 158 °F (70 °C) or m o r e .
T h e v e h i c l e h a s c e r t a i n " r e a d i n e s s c o d e s " t h a t a r e part • I A T S E N S O R at 20 °F ( - 7 °C) or m o r e .
of the o n - b o a r d d i a g n o s t i c s for the e m i s s i o n s s y s t e m s . • V e h i c l e s p e e d is s t e a d y , a n d v e h i c l e s p e e d s e n s o r
If the v e h i c l e ' s battery h a s b e e n d i s c o n n e c t e d or g o n e ( V S S ) r e a d s m o r e t h a n 2 5 m p h (40 k m / h ) .
d e a d , if t h e D T C s h a v e b e e n c l e a r e d , or if t h e E C M h a s
b e e n r e s e t , t h e s e c o d e s a r e r e s e t to i n c o m p l e t e . In Procedure
s o m e s t a t e s , part of the e m i s s i o n s testing i s to m a k e
s u r e t h e s e c o d e s a r e s e t to c o m p l e t e . If all o f t h e m a r e When using the HDS
not s e t to c o m p l e t e , t h e v e h i c l e m a y fail t h e e m i s s i o n
test, or t h e t e s t c a n n o t be f i n i s h e d . 1. C o n n e c t t h e H D S to the v e h i c l e ' s data link
c o n n e c t o r ( D L C ) , a n d bring up the R E A D I N E S S
T o c h e c k if t h e r e a d i n e s s c o d e s a r e c o m p l e t e , turn the C O D E s s c r e e n for C a t a l y s t in the D T C s M E N U .
ignition s w i t c h O N (II), but d o not start the e n g i n e . T h e
M I L will c o m e o n for 1 5 — 2 0 s e c o n d s . If it t h e n g o e s off, 2. S t a r t the e n g i n e .
the r e a d i n e s s c o d e s a r e c o m p l e t e . If it blinks s e v e r a l
t i m e s , o n e o r m o r e r e a d i n e s s c o d e s a r e not c o m p l e t e . 3. T e s t - d r i v e t h e v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
T o s e t r e a d i n e s s c o d e s f r o m i n c o m p l e t e to c o m p l e t e , w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . After a b o u t
d o t h e p r o c e d u r e for the a p p r o p r i a t e c o d e . 5 m i l e s (8 k m ) , the r e a d i n e s s c o d e s h o u l d s w i t c h to
completed.
Catalytic Converter Monitor and Readiness
Code 4. If the r e a d i n e s s c o d e is still not s e t to c o m p l e t e ,
c h e c k for a T e m p o r a r y D T C w i t h the H D S . If t h e r e is
NOTE: n o D T C , o n e or m o r e of the e n a b l e criteria w e r e
• Do not t u r n the ignition s w i t c h off d u r i n g t h e p r o b a b l y not met; r e p e a t the p r o c e d u r e .
procedure.
• All r e a d i n e s s c o d e s a r e c l e a r e d w h e n the battery is When using a scan tool
d i s c o n n e c t e d or w h e n t h e E C M is c l e a r e d w i t h a n
O B D II s c a n tool or t h e H D S . 1. C o n n e c t a s c a n tool to t h e v e h i c l e ' s data link
• L o w a m b i e n t t e m p e r a t u r e s or e x c e s s i v e s t o p - a n d - g o c o n n e c t o r ( D L C ) , a n d bring up the t o o l ' s g e n e r i c
traffic m a y i n c r e a s e t h e d r i v e t i m e n e e d e d to s w i t c h O B D II m o d e .
the r e a d i n e s s c o d e f r o m i n c o m p l e t e to c o m p l e t e .
• T h e r e a d i n e s s c o d e w i l l not s w i t c h to c o m p l e t e until 2. S t a r t the e n g i n e .
all t h e e n a b l e criteria a r e met.
• If a fault in t h e s e c o n d a r y H 0 2 S s y s t e m c a u s e d the 3. T e s t - d r i v e t h e v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
MIL to c o m e o n , t h e r e a d i n e s s c o d e c a n n o t be s e t to w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . After a b o u t
c o m p l e t e until y o u c o r r e c t the fault. 5 m i l e s (8 k m ) , the r e a d i n e s s c o d e s h o u l d s w i t c h
f r o m i n c o m p l e t e to c o m p l e t e .
4. If the r e a d i n e s s c o d e is still s e t to i n c o m p l e t e , c h e c k
for a T e m p o r a r y D T C . If t h e r e is no D T C , o n e or
m o r e of the e n a b l e criteria w e r e p r o b a b l y not m e t ;
r e p e a t the p r o c e d u r e .
11-40
Evaporative Emission (EVAP) Control H02S Monitor and Readiness Code
System Monitor and Readiness Code NOTE:
• Do not turn t h e ignition s w i t c h off d u r i n g t h e
NOTE: procedure.
• All r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery i s • All r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery is
d i s c o n n e c t e d or w h e n t h e E C M is c l e a r e d w i t h a n d i s c o n n e c t e d o r w h e n t h e E C M is c l e a r e d w i t h a n
O B D II s c a n tool or the H D S . O B D II s c a n tool or the H D S .
• T h e e n a b l e criteria m u s t be r e p e a t e d if the intake air
t e m p e r a t u r e (IAT) d r o p s l o w e r t h e n 3 6 °F (20 °C) f r o m Enable Criteria
its v a l u e at e n g i n e start up.
E C T S E N S O R at 140 °F (60 <€) o r m o r e .
Enable Criteria
• At e n g i n e start u p , E C T S E N S O R a n d I A T S E N S O R Procedure
a r e higher t h a n 32 °F (0 ° C ) , but l o w e r t h e n 9 5 °F
(35 °C). When using the HDS
• A t e n g i n e start u p , the E C T S E N S O R a n d I A T S E N S O R 1. Start the e n g i n e .
a r e within 1 2 ° F ( 7 °C) of e a c h other. 2. T e s t - d r i v e t h e v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . D u r i n g t h e
Procedure d r i v e , d e c e l e r a t e (with t h e throttle fully c l o s e d ) for
5 s e c o n d s . After a b o u t 3.5 m i l e s (5.6 k m ) , t h e
When using the HDS r e a d i n e s s c o d e s h o u l d s w i t c h f r o m i n c o m p l e t e to
1. C o n n e c t the H D S to the v e h i c l e ' s data link completed.
connector (DLC).
3. C h e c k the r e a d i n e s s c o d e s s c r e e n for t h e H 0 2 S in
2. Start t h e e n g i n e . the D T C s M E N U w i t h t h e H D S .
• If the s c r e e n s h o w s c o m p l e t e , r e a d i n e s s i s
3. S e l e c t E V A P T E S T in the I N S P E C T I O N M E N U w i t h complete.
t h e H D S , t h e n s e l e c t the F U N C T I O N T E S T in the • If the s c r e e n s h o w s not c o m p l e t e , g o to t h e next
EVAP T E S T MENU. step.
• If the f u n c t i o n s a r e n o r m a l , r e a d i n e s s is c o m p l e t e . 4. C h e c k for a T e m p o r a r y D T C . If t h e r e i s n o D T C , t h e
• If the f u n c t i o n s a r e not n o r m a l , g o to t h e next e n a b l e criteria w a s p r o b a b l y not m e t . S e l e c t the
step. D A T A L I S T M e n u . C h e c k t h e E C T in t h e A L L D A T A
L I S T w i t h t h e H D S . If the E C T is l o w e r t h a n 140 °F
4. If the r e a d i n e s s c o d e is still not s e t to c o m p l e t e , (60 °C), run t h e e n g i n e until it is h i g h e r t h a n 140 T
c h e c k for a T e m p o r a r y D T C . If t h e r e is n o D T C , o n e (60 °C), t h e n r e p e a t the p r o c e d u r e .
or m o r e of the e n a b l e criteria w e r e p r o b a b l y not
met; repeat the p r o c e d u r e . When using a scan tool
1. C o n n e c t a s c a n tool to t h e v e h i c l e ' s data link
When using a scan tool c o n n e c t o r ( D L C ) , a n d bring u p t h e t o o l ' s g e n e r i c
1. C o n n e c t a s c a n tool to t h e v e h i c l e ' s data link O B D II m o d e .
c o n n e c t o r ( D L C ) , a n d bring u p the t o o l ' s g e n e r i c
O B D II m o d e . 2. Start the e n g i n e .
2. Start t h e e n g i n e . 3. T e s t - d r i v e the v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . D u r i n g the
3. T e s t - d r i v e t h e v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s d r i v e , d e c e l e r a t e (with t h e throttle fully c l o s e d ) for
w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . After a b o u t 5 s e c o n d s . After a b o u t 3.5 m i l e s (5.6 k m ) , t h e
2.5 m i l e s (4.0 k m ) , the r e a d i n e s s c o d e s h o u l d r e a d i n e s s c o d e s h o u l d s w i t c h f r o m i n c o m p l e t e to
s w i t c h f r o m i n c o m p l e t e to c o m p l e t e . complete.
4. If the r e a d i n e s s c o d e is still s e t to i n c o m p l e t e , c h e c k 4. If the r e a d i n e s s c o d e is still s e t to i n c o m p l e t e , c h e c k

for a T e m p o r a r y D T C . If t h e r e is no D T C , o n e or for a T e m p o r a r y D T C . if t h e r e is no D T C , the e n a b l e
m o r e of the e n a b l e criteria w e r e p r o b a b l y not m e t ; criteria w a s p r o b a b l y not m e t ; r e p e a t the p r o c e d u r e .
repeat the p r o c e d u r e .
(cont'd)
11-41
How to Set Readiness Codes (cont'd)
H02S Heater Monitor Readiness Code Misfire Monitor and Readiness Code
N O T E : All r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery • T h i s r e a d i n e s s c o d e is a l w a y s s e t to a v a i l a b l e
is d i s c o n n e c t e d o r w h e n t h e E C M i s c l e a r e d w i t h a n b e c a u s e m i s f i r i n g is c o n t i n u o u s l y m o n i t o r e d .
O B D II s c a n t o o l or the H D S . • M o n i t o r i n g p a u s e s , a n d the m i s f i r e c o u n t e r r e s e t s , if
the vehicle is driven over a rough road.
Procedure • Monitoring also p a u s e s , a n d the misfire counter
h o l d s at its c u r r e n t v a l u e , if the throttle position
1. C o n n e c t a s c a n tool o r t h e H D S to t h e v e h i c l e ' s data c h a n g e s m o r e t h a n a p r e d e t e r m i n e d v a l u e , or if
link c o n n e c t o r ( D L C ) . B r i n g u p t h e t o o l ' s g e n e r i c d r i v i n g c o n d i t i o n s fall o u t s i d e the r a n g e of a n y
O B D II m o d e ( s c a n tool o n l y ) . related e n a b l e criteria.
2 . Start t h e e n g i n e , a n d let it idle for 1 m i n u t e . T h e Fuel System Monitor and Readiness Code
r e a d i n e s s c o d e s h o u l d s w i t c h f r o m i n c o m p l e t e to
complete. • T h i s r e a d i n e s s c o d e is a l w a y s s e t to a v a i l a b l e
b e c a u s e t h e fuel s y s t e m is c o n t i n u o u s l y m o n i t o r e d
3. If the r e a d i n e s s c o d e is still s e t to i n c o m p l e t e , c h e c k d u r i n g c l o s e d loop o p e r a t i o n .
for a T e m p o r a r y D T C . If t h e r e is n o D T C , r e p e a t t h e • M o n i t o r i n g p a u s e s w h e n the c a t a l y t i c c o n v e r t e r ,
procedure. E V A P control s y s t e m , a n d H 0 2 S monitors are active.
• M o n i t o r i n g a l s o p a u s e s w h e n a n y related e n a b l e
Secondary Air Injection (AIR) System criteria a r e not b e i n g m e t . M o n i t o r i n g r e s u m e s w h e n
Monitor and Readiness Code t h e e n a b l e criteria is a g a i n b e i n g met.
NOTE: Comprehensive Component Monitor and

• A l l r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery is Readiness Code
d i s c o n n e c t e d o r the E C M i s c l e a r e d w i t h a n O B D II
s c a n tool or the H D S . T h i s r e a d i n e s s c o d e is a l w a y s s e t to a v a i l a b l e b e c a u s e
the c o m p r e h e n s i v e component monitor is continuously
Enable Criteria r u n n i n g w h e n e v e r t h e e n g i n e is c r a n k i n g o r r u n n i n g .
• A t e n g i n e start u p , E C T S E N S O R a n d I A T S E N S O R
h i g h e r t h a n 3 2 °F (0 °C), but l o w e r t h a n 9 5 °F (35 °C).
• A t e n g i n e start u p , E C T S E N S O R a n d I A T S E N S O R
a r e within 12 °F (7 *€) of e a c h other.
• Altitude b e l o w 2,400 m (7,874 ft).
Procedure
1. C o n n e c t a s c a n tool o r t h e H D S to t h e v e h i c l e ' s data

link c o n n e c t o r ( D L C ) . B r i n g u p t h e t o o l ' s g e n e r i c
O B D II m o d e ( s c a n tool o n l y ) .
2. Start the e n g i n e , a n d let it idle for 1 m i n u t e . T h e

complete.
3. If the r e a d i n e s s c o d e is still s e t to i n c o m p l e t e , c h e c k
for a T e m p o r a r y D T C . If t h e r e i s n o D T C , r e p e a t t h e
procedure.
11-42
PGM-FI System
C R A N K S H A F T POSITION (CKP) S E N S O R
R e p l a c e m e n t , page 11-114
(cont'd)
11-43
PGM-FI System
INJECTORS
R e p l a c e m e n t page 11-112
D A T A LINK C O N N E C T O R (DLC)
('02-05 m o d e l s )
General Troubleshooting Information,
p a g e 11-3
T r o u b l e s h o o t i n g , p a g e 11-110
ENGINE CONTROL MODULE D A T A LINK C O N N E C T O R (DLC)

(ECM) ('00-01 m o d e l s )
General Troubleshooting Information General Troubleshooting Information,
p a g e 11-3 p a g e 11-3
R e p l a c e m e n t , page 11-115 T r o u b l e s h o o t i n g , p a g e 11-110
11-44
DTC Troubleshooting
DTC P0107: MAP Sensor Circuit Low Voltage 7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r

terminals C19 and C7.
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n
(see p a g e 11-3).
1. T u r n the ignition s w i t c h O N (II). SGI (GRN/WHT)
2. C h e c k t h e M A P w i t h a s c a n tool or t h e H D S .
1 2
/ 4 5
/ 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
Is about
indicated?
101 kPa (30 in.Hg, 760 mmHg), or 2.9 V
/ 24 25 26
VCC1 (YEL/RED)
27 28 29 30
/
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at this
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
at t h e M A P s e n s o r a n d at the E C M . •
N O — G o to s t e p 3. Is there about 5 V?
3. T u r n the ignition s w i t c h O F F . Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
(C19) a n d the M A P s e n s o r . •
4. D i s c o n n e c t the M A P s e n s o r 3 P c o n n e c t o r .
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
5. T u r n t h e ignition s w i t c h O N (II). t h e n r e c h e c k . If n o r m a l M A P is i n d i c a t e d , r e p l a c e
t h e original E C M ( s e e p a g e 11-115). •
6. M e a s u r e v o l t a g e b e t w e e n M A P s e n s o r 3 P
c o n n e c t o r t e r m i n a l s No. 1 a n d No. 2.
M A P S E N S O R 3P C O N N E C T O R
VCC1
(YEL/RED)
SGI (GRN/WHT)
Is there about 5 V?
(cont'd)
11-45
PGM-FI System
DTC Troubleshooting (cont'd)
Is about 2 kPa (0.6 in.Hg, 15 mmHg), or 0.5 V or

less indicated?
N O — R e p l a c e the M A P s e n s o r (see page 11-166).H
9. T u r n t h e ignition s w i t c h O F F .
11. C h e c k for continuity b e t w e e n M A P s e n s o r

connector terminal No. 3 a n d body ground.
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
(C17) a n d t h e M A P s e n s o r . •
t h e n r e c h e c k . If n o r m a l M A P is i n d i c a t e d , r e p l a c e
t h e o r i g i n a l E C M ( s e e p a g e 11-115). •
11-46
DTC P0108: MAP Sensor Circuit High Voltage 6. T u r n the ignition s w i t c h O N (II).
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data 7. C h e c k the M A P w i t h a s c a n tool or t h e H D S .

a n d r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g information
( s e e p a g e 11-3). Is about 101 kPa (30 in.Hg, 760 mmHg), or 2.9 V
or more indicated?
3,000 r p m w i t h o u t l o a d (in neutral) until the Y E S — G o to s t e p 8.
N O — R e p l a c e the M A P s e n s o r (see page 1 1 - 1 6 6 ) . !
Is about 101 kPa (30 in.Hg, 760 mmHg), or 2.9 V
or more indicated ? 9. R e m o v e t h e j u m p e r w i r e .
Y E S — G o to s t e p 3. 10. T u r n the ignition s w i t c h O N (II).
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s 11. M e a s u r e v o l t a g e b e t w e e n M A P s e n s o r c o n n e c t o r
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s t e r m i n a l s N o . 1 a n d No. 2.
at t h e M A P s e n s o r a n d at the E C M . •
MAP S E N S O R 3P C O N N E C T O R
4. D i s c o n n e c t t h e M A P s e n s o r 3 P c o n n e c t o r . VCC1
(YEL/RED)
5. Install a j u m p e r w i r e b e t w e e n M A P s e n s o r 3 P
c o n n e c t o r t e r m i n a l s No. 2 a n d No. 3.
SGI (GRN/WHT)
Is there about 5 V?
SG1 (GRN/WHT) MAP (GRN/RED)
JUMPER WIRE
(cont'd)
11-47
PGM-FI System
12. T u r n t h e ignition s w i t c h O F F . 16. T u r n t h e ignition s w i t c h O F F .
13. D i s c o n n e c t E C M c o n n e c t o r C (31P). 17. Install a j u m p e r w i r e o n t h e E C M c o n n e c t o r

terminals between C7 and C17.
14. C o n n e c t M A P s e n s o r 3 P c o n n e c t o r t e r m i n a l N o . 3
to b o d y g r o u n d w i t h a j u m p e r w i r e .
SGI (GRN/WHT)
1 2 3
1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20
9
21
10
22
M AP (GRN/RED)
/ 24 25
MAP (GRN/RED)
26 27 28 29 30
/
JUMPER WIRE
J lJ M P E R W I R E
W i r e s i d e of f e m a l e t e r m i n a l s 18. T u r n t h e ignition s w i t c h O N (II).
15. C h e c k f o r continuity b e t w e e n E C M c o n n e c t o r 19. C h e c k t h e M A P w i t h a s c a n tool o r t h e H D S .

terminal C7 and body ground.
Is about 101 kPa (30 in.Hg, 760 mmHg), or 2.9 V
or more indicated ?
Y E S — S u b s t i t u t e a known-good E C M (see page

SGI (GRN/WHT) 11-5), t h e n r e c h e c k . If n o r m a l M A P is i n d i c a t e d ,
/ /
r e p l a c e t h e original E C M ( s e e p a g e 11-115). •
1 2 4 5 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E C M
/ 24 25 26 27 28 29 30
/ (C17) a n d t h e M A P s e n s o r . •

11-5), t h e n r e c h e c k . If n o r m a l M A P i s i n d i c a t e d ,
r e p l a c e t h e original E C M ( s e e p a g e 1 1 - 1 1 5 ) . B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M (C7)
a n d the M A P sensor. •
11-48
DTC P0112: IAT Sensor Circuit Low Voltage 9. C h e c k t h e continuity b e t w e e n I A T s e n s o r 2 P
c o n n e c t o r t e r m i n a l No. 2 a n d b o d y g r o u n d .
IAT S E N S O R 2P C O N N E C T O R
( s e e p a g e 11-3).
1. T u r n t h e ignition s w i t c h O N (II).
2. C h e c k t h e I A T with a s c a n tool or t h e H D S .
Is about 302 °F (150 °C) or more, orOV

Indicated?
N O — G o to s t e p 10. W i r e s i d e of f e m a l e t e r m i n a l s
3. T u r n t h e ignition s w i t c h O F F . Is there continuity?
4. D i s c o n n e c t t h e IAT s e n s o r 2 P c o n n e c t o r . Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
(C25) a n d t h e I A T s e n s o r . •
6. C h e c k t h e I A T w i t h a s c a n tool or the H D S . t h e n r e c h e c k . If n o r m a l I A T i s i n d i c a t e d , r e p l a c e t h e
original E C M ( s e e p a g e 1 1 - 1 1 5 ) . B
Is about 302 °F (150 °C) or more, orOV
indicated? 10. C h e c k t h e t e m p e r a t u r e r e a d i n g o n t h e s c a n tool or
t h e H D S . B e a w a r e that if t h e e n g i n e is w a r m , the
Y E S — G o to s t e p 7. r e a d i n g w i l l be h i g h e r t h a n a m b i e n t t e m p e r a t u r e . If
t h e e n g i n e is c o l d , t h e I A T a n d E C T will h a v e t h e
N O — R e p l a c e the I A T s e n s o r ( s e e p a g e 9-2). • same value.
7. T u r n t h e ignition s w i t c h O F F . Is the correct ambient temperature indicated?
8. D i s c o n n e c t E C M c o n n e c t o r C (31P). Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
at t h e I A T s e n s o r a n d at t h e E C M . •
N O — R e p l a c e the I A T s e n s o r ( s e e p a g e 9-2). •
11-49
PGM-FI System
DTC P0113: IAT Sensor Circuit High Voltage 8. T u r n the ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a 9. R e m o v e t h e j u m p e r w i r e .
a n d review the general troubleshooting information
( s e e p a g e 11-3). 10. T u r n t h e ignition s w i t c h O N (II).
1. T u r n t h e ignition s w i t c h O N (II). 11. M e a s u r e v o l t a g e b e t w e e n I A T s e n s o r 2 P c o n n e c t o r

terminal No. 2 and body ground.
2. C h e c k t h e I A T w i t h a s c a n tool or t h e H D S .
Is about -4°F ( -20 °C) or less, or5V indicated?
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
IAT (RED/YEL)
at t h e I A T s e n s o r a n d t h e E C M . •
4. D i s c o n n e c t t h e I A T s e n s o r 2 P c o n n e c t o r . W i r e s i d e of f e m a l e t e r m i n a l s
5. C o n n e c t I A T s e n s o r 2 P c o n n e c t o r t e r m i n a l s N o . 1
and No. 2 with a j u m p e r wire. Is there about 5 V?
SG2 (GRN/YEL)
12. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l
JUMPER C25 and body ground.
WIRE
IAT ( R E D / Y E L ) E C M C O N N E C T O R C (31P)
1 2
/ 4 5
/ 7 8 9 10
W i r e s i d e of f e m a l e t e r m i n a l s 11 12 13 14 15 16 17 18 19 20 21 22
/ 24 25 26 27 28 29 30
/
IAT ( R E D / Y E L )
7. C h e c k t h e I A T w i t h a s c a n tool or t h e H D S .
Is about ~4°F ( -20 °C) or less, or5V indicated? W i r e s i d e of f e m a l e t e r m i n a l s
Is there about 5 V?
N O — R e p l a c e t h e I A T s e n s o r ( s e e p a g e 9-2). •
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
t h e n r e c h e c k . If n o r m a l I A T is i n d i c a t e d , r e p l a c e the
original E C M ( s e e p a g e 1 1 - 1 1 5 J . B
11-50
15. C o n n e c t I A T s e n s o r 2 P c o n n e c t o r t e r m i n a l No. 1 to
16. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

11
2
12
/
13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
/ 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/

11-5), t h e n r e c h e c k . If n o r m a l I A T i s i n d i c a t e d ,
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
PGM-FI System
DTC P0116: ECT Sensor Circuit Range/ DTC P0117: ECT Sensor Circuit Low Voltage
Performance Problem
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d ail f r e e z e d a t a
NOTE: a n d r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g information
• B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a a n d ( s e e p a g e 11-3).
review the general troubleshooting information
• If D T C P 0 1 1 7 a n d / o r P 0 1 1 8 a r e s t o r e d at t h e s a m e
t i m e a s D T C P 0 1 1 6 , t r o u b l e s h o o t t h o s e D T C s first, 2. C h e c k t h e E C T w i t h a s c a n tool or t h e H D S .
t h e n r e c h e c k for D T C P 0 1 1 6 .
Is 302 °F (150 °C) or higher, orOV indicated?
2. C h e c k t h e E C T w i t h a s c a n tool or t h e H D S .
Is about 176 °F (80 °C) or more, or 0.86 V or less t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e w i r e s at
indicated? t h e E C T s e n s o r a n d at the E C M . H
Y E S — G o to s t e p 3. 3. T u r n t h e ignition s w i t c h O F F .
N O — G o to s t e p 7. 4. D i s c o n n e c t t h e E C T s e n s o r 2 P c o n n e c t o r .
3. Note t h e c o o l a n t t e m p e r a t u r e f r o m s t e p 2. 5. T u r n t h e ignition s w i t c h O N (II).
4. T u r n t h e ignition s w i t c h O F F . 6. C h e c k t h e E C T w i t h a s c a n tool or the H D S .
5. C o o l t h e e n g i n e for 1 h o u r . Is 302 °F (150 °C) or higher, orOV indicated?
6. C h e c k t h e E C T w i t h a s c a n tool or t h e H D S . Y E S — G o to s t e p 7.
Did the ECT change 3.6 °F (2 °C) or more? N O — R e p l a c e the E C T s e n s o r ( s e e p a g e 9-2). •
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 7. T u r n t h e ignition s w i t c h O F F .
time. C h e c k the thermostat a n d the cooling
system.! 8. D i s c o n n e c t E C M c o n n e c t o r C (31P).
N O — R e p l a c e t h e E C T s e n s o r ( s e e p a g e 9-2). •
7. Note t h e c o o l a n t t e m p e r a t u r e f r o m s t e p 2.
8. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
3,000 r p m w i t h o u t l o a d (in neutral) until t h e
9. C h e c k t h e E C T with a s c a n tool or t h e H D S .
Does the ECT change 3.6 °F (2 °C) or more?
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
time. C h e c k the thermostat a n d the cooling
system. •
11-52
9. C h e c k for continuity b e t w e e n E C T s e n s o r 2 P
E C T S E N S O R 2P C O N N E C T O R
ECT
(RED/WHT)
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n t h e E C M
(C26) a n d t h e E C T s e n s o r . •
N O — S u b s t i t u t e a known-good E C M (see page 11-5),

t h e n r e c h e c k . If n o r m a l E C T is i n d i c a t e d , r e p l a c e the
original E C M ( s e e p a g e 1 1 - 1 1 5 ) . B
PGM-FI System
DTC P0118: ECT Sensor Circuit High Voltage 8. T u r n the ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a 9. R e m o v e the j u m p e r w i r e .
1. T u r n t h e ignition s w i t c h O N (II). 11. M e a s u r e v o l t a g e b e t w e e n E C T s e n s o r 2 P c o n n e c t o r

ECT S E N S O R 2P C O N N E C T O R
Is-4°F ( -20 °C) or less, or5V Indicated?
ECT (RED/WHT)
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s
at t h e E C T s e n s o r a n d at the E C M . •
4. D i s c o n n e c t t h e E C T s e n s o r 2 P c o n n e c t o r . W i r e s i d e of f e m a l e t e r m i n a l s
5. C o n n e c t E C T s e n s o r 2 P c o n n e c t o r t e r m i n a l s No. 1
a n d No. 2 with a j u m p e r wire. Is there about 5 V?
YES-Gotostep13.
E C T S E N S O R 2P C O N N E C T O R
SG2 (GRN/YEL)
JUMPER
WIRE
ECT (RED/WHT)
Is-4°F ( -20 °C) or less, or 5 V indicated?
11-54
12. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 16. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
C26 and body ground. terminal C 1 8 and body ground.
E C M C O N N E C T O R C (31P) E C M C O N N E C T O R C (31P)
11
2
12
/13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20
9
21
10
22
/ 24 25 26 27 28
ECT (RED/WHT)
29 30
/ / 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/
W i r e s i d e of f e m a l e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
Is there about 5 V? Is there continuity?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M Y E S — S u b s t i t u t e a known-good E C M (see page

(C26) a n d t h e E C T s e n s o r . • 11-5), t h e n r e c h e c k . If n o r m a l E C T is i n d i c a t e d ,
replace the original E C M (see page 11-115).H
t h e n r e c h e c k . If n o r m a l E C T is i n d i c a t e d , r e p l a c e t h e N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
original E C M ( s e e p a g e 1 1 - 1 1 5 ) . • (C18) a n d t h e E C T s e n s o r . •
15. C o n n e c t E C T s e n s o r 2 P c o n n e c t o r t e r m i n a l N o . 1 to
ECT S E N S O R 2P C O N N E C T O R
SG2 (GRN/YEL)
JUMPER WIRE
W i r e side of f e m a l e terminals
11-55
PGM-FI System
DTC P0122:TP Sensor Circuit Low Voltage 8. At t h e s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n T P

s e n s o r 3 P c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 2 with
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a the throttle fully c l o s e d .
and review the general troubleshooting information
T P S E N S O R 3P C O N N E C T O R
( s e e p a g e 11-3).
2. C h e c k t h e throttle p o s i t i o n w i t h a s c a n tool or t h e
HDS.
Is there about 6 % when the throttle is fully closed

and about 90 % when the throttle is fully opened?
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e w i r e s at
t h e T P s e n s o r a n d at t h e E C M . • T e r m i n a l s i d e of m a l e t e r m i n a l s
N O — G o to s t e p 3. Is there about 0.5- 0.9 kQ ?
3. T u r n t h e ignition s w i t c h O F F . Y E S — G o to s t e p 9.
4. D i s c o n n e c t t h e T P s e n s o r 3 P c o n n e c t o r . N O — R e p l a c e t h e throttle b o d y ( s e e p a g e 11-165). •
5. T u r n t h e ignition s w i t c h O N (II). 9. A t t h e s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n T P
s e n s o r 3 P c o n n e c t o r t e r m i n a l s N o . 2 a n d N o . 3 with
6. M e a s u r e v o l t a g e b e t w e e n T P s e n s o r 3 P c o n n e c t o r the throttle fully c l o s e d .
t e r m i n a l s N o . 1 a n d N o . 3.
VCC2
1 2 3
SG2 (GRN/YEL) VCC2 (YEL/BLU)
Is there about 4.5 kQ.?

Is there about 5 V?
N O — R e p l a c e t h e throttle b o d y ( s e e p a g e 11-165).
10. R e c o n n e c t t h e T P s e n s o r 3 P c o n n e c t o r .
11-56
11. T u r n t h e ignition s w i t c h O N (II). 13. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r
12. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r
terminals C18 and C27. E C M C O N N E C T O R C (31P)
E C M C O N N E C T O R C (31P) SG2 (GRN/YEL)
1 2
/ 4 5
/ 8 9 10
1
11
2
12
/
13
4
14 15
5
16
/ 17
J
18 19
8
20
9
21
10
22
11 12 13 14 15 16 17 18 19 20 2!1 22
/ 24 25 26 27 23 29 30
/ / 24 25
VCC2 (YEL/BLU)
26 27 28 29 30
/
TPS (RED/BLK) SG2 (GRN/YEL)
4vH W i r e s i d e of f e m a l e t e r m i n a l s
Is there about 5 V?
Is there about 0.3 V when the throttle is fully Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M

closed and about 4.5 V when the throttle is fully (C28) a n d t h e T P s e n s o r . •
opened?
YES—Substitute a known-good E C M (see page t h e n r e c h e c k . If t h e p r e s c r i b e d v o l t a g e is n o w
11-5), t h e n r e c h e c k . If t h e T P s e n s o r v o l t a g e is n o w a v a i l a b l e , r e p l a c e t h e original E C M ( s e e p a g e
n o r m a l , r e p l a c e t h e original E C M ( s e e p a g e 11-115). 11-115).B
N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
(C27) a n d t h e T P s e n s o r . •
11-57
PGM-FI System
DTC P0123: TP Sensor Circuit High Voltage 7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r

N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a
( s e e p a g e 11-3).
SG2 (GRN/YEL)
2. C h e c k t h e throttle p o s i t i o n w i t h a s c a n tool or t h e
1
11
2
12
/13
4
14
5
16
/17 18
r 8
20
9
21
10
22
HDS.
Is there about 6 % when the throttle is fully closed / 24 25
VCC2 (YEL/BLU)
26 27 28 29 30
/
and about 90 % when the throttle is fully opened?
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s W i r e s i d e of f e m a l e t e r m i n a l s
at t h e T P s e n s o r a n d at t h e E C M . •
Is there about 5 V?
3. T u r n t h e ignition s w i t c h O F F . (C18) a n d t h e T P s e n s o r . •
4. D i s c o n n e c t t h e T P s e n s o r 3 P c o n n e c t o r . N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
t h e n r e c h e c k . If t h e p r e s c r i b e d v o l t a g e is n o w
5. T u r n t h e ignition s w i t c h O N (II). a v a i l a b l e r e p l a c e t h e original E C M ( s e e p a g e
11-115).B
6. M e a s u r e v o l t a g e b e t w e e n T P s e n s o r 3 P c o n n e c t o r
TP S E N S O R 3P C O N N E C T O R
SG2 (GRN/YEL) VCC2 (YEL/BLU)
Wire s i d e of f e m a l e t e r m i n a l s
Is there about 5 V?
Y E S — R e p l a c e t h e throttle b o d y ( s e e p a g e 11-165).
•
11-58
DTC P0125: ECT Sensor Malfunction/Slow DTC P0128: Cooling System Malfunction
Response ('02-05 models)
('04-05 models)
NOTE:
N O T E : Before y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data • B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n
( s e e p a g e 11-3). ( s e e p a g e 11-3).
• If t h e D T C s listed b e l o w a r e s t o r e d at t h e s a m e t i m e
1. S t a r t the e n g i n e , a n d let it idle. a s D T C P 0 1 2 8 , t r o u b l e s h o o t t h o s e D T C s first, t h e n
r e c h e c k for P 0 1 2 8 .
2. C h e c k the E C T w i t h a s c a n tool or the H D S .
P0107, P0108, P1128, P1129: Manifold absolute
Is about 86 °F (30 °C) or less, or 2.61 V or more p r e s s u r e (MAP) s e n s o r
indicated? P 1 1 0 6 * *, P 1 1 0 7 * * , P 1 1 0 8 * * (P2227, P 2 2 2 8 , P 2 2 2 9 ) * :
Barometric pressure (BARO) sensor
Y E S — G o to s t e p 3. P 1 2 5 9 * * (P2646, P 2 6 4 7 ) * : V T E C s y s t e m
P0116, P0117, P0118 (P0125)*: Engine coolant
N O — I n t e r m i t t e n t failure, the s y s t e m i s O K at t h i s temperature (ECT) sensor
t i m e . C h e c k the t h e r m o s t a t a n d the c o o l i n g P0112, P0113: Intake air t e m p e r a t u r e (|AT) s e n s o r
system. • P0335, P0336: C r a n k s h a f t position ( C K P ) s e n s o r
P0300: R a n d o m misfire detected
3. Let the e n g i n e idle for 6 m i n u t e s . P0301, P 0 3 0 2 , P 0 3 0 3 , P 0 3 0 4 : No. 1, N o . 2 , N o . 3, or
No. 4 C y l i n d e r m i s f i r e d e t e c t e d
4. C h e c k the E C T w i t h a s c a n tool or the H D S . P 0 5 0 5 * * (P0506, P 0 5 0 7 ) * : Idle control s y s t e m
P 1 5 1 9 * * ( P 0 5 1 1 ) * : Idle air control (IAC) v a l v e
Is about 86 °F (30 °C) or less, or 2.61 V or more * : '04-05 m o d e l s
indicated? * * : ' 0 2 - 0 3 models
Y E S — R e p l a c e t h e E C T s e n s o r ( s e e p a g e 9-2). • D T C P 0 1 2 8 c a n o c c a s i o n a l l y s e t w h e n t h e h o o d is
o p e n e d w h i l e the e n g i n e i s r u n n i n g .
N O — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s
t i m e . C h e c k the t h e r m o s t a t a n d t h e c o o l i n g 1. C h e c k the e n g i n e c o o l a n t l e v e l .
system. •
Is the engine coolant level low?
Y E S — R e f i l l the e n g i n e c o o l a n t . If n e c e s s a r y , repair
the c o o l a n t l e a k a g e . •
2. T u r n the ignition s w i t c h O N (II), a n d m a k e s u r e the

A / C is off.
(cont'd)
11-59
PGM-FI System
3. C h e c k t h e radiator f a n .
Does the radiator fan keep running?
Y E S — C h e c k t h e radiator f a n circuit ( s e e p a g e
10-18), r a d i a t o r f a n s w i t c h circuit for o p e n
( s e e p a g e 10-22), radiator f a n s w i t c h c i r c u i t f o r
s h o r t ( s e e p a g e 10-23) a n d t h e radiator f a n s w i t c h
( s e e p a g e 10-23). if t h e y a r e O K , s u b s t i t u t e a
k n o w n - g o o d E C M ( s e e p a g e 11-5), t h e n r e c h e c k . If
the symptom/indication g o e s a w a y , replace the
original E C M ( s e e p a g e 11-115). •
N O — R e p l a c e t h e t h e r m o s t a t ( s e e p a g e 10-11). •
11-60
4fi
DTC P0131: Primary H02S (Sensor 1) Circuit 11. C h e c k for c o n t i n u i t y b e t w e e n p r i m a r y H 0 2 S
Low Voltage ( S e n s o r 1) 4 P c o n n e c t o r t e r m i n a l N o . 1 a n d b o d y
('00-03 models) ground.
P R I M A R Y H 0 2 S ( S E N S O R 1) 4 P C O N N E C T O R
( s e e p a g e 11-3).
PH02S
(WHT)
1. R e s e t the E C M ( s e e p a g e 11-4). 1 2
2. S t a r t the e n g i n e . Hold the e n g i n e s p e e d at 3 4

3,000 rpm without l o a d (in neutral) until the
radiator fan c o m e s o n .
3. C h e c k the p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e
w i t h a s c a n tool o r t h e H D S d u r i n g a c c e l e r a t i o n W i r e s i d e of f e m a l e t e r m i n a l s
u s i n g w i d e o p e n throttle.
Does the voltage stay at 0.5 V or less? Is there continuity?
Y E S — G o to s t e p 4. Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
(C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1 ) . B
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at the E C M . • t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
4. C h e c k the fuel p r e s s u r e ( s e e p a g e 11-145).
Is it normal?
N O — R e p a i r t h e fuel s u p p l y s y s t e m . •
6. D i s c o n n e c t the p r i m a r y H 0 2 S ( S e n s o r 1) 4 P
connector.
7. S t a r t the e n g i n e , a n d let it idle.
w i t h a s c a n tool or t h e H D S .
Does it stay at 0.5 V or less?
N O — R e p l a c e t h e p r i m a r y H 0 2 S ( S e n s o r 1)
(see page 11-114).H
11-61
PGM-FI System
DTC P0131: Primary H02S (Sensor 1) Circuit 10. C h e c k for continuity b e t w e e n p r i m a r y H 0 2 S

Low Voltage ( S e n s o r 1) 4 P c o n n e c t o r t e r m i n a l N o . 1 a n d b o d y
('04-05 models) ground.
( s e e p a g e 11-3).
PH02S
(WHT)
1. R e s e t t h e E C M ( s e e p a g e 11-4). 1 2
2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 3 4
radiator fan c o m e s o n .
(C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1).B
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . • t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). •
5. D i s c o n n e c t t h e p r i m a r y H 0 2 S ( S e n s o r 1) 4 P
connector.
7. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e
Is there 0.1 V or less?
( s e e p a g e 11-114). •
11-62
DTC P0132: Primary H02S (Sensor 1) Circuit 8. T u r n t h e ignition s w i t c h O N (II).
High Voltage
('00-03 models) 9. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e
w i t h a s c a n tool o r t h e H D S .
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n Is there 0.9 V or more?
( s e e p a g e 11-3).
1. R e s e t t h e E C M ( s e e p a g e 11-4).
2. S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at ( s e e p a g e 11-114). •
3,000 r p m w i t h o u t l o a d (in neutral) until the
radiator f a n c o m e s o n . 10. T u r n the ignition s w i t c h O F F .
3. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e 11. C o n n e c t E C M c o n n e c t o r t e r m i n a l s C 1 6 a n d C 1 8
w i t h a s c a n tool o r t h e H D S . with a j u m p e r wire.
Does the voltage stay at 0.9 V or more?

N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s
1
11
2
12
/ 4
14 15
5
16
/17 18 19
8
20
9
21
10
22
A
13
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . B
4. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-145).
24 25
P H 0 2 S (WHT)
26 27 28 29
SG2 (GRN/YEL)
30
/
JUMPER WIRE
Is it normal?
N O — R e p a i r t h e fuel s u p p l y s y s t e m . • 12. T u r n t h e ignition s w i t c h O N (II).
5. T u r n the ignition s w i t c h O F F . 13. C h e c k the p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e

connector. Is there 0.9 V or more?
7. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r Y E S — S u b s t i t u t e a known-good E C M (see page

t e r m i n a l s N o . 1 a n d No. 2 w i t h a j u m p e r w i r e . 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
JUMPER WIRE
(C16, C 1 8 ) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1 ) . B
1 ?
PH02S SG2
(WHT) (GRN/YEL)
3 4
11-63
PGM-FI System
DTC P0132: Primary H02S (Sensor 1) Circuit 8. C h e c k the p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e

High Voltage w i t h a s c a n tool or t h e H D S .
('04-05 models)
Is there 3.5 V or more?
and review the general troubleshooting information Y E S — G o to s t e p 9.
( s e e p a g e 11-3).
1. R e s e t t h e E C M ( s e e p a g e 11-4). ( s e e p a g e 11-114). •
2. S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at 9. T u r n the ignition s w i t c h O F F .

radiator f a n c o m e s o n . 10. D i s c o n n e c t t h e j u m p e r w i r e .
3. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e 11. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r
w i t h a s c a n tool or t h e H D S . t e r m i n a l N o . 1 to b o d y g r o u n d w i t h a j u m p e r w i r e .

PH02S
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s
(WHT)
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s 1 2
3 4
JUMPER WIRE
connector. W i r e side of f e m a l e t e r m i n a l s
6. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r
terminals No. 1 and No. 2 with a j u m p e r wire. 12. T u r n the ignition s w i t c h O N (II).
JUMPER WIRE
Y E S - ^ R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
1 '•?• (C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1 ) . B
PH02S SG2
(WHT) (GRN/YEL)
3 4 N O — G o to s t e p 14.

15. D i s c o n n e c t t h e j u m p e r w i r e .
7. T u r n t h e ignition s w i t c h O N (II). 16. D i s c o n n e c t E C M c o n n e c t o r C (31P).
11-64
17. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4P c o n n e c t o r
t e r m i n a l N o . 2 to b o d y g r o u n d w i t h a j u m p e r w i r e .
SG2
(GRN/YEL)
1 2
JUMPER WIRE
3 4
18. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
11
2
12
/13
4
14 15 16
5
/
17 18 19
8
20
9
21
10
22
/ 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/

11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e the original E C M ( s e e p a g e 11-115).
(C18) a n d t h e p r i m a r y H 0 2 S ( S e n s o r
PGM-FI System
DTC P0133: Primary H02S (Sensor 1) Circuit

Slow Response
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d
( s e e p a g e 11-3).
• If D T C P 0 1 3 1 , P 0 1 3 2 , a n d / o r P 0 1 3 5 a r e s t o r e d at t h e
s a m e time a s D T C P0133, troubleshoot those D T C s
first, t h e n r e c h e c k f o r D T C P 0 1 3 3 .
2 . S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
radiator f a n c o m e s o n .
3. Test-drive under t h e s e conditions:
• T r a n s m i s s i o n in 6th g e a r
• 5 5 m p h (89 k m / h ) s t e a d y s p e e d
• Until r e a d i n e s s c o d e or T e m p o r a r y D T C P 0 1 3 3
c o m e s on
4. C h e c k for a T e m p o r a r y D T C w i t h a s c a n tool o r t h e
HDS.
Is Temporary DTC P0133 indicated?
Y E S — R e p l a c e t h e p r i m a r y H 0 2 S ( S e n s o r 1)
( s e e p a g e 11-114). •
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . •
11-66
DTC P0134: Primary H02S (Sensor 1) Heater 7. T u r n t h e ignition s w i t c h O N .
System Malfunction
('04 model) 8. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) o u t p u t v o l t a g e
with the H D S or a s c a n tool.
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e a n d r e v i e w Is there 1.5 V or more?
the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e
11-3). Y E S — G o to s t e p 9.
• If the v e h i c l e w a s out of fuel a n d the e n g i n e s t a l l e d
before t h i s D T C w a s s t o r e d , refuel, a n d c l e a r t h e D T C N O — R e p l a c e t h e p r i m a r y H 0 2 S ( S e n s o r 1)
with the H D S . (see p a g e 1 1 - 1 1 4 ) . B
1. R e s e t t h e E C M ( s e e p a g e 11-4). 9. T u r n t h e ignition s w i t c h O F F .
2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 10. D i s c o n n e c t t h e j u m p e r w i r e .
3,000 r p m w i t h o u t load (in neutral) until t h e
radiator f a n c o m e s o n . 11. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r
PH02S
(WHT)
1 2
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s JUMPER WIRE
5. D i s c o n n e c t the p r i m a r y H 0 2 S ( S e n s o r 1) 4P
connector.
t e r m i n a l s No. 1 a n d N o . 2 w i t h a j u m p e r w i r e .
JUMPER WIRE
2
PH02S SG2
(WHT) (GRN/YEL)
4
(cont'd)
11-67
PGM-FI System

12. T u r n t h e ignition s w i t c h O N (II). 18. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
w i t h a s c a n tool o r t h e H D S . E C M C O N N E C T O R C (31P)
Y E S — R e p a i r o p e n in the w i r e b e t w e e n the E C M
1
11
2
12
/
13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
(C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1 ) . B
/ 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/
15. D i s c o n n e c t t h e j u m p e r w i r e . W i r e s i d e of f e m a l e t e r m i n a l s
t e r m i n a l N o . 2 to b o d y g r o u n d w i t h a j u m p e r w i r e . Y E S — S u b s t i t u t e a known-good E C M (see page
11-5), t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s
SG2
(GRN/YEL) (C18) a n d the primary H 0 2 S ( S e n s o r 1 ) . B
1 2
JUMPER WIRE
3 4
11-68
DTC P0134: Primary H02S (Sensor 1) Heater 7. T u r n t h e ignition s w i t c h O N .
System Malfunction
('05 model) 8. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d Is there 1.5-3.5 V?
r e v i e w the g e n e r a l t r o u b l e s h o o t i n g information
( s e e p a g e 11-3). Y E S — G o to s t e p 9 .
• If t h e v e h i c l e w a s out of fuel a n d t h e e n g i n e s t a l l e d
b e f o r e t h i s D T C w a s s t o r e d , refuel, a n d c l e a r t h e D T C N O — R e p l a c e t h e p r i m a r y H 0 2 S ( S e n s o r 1)
w i t h a s c a n tool o r t h e H D S . ( s e e p a g e 11-114). •
1. R e s e t t h e E C M ( s e e p a g e 11-4). 9. T u r n t h e ignition s w i t c h O F F .
2. S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at 10. D i s c o n n e c t the j u m p e r w i r e .

radiator f a n c o m e s o n . 11. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r
Does the voltage stay at 1.5-3.5 V?
PH02S
Y E S — G o to s t e p 4. (WHT)
1 2
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s JUMPER WIRE
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . •
connector.
t e r m i n a l s N o . 1 a n d No. 2 w i t h a j u m p e r w i r e . 13. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) output v o l t a g e
Is there 1.5-3.5 V?
JUMPER WIRE
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M
( C 1 6 ) a n d the p r i m a r y H 0 2 S ( S e n s o r 1 ) . B
1 ? N O — G o to s t e p 14.
PH02S SG2
(WHT) (GRN/YEL)
3 4 14. T u r n t h e ignition s w i t c h O F F .
15. D i s c o n n e c t the j u m p e r w i r e .
(cont'd)
11-69
PGM-FI System
17. C o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P c o n n e c t o r DTC P0135: Primary H02S (Sensor 1) Heater
t e r m i n a l N o . 2 to b o d y g r o u n d w i t h a j u m p e r w i r e . Circuit Malfunction
DTC P0141: Secondary H02S (Sensor 2)
Heater Circuit Malfunction
NOTE:
SG2
(GRN/YEL) • B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d
1 2 review the general troubleshooting information
( s e e p a g e 11-3).
JUMPER WIRE
3 4 • Information m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s to
DTCP0141.
1. R e s e t t h e E C M ( s e e p a g e 11 -4).
2. S t a r t the e n g i n e .
18. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 3. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool

terminal C 1 8 and body ground. or t h e H D S .
Is DTC P0135 or P0141 indicated?

1
11
2
12
/
13
4
14 15 16
5
/
17
7
18 19
8
20
9
21
10
22 N O ^ - l n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
/ 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/ at t h e p r i m a r y H 0 2 S ( S e n s o r 1) or s e c o n d a r y H 0 2 S
( S e n s o r 2) a n d at t h e E C M . •
Is there continuity ?

(C18) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1 ) . H
11-70
4. T u r n the ignition s w i t c h O F F . 7. A t t h e H 0 2 S s i d e , c h e c k c o n t i n u i t y b e t w e e n b o d y
ground a n d H 0 2 S 4P connector terminals No. 3
5. D i s c o n n e c t t h e H 0 2 S ( p r i m a r y o r s e c o n d a r y * ) a n d No. 4 i n d i v i d u a l l y .
( S e n s o r 1 or S e n s o r 2*) 4 P c o n n e c t o r .
P R I M A R Y H 0 2 S ( S E N S O R 1) S E C O N D A R Y H 0 2 S ( S E N S O R 2)
6. A t t h e H 0 2 S s i d e , m e a s u r e r e s i s t a n c e b e t w e e n 4P C O N N E C T O R 4P C O N N E C T O R *
H 0 2 S 4 P c o n n e c t o r t e r m i n a l s N o . 3 a n d No. 4.
P R I M A R Y H 0 2 S ( S E N S O R 1) S E C O N D A R Y H 0 2 S ( S E N S O R 2) 1 2 1 2
4P C O N N E C T O R 4P C O N N E C T O R *
• 3 4 • 3 4
1 2 1 2
• 3 4 • 3 4
T e r m i n a l s i d e of W i r e s i d e of
male terminals female terminals
T e r m i n a l s i d e of W i r e s i d e of
male terminals female terminals
( s e e p a g e 11-114) o r s e c o n d a r y H 0 2 S ( S e n s o r 2)*
Is there about 3.3 Q (12- 14.3 ay? ( s e e p a g e 11-114). •
Y E S — G o to s t e p 7. N O — G o to s t e p 8.
N O — R e p l a c e t h e p r i m a r y H 0 2 S ( S e n s o r 1) 8. T u r n the ignition s w i t c h O N (II).

( s e e p a g e 11-114) or s e c o n d a r y H 0 2 S ( S e n s o r 2Y
( s e e p a g e 11-1.14). • 9. M e a s u r e v o l t a g e b e t w e e n H 0 2 S 4 P c o n n e c t o r
4P C O N N E C T O R 4P C O N N E C T O R *
IG1 P02SHTC S02SHTC IG1

(BLK/ 1 2 (BLK/WHT) (BLK/WHT) 1 2 (BLK/
YEL) YEL)
3 A • 3 4 •
W i r e s i d e of T e r m i n a l s i d e of
female terminals male terminals
(cont'd)
11-71
PGM-FI System

10. T u r n t h e ignition s w i t c h O F F . Is there battery voltage?
11. D i s c o n n e c t E C M c o n n e c t o r C (31P). Y E S — G o to s t e p 14.
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r N O — R e p a i r o p e n in the w i r e b e t w e e n t h e p r i m a r y

terminal C l (C11)* a n d body ground. H 0 2 S ( S e n s o r 1), t h e s e c o n d a r y H 0 2 S ( S e n s o r 2 ) *
a n d t h e N o . 6 A C G (15 A ) f u s e . •
P02SHTC
/ /
(BLK/WHT) 15. R e c o n n e c t the H 0 2 S 4 P c o n n e c t o r .
1 2 4 5 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
// 25 26 27 28 29 30
/ 17. T u r n t h e ignition s w i t c h O N (II).
S02SHTC
(BLK/WHT)*
t e r m i n a l s B 2 a n d C1 (B2 a n d C 1 1 ) \
ECMCONNECTORS
PG1 (BLK)
1 2 3 4 5
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M 9 10 11 12
//
( C I , C11 *) a n d the H 0 2 S ( p r i m a r y or s e c o n d a r y * ) 20 21 22
( S e n s o r 1 o r S e n s o r 2 *). •
P02SHTC
(BLK/WHT) C(31P)
t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
1
/ 2 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10
S02SHTC
(BLK/WHT)* // 25 26 27 28 29 30
/
13. M e a s u r e v o l t a g e b e t w e e n p r i m a r y H 0 2 S 4 P W i r e s i d e of f e m a l e t e r m i n a l s
c o n n e c t o r t e r m i n a l N o . 3 ( s e c o n d a r y H 0 2 S N o . 4)*
and body ground. Is there 0.1 V or less?
4P C O N N E C T O R 4P C O N N E C T O R * (C1 a n d C 1 1 * ) a n d t h e H 0 2 S ( p r i m a r y or
s e c o n d a r y * ) ( S e n s o r 1 or S e n s o r 2 * ) . •
1 2 1 2 IG1 N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
(BLK/YEL)
3 4 3 4 • t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
I IG1
(V) (BLK/YEL)
W i r e s i d e of T e r m i n a l s i d e of
female terminals male terminals
11-72
DTC P0137: Secondary H02S (Sensor 2) 10. C h e c k for c o n t i n u i t y b e t w e e n s e c o n d a r y H 0 2 S
Circuit Low Voltage ( S e n s o r 2) 4 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
ground.
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all freeze d a t a
SECONDARY H02S
a n d r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g information ( S E N S O R 2) 4 P C O N N E C T O R
(see p a g e 11-3).
S H 0 2 S (WHT/RED)
1 2 -
3,000 r p m w i t h o u t load (in neutral) until the
3 4
3. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e at 3,000 r p m w i t h a s c a n tool or t h e H D S .
Does the voltage stay at 0.3 V or less? T e r m i n a l s i d e of m a l e t e r m i n a l s
Y E S — G o to s t e p 4. Is there continuity?
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s ( C I 5 ) a n d t h e s e c o n d a r y H 0 2 S ( S e n s o r 2). •
at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d at t h e
ECM.B N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s a w a y ,
4. T u r n t h e ignition s w i t c h O F F . r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). •
5. D i s c o n n e c t t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P
connector.
6. S t a r t t h e e n g i n e .
7. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e w i t h a s c a n tool or t h e H D S .
Does the voltage stay at 0.3 V or less?
N O — R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2) *
(see p a g e 1 1 - 1 1 4 ) . H -
11-73
PGM-FI System
DTC P0138: Secondary H02S (Sensor 2) 7. T u r n t h e ignition s w i t c h O N (II).
Circuit High Voltage
('00-04 models) 8. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e w i t h a s c a n tool or the H D S .
a n d review the general troubleshooting information Is there 0.6 V or more?
( s e e p a g e 11-3).
N O — R e p l a c e t h e s e c o n d a r y H 0 2 S ( S e n s o r 2)*
2. S t a r t t h e e n g i n e . H o l d t h e e n g i n e s p e e d at ( s e e p a g e 11-114). •
radiator f a n c o m e s o n 9. T u r n t h e ignition s w i t c h O F F .
3. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output 10. D i s c o n n e c t t h e j u m p e r w i r e .
11. C o n n e c t E C M c o n n e c t o r t e r m i n a l s C 1 5 a n d C 1 8
Does the voltage stay at 0.6 V or more? with a jumper wire.
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s JUMPER WIRE
S H 0 2 S (WHT/RED) SG2 (GRN/YEL)
ECM.B
1 2 3
/ 5 6 8 9 10
// 13 14 15 16 17 18 19 20 21
/
connector.
23
/ 25 26 27 28 29
Wire s i d e of f e m a l e terminals
30
/
6. C o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r
terminals No. 1 a n d No. 2 with a j u m p e r wire.
12. T u r n t h e ignition s w i t c h O N (H).
SECONDARY H02S
( S E N S O R 2) 4 P C O N N E C T O R 13. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output
JUMPER WIRE

SG2 (GRN/YEL) S H 0 2 S (WHT/RED)
a w a y , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115).
T e r m i n a l s i d e of m a l e t e r m i n a l s N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
(C15, C18) a n d the s e c o n d a r y H 0 2 S ( S e n s o r 2).l
11-74
('05 model) 8. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e w i t h a s c a n tool o r t h e H D S .
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n Is there 3.0 V or more?
(see p a g e 11-3).
N O — R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2)
2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at ( s e e p a g e 11 -114). •
3,000 r p m without l o a d (in neutral) until t h e
radiator f a n c o m e s o n . 9. T u r n t h e ignition s w i t c h O F F .
3. C h e c k the s e c o n d a r y H 0 2 S ( S e n s o r 2) output 10. D i s c o n n e c t t h e j u m p e r w i r e .

11. C o n n e c t E C M c o n n e c t o r t e r m i n a l s C 1 5 a n d C 1 8
Does the voltage stay at 3.0 V or more? with a j u m p e r wire.
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m i s O K at t h i s JUMPER WIRE

S H 0 2 S (WHT/RED) SG2 (GRN/YEL)
ECM.B
/
r
1 2 3 5 6 8 9 10
// 13 14 15 16 17 18 19 20 21
/
5. D i s c o n n e c t the s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P
connector.
23
/ 25 26 27 28 29 30
/
t e r m i n a l s No. 1 a n d No. 2 w i t h a j u m p e r w i r e .
SECONDARY H02S
( S E N S O R 2) 4 P C O N N E C T O R
JUMPER WIRE
SG2 (GRN/YEL) S H 0 2 S (WHT/RED)
(cont'd)
11-75
PGM-FI System
13. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) o u t p u t 18. T u r n t h e ignition s w i t c h O F F .

YES—Substitute a known-good E C M (see page
11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s 2 1 . C o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r
a w a y , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). t e r m i n a l No. 1 to b o d y g r o u n d w i t h a j u m p e r w i r e .
SECONDARY H02S
N O — G o to s t e p 14. ( S E N S O R 2) 4 P C O N N E C T O R
S G 2 (GRN/YEL)
15. D i s c o n n e c t t h e j u m p e r w i r e . - 1 2
JUMPER WIRE
16. C o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r 3 4
t e r m i n a l No. 2 to b o d y g r o u n d w i t h a j u m p e r w i r e .
SECONDARY H02S
( S E N S O R 2) 4P C O N N E C T O R T e r m i n a l s i d e of m a l e t e r m i n a l s
S H 0 2 S (WHT/RED) 2 2 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r

1 2 - terminal C18 and body ground.
JUMPER WIRE
3 4
1
11
2
12
/ 13
4
14 15 16
5
/
17 18 19
8
20
9
21
10
22
17. C h e c k the s e c o n d a r y H 0 2 S ( S e n s o r 2) o u t p u t
/ 24 25 26 27 23 29
SG2 (GRN/YEL)
30
/

( C 1 5 ) a n d t h e s e c o n d a r y H 0 2 S ( S e n s o r 2).m
(C18) a n d t h e s e c o n d a r y H 0 2 S ( S e n s o r 2)M
11-76
Circuit Slow Response
('00-04 models)
( s e e p a g e 11-3).
1. R e s e t the E C M ( s e e p a g e 11-4).
2. Start t h e e n g i n e . Hold the e n g i n e s p e e d at

3. C h e c k the s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e at 3,000 r p m with a s c a n tool or t h e H D S .
Does the voltage stay within 0.3- 0.6 V for

2 minutes?
Y E S — R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2)
(see page 11-114).H
ECM.B
11-77
PGM-FI System
DTC P0171: Fuel System Too Lean 4. T u r n t h e ignition s w i t c h O F F .
DTC P0172: Fuel System Too Rich 5. W i t h a v a c u u m p u m p , a p p l y v a c u u m to the E V A P

c a n i s t e r p u r g e v a l v e f r o m t h e intake m a n i f o l d s i d e .
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d Does it hold vacuum?
( s e e p a g e 11-3). Y E S — C h e c k t h e v a l v e c l e a r a n c e s a n d a d j u s t if
• If s o m e of t h e D T C s listed b e l o w a r e s t o r e d at t h e n e c e s s a r y . If t h e v a l v e c l e a r a n c e s a r e O K , r e p l a c e
s a m e t i m e a s D T C P0171 a n d / o r P 0 1 7 2 , t r o u b l e s h o o t the injectors. •
t h o s e D T C s first, t h e n r e c h e c k for P0171 a n d / o r
P0172. N O — R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e . •
P0107, P0108, P1128, P1129: Manifold absolute

pressure (MAP) s e n s o r
P0135: Primary heated oxygen s e n s o r (primary
H 0 2 S ) ( S e n s o r 1) h e a t e r
P 0 1 3 7 , P 0 1 3 8 : S e c o n d a r y H 0 2 S ( S e n s o r 2)
P 0 1 4 1 : S e c o n d a r y H 0 2 S ( S e n s o r 2) h e a t e r
P 1 2 5 9 ( P 2 6 4 6 , P 2 6 4 7 ) *: V T E C s y s t e m
* : '04-05 m o d e l s
1. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-145).
Is fuel pressure OK?
N O — C h e c k these items:
• If t h e p r e s s u r e i s t o o h i g h . C h e c k t h e fuel
p r e s s u r e r e g u l a t o r , a n d t h e fuel return p i p e . B
• If t h e p r e s s u r e is t o o l o w . C h e c k t h e fuel p u m p ,
t h e fuel f e e d p i p e , t h e fuel filter, a n d t h e fuel
pressure regulator.!
2. S t a r t t h e e n g i n e . H o l d t h e e n g i n e s p e e d at
3. C h e c k the p r i m a r y H 0 2 S ( S e n s o r 1) output w i t h a
s c a n tool or t h e H D S .
Does it stay less than 0.3 V or more than 0.6 V?
( s e e p a g e 11-114). •
11-78
DTC P0300: Random Misfire and Any Combination of the Following:
DTC P0301: No. 1 Cylinder Misfire Detected
NOTE:
• B e f o r e y o u t r o u b l e s h o o t r e c o r d all freeze data a n d r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-3).
• If t h e misfiring is f r e q u e n t e n o u g h to trigger detection of i n c r e a s e d e m i s s i o n s d u r i n g t w o c o n s e c u t i v e d r i v i n g c y c l e s ,
t h e M I L will c o m e o n , a n d D T C P 0 3 0 0 (and s o m e c o m b i n a t i o n of P0301 t h r o u g h P0304) will be s t o r e d .
• If t h e misfiring is f r e q u e n t e n o u g h to d a m a g e t h e c a t a l y s t , t h e M I L will blink w h e n e v e r t h e m i s f i r i n g o c c u r s , a n d D T C
P 0 3 0 0 (and s o m e c o m b i n a t i o n of P0301 t h r o u g h P0304) will b e s t o r e d . W h e n t h e m i s f i r i n g s t o p s , t h e M I L will r e m a i n
on.
1. T r o u b l e s h o o t the f o l l o w i n g D T C s first if a n y of t h e m w e r e s t o r e d a l o n g w i t h t h e r a n d o m m i s f i r e D T C ( s ) :
P 0 1 0 7 , P 0 1 0 8 , P 1 1 2 8 , P1129: M a n i f o l d a b s o l u t e p r e s s u r e ( M A P ) s e n s o r
P 0 1 3 1 , P 0 1 3 2 : P r i m a r y h e a t e d o x y g e n s e n s o r ( p r i m a r y H 0 2 S ) ( S e n s o r 1)
P0171, P0172: Fuel metering
P 0 3 3 5 , P0336: Crankshaft position (CKP) s e n s o r
P 0 5 0 5 (P0506, P 0 5 0 7 ) * : Idle control s y s t e m
P1259 (P2646, P2647)*: V T E C s y s t e m
P 1 3 6 1 , P 1 3 6 2 , P 1 3 6 6 , P1367 ( P 0 3 4 0 , P 0 3 4 4 , P 0 3 6 5 , P 0 3 6 9 K : C a m s h a f t p o s i t i o n ( C M P ) s e n s o r (top d e a d c e n t e r
(TDC) Sensor) A / B
P 0 5 1 V : Idle air control (IAC) v a l v e
* : '04-05 m o d e l s
2. T e s t - d r i v e t h e v e h i c l e to verify the s y m p t o m .
3. F i n d the s y m p t o m in t h e c h a r t , a n d d o t h e related p r o c e d u r e s in t h e o r d e r listed until y o u find t h e c a u s e .
Symptom Procedure(s) A l s o c h e c k for:

R a n d o m m i s f i r e o n l y at C h e c k fuel p r e s s u r e ( s e e p a g e 11-145). • Low compression.
l o w R P M a n d load • L o w quality f u e l .
R a n d o m misfire only C h e c k fuel p r e s s u r e ( s e e p a g e 11-145). M a l f u n c t i o n in t h e
during acceleration VTEC system
( s e e p a g e 6-8).
R a n d o m m i s f i r e at high C h e c k fuel p r e s s u r e ( s e e p a g e 11-145). Correct valve
R P M a n d l o a d , or u n d e r clearance (see page
random conditions 6-10).
11-79
PGM-FI System
DTCP0301: No. 1 Cylinder Misfire Detected 7. D e t e r m i n e w h i c h c y l i n d e r ( s ) h a d t h e m i s f i r e .
DTC P0302: No. 2 Cylinder Misfire Detected Does the misfire occur in the other cylinder where
the ignition coil was exchanged?
Y E S — R e p l a c e t h e faulty ignition c o i l . B
NOTE:
• B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e data a n d 8. T u r n t h e ignition s w i t c h O F F .
( s e e p a g e 11-3). 9. E x c h a n g e t h e s p a r k plug f r o m the p r o b l e m c y l i n d e r
• Information m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s with one from another cylinder.
to'00-04 models.
• Information m a r k e d w i t h d o u b l e a s t e r i s k (* *) a p p l i e s 10. T e s t - d r i v e t h e v e h i c l e s e v e r a l t i m e s in t h e r a n g e of
to'05 model. t h e f r e e z e d a t a or u n d e r v a r i o u s c o n d i t i o n s if t h e r e
w a s no freeze data.
1. After c h e c k i n g a n d r e c o r d i n g t h e f r e e z e d a t a , r e s e t
t h e E C M ( s e e p a g e 11-4). If t h e r e is n o f r e e z e d a t a of 11. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool
the misfire, just clear the D T C . or t h e H D S .
2. S t a r t t h e e n g i n e , listen for a c l i c k i n g s o u n d at t h e Is DTC P0301, P0302,P0303 or P0304 or

injector at t h e p r o b l e m c y l i n d e r . Temporary DTC P1399* (P0301, P0302, P0303,
or P0304)* * indicated?
Does it click?
N O — I n t e r m i t t e n t m i s f i r e d u e to s p a r k plug f o u l i n g ,
N O — G o to s t e p 30. etc. (no m i s f i r e at t h i s t i m e ) . •
3. T u r n t h e ignition s w i t c h O F F . 12. D e t e r m i n e w h i c h c y l i n d e r h a d t h e m i s f i r e .
4. E x c h a n g e t h e ignition coil f r o m t h e p r o b l e m Does the misfire occur in the other cylinder where
cylinder with one from another cylinder. the spark plug was exchanged?
5. T e s t - d r i v e t h e v e h i c l e s e v e r a l t i m e s in t h e r a n g e of Y E S — R e p l a c e t h e faulty s p a r k p l u g . •
t h e f r e e z e d a t a or u n d e r v a r i o u s c o n d i t i o n s if t h e r e
w a s no f r e e z e d a t a . N O — G o to s t e p 13.
6. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool 13. T u r n t h e ignition s w i t c h O F F .

or t h e H D S .
14. E x c h a n g e t h e injector f r o m t h e p r o b l e m c y l i n d e r
Is DTC P0301, P0302, P0303, or P0304 or with one from the another cylinder.
Temporary DTC P1399* (P0301, P0302, P0303,
orP0304)** indicated? 15. L e t the e n g i n e idle for 2 m i n u t e s .
Y E S — G o to s t e p 7. 16. T e s t - d r i v e t h e v e h i c l e s e v e r a l t i m e s in t h e r a n g e of
t h e f r e e z e d a t a or u n d e r v a r i o u s c o n d i t i o n s if t h e r e
N O — I n t e r m i t t e n t m i s f i r e d u e to p o o r c o n t a c t at t h e w a s no f r e e z e d a t a .
ignition coil c o n n e c t o r (no m i s f i r e at t h i s t i m e ) . •
11-80
17. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool 24. C h e c k for c o n t i n u i t y b e t w e e n ignition c o i l 3 P
or the H D S . connector terminal No. 2 and body ground.
IGNITION COIL 3P C O N N E C T O R
Is DTC P0301, P0302, P0303, or P0304 or
Temporary DTC P1399* (P0301,P0302, P0303,
orP0304)** indicated?
G N D (BLK)
N O — I n t e r m i t t e n t m i s f i r e d u e to b a d c o n t a c t in the
injector c o n n e c t o r (no m i s f i r e at this t i m e ) . •
18. D e t e r m i n e w h i c h c y l i n d e r h a d t h e m i s f i r e .
Does the misfire occur in the other cylinder where W i r e s i d e of f e m a l e terminals
the injector was exchanged?

Y E S — R e p l a c e the faulty injector ( s e e p a g e 11-112).
Y E S — G o to s t e p 2 5 .
N O — G o to s t e p 19. N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e ignition
coil a n d G 1 0 1 . B
2 5 . D i s c o n n e c t E C M c o n n e c t o r C (31P).
20. D i s c o n n e c t the ignition coil 3 P c o n n e c t o r f r o m t h e
problem cylinder. 2 6 . C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d the
E C M c o n n e c t o r t e r m i n a l ( s e e table).
2 1 . T u r n t h e ignition s w i t c h O N (II).
PROBLEM DTC ECM WIRE
2 2 . M e a s u r e v o l t a g e b e t w e e n ignition coil 3 P CYLINDER TERMINAL COLOR
connector terminal No. 3 a n d body ground. No. 1 P0301 C4 WHT
No. 2 P0302 C12 WHT/GRN
IGNITION C O I L 3P C O N N E C T O R
No. 3 P0303 C13 WHT/BLK
No. 4 P0304 C14 WHT/BLU
IG I G P L S 1 (WHT)
(BLK/YEL) IGPLS2
(WHT/ 10
GRN)
12 13 14 15 16 17 18 19 20 22
24 25 26 27 28 29 30
IGPLS3 . IGPLS4
(WHT/BLK) (WHT/BLU)
Is there battery voltage? Wire side of f e m a l e terminals
Y E S — G o to s t e p 2 3 . Is there continuity ?
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e N o . 4 Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
I G N C O I L (15 A ) f u s e a n d the ignition c o i l . B a n d the ignition c o i l . •
2 3 . T u r n t h e ignition s w i t c h O F F . N O — G o to s t e p 27.
(cont'd)
11-81
PGM-FI System
2 7 . C o n n e c t a p p r o p r i a t e ignition c o i l 3 P c o n n e c t o r 2 9 . C h e c k the e n g i n e c o m p r e s s i o n .
t e r m i n a l N o . 1 to b o d y g r o u n d w i t h a j u m p e r w i r e
(see table). Is the engine compression OK?
PROBLEM DTC WIRE Y E S — S u b s t i t u t e a known-good E C M (see page

CYLINDER COLOR 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
No. 1 P0301 WHT a w a y , r e p l a c e the o r i g i n a l E C M ( s e e p a g e 11-115).
No. 2 P0302 WHT/GRN •
No. 3 P0303 WHT/BLK
No. 4 P0304 WHT/BLU N O — R e p a i r the e n g i n e . •
3 0 . T u r n the ignition s w i t c h O F F .
JUMPER WIRE
1
3 2 . T u r n the ignition s w i t c h O N (II).
33. M e a s u r e voltage between body ground a n d the

E C M connector terminal (see table).

CYLINDER TERMINAL COLOR
W i r e s i d e of f e m a l e t e r m i n a l s No. 1 P0301 B11 BRN
No. 2 P0302 B3 RED
No. 3 P0303 B4 BLU
2 8 . C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e No. 4 P0304 B5 YEL
E C M connector terminal (see table).
PROBLEM DTC ECM WIRE INJ3 (BLU) INJ4(YEL)

No. 1 P0301 C4 WHT
No. 2 P0302 C12 WHT/GRN
10 12
No. 3 P0303 C13 WHT/BLK
No. 4 P0304 C14 WHT/BLU 20 21 22 23
INJ2 (RED) INJ1 (BRN)

IGPLS1 (WHT) (V)(Y)

IGPLS2
(WHT/ 10
GRN) W i r e s i d e of f e m a l e t e r m i n a l s
12 13 14 15 16 17 18 19 20 21 22
24 25 26 27 28 29 30
IGPLS3 , IGPLS4
(WHT/BLK) I (WHT/BLU)
W i r e s i d e of f e m a l e t e r m i n a l s 34. T u r n t h e ignition s w i t c h O F F .
Is there continuity? 3 5 . D i s c o n n e c t t h e injector 2 P c o n n e c t o r f r o m t h e

problem cylinder.
Y E S — G o to s t e p 2 9 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M a n d
t h e ignition c o i l . B
11-82
36. A t t h e injector s i d e , m e a s u r e r e s i s t a n c e b e t w e e n 41. Determine w h i c h cylinder h a d the misfire.
injector 2 P c o n n e c t o r t e r m i n a l s No. 1 a n d N o . 2.
Does the misfire occur in the other cylinder where
the injector was exchanged?
INJECTOR 2P C O N N E C T O R
Y E S — R e p l a c e the faulty injector. •
EE N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
IGP INJ
4 2 . T u r n t h e ignition s w i t c h O F F .
4 3 . D i s c o n n e c t injector 2 P c o n n e c t o r f r o m t h e p r o b l e m
T e r m i n a l s i d e of m a l e t e r m i n a l s cylinder.

Is there 10-13 Q?
4 5 . M e a s u r e v o l t a g e b e t w e e n injector 2 P c o n n e c t o r
Y E S — G o to s t e p 3 7 . terminal No. 2 and body ground.
N O — R e p l a c e the injector ( s e e p a g e 11-112). • INJECTOR 2P CONNECTOR
3 7 . E x c h a n g e the injector f r o m the p r o b l e m c y l i n d e r

with one from another cylinder.
3 8 . L e t t h e e n g i n e idle for 2 m i n u t e s .
1 z
IGP (YEL/BLK)
3 9 . T e s t - d r i v e t h e v e h i c l e s e v e r a l t i m e s in t h e r a n g e of
t h e f r e e z e data or u n d e r v a r i o u s c o n d i t i o n s if t h e r e
w a s n o freeze d a t a .
40. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool. Wire side of f e m a l e terminals
Is DTC P0301, P0302, P0303, or P0304 or

Temporary DTC P1399* (P0301, P0302 t P0303, Is there battery voltage?
or P0304)* * indicated?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e injector
N O — I n t e r m i t t e n t m i s f i r e d u e to injector a n d t h e P G M - F I m a i n relay. •
malfunction, e t c . B
(cont'd)
11-83
PGM-FI System
4 7 . C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e 49. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d t h e

E C M connector terminal (see table). E C M c o n n e c t o r t e r m i n a l s ( s e e table).
PROBLEM DTC ECM WIRE PROBLEM DTC ECM WIRE

CYLINDER TERMINAL COLOR CYLINDER TERMINAL COLOR
No. 1 P0301 B11 BRN No.1 P0301 B11 BRN
No. 2 P0302 B3 RED No. 2 P0302 B3 RED
No. 3 P0303 B4 BLU No. 3 P0303 B4 BLU
No. 4 P0304 B5 YEL No. 4 P0304 B5 YEL
E C M C O N N E C T O R B (25P) E C M C O N N E C T O R B (25P)
INJ3 (BLU) INJ4(YEL) INJ3 (BLU) INJ4(YEL)
1 2
9 10
20
INJ2 (RED)
Is there continuity? Is there continuity?
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M Y E S — R e p l a c e t h e injector, t h e n r e c h e c k . •
a n d t h e injector. •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M a n d
N O — G o to s t e p 4 8 . t h e injector. •
48. C o n n e c t injector 2 P c o n n e c t o r t e r m i n a l N o . 1 to
body ground with a j u m p e r wire (see table).
PROBLEM DTC WIRE

CYLINDER COLOR
No. 1 P0301 BRN
No. 2 P0302 RED
No. 3 P0303 BLU
No. 4 P0304 YEL
2
INJ
JUMPER WIRE
11-84
DTC P0325: Knock Sensor Circuit Malfunction 7. D i s c o n n e c t E C M c o n n e c t o r C ( 3 1 P ) , t h e n c h e c k for
continuity between E C M connector terminals C 2 2
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data and body ground.
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g information
( s e e p a g e 11-3). E C M C O N N E C T O R C (31P)
2. S t a r t the e n g i n e . Hold the e n g i n e s p e e d at

1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20
9
21
10
22
KS
(RED/BLU)
3. Hold the e n g i n e s p e e d at 3 , 0 0 0 — 4 , 0 0 0 r p m for

/ 24 25 26 27 28 29 30
/
10 s e c o n d s .
4. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool W i r e s i d e of f e m a l e t e r m i n a l s
or t h e H D S .
Is DTC P0325 indicated? Is there continuity?
(C22) a n d t h e k n o c k s e n s o r . •
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s N O — G o to s t e p 8.
at t h e knock s e n s o r a n d at the E C M . •
8. C o n n e c t t h e k n o c k s e n s o r 1P c o n n e c t o r t e r m i n a l
5. T u r n the ignition s w i t c h O F F . body ground with a jumper wire.
6. F r o m u n d e r n e a t h t h e v e h i c l e , r e a c h a b o v e the front
K N O C K S E N S O R 1P C O N N E C T O R
of t h e starter m o t o r , a n d d i s c o n n e c t t h e knock
s e n s o r 1P c o n n e c t o r .
KS (RED/BLU)
JUMPER WIRE
(cont'd)
11-85
PGM-FI System
9. C h e c k for continuity b e t w e e n E C M c o n n e c t o r DTC P0335: CKP Sensor No Signal

terminal C 2 2 and body ground.
DTC P0336: CKP Sensor Circuit Intermittent
Interruption
('00-03 models)
DTC P0339: CKP Sensor Circuit Intermittent

1
11
2
12
/13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
KS
(RED/BLU) Interruption
('04-05 models)
/ 24 25 26 27 28 29 30
/ NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d
r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g information
( s e e p a g e 11-3).
W i r e s i d e of f e m a l e t e r m i n a l s • I n f o r m a t i o n m a r k e d with a n a s t e r i s k (*) a p p l i e s
to'00-03 models.
• I n f o r m a t i o n m a r k e d with d o u b l e a s t e r i s k (* *) a p p l i e s
Is there continuity ? to'04-05 models.
Y E S — G o to s t e p 10. 1. R e s e t t h e E C M ( s e e p a g e 11-4).
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M 2. S t a r t t h e e n g i n e .
(C22) a n d t h e knock s e n s o r . •
3. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool
10. S u b s t i t u t e a k n o w n - g o o d k n o c k s e n s o r . or t h e H D S .
#
11. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool Is DTC P0335 and/or P0336* (PQ339Y
or t h e H D S . indicated?
Is DTC P0325 indicated? Y E S — G o to s t e p 4.
YES—Substitute a known-good E C M (see page N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s

11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
a w a y , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). at t h e C K P s e n s o r a n d at t h e E C M . •
N O — R e p l a c e the original knock s e n s o r . •
5. D i s c o n n e c t t h e C K P s e n s o r 3 P c o n n e c t o r .
11-86
6. A t t h e s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n 9. D i s c o n n e c t E C M c o n n e c t o r C ( 3 1 P ) , a n d m e a s u r e
C K P s e n s o r 3 P c o n n e c t o r t e r m i n a l s No. 1 a n d N o . 2. r e s i s t a n c e b e t w e e n the E C M c o n n e c t o r t e r m i n a l s
C8 and C9.
C K P S E N S O R 3P C O N N E C T O R
1 2 3 CKP+
(BLU)
D
I" ICKP-
(WHT)
CKP-
(WHT)
CKP+
(BLU)
1
11 12
2
/
13
4
14 15
5
16
/ 17
7
18 19
8
20
9
21
10
22
/ 24 25 26 27 28 29 30
/
Is there 1,850-2,450 Q ?
Is there 1,850- 2,450 Q?
N O — R e p l a c e t h e C K P s e n s o r ( s e e p a g e 6-6). •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M ( C 8 ,
7. A t t h e s e n s o r s i d e , c h e c k for continuity b e t w e e n C9) and the C K P sensor. •
C K P s e n s o r 3P connector terminal No. 1 a n d body
g r o u n d a n d t e r m i n a l No. 2 a n d b o d y g r o u n d 10. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
individually. terminal C 8 and body ground.
CKP S E N S O R 3P C O N N E C T O R E C M C O N N E C T O R C (31P)
CKP+(BLU)
11
2
12
/
13
4
14 15
5
16
/
17 18 19
8
20
9
21
10
22
CKP-
(WHT)
(H)
J
(GpCKP+
I (BLU)
/ 24 25 26 27 28 29 30
/
Is there continuity? Is there continuity?
Y E S — R e p l a c e the C K P s e n s o r ( s e e p a g e 6-3). Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n E C M
terminal C 8 a n d the C K P s e n s o r . •
8. R e c o n n e c t the C K P s e n s o r 3 P c o n n e c t o r . t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
11-87
PGM-FI System
DTC P0340: CMP Sensor A No Signal 6. A t t h e s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n
('04-05 models) C M P ( T D C ) s e n s o r 2 P c o n n e c t o r t e r m i n a l s No. 1
a n d N o . 2.
DTC P0344: CMP Sensor A Circuit
I nterm ittent I nterru ption C M P (TDC) S E N S O R A 2P C O N N E C T O R
('04-05 models)
DTC P1361: CMP (TDC) Sensor A Circuit

-., 1 . L—.
Intermittent Interruption
('00-03 models) 1 2
DTC P1362: CMP (TDC) Sensor A No Signal

('00-03 models)
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d T e r m i n a l s i d e of m a l e t e r m i n a l s
( s e e p a g e 11-3).
• Information m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s Is there 1,850- 2,450 Q?
to '04-05 m o d e l s .
• Information m a r k e d w i t h d o u b l e a s t e r i s k ('*•*) a p p l i e s Y E S — G o to s t e p 7.
to '00-03 m o d e l s .
N O — R e p l a c e C M P ( T D C ) s e n s o r A ( s e e p a g e 6-3).
7. A t t h e s e n s o r s i d e , c h e c k for continuity to b o d y
2. S t a r t t h e e n g i n e . g r o u n d o n both t e r m i n a l s i n d i v i d u a l l y .
3. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool C M P (TDC) S E N S O R A 2P C O N N E C T O R

or the H D S .
ISDTCP0344* (P1361)** or P0340* (P1362)**

indicated?
at C M P ( T D C ) s e n s o r A a n d at t h e E C M . •
5. D i s c o n n e c t C M P ( T D C ) s e n s o r A 2 P c o n n e c t o r . Is there continuity?
Y E S — R e p l a c e C M P ( T D C ) s e n s o r A ( s e e p a g e 6-3).
•
8. R e c o n n e c t C M P ( T D C ) s e n s o r A 2 P c o n n e c t o r .
11-88
10. M e a s u r e r e s i s t a n c e b e t w e e n E C M c o n n e c t o r DTG P0365: CMP Sensor B No Signal
terminals C20 and C21. ('04-05 models)
DTC P0369: CMP Sensor B Circuit Intermittent
Interruption
('04-05 models)
CMP1P CMP1M
(GRN) (RED) DTC P1366: CMP (TDC) Sensor B Circuit
Intermittent Interruption
1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20
9
21
10
22
('00-03 models)
DTC P1367: CMP (TDC) Sensor B No Signal

/ 24 25 26 27 28 29 30
/ ('00-03 models)
W i r e s i d e of f e m a l e t e r m i n a l s NOTE:
r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n
Is there 1,850-2,450 Q? ( s e e p a g e 11-3).
• Information m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s
Y E S — G o to s t e p 11. to '04-05 m o d e l s .
• Information m a r k e d w i t h d o u b l e a s t e r i s k (* *) a p p l i e s
N O — R e p a i r o p e n or s h o r t in the faulty s e n s o r to '00-03 m o d e l s .
wire(s).B
11. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d
E C M connector terminal C20. 2. S t a r t the e n g i n e .
or t h e H D S .
CMPIP(GRN)
11
2
12
/13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
lsDTCP0369*
indicated?
(P1366)** or P0365* (P1367)**
/ 24 25 26 27 28 29 30
/ Y E S — G o to s t e p 4.
N O — I n t e r m i t t e n t failure, the s y s t e m is O K at this

at C M P ( T D C ) s e n s o r B a n d at t h e E C M . B
Is there continuity? 5. D i s c o n n e c t the C M P ( T D C ) s e n s o r B 2 P c o n n e c t o r .
Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e faulty
sensor wire(s).B
r e p l a c e the original E C M ( s e e p a g e 11-115). •
(cont'd)
11-89
PGM-FI System
6. A t t h e s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n 10. M e a s u r e r e s i s t a n c e b e t w e e n E C M c o n n e c t o r
C M P (TDC) s e n s o r 2P connector terminals No. 1 terminals C29 and C30.
a n d N o . 2.
C M P (TDC) S E N S O R B 2P C O N N E C T O R
11
2
12
/13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
/ 24 25 26 27 28
CMP2P (YEL)
29 30
/
C M P 2 M (BLK)
Is there 1,850-2,450 0.?

Is there 1,850-2,450 Q?
N O — R e p a i r o p e n or s h o r t in t h e faulty s e n s o r
N O — R e p l a c e C M P ( T D C ) s e n s o r B ( s e e p a g e 6-3). wire(s).B
7. A t the s e n s o r s i d e , c h e c k for c o n t i n u i t y to b o d y 11. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d

g r o u n d o n both t e r m i n a l s i n d i v i d u a l l y . E C M connector terminal C29.
C M P (TDC) S E N S O R B 2P C O N N E C T O R E C M C O N N E C T O R C (31P)
. ' . 1
1 "!
1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20
9
21
10
22
1 2
/ 24 25 26 27 28 29 30
/
CMP2P (YEL)
T e r m i n a l s i d e of m a l e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
Is there continuity? Is there continuity ?
Y E S — R e p l a c e C M P ( T D C ) s e n s o r B ( s e e p a g e 6-3). Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e faulty
• sensor wire(s).B
N O — G o to s t e p 8. N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
8. R e c o n n e c t C M P ( T D C ) s e n s o r B 2 P c o n n e c t o r s . r e p l a c e the o r i g i n a l E C M ( s e e p a g e 11-115). •
11-90
DTC P0500: V S S Circuit Malfunction 9. M e a s u r e v o l t a g e b e t w e e n V S S 3 P c o n n e c t o r
terminal No. 1 a n d body ground.
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data
( s e e p a g e 11-3). V S S 3P C O N N E C T O R
3,000 r p m w i t h o u t l o a d (in neutral) until t h e VCC2(YEL/BLU)
3. T e s t - d r i v e w i t h t h e t r a n s m i s s i o n in 2 n d g e a r .
A c c e l e r a t e to 4,000 r p m , t h e n d e c e l e r a t e to
1,500 r p m w i t h the throttle fully c l o s e d for at l e a s t W i r e s i d e of f e m a l e t e r m i n a l s
5 seconds.
4. C h e c k for a D T C w i t h a s c a n tool or t h e H D S . Is there about 5 V?
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 10. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s C28 and body ground.
b e t w e e n t h e V S S a n d at t h e E C M . •
E C M C O N N E C T O R C (3IP)
6. R a i s e the v e h i c l e .
1 2
/ 4 5
11 12 13 14- 15 16 17 18 19 20 21 22
/ 7 8 9 10
7. D i s c o n n e c t t h e V S S 3 P c o n n e c t o r .
/ 24 25 26 27 28 29 30
VCC2 (YEL/BLU)
/
Is there about 5 V?
Y E S — R e p a i r o p e n in the w i r e b e t w e e n t h e E C M
(C28)andtheVSS.B
(cont'd)
11-91
PGM-FI System
11. M e a s u r e v o l t a g e b e t w e e n V S S 3 P c o n n e c t o r Does voltage pulse between 0 V and about 5 V?

V S S 3P C O N N E C T O R
VCC2 LG2
(YEL/BLU) (BRN/YEL)
18. D i s c o n n e c t E C M c o n n e c t o r A (32P).

20. Hold o n e w h e e l , a n d s l o w l y rotate t h e other.
Is there about 5 V? 21. M e a s u r e voltage between E C M connector

terminals A9 and B22.
ECM CONNECTORS
( B 2 2 ) a n d the V S S . B 1 2 3 4 5
///
9 10 11 12
/////
13. R e c o n n e c t t h e V S S 3 P c o n n e c t o r .
20 21 22
// 23
LG2 (BRN/YEL)

A (32P) ]VSS(BLU/WHT)
15. R a i s e t h e r e a r of t h e v e h i c l e , a n d m a k e s u r e it is 0
s e c u r e l y s u p p o r t e d . Hold o n e w h e e l , a n d s l o w l y
29
rotate t h e other.
terminals A9 and B22. Does voltage pulse between 0 V and about 5 V?
ECM CONNECTORS
B (25P) 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
N O — R e p a i r s h o r t or o p e n in the w i r e b e t w e e n t h e
V S S a n d t h e E C M , if t h e w i r e is O K , r e p l a c e the V S S
( s e e p a g e 22-93). •
A (32P)
I V S S (BLU/W
1 2 3 4
/ / / 6 9 10
12 13
/ / 15
/
17 18 19 20 21 24
25 26 27
/28 29 30 32
11-92
DTC P0607: ECM Internal Circuit Malfunction
('04-05 models)
DTC P1607: ECM Internal Circuit Malfunction

('00-03 models)
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data a n d
( s e e p a g e 11-3).
• Information m a r k e d with a n a s t e r i s k (*) a p p l i e s
to '04-05 m o d e l s .
• Information m a r k e d with d o u b l e a s t e r i s k (* *) a p p l i e s
to '00-03 m o d e l s .
• If t h e No. 2 5 B A C K U P (7.5 A ) f u s e is r e m o v e d a n d t h e
ignition s w i t c h is O N (II), M I L will report o n a n d E C M
will s t o r e t h e D T C P 0 6 0 7 * ( P 1 6 0 7 ) * \
or the H D S .
lsDTCP0607* (P1607)** indicated?

5. C y c l e the ignition s w i t c h O F F a n d O N (II) five t i m e s .
or the H D S .
lsDTCP0607* (P1607)** indicated?
Y E S - l n s p e c t the No. 2 5 B A C K U P (7.5 A ) f u s e . If

t h e f u s e is O K , repair o p e n in V B U w i r e b e t w e e n
the under-dash fuse/relay box a n d the E C M . B
N O — I n t e r m i t t e n t failure, t h e s y s t e m i s O K at t h i s
t i m e . A l o w battery c a n c a u s e t h i s p r o b l e m . A s k t h e
c u s t o m e r if t h e e n g i n e h a d to b e j u m p - s t a r t e d
recently. •
PGM-FI System
DTC P0630: VIN Not Programmed or 8. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .

Mismatch
('04-05 models) Are any Temporary DTCs or DTCs indicated?
NOTE: Y E S — I f D T C P 0 6 3 0 is i n d i c a t e d , substitute a k n o w n -
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d g o o d E C M ( s e e p a g e 11-5), t h e n r e c h e c k . If a n y
review the general troubleshooting information o t h e r T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to
( s e e p a g e 11-3). the indicated D T C s troubleshooting. •
• T h i s D T C is s t o r e d o n l y w h e n t h e E C M d o e s not h a v e
t h e V I N i n f o r m a t i o n of t h e v e h i c l e . U s e t h e H D S to fill N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
the m i s s i n g VIN information. time.B
2. C h e c k t h e V I N w i t h t h e H D S .
Does the HDS show the vehicle's VIN?
3. Input t h e V I N to t h e E C M w i t h t h e H D S .
Does the screen show COMPLETE?
4. C h e c k for D T C s w i t h t h e H D S .
Is DTC P0607 indicated?
Y E S — G o to t h e D T C P 0 6 0 7 t r o u b l e s h o o t i n g . •
then recheck. •
5. C l e a r t h e D T C w i t h t h e H D S .
7. T u r n t h e ignition s w i t c h O N (II), a n d w a i t 5 s e c o n d s .
11-94
DTC P1106: BARO Sensor Range/ DTC P1107: BARO Sensor Circuit Low Voltage
Performance Problem ('00-03 models)
('00-03 models)
DTC P1108: BARO Sensor Circuit High
DTC P2227: BARO Sensor Range/ Voltage
Performance Problem ('00-03 models)
('04-05 models)
DTC P2228: BARO Sensor Circuit Low Voltage
NOTE: ('04-05 models)
review the general troubleshooting information DTC P2229: BARO Sensor Circuit High
( s e e p a g e 11-3). Voltage
• Information m a r k e d with a n a s t e r i s k (*) a p p l i e s ('04-05 models)
to ' 0 0 - 0 3 m o d e l s .
• Information m a r k e d with d o u b l e a s t e r i s k (* *) a p p l i e s NOTE:
to ' 0 4 - 0 5 m o d e l s . • B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d
1. R e s e t t h e E C M ( s e e p a g e 11-4). ( s e e p a g e 11-3).
• I n f o r m a t i o n m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s
2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at to'00-03 models.
3,000 r p m w i t h o u t load (in neutral) until t h e • Information m a r k e d w i t h d o u b l e a s t e r i s k (* *) a p p l i e s
radiator f a n c o m e s o n , t h e n let it idle. to'04-05 models.
3. T e s t - d r i v e with t h e t r a n s m i s s i o n in 4th g e a r . 1. R e s e t t h e E C M ( s e e p a g e 11-4).
4. A c c e l e r a t e for 5 s e c o n d s u s i n g w i d e o p e n throttle. 2. T u r n t h e ignition s w i t c h O N (II).
5. C h e c k for a T e m p o r a r y D T C with a s c a n tool or t h e 3. C h e c k for T e m p o r a r y D T C s o r D T C s with a s c a n tool

HDS. o r the H D S .
Is Temporary DTC P1106* (P2227)** indicated? Is DTC P1107* (P2228)** or P1108* (P2229)**
indicated?
11-5), t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s Y E S — S u b s t i t u t e a known-good E C M (see page
a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115). 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at this
time.B N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
time.B
11-95
PGM-FI System
DTC P1109: BARO Sensor Circuit Out of

Range High
('04-05 models)
( s e e p a g e 11-3).
3. C h e c k for T e m p o r a r y D T C s or D T C s w i t h a s c a n tool
or the H D S .

time.B
11-96
DTC P1121: TP Sensor Signal Lower Than DTC P1122: TP Sensor Signal Higher Than
Expected Expected
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e data N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data

and review the general troubleshooting information and r e v i e w the general troubleshooting information
( s e e p a g e 11-3). ( s e e p a g e 11-3).
1. T u r n t h e ignition s w i t c h O N (II). 1. T u r n t h e ignition s w i t c h O N (II).
2. C h e c k t h e throttle p o s i t i o n w i t h a s c a n tool o r the 2 . C h e c k t h e throttle p o s i t i o n w i t h a s c a n tool o r the

HDS. HDS.
Is 9.4 % or more indicated when the throttle is Is 14.1 %or less indicated when the throttle is
fully opened? fully closed?
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
time.B time.B
N O — R e p l a c e t h e throttle b o d y ( s e e p a g e 11-165). • N O — R e p l a c e t h e throttle b o d y ( s e e p a g e 1 1 - 1 6 5 ) . B
11-97
PGM-FI System
DTC P1128: MAP Sensor Signal Lower Than DTC P1129: MAP Sensor Signal Higher Than
Expected Expected
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a
a n d review the general troubleshooting information a n d review the general troubleshooting information
( s e e p a g e 11-3). ( s e e p a g e 11-3).
1. T u r n t h e ignition s w i t c h O N (II). 1. S t a r t t h e e n g i n e . Hold the e n g i n e s p e e d at

2 . C h e c k t h e M A P w i t h a s c a n tool or t h e H D S . radiator f a n c o m e s o n , t h e n let it idle.
Is about 54.1 kPa (16.0 in.Hg, 406 mmHg), or 1.6 V 2 . C h e c k t h e M A P w i t h a s c a n tool or t h e H D S .

or more indicated?
Is about 36.9 kPa (10.9 in.Hg, 277 mmHg), or 1.1 V
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s or less indicated?
time.B
N O — R e p l a c e t h e M A P s e n s o r ( s e e p a g e 11-166). B time.B
N O — R e p l a c e the M A P s e n s o r ( s e e p a g e 1 1 - 1 6 6 ) . B
11-98
DTC P1297: ELD Circuit Low Voltage 9. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data 10. D i s c o n n e c t E C M c o n n e c t o r A (32P).

( s e e p a g e 11-3). 11. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
terminal A30 and body ground.
E C M C O N N E C T O R A (32P)
2 . S t a r t the e n g i n e .
3. T u r n o n the h e a d l i g h t s . 1 2 3 4 6
/ / 9 10
12 13
/ 15 17 18 19 20 21
/ 24
or the H D S .
25 26 27
/
28 29 30
ELD (GRN/RED)
32
Y E S - G o to s t e p 5.
at the E L D a n d at t h e E C M . • Is there continuity?
5. T u r n the ignition s w i t c h a n d h e a d l i g h t s O F F . Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
(A30)andtheELD.B
6. D i s c o n n e c t the E L D 3 P c o n n e c t o r .
7. T u r n the ignition s w i t c h O N (II). t h e n r e c h e c k . if t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
8. M e a s u r e v o l t a g e b e t w e e n E L D 3 P c o n n e c t o r
t e r m i n a l No. 3 a n d b o d y g r o u n d .
E L D 3P C O N N E C T O R
ELD (GRN/RED)
Is thereabouts V?
Y E S — R e p l a c e the main under-hood fuse/relay

box.H
11-99
PGM-FI System
DTC P1298: ELD Circuit High Voltage 10. C o n n e c t E L D 3 P c o n n e c t o r t e r m i n a l N o . 3 to b o d y

ground with a jumper wire.
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a
a n d review the general troubleshooting information ELD 3P C O N N E C T O R
( s e e p a g e 11-3).
1 2 3
JUMPER WIRE ELD (GRN/RED)
3. T u r n o n t h e h e a d l i g h t s .
4. C h e c k for T e m p o r a r y D T C o r D T C w i t h a s c a n tool
or t h e H D S .
Y E S — G o to s t e p 5. 11. D i s c o n n e c t E C M c o n n e c t o r A (32P).
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s terminal A30 and body ground.
at t h e E L D a n d at t h e E C M . •
5. T u r n t h e ignition s w i t c h a n d h e a d l i g h t s O F F .
6. D i s c o n n e c t t h e E L D 3 P c o n n e c t o r .
/ 2 3 4 5 6
/ 8 9 10
7. T u r n t h e ignition s w i t c h O N (II). 12 13 14 15
25 26 27 / 17 18 19 20 21
28 29 30
23
32
24
8. M e a s u r e v o l t a g e b e t w e e n E L D 3 P c o n n e c t o r I ELD (GRN/RED)
@
ELD 3P C O N N E C T O R
IG1 ( B L K / Y E L )
1 2 3 Is there continuity?
( A 3 0 ) a n d the E L D . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 6
A C G (15 A ) f u s e a n d t h e E L D . •
11-100
13. C h e c k for continuity b e t w e e n E L D 3 P c o n n e c t o r 16. W h i l e m e a s u r i n g v o l t a g e b e t w e e n E C M c o n n e c t o r
t e r m i n a l No. 2 a n d b o d y g r o u n d . t e r m i n a l s A 3 0 a n d B 2 0 , turn t h e h e a d l i g h t s o n (low).
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 2A
25 26 27
/ 28 29 30
ELD (GRN/RED)
32
G N D (BLK)
B (25P)
0
21
LG1 (BRN/YEL)
Does the voltage drop?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n E L D 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
c o n n e c t o r t e r m i n a l No. 2 a n d G 2 0 1 . B a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
•
14. R e c o n n e c t t h e E L D 3 P c o n n e c t o r a n d E C M
c o n n e c t o r A (32P). N O — R e p l a c e the under-hood fuse/relay b o x . H
15. S t a r t t h e e n g i n e , a n d let it idle.
11-101
PGM-FI System
DTC P2195: Primary H02S (Sensor 1) Circuit 9 . T u r n t h e ignition s w i t c h O F F .

Low Voltage
('04 model) 10. D i s c o n n e c t E C M c o n n e c t o r C (31P).
NOTE: 11. C h e c k for c o n t i n u i t y b e t w e e n p r i m a r y H 0 2 S

• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d ( S e n s o r 1) 4 P c o n n e c t o r t e r m i n a l N o . 1 a n d b o d y
review the general troubleshooting information ground.
( s e e p a g e 11-3).
• If t h e v e h i c l e w a s out of fuel a n d t h e e n g i n e s t a l l e d
before this D T C w a s s t o r e d , refuel a n d c l e a r t h e D T C
PH02S
2
(WHT)
1. R e s e t t h e E C M ( s e e p a g e 11-4). 1
3. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) o u t p u t v o l t a g e
Y E S — G o to s t e p 4. Y E S — R e p a i r s h o r t in the w i r e b e t w e e n t h e E C M
(C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r 1).B
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s N O — S u b s t i t u t e a k n o w n - g o o d ( s e e p a g e 11-5),
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . B t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). •
4. C h e c k t h e f u e l p r e s s u r e ( s e e p a g e 11-145).
Is It normal?
connector.
8. C h e c k t h e p r i m a r y H 0 2 S ( S e n s o r 1) o u t p u t v o l t a g e
N O — R e p l a c e the p r i m a r y H 0 2 S ( S e n s o r 1)
( s e e p a g e 11-114). •
11-102
DTC P2195: Primary H02S (Sensor 1) Circuit 9. T u r n t h e ignition s w i t c h O F F .
Low Voltage
('05 model) 10. D i s c o n n e c t E C M c o n n e c t o r C (31P).
NOTE: 11. C h e c k for continuity b e t w e e n p r i m a r y H 0 2 S

• B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a a n d ( S e n s o r 1) 4 P c o n n e c t o r t e r m i n a l N o . 1 a n d b o d y
review the general troubleshooting information ground.
( s e e p a g e 11-3).
• If the v e h i c l e w a s out of fuel a n d the e n g i n e s t a l l e d
before t h i s D T C w a s s t o r e d , r e f u e l , a n d c l e a r t h e D T C
PH02S
(WHT)
1 2
3,000 r p m without load (in neutral) until t h e
w i t h a s c a n tool o r t h e H D S . W i r e s i d e of f e m a l e t e r m i n a l s
Does the voltage stay at 0.1- 0.5 V?

Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at this (C16) a n d t h e p r i m a r y H 0 2 S ( S e n s o r
at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . B N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
4. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-145). r e p l a c e t h e original E C M ( s e e p a g e 11-115). •
Is it normal?
6. D i s c o n n e c t the p r i m a r y H 0 2 S ( S e n s o r 1) 4 P
connector.
Does it stay at 0.5 V or less?
(see page 11-114).B
11-103
PGM-FI System

Circuit Signal Stuck Lean
('04-05 models)
( s e e p a g e 11-3).
3,000 r p m without load (in neutral) until the
3. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
• T r a n s m i s s i o n in 6th g e a r .
• V e h i c l e s p e e d at 6 5 m p h (105 k m / h ) ; s t e a d y
s p e e d for at l e a s t 1 m i n u t e .
• W h i l e d r i v i n g , d e c e l e r a t e (with t h e throttle fully
c l o s e d ) for 4 s e c o n d s , t h e n o p e n t h e throttle
s l o w l y , a n d c r u i s e 40 s e c o n d s or m o r e .
4. C h e c k the s e c o n d a r y H 0 2 S ( S e n s o r 2) output
v o l t a g e w i t h a s c a n tool o r t h e H D S .
Does the voltage stay at 0.0— 0.6 V?
Y E S — R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2)
( s e e p a g e 11-114). •
ECM.B
11-104
DTC P2271: Secondary H02S (Sensor 2) DTC P2297: Primary H02S (Sensor 1) Circuit
Circuit Signal Stuck Rich High Voltage
('04-05 models) ('04-05 models)
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data

and r e v i e w the general troubleshooting information and r e v i e w the general troubleshooting information
(see p a g e 11-3). ( s e e p a g e 11-3).
1. R e s e t t h e E C M ( s e e p a g e 11-4). 1. R e s e t t h e E C M ( s e e p a g e 11-4).
2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 2. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
3,000 r p m w i t h o u t load (in neutral) until the 3,000 r p m w i t h o u t l o a d (in neutral) until the
radiator f a n c o m e s o n . radiator f a n c o m e s o n .
3. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : 3. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
• T r a n s m i s s i o n in 6th g e a r . • T r a n s m i s s i o n in 6th g e a r .
• V e h i c l e s p e e d at 6 5 m p h (105 k m / h ) ; s t e a d y • V e h i c l e s p e e d at 6 5 m p h (105 k m / h ) ; s t e a d y
s p e e d for at l e a s t 1 m i n u t e , s p e e d for at l e a s t 1 m i n u t e , t h e n s l o w d o w n w i t h
• W h i l e d r i v i n g , d e c e l e r a t e (with t h e throttle fully t h e throttle c o m p l e t e l y c l o s e d for at l e a s t
c l o s e d ) for 4 s e c o n d s , t h e n o p e n t h e throttle 5 seconds.
s l o w l y , a n d c r u i s e 40 s e c o n d s or m o r e .
4. C h e c k t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) output w i t h a s c a n tool or the H D S .
Y E S — R e p l a c e t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) ( s e e p a g e 11-114). •
( s e e p a g e 11-114). •
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at this
N O — I n t e r m i t t e n t failure, the s y s t e m i s O K at t h i s t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e p r i m a r y H 0 2 S ( S e n s o r 1) a n d at t h e E C M . •
at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d at the
ECM.B
11-105
PGM-FI System
MIL Circuit Troubleshooting

1. T u r n the ignition s w i t c h O N (II), a n d w a t c h t h e 3. T r y to start t h e e n g i n e .
m a l f u n c t i o n i n d i c a t o r l a m p (MIL).
Does the engine start?
Does the MIL come on and stay on?
Y E S — I f the MIL a l w a y s c o m e on and s t a y s o n , go
to s t e p 2 0 . B u t if t h e M I L s o m e t i m e s w o r k s N O — G o to s t e p 7.
n o r m a l l y , first c h e c k for t h e s e p r o b l e m s . •
• A n intermittent s h o r t in t h e w i r e b e t w e e n the
E C M (A10) a n d t h e d a t a link c o n n e c t o r ( D L C ) . 5. C o n n e c t E C M c o n n e c t o r t e r m i n a l A 1 8 to b o d y
• A n intermittent s h o r t in the w i r e b e t w e e n the ground with a jumper wire.
E C M (A18) a n d t h e g a u g e a s s e m b l y .
N O — I f t h e M I L i s a l w a y s off, g o to s t e p 2. B u t if t h e
M I L s o m e t i m e s w o r k s n o r m a l l y , first c h e c k for
these problems. •
1 2 3
/ / /
4 6 9 10
• A loose No. 5 I N S T R U M E N T L I G H T B A C K U P 12 13
/ / 15 17 18 19 20 21 24
L I G H T (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y
box.
• A loose No. 46 A C G S (15 A ) f u s e in t h e m a i n
/
25 26 27
JUMPER WIRE
2 3 29 30
MIL (GRN/ORN)
32
under-hood fuse/relay box.

• A loose No. 2 F U E L P U M P S R S (15 A ) f u s e in t h e
under-dash fuse/relay box. W i r e s i d e of f e m a l e t e r m i n a l s
• A p o o r c o n n e c t i o n at E C M t e r m i n a l A 1 8 .
• A n intermittent o p e n in t h e G R N / O R N w i r e
b e t w e e n t h e E C M (A18) a n d t h e g a u g e a s s e m b l y . 6. T u r n t h e ignition s w i t c h O N (II).
• A n intermittent s h o r t in the w i r e b e t w e e n the
E C M (C19) a n d t h e m a n i f o l d a b s o l u t e p r e s s u r e Is the MIL on?
(MAP) s e n s o r .
• A n intermittent s h o r t in t h e w i r e b e t w e e n t h e Y E S — S u b s t i t u t e a known-good E C M (see page
E C M (C28) a n d throttle p o s i t i o n (TP) s e n s o r , 11-5), t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s
v e h i c l e s p e e d s e n s o r ( V S S ) , air p u m p e l e c t r i c a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
c u r r e n t s e n s o r , o r fuel t a n k p r e s s u r e ( F T P ) s e n s o r .
• Faulty PGM-FI m a i n relay.
N O — C h e c k for a n o p e n in the w i r e s b e t w e e n t h e
2 . T u r n t h e ignition s w i t c h O F F , a n d t h e n O N (II) a g a i n . E C M (A18) a n d t h e g a u g e a s s e m b l y . A l s o c h e c k for
a blown MIL b u l b . B
Is the low oil pressure indicator on?
N O — C h e c k for t h e s e p r o b l e m s . •
• A blown No. 5 I N S T R U M E N T L I G H T B A C K U P
L I G H T (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y
box.
• A s h o r t or o p e n in t h e w i r e b e t w e e n t h e No. 5
I N S T R U M E N T L I G H T B A C K U P L I G H T (7.5 A )
fuse and the gauge a s s e m b l y .
11-106
7. T u r n the ignition s w i t c h O F F . 10. D i s c o n n e c t E C M c o n n e c t o r C (31P).
8. Inspect the A C G S (15 A ) f u s e in t h e m a i n u n d e r - 11. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d

h o o d f u s e / r e l a y box. E C M connector terminals C I 9 a n d C 2 8 individually.
Is the fuse OK?

N O — C h e c k for t h e s e p r o b l e m s . •
1
11
2
12
/
13 ,14
4
15
5
16
/ 17
7
18 19
8
20
9
21
10
22
• A s h o r t in t h e w i r e b e t w e e n t h e N o . 46 A C G S
(15 A ) f u s e a n d t h e P G M - F I m a i n r e l a y .
/ 24 25
VCC2
(YEL/BLU)
26 27 28
Vi^
29 30
/ ^ \ / ? v \ VV C C 11
(YEL/RED)
/
• A s h o r t in t h e w i r e b e t w e e n t h e P G M - F I m a i n
relay a n d t h e E C M , i n j e c t o r s , o r I A C v a l v e .
9. Inspect the No. 2 F U E L P U M P S R S (15 A ) f u s e in t h e W i r e s i d e of f e m a l e t e r m i n a l s

u n d e r - d a s h f u s e / r e l a y box.
Is the fuse OK? Is there continuity?
Y E S — G o to s t e p 10. Y E S — G o to s t e p 12.
N O — C h e c k for t h e s e p r o b l e m s . • N O — G o to s t e p 13.
• A s h o r t in t h e w i r e b e t w e e n t h e N o . 2 F U E L 12. D i s c o n n e c t t h e 3 P c o n n e c t o r f r o m e a c h of t h e s e
P U M P S R S (15 A ) f u s e a n d t h e P G M - F I m a i n r e l a y s e n s o r s , o n e at a t i m e , a n d c h e c k for continuity
or the S R S unit. between body ground and E C M connector
• A s h o r t in t h e w i r e b e t w e e n t h e P G M - F I m a i n terminals C 1 9 a n d C 2 8 individually.
relay a n d t h e f u e l p u m p .
• A faulty P G M - F I m a i n r e l a y or faulty f u e l p u m p . • Manifold absolute pressure (MAP) s e n s o r
• Vehicle speed sensor (VSS)
• F u e l tank p r e s s u r e ( F T P ) s e n s o r
• T h r o t t l e position (TP) s e n s o r
• Air p u m p electrical current s e n s o r
Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e
b e t w e e n t h e E C M (C19) a n d t h e M A P s e n s o r , or t h e
E C M (C28) a n d t h e T P s e n s o r , t h e V S S , t h e F T P
s e n s o r , o r air p u m p electrical c u r r e n t s e n s o r . •
N O — R e p l a c e t h e s e n s o r that m a d e continuity to
body ground go a w a y w h e n disconnected. •
13. D i s c o n n e c t t h e i n j e c t o r s a n d I A C v a l v e c o n n e c t o r s .
(cont'd)
11-107
PGM-FI System
MIL Circuit Troubleshooting (cont'd)
14. T u r n t h e ignition s w i t c h O N (II). 16. T u r n t h e ignition s w i t c h O F F .
15. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M 17. R e c o n n e c t t h e c o n n e c t o r s to t h e s e n s o r s , t h e n
c o n n e c t o r t e r m i n a l s B1 a n d B 9 i n d i v i d u a l l y . r e c o n n e c t E C M c o n n e c t o r C (31P).
E C M C O N N E C T O R B (25P) 18. T u r n t h e ignition s w i t c h O N (II).
IGP1 ( Y E L / B L K ) 19. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M
connector terminals B2, B10, B20, and B22
individually.
PG1 (BLK)
Y E S — G o to s t e p 16. LG1 (BRN/YEL)
N O — C h e c k for t h e s e p r o b l e m s . • W i r e s i d e of f e m a l e t e r m i n a l s
• A n o p e n in t h e w i r e ( s ) b e t w e e n t h e P G M - F I m a i n Is there less than 1.0 V?

r e l a y a n d E C M c o n n e c t o r t e r m i n a l s B1 a n d B 9 .
• P o o r c o n n e c t i o n s at t h e P G M - F I m a i n r e l a y . Y E S — S u b s t i t u t e a known-good E C M (see page
• A f a u l t y P G M - F I m a i n r e l a y ( s e e p a g e 11-142). 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
R e p a i r or r e p l a c e parts a s n e e d e d . a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
N O — R e p a i r o p e n in the w i r e ( s ) that h a d m o r e t h a n
1.0 V b e t w e e n G 1 0 1 a n d the E C M ( B 2 , B 1 0 , B 2 0 ,
B22).B
2 1 . C o n n e c t a s c a n tool or t h e H D S .
2 3 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h a s c a n tool
or t h e H D S .
Are any Temporary DTCs or DTCs indicated?
Y E S — G o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
N O — G o to s t e p 2 4 .
11-108
24. T u r n the ignition s w i t c h O F F . 2 7 . T u r n t h e ignition s w i t c h O N (II).
2 5 . D i s c o n n e c t E C M c o n n e c t o r A (32P). 28. M e a s u r e voltage between E C M connector terminal

A10 and body ground.
d a t a link c o n n e c t o r ( D L C ) (16P) t e r m i n a l No. 7.
D A T A LINK C O N N E C T O R (DLC) S C S (BRN)
1 2 3
/ / /
4 6 9 10
K-LINE 12 13
/ / 15
/ 17 18 19 20 21 24
(GRY) 25 26 27
/ 28 29 30 32
Is there about 5 V?
Is there continuity? Y E S — G o to s t e p 2 9 .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e D L C a n d N O — R e p a i r s h o r t in t h e w i r e b e t w e e n the D L C a n d
the E C M ( A 2 D . B the E C M ( A 1 0 ) . B
N O — G o to s t e p 2 7 . 2 9 . T u r n t h e ignition s w i t c h O F F .
3 0 . D i s c o n n e c t E C M c o n n e c t o r A (32P).
Is the MIL on?
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e g a u g e
a s s e m b l y a n d the E C M (A18). B
r e p l a c e t h e original E C M ( s e e p a g e 11-115). B
11-109
PGM-FI System
DLC Circuit Troubleshooting
If the E C M d o e s not c o m m u n i c a t e w i t h a s c a n t o o l , t h e 3. M e a s u r e v o l t a g e b e t w e e n D L C t e r m i n a l s No. 5 a n d

H D S , or l/M t e s t e q u i p m e n t , d o t h i s t r o u b l e s h o o t i n g N o . 16.
procedure.
DATA LINK C O N N E C T O R (DLC)
1. M e a s u r e v o l t a g e b e t w e e n D L C t e r m i n a l N o . 16 a n d
body ground.
L G 2 (BRN)
+B
(WHT/GRN) +B (WHT/GRN)

Is there battery voltage? N O — R e p a i r o p e n in the w i r e b e t w e e n D L C t e r m i n a l

No. 8 a n d b o d y g r o u n d ( G 1 0 1 ) . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n D L C t e r m i n a l
No. 8 a n d t h e A C G S (15 A ) f u s e in the u n d e r - h o o d 5. M e a s u r e v o l t a g e b e t w e e n D L C t e r m i n a l s No. 5 a n d
fuse/relay box.H No. 7.
2. M e a s u r e voltage between D L C terminals No. 4 a n d D A T A LINK C O N N E C T O R (DLC)

No. 16.
LG2 HYh KLINE
w
(BRN) (GRY)
Z7
P G (BLK) K I—|— W
9
v
ZZi27i Z
' I I * r
4 16
I I I I*
+B (WHT/GRN)
T e r m i n a l s i d e of f e m a l e t e r m i n a l s Is there 8.5 V or more?
Y E S — G o to s t e p 3 .
N O — R e p a i r o p e n in the w i r e b e t w e e n D L C t e r m i n a l
No. 8 and body ground (G401). •
11-110
7. D i s c o n n e c t E C M c o n n e c t o r A (32P). M a k e s u r e the Is there continuity?
s c a n tool or t h e H D S i s d i s c o n n e c t e d f r o m the D L C .
8. C h e c k for continuity b e t w e e n D L C t e r m i n a l No. 7 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
and body ground. a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
DATA LINK C O N N E C T O R (DLC)

N O — R e p a i r o p e n in t h e w i r e b e t w e e n D L C t e r m i n a l
N o . 7 a n d t h e E C M (A21). After r e p a i r i n g the w i r e ,
c h e c k t h e D T C with a s c a n tool o r t h e H D S , a n d g o
KLINE
yyyy
(GRY)
to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
11. D i s c o n n e c t E C M c o n n e c t o r A (32P). M a k e s u r e a
s c a n tool or the H D S is d i s c o n n e c t e d f r o m t h e D L C .
T e r m i n a l s i d e of f e m a l e t e r m i n a l s 12. T u r n t h e ignition s w i t c h O N (II).
13. M e a s u r e v o l t a g e b e t w e e n D L C t e r m i n a l s No. 5 a n d
Is there continuity? N o . 7.
Y E S — R e p a i r s h o r t to g r o u n d in t h e w i r e b e t w e e n D A T A LINK C O N N E C T O R (DLC)
D L C t e r m i n a l No. 15 a n d t h e E C M (A21). After
r e p a i r i n g the w i r e , c h e c k t h e D T C w i t h a s c a n tool
or t h e H D S , a n d g o to t h e i n d i c a t e d D T C s
1
troubleshooting. • LG2 KVh K-LINE
W
(BRN) (GRY)
44^-
9. C h e c k for continuity b e t w e e n D L C t e r m i n a l No. 7 7t7li2
and E C M terminal A 2 1 .
1 2
/ / / / 6 9 10
12 13 15
25 26 27 / 17 18 19 20 21
28 29 30 32
24
Is there OV?
W i r e s i d e of f e m a l e t e r m i n a l s KLINE Y E S — S u b s t i t u t e a known-good E C M (see page

(GRY)
LINE a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
(GRY)
/ 1 2 N O — R e p a i r s h o r t to p o w e r in t h e w i r e b e t w e e n the
D L C t e r m i n a l No. 7 a n d the E C M (A21). After
T e r m i n a l s i d e of f e m a l e t e r m i n a l s r e p a i r i n g t h e w i r e , c h e c k t h e D T C w i t h a s c a n tool
or t h e H D S , a n d g o to t h e i n d i c a t e d D T C s
11-11
PGM-FI System
Injector Replacement
1. R e l i e v e t h e fuel p r e s s u r e ( s e e p a g e 11-145).
2. R e m o v e t h e fuel rail c o v e r (A), t h e n d i s c o n n e c t t h e c o n n e c t o r s f r o m t h e i n j e c t o r s (B).
12 N m
(1.2 k g f - m , 8.7 Ibf-ft)
3. D i s c o n n e c t t h e v a c u u m h o s e a n d fuel return h o s e f r o m t h e fuel p r e s s u r e regulator (C). P l a c e a rag or s h o p t o w e l

over the h o s e s before disconnecting t h e m .
4. D i s c o n n e c t t h e f u e l h o s e (D) f r o m t h e fuel rail ( E ) . R e m o v e t h e v a c u u m l i n e s (F).
5. R e m o v e t h e retainer n u t s (G) a n d bolts (H) f r o m t h e fuel rail a n d h a r n e s s h o l d e r (I).
6. D i s c o n n e c t t h e P C V v a l v e ( J ) .
7. D i s c o n n e c t t h e f u e l rail.
8. R e m o v e t h e i n j e c t o r s f r o m t h e intake m a n i f o l d (K).
11-112
9. S l i d e n e w c u s h i o n r i n g s (A) onto the i n j e c t o r s (B).
10. C o a t n e w O - r i n g s (C) w i t h c l e a n e n g i n e o i l , a n d put t h e m o n t h e i n j e c t o r s .
11. Insert t h e i n j e c t o r s into t h e fuel rail (D).
12. C o a t n e w s e a l r i n g s (E) w i t h c l e a n e n g i n e o i l , a n d p r e s s t h e m into t h e intake m a n i f o l d .
13. Install t h e i n j e c t o r s in t h e intake m a n i f o l d .
14. Install a n d tighten t h e retainer nuts.
15. C o n n e c t t h e f u e l h o s e to t h e fuel rail w i t h n e w w a s h e r s .
16. C o n n e c t t h e v a c u u m h o s e s a n d fuel return h o s e to t h e fuel p r e s s u r e regulator.
17. C o n n e c t t h e P C V v a l v e .
18. T u r n t h e ignition s w i t c h O N (II), but d o not o p e r a t e t h e starter. After t h e fuel p u m p r u n s for a b o u t 2 s e c o n d s , t h e

fuel p r e s s u r e in t h e fuel line r i s e s . R e p e a t t h i s 2 o r 3 t i m e s , t h e n c h e c k for fuel l e a k a g e .
11-113
PGM-FI System
Primary H02S Replacement Secondary H02S Replacement
1. D i s c o n n e c t p r i m a r y H 0 2 S ( S e n s o r 1) 4 P 1. D i s c o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P
c o n n e c t o r (A). c o n n e c t o r (A).
2. R e m o v e t h e p r i m a r y H 0 2 S ( S e n s o r 1) (A). 2. R e m o v e t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) (A).
A A
4 4 N m (4.5 k g f - m , 3 3 I b f f t ) 4 4 N m (4.5 k g f - m , 3 3 I b f f t )
3 . Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l . 3 . Install t h e parts in the r e v e r s e o r d e r of r e m o v a l .
11-114
ECM Replacement
1. T u r n the ignition s w i t c h O F F . '02-05 m o d e l s
2. D i s c o n n e c t the n e g a t i v e c a b l e f r o m the battery.
3. R e m o v e t h e left s i d e kick p a n e l (A) to e x p o s e t h e

E C M (B).
8. T u r n the ignition s w i t c h O N (II).
N O T E : If D T C P 0 6 3 0 " V I N Not P r o g r a m m e d o r
M i s m a t c h " i s s t o r e d at t h i s t i m e , ignore it a n d
c o n t i n u e t h i s p r o c e d u r e ('04-05 m o d e l s ) .
9. Input t h e V I N to t h e E C M w i t h t h e H D S .
10. R e w r i t e t h e i m m o b i l i z e r c o d e w i t h the E C M
r e p l a c e m e n t p r o c e d u r e in t h e H D S ; it a l l o w s y o u to
4. R e m o v e t h e t w o bolts f r o m t h e E C M . start the e n g i n e .
5. D i s c o n n e c t the E C M c o n n e c t o r s . 11. R e s e t t h e E C M w i t h t h e H D S .
6. Install the E C M in the r e v e r s e o r d e r of r e m o v a l . 12. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-140).
7. C o n n e c t the H D S to the D L C (A) located u n d e r t h e

p a s s e n g e r ' s s i d e of d a s h b o a r d ('00-01 m o d e l s ) or
b e h i n d the d r i v e r ' s s i d e of t h e front c o n s o l e
('02-05 m o d e l s ) .
'00-01 m o d e l s
11-115
VTEC
11-116
DTC Troubleshooting
DTC P1259: VTEC System Malfunction 7. A t t h e s w i t c h s i d e , c h e c k for continuity o n t h e

('00-03 models) r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e
s w i t c h ) b e t w e e n r o c k e r a r m oil p r e s s u r e s w i t c h
Special Tools Required ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r t e r m i n a l s
• P r e s s u r e gauge adapter 07NAJ-P07010A No. 1 a n d N o . 2.
• A / T low pressure gauge w/panel 07406-0070301
• A / T pressure hose 07406-0020201 R O C K E R A R M OIL P R E S S U R E SWITCH
• A / T p r e s s u r e h o s e , 2,210 m m 0 7 M A J - P Y 4 0 1 1 A (VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R
• A / T pressure hose, adapter 07MAJ-PY40120
( s e e p a g e 11-3).
1. R e s e t t h e e n g i n e control m o d u l e ( E C M ) ( s e e p a g e
11-4).
2. C h e c k t h e e n g i n e oil l e v e l , a n d refill if n e c e s s a r y . T e r m i n a l s i d e of m a l e t e r m i n a l s
3. Start t h e e n g i n e . Hold t h e e n g i n e s p e e d at
3,000 r p m w i t h o u t l o a d (in neutral) until t h e Is there continuity?
4. R o a d test the v e h i c l e :
A c c e l e r a t e in 1st g e a r to a n e n g i n e s p e e d o v e r N O — R e p l a c e t h e r o c k e r a r m oil p r e s s u r e s w i t c h
6,000 r p m . Hold that e n g i n e s p e e d for at l e a s t ( V T E C oil p r e s s u r e s w i t c h ) . •
2 s e c o n d s . If D T C P I 2 5 9 is not r e p e a t e d d u r i n g the
first r o a d test, repeat t h i s test t w o m o r e t i m e s . 8. T u r n the ignition s w i t c h O N (II).
Is DTC P1259 Indicated? 9. M e a s u r e the v o l t a g e b e t w e e n t h e rocker a r m oil

p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) h a r n e s s
Y E S — G o to s t e p 5. 2P connector terminal No. 1 and body ground.
N O — I n t e r m i t t e n t failure, the s y s t e m i s O K at this R O C K E R A R M OIL P R E S S U R E SWITCH

t i m e . C h e c k for poor c o n n e c t i o n s or l o o s e w i r e s at (VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R
the r o c k e r a r m oil control s o l e n o i d ( V T E C s o l e n o i d
v a l v e ) , the rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil
p r e s s u r e s w i t c h ) , a n d the E C M . B
6. D i s c o n n e c t the rocker a r m oil p r e s s u r e s w i t c h

( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r .
(cont'd)
11-117
VTEC
10. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 13. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

C10 and body ground. terminal C10 and body ground.
VTM VTM
(BLU/BLK) (BLU/BLK)
1 2
/ 4 5
/ 7
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10 1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
7 8 9 10
/ 24 25 26 27 28 29 30
/ / 24 25 26 27 28 29 30
/
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the r o c k e r Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e r o c k e r
a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h )
a n d the E C M . B andtheECM(C9).B
N O — G o to s t e p 11. N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),
11. T u r n t h e ignition s w i t c h O F F . r e p l a c e t h e original E C M ( s e e p a g e 11-115). •
12. D i s c o n n e c t E C M c o n n e c t o r C (31P). 14. M e a s u r e v o l t a g e b e t w e e n rocker a r m oil p r e s s u r e

s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r
ROCKER A R M OIL P R E S S U R E SWITCH

(VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R
N O — R e p a i r o p e n in the w i r e b e t w e e n the r o c k e r
a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h )
andG101.B
11-118
15. T u r n the ignition s w i t c h O F F . 19. R e c o n n e c t t h e r o c k e r a r m oil c o n t r o l s o l e n o i d
( V T E C s o l e n o i d v a l v e ) 1P c o n n e c t o r a n d rocker a r m
16. D i s c o n n e c t the rocker a r m oil control s o l e n o i d oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) 2 P
( V T E C s o l e n o i d v a l v e ) 1P c o n n e c t o r . connector.
17. A t t h e v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n the 20. C o n n e c t a t a c h o m e t e r .

r o c k e r a r m oil control s o l e n o i d ( V T E C s o l e n o i d
v a l v e ) 1P c o n n e c t o r a n d b o d y g r o u n d . 2 1 . S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at
ROCKER A R M OIL C O N T R O L S O L E N O I D
(VTEC SOLENOID VALVE) IP CONNECTOR
2 2 . C h e c k the oil p r e s s u r e at e n g i n e s p e e d s of 1,000,
, i—i . 2,000 a n d 6,000 r p m . K e e p m e a s u r i n g t i m e a s s h o r t
a s p o s s i b l e ( l e s s t h a n 1 m i n u t e ) b e c a u s e the e n g i n e
is r u n n i n g w i t h o u t l o a d .
Is the oil pressure below 49 kPa (0.5 kgf/crrf,

7 psi)?
Y E S — G o to s t e p 2 3 .
N O — I n s p e c t the r o c k e r a r m oil control s o l e n o i d
( V T E C s o l e n o i d v a l v e ) ( s e e p a g e 11-126). •
Is there 14-30 Q ?
24. D i s c o n n e c t t h e r o c k e r a r m oil control s o l e n o i d
N O — R e p l a c e the rocker a r m oil control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) 1P c o n n e c t o r .
(VTEC solenoid valve). •
2 5 . A t t a c h t h e battery p o s i t i v e c a b l e to t h e rocker a r m
18. R e m o v e the rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) t e r m i n a l .
oil p r e s s u r e s w i t c h ) (A) a n d install t h e s p e c i a l t o o l s
a s s h o w n , t h e n reinstall t h e r o c k e r a r m oil p r e s s u r e 26. S t a r t the e n g i n e , a n d c h e c k the oil p r e s s u r e at
s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) . 6,000 r p m .
N O T E : Install the parts in the r e v e r s e o r d e r of Is the oil pressure above 390 kPa (4.0 kgf/crrf,
r e m o v a l w i t h a n e w O-ring. 57 psi)?
Y E S — G o to s t e p 2 7 .
N O — I n s p e c t the r o c k e r a r m oil control s o l e n o i d

( V T E C s o l e n o i d v a l v e ) ( s e e p a g e 11-126). •
(2.2 k g f - m , 16 Ibf-ft)
(cont'd)
11-119
VTEC
2 7 . W i t h t h e battery p o s i t i v e t e r m i n a l still c o n n e c t e d to Is there continuity?

the r o c k e r a r m oil control s o l e n o i d ( V T E C s o l e n o i d
valve), m e a s u r e voltage between E C M connector Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e rocker
terminal C10 and body ground. a r m oil control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) a n d
the E C M (B12). •
E C M C O N N E C T O R C (3IP)
N O — G o to s t e p 3 2 .
VTM 3 2 . C o n n e c t the r o c k e r a r m oil control s o l e n o i d ( V T E C

(BLU/BLK)
1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10 solenoid valve) I P connector terminal body ground
with a jumper wire.
/ 24 25 26 27 28 29 30
/ X ROCKER A R M OIL C O N T R O L SOLENOID
(VTEC SOLENOID VALVE) I P CONNECTOR
Is there battery voltage above 5,000 rpm? JUMPER WIRE
N O — R e p l a c e the rocker a r m oil p r e s s u r e s w i t c h W i r e s i d e of f e m a l e t e r m i n a l s

( V T E C oil p r e s s u r e s w i t c h ) . •
28. T u r n the ignition s w i t c h O F F . 3 3 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r

2 9 . D i s c o n n e c t the battery p o s i t i v e c a b l e f r o m t h e
valve) terminal.
1 2 3 4
///5
9 10 11 12
//////
20 2 1 22
// 23
VTS (GRN/YEL) Is there continuity?

N O — R e p a i r a o p e n in the w i r e b e t w e e n t h e E C M
(B12) a n d the r o c k e r a r m oil control s o l e n o i d ( V T E C
solenoid v a l v e ) . !
11-120
DTC P2646: Rocker Arm Oil Pressure Switch 8. T u r n t h e ignition s w i t c h O F F .
(VTEC Oil Pressure Switch) Circuit Low
Voltage 9. R e m o v e the r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C
('04-05 models) oil p r e s s u r e s w i t c h ) (A) a n d install t h e s p e c i a l t o o l s
a s s h o w n , t h e n install the r o c k e r a r m oil p r e s s u r e
Special Tools Required s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) (A) to t h e oil
• Pressure gauge adapter 07NAJ-P07010A p r e s s u r e g a u g e a d a p t e r (B).
• A / T low pressure g a u g e w/panel 07406-0070301
• A / T p r e s s u r e h o s e 07406-0020201 N O T E : Install t h e p a r t s in the r e v e r s e or o r d e r of
• A / T p r e s s u r e h o s e , 2,210 m m 0 7 M A J - P Y 4 0 1 1 A removal with a n e w O-ring.
( s e e p a g e 11-3).
2. C h e c k t h e e n g i n e oil l e v e l .
7 s the engine oil level OK?
(2.2 k g f - m , 16 Ibf-ft)
N O — A d j u s t t h e e n g i n e oil to t h e p r o p e r l e v e l . •
3. T u r n the ignition s w i t c h O N (II). 10. D i s c o n n e c t t h e r o c k e r a r m oil c o n t r o l s o l e n o i d

( V T E C s o l e n o i d v a l v e ) 1P c o n n e c t o r .
4. R e s e t the e n g i n e control m o d u l e ( E C M ) ( s e e p a g e
11-4). 11. S t a r t t h e e n g i n e . Hold the e n g i n e s p e e d at
3,000 r p m w i t h o u t load until t h e radiator f a n c o m e s
5. S t a r t t h e e n g i n e . Hold the e n g i n e s p e e d at o n , t h e n let it idle.
3,000 r p m w i t h o u t l o a d until t h e radiator f a n c o m e s
o n , t h e n let it idle. 12. A t t a c h t h e battery p o s i t i v e t e r m i n a l to the rocker
a r m oil control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) 1P
6. T e s t - d r i v e u n d e r f o l l o w i n g c o n d i t i o n s : connector terminal.
A c c e l e r a t e in 1st g e a r to a n e n g i n e s p e e d o v e r
6,000 r p m . H o l d t h e s p e e d for at l e a s t 2 s e c o n d s . 13. S t a r t t h e e n g i n e , a n d c h e c k t h e oil p r e s s u r e at a n
e n g i n e s p e e d of 3,000 r p m .
or t h e H D S . Is the oil pressure above 390 kPa (4.0 kgf/crrf,
57 psi)?
t i m e . C h e c k f o r p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
at t h e r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil
p r e s s u r e s w i t c h ) , t h e rocker a r m oil control
solenoid ( V T E C solenoid valve), a n d the E C M . H
(cont'd)
11-121
VTEC
14. C h e c k t h e e n g i n e oil p r e s s u r e ( s e e p a g e 8-6). 20. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

Is the engine oil pressure OK ?
Y E S — R e p l a c e the r o c k e r a r m oil control s o l e n o i d
( V T E C s o l e n o i d v a l v e ) ( s e e s t e p 3 o n p a g e 11-126).
VTM
(BLU/BLK)
N O — R e p a i r the c a u s e of t h e l o w oil p r e s s u r e ( s e e
s t e p 4 o n p a g e 8-6).
1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
7 8 9 10
15. D i s c o n n e c t t h e r o c k e r a r m oil p r e s s u r e s w i t c h / 24 25 26 27 28 29 30
/
16. A t t h e r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil

p r e s s u r e s w i t c h ) s i d e , c h e c k for continuity b e t w e e n W i r e s i d e of f e m a l e terminals
r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e
switch) terminals No. 1 a n d No. 2 with the engine
s p e e d at 3,000 r p m . Is there continuity?
R O C K E R A R M OIL P R E S S U R E S W I T C H
Y E S — R e p a i r a s h o r t in t h e w i r e b e t w e e n the E C M
(VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R (C10) a n d the rocker a r m oil p r e s s u r e s w i t c h ( V T E C
oil p r e s s u r e s w i t c h ) . •
N O — G o to s t e p 2 1 .

E C M C O N N E C T O R S (25P)
3 4 5
12
Is there continuity? 20 21 22 23
VTS (GRN/YEL)
Y E S — R e p l a c e the r o c k e r a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) ( s e e p a g e 11-126). •
18. D i s c o n n e c t t h e battery t e r m i n a l s f r o m t h e r o c k e r Is there continuity ?

a r m oil c o n t r o l s o l e n o i d ( V T E C s o l e n o i d v a l v e )
terminal connector. Y E S — R e p a i r a s h o r t in t h e w i r e b e t w e e n the E C M
(B12) a n d the rocker a r m oil control s o l e n o i d ( V T E C
19. D i s c o n n e c t E C M c o n n e c t o r B (24P). solenoid valve). •
N O — G o to s t e p 2 2 .
11-122
2 2 . C o n n e c t t h e rocker a r m o i l c o n t r o l s o l e n o i d ( V T E C
s o l e n o i d v a l v e ) I P c o n n e c t o r t e r m i n a l to b o d y
R O C K E R A R M OIL C O N T R O LS O L E N O I D
(VTEC SOLENOIDVALVE) I P CONNECTOR
JUMPER WIRE
10
3
12
H J V\
5
20 21 22 23
V T S (GRN/YEL)

a w a y w i t h a k n o w n - g o o d E C M , r e p l a c e t h e original
E C M ( s e e p a g e 11-115). •
N O — R e p a i r a n o p e n in t h e w i r e b e t w e e n t h e E C M
(B12) a n d t h e r o c k e r a r m oil control s o l e n o i d ( V T E C
solenoid valve). •
VTEC

(VTEC Oil Pressure Switch) Circuit High
Voltage 8. R e m o v e t h e r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C
('04-05 models) oil p r e s s u r e s w i t c h ) (A) a n d install t h e s p e c i a l t o o l s
a s s h o w n , t h e n install the rocker a r m oil p r e s s u r e
Special Tools Required s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) to t h e oil
• Pressure gauge adapter 07NAJ-P07010A p r e s s u r e g a u g e a d a p t e r (B).
• A / T low pressure gauge w/panel 07406-0070301
• A / T pressure hose 07406-0020201 N O T E : Install t h e parts in t h e r e v e r s e or o r d e r of
• A / T p r e s s u r e h o s e , 2,210 m m 0 7 M A J - P Y 4 0 1 1 A removal with a n e w O-ring.
( s e e p a g e 11-3).
2. C h e c k t h e e n g i n e oil l e v e l .
Is the engine oil level OK ?
(2.2 k g f - m , 16 Ibf-ft)
N O — A d j u s t t h e e n g i n e oil to t h e p r o p e r l e v e l . •
3. T u r n t h e ignition s w i t c h O N (II). 9. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at

3,000 r p m w i t h o u t l o a d until the radiator f a n c o m e s
4. R e s e t t h e e n g i n e c o n t r o l m o d u l e ( E C M ) ( s e e p a g e o n , t h e n let it idle.
11-4).
10. C h e c k t h e oil p r e s s u r e at e n g i n e s p e e d s of 1,000
5. S t a r t t h e e n g i n e . H o l d t h e e n g i n e s p e e d at a n d 2,000 r p m . K e e p t h e m e a s u r i n g t i m e a s s h o r t
3,000 r p m w i t h o u t l o a d until radiator f a n c o m e s o n , a s p o s s i b l e ( l e s s t h a n 1 minute) b e c a u s e t h e e n g i n e
t h e n let it idle. is r u n n i n g w i t h o u t l o a d .
6. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool Is the oil pressure below 49 kPa (0.5 kgf/crrf,

or t h e H D S . 7 psi)?
Y E S - G o to s t e p 7. N O — I n s p e c t t h e r o c k e r a r m oil control s o l e n o i d
( V T E C solenoid valve) (see page 11-126).B
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s 11. T u r n t h e ignition s w i t c h O F F .
p r e s s u r e s w i t c h ) , t h e r o c k e r a r m oil c o n t r o l 12. D i s c o n n e c t t h e r o c k e r a r m oil p r e s s u r e s w i t c h
solenoid ( V T E C solenoid valve), a n d the E C M . B ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r .
11-124
13. A t the rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil 15. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l
p r e s s u r e s w i t c h ) s i d e , c h e c k for continuity b e t w e e n C10 and body ground.
rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e
s w i t c h ) 2 P c o n n e c t o r t e r m i n a l s N o . 1 a n d N o . 2.
R O C K E R A R M OIL P R E S S U R E SWITCH
(VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R VTM
(BLU/BLK)
1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10
/ 24 25 26 27 28 29 30
/
Is there continuity? Y E S — R e p a i r a n o p e n in t h e w i r e b e t w e e n t h e E C M
(C10) a n d the rocker a r m oil p r e s s u r e s w i t c h ( V T E C
Y E S — G o to s t e p 14. oil p r e s s u r e s w i t c h ) . !
N O — R e p l a c e the r o c k e r a r m oil p r e s s u r e s w i t c h N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),

( V T E C oil p r e s s u r e s w i t c h ) ( s e e p a g e 11-126). • t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y
w i t h a k n o w n - g o o d E C M , r e p l a c e the original E C M
14. M e a s u r e v o l t a g e b e t w e e n rocker a r m oil p r e s s u r e (see page 11-115).B
R O C K E R A R M OIL P R E S S U R E SWITCH
( V T E C OIL P R E S S U R E SWITCH) 2P C O N N E C T O R
Y E S — R e p a i r a n o p e n in the w i r e b e t w e e n the
rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e
switch) and G 1 0 1 . B
N O — G o t o step 15.
11-125
VTEC
Rocker Arm Oil Control Solenoid (VTEC Solenoid Valve) Inspection
1. D i s c o n n e c t the 1P c o n n e c t o r f r o m t h e r o c k e r a r m
oil control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) .
2 . Measure resistance between the terminal and body

ground.
Resistance: 14—30 Q
3. If t h e r e s i s t a n c e is w i t h i n s p e c i f i c a t i o n s , r e m o v e the
r o c k e r a r m oil control v a l v e ( V T E C s o l e n o i d v a l v e )
(A) f r o m the c y l i n d e r h e a d , a n d c h e c k t h e r o c k e r
a r m oil control v a l v e ( V T E C s o l e n o i d v a l v e ) filter (R)
for c l o g g i n g . If t h e r e i s c l o g g i n g , r e p l a c e t h e e n g i n e
oil filter, the r o c k e r a r m oil c o n t r o l v a l v e ( V T E C
s o l e n o i d v a l v e ) filter, a n d t h e e n g i n e oil.
If t h e filter is not c l o g g e d , r e p l a c e t h e r o c k e r a r m oil
control valve ( V T E C solenoid valve).
11-126
Idle Control System
STARTER SWITCH BRAKE PEDAL POSITION SWITCH

Troubleshooting, p a g e 11-136 T r o u b l e s h o o t i n g , p a g e 11-139
11-127
Idle Control System
DTC Troubleshooting
DTC P0505: Idle Control System Malfunction 7. Put y o u r f i n g e r s o n t h e u p p e r a n d l o w e r ports (A) in

('00-03 models) t h e throttle b o d y .
NOTE:
( s e e p a g e 11-3).
• If D T C P 1 5 1 9 is s t o r e d at t h e s a m e t i m e a s D T C P 0 5 0 5 ,
t r o u b l e s h o o t i n g D T C P 1 5 1 9 first, t h e n r e c h e c k for
DTCP0505.
2. C h e c k the e n g i n e s p e e d at idle w i t h o u t load

c o n d i t i o n s : h e a d l i g h t s , b l o w e r f a n , radiator f a n ,
a n d air c o n d i t i o n e r off. Does the engine speed drop below 750 rpm?
Is the idle speed 800± 50 rpm? Y E S — C h e c k t h e idle s p e e d w i t h a different l o a d

c o n d i t i o n ( e l e c t r i c a l , A / C , etc.). If it is out of
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s s p e c i f i c a t i o n , r e p l a c e t h e I A C v a l v e ( s e e p a g e 9-2).
time.B
N O — I f t h e idle s p e e d is l e s s t h a n 7 5 0 r p m , g o to N O — C h e c k for v a c u u m l e a k s at t h e s e p a r t s . •
s t e p 3 ; if it is 8 5 0 r p m o r h i g h e r , g o to s t e p 4.
• PCV valve
3. D i s c o n n e c t t h e idle air control (IAC) v a l v e 3 P • PCV hose
connector. • E V A P canister purge valve
• Intake m a n i f o l d
Dose the engine speed increase or fluctuate? • Throttle b o d y
• Brake booster hose
Y E S — C h e c k the idle s p e e d w i t h a different l o a d
c o n d i t i o n ( e l e c t r i c a l , A / C , etc.). If it is out of
s p e c i f i c a t i o n , r e p l a c e t h e I A C v a l v e ( s e e p a g e 9-2).
N O — R e p l a c e t h e I A C v a l v e ( s e e p a g e 9-2). •
5. R e m o v e the intake air d u c t f r o m the throttle b o d y .
11-128
DTC P0506: Idle Control System RPM Lower
Than Expected
('04-05 models)
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d
( s e e p a g e 11-3).
• If D T C P0511 is s t o r e d at the s a m e t i m e a s D T C P 0 5 0 6 ,
t r o u b l e s h o o t D T C P0511 first, t h e n r e c h e c k for D T C
P0506.
2. C h e c k t h e e n g i n e s p e e d at idle w i t h o u t l o a d
c o n d i t i o n s ; h e a d l i g h t s , b l o w e r f a n , radiator f a n ,
a n d air c o n d i t i o n e r off.
Is the idle speed 800± 50 rpm?
Y E S — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s
time.B
4. D i s c o n n e c t t h e I A C v a l v e 3 P c o n n e c t o r .
6. C h e c k the e n g i n e s p e e d at idle w i t h o u t l o a d
c o n d i t i o n s ; h e a d l i g h t s , b l o w e r f a n , radiator f a n ,
Does the idle speed increase or fluctuate?
Y E S — C h e c k t h e idle s p e e d w i t h a different l o a d
c o n d i t i o n ( e l e c t r i c a l , A / C , etc.). If it is o u t of
s p e c i f i c a t i o n , r e p l a c e the I A C v a l v e ( s e e p a g e 9-2).
Idle Control System
DTC P0507: Idle Control System RPM Higher 6. Put y o u r f i n g e r s o n the u p p e r a n d l o w e r ports (A) in
Than Expected t h e throttle b o d y .
('04-05 models)
NOTE:
• B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a a n d
( s e e p a g e 11-3).
• If D T C P0511 i s s t o r e d at t h e s a m e t i m e a s D T C P 0 5 0 7 , A
t r o u b l e s h o o t i n g D T C P0511 first, t h e n r e c h e c k for
D T C P0507.
2 . C h e c k the e n g i n e s p e e d at idle w i t h o u t l o a d
c o n d i t i o n s : h e a d l i g h t s , b l o w e r f a n , radiator f a n , Does the idle speed drop below 850 rpm?
Y E S — C h e c k t h e idle s p e e d w i t h a different l o a d
Is the idle speed 800± 50 rpm? c o n d i t i o n ( e l e c t r i c a l , A / C , etc.). If it is out of
s p e c i f i c a t i o n , r e p l a c e the I A C v a l v e ( s e e p a g e 9-2).
time.B
N O — C h e c k for v a c u u m l e a k s at t h e s e p a r t s . •
• PCV valve
3. T u r n t h e ignition s w i t c h O F F . • PCV hose
• E V A P canister purge valve
4. R e m o v e t h e intake air d u c t f r o m t h e throttle b o d y . • Intake m a n i f o l d
• Throttle b o d y
5. S t a r t the e n g i n e , a n d let it idle. • Brake booster hose
11-130
DTC P0511: IAC Valve Circuit Malfunction 7. M e a s u r e v o l t a g e b e t w e e n I A C v a l v e 3 P c o n n e c t o r
('04-05 models) terminal No. 2 a n d body ground.
IAC V A L V E 3P C O N N E C T O R
DTC P1519: IAC Valve Circuit Malfunction
('00-03 models)
NOTE:
1 2 3
• B e f o r e y o u t r o u b l e s h o o t r e c o r d ail f r e e z e d a t a a n d
IGP ( Y E L / B L K )
(see p a g e 11-3).
to '04-05 m o d e l s .
to '00-03 m o d e l s .
1. R e s e t t h e E C M ( s e e p a g e 11-4). Wire side of female terminals
2. T u r n t h e ignition s w i t c h O N (II). Is there battery voltage?
3. C h e c k for T e m p o r a r y D T C or D T C w i t h a s c a n tool Y E S — G o to s t e p 8.
or the H D S .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e I A C v a l v e
Is DTC P051V (P1519)* * indicated? a n d the PGM-FI m a i n relay. •
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 9. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d I A C
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s v a l v e 3 P c o n n e c t o r t e r m i n a l N o . 1.
at t h e I A C v a l v e a n d at t h e E C M . •
5. D i s c o n n e c t the I A C v a l v e 3 P c o n n e c t o r . 1 2 3
PG1 (BLK)
N O — R e p a i r o p e n in the w i r e b e t w e e n the I A C v a l v e
andG101.B
(cont'd)
11-131
Idle Control System
D T C T r o u b l e s h o o t i n g (cont'd)
10. D i s c o n n e c t E C M c o n n e c t o r B (25P). 13. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

E C M connector terminal B23.
1 2 3 4 5
9 10 11 12
1 2 3 4 5
9 10
20
11 12
21
/ /
22
20 21 22
IACV (BLK/RED)
IACV (BLK/RED)
Is there continuity? Y E S — G o to s t e p 14.
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e I A C N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e I A C v a l v e
valve and the E C M (B23).H and the E C M ( B 2 3 ) . «
N O — G o to s t e p 12. 14. R e m o v e t h e j u m p e r w i r e f r o m the I A C v a l v e 3 P

connector, then reconnect the IAC valve 3P
12. C o n n e c t I A C v a l v e 3 P c o n n e c t o r t e r m i n a l N o . 3 a n d connector.
body ground with a jumper wire.
16. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M
connector terminal B23.
IACV
(BLK/RED)
1 2 3 4 5
JUMPER WIRE
9 10 11 12
20 21 22 23
W i r e s i d e of f e m a l e t e r m i n a l s IACV (BLK/RED)

11-132
A / C Signal Circuit Troubleshooting
1. T u r n the ignition s w i t c h O F F . 8. M o m e n t a r i l y c o n n e c t E C M c o n n e c t o r t e r m i n a l s A 1 7
and B20 with a jumper wire several times.
2. D i s c o n n e c t the A / C p r e s s u r e s w i t c h c o n n e c t o r .
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10

12 13
/ / 15
/ 17 18 19 20 21 24
ECM CONNECTORS
/
25 26 27 28 29 30
A C C (RED)
32
JUMPER WIRE
1 2 3
/ / /
4 6 9 10 B (25P)
12 13
/ / 15 17 18 19 20 21 24
/
25 26 27 28 29 30 32
Is there a clicking noise from the A/C compressor

clutch?
Is there about 5 V?
10. T u r n the b l o w e r s w i t c h O N .
11. T u r n t h e A / C s w i t c h O N .
Does the A/C operate?
6. R e c o n n e c t the A / C p r e s s u r e s w i t c h c o n n e c t o r .
Y E S — T h e air c o n d i t i o n i n g s i g n a l is O K . •
(cont'd)
11-133
Idle Control System
A / C Signal Circuit Troubleshooting (cont'd)
14. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d arid Is there a clicking noise from the A/C compressor
E C M connector terminal A27. clutch?
(A17) a n d t h e A / C c l u t c h r e l a y . •
1 2 3
/ / /4 6 9 10 N O — C h e c k t h e A / C s y s t e m for other s y m p t o m s . •
12 13
/ / 15 17 18 19 20 21 24
/
25 26 27 28 29 30
A C S (BLU/RED)
32
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10
Wire side of f e m a l e terminals 12 13
/ / 15
/ 17 18 19 20 21 24
25 26 27
/ 28 29 30
J A C S (BLU/RED)
32
(A27) a n d t h e A / C p r e s s u r e s w i t c h . • 1 2 3 4
///
5
9 10 11 12
//// /
t h e n r e c h e c k . If v o l t a g e is n o w n o r m a l , r e p l a c e t h e
20 21 22
LG1 (BRN/YEL) // 23
original E C M ( s e e p a g e 11-115). If not, c h e c k t h e W i r e s i d e of f e m a l e t e r m i n a l s

A / C s y s t e m for o t h e r s y m p t o m s . •
Is there less than 1.0 V?
15. M o m e n t a r i l y c o n n e c t m a i n u n d e r - h o o d f u s e / r e l a y
b o x 16P c o n n e c t o r t e r m i n a l N o . 11 to b o d y g r o u n d Y E S — S u b s t i t u t e a known-good E C M (see page
with a j u m p e r wire s e v e r a l times. 11-5), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e t h e original E C M ( s e e p a g e 11-115). If
N O T E : T h e m a i n u n d e r - h o o d f u s e / r e l a y b o x 14P not, i n s p e c t t h e A / C s y s t e m for other s y m p t o m s . •
c o n n e c t o r is o n t h e b o t t o m of t h e f u s e b o x . W h e n
y o u u n b o l t a n d invert t h e f u s e b o x , l e a v e t h e u p p e r N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M
c o v e r o n it to p r e v e n t s h o r t c i r c u i t s . (A27) a n d t h e A / C p r e s s u r e s w i t c h , or b e t w e e n t h e
A / C p r e s s u r e s w i t c h a n d t h e h e a t e r control p a n e l . •
MAIN UNDER-HOOD F U S E / R E L A Y B O X
C O N N E C T O R D (16P)
1
/ 3
// 4
/ / 9
A C C (RED)
11 12
/ /
JUMPER WIRE
14 16
11-134
Alternator FR Signal Circuit Troubleshooting
1. D i s c o n n e c t alternator 4 P c o n n e c t o r . 11. C o n n e c t alternator 4 P c o n n e c t o r t e r m i n a l N o . 4 to

t e r m i n a l s B20 a n d C 5 .
ECM CONNECTORS 1 2 ALTF

B(25P)
(WHT/RED)
1 3 4
JUMPER WIRE
20 21 22 23
LG1 (BRN/YEL)
1 2
/ 4 5
/
11 12 .13 14 15 16 17 18 19 20 21 22
7 8 9 10
E C M connector terminal C 5 .
/ 24 25 26 27 28 29 30
/
Is there about 5 V?
Y E S — G o to s t e p 4. 1
11
2
12
/13
4
14 15
5
16
/17
7
18 19
8
20
9
21
10
22
/ 24 25 26 27 28 29 30
/
5. R e c o n n e c t t h e alternator 4 P c o n n e c t o r .
radiator f a n c o m e s o n , t h e n let it idle. Is there continuity?
7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r Y E S — T e s t the alternator ( s e e p a g e 4-38). •

terminals B20 and C5.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M (C5)
Does the voltage decrease when the headlights a n d the alternator. •
and rear window defogger are turned on?
Y E S — T h e alternator F R s i g n a l is O K . •
10. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r .
(cont'd)
11-135
Idle Control System
Alternator FR Signal Circuit Starter Switch Signal Circuit

Troubleshooting (cont'd) Troubleshooting
15. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d N O T E : T h e c l u t c h p e d a l m u s t be p r e s s e d .
E C M connector terminal C5.
t e r m i n a l s A 2 4 a n d B 2 0 w i t h the ignition s w i t c h in
the O N (II) position a n d t h e e n g i n e start button
pressed.
11
2
12
/ 13
4
14 15
5
16
/ 17
7
18 19
8
20
9
21
10
22
A (32P)
ECM CONNECTORS
/ 24 25 26 27 28 29 30
/
1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 24
/
25 26 27 28 29 30
S T S (BLU/ORN)
32
B (25P)
1
20 22
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M LG1 (BRN/YEL)
(C5) a n d the alternator. • W i r e s i d e of f e m a l e t e r m i n a l s
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5), Is there battery voltage?

t h e n r e c h e c k . If t h e p r e s c r i b e d v o l t a g e i s n o w
n o r m a l , r e p l a c e the original E C M ( s e e p a g e 11-115). Y E S — T h e starter s w i t c h s i g n a l is O K . I
2. I n s p e c t t h e N o . 21 S T A R T E R S I G N A L (7.5 A ) f u s e in
the u n d e r - d a s h f u s e / r e l a y b o x .
Is the fuse OK ?
(A24) a n d t h e No. 21 S T A R T E R S I G N A L (7.5 A )
fuse.B
(A24) a n d t h e No. 21 S T A R T E R S I G N A L (7.5 A ) f u s e
or the P G M - F I m a i n r e l a y . R e p l a c e t h e N o . 21
S T A R T E R S I G N A L (7.5 A ) f u s e . •
11-136
Electrical Power Steering (EPS) Signal Circuit Troubleshooting
1. T u r n the ignition s w i t c h O N (II). 9. M e a s u r e v o l t a g e b e t w e e n E P S c o n t r o l unit 14P
c o n n e c t o r t e r m i n a l N o . 13 a n d b o d y g r o u n d .
terminals A26 and B20. E P S C O N T R O L U N I T 14P C O N N E C T O R
ECM CONNECTORS
1 2 3
1 2 3
/ / /
4 6 9 10 4 5 6 7
12 13
/ / 15
/ 17 18 19 20 21 24
8
/ / 11
25 26 27
/ 28 29 30
EPSLD (BLU/BLK)
32
12 13 14
(V) EPSLD (BLU/BLK)

B (25P)
1
iiZZ
W i r e side of f e m a l e t e r m i n a l s
20 21 22 23
LG1 (BRN/YEL) Is there battery voltage?
Y E S — S u b s t i t u t e a k n o w n - g o o d E P S control unit,
Is there battery voltage? then recheck. •
Y E S — G o to s t e p 6. N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M
(A26) a n d t h e E P S control u n i t . B
3. Start t h e e n g i n e .
11. D i s c o n n e c t t h e E P S control unit 14P c o n n e c t o r .
4. T u r n the s t e e r i n g w h e e l to t h e full lock p o s i t i o n .
terminals A 2 6 a n d B20.
Is there battery voltage briefly?
Y E S - T h e E P S s i g n a l is O K . B
7. D i s c o n n e c t the E P S control unit 14P c o n n e c t o r .
(cont'd)
11-137
Idle Control System
Electrical Power Steering (EPS) Signal Circuit Troubleshooting (cont'd)
13. M e a s u r e v o l t a g e b e t w e e n E P S c o n t r o l unit 1 4 P
c o n n e c t o r t e r m i n a l N o . 13 a n d b o d y g r o u n d .
E P S C O N T R O L U N I T 14P C O N N E C T O R
1 2 3
4 5 6 7
8
/ / 11
12 13 14
^ EPSLD (BLU/BLK)
Y E S — S u b s t i t u t e a k n o w n - g o o d E P S c o n t r o l unit,
then recheck. •
16. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d
E C M connector terminal A26.
1 2
/
3 4
/ / / 6 9 10
12 13 15
/ 17 18 19 20 21 24
25 26 27
/
EPSLD (BLU/BLK)
28 29 30 32
Wire side of f e m a l e terminals
(A26) a n d t h e E P S c o n t r o l u n i t . B
t h e n r e c h e c k . If t h e v o l t a g e i s n o w n o r m a l , r e p l a c e
t h e o r i g i n a l E C M ( s e e p a g e 11-115). •
11-138
Brake Pedal Position Switch Signal Circuit Troubleshooting
1. C h e c k t h e brake lights. 4. I n s p e c t t h e N o . 47 S T O P ('00-01 m o d e l s : 10 A ,

' 0 2 - 0 5 m o d e l s : 15 A ) f u s e in t h e m a i n u n d e r - h o o d
Are the brake lights on without pressing the brake fuse/relay box.
pedal?
Is the fuse OK?
Y E S — I n s p e c t t h e brake p e d a l position s w i t c h
a d j u s t m e n t ( s e e p a g e 19-6). • Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e brake
p e d a l position s w i t c h a n d t h e N o . 47 S T O P ('00-01
N O — G o to s t e p 2. m o d e l s : 10 A , ' 0 2 - 0 5 m o d e l s : 15 A ) f u s e . I n s p e c t t h e
brake p e d a l position s w i t c h ( s e e p a g e 22-144). •
2. P r e s s t h e brake p e d a l .
Do the brake lights come on? (A32) a n d t h e N o . 47 S T O P ('00-01 m o d e l s : 10 A ,
' 0 2 - 0 5 m o d e l s : 15 A ) f u s e . R e p l a c e t h e N o . 47 S T O P
Y E S — G o to s t e p 3. ('00-01 m o d e l s : 10 A , ' 0 2 - 0 5 m o d e l s : 15 A ) f u s e . B
t e r m i n a l s A 3 2 a n d B 2 0 w i t h t h e brake p e d a l
pressed.
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 24
25 26 27
/ 28 29 30 32
B K S W (WHT/BLK)
Y E S — T h e brake p e d a l p o s i t i o n s w i t c h s i g n a l is
OK.B
(A32) a n d t h e brake p e d a l position s w i t c h . •
11-139
Idle Control System
Idle Speed Inspection ECM Idle Learn Procedure
NOTE: T h e idle l e a r n p r o c e d u r e m u s t be d o n e s o that the E C M

• L e a v e the IAC valve c o n n e c t e d . c a n l e a r n t h e e n g i n e idle c h a r a c t e r i s t i c s .
• B e f o r e c h e c k i n g the idle s p e e d , c h e c k t h e s e i t e m s : D o the idle l e a r n p r o c e d u r e w h e n e v e r y o u d o a n y of
- T h e M I L h a s not b e e n r e p o r t e d o n . these actions:
- Ignition t i m i n g
- Spark plugs • D i s c o n n e c t t h e battery.
- A i r cleaner • R e p l a c e t h e E C M or d i s c o n n e c t its c o n n e c t o r .
- PCV system • Reset the E C M .
• O n C a n a d i a n m o d e l s , pull t h e p a r k i n g b r a k e l e v e r u p . N O T E : E r a s i n g D T C s w i t h H D S d o e s r e q u i r e s the idle
S t a r t the e n g i n e , t h e n c h e c k that t h e h e a d l i g h t s a r e learn p r o c e d u r e to be d o n e a g a i n .
off. • R e m o v e t h e N o . 6 E C U ( E C M ) (15 A ) f u s e f r o m the
u n d e r - d a s h f u s e / r e l a y box.
1. D i s c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e 2 P • R e m o v e t h e N o . 41 B A T T E R Y (100 A ) f u s e f r o m the
connector. u n d e r - h o o d f u s e / r e l a y box.
• R e m o v e t h e P G M - F I m a i n relay.
2. C o n n e c t a t a c h o m e t e r . • R e m o v e t h e battery w i r e f r o m the u n d e r - h o o d f u s e /
r e l a y box.
TACHOMETER
• D i s c o n n e c t a n y of the c o n n e c t o r s f r o m the u n d e r -
hood fuse/relay box.
• D i s c o n n e c t t h e c o n n e c t o r ( C 4 0 4 ) b e t w e e n the
dashboard wire harness A and dashboard wire
h a r n e s s B.
• D i s c o n n e c t the G1 t e r m i n a l .
• A d j u s t t h e idle s p e e d .
Procedure
1. M a k e s u r e all electrical i t e m s ( A / C , a u d i o , rear

w i n d o w d e f o g g e r , lights, etc.) a r e off.
2. Start t h e e n g i n e . Hold the e n g i n e s p e e d at

3. S t a r t t h e e n g i n e . Hold the e n g i n e s p e e d at radiator f a n c o m e s o n , or the e n g i n e c o o l a n t
3,000 r p m w i t h o u t l o a d (in neutral) until the t e m p e r a t u r e r e a c h e s 176 °F (80 *€) —212 °F (100 °C).
3. Let t h e e n g i n e idle for a b o u t 5 m i n u t e s w i t h the
4. C h e c k the idle s p e e d w i t h o u t l o a d c o n d i t i o n s ; throttle fully c l o s e d a n d w i t h all electrical i t e m s off.
h e a d l i g h t s , b l o w e r f a n , radiator f a n , a n d air
c o n d i t i o n e r off. N O T E : If t h e radiator f a n c o m e s o n , d o not i n c l u d e its
r u n n i n g t i m e in t h e 5 m i n u t e s .
Idle s p e e d s h o u l d b e : 8 0 0 ± 5 0 r p m
5. Let t h e e n g i n e idle for 1 m i n u t e w i t h h i g h e l e c t r i c

load ( A / C s w i t c h O N , t e m p e r a t u r e s e t to M a x c o o l ,
b l o w e r f a n o n H i g h , a n d h e a d light o n h i g h b e a m ) .
Idle s p e e d s h o u l d b e : 9 0 0 ± 5 0 r p m
N O T E : If t h e idle s p e e d is not w i t h i n s p e c i f i c a t i o n ,
d o the s y m p t o m t r o u b l e s h o o t i n g .
6. R e c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e 2 P
connector.
11-140
Fuel Supply System
11-141
Fuel Supply System
PGM-FI Main Relay Circuit Troubleshooting
1. T u r n t h e ignition s w i t c h O F F , t h e n d i s c o n n e c t t h e 4. C h e c k for a b l o w n N o . 46 A C G S (15 A ) f u s e in t h e

PGM-FI main relay 7 P connector. main under-hood fuse/relay box.
2. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d Is the fuse blown?

PGM-FI main relay 7P connector terminal No. 3.
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e P G M - F I
PGM-FI MAIN R E L A Y 7P C O N N E C T O R m a i n r e l a y a n d t h e N o . 4 6 A C G S (15 A ) f u s e . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e P G M - F I
1 ? 3 GND(BLK) m a i n r e l a y a n d t h e N o . 4 6 A C G S (15 A ) f u s e . B
4 5 6 7 5. T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e
voltage between body ground a n d PGM-FI main
r e l a y 7 P c o n n e c t o r t e r m i n a l N o . 5.
PGM-FI MAIN RELAY 7P C O N N E C T O R
W i r e s i d e of f e m a l e t e r m i n a l s 1 ?. 3
Is there continuity? 4 5 6 7
IG1 ( B L K / Y E L )
main relay a n d G 1 0 1 . B
3. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d P G M - F I W i r e s i d e of f e m a l e t e r m i n a l s
m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l N o . 7.
PGM-FI MAIN R E L A Y 7P C O N N E C T O R
1 ? 3 N O — G o to s t e p 6.
BAT (WHT/GRN)
4 5 6 / 6. C h e c k f o r a b l o w n N o . 2 F U E L P U M P S R S (15 A )
f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x .
Is the fuse blown?
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e P G M - F I
m a i n r e l a y a n d t h e N o . 2 F U E L P U M P S R S (15 A )
Wire side of female terminals fuse.!
Is there battery voltage? N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e P G M - F I

m a i n r e l a y a n d t h e N o . 2 F U E L P U M P S R S (15 A )
Y E S — G o to s t e p 5. fuse.B
11-142
7. P u s h t h e c l u t c h p e d a l i n , t h e n t u r n t h e ignition 10. C h e c k for c o n t i n u i t y b e t w e e n P G M - F I m a i n r e l a y 7 P
s w i t c h O N (II), a n d p r e s s t h e e n g i n e start button. connector terminal No. 1 a n d E C M connector
M e a s u r e voltage between body ground and PGM-FI terminal A15.
m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l N o . 2.
PGM-FI MAIN R E L A Y 7P C O N N E C T O R ' 1IMOFLR (GRN/YEL)
1 2 3
S T S (BLU/ORN)
4 5 6 7
1 ? 3
4 5 6 7 E C M C O N N E C T O R A (32P)
1 2 3 4
/ / / 6 9 10
12 13 15
/ /
17 18 19 20 21 24
25 2 3 27
/ 28 29 30
IMOFLR (GRN/YEL)
32
N O — G o to s t e p 8. m a i n r e l a y a n d t h e E C M (A15). •
8. C h e c k f o r a b l o w n N o . 21 S T A R T E R S I G N A L (7.5 A ) 11. R e c o n n e c t E C M c o n n e c t o r A (32P) a n d t h e P G M - F I

f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x . main relay 7P connector.
Is the fuse blown? 12. T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e

v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l s B1 a n d
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e P G M - F I B 2 0 , a n d b e t w e e n B 9 a n d B 2 0 individually.
m a i n r e l a y a n d the N o . 21 S T A R T E R S I G N A L (7.5 A )
fuse.B E C M C O N N E C T O R B (25P)
m a i n r e l a y a n d the N o . 21 S T A R T E R S I G N A L IGP1 ( Y E L / B L K )
(7.5 A ) . • IGP2
(YEL/ 1 2 3 4 5
BLK)
9. T u r n t h e ignition s w i t c h O F F , a n d d i s c o n n e c t E C M
c o n n e c t o r A (32P).
9 10
20
11 12
//
21 22 23
LG1 (BRN/YEL)
N O — C h e c k for a n o p e n in t h e w i r e s b e t w e e n t h e
P G M - F I m a i n relay a n d t h e E C M ( B 1 , B 9 ) . If the
w i r e s a r e O K , r e p l a c e the P G M - F I m a i n r e l a y . •
(cont'd)
11-143
Fuel Supply System
PGM-FI Main Relay Circuit Troubleshooting (cont'd)

13. T u r n t h e ignition s w i t c h O F F , t h e n O N (II) a g a i n ,
and m e a s u r e voltage between E C M connector No. 1
terminals A 1 5 and B2 within 2 s e c o n d s .
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10
12 13
/ / 15 17 18 19 20 21 24
25
/ 27 28 29 30
IMOFLR (GRN/YEL)
32
No. 4
To GROUND
To ST. SWITCH

To ECM [J] ^ i^—[4] To FUEL PUMP
(A15)
Y E S — T h e P G M - F I m a i n r e l a y m a y be faulty; g o to
s t e p 14. Is there continuity?
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5), Y E S — G o to s t e p 16.
t h e n r e c h e c k . If t h e v o l t a g e is n o w n o r m a l , r e p l a c e
t h e original E C M ( s e e p a g e 11-115). • N O — R e p l a c e the PGM-FI main relay, then recheck
t h e circuit. •
14. R e m o v e t h e P G M - F I m a i n r e l a y .
16. C o n n e c t battery p o w e r to P G M - F I m a i n r e l a y 7 P
15. C o n n e c t battery p o w e r to P G M - F I m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l No. 5, a n d c o n n e c t g r o u n d to
c o n n e c t o r t e r m i n a l N o . 2 a n d c o n n e c t g r o u n d to P G M - F I m a i n relay 7 P c o n n e c t o r t e r m i n a l N o . 3.
P G M - F I m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l N o . 1. T h e n c h e c k for continuity b e t w e e n P G M - F I m a i n
T h e n c h e c k for continuity between PGM-FI m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l s No. 7 a n d N o . 6.
r e l a y 7 P c o n n e c t o r t e r m i n a l s N o . 5 a n d N o . 4.
N O T E : U s e the terminal n u m b e r s s h o w n . Ignore
t h e t e r m i n a l n u m b e r s m o l d e d into t h e relay. Y E S — G o t o s t e p 17.
N O — R e p l a c e the PGM-FI main relay, then recheck

t h e circuit. •
17. C o n n e c t battery p o w e r to P G M - F I m a i n r e l a y 7 P
c o n n e c t o r t e r m i n a l No. 6, a n d c o n n e c t g r o u n d to
P G M - F I m a i n r e l a y 7 P c o n n e c t o r t e r m i n a l No. 1.
T h e n c h e c k for continuity b e t w e e n P G M - F I m a i n
r e l a y 7 P c o n n e c t o r t e r m i n a l s No. 5 a n d N o . 4.
Y E S — T h e P G M - F I m a i n relay is O K . B
N O — R e p l a c e the PGM-FI main relay, then recheck

t h e circuit. •
11-144
Fuel Pressure Relieving Fuel Pressure Test
B e f o r e d i s c o n n e c t i n g fuel l i n e s or h o s e s , r e l e a s e Special Tools Required
p r e s s u r e f r o m t h e s y s t e m b y l o o s e n i n g t h e fuel • F u e l pressure gauge 07406-004000B
p u l s a t i o n d a m p e r o n t o p of t h e fuel rail. • Fuel pressure gauge adapter 07VAJ-0040100
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e 1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e

audio s y s t e m , then write d o w n the audio presets. audio s y s t e m , then write d o w n the audio presets.
2. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery. 2. D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery.
3. R e m o v e t h e fuel fill c a p . 3. R e m o v e t h e fuel fill c a p .
4. R e m o v e t h e intake m a n i f o l d c o v e r (A). 4. R e m o v e t h e intake m a n i f o l d c o v e r (A).
* : T h i s illustration s h o w s '00-03 m o d e l s . * : T h i s illustration s h o w s '00-03 m o d e l s .
5. U s e a w r e n c h o n t h e fuel p u l s a t i o n d a m p e r (A) at 5. U s e a w r e n c h o n t h e fuel p u l s a t i o n d a m p e r (A) at

t h e fuel rail. t h e fuel rail.
6. P l a c e a r a g o r s h o p t o w e l (B) o v e r t h e fuel p u l s a t i o n 6. P l a c e a r a g or s h o p t o w e l (B) o v e r t h e fuel p u l s a t i o n

damper. damper.
7, S l o w l y l o o s e n t h e fuel p u l s a t i o n d a m p e r o n e 7. S l o w l y l o o s e n the fuel p u l s a t i o n d a m p e r o n e

complete turn. c o m p l e t e turn.
N O T E : R e p l a c e all w a s h e r s w h e n e v e r t h e fuel
p u l s a t i o n d a m p e r i s l o o s e n e d or r e m o v e d .
(cont'd)
11-145
Fuel Supply System
F u e l P r e s s u r e T e s t (cont'd)
8. R e m o v e the fuel p u l s a t i o n d a m p e r f r o m the fuel 14. W i t h t h e e n g i n e r u n n i n g , u n p i n c h a n d r e c o n n e c t

rail. the v a c u u m h o s e a n d r e a d the g a u g e a g a i n .
T h e p r e s s u r e s h o u l d be 2 6 0 — 3 1 0 kPa
2
9. A t t a c h t h e fuel p r e s s u r e g a u g e a t t a c h m e n t a n d f u e l ( 2 . 7 - 3 . 2 k g f / c m , 3 8 - 4 6 psi).
pressure gauge.
• If t h e fuel p r e s s u r e is O K , the t e s t is c o m p l e t e .
07VAJ-0040100 • If t h e p r e s s u r e i s out of s p e c , g o to s t e p 15.
15. D i s c o n n e c t t h e v a c u u m h o s e f r o m t h e p r e s s u r e
regulator a g a i n w h i l e y o u w a t c h t h e p r e s s u r e
gauge. T h e p r e s s u r e s h o u l d rise w h e n you
disconnect the hose.
• If t h e p r e s s u r e d i d not r i s e , r e p l a c e the fuel

p r e s s u r e r e g u l a t o r ( s e e p a g e 11-154).
• If t h e p r e s s u r e r i s e s , but all y o u r r e a d i n g s w e r e
l o w e r t h a n s p e c i f i e d , c h e c k for a c l o g g e d fuel
filter a n d for l e a k s in the fuel l i n e s .
C A B • If the p r e s s u r e r i s e s , but all y o u r r e a d i n g s w e r e
h i g h e r t h a n s p e c i f i e d , c h e c k for a p i n c h e d or
* : T h i s illustration s h o w s '00-03 m o d e l s .
c l o g g e d fuel return h o s e or line.
10. D i s c o n n e c t the v a c u u m h o s e (A) f r o m t h e fuel
p r e s s u r e regulator (B) a n d p i n c h it c l o s e d w i t h a 16. R e c o n n e c t t h e v a c u u m h o s e , r e m o v e the p r e s s u r e
c l a m p (C). g a u g e , a n d reinstall t h e fuel p u l s a t i o n d a m p e r w i t h
a n e w w a s h e r . T i g h t e n the fuel p u l s a t i o n d a m p e r to
11. R e c o n n e c t the n e g a t i v e battery c a b l e , t h e n start t h e 22 N-m (2.2 k g f m , 16 Ibfft).
e n g i n e , a n d let it idle.
N O T E : D i s a s s e m b l e a n d c l e a n the fuel p r e s s u r e
• If the e n g i n e s t a r t s , g o to s t e p 13. g a u g e a t t a c h m e n t t h o r o u g h l y after u s e .
• If t h e e n g i n e d o e s not start, g o t o s t e p 12.
12. C h e c k to s e e if t h e fuel p u m p is r u n n i n g : r e m o v e
t h e fuel fill c a p a n d listen to the fuel fill port w h i l e
a n a s s i s t a n t t u r n s t h e ignition s w i t c h O N (II), y o u
s h o u l d h e a r the p u m p r u n for a b o u t 2 s e c o n d s
w h e n the ignition s w i t c h is t u r n e d O N (II).
• If the fuel p u m p r u n s , g o to s t e p 13.

• If the fuel p u m p d o e s not r u n , t e s t it ( s e e p a g e
11-147).
13. R e a d the p r e s s u r e g a u g e (with the fuel p r e s s u r e

regulator v a c u u m h o s e d i s c o n n e c t e d a n d c l a m p e d ) .
T h e p r e s s u r e s h o u l d be 3 2 0 — 3 7 0 k P a
2
(3.3—3.8 k g f / c m , 4 7 - 5 4 p s i ) .
• If the p r e s s u r e is O K a n d the e n g i n e is r u n n i n g ,
g o to s t e p 14. If the e n g i n e is not r u n n i n g , r e p a i r
t h e c a u s e , t h e n c o n t i n u e this t e s t
• If the p r e s s u r e is out of s p e c , g o to s t e p 14.
11-146
Fuel Pump Test
If y o u s u s p e c t a p r o b l e m w i t h t h e fuel p u m p , c h e c k that 6. T u r n t h e ignition s w i t c h O N (II).

t h e fuel p u m p a c t u a l l y r u n s ; w h e n it is O N , y o u will hear
s o m e n o i s e if y o u listen to t h e fuel fill port w i t h t h e fuel 7. C h e c k t h a t battery v o l t a g e is a v a i l a b l e b e t w e e n fuel
fill c a p r e m o v e d . T h e fuel p u m p s h o u l d r u n for p u m p 5P connector terminal No. 5 a n d body
2 s e c o n d s w h e n ignition s w i t c h is first t u r n e d o n . If the g r o u n d w h e n t h e ignition s w i t c h is t u r n e d O N (II).
fuel p u m p d o e s not m a k e n o i s e , c h e c k a s f o l l o w s :
• If battery v o l t a g e is a v a i l a b l e , c h e c k t h e f u e l
1. R e m o v e t h e r e a r t r a y ( s e e p a g e 20-73). p u m p g r o u n d . If t h e g r o u n d is O K , r e p l a c e t h e
fuel p u m p ( s e e p a g e 11-155).
2. R e m o v e the a c c e s s p a n e l f r o m t h e floor. • If t h e r e is n o v o l t a g e , c h e c k t h e w i r e h a r n e s s
(see p a g e 11-142).
4. D i s c o n n e c t t h e fuel p u m p 5 P c o n n e c t o r . F U E L PUMP 5P C O N N E C T O R
5. C o n n e c t the P G M - F I m a i n r e l a y 7 P c o n n e c t o r
terminals No. 4 and No. 5 with a j u m p e r wire. 1 2
/
V (Y) FUEL PUMP
^ (YEL/GRN)
1 2 3
4 5 6 7 W i r e s i d e of f e m a l e t e r m i n a l s
FUEL PUMP IG1

(YEL/GRN) (BLK/YEL)
JUMPER WIRE
11-147
Fuel Supply System
Fuel Line Inspection
C h e c k the fuel s y s t e m l i n e s , h o s e s , a n d fuel filter for d a m a g e , l e a k s , or d e t e r i o r a t i o n , a n d r e p l a c e parts a s n e e d e d .
22 N m (2.2 k g f m , 16 Ibf ft)
37 N m (3.8 k g f - m , 2 7 I b f f t )
11-148
11-149
Fuel Supply System
Fuel Line/Quick-Connect Fitting Fuel Line/Quick-Connect Fitting
Precautions Remowai
The fuel tube/quick-connect fittings assembly connects NOTE: Before you work on the fuel line and fittings,
the in-tank fuel pump to the fuel feed line and the fuel read the "Fuel Line/Quick-Connect Fitting Precautions"
return line. When removing or installing the fuel pump (see page 11-150).
and fuel tank, it is necessary to disconnect or connect
the quick-connect fittings. 1. Relieve fuel pressure (see page 11-145).
Pay attention to the following:
2. Check the fuel quick-connect fittings for dirt, and
• The fuel tubes (A) and quick-connect fittings (B) are clean them if necessary.
not heat-resistant; be careful not to damage them
during welding or other heat-generating procedures. 3. Hold the connector (A) with one hand, and squeeze
• The fuel tubes and quick-connect fittings are not the retainer tabs (B) with the other hand to release
acid-proof; do not touch it with a shop towel which them from the locking pawls (C). Pull the connector
was used for wiping battery electrolyte. Replace them off.
if they came into contact with electrolyte or
something similar. NOTE:
• When connecting or disconnecting the fuel tubes and • Be careful not to damage the line (D) or other
quick-connect fittings, be careful not to bend or twist parts. Do not use tools.
them excessively. Replace them when damaged. • If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
A disconnected quick-connect fittings can be the connector until it comes off easily.
reconnected, but the retainer on the mating line cannot • Do not remove the retainer from the line; once
be reused once it has been removed from the line. removed, the retainer must be replaced with a
Replace the retainer when: new one.
• replacing the fuel tank unit.

• replacing the fuel filter.
• replacing the fuel feed line.
• replacing the fuel return line.
• it has been removed from the line.
• it is damaged.
11-150
Installation
4. Check the contact area (A) of the line (B) for dirt and
damage.
NOTE: Before you work on the fuel line and fittings,
• If the surface is dirty, clean it. read the "Fuel Line/Quick-Connect Fitting Precautions"
• If the surface is rusty or damaged, replace the (see page 11-150).
fuel tank unit, fuel filter, fuel feed line, or fuel
return line. 1. Check the contact area (A) of the line (B) for dirt and
damage, and clean if necessary.
5. To prevent damage and keep foreign matter out,

cover the disconnected connector and line end with 2. Insert a new retainer (A) into the connector (B) if the
plastic bags (A). retainer is damaged, or after:
NOTE: • replacing the fuel tank unit.

• The retainer cannot be reused once it has been • replacing the fuel filter.
removed from the pipe. • replacing the fuel feed line.
• Replace the retainer when: • replacing the fuel return line.
- replacing the fuel tank unit. • removing the retainer from the line.
- replacing the fuel filter.
- replacing the fuel feed line.
- replacing the fuel return line.
- it has been removed from the line.
- it is damaged.
(cont'd)
11-151
Fuel Supply System
Fuel Line/Quick-Connect Fitting Installation (cont'd)

3 . B e f o r e c o n n e c t i n g a n e w fuel t u b e / q u i c k - c o n n e c t C o n n e c t i o n t o n e w f u e l line
fitting a s s e m b l y (A), r e m o v e t h e old retainer f r o m
t h e m a t i n g line.
Reconnection to existing retainer
4 . A l i g n t h e q u i c k - c o n n e c t fittings with t h e line (A),

a n d a l i g n t h e retainer (B> l o c k i n g p a w l s w i t h t h e .-
c o n n e c t o r (C) g r o o v e s . T h e n p r e s s t h e quick-
c o n n e c t fittings onto t h e line until both retainer
p a w l s lock w i t h a c l i c k i n g s o u n d .
N O T E : If it is h a r d to c o n n e c t , put a s m a l l a m o u n t of
n e w e n g i n e oil o n t h e line e n d i
Connection w i t h n e w retainer
11-152
5 . W h e n y o u r e c o n n e c t the c o n n e c t o r w i t h t h e o l d
retainer, m a k e s u r e t h e c o n n e c t i o n is s e c u r e a n d
t h e t a b s (A) a r e f i r m l y l o c k e d into p l a c e ; c h e c k
v i s u a l l y a n d a l s o by pulling t h e c o n n e c t o r (B).
W h e n y o u r e p l a c e t h e fuel line w i t h a n e w o n e ,
m a k e s u r e y o u r e m o v e the ring pull (C) u p w a r d s
after y o u c o n f i r m t h e c o n n e c t i o n is s e c u r e .
N O T E : B e f o r e y o u r e m o v e t h e ring p u l l , m a k e s u r e
t h e fuel line c o n n e c t i o n is s e c u r e . If t h e c o n n e c t i o n
is not s e c u r e , t h e ring pull c o u l d b r e a k w h e n y o u try
to r e m o v e it.
C o n n e c t i o n t o n e w fuel line
6 . R e c o n n e c t t h e n e g a t i v e c a b l e to the battery, a n d
turn t h e ignition s w i t c h O N (II). T h e fuel p u m p will
run for a b o u t 2 s e c o n d s , a n d f u e l p r e s s u r e w i l l r i s e .
R e p e a t t h i s t w o o r t h r e e t i m e s , a n d c h e c k that t h e r e
is no l e a k a g e in t h e fuel s u p p l y s y s t e m .
11-153
Fuel Supply System
Fuel Pressure Regulator Fuel Filter Replacement

Replacement
T h e fuel filter s h o u l d be r e p l a c e d w h e n e v e r the fuel
pressure drops below the specified value (320—370 kPa,
2
1. P l a c e a s h o p t o w e l u n d e r t h e f u e l p r e s s u r e 3 . 3 — 3 . 8 k g f / c m , 4 7 — 5 4 psi w i t h t h e fuel p r e s s u r e
regulator, then relieve fuel p r e s s u r e (see page regulator v a c u u m h o s e d i s c o n n e c t e d a n d p i n c h e d ) after
11-145). m a k i n g s u r e that the fuel p u m p a n d t h e fuel p r e s s u r e
regulator a r e O K .
2. D i s c o n n e c t t h e v a c u u m h o s e a n d fuel return h o s e .
1. R e m o v e t h e fuel tank unit ( s e e p a g e 11-155).
3. R e m o v e t h e t w o 6 m m r e t a i n e r bolts (A) a n d t h e
fuel p r e s s u r e r e g u l a t o r (B). 2. R e m o v e t h e fuel filter (A).
4. A p p l y c l e a n e n g i n e oil to a n e w o-ring ( C ) , a n d
c a r e f u l l y install it into its p r o p e r p o s i t i o n .
5. Install t h e f u e l p r e s s u r e r e g u l a t o r a n d t h e 6 m m
retainer b o l t s .
6. R e c o n n e c t t h e v a c u u m h o s e a n d f u e l return h o s e . 3. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l

with a n e w base gasket, then check t h e s e items:
7. T u r n t h e ignition s w i t c h O N (II), but d o not o p e r a t e
t h e starter. After t h e f u e l p u m p r u n s for a b o u t • W h e n connecting the wire harness, make sure
2 s e c o n d s , t h e fuel p r e s s u r e in t h e fuel line r i s e s . t h e c o n n e c t i o n is s e c u r e a n d the t e r m i n a l (B) is
R e p e a t t h i s t w o or t h r e e t i m e s , t h e n c h e c k w h e t h e r f i r m l y l o c k e d into p l a c e .
t h e r e is a n y f u e l l e a k a g e . • C h e c k that the t a b of t h e c l a m p (C) d o e s not
interfere w i t h t h e w i r e h a r n e s s .
• D o not p u s h t h e l o w e r part of the s u c t i o n filter (D).
• W h e n installing t h e fuel g a u g e s e n d i n g unit ( E ) ,
m a k e s u r e the c o n n e c t i o n is s e c u r e a n d the
c o n n e c t o r is f i r m i y l o c k e d into p l a c e . B e c a r e f u l
not to b e n d or t w i s t it e x c e s s i v e l y .
11-154
Fuel Pump/Fuel Gauge Sending Unit Replacement
1. R e m o v e t h e r e a r t r a y ( s e e p a g e 20-73). 8. R e m o v e t h e b r a c k e t (A), t h e fuel filter ( B ) , t h e f u e l

g a u g e s e n d i n g unit ( C ) , t h e h o s e (D), a n d t h e w i r e
2. R e m o v e the a c c e s s p a n e l f r o m t h e floor. h a r n e s s (E).
3. D i s c o n n e c t t h e fuel p u m p 5 P c o n n e c t o r .
4. R e m o v e the fuel fill c a p .
5. R e l i e v e the fuel p r e s s u r e ( s e e p a g e 11-145).
6. D i s c o n n e c t t h e q u i c k - c o n n e c t fittings f r o m t h e fuel
pump.
7. R e m o v e t h e bolts (A) a n d t h e fuel tank unit (B).
Nm H
4 kgf-m,
Ibfft) 9. W h e n c o n n e c t i n g t h e fuel p u m p , m a k e s u r e t h e
c o n n e c t i o n s a r e s e c u r e a n d t h e s u c t i o n filter (H) is
f i r m l y c o n n e c t e d the fuel p u m p (I).
10. Install t h e p a r t s in the r e v e r s e o r d e r of r e m o v a l

with a n e w b a s e gasket, then check t h e s e items:
• W h e n connecting the wire h a r n e s s , make s u r e

the c o n n e c t i o n is s e c u r e a n d t h e t e r m i n a l (F) i s
f i r m l y l o c k e d into p l a c e .
• C h e c k that t h e t a b of t h e c l a m p (G) d o e s not
interfere w i t h the w i r e h a r n e s s .
• D o not p u s h t h e l o w e r part of t h e s u c t i o n filter.
• W h e n installing the fuel g a u g e s e n d i n g unit,
m a k e s u r e t h e c o n n e c t i o n is s e c u r e a n d t h e
c o n n e c t o r is f i r m l y l o c k e d into p l a c e . B e c a r e f u l
• C h e c k for fuel l e a k s .
11-155
Fuel Supply System
Fuel Tank Replacement
Removal 8. D i s c o n n e c t both A B S r e a r w h e e l s e n s o r s 2 P
c o n n e c t o r s (A), a n d p u s h t h e c o n n e c t o r s out (B).
1. R e m o v e t h e fuel fill c a p .
3. R e m o v e t h e r e a r t r a y ( s e e p a g e 20-73).
4. D r a i n t h e fuel tank: R e m o v e t h e fuel t a n k unit

( s e e p a g e 11-155). U s i n g a h a n d p u m p , h o s e , a n d a
container suitable for fuel, d r a w the fuel from the
fuel tank.
5. R e i n s t a l l t h e fuel t a n k unit.
6. R e m o v e t h e brake fluid f r o m t h e m a s t e r c y l i n d e r
reservoir with a syringe.
A
N O T E : D o not spill b r a k e fluid o n t h e v e h i c l e ; it m a y
d a m a g e t h e paint; if b r a k e fluid d o e s c o n t a c t t h e
paint, w a s h it off i m m e d i a t e l y w i t h w a t e r . 9. R e m o v e t h e fuel pipe c o v e r (A), a n d d i s c o n n e c t t h e
fuel fill n e c k t u b e ( B ) , t h e fuel tank v a p o r
7. R e m o v e t h e a c c e s s p a n e l (A) f r o m t h e floor, a n d r e c i r c u l a t i o n t u b e (C) a n d t h e fuel tank v a p o r s i g n a l
d i s c o n n e c t t h e fuel t a n k 5 P c o n n e c t o r (B). t u b e (D) f r o m t h e fuel fill p i p e s ( E ) .
E B
10. L o o s e n t h e r e a r w h e e l nuts s l i g h t l y , t h e n r a i s e t h e
v e h i c l e a n d m a k e s u r e it is s e c u r e l y s u p p o r t e d .
11. R e m o v e t h e r e a r w h e e l s .
11-156
12. R e m o v e the bolts f r o m both A B S r e a r w h e e l s e n s o r 14. D i s c o n n e c t both p a r k i n g b r a k e c a b l e s (A), a n d
h a r n e s s b r a c k e t s (A). m o v e t h e m out of t h e w a y .
6x1.0 mm
9.8 N m (1.0 k g f - m , 7.2 Ibf-ft)
* : T h i s i l l u s t r a t i o n s h o w s t h e left s i d e of t h e v e h i c l e .
13. R e m o v e both c a l i p e r s h i e l d s (A).
6 x 1.0 m m
9.8 N - m (1.0 k g f - m , 7.2 Ibf-ft)
8 x 1.25 m m
2 2 N m (2.2 k g f m , 16 Ibf-ft)
15. D i s c o n n e c t t h e brake h o s e s f r o m both r e a r brake

l i n e s u s i n g a 10 m m f l a r e - n u t w r e n c h .
* : T h i s i l l u s t r a t i o n s h o w s t h e left s i d e o f t h e v e h i c l e .
(cont'd)
11-157
Fuel Supply System
Fuel Tank Replacement (cont'd)
16. R e m o v e the f l a n g e bolt (A) f r o m both r e a r d a m p e r s 18. R e m o v e the muffler (A).

(B).
* : T h i s i l l u s t r a t i o n s h o w s t h e left s i d e o f t h e v e h i c l e .
19. D i s c o n n e c t t h e q u i c k - c o n n e c t fittings (A) ( s e e p a g e
17. R e m o v e t h e c a n i s t e r c o v e r (A), r e a r s u s p e n s i o n 11-150).
stiffener ( B ) , a n d t h e p r o p e l l e r s h a f t (C) ( s e e p a g e
16-18).
11-158
2 0 . D i s c o n n e c t the fuel tank v a p o r v e n t t u b e (A), t h e n 22. Place a jack or other support under the rear
r e m o v e t h e bolt (B) a n d t h e E V A P c a n i s t e r ( C ) . s u s p e n s i o n s u b f r a m e (A). R e m o v e t h e m o u n t i n g
bolts (B) a n d t h e r e a r s u s p e n s i o n s u b f r a m e (A).
B
22 N m
1 4 x 1.5 m m
(2.2 k g f - m ,
103 N-m
1 6 Ibf-ft)
( 1 0 . 5 k g f - m , 7 6 Ibf ft)
1
2 1 . D i s c o n n e c t the h o s e (A) a n d f u e l v e n t t u b e ( B ) , t h e n B
1 2 x 1.5 m m
r e m o v e t h e fuel t a n k v a p o r v e n t t u b e f r o m t h e t u b e
5 9 N - m (6.0 k g f - m , 4 3 Ibf ft)
h o l d e r ( C ) . R e m o v e t h e bolts (D) a n d t h e fuel v e n t
a s s e m b l y (E). 2 3 . P l a c e t h e j a c k o r s u p p o r t u n d e r t h e f u e l tank (A) a n d
r e m o v e t h e m o u n t i n g bolts (B) a n d t h e fuel tank.
B
8x1.25 mm
4 5 N - m ( 4 . 6 k g f m , 3 3 Ibf-ft)
(cont'd)
11-159
Fuel Supply System
Fuel Tank Replacement (cont'd) Fuel Gauge Sending Unit Test

Installation N O T E : F o r t h e fuel g a u g e s y s t e m circuit d i a g r a m , refer
to the G a u g e s Circuit D i a g r a m .
• ' 0 0 - 0 3 m o d e l s ( s e e p a g e 22-63)
2. After i n s t a l l i n g , b l e e d t h e b r a k e s y s t e m ( s e e p a g e • ' 0 4 - 0 5 m o d e l s ( s e e p a g e 22-68)
19-9), a n d a d j u s t t h e w h e e l a l i g n m e n t ( s e e p a g e
18-7). 1. C h e c k t h e No. 5 I N S T R U M E N T L I G H T B A C K U P
L I G H T (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x .
3. C h e c k for fuel l e a k s .
• If t h e f u s e is O K , c h e c k for a n o p e n in t h e Y E L
w i r e b e t w e e n t h e g a u g e a s s e m b l y a n d t h e No. 5
I N S T R U M E N T L I G H T B A C K U P L I G H T (7.5 A )
fuse.
• If t h e f u s e is b l o w n , r e p l a c e it, a n d c h e c k for a n
o p e n in t h e Y E L w i r e b e t w e e n t h e g a u g e
a s s e m b l y and the No. 5 I N S T R U M E N T L I G H T
B A C K U P L I G H T (7.5 A ) f u s e .
2. R e m o v e the rear t r a y ( s e e p a g e 20-73).
3. R e m o v e t h e a c c e s s p a n e l f r o m t h e floor.
4. D i s c o n n e c t t h e fuel p u m p 5 P c o n n e c t o r .
5. M e a s u r e v o l t a g e b e t w e e n fuel p u m p 5 P c o n n e c t o r
t e r m i n a l s N o . 1 a n d No. 2 w i t h t h e ignition s w i t c h
O N (II). T h e r e s h o u l d b e a b o u t 5 to 8 V .
• If t h e v o l t a g e is a s s p e c i f i e d , g o to s t e p 6.
• If t h e v o l t a g e is not a s s p e c i f i e d , c h e c k for:
- a n o p e n or s h o r t in t h e Y E L / B L K or B L K w i r e .
- p o o r g r o u n d (G 601).
- a faulty m a i n printed circuit b o a r d in the g a u g e
assembly.
F U E L P U M P 5P C O N N E C T O R
(YEL/BLK)
r V
1 2
(BLK)
»/
11-160
Low Fuel Indicator Test
6. T u r n t h e ignition s w i t c h O F F . 1. D o t h e fuel g a u g e s e n d i n g unit t e s t ( s e e p a g e

11-160).
7. R e m o v e t h e bolts a n d t h e fuel t a n k unit ( s e e p a g e
11-155). • If the s y s t e m is O K , g o to s t e p 2.
• If the s y s t e m h a s a n y m a l f u n c t i o n , repair it.
8. M e a s u r e t h e r e s i s t a n c e b e t w e e n t h e N o . 1 a n d
No. 2 t e r m i n a l s w i t h the float at E ( E M P T Y ) , L O W 2. T u r n the ignition s w i t c h O N (II) w i t h the float at
( L O W F U E L I N D I C A T O R L I G H T I S O N ) , 1/2 ( H A L F E (EMPTY) position.
F U L L ) and F (FULL) positions.
If y o u d o not get t h e f o l l o w i n g r e a d i n g s , r e p l a c e the • If t h e l o w fuel indicator is o n , g o to s t e p 3.
fuel g a u g e s e n d i n g unit. • If the l o w fuel indicator is not o n , refer to t h e l o w
fuel indicator C i r c u i t D i a g r a m , ' 0 0 - 0 3 m o d e l s
Float Position R e s i s t a n c e (£>) Height (mm) (see page 22-63), '04-05 m o d e l s (see page 22-68),
(in.) a n d c h e c k t h e circuit.
F 11-13 82.9±1.9
(3.26±0.0748) 3. Lift t h e float a b o v e L O W p o s i t i o n .
1/2 52-58 154.2±1.2
(6.07±0.0472) • If the l o w fuel indicator g o e s off, t h e s y s t e m is O K .
LOW 114.4-120.4 215.5 • If t h e l o w fuel indicator is still o n , refer to t h e l o w
(8.48) fuel indicator C i r c u i t D i a g r a m , ' 0 0 - 0 3 m o d e l s
E 130-132 222.8±1.9 ( s e e p a g e 2 2 - 6 3 ) , ' 0 4 - 0 5 m o d e l s ( s e e p a g e 22-68),
(8.77±0.0748) a n d c h e c k t h e circuit.
9. T o p r e v e n t t h e fuel p u m p f r o m r u n n i n g , r e m o v e t h e
No. 2 F U E L P U M P S R S (15 A ) f u s e f r o m t h e u n d e r -
d a s h f u s e / r e l a y box.
10. C o n n e c t t h e fuel p u m p 5 P c o n n e c t o r .
11. T u r n the ignition s w i t c h O N (II) w i t h t h e float at F

(FULL) position.
• If t h e fuel g a u g e i n d i c a t e s " F " , t h e s y s t e m is O K .

• If t h e fuel g a u g e d o e s not indicate " F " , r e p l a c e
the g a u g e a s s e m b l y .
11-161
Intake Air System
THROTTLE BODY
T e s t , p a g e 11-163
Removal/Installation, p a g e 11-165
D i s a s s e m b l y / R e a s s e m b l y , p a g e 11-166
11-162
Throttle Body Test
N O T E : Do not a d j u s t the throttle s t o p s c r e w . It is p r e s e t
at the factory.
1. W i t h t h e e n g i n e off, c h e c k the throttle c a b l e

o p e r a t i o n . T h e c a b l e s h o u l d operate w i t h o u t
b i n d i n g or s t i c k i n g .
• If the c a b l e o p e r a t e s O K , g o to s t e p 2.
• If t h e c a b l e b i n d s o r s t i c k s , c h e c k it a n d its routing.
If it's faulty, reroute it or r e p l a c e it a n d a d j u s t it
( s e e p a g e 11-168), t h e n g o to s t e p 2.
2. O p e r a t e the throttle l e v e r b y h a n d to s e e if t h e
throttle v a l v e a n d / o r s h a f t a r e too l o o s e or too tight.
• If t h e r e is e x c e s s i v e p l a y in the throttle v a l v e
s h a f t , or a n y binding in t h e throttle v a l v e at the
fully c l o s e d p o s i t i o n , r e p l a c e the throttle b o d y .
• If the throttle v a l v e a n d s h a f t a r e O K , g o to s t e p 3.
3. C h e c k for c l e a r a n c e (A) b e t w e e n the throttle s t o p

s c r e w (B) a n d the throttle l e v e r (C) at the fully
c l o s e d p o s i t i o n . If t h e r e i s a n y c l e a r a n c e , r e p l a c e
t h e throttle b o d y ( s e e p a g e 11-165). D o not a d j u s t
t h e throttle s t o p s c r e w .
A B
11-163
Intake Air System
Throttle Position Sensor Signal Inspection
NOTE: 2. T u r n the ignition s w i t c h O N (II).
• T h i s p r o c e d u r e c h e c k s t h e A P P s e n s o r in its fully
c l o s e d p o s i t i o n . In a n y o t h e r p o s i t i o n , t h e A P P s e n s o r 3. M a k e s u r e t h e H D S or a n O B D II s c a n tool
s t o r e s D T C s w h i c h a r e c o v e r e d in o t h e r c o m m u n i c a t e s w i t h t h e E C M a n d other v e h i c l e
troubleshooting procedures. s y s t e m s . If it d o e s n ' t , g o to t h e D L C circuit
• C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S t r o u b l e s h o o t i n g ( s e e p a g e 11-110).
before d o i n g t h i s p r o c e d u r e . If a n y D T C s a r e
i n d i c a t e d , t r o u b l e s h o o t t h e m first, t h e n d o t h i s 4. M a k e s u r e t h e a c c e l e r a t o r p e d a l is not p r e s s e d ,
procedure. t h e n c h e c k the T P S E N S O R in t h e D A T A L I S T w i t h
• P r e s s t h e a c c e l e r a t o r p e d a l s e v e r a l t i m e s to c h e c k its the H D S .
m o v e m e n t . If it d o e s not m o v e s m o o t h l y , c h e c k t h e
p e d a l , t h e throttle c a b l e , a n d t h e throttle l i n k a g e • If it is b e l o w 0.5 V , t h e throttle position s e n s o r is
individually. If y o u find a p r o b l e m in o n e of t h e m , OK.
r e p l a c e t h e part(s) that c a u s e d t h e p r o b l e m . • If it is a b o v e 0.5 V , a d j u s t t h e throttle c a b l e
1. C o n n e c t t h e H D S o r a n O B D II s c a n tool to t h e d a t a
link c o n n e c t o r ( D L C ) (A). O n '00-01 m o d e l s , t h e D L C 5. M a k e s u r e t h e a c c e l e r a t o r p e d a l is not p r e s s e d ,
is l o c a t e d u n d e r t h e p a s s e n g e r ' s s i d e of t h e t h e n c h e c k t h e T P S E N S O R in t h e D A T A L I S T w i t h
d a s h b o a r d . O n ' 0 2 - 0 5 m o d e l s , t h e D L C is l o c a t e d the H D S .
b e h i n d t h e d r i v e r ' s s i d e of t h e front c o n s o l e .
• If it is b e l o w 0.5 V , t h e throttle position s e n s o r is
'00-01 m o d e l s OK.
• If it is a b o v e 0.5 V , s u b s t i t u t e a k n o w n - g o o d E C M
6. M a k e s u r e t h e a c c e l e r a t o r p e d a l is not p r e s s e d ,
t h e n c h e c k the T P S E N S O R in t h e D A T A L I S T w i t h
the H D S .
• If it is b e l o w 0.5 V , t h e throttle position s e n s o r is

OK.
• If it is a b o v e 0.5 V , r e p l a c e t h e throttle b o d y
( s e e p a g e 11-165), t h e n g o t o s t e p 1.
'02-05 m o d e l s
11-164
Throttle Body Removal/Installation
NOTE:
• Do not a d j u s t t h e throttle s t o p s c r e w .
• After r e a s s e m b l y , a d j u s t the c r u i s e c o n t r o l a c t u a t o r c a b l e ( s e e p a g e 4-71), a n d the throttle c a b l e ( s e e p a g e 11-168).
• T h e T P s e n s o r is not r e m o v a b l e .
22 N m
(2.2 k g f - m , 16 Ibf ft)
11-165
Intake Air System
Throttle Body Disassembly/Reassembly
2.1 N m
(0.21 k g f - m , 1.5 Ibf-ft)
MAP SENSOR
O-RING
Replace.
TP SENSOR
11-166
Throttle Cable Removal/Installation
1. F u l l y o p e n the throttle v a l v e , t h e n r e m o v e the 5. R e m o v e t h e throttle c a b l e (A) a n d t h e a c t u a t o r

throttle c a b l e (A) f r o m the throttle link (B). c a b l e (B) f r o m t h e a c c e l e r a t o r p e d a l b r a c k e t (C).
(P/N 08798-9002)
7. After i n s t a l l i n g , start t h e e n g i n e . H o l d t h e e n g i n e
2. R e m o v e t h e c a b l e h o u s i n g (C) f r o m t h e c a b l e s p e e d at 3,000 r p m w i t h o u t l o a d (in neutral) until
b r a c k e t (D). t h e radiator f a n c o m e s o n , t h e n let it idle.
3. R e m o v e the nuts (A), t h e n r e m o v e t h e a c c e l e r a t o r 8. Hold t h e c a b l e s h e a t h , r e m o v i n g all s l a c k f r o m t h e

p e d a l (B) a l o n g w i t h t h e throttle c a b l e (C) a n d t h e cable.
a c t u a t o r c a b l e (D).
9. T u r n t h e a d j u s t i n g nut (A) until it i s 3 m m (0.1 in.)
a w a y f r o m t h e c a b l e bracket (B).
9.8 N-m
(1.0 k g f - m ,
7.2 Ibf-ft)
4. Pull t h e throttle c a b l e (C) a n d t h e actuator c a b l e (D)

out t o w a r d t h e p a s s e n g e r c o m p a r t m e n t . 10. T i g h t e n t h e locknut (C). T h e c a b l e f r e e play s h o u l d
n o w b e 4 — 6 m m (0.2—0.3 in.). If f r e e p l a y i s not
w i t h i n s p e c s , l o o s e n the locknut, turn t h e a d j u s t i n g
nut until t h e f r e e p l a y is a s s p e c i f i e d , t h e n retighten
t h e locknut.
11. W i t h t h e c a b l e p r o p e r l y a d j u s t e d , c h e c k the throttle

v a l v e to be s u r e it o p e n s fully w h e n y o u p u s h t h e
a c c e l e r a t o r p e d a l to the floor. A l s o c h e c k t h e
throttle v a l v e to b e s u r e it r e t u r n s to the idle
position w h e n e v e r you release the accelerator
pedal.
11-167
Intake Air System
Throttle Cable Adjustment
1. C h e c k c a b l e f r e e p l a y at t h e throttle l i n k a g e . C a b l e
free p l a y (A) s h o u l d be 4 — 6 m m ( 0 . 2 — 0 . 3 in.).
2. If free p l a y (A) is not w i t h i n s p e c (4—6 m m ,

0 . 2 — 0 . 3 in.) l o o s e n t h e locknut ( B ) , t u r n t h e
a d j u s t i n g nut (C) until t h e f r e e p l a y is a s s p e c i f i e d ,
t h e n retighten t h e locknut.
3. W i t h t h e c a b l e p r o p e r l y a d j u s t e d , c h e c k t h e throttle
v a l v e to be s u r e it o p e n s f u l l y w h e n y o u p u s h the
a c c e l e r a t o r p e d a l to t h e floor. A l s o c h e c k t h e
throttle v a l v e to be s u r e it r e t u r n s to t h e idle
position w h e n e v e r y o u r e l e a s e t h e a c c e l e r a t o r
pedal.
11-168
Air Cleaner Element Inspection/Replacement
1. R e m o v e the air c l e a n e r h o u s i n g c o v e r (A).
2 . R e m o v e the air c l e a n e r e l e m e n t (B) f r o m the air c l e a n e r h o u s i n g (C).
3 . C h e c k the air c l e a n e r e l e m e n t for d a m a g e or c l o g g i n g . If t h e r e i s d a m a g e or c l o g g i n g , r e p l a c e t h e air c l e a n e r

element.
N O T E : D o not c l e a n t h e air c l e a n e r e l e m e n t b y b l o w i n g if off w i t h c o m p r e s s e d air.
4 . C l e a n a n d r e m o v e a n y d e b r i s f r o m i n s i d e t h e air c l e a n e r h o u s i n g .
5 . Install the parts in the r e v e r s e o r d e r of r e m o v a l .
11-169
Catalytic Converter System
DTC Troubleshooting
DTC P0420: Catalyst System Efficiency Below

Threshold
NOTE:
r e v i e w the general troubleshooting information
( s e e p a g e 11-3).
• If s o m e of t h e D T C s listed b e l o w a r e s t o r e d at t h e
s a m e time a s D T C P0420, troubleshoot those D T C s
first, t h e n r e c h e c k for D T C P 0 4 2 0 .
P0137, P0138: S e c o n d a r y heated o x y g e n s e n s o r

( s e c o n d a r y H 0 2 S ( S e n s o r 2))
P 0 1 4 1 : S e c o n d a r y H 0 2 S ( S e n s o r 2) h e a t e r
1. R e s e t t h e E C M ( s e e p a g e 11-4), t h e n c o n t i n u e to
s t e p s 2 t h r o u g h 5 to r e s e t t h e r e a d i n e s s c o d e .
3. D r i v e o n a h i g h w a y for a b o u t 10 m i n u t e s w i t h o u t
stopping. Y o u r s p e e d can vary.
4. W i t h t h e t r a n s m i s s i o n in 4th g e a r , d r i v e at a s t e a d y
s p e e d between 50—62 m p h (80—100 km/h) for
30 s e c o n d s .
5. R e p e a t s t e p 4 t h r e e t i m e s . B e t w e e n e a c h repetition,
c l o s e t h e throttle c o m p l e t e l y for 1 — 2 s e c o n d s . If
t h e e n g i n e is s t o p p e d d u r i n g t h i s part of t h e
p r o c e d u r e , g o to s t e p 3 a n d d o t h e p r o c e d u r e a g a i n .
6. C h e c k for a T e m p o r a r y D T C w i t h t h e s c a n t o o l .
Does the scan tool Indicate Temporary DTC

P0420?
Y E S — C h e c k the three w a y catalytic converter

( T W C ) . If n e c e s s a r y , r e p l a c e t h e T W C ( s e e p a g e 9-5).
•
N O — C h e c k for r e a d i n e s s c o d e c o m p l e t i o n . If t h e
r e a d i n e s s i s c o m p l e t e , it w a s a intermittent f a i l u r e ,
t h e s y s t e m is O K at t h i s t i m e . If t h e r e a d i n e s s is
incomplete, repeat steps 2 through 5.H
11-170
PCV System
DTC Troubleshooting PCW a i v e Inspection
DTC P2279: Intake Air System Leak Detected 1. C h e c k the P C V v a l v e (A), h o s e s ( B ) , a n d

('04-05 models) c o n n e c t i o n s for l e a k s o r r e s t r i c t i o n s .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data B
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g information A
( s e e p a g e 11-3).
3,000 r p m without l o a d (in neutral) until the
3. Let the e n g i n e idle for at l e a s t 40 s e c o n d s w i t h the

throttle fully c l o s e d .
B
4. C h e c k for D T C w i t h a s c a n tool or the H D S . * : T h i s illustration s h o w s '00-03 m o d e l s .
Is DTC P2279 indicated? 2. A t idle, m a k e s u r e t h e r e i s a c l i c k i n g s o u n d f r o m the

P C V v a l v e w h e n the h o s e b e t w e e n the P C V v a l v e
Y E S — C h e c k t h e s e parts for v a c u u m l e a k s . • a n d intake m a n i f o l d i s lightly p i n c h e d (A) w i t h y o u r
f i n g e r s or p l i e r s .
• PCV valve If t h e r e i s n o c l i c k i n g s o u n d , c h e c k the P C V v a l v e
• PCV hose g r o m m e t f o r c r a c k s or d a m a g e . If the g r o m m e t is
• E V A P canister purge valve O K , r e p l a c e t h e P C V v a l v e ('04-05 m o d e l s )
• Throttle b o d y ( s e e p a g e 11-172), t h e n r e c h e c k .
• Intake m a n i f o l d g a s k e t
time.B
* : T h i s illustration s h o w s '00-03 m o d e l s .
11-171
PCV System
PCV Valve Replacement
'04-05 models
1. D i s c o n n e c t t h e P C V h o s e .
2 . R e m o v e t h e P C V v a l v e (A).
B 44 N m
(4.5 kgf m , 3 3 I b f f t )
3 . Install t h e p a r t s in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w w a s h e r (B).
11-172
EVAP System
CANISTER PURGE VALVE EVAPORATIVE EMISSION (EVAP) T W O W A Y V A L V E

T e s t , p a g e 11-194
11-173
EVAP System
DTC Troubleshooting
DTC P0451: FTP Sensor Circuit Range/ 6. C o n n e c t a c o m m e r c i a l l y a v a i l a b l e v a c u u m p u m p /

Performance Problem g a u g e , 0 — 3 0 i n . H g , to the o p e n e n d of the h o s e .

V a c u u m pump/gauge, 0—30 in.Hg, S n a p - o n Y A 4 0 0 0 A
or e q u i v a l e n t , c o m m e r c i a l l y a v a i l a b l e
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a
( s e e p a g e 11-3).
2. T u r n t h e ignition s w i t c h ON(II).
3. M o n i t o r F T P s e n s o r v o l t a g e w i t h t h e H D S , or
m e a s u r e voltage between E C M connector 7. T u r n t h e ignition s w i t c h O N (II).
terminals A29 and C18.
8. M o n i t o r F T P s e n s o r v o l t a g e w i t h the H D S , or
ECM CONNECTORS
m e a s u r e voltage between E C M connector
A(32P) , b
terminals A29 and C 1 8 , and slowly squeeze the
1 2 3
/ / /
4 6 9 10 vacuum pump/gauge.
12 13
/ / 15
/ 17 18 19 20 21 24
ECM CONNECTORS
25 26 27
/ 28 29 30 32
A (32P)
J PTANK (LTGRN)
1 2 3
/ / /
4 6 9 10
12 13
/ / 15 17 18 19 20 21 24
C (31P)
1 2
/ 4 5
/ 7 8 9 10
25 26 27
/ 28 29 30 32
11 12 13 14 15 16 17 18 19 20 21 22
J P T A N K (LT G R N )
.
/ 24 25 26 27 23 29 30
/
I S G 2 (GRN/YEL) C (31P)
W i r e s i d e of f e m a l e t e r m i n a l s 1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
7 8 9 10
26 27 2 3
Is there about 2.5 V?
/ 24 25 29 30
I SG2 (GRN/YEL)
/
Y E S — G o t o s t e p 4. W i r e s i d e of f e m a l e t e r m i n a l s
N O — R e p l a c e the F T P sensor. • 9. T h e v o l t a g e s h o u l d s m o o t h l y d r o p f r o m a b o u t 2.5 V

d o w n to a b o u t 1.5 V . S t o p a p p l y i n g v a c u u m w h e n
4. T u r n t h e ignition s w i t c h O F F . t h e v o l t a g e d r o p s to a b o u t 1.5 V or d a m a g e to t h e
F T P sensor m a y occur.
5. D i s c o n n e c t t h e h o s e b e t w e e n t h e E V A P t w o w a y
v a l v e a n d t h e F T P s e n s o r at t h e E V A P t w o w a y Does the voltage drop to about 1.5 V and hold?
valve end.
Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s
t i m e . C h e c k for p o o r c o n n e c t i o n s at the F T P s e n s o r
a n d the E C M . B
N O — R e p l a c e the F T P s e n s o r . •
11-174
DTC P0452: FTP Sensor Circuit Low Voltage 6. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data 7. R e i n s t a l l the fuel fill c a p .

( s e e p a g e 11-3). 8. D i s c o n n e c t t h e F T P s e n s o r 3 P c o n n e c t o r .
1. C h e c k the v a c u u m lines of t h e F T P s e n s o r for 9. T u r n t h e ignition s w i t c h O N (II).

misrouting, leakage, breakage, and clogging.
10. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
Are the vacuum lines OK? t e r m i n a l s No. 1 a n d N o . 2.
FTP S E N S O R 3P C O N N E C T O R
N O — R e p a i r or r e p l a c e v a c u u m l i n e s a s
necessary. •
5. M o n i t o r F T P s e n s o r v o l t a g e w i t h the H D S , or
m e a s u r e voltage between body ground and E C M W i r e s i d e of f e m a l e t e r m i n a l s
connector terminal A29.

Is there about 5 V?
1 2 3
/ / /A
A 6 9 10 N O — G o to s t e p 11.
12 13
/ / 18 19 20 21 24
25 26 27
/ 28 29 30
JL PTANK(LTGRN)
32
X)
Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s
at t h e F T P s e n s o r a n d at the E C M . •
(cont'd)
11-175
EVAP System

11. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r 12. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
terminals C28 and C18. t e r m i n a l s N o . 2 a n d N o . 3.
FTP S E N S O R 3P CONNECTOR
SG2 (GRN/YEL)
PTANK (LTGRN)
/ /
r
1 2 4 5 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
/ 24 25 26 27 28 29 30
/ S G 2 (GRN)
VCC2 (YEL/BLU)
Is there about 5 V? Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M Y E S — R e p l a c e the F T P sensor. •
(C28) a n d t h e F T P s e n s o r . •
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5).
If t h e F T P s e n s o r r e a d i n g s a r e n o w n o r m a l , r e p l a c e 13. T u r n t h e ignition s w i t c h O F F .
t h e original E C M ( s e e p a g e 11-115). •
15. C h e c k for c o n t i n u i t y b e t w e e n F T P s e n s o r 3 P
PTANK (LTGRN)
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e F T P
s e n s o r and the E C M ( A 2 9 ) . B
t h e n r e c h e c k . If t h e F T P s e n s o r r e a d i n g s a r e n o w
n o r m a l , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
11-176
DTC P0453: FTP Sensor Circuit High Voltage 6. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data 7. R e i n s t a l l the fuel fill c a p .

( s e e p a g e 11-3). 8. D i s c o n n e c t t h e F T P s e n s o r 3 P c o n n e c t o r .
1. C h e c k the v a c u u m l i n e s of t h e F T P s e n s o r for 9. T u r n t h e ignition s w i t c h O N (II).

10. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
Are the vacuum lines OK? t e r m i n a l s N o . 1 a n d N o . 2.
necessary. •
5. Monitor F T P s e n s o r v o l t a g e w i t h the H D S , o r
m e a s u r e voltage between body ground and E C M W i r e s i d e of f e m a l e t e r m i n a l s

Is there about 5 V?
1 2 3
/ / /
4 6 9 10 N O — G o to s t e p 11.
12 13
/ / 15
/ 17 18 19 20 21 24
25 26 27
/ 28 29 30 32
i PTANK (LTGRN)
at the F T P s e n s o r a n d at the E C M . •
(cont'd)
11-177
EVAP System

11. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r 12. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
terminals C28 and C18. t e r m i n a l s N o . 2 a n d N o . 3.
SG2 (GRN/YEL)
PTANK (LTGRN)
1
11
2
12
/
13
4
14 15
5
16
/ 17 18 19
8
20
9
21
10
22
/ 24 25 26 27 28 29
VCC2 (YEL/BLU)
30
/ S G 2 (GRN)
Is there about 5 V? Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M Y E S — R e p l a c e the F T P s e n s o r . •
(C18) a n d the F T P s e n s o r . •
t h e n r e c h e c k . If t h e F T P s e n s o r r e a d i n g s a r e n o w 13. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r
n o r m a l , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115). terminals A29 and C18.
ECM CONNECTORS
1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 24
25 26 27
/ 28 29 30
PTANK (LTGRN)
32
1 2
/ 4 5
/ 7
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10
/ 24 25 26 27 2 3 29 30
SG2 (GRN/YEL)
/
Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e F T P
s e n s o r a n d the E C M ( A 2 9 ) . H
t h e n r e c h e c k . If t h e F T P s e n s o r r e a d i n g s a r e n o w
n o r m a l , r e p l a c e t h e original E C M ( s e e p a g e 11-115).
11-178
DTC P0497: EVAP System Low Purge Flow 4. D i s c o n n e c t the v a c u u m h o s e f r o m t h e E V A P p u r g e
('04-05 models) joint (A), a n d c o n n e c t a c o m m e r c i a l l y a v a i l a b l e
v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to t h e h o s e .
V a c u u m p u m p / g a u g e , 0 — 3 0 in.Hg, S n a p - o n Y A 4 0 0 0 A
( s e e p a g e 11-3).
A 6 and body ground.
• PCS (RED/YEL) 5. C o n n e c t E C M c o n n e c t o r t e r m i n a l A 6 to b o d y
1 2 3 4
/ / / 6 9 10 ground with a jumper wire.
12 13
/ / 15
/
17 18 19 20 21 24
25 26 27
/28 29 30 32 E C M C O N N E C T O R A (32P)
1 2 3
/ / /
4 6 9 10
/ / 15
/ 17 18 19 20 21 24
Is there battery voltage? JUMPER WIRE

25 26 27
/ 28 29 30 32
3. T u r n the ignition s w i t c h O F F . 6. T u r n t h e ignition s w i t c h O N (II).
7. A p p l y v a c u u m to the h o s e .
Does the valve hold vacuum?
Y E S — R e p l a c e the E V A P canister purge v a l v e . •
9. D i s c o n n e c t the E V A P c a n i s t e r p u r g e v a l v e 2 P
connector.
(cont'd)
11-179
EVAP System
10. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e 13. A t the v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n

valve 2P connector terminal No. 2 a n d body ground. E V A P canister purge valve 2P connector terminals
No. 1 a n d N o . 2.
EVAP CANISTER PURGE
V A L V E 2P C O N N E C T O R
EVAP CANISTER PURGE
1 2 1 . . 1
PCS (RED/YEL)
1 2
Is there about 33 Q at room temperature?
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E V A P
c a n i s t e r p u r g e v a l v e a n d t h e E C M <A6).B N O — R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e . •
11. T u r n t h e ignition s w i t c h O N (II). 14. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l

A4 and body ground.
12. M e a s u r e v o l t a g e b e t w e e n E V A P c a n i s t e r p u r g e
valve 2P connector terminal No. 1 and body ground. E C M C O N N E C T O R A (32P)
EVAP CANISTER PURGE

1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 lAr
IG1
25 26 27
/ 28 29 30 32
(BLK/YEL)
W i r e s i d e of f e m a l e t e r m i n a l s Is there battery voltage?
Is there battery voltage? Y E S — G o t o s t e p 15.
Y E S — G o t o s t e p 13. N O — G o to s t e p 20.
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E V A P 15. T u r n t h e ignition s w i t c h O F F .

c a n i s t e r p u r g e v a l v e a n d the N o . 6 A C G (15 A ) f u s e
in t h e u n d e r - d a s h f u s e / r e l a y box.m
11-180
16. D i s c o n n e c t t h e v a c u u m h o s e f r o m the E V A P 2 2 . C h e c k for c o n t i n u i t y b e t w e e n E V A P c a n i s t e r v e n t
c a n i s t e r v e n t filter line (A), a n d c o n n e c t a shut valve 2P connector terminal No. 2 and body
commercially available v a c u u m pump/gauge, ground.
0 — 3 0 i n . H g , to t h e h o s e .
EVAP CANISTER V£NT
S H U T V A L V E 2P C O N N E C T O R
1
1 2
VSV
(LT G R N / W H T )
17. C o n n e c t E C M c o n n e c t o r t e r m i n a l A 4 to b o d y
ground with a j u m p e r wire. Y E S — G o to s t e p 2 3 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E V A P
canister vent s h u t v a l v e a n d the E C M . •
1 V S V (LT G R N / W H T ) 2 3 . T u r n t h e ignition s w i t c h O N (II).
/ 7 /
1 2 3 4 6 9 10
24. M e a s u r e voltage between E V A P canister vent shut
12 13
/ / 15 17 18 19 20 21
/ 24
valve 2P connector terminal No. 1 and body ground.
JUMPER WIRE
25 26 27 28 29 30
/ 32
EVAP CANISTER VENT

1 2
p
IG1
18. T u r n the ignition s w i t c h O N (II). (BLK/YEL)
19. A p p l y v a c u u m to t h e h o s e .
Y E S — I n s p e c t t h e v a c u u m line b e t w e e n the E V A P Wire side of female terminals

canister purge valve and the E V A P canister. •
N O — R e p l a c e the E V A P canister vent shut valve. •
Y E S — G o to s t e p 2 5 .
21. Disconnect the E V A P canister vent shut valve 2P c a n i s t e r v e n t s h u t v a l v e a n d t h e No. 6 A C G (15 A )
connector. f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x . H
(cont'd)
11-181
EVAP System
25. At the v a l v e s i d e , m e a s u r e resistance between

E V A P canister vent shut valve 2P connector
EVAP CANISTER VENT

Is there about 33 Q at room temperature?

11-5) a n d retest. If t h e s y m p t o m / i n d i c a t i o n g o e s
N O — R e p l a c e the E V A P canister vent shut valve. •
11-182
DTC P1456: EVAP Control System Leakage 2 . C h e c k the fuel fill c a p s e a l a n d t h e f u e l fill pipe
(Fuel Tank System) sealing surface.
INOTlCEl Is the fuel fill cap seal missing or damaged, or is

T h e fuel s y s t e m is d e s i g n e d to a l l o w s p e c i f i e d the fill pipe damaged?
m a x i m u m v a c u u m a n d p r e s s u r e c o n d i t i o n s . D o not
d e v i a t e f r o m the v a c u u m a n d p r e s s u r e t e s t s a s Y E S — R e p l a c e t h e fuel fill c a p ( g r a y o r black
i n d i c a t e d in t h e s e p r o c e d u r e s . E x c e s s i v e p r e s s u r e / c o l o r e d c a p ) , or t h e fuel fill p i p e . H
v a c u u m w o u l d d a m a g e the E V A P c o m p o n e n t s or
c a u s e e v e n t u a l fuel tank failure. N O — T h e fuel fill c a p i s O K . G o t o s t e p 3.
Special Tools Required E V A P Canister Purge Valve T e s t

V a c u u m p u m p / g a u g e , 0 — 3 0 in.Hg, S n a p - o n Y A 4 0 0 0 A
or equivalent, commercially available 3. D i s c o n n e c t the v a c u u m h o s e f r o m t h e E V A P p u r g e
joint (A), a n d c o n n e c t a c o m m e r c i a l l y a v a i l a b l e
T h i s i s a two-trip c o d e ; o n c e c l e a r e d , it c a n n o t be v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to the h o s e .
r e p r o d u c e d in o n e trip. A l s o , c e r t a i n s p e c i f i c d r i v i n g
a n d a m b i e n t c o n d i t i o n s m u s t o c c u r b e f o r e the E C M w i l l
c o m p l e t e the s y s t e m c h e c k s . A d d i t i o n a l t e s t d r i v e s m a y
still not m e e t the s p e c i f i c c o n d i t i o n s n e e d e d to
r e p r o d u c e the c o d e . If n e c e s s a r y , u s e t h e test d r i v e
p r o c e d u r e s for setting t h e r e a d i n e s s c o d e ( s e e p a g e
11-40).
F o l l o w t h e s e t r o u b l e s h o o t i n g p r o c e d u r e s c a r e f u l l y to
e n s u r e t h e integrity of t h e s y s t e m a n d to c o n f i r m the
c a u s e of t h e p r o b l e m or c o d e .
NOTE:
( s e e p a g e 11-3). 4. T u r n the ignition s w i t c h O N (II).
• F r e s h fuel h a s a h i g h e r volatility t h a t w i l l c r e a t e
g r e a t e r p r e s s u r e / v a c u u m . T h e o p t i m u m c o n d i t i o n for 5. A p p l y v a c u u m to the h o s e .
t e s t i n g is f r e s h f u e l , a n d m u s t be l e s s t h a n a full tank
of g a s . If p o s s i b l e , to a s s i s t in leak d e t e c t i o n , a d d Does the valve hold vacuum?
1 g a l l o n of f r e s h fuel to the tank ( a s long a s it w i l l not
fill the tank), j u s t before starting t h e s e p r o c e d u r e s . Y E S — T h e E V A P c a n i s t e r p u r g e v a l v e is O K . G o to
s t e p 11.
F u e l Fill C a p C h e c k
1. C h e c k the fuel fill c a p (the c a p m u s t s a y "If not
t i g h t e n e d 3 c l i c k s c h e c k e n g i n e light m a y c o m e o n . " ) 6. T u r n the ignition s w i t c h O F F .
Is the proper fuel fill cap installed and properly 7. D i s c o n n e c t the E V A P c a n i s t e r p u r g e v a l v e 2 P

tightened? connector.
N O — R e p l a c e o r tighten t h e c a p . •
(cont'd)
11-183
EVAP System
8. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e E V A P Bypass Solenoid Valve Test
valve 2P connector terminal No. 2 a n d body ground.
11. D i s c o n n e c t both v a c u u m h o s e s f r o m t h e E V A P t w o
EVAP CANISTER PURGE
w a y v a l v e (A), a n d c o n n e c t a c o m m e r c i a l l y
a v a i l a b l e v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to t h e
c a n i s t e r port o n the t w o w a y v a l v e .
1 2
PCS (RED/YEL)
N O — R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e . • 12. T u r n t h e E V A P b y p a s s s o l e n o i d v a l v e O N w i t h the

H D S , or c o n n e c t E C M c o n n e c t o r t e r m i n a l A 3 to
9. D i s c o n n e c t E C M c o n n e c t o r A (32P). body ground with a j u m p e r wire.
10. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e

valve 2P connector terminal No. 2 and body ground.
EVAP CANISTER PURGE 2 W B S (ORN)

1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 24
1 2
25 26 27
/ 28 29 30 32
JUMPER WIRE
PCS (RED/YEL)

Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E V A P
c a n i s t e r p u r g e v a l v e a n d t h e E C M (A6). • Y E S — G o t o s t e p 15.
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5), N O — G o to s t e p 20.
t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s a w a y ,
11-184
15. T u r n t h e ignition s w i t c h O F F . 18. T u r n the ignition s w i t c h O N (II).
16. D i s c o n n e c t the E V A P b y p a s s s o l e n o i d v a l v e 2 P 19. M e a s u r e v o l t a g e b e t w e e n E V A P b y p a s s s o l e n o i d

connector. valve 2P connector terminal No. 1 and body ground.
EVAP BYPASS SOLENOID

17. C h e c k for continuity b e t w e e n E V A P b y p a s s
solenoid valve 2P connector terminal No. 2 and
body ground.

V A L V E 2P CONNECTOR
IG1 ( B L K / Y E L )
1 2
2 W B S (ORN)
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E V A P
b y p a s s s o l e n o i d v a l v e a n d the E C M ( A 3 ) . B
Y E S — R e p l a c e the E V A P b y p a s s s o l e n o i d v a l v e (A)
a n d the O - r i n g s ( B ) . B
b y p a s s s o l e n o i d v a l v e a n d t h e N o . 6 A C G (15 A )
fuse. •
(cont'd)
11-185
EVAP System
2 0 . P l u g t h e u p p e r port (A) of t h e E V A P t w o w a y v a l v e . E V A P Canister Vent Shut Valve Test
A
22. Disconnect the v a c u u m hose from the E V A P
c a n i s t e r v e n t filter line (A), a n d c o n n e c t a
commercially available v a c u u m pump/gauge,
0 — 3 0 i n . H g , to t h e h o s e .
21. While monitoring F T P s e n s o r voltage with the H D S ,

or m e a s u r i n g t h e v o l t a g e b e t w e e n E C M c o n n e c t o r
t e r m i n a l s A 2 9 a n d C 1 8 , s l o w l y p u m p the v a c u u m
p u m p / g a u g e until t h e v o l t a g e d r o p s to a b o u t 1.5 V .
ECM CONNECTORS
24. A p p l y v a c u u m to the h o s e w i t h 5 s t r o k e s of the

1 2 3 4
/ / /6 9 10 pump.
12 13
/ / 15
/
17 18 19 20 21 24
25 26 27
/28 29 30
P T A N K (LT GRN)
32
Y E S — G o to s t e p 2 5 .
C(31P) N O — T h e E V A P c a n i s t e r v e n t s h u t v a l v e is O K . G o
to s t e p 3 0 .
1 2
/ 4 5
/ 7
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10
/ 24 25 26 27 23 29 30
SG2 (GRN/YEL)/ 2 5 . T u r n t h e ignition s w i t c h O F F .
26. D i s c o n n e c t the E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
connector.
Does the voltage drop to 1.5 V and hold for at
least 20 seconds? 2 7 . C h e c k for continuity b e t w e e n E V A P c a n i s t e r v e n t
shut valve 2P connector terminal No. 2 and body
Y E S — T h e E V A P bypass solenoid valve/EVAP two ground.
w a y v a l v e is O K . G o to s t e p 2 2 .
EVAP CANISTER VENT
N O — R e p a i r leak f r o m t h e E V A P b y p a s s s o l e n o i d
v a l v e , E V A P t w o w a y v a l v e , F T P s e n s o r , or
O-rings.B 1 2
VSV
(LT G R N / W H T )
11-186
Vacuum Hoses and Connections Test
B
30. P e r f o r m t h e fuel tank v a p o r c o n t r o l v a l v e test
( s e e p a g e 11-195).
Is the fuel tank vapor control valve OK ?
Y E S — G o to s t e p 3 1 .
N O — R e p l a c e the fuel t a n k v a p o r c o n t r o l v a l v e . •
3 1 . T i g h t e n t h e fuel c a p t h r e e " c l i c k s " , t h e n m o n i t o r

the F T P readings with the H D S .
3 2 . S t a r t t h e e n g i n e , a n d let it idle for 5 m i n u t e s .

33. C h e c k the F T P s e n s o r reading.
N O — R e p l a c e t h e E V A P c a n i s t e r v e n t s h u t v a l v e (A)
a n d t h e O-ring ( B ) . B
29. C h e c k for continuity b e t w e e n E V A P c a n i s t e r v e n t

shut valve 2P connector terminal No. 2 and body
ground.
EVAP CANISTER VENT

1 2
Is the reading above 4 mmHg pressure or below
VSV — 4 mmHg vacuum?
i
(LT G R N / W H T )
Y E S ~-Substitute a known-good E C M (see page

11-5) a n d retest. If t h e s y m p t o m / i n d i c a t i o n g o e s
W i r e s i d e of f e m a l e t e r m i n a l s N O — C h e c k t h e s e parts for v a c u u m l e a k s . •
Is there continuity? • F u e l t a n k (A)

• F u e l fill c a p (B)
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E V A P • F u e l fill pipe (C)
c a n i s t e r v e n t s h u t v a l v e a n d the E C M ( A 4 ) . H • F u e l tank v a p o r control v a l v e (D)
• F u e l tank v a p o r recirculation v a l v e (E)
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5), • F u e l tank v a p o r recirculation t u b e (F)
t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y , • F u e l t a n k v a p o r s i g n a l t u b e (G)
r e p l a c e t h e original E C M ( s e e p a g e 1 1 - 1 1 5 ) . B • F u e l t a n k v a p o r control v e n t t u b e (H)
- R e p a i r or r e p l a c e parts a s n e e d e d .
11-187
EVAP System
DTC P1457: EVAP Control System Leakage E V A P Canister Purge Valve Test
(EVAP Canister System)
1. D i s c o n n e c t t h e v a c u u m h o s e f r o m t h e E V A P p u r g e
INOTICEI j o i n t (A), a n d c o n n e c t a c o m m e r c i a l l y a v a i l a b l e
T h e fuel s y s t e m i s d e s i g n e d to a l l o w s p e c i f i e d v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to t h e h o s e .
A
deviate f r o m the v a c u u m a n d p r e s s u r e tests a s
i n d i c a t e d in t h e s e p r o c e d u r e s . E x c e s s i v e p r e s s u r e /
v a c u u m w o u l d d a m a g e the E V A P c o m p o n e n t s or
c a u s e e v e n t u a l fuel t a n k f a i l u r e .

V a c u u m p u m p / g a u g e , 0—30 in.Hg, S n a p - o n Y A 4 0 0 0 A
or equivalent, c o m m e r c i a l l y available
T h i s i s a t w o - t r i p c o d e ; o n c e c l e a r e d , it c a n n o t be
r e p r o d u c e d in o n e trip. A l s o , c e r t a i n s p e c i f i c d r i v i n g
a n d ambient conditions m u s t o c c u r before the E C M will
complete the s y s t e m c h e c k s . Additional test drives m a y
still not m e e t t h e s p e c i f i c c o n d i t i o n s n e e d e d to
r e p r o d u c e t h e c o d e . If n e c e s s a r y , u s e t h e t e s t d r i v e 2. T u r n the E V A P canister purge v a l v e o n with the
p r o c e d u r e s for s e t t i n g t h e r e a d i n e s s c o d e ( s e e p a g e H D S , o r c o n n e c t E C M c o n n e c t o r t e r m i n a l A 6 to
11-40). body ground with a jumper wire.
F o l l o w t h e s e t r o u b l e s h o o t i n g p r o c e d u r e s c a r e f u l l y to
e n s u r e t h e integrity of t h e s y s t e m a n d to c o n f i r m t h e
c a u s e of t h e p r o b l e m or c o d e .
PCS (RED/YEL)
NOTE:
1 2 3
/ / /
4 6 9 10

12 13
/ / 15 17 18 19 20 21 24
( s e e p a g e 11-3).
• F r e s h f u e l h a s a h i g h e r volatility t h a t w i l l c r e a t e JUMPER WIRE
25 26 27
/ 28 29 30 32
greater p r e s s u r e / v a c u u m . T h e o p t i m u m condition for

t e s t i n g i s f r e s h f u e l , at l e a s t half, but l e s s t h a n a full
tank. If p o s s i b l e , to a s s i s t in leak d e t e c t i o n , a d d W i r e s i d e of f e m a l e t e r m i n a l s
1 g a l l o n of f r e s h fuel to t h e t a n k ( a s l o n g a s it will not
fill the t a n k ) , j u s t b e f o r e s t a r t i n g t h e s e p r o c e d u r e s .
N O — T h e E V A P c a n i s t e r p u r g e v a l v e is O K . G o to
s t e p 10.
6. D i s c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e 2 P
connector.
11-188
7. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e E V A P Bypass Solenoid Valve Test
valve 2 P connector terminal No. 2 and body ground.
10. D i s c o n n e c t both v a c u u m h o s e s f r o m t h e E V A P t w o
EVAP CANISTER PURGE
w a y v a l v e (A), a n d c o n n e c t a c o m m e r c i a l l y
a v a i l a b l e v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to t h e
c a n i s t e r port o n the t w o w a y v a l v e .
r~~T
1 2
[PCS (RED/YEL)
c a n i s t e r p u r g e v a l v e a n d the E C M (A6). • 12. A p p l y v a c u u m to the h o s e .
8. T u r n the ignition s w i t c h O N (II). Does the valve hold vacuum?
9. M e a s u r e v o l t a g e b e t w e e n E V A P c a n i s t e r p u r g e Y E S — T h e E V A P bypass solenoid valve/EVAP two

v a l v e 2 P c o n n e c t o r t e r m i n a l No. 1 a n d b o d y g r o u n d . w a y v a l v e is O K . G o to s t e p 18.
EVAP CANISTER PURGE

1 2
14. D i s c o n n e c t the E V A P b y p a s s s o l e n o i d v a l v e 2 P
connector.
IG1 ( B L K / Y E L )

solenoid valve 2P connector terminal No. 2 and
body ground.

r~i
Is there battery voltage? 1 2
2WBS
Y E S — R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e . • (ORN)
c a n i s t e r p u r g e v a l v e a n d the No. 6 A C G (15 A )
fuse.B
(cont'd)
11-189
EVAP System
E V A P Canister Vent Shut Valve Test
18. D i s c o n n e c t t h e v a c u u m h o s e f r o m the E V A P
c a n i s t e r v e n t filter line (A), a n d c o n n e c t a
0 — 3 0 i n . H g , to the h o s e .
N O — R e p l a c e t h e E V A P b y p a s s s o l e n o i d v a l v e (A)
and O-rings {B)M
19. T u r n the E V A P c a n i s t e r v e n t s h u t v a l v e o n w i t h t h e
16. D i s c o n n e c t E C M c o n n e c t o r A (32P). H D S , or c o n n e c t E C M c o n n e c t o r t e r m i n a l A 4 to
solenoid valve 2P connector terminal No. 2 and ECM CONNECTOR A (32P)
body ground.
EVAP BYPASS SOLENOID VSV (LT GRN/WHT)

VALVE 2P CONNECTOR
1 2 3
/ / /
4 6 9 10
12 13
/ / 15
/ 17 18 19 20 21 24
1 2
25 26 27
/ 28 29 30 32
2WBS JUMPER WIRE

(ORN)
p .
20. T u r n the ignition s w i t c h O N (II)

2 1 . A p p l y v a c u u m to t h e h o s e .
Y E S — R e p a i r t h e s h o r t in t h e w i r e b e t w e e n t h e
E V A P b y p a s s solenoid v a l v e and the E C M ( A 3 ) . B Y E S — T h e E V A P c a n i s t e r v e n t s h u t v a l v e is O K . G o
to s t e p 2 7 .
t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y , N O — G o to s t e p 2 2 .
replace the original E C M (see page 11-115).B
2 3 . D i s c o n n e c t the E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
connector.
1.1-190
2 4 . C h e c k for continuity b e t w e e n E V A P c a n i s t e r v e n t Canister S y s t e m Leak Test
shirt v a l v e 2 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
g r o u n d . If u s i n g t h e H D S to t u r n the E V A P c a n i s t e r 2 7 . T u r n t h e ignition s w i t c h O F F .
v e n t s h u t v a l v e o n , turn the ignition s w i t c h O N (II).
28. C o n n e c t t w o t h r e e - w a y T-fittings (A) into the h o s e
E
VAPC ANS
ITERV ENT
SHUTVAL
V E 2P C
O NNEC
TOR f r o m t h e E V A P c a n i s t e r to the E V A P t w o w a y v a l v e .
C o n n e c t t h e F T P s e n s o r to o n e of t h e T-fittings a n d
r~i a commercially available v a c u u m pump/gauge,
1 2 0 — 3 0 i n . H g , to t h e o t h e r .
VSV
(LT GRNW
/ HT
)
Y E S — G o to s t e p 2 5 .
c a n i s t e r v e n t s h u t v a l v e a n d the E C M ( A 4 ) . B

2 9 . R e m o v e the v e n t h o s e f r o m the E V A P c a n i s t e r v e n t
26. M e a s u r e v o l t a g e b e t w e e n E V A P c a n i s t e r v e n t s h u t s h u t v a l v e (A), a n d c a p t h e port (B) to s e a l the f r e s h
valve 2P connector terminal No. 1 and body ground. air v e n t for the E V A P c a n i s t e r .
EVAP CONTROL CANISTER VENT

3 1 . W h i l e m o n i t o r i n g F T P s e n s o r v o l t a g e w i t h the H D S ,
Is there battery voltage? or m e a s u r i n g v o l t a g e b e t w e e n E C M c o n n e c t o r
Y E S — R e p l a c e the E V A P c a n i s t e r v e n t s h u t v a l v e pump.
(A) a n d the O - r i n g ( B ) . B
c a n i s t e r v e n t s h u t v a l v e a n d the N o . 6 A C G (15 A )
fuse.B
(cont'd)
11-191
EVAP System
3 2 . C o n t i n u e to p u m p v a c u u m until the v o l t a g e d r o p s 3 7 . W h i l e m o n i t o r i n g F T P s e n s o r v o l t a g e w i t h the H D S ,

to a b o u t 1.5 V . M a k e s u r e that the e n g i n e c o o l a n t or m e a s u r i n g v o l t a g e b e t w e e n E C M c o n n e c t o r
t e m p e r a t u r e is still a b o v e 9 5 °F (35 °C) a n d y o u r t e r m i n a l s A 2 9 a n d C 1 8 , s l o w l y p u m p the v a c u u m
v a c u u m p u m p h a s no leak. pump.
ECM CONNECTORS
3 3 . C h e c k the v o l t a g e for 20 s e c o n d s .
Does
least 20
the voltage
seconds?
drop to 1.5 V and hold for at 1 2 3 4
/ 6
/ / 9 10
12 13
/ / 15
/
17 18 19 20 21 24
Y E S — I n s p e c t the E V A P canister vent shut v a l v e

25 26 27
/
28 29 30
PTANK (LTGRN)
32
line a n d c o n n e c t i o n s . •
1 2
/ 4 5
/
11 12 13 14 15 16 17 18 19 20 21 22
8 9 10
3 5 . D i s c o n n e c t t h e q u i c k - c o n n e c t fitting (A) f r o m t h e / 24 25 26 27 23 29 30
SG2 (GRN/YEL)
/
E V A P c a n i s t e r , a n d plug t h e c a n i s t e r port (B). W i r e s i d e of f e m a l e t e r m i n a l s
3 8 . C o n t i n u e to p u m p v a c u u m until t h e v o l t a g e d r o p s
to a b o u t 1.5 V . M a k e s u r e the e n g i n e c o o l a n t
t e m p e r a t u r e is still a b o v e 9 5 °F (35 *€) a n d y o u r
v a c u u m p u m p / g a u g e h a s n o leak.
11-192
3 9 . Monitor the v o l t a g e c o n t i n u o u s l y for 20 s e c o n d s .
Does the voltage drop to 1.5 V and hold for at

least 20 seconds?
Y E S — I n s p e c t the fuel tank v a p o r control line a n d

connections. •
41. D i s c o n n e c t t h e p u r g e line h o s e (A) f r o m the

c a n i s t e r at the m e t a l line, a n d plug t h e h o s e (B).
43. W h i l e m o n i t o r i n g F T P s e n s o r v o l t a g e w i t h t h e H D S ,
or m e a s u r i n g v o l t a g e b e t w e e n E C M c o n n e c t o r
pump/gauge.
44. C o n t i n u e to p u m p v a c u u m until the v o l t a g e d r o p s

to a b o u t 1.5 V . M a k e s u r e that the e n g i n e c o o l a n t
t e m p e r a t u r e is still a b o v e 9 5 °F (35 *€) a n d y o u r
v a c u u m p u m p / g a u g e h a s n o leak.
4 5 . C h e c k the v o l t a g e for 20 s e c o n d s .
Does the voltage drop to 1.5 V and hold at least

20 seconds?
Y E S — I n s p e c t t h e E V A P c a n i s t e r p u r g e v a l v e line
a n d c o n n e c t i o n s . If t h e y a r e O K , t e s t the E V A P t w o
w a y v a l v e ( s e e p a g e 11-194), a n d the fuel tank
v a p o r control v a l v e ( s e e p a g e 1 1 - 1 9 5 ) . B
N O — R e p l a c e the E V A P canister. •
11-193
EVAP System
EVAP Two Way Valve Test

Special Tools Required M o v e the v a c u u m p u m p h o s e f r o m t h e v a c u u m
• V a c u u m / p r e s s u r e g a u g e , 0 — 4 in.Hg 0 7 J A Z - 0 0 1 0 0 0 B fitting to the p r e s s u r e fitting, a n d m o v e the v a c u u m
• V a c u u m p u m p / g a u g e , 0—30 in.Hg, S n a p - o n Y A 4 0 0 0 A g a u g e h o s e f r o m the v a c u u m s i d e to the p r e s s u r e
or equivalent, commercially available s i d e (A) a s s h o w n .
2. D i s c o n n e c t t h e v a p o r line f r o m the E V A P t w o w a y 07JAZ-001000B
v a l v e (A). C o n n e c t it to a T-fitting (B) f r o m the

v a c u u m gauge and a commercially available
v a c u u m p u m p / g a u g e , 0—30 in.Hg, a s s h o w n .
07JAZ-001000B
S l o w l y p r e s s u r i z e the v a p o r line w h i l e w a t c h i n g the

g a u g e . T h e p r e s s u r e s h o u l d stabilize m o m e n t a r i l y
a b o v e 1.0 kPa (0.3 in.Hg, 8 m m H g ) .
• If t h e p r e s s u r e m o m e n t a r i l y s t a b i l i z e s ( v a l v e
o p e n s ) a b o v e 1.0 kPa (0.3 i n . H g , 8 m m H g ) , t h e
valve is O K .
Apply v a c u u m slowly and continuously while • If the p r e s s u r e s t a b i l i z e s b e l o w 1.0 kPa (0.3 i n . H g ,
watching the gauge. 8 m m H g ) , install a n e w v a l v e a n d retest.
T h e v a c u u m s h o u l d stabilize m o m e n t a r i l y at
0 . 8 - 2 . 1 kPa ( 0 . 2 - 0 . 6 in.Hg, 6 - 1 6 mmHg).
If t h e v a c u u m s t a b i l i z e s ( v a l v e o p e n s ) b e l o w 0.8 k P a
(0.2 i n . H g , 6 m m H g ) or a b o v e 2.1 k P a (0.6 i n . H g ,
16 m m H g ) , install a n e w v a l v e a n d retest.
11-194
Fuel Tank Vapor Control Valve Test
Special Tools Required Valve Test
V a c u u m pump/gauge, 0—30 in.Hg, S n a p - o n Y A 4 0 0 0 A
or e q u i v a l e n t , c o m m e r c i a l l y a v a i l a b l e 1. M a k e s u r e t h e fuel tank is l e s s t h a n half full.
Float Test 2. R e m o v e t h e fuel fill c a p .
1. M a k e s u r e the fuel tank is l e s s t h a n half full. 3. R e m o v e t h e fuel pipe c o v e r . D i s c o n n e c t t h e f u e l

tank v a p o r s i g n a l t u b e (A).
2. R e m o v e t h e fuel fill c a p to r e l i e v e the fuel tank
A
p r e s s u r e , t h e n reinstall t h e c a p .
3. R e m o v e the fuel pipe c o v e r . D i s c o n n e c t t h e fuel

tank v a p o r recirculation t u b e (A), a n d c o n n e c t a
0 — 3 0 i n . H g , to the h o s e .
4. D i s c o n n e c t t h e v a c u u m h o s e s (A) f r o m t h e E V A P
c a n i s t e r ( B ) , a n d t h e n p l u g t h e ports w i t h p l u g s (C).
4. Plug the fuel tank v a p o r r e c i r c u l a t i o n pipe (B).
5. A p p l y v a c u u m to the fuel tank v a p o r recirculation

t u b e (A).
• If t h e v a c u u m h o l d s , r e p l a c e the fuel tank v a p o r

control v a l v e ( s e e p a g e 11-196).
• If the v a c u u m d o e s not h o l d , the float is O K . G o
to s t e p 1 of t h e v a l v e test.
E B A C
5. D i s c o n n e c t t h e v a c u u m h o s e (D) f r o m the E V A P
canister vent shut valve (E), and connect a
0 — 3 0 i n . H g , to t h e E V A P c a n i s t e r v e n t s h u t v a l v e .
6. P u m p t h e v a c u u m p u m p 8 0 t i m e s .
• If the v a c u u m h o l d s , g o to s t e p 7.
• If the v a c u u m d o e s not h o l d , g o to s t e p 9.
(cont'd)
11-195
EVAP System
Fuel Tank Vapor Control Valve Test Fuel Tank Vapor Control Valve
(cont'd) Replacement
7. C o n n e c t a s e c o n d v a c u u m p u m p / g a u g e to t h e fuel 1. R e m o v e t h e fuel tank ( s e e p a g e 11 -156).

tank v a p o r s i g n a l t u b e (A).
2. R e m o v e t h e fuel tank v a p o r control v a l v e (A) f r o m
A
t h e fuel tank (B).
8. A p p l y v a c u u m (1 p u m p ) to t h e fuel tank v a p o r
s i g n a l t u b e (A), t h e n c h e c k t h e v a c u u m o n t h e
p u m p in s t e p 6.
• If t h e v a c u u m h o l d s , r e p l a c e t h e f u e l t a n k v a p o r
control v a l v e ( s e e p a g e 11-196). 3. R e p l a c e t h e b a s e g a s k e t (C).
• If t h e v a c u u m is r e l e a s e d , the fuel tank v a p o r
control v a l v e i s O K . 4. Install the fuel tank v a p o r control v a l v e .
9. D i s c o n n e c t t h e f u e l t a n k v a p o r q u i c k d i s c o n n e c t 5. Install t h e fuel tank.

f r o m the E V A P c a n i s t e r , t h e n plug t h e port o n t h e
c a n i s t e r . R e a p p l y v a c u u m (80 p u m p s ) .
• If t h e v a c u u m h o l d s , r e p l a c e the fuel tank v a p o r

control v a l v e ( s e e p a g e 11-196).
• If t h e v a c u u m d o e s not h o l d , i n s p e c t t h e E V A P
c a n i s t e r v e n t s h u t v a l v e O - r i n g . If t h e O-ririg is O K ,
r e p l a c e t h e E V A P c a n i s t e r a n d r e p e a t s t e p 4.
11-196
Pulsed Secondary Air Injection System
AIR P U M P R E L A Y
T e s t , p a g e 11-209
11-197
DTC Troubleshooting
DTC P0410: Air Pump Circuit Malfunction 8. R e m o v e t h e left-front i n n e r f e n d e r ( s e e p a g e

20-126).
a n d review the general troubleshooting information 9. D i s c o n n e c t t h e air p u m p e l e c t r i c a l c u r r e n t s e n s o r
( s e e p a g e 11-3). 2P connector.
1. R e s e t t h e E C M ( s e e p a g e 11-4). 10. T u r n t h e ignition s w i t c h O N (II).
2. M a k e s u r e t h e e n g i n e c o o l a n t t e m p e r a t u r e is o v e r 11. A t t h e left e n g i n e c o m p a r t m e n t w i r e h a r n e s s s i d e ,
3 2 °F (0 °C) a n d b e l o w 158 T (60 °C) w i t h a s c a n m e a s u r e v o l t a g e b e t w e e n air p u m p electrical
tool or t h e H D S . current s e n s o r 2P connector terminal No. 1 and
body ground.
3. S t a r t t h e e n g i n e . D u r i n g air p u m p o p e r a t i o n , h o l d
AIR P U M P E L E C T R I C A L C U R R E N T S E N S O R
t h e e n g i n e at idle s p e e d w i t h o u t l o a d (in neutral) for 2P C O N N E C T O R
at l e a s t 10 s e c o n d s .
IG
4. C h e c k for a T e m p o r a r y D T C w i t h a s c a n tool o r t h e (WHT)
HDS.
Is Temporary DTC P0410 Indicated?
at t h e air c o n t r o l v a l v e v a c u u m c o n t r o l s o l e n o i d W i r e s i d e of f e m a l e t e r m i n a l s
v a l v e a n d at t h e E C M . H
5. C h e c k the air p u m p .
Does the air pump operate?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e air p u m p
Y E S — G o to s t e p 3 5 . electrical current s e n s o r a n d the No. 32 AIR P U M P
(60 A ) f u s e in the a u x i l i a r y u n d e r - h o o d f u s e b o x . H
7. C h e c k t h e No. 32 A I R P U M P (60 A ) f u s e in the

auxiliary under-hood fuse box.
Is the fuse OK?
N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e N o . 3 2
A I R P U M P (60 A ) f u s e a n d t h e a i r p u m p . T h e n
r e p l a c e t h e N o . 32 A I R P U M P (60 A ) f u s e . B
11-198
13. A t the air p u m p electrical c u r r e n t s e n s o r s i d e , c h e c k 18. T u r n the ignition s w i t c h O F F .
for continuity b e t w e e n air p u m p e l e c t r i c a l c u r r e n t
s e n s o r 2 P c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 2. 19. D o t h e air p u m p r e l a y t e s t ( s e e p a g e 11-209).
Is the air pump relay OK?
Y E S — G o to s t e p 2 0 .
N O — R e p l a c e the a i r p u m p r e l a y ( s e e p a g e 11-208).
•
2 1 . C o n n e c t large air p u m p r e l a y 2 P c o n n e c t o r
(WHT) ^ (WHT/RED)
terminals No. 1 a n d No. 2 with a j u m p e r wire.
T e r m i n a l side of m a l e t e r m i n a l s L A R G E AIR P U M P R E L A Y 2P C O N N E C T O R
1 2
N O — R e p l a c e t h e air p u m p e l e c t r i c a l c u r r e n t s e n s o r
( s e e p a g e 11-209). • (WHT/RED) (WHT/GRN)
JUMPER WIRE
14. R e c o n n e c t the air p u m p e l e c t r i c a l c u r r e n t s e n s o r 2 P
connector.
15. D i s c o n n e c t the large air p u m p r e l a y 2 P c o n n e c t o r .
16. T u r n the ignition s w i t c h O N (II). Does the air pump operate when the jumper wire is
connected?
17. M e a s u r e v o l t a g e b e t w e e n large air p u m p r e l a y 2 P
c o n n e c t o r t e r m i n a l No. 1 a n d b o d y g r o u n d . Y E S — G o to s t e p 2 2 .
L A R G E AIR P U M P R E L A Y 2P C O N N E C T O R
N O — G o to s t e p 3 0 .
(WHT/RED)
2 3 . D i s c o n n e c t t h e j u m p e r w i r e f r o m the large air
p u m p relay 2P connector.
24. D i s c o n n e c t the s m a l l air p u m p r e l a y 2 P c o n n e c t o r .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the air p u m p
electrical c u r r e n t s e n s o r a n d t h e air p u m p relay. •
(cont'd)
11-199
25. C h e c k for c o n t i n u i t y b e t w e e n s m a l l air p u m p r e l a y 28. C o n n e c t s m a l l air p u m p relay 2P connector

2P connector terminal No. 2 a n d body ground. t e r m i n a l N o . 1 to b o d y g r o u n d w i t h a j u m p e r w i r e .
S M A L L AIR P U M P R E L A Y 2P C O N N E C T O R S M A L L AIR P U M P R E L A Y 2P C O N N E C T O R
GND APR
(BLK) (BLU)
JUMPER WIRE
Is there continuity? 29. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

Y E S — G o to s t e p 2 6 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e air p u m p
relay a n d body g r o u n d . !
1 2 3
/ / /
4 6 9 10
2 6 . D i s c o n n e c t E C M c o n n e c t o r A (32P). 12 13
/ / 15
/ 17 18 19 20 21 24
2 7 . C h e c k for t h e c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
terminal A 2 8 and body ground.
/
25 26 27 28 29 30
APR (BLU)
32
1 2 3 4 6
/ / 9 10 W i r e s i d e of f e m a l e t e r m i n a l s
12 13
/ 15
25 26 27
17 18 19 20 21
28 29 30 32
24
APR (BLU)
W i r e s i d e of f e m a l e t e r m i n a l s N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e air p u m p
relay a n d the E C M ( A 2 8 ) . B
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e air
p u m p relay a n d the E C M ( A 2 8 ) . B 31. D i s c o n n e c t t h e j u m p e r w i r e f r o m t h e large air
p u m p relay 2P connector.
N O — G o to s t e p 2 8 .
32. D i s c o n n e c t t h e air p u m p 2 P c o n n e c t o r .
11-200
33. C h e c k for c o n t i n u i t y b e t w e e n large air p u m p r e l a y 3 5 . T u r n t h e ignition s w i t c h O F F .
2P c o n n e c t o r t e r m i n a l No. 2 a n d air p u m p 2 P
c o n n e c t o r t e r m i n a l N o . 1. 3 6 . D o t h e air p u m p r e l a y t e s t ( s e e p a g e 11-209).
L A R G E AIR P U M P R E L A Y 2P C O N N E C T O R
Is the air pump relay OK?
Y E S — G o to s t e p 3 7 .
W i r e s i d e of I (WHT/GRN) N O — R e p l a c e t h e a i r p u m p r e l a y ( s e e p a g e 11-208).
female terminals /Q\
•
' AIR P U M P 3 7 . D i s c o n n e c t E C M c o n n e c t o r A (32P).

(WHT/GRN) 2P C O N N E C T O R
1
39. Measure voltage between E C M connector terminal

W i r e s i d e of f e m a l e t e r m i n a l s A28 and body ground.
Is there continuity? E C M C O N N E C T O R A (32P)
Y E S — G o to s t e p 3 4 .
1 2 3
/ / /
4 6 9 10
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e air p u m p 12 13
/ / 15
/ 17 18 19 20 21 24
r e l a y a n d t h e air p u m p . •
3 4 . C h e c k for c o n t i n u i t y b e t w e e n air p u m p 2 P
25 26 27
/ 28 29 30
APR (BLU)
32
AIR P U M P 2P C O N N E C T O R
GND
(BLK)
Is there voltage?
Y E S — R e p a i r s h o r t to p o w e r in t h e w i r e b e t w e e n
t h e air p u m p r e l a y a n d the E C M ( A 2 8 ) . B
Y E S — R e p l a c e t h e air p u m p ( s e e p a g e 11-208). •
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e a i r p u m p
and body ground. •
11-201
DTC P0411: Secondary Air Injection System 9. D i s c o n n e c t t h e v a c u u m h o s e f r o m t h e air control

Incorrect Flow v a l v e (A), a n d c o n n e c t a c o m m e r c i a l l y a v a i l a b l e
v a c u u m p u m p / g a u g e , 0 — 3 0 in.Hg, to the h o s e .
( s e e p a g e 11-3).
2. M a k e s u r e t h e e n g i n e c o o l a n t t e m p e r a t u r e is o v e r
3 2 °F (0 °C) a n d b e l o w 158 °F (60 °C) w i t h a s c a n
tool or t h e H D S .
3. S t a r t the e n g i n e . W h i l e t h e air p u m p o p e r a t e s , let 10. S t a r t the e n g i n e . W h i l e the air p u m p o p e r a t e s , let

t h e e n g i n e idle w i t h o u t l o a d (in neutral) for at l e a s t t h e e n g i n e idle w i t h o u t l o a d (in neutral).
10 s e c o n d s .
Is there vacuum while the air pump operates?
4. C h e c k for a T e m p o r a r y D T C w i t h a s c a n tool o r the
HDS. Y E S — G o to s t e p 11.
Is Temporary DTC P0411 Indicated? N O — G o to s t e p 16.
Y E S — G o to s t e p 5. 11. T u r n the ignition s w i t c h O F F .
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 12. D i s c o n n e c t t h e air control v a l v e v a c u u m control

t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s solenoid valve 2P connector.
at t h e air c o n t r o l v a l v e v a c u u m control s o l e n o i d
v a l v e a n d at the E C M . • 13. C h e c k for continuity b e t w e e n air control v a l v e
v a c u u m control s o l e n o i d v a l v e 2 P c o n n e c t o r
5. T u r n t h e ignition s w i t c h O F F . terminal No. 2 and body ground.
AIR C O N T R O L V A L V E V A C U U M C O N T R O L
6. C h e c k t h e v a c u u m l i n e s of t h e air p u m p s y s t e m for S O L E N O I D V A L V E 2P C O N N E C T O R
Are the vacuum lines OK?
necessary. •
Wire s i d e of female terminals
8. M a k e s u r e t h e e n g i n e c o o l a n t t e m p e r a t u r e i s o v e r
3 2 °F (0 °C) a n d b e l o w 158 °F (60 °C) w i t h a s c a n Is there continuity?
N O — R e p l a c e the air control v a l v e v a c u u m control

solenoid valve. •
11-202
14. D i s c o n n e c t E C M c o n n e c t o r A (32P). 18. D i s c o n n e c t t h e air control v a l v e v a c u u m c o n t r o l
solenoid valve 2P connector.
15. C h e c k for continuity b e t w e e n air control v a l v e
v a c u u m control s o l e n o i d v a l v e 2 P c o n n e c t o r 19. T u r n the ignition s w i t c h O N (II).
2 0 . M e a s u r e v o l t a g e b e t w e e n air control v a l v e v a c u u m
control s o l e n o i d v a l v e 2 P c o n n e c t o r t e r m i n a l No. 1
S O L E N O I D V A L V E 2P C O N N E C T O R
and body ground.
S O L E N O I D V A L V E 2P C O N N E C T O R
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the air

control v a l v e v a c u u m control s o l e n o i d v a l v e a n d Is there battery voltage?
theECM(A2).«
t h e n r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s a w a y , N O — R e p a i r o p e n in t h e w i r e b e t w e e n the N o . 6
r e p l a c e the original E C M ( s e e p a g e 11-115). • A C G (15 A ) f u s e in the u n d e r - d a s h f u s e / r e l a y b o x
a n d the air control s o l e n o i d v a l v e . •
17. C h e c k t h e No. 6 A C G (15 A ) f u s e in t h e u n d e r - d a s h
f u s e / r e l a y box. 2 2 . R e c o n n e c t t h e air control v a l v e v a c u u m control
solenoid valve 2P connector.
Is the fuse OK?
N O — R e p a i r s h o r t in the w i r e b e t w e e n t h e N o . 6
A C G (15 A ) f u s e a n d t h e g a u g e a s s e m b l y . T h e n
r e p l a c e the No. 6 A C G (15 A ) f u s e . •
(cont'd)
11-203

24. T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e DTC P1410: Air Pump Malfunction
voltage between E C M connector terminal A 2 and ('00-03 models)
body ground.
DTC P2445: Air Pump Malfunction
('04-05 models)
NOTE:
1 2 3 4
/ / / 6 9 JO r e v i e w t h e g e n e r a l t r o u b l e s h o o t i n g information
( s e e p a g e 11-3).
12 13
/ / 15 17 18 19 20 21 24
25 26 27 28 29 30
/ 32
to'00-03 models.
to ' 0 4 - 0 5 m o d e l s .
W i r e s i d e of f e m a l e t e r m i n a l s 1. R e s e t t h e E C M ( s e e p a g e 11-4).
2. M a k e s u r e t h e e n g i n e c o o l a n t t e m p e r a t u r e is o v e r
Is there less than 1.0 V? 3 2 °F (0 °C) a n d b e l o w 158 °F (60 °C) w i t h a s c a n
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e air
control v a l v e v a c u u m c o n t r o l s o l e n o i d v a l v e a n d 3. S t a r t t h e e n g i n e . W h i l e t h e air p u m p o p e r a t e s , let
t h e E C M (A2). If t h e w i r e is O K , r e p l a c e t h e air the e n g i n e idle w i t h o u t l o a d (in neutral) for at l e a s t
control v a l v e v a c u u m c o n t r o l s o l e n o i d v a l v e . • 10 s e c o n d s .
N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5), 4. C h e c k for a T e m p o r a r y D T C w i t h a s c a n tool or t h e

t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y , HDS.
replace the original E C M (see page 11-115).B
Is Temporary DTC P1410* (P2445)** indicated?
Y E S — R e p l a c e t h e air p u m p . •
at t h e air p u m p a n d t h e air p u m p relay. •
11-204
DTC P1415: Air Pump Electrical Current 8. T u r n the ignition s w i t c h O F F .
Sensor Circuit Low Voltage
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g information 10. C h e c k for continuity b e t w e e n air p u m p electrical
( s e e p a g e 11-3). current s e n s o r 3P connector terminal No. 3 and
body ground.
2. t u r n the ignition s w i t c h O N (II).
3. C h e c k for a D T C w i t h a s c a n tool or the H D S .

ECS
Is DTC P1415 Indicated? (WHT/BLK)
NO—Intermittent f a i l u r e , t h e s y s t e m is O K at t h i s
at the a i r p u m p electrical c u r r e n t s e n s o r a n d the
ECM.B W i r e s i d e of f e m a l e terminals
4. T u r n the ignition s w i t c h O F F . Is there continuity ?
5. D i s c o n n e c t the air p u m p electrical c u r r e n t s e n s o r Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e air

3P connector. p u m p electrical current s e n s o r and the E C M
(C24).B
7. M e a s u r e v o l t a g e b e t w e e n air p u m p electrical
c u r r e n t s e n s o r 3 P c o n n e c t o r t e r m i n a l s No. 1 a n d 11. C o n n e c t air p u m p electrical c u r r e n t s e n s o r 3 P
N o . 2. c o n n e c t o r t e r m i n a l s N o . 2 a n d No. 3 w i t h a j u m p e r
wire.
VCC2 W SG2 SG2 ECS

(GRN) (WHT/BLK)
(YEL/BLU) (GRN)
JUMPER WIRE
Is there about 5 V?
(cont'd)
11-205
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 16. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M

terminals C24 and C18. connector terminal C24.
1 2
/ 4 5
/ 8 9 10
1
11
2
12
/
13
4
14 15 16
5
/17
7
18 19
8
20
9
21
10
22
/ /
11 12 13 14 15 16 17 18 19 20 21 22
/ 24 25 26 27 23 29 30
/ 24 25
ECS
26 27 28 29 30
ECS (WHT/BLK)
SG2
(WHT/BLK) (GRN/YEL)
Is there continuity? Is there about 0.5 V?
Y E S — G o to s t e p 13. Y E S — S u b s t i t u t e a known-good E C M (see page

N O — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M a w a y , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-115).
(C24) a n d the air p u m p e l e c t r i c a l c u r r e n t s e n s o r . •
13. D i s c o n n e c t the j u m p e r w i r e f r o m t h e a i r p u m p N O — R e p l a c e t h e air p u m p electrical c u r r e n t s e n s o r

electrical current s e n s o r 3 P connector. (see page 11-209).B
14. R e c o n n e c t E C M c o n n e c t o r C (31P) a n d t h e air p u m p 17. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r

electrical current s e n s o r 3 P connector. terminals C18 and C28.
SG2
(GRN/YEL)
11
2
12
/13
4
14 15
5
16
/ 17 18 19
8
20 21
9 10
22
/ 24 25 26 27 28 29 30
/
VCC2
(YEL/BLU)
Is there about 5 V?
(C28) a n d t h e air p u m p e l e c t r i c a l c u r r e n t s e n s o r . •
t h e n r e c h e c k . If v o l t a g e is n o r m a l , r e p l a c e t h e
original E C M ( s e e p a g e 11-115). •
11-206
DTC P1416: Air Pump Electrical Current 8. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r
Sensor Circuit High Voltage terminals C I 8 and C28.
a n d r e v i e w the g e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n SG2
( s e e p a g e 11-3). (GRN/YEL)
1
11
2
12
/13
4
14 15
5
16
/17 18 19
8
20 21
9 10
22
3. C h e c k for a D T C w i t h a s c a n tool or t h e H D S .
/ 24 25 26 27 28 29 30
/
VCC2
(YEL/BLU)
Is DTC P1416 Indicated?
Y E S — G o to s t e p 4. W i r e s i d e of f e m a l e t e r m i n a l s
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Is there about 5 V?
at t h e air p u m p e l e c t r i c a l c u r r e n t s e n s o r a n d at t h e Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
ECM.B (C18) a n d t h e air p u m p e l e c t r i c a l c u r r e n t s e n s o r . •
4. T u r n the ignition s w i t c h O F F . N O — S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-5),

t h e n r e c h e c k . If v o l t a g e i s n o r m a l , r e p l a c e t h e
5. D i s c o n n e c t the air p u m p e l e c t r i c a l c u r r e n t s e n s o r original E C M ( s e e p a g e 11-115). B
3P connector.
7. M e a s u r e v o l t a g e b e t w e e n air p u m p e l e c t r i c a l
c u r r e n t s e n s o r 3 P c o n n e c t o r t e r m i n a l s No. 1 a n d
N o . 2.
VCC2 SG2
(YEL/BLU) (GRN)
Is there about 5 V?
Y E S — R e p l a c e t h e air p u m p e l e c t r i c a l c u r r e n t
s e n s o r (see page 11-209).fl
11-207
Air Pump/Air Pump Relay Removal/Installation
1. R e m o v e the front b u m p e r ; ' 0 0 - 0 3 m o d e l s ( s e e p a g e 2 0 - 1 0 4 ) , ' 0 4 - 0 5 m o d e l s ( s e e p a g e 20-105).
2. R e m o v e t h e air p u m p (A), a n d t h e air p u m p r e l a y (B).
(Small)
11-208
Air Pump Relay Test Air Pump Electrical Current Sensor
Removal/Installation
C h e c k for continuity b e t w e e n the t e r m i n a l s a c c o r d i n g to
the table.
1. Pull a w a y the left i n n e r f e n d e r a s n e c e s s a r y
• T h e r e s h o u l d be continuity b e t w e e n the A1 a n d A 2 ( s e e p a g e 20-126).
t e r m i n a l s of t h e large air p u m p r e l a y 2 P c o n n e c t o r
w h e n p o w e r a n d g r o u n d are c o n n e c t e d to the B1 a n d 2 . D i s c o n n e c t the air p u m p electrical c u r r e n t s e n s o r
B 2 t e r m i n a l s of the s m a l l air p u m p r e l a y 2 P c o n n e c t o r . 2 P c o n n e c t o r (A), a n d r e m o v e t h e l o w e r c o v e r ( B ) ,
• T h e r e s h o u l d be n o continuity b e t w e e n the A1 a n d A 2 t h e n d i s c o n n e c t t h e air p u m p e l e c t r i c a l c u r r e n t
t e r m i n a l s w h e n p o w e r is d i s c o n n e c t e d f r o m the s m a l l s e n s o r 3 P c o n n e c t o r (C).
air p u m p 2 P c o n n e c t o r .
\ Terminal
A1 A2
P o w e r (B1) \
Connected
O — — O
Disconnected
AIR P U M P AIR P U M P R E L A Y
RELAY 2P C O N N E C T O R
(Large)
A B
3. R e m o v e the air p u m p e l e c t r i c a l c u r r e n t s e n s o r (D).
male terminals 4. Install the parts in the r e v e r s e o r d e r of r e m o v a l .
AIR P U M P R E L A Y
(Small)
male terminals
11-209
'06-08 Models
Fuel and Emissions Systems Fuel Supply System
SpecialTools . 11-212 C o m p o n e n t Location Index 11-463
General Troubleshooting Information 11-213 D T C Troubleshooting 11-464
D T C Troubleshooting Index .. 11-219 Fuel P u m p Circuit Troubleshooting 11-470
S y m p t o m Troubleshooting Index 11-222 Fuel P r e s s u r e Relieving 11-474
S y s t e m Description 11-224 Fuel Pressure T e s t .11-477
How to S e t R e a d i n e s s C o d e s 11-256 Fuel T a n k Draining 11-477
Fuel Line Inspection 11-478
PGM-FI System Fuel Line/Quick-Connect Fitting
C o m p o n e n t Location Index 11-259 Precautions - 11-480
D T C Troubleshooting 11-261 Fuel Line/Quick-Connect Fitting
F-CAN Circuit Troubleshooting 11-360 Removal • 11-481
MIL Circuit Troubleshooting 11-366 Fuel Line/Quick-Connect Fitting
D L C Circuit Troubleshooting 11-367 Installation 11-483
Injector Replacement 11-382 Fuel Pulsation D a m p e r Replacement 11-485
M A P S e n s o r Replacement 11-384 Fuel Pressure Regulator Replacement 11-486
IAT S e n s o r Replacement 11-384 Fuel Filter Replacement ... 11-486
E C T S e n s o r 1 Replacement 11-385 Fuel T a n k Unit R e m o v a l and Installation 11-487
E C T S e n s o r 2 Replacement 11-385 Fuel Pump/Fuel G a u g e Sending Unit
A / F S e n s o r Replacement 11-386 Replacement 11-488
S e c o n d a r y H 0 2 S Replacement 11-386 Fuel T a n k Replacement 11-489
C M P S e n s o r Replacement 11-387 Fuel G a u g e S e n d i n g Unit T e s t 11-494
C K P S e n s o r Replacement 11-387 L o w Fuel Indicator T e s t 11-496
Output Shaft (Countershaft) S p e e d S e n s o r
Replacement 11-388 Intake Air System
Knock S e n s o r Replacement 11-388 C o m p o n e n t Location Index 11-497
E C M Replacement 11-389 Throttle Body T e s t 11-498
Throttle Body Cleaning 11-499
Electronic Throttle Control System Throttle Body Removal/Installation 11-500
Component Location Index 11-391 Throttle Body D i s a s s e m b l y / R e a s s e m b l y 11-501
D T C Troubleshooting 11-392 Accelerator Pedal Replacement 11-502
A P P S e n s o r Signal inspection 11-436 Throttle Cable Removal/Installation 11-503
A P P S e n s o r Replacement 11-437 Throttle Cable Adjustment 11-504
Throttle Actuator Control Module A i r Cleaner Removal/Installation 11-504
Replacement 11-437 Air Cleaner Element
Inspection/Replacement 11-505
VTEC
Component Location Index 11-438 Catalytic Converter System
D T C Troubleshooting 11-439 C o m p o n e n t Location Index 11-506
Rocker A r m Oil Control Valve D T C Troubleshooting 11-507
( V T E C Solenoid Valve)
Removal/Installation 11-449 PCV System
Rocker A r m Oil Pressure Switch C o m p o n e n t Location Index 11-509
( V T E C Oil Pressure Switch) D T C Troubleshooting 11-510
Removal/Installation 11-449 P C V Valve Inspection 11-511
P C V Valve Replacement 11-511
Idle Control System
Component Location Index 11-450 EVAP System
D T C Troubleshooting 11-451 C o m p o n e n t Location Index 11-512
A / C Signal Circuit Troubleshooting 11-455 D T C Troubleshooting 11-514
Alternator FR Signal Circuit F T P S e n s o r Replacement 11-542
Troubleshooting 11-456 E V A P Canister Purge Valve Replacement .... 11-542
Electrical Power Steering (EPS) Signal Circuit E V A P Canister Vent Shut Valve
Troubleshooting 11-458 Replacement 11-543
Brake Pedal Position Switch Signal Circuit E V A P Canister Replacement 11-544
Troubleshooting 11-460 Fuel Tank Vapor Control Float
Idle S p e e d Inspection 11-461 Replacement • 11-545
E C M Idle Learn Procedure 11-462
Special Tools
Ref. No. Tool Number Description Qty

® 07AAJ-S6MA150 Fuel Pressure Gauge Attachment Set 1
® 07JAZ-001000B V a c u u m / P r e s s u r e G a u g e , 0 — 4 in.Hg 1
® 07SAZ-001000A Backprobe Set
® 07NAJ-P07010A Pressure Gauge Adapter 1
®-1 07406-0020201 A / T Pressure Hose 1
®-2 07406-0070301 A / T L o w Pressure Gauge W/Panel 1
®-3 07MAJ-PY4011A A / T P r e s s u r e H o s e , 2,210 m m 1
®-4 07MAJ-PY40120 A / T Pressure Hose, Adapter 1
® 07406-004000B Fuel Pressure G a u g e 1
© ©-1,®-2,©-3,©-4 ©
11-212
Intermittent Failures 2. If t h e M I L s t a y s o n , c o n n e c t t h e H D S to t h e d a t a link

c o n n e c t o r ( D L C ) (A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e
T h e t e r m "intermittent f a i l u r e " m e a n s a s y s t e m m a y of t h e front c o n s o l e .
h a v e h a d a f a i l u r e , but it c h e c k s O K n o w . If t h e
m a l f u n c t i o n indicator l a m p (MIL) o n t h e d a s h d o e s not
c o m e o n , c h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
at all c o n n e c t o r s related to t h e circuit that y o u a r e
t r o u b l e s h o o t i n g . If t h e M I L w a s o n , but t h e n w e n t out,
t h e original p r o b l e m m a y h a v e b e e n intermittent.
Service Information
P e r i o d i c a l l y , n e w E C M s o f t w a r e or n e w s e r v i c e
procedures m a y become available. A l w a y s check
online for t h e latest s o f t w a r e or s e r v i c e i n f o r m a t i o n
related to t h e D T C s o r s y m p t o m s y o u a r e
troubleshooting.
Opens and Shorts 3. T u r n t h e ignition s w i t c h O N (II).
" O p e n " a n d " s h o r t " a r e c o m m o n electrical t e r m s . A n 4. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M

o p e n is a b r e a k in a w i r e or at a c o n n e c t i o n . A s h o r t is a n d o t h e r v e h i c l e s y s t e m s . If it d o e s n ' t g o to t h e
a n a c c i d e n t a l c o n n e c t i o n of a w i r e to g r o u n d or to D L C circuit t r o u b l e s h o o t i n g ( s e e p a g e 11-367).
a n o t h e r w i r e . In s i m p l e e l e c t r o n i c s , t h i s u s u a l l y m e a n s
s o m e t h i n g w o n ' t w o r k at a l l . W i t h c o m p l e x e l e c t r o n i c s 5. C h e c k t h e d i a g n o s t i c t r o u b l e c o d e ( D T C ) a n d note it.
(such a s E C M s ) this c a n s o m e t i m e s m e a n s o m e t h i n g A l s o c h e c k the freeze data a n d on-board s n a p s h o t
w o r k s , but not t h e w a y it's s u p p o s e d to. d a t a , a n d d o w n l o a d a n y d a t a f o u n d . T h e n refer to
t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g , a n d b e g i n the
How to Use the HDS (Honda Diagnostic appropriate troubleshooting procedure.
System)
NOTE:
If t h e M I L ( m a l f u n c t i o n i n d i c a t o r l a m p ) h a s c o m e o n • Freeze data indicates the engine conditions w h e n
t h e first m a l f u n c t i o n , m i s f i r e , or f u e l t r i m
1. S t a r t t h e e n g i n e , a n d c h e c k the M I L (A). malfunction w a s detected.
• T h e H D S c a n read the D T C , freeze data, current
N O T E : If t h e ignition s w i t c h is t u r n e d O N (II), a n d d a t a , a n d o t h e r e n g i n e control m o d u l e ( E C M )
t h e e n g i n e is not s t a r t e d , t h e M I L will s t a y o n for data.
1 5 — 2 0 s e c o n d s ( s e e p a g e 11-256). • F o r s p e c i f i c o p e r a t i o n s , refer to t h e u s e r ' s
m a n u a l that c a m e w i t h the H D S .
6. If n o D T C s a r e f o u n d , g o to M I L t r o u b l e s h o o t i n g
( s e e p a g e 11-366).
If t h e M I L d i d n o t s t a y o n
If the M I L d i d not s t a y o n but t h e r e is a driveability
problem, do the s y m p t o m troubleshooting.
If y o u c a n ' t d u p l i c a t e t h e D T C
S o m e of t h e t r o u b l e s h o o t i n g r e q u i r e s y o u to r e s e t the
E C M a n d try to d u p l i c a t e t h e D T C . If t h e p r o b l e m is
intermittent a n d y o u c a n ' t d u p l i c a t e t h e c o d e , d o not
continue through the procedure. T o do s o will only
result in c o n f u s i o n a n d p o s s i b l y , a n e e d l e s s l y r e p l a c e d
ECM.
(cont'd)
11-213
HDS Clear Command ECM Reset
T h e E C M s t o r e s v a r i o u s s p e c i f i c data to c o r r e c t t h e 1. R e s e t t h e E C M w i t h the H D S w h i l e t h e e n g i n e is
s y s t e m e v e n if t h e r e is n o e l e c t r i c a l p o w e r s u c h a s stopped.
w h e n t h e battery n e g a t i v e t e r m i n a l or N o . 46 A C G S
(15 A ) f u s e a r e d i s c o n n e c t e d . S t o r e d d a t a b a s e d o n 2. T u r n t h e ignition s w i t c h O F F .
failed parts s h o u l d b e c l e a r e d by u s i n g t h e " C L E A R
C O M M A N D " of t h e H D S if parts a r e r e p l a c e d .
f 3. T u r n t h e ignition s w i t c h O N (II), a n d w a i t
30 s e c o n d s .
T h e H D S h a s t h r e e k i n d s of c l e a r c o m m a n d s to m e e t
this purpose. T h e y are D T C clear, E C M reset, a n d crank 4. T u r n t h e ignition s w i t c h O F F , a n d d i s c o n n e c t t h e
( C K P ) pattern c l e a r . D T C c l e a r c o m m a n d e r a s e s all H D S f r o m the D L C .
stored D T C c o d e s , freeze data, readiness c o d e s , and the
o n - b o a r d s n a p s h o t . T h i s m u s t be d o n e w i t h t h e H D S 5. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
after r e p r o d u c i n g t h e D T C d u r i n g t r o u b l e s h o o t i n g .
T h e E C M r e s e t c o m m a n d e r a s e s all s t o r e d D T C c o d e s , Crank (CKP) Pattern Clear/Crank (CKP)
freeze data, r e a d i n e s s c o d e s , on-board s n a p s h o t , and Pattern Learn
all s p e c i f i c d a t a to c o r r e c t the s y s t e m e x c e p t c r a n k
( C K P ) pattern. If t h e c r a n k ( C K P ) pattern d a t a in t h e E C M Clear/Learn Procedure (with the HDS)
w a s c l e a r e d , y o u m u s t d o t h e c r a n k ( C K P ) pattern l e a r n
p r o c e d u r e . T h e c r a n k ( C K P ) pattern c l e a r c o m m a n d 1. C o n n e c t t h e H D S to t h e data link c o n n e c t o r ( D L C )
e r a s e s o n l y c r a n k ( C K P ) pattern d a t a . T h i s c o m m a n d is (A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e of t h e front
for r e p a i r of a m i s f i r e o r t h e C K P s e n s o r . console.
Scan Tool Clear Command
If y o u a r e u s i n g a g e n e r i c s c a n tool to c l e a r c o m m a n d s ,
be a w a r e that t h e r e is o n l y o n e setting for c l e a r i n g t h e
E C M , a n d it c l e a r s all c o m m a n d s at t h e s a m e t i m e
(crank ( C K P ) pattern l e a r n , idle l e a r n , r e a d i n e s s c o d e s ,
f r e e z e d a t a , o n - b o a r d s n a p s h o t , a n d D T C s ) . After y o u
c l e a r a l l c o m m a n d s , y o u t h e n n e e d to d o t h e s e
p r o c e d u r e s , in t h i s o r d e r : E C M idle l e a r n p r o c e d u r e
( s e e p a g e 11-462); c r a n k ( C K P ) pattern l e a r n p r o c e d u r e ;
T e s t - d r i v e to s e t r e a d i n e s s c o d e s to c o m p l e t e ( s e e p a g e
11-256).
DTC Clear
1. C l e a r t h e D T C w i t h t h e H D S w h i l e t h e e n g i n e i s
stopped. 3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M
a n d o t h e r v e h i c l e s y s t e m s . If it d o e s n ' t , g o to t h e
2. T u r n t h e ignition s w i t c h O F F . D L C circuit t r o u b l e s h o o t i n g ( s e e p a g e 11-367).
3. T u r n t h e ignition s w i t c h O N (II), a n d w a i t 4. S e l e c t C R A N K P A T T E R N in t h e A D J U S T M E N T
30 s e c o n d s . M E N U with the H D S .
4. T u r n t h e ignition s w i t c h O F F , a n d d i s c o n n e c t the 5. S e l e c t C R A N K P A T T E R N L E A R N I N G with the H D S ,

H D S from the D L C . and follow the s c r e e n prompts.
11-214
Learn Procedure (without the HDS) How to Troubleshoot Circuits at the ECM
1. S t a r t the e n g i n e . Hold the e n g i n e s p e e d at Special Tools Required

3,000 r p m without l o a d (in neutral) until the • Digital m u l t i m e t e r K S - A H M - 3 2 - 0 0 3 (1) or a
radiator f a n c o m e s o n . c o m m e r c i a l l y a v a i l a b l e digital m u l t i m e t e r
• B a c k p r o b e s e t 0 7 S A Z - 0 0 1 0 0 0 A (2)
2. T e s t - d r i v e the v e h i c l e o n a level r o a d : D e c e l e r a t e
(with the throttle fully c l o s e d ) f r o m a n e n g i n e s p e e d 1. C o n n e c t t h e b a c k p r o b e a d a p t e r s (A) to t h e s t a c k i n g
of 2,500 r p m d o w n to 1,000 r p m w i t h the p a t c h c o r d s ( B ) , a n d c o n n e c t the c o r d s to a digital
t r a n s m i s s i o n in 1st g e a r . multimeter (C).
3. R e p e a t s t e p 2 s e v e r a l t i m e s .
5. T u r n the ignition s w i t c h O N (II), a n d w a i t

30 s e c o n d s .
How to End a Troubleshooting Session

(required after any troubleshooting)
1. R e s e t t h e E C M w i t h the H D S .
2 . D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 . U s i n g t h e w i r e i n s u l a t i o n a s a g u i d e for t h e
4. D i s c o n n e c t the H D S f r o m t h e D L C . c o n t o u r e d tip of t h e b a c k p r o b e a d a p t e r , gently s l i d e
the tip into t h e c o n n e c t o r f r o m the w i r e s i d e until it
N O T E : T h e E C M is part of t h e i m m o b i l i z e r s y s t e m . t o u c h e s t h e e n d of t h e w i r e t e r m i n a l .
If y o u r e p l a c e t h e E C M , it will h a v e a different
i m m o b i l i z e r c o d e . In o r d e r for the e n g i n e to start, 3. If y o u c a n n o t get to t h e w i r e s i d e of t h e c o n n e c t o r
y o u m u s t rewrite t h e i m m o b i l i z e r c o d e w i t h t h e or t h e w i r e s i d e is s e a l e d (A), d i s c o n n e c t t h e
HDS. c o n n e c t o r a n d p r o b e t h e t e r m i n a l s (B) f r o m t h e
t e r m i n a l s i d e . D o not f o r c e the p r o b e into the
connector.
INOTICEI
D o not p u n c t u r e t h e i n s u l a t i o n o n a w i r e .
P u n c t u r e s c a n c a u s e p o o r or intermittent
electrical connections.
(cont'd)
11-215
Updating the ECM 1. T u r n t h e ignition s w i t c h O N (II), but d o not start the

engine.
• H o n d a d i a g n o s t i c s y s t e m ( H D S ) tablet t e s t e r 2. C o n n e c t t h e H D S to t h e data link c o n n e c t o r ( D L C )
• H o n d a interface m o d u l e (HIM) a n d a n iN w o r k s t a t i o n (A) l o c a t e d u n d e r the d r i v e r ' s s i d e of t h e d a s h b o a r d .
with H D S a n d C M update software
• H D S pocket t e s t e r
• G N A - 6 0 0 a n d a n iN w o r k s t a t i o n w i t h H D S a n d C M
update s o f t w a r e
U s e a n y o n e of t h e s e u p d a t e t o o l s .
NOTE:
• U s e t h i s p r o c e d u r e w h e n y o u n e e d to u p d a t e t h e E C M
during troubleshooting procedures.
• M a k e s u r e t h e H D S / H I M h a s t h e latest s o f t w a r e
version.
• B e f o r e y o u u p d a t e t h e E C M , m a k e s u r e t h e battery in
t h e v e h i c l e is fully c h a r g e d , a n d c o n n e c t a j u m p e r
battery (not a battery c h a r g e r ) to m a i n t a i n s y s t e m
voltage.
• N e v e r turn t h e ignition s w i t c h O F F d u r i n g t h e u p d a t e . 3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M
If t h e r e is a p r o b l e m w i t h t h e u p d a t e , l e a v e t h e a n d o t h e r v e h i c l e s y s t e m . If it d o e s n ' t , g o to t h e
ignition s w i t c h O N . D L C circuit t r o u b l e s h o o t i n g ( s e e p a g e 11-367). If
• T o p r e v e n t E C M d a m a g e , d o not o p e r a t e a n y t h i n g y o u a r e returning f r o m t h e D L C circuit
electrical (headlights, audio s y s t e m , brakes, A / C , t r o u b l e s h o o t i n g , s k i p s t e p s 4 a n d 5, t h e n c l e a n t h e
p o w e r w i n d o w s , d o o r l o c k s , etc.) d u r i n g t h e u p d a t e . throttle b o d y after u p d a t i n g t h e E C M ( s e e p a g e
• T o e n s u r e t h e latest p r o g r a m is i n s t a l l e d , d o E C M 11-499).
update w h e n e v e r the E C M is substituted or replaced.
• Y o u cannot update E C M with a p r o g r a m it a l r e a d y 4. S e l e c t t h e I N S P E C T I O N M E N U w i t h t h e H D S .
h a s . It will o n l y a c c e p t a n e w program.
• If y o u n e e d to d i a g n o s e t h e H o n d a interface m o d u l e 5. S e l e c t t h e E T C S T E S T , t h e n s e l e c t t h e T P P O S I T I O N
(HIM) b e c a u s e t h e H I M ' s r e d ( # 3 ) light c a m e o n o r C H E C K , a n d follow the s c r e e n prompts.
w a s f l a s h e d d u r i n g t h e u p d a t e , l e a v e t h e ignition
s w i t c h in t h e O N (II) p o s i t i o n w h e n y o u d i s c o n n e c t t h e N O T E : If t h e T P P O S I T I O N C H E C K i n d i c a t e s F A I L E D ,
HIM f r o m t h e d a t a link c o n n e c t o r ( D L C ) . T h i s w i l l continue this procedure.
prevent E C M d a m a g e .
6. E x i t t h e H D S , t h e n s e l e c t t h e update m o d e , a n d
f o l l o w t h e s c r e e n p r o m p t s to u p d a t e t h e E C M .
11-216
7. If t h e s o f t w a r e in t h e E C M i s t h e latest, d i s c o n n e c t Substituting the ECM
t h e H D S / H I M f r o m the D L C , a n d g o back to t h e
p r o c e d u r e that y o u w e r e d o i n g . If the s o f t w a r e in Special Tools Required
t h e E C M is not t h e latest, f o l l o w the i n s t r u c t i o n s o n • H o n d a d i a g n o s t i c s y s t e m ( H D S ) tablet t e s t e r
t h e s c r e e n . If p r o m p t e d to c h o o s e the P G M - F I • H o n d a interface m o d u l e (HIM) a n d a n iN w o r k s t a t i o n
s y s t e m , m a k e s u r e y o u u p d a t e both. w i t h H D S a n d C M update s o f t w a r e
• H D S pocket t e s t e r
N O T E : If t h e E C M u p d a t e s y s t e m r e q u i r e s y o u to • G N A - 6 0 0 a n d a n iN w o r k s t a t i o n w i t h H D S a n d C M
c o o l t h e E C M , f o l l o w t h e s c r e e n p r o m p t s . If y o u run update software
into a p r o b l e m ( p r o g r a m m i n g t a k e s o v e r U s e a n y o n e of t h e s e update t o o l s .
15 m i n u t e s , s t a t u s b a r g o e s o v e r 100 % , o r
i m m o b i l i z e r indicator f l a s h e s , H D S tablet f r e e z e s , N O T E : U s e t h i s p r o c e d u r e w h e n y o u n e e d to s u b s t i t u t e
etc.) d u r i n g t h e u p d a t e p r o c e d u r e , f o l l o w t h e s e a known-good E C M during troubleshooting procedures.
s t e p s to m i n i m i z e t h e c h a n c e of d a m a g i n g t h e
ECM: 1. C o n n e c t t h e H D S to t h e d a t a link c o n n e c t o r ( D L C )
• L e a v e t h e ignition s w i t c h in t h e " O N (II)" p o s i t i o n . (A) l o c a t e d b e h i n d the d r i v e r ' s s i d e of t h e front
• C o n n e c t a j u m p e r battery (do not c o n n e c t a console.
battery c h a r g e r ) .
• S h u t d o w n the H D S .
• Disconnect the H D S from the D L C .
• Reboot the H D S .
• R e c o n n e c t t h e H D S to the D L C , a n d try t h e
update procedure again.
8. If t h e T P P O S I T I O N C H E C K f a i l e d in s t e p 6, c l e a n
t h e throttle b o d y ( s e e p a g e 11-499).
9. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
10. D o the c r a n k ( C K P ) pattern l e a r n p r o c e d u r e .
2 . T u r n the ignition s w i t c h O N (II).
3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M
a n d other v e h i c l e s y s t e m s . If it d o e s n ' t , g o to t h e
D L C circuit t r o u b l e s h o o t i n g ( s e e p a g e 11-367). If
y o u a r e returning f r o m D L C circuit t r o u b l e s h o o t i n g ,
s k i p s t e p s 4 t h r u 10, t h e n c l e a n t h e throttle b o d y
after s u b s t i t u t i n g t h e E C M ( s e e p a g e 11-499).
4. S e l e c t t h e I N S P E C T I O N M E N U w i t h t h e H D S .
5. S e l e c t t h e E T C S T E S T , t h e n s e l e c t t h e T P P O S I T I O N
C H E C K , a n d follow the s c r e e n prompts.
N O T E : If the T P P O S I T I O N C H E C K i n d i c a t e s F A I L E D ,
continue this procedure.
7. J u m p the S C S line with the H D S .
(cont'd)
11-217
8. R e m o v e t h e left s i d e kick p a n e l ( s e e p a g e 2 0 - 7 1 ) . OBD Status
9. D i s c o n n e c t t h e E C M c o n n e c t o r s (A). T h e O B D s t a t u s s h o w s the c u r r e n t s y s t e m s t a t u s of
e a c h D T C a n d all of t h e p a r a m e t e r s . T h i s f u n c t i o n is
u s e d to s e e if t h e repair w a s s u c c e s s f u l l y c o m p l e t e d .
T h e r e s u l t s of d i a g n o s t i c t e s t s for t h e D T C a r e d i s p l a y e d
as:
• P A S S E D : T h e o n b o a r d d i a g n o s i s is s u c c e s s f u l l y
finished.
• F A I L E D : T h e o n b o a r d d i a g n o s i s h a s f i n i s h e d but
failed.
• E X E C U T I N G : T h e v e h i c l e is in e n a b l e criteria
c o n d i t i o n s for t h e D T C a n d t h e o n b o a r d d i a g n o s i s is
running.
• N O T C O M P L E T E D : T h e on board diagnosis w a s
r u n n i n g but is out of the e n a b l e c o n d i t i o n s of t h e D T C .
• O U T O F C O N D I T I O N : T h e v e h i c l e h a s s t a y e d out of
the e n a b l e c o n d i t i o n s for the D T C .
10. R e m o v e t h e bolts (R), t h e n r e m o v e the E C M (C).
11. Install t h e E C M in the r e v e r s e o r d e r of r e m o v a l .
12. O p e n the S C S w i t h the H D S .
N O T E : D T C P 0 6 3 0 " V I N Not P r o g r a m m e d o r
M i s m a t c h " m a y be s t o r e d b e c a u s e t h e V I N h a s not
b e e n p r o g r a m m e d into t h e E C M ; i g n o r e it, a n d
14. M a n u a l l y input the V I N to t h e E C M w i t h t h e H D S .
15. U p d a t e t h e E C M if it d o e s not h a v e the latest

software.
16. S e l e c t the I M M O B I S Y S T E M w i t h the H D S .
17. E n t e r the i m m o b i l i z e r c o d e w i t h the E C M

r e p l a c e m e n t p r o c e d u r e in t h e H D S ; it a l l o w s y o u to
start the e n g i n e .
18. R e s e t the E C M w i t h the H D S .
19. If the T P P O S I T I O N C H E C K f a i l e d in s t e p 5, c l e a n
the throttle b o d y ( s e e p a g e 11-499).
2 0 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 1 . Do the c r a n k ( C K P ) pattern l e a r n p r o c e d u r e .
11-218
DTC T w o Drive C y c l e Detection Item MIL Note
1
(MIL indication' ) Detection
P0107(3) Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r Circuit L o w Voltage ON (see page 11-261)
P0108(3) Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r Circuit High Voltage ON (see page 11-263)
P0111 (10)
O Intake Air T e m p e r a t u r e (IAT) S e n s o r Circuit R a n g e / P e r f o r m a n c e
Problem
ON (see p a g e 11-266)
P0112(10) Intake Air T e m p e r a t u r e (IAT) S e n s o r Circuit L o w Voltage ON (see p a g e 11-267)

P0113(10) Intake Air T e m p e r a t u r e (IAT) S e n s o r Circuit High V o l t a g e ON (see p a g e 11-269)
P0116(86)
o E n g i n e C o o l a n t T e m p e r a t u r e ( E C T ) S e n s o r 1 Circuit R a n g e /
P e r f o r m a n c e Problem
ON (see page 11-271)
P0117(6) E n g i n e C o o l a n t T e m p e r a t u r e ( E C T ) S e n s o r 1 Circuit L o w Voltage ON (see page 11-272)

P0118(6) E n g i n e C o o l a n t T e m p e r a t u r e ( E C T ) S e n s o r 1 Circuit High Voltage ON (see page 11-274)
P0122(7) Throttle Position (TP) S e n s o r A Circuit L o w Voltage ON (see page 11-392)
P0123 (7) Throttle Position (TP) S e n s o r A Circuit High Voltage ON (see page 11-395)
P0125 (86)
o Engine Coolant Temperature (ECT) S e n s o r 1 Malfunction/Slow
Response
P0128 (87)
o Cooling S y s t e m Malfunction ON (see page 11-277)
P0133 (61)
o Air Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) S l o w R e s p o n s e ON (see page 11-279)
P0134(41)
P0135 (41)
o Air Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) Heater S y s t e m Malfunction
Air Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) Heater Circuit Malfunction
ON
ON
(see
(see
page
page
11-280)
11-281)
P0137 (63) S e c o n d a r y Heated O x y g e n S e n s o r ( S e c o n d a r y H 0 2 S ( S e n s o r 2)) ON (see page 11-285)
Circuit L o w Voltage
P0139 (63)
o S e c o n d a r y Heated O x y g e n S e n s o r ( S e c o n d a r y H 0 2 S ( S e n s o r 2))
Slow Response
ON (see p a g e 11-290)

Heater Circuit Malfunction
P0171 (45)
o Fuel S y s t e m T o o L e a n ON (see page 11-294)
P0172 (45)
P0222(7)
o Fuel S y s t e m T o o Rich
Throttle Position (TP) S e n s o r B Circuit L o w Voltage
ON
ON
(see
(see
page
page
11-294)
11-398)
P0223 (7) Throttle Position (TP) S e n s o r B Circuit High Voltage ON (see page 11-401)
P0300 (75)
a n y combination
o R a n d o m Misfire Detected ON (see page 11-295)
of the following
P0301 (71)
P0302 (72)
P0303 (73)
P0304 (74)
P0301(71)
o No. 1 C y l i n d e r Misfire Detected ON (see page 11-298)
P0302 (72)
P0303 (73)
P0304 (74)
P0325 (23)
o No. 4 C y l i n d e r Misfire Detected
Knock S e n s o r Circuit Malfunction
ON
ON
(see
(see
page
page
11-298)
11-306)
P0335(4) Crankshaft Position ( C K P ) S e n s o r N o S i g n a l ON (see page 11-308)
P0339(4) Crankshaft Position ( C K P ) S e n s o r Circuit Intermittent Interruption ON (see page 11-310)
P0365 (8) C a m s h a f t Position (CMP) S e n s o r No S i g n a l ON (see page 11-311)
P0369 (8) C a m s h a f t Position (CMP) S e n s o r Circuit Intermittent Interruption ON (see page 11-313)
P0420 (67)
P0443 (92)
o Catalyst S y s t e m Efficiency B e l o w T h r e s h o l d
Evaporative E m i s s i o n ( E V A P ) C a n i s t e r Purge V a l v e Circuit
ON
ON
(see
(see
page
page
11-507)
11-514)
Malfunction
* 1: T h e s e D T C s are indicated by a blinking MIL w h e n the S C S line is j u m p e d with the H D S .
(cont'd)
11-219
DTC Troubleshooting Index (cont'd)

DTC T w o Drive C y c l e Detection Item MIL Note
Detection
P0451(91) O Fuel T a n k P r e s s u r e (FTP) S e n s o r Circuit R a n g e / P e r f o r m a n c e P r o b l e m ON (see page 11-518)
P0452O1) Fuel T a n k P r e s s u r e (FTP) S e n s o r Circuit L o w Voltage ON (see page 11-519)
P0453(91) Fuel T a n k P r e s s u r e (FTP) S e n s o r Circuit High Voltage ON (see page 11-522)
P0455(90) O E v a p o r a t i v e E m i s s i o n ( E V A P ) S y s t e m L a r g e L e a k Detected ON (see page 11-525)
P0456(90)
o E v a p o r a t i v e E m i s s i o n ( E V A P ) S y s t e m V e r y S m a l l Leak Detected ON (see page 11-525)
P0457(90)
o E v a p o r a t i v e E m i s s i o n ( E V A P ) S y s t e m L e a k Detected/Fuel Fill C a p
L o o s e or M i s s i n g
P0461(121) Fuel Level S e n s o r (Fuel G a u g e S e n d i n g Unit) Circuit R a n g e / OFF (see p a g e 11-464)

Performance Problem
P0462(121) Fuel Level S e n s o r (Fuel G a u g e S e n d i n g Unit) Circuit L o w Voltage OFF (see page 11-465)
P0463(121) Fuel Level S e n s o r (Fuel G a u g e S e n d i n g Unit) Circuit High Voltage OFF (see page 11-467)
P0496(92)
o E v a p o r a t i v e E m i s s i o n ( E V A P ) S y s t e m High Purge F l o w Detected ON (see page 11-530)
P0497(90)
P0498O17)
o E v a p o r a t i v e E m i s s i o n ( E V A P ) S y s t e m L o w Purge F l o w Detected
E v a p o r a t i v e E m i s s i o n ( E V A P ) C a n i s t e r V e n t S h u t V a l v e Circuit L o w
ON
ON
(see
(see
page
page
11-531)
11-534)
Voltage
P0499O17) E v a p o r a t i v e E m i s s i o n ( E V A P ) C a n i s t e r V e n t S h u t V a l v e Circuit High ON (see page 11-536)
Voltage
P0506(14)
o Idle Control S y s t e m R P M L o w e r T h a n E x p e c t e d ON (see p a g e 11-451)
P0507(14)
P0563(34)
o Idle Control S y s t e m R P M Higher T h a n E x p e c t e d
E n g i n e Control M o d u l e ( E C M ) P o w e r S o u r c e Circuit U n e x p e c t e d
ON
OFF
(see page 11-453)
(see page 11-314)
Voltage
P0600(39) S e r i a l C o m m u n i c a t i o n Link Malfunction ON (see page 11-317)
P0602(196) E n g i n e Control M o d u l e ( E C M ) P r o g r a m m i n g E r r o r ON (see page 11-317)
P0603(131) E n g i n e Control M o d u l e ( E C M ) Internal Control Module K e e p Alive ON (see page 11-318)
M e m o r y (KAM) E r r o r
P0606 (0) E n g i n e Control M o d u l e ( E C M ) P r o c e s s o r Malfunction ON (see page 11-318)
P0630(139) VIN Not P r o g r a m m e d or M i s m a t c h ON (see page 11-319)
P0685(135)
o E n g i n e Control M o d u l e ( E C M ) P o w e r Control Circuit/Internal Circuit
Malfunction
P0720 0 2 2 ) Output S h a f t (Countershaft) S p e e d S e n s o r Circuit Malfunction ON (see page 11-321)

P1109(13) B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r Circuit O u t of R a n g e High ON (see page 11-324)
P1116 (86)
Performance Problem
P1128(5)
o Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r S i g n a l L o w e r T h a n
Expected
P1129(5)
o Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r S i g n a l Higher T h a n
Expected
PI157(48) A i r Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) A F S Circuit High Voltage ON (see page 11-330)
P1172 (61) A i r Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) Circuit Out of R a n g e High ON (see page 11-333)
* 1: T h e s e D T C s a r e indicated by a blinking MIL w h e n the S C S line is j u m p e d w i t h the H D S .
11-220
DTC T w o Drive C y c l e D e t e c t i o n Item MIL Note
(MIL indication' ) 1
Detection
P1297 (20) Electrical L o a d Detector ( E L D ) Circuit L o w V o l t a g e OFF (see page 11-334)
P1298 (20) Electrical L o a d Detector ( E L D ) Circuit High Voltage OFF (see page 11-336)
P1454(91) O Fuel T a n k P r e s s u r e (FTP) S e n s o r R a n g e / P e r f o r m a n c e Problem ON (see page 11-539)
P1683(40) Throttle V a l v e Default Position S p r i n g P e r f o r m a n c e P r o b l e m ON (see page 11-404)
PI684(40) Throttle V a l v e Return S p r i n g P e r f o r m a n c e P r o b l e m ON (see page 11-405)
P2101(40) Throttle Actuator S y s t e m Malfunction ON (see page 11-406)
P2108 (40) Throttle Actuator Control M o d u l e Problem ON (see page 11-408)
P2118(40) Throttle Actuator Current R a n g e / P e r f o r m a n c e P r o b l e m ON (see page 11-409)
P2122(37) Accelerator Pedal Position (APP) S e n s o r A (Throttle Position (TP) ON (see page 11-411)
S e n s o r D) Circuit L o w Voltage
P2123 (37) Accelerator Pedal Position (APP) S e n s o r A (Throttle Position (TP) ON (see p a g e 11-414)
S e n s o r D) Circuit High Voltage
P2127 (37) A c c e l e r a t o r Pedal Position (APP) S e n s o r B (Throttle Position (TP) ON (see p a g e 11-416)
S e n s o r E ) Circuit L o w Voltage
P2128 (37) A c c e l e r a t o r Pedal Position (APP) S e n s o r B (Throttle Position (TP) ON (see p a g e 11-419)
S e n s o r E ) Circuit High Voltage
P2135(7) Throttle Position (TP) S e n s o r A / B Incorrect Voltage Correlation ON (see p a g e 11-421)
P2138 (37) A c c e l e r a t o r Pedal Position (APP) S e n s o r A / B (Throttle Position (TP) ON (see p a g e 11-423)
S e n s o r D/E) Incorrect Voltage Correlation
P2176(40) Throttle Actuator Control S y s t e m Idle Position Not L e a r n e d ON (see p a g e 11-425)
P2183(192)
P e r f o r m a n c e Problem
ON (see p a g e 11-338)
P2184(192) E n g i n e Coolant T e m p e r a t u r e ( E C T ) S e n s o r 2 Circuit L o w Voltage ON (see p a g e 11-340)

P2185(192) E n g i n e C o o l a n t T e m p e r a t u r e ( E C T ) S e n s o r 2 Circuit High Voltage ON (see p a g e 11-342)
P2195(48) A i r Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) S i g n a l S t u c k L e a n ON (seepage 11-345)
P2227(13)
o B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r Circuit R a n g e / P e r f o r m a n c e
Problem
ON (see p a g e 11-347)
P2228(13) B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r Circuit L o w Voltage ON (see page 11-349)

P2229(13) B a r o m e t r i c P r e s s u r e ( B A R O ) S e n s o r Circuit High Voltage ON (see page 11-349)
P2238(48) Air Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) A F S + Circuit L o w Voltage ON (see page 11-350)
P2252(48) A i r F u e l Ratio (A/F) S e n s o r ( S e n s o r 1) A F S — Circuit L o w Voltage ON (see page 11-352)
P2270(63)
Circuit S i g n a l S t u c k L e a n
P2271(63)
Circuit S i g n a l S t u c k Rich
ON (see p a g e 11-354)
P2279(109)
o Intake A i r S y s t e m Leak Detected ON (see p a g e 11-510)
P2422(117)
o E v a p o r a t i v e E m i s s i o n ( E V A P ) C a n i s t e r V e n t S h u t V a l v e St u ck C l o s e d
Malfunction
ON (see p a g e 11-539)
P2552(40) Throttle Actuator Control Module R e l a y Malfunction ON (see p a g e 11-427)

P2610(132) E n g i n e Control Module ( E C M ) Ignition Off Internal T i m e r ON (see p a g e 11-355)
P e r f o r m a n c e Ploblem
P2646(22) Rocker A r m Oil P r e s s u r e S w i t c h ( V T E C Oil P r e s s u r e S w i t c h ) Circuit ON (see p a g e 11-439)
L o w Voltage
P2647 (22) Rocker A r m Oil P r e s s u r e S w i t c h ( V T E C Oil P r e s s u r e S w i t c h ) Circuit ON (see p a g e 11-442)
High Voltage
P2648(21) R o c k e r A r m Oil Control S o l e n o i d ( V T E C S o l e n o i d V a l v e ) Circuit L o w ON (see p a g e 11-445)
Voltage
P2649(21) R o c k e r A r m Oil Control S o l e n o i d ( V T E C S o l e n o i d Valve) Circuit High ON (see p a g e 11-447)
Voltage
P2A00 (61)
o A i r Fuel Ratio (A/F) S e n s o r ( S e n s o r 1) Circuit R a n g e / P e r f o r m a n c e
Problem
ON (see p a g e 11-356)
U0107 (30) L o s t C o m m u n i c a t i o n With Throttle Actuator Control Module ON (see p a g e 11-429)

U0122O26) F - C A N Malfunction ( E n g i n e Control Module ( E C M ) - V e h i c l e Stability OFF (see p a g e 11-357)
A s i s t ( V S A ) Modulator-Control Unit)
U1102 (126) F - C A N Malfunction ( B U S - O F F ) OFF (see p a g e 11-359)
* 1: T h e s e D T C s are indicated by a blinking MIL w h e n the S C S line is j u m p e d with the H D S .
11-221
W h e n t h e v e h i c l e h a s o n e of t h e s e s y m p t o m s , c h e c k f o r a d i a g n o s t i c t r o u b l e c o d e ( D T C ) w i t h the H D S . If t h e r e is no
D T C , d o the d i a g n o s t i c p r o c e d u r e for t h e s y m p t o m , in t h e s e q u e n c e l i s t e d , until y o u find t h e c a u s e .

E n g i n e will not start 1. T e s t t h e battery ( s e e p a g e 22-47). • Low compression
(MIL w o r k s O K , no D T C s s e t ) 2. T e s t t h e s t a r t e r ( s e e p a g e 4-10). • No ignition s p a r k
3. C h e c k t h e f u e l p r e s s u r e ( s e e p a g e 11-477). • Intake air l e a k s
4. T r o u b l e s h o o t t h e fuel p u m p circuit ( s e e p a g e 11-470). • L o c k e d up e n g i n e
• Broken c a m chain
E n g i n e will not start C h e c k t h e i m m o b i l i z e r s y s t e m ( s e e p a g e 22-213).
(MIL w o r k s O K , no D T C s s e t ,
immobilizer indicator s t a y s
MIL c o m e s on and stays o n , T r o u b l e s h o o t t h e M I L c i r c u i t ( s e e p a g e 11-366).
or n e v e r c o m e s o n at a l l , n o
D T C s set
E n g i n e s t a r t s but s t a l l s C h e c k t h e i m m o b i l i z e r s y s t e m ( s e e p a g e 22-213).
immediately
(MIL w o r k s O K , no D T C s s e t ,
i m m o b i l i z e r indicator s t a y s
E n g i n e is h a r d to start 1. T e s t t h e battery ( s e e p a g e 22-47). • Low compression
(MIL w o r k s O K , no D T C s s e t ) 2. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-477). • Intake air l e a k s
3. C l e a n t h e throttle b o d y ( s e e p a g e 11-499). • C o n t a m i n a t e d fuel
• Weak spark
C o l d f a s t idle t o o l o w 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
(MIL w o r k s O K , no D T C s s e t ) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11-461).
3. C l e a n t h e throttle b o d y ( s e e p a g e 11-499).
C o l d f a s t idle t o o high 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). Intake air l e a k s
(MIL w o r k s O K , no D T C s s e t ) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11 -461).
3. A d j u s t t h e throttle c a b l e ( s e e p a g e 11-504).
4. D o t h e throttle p o s i t i o n l e a r n i n g c h e c k ( s e e p a g e
11-498).
Idle s p e e d f l u c t u a t e s 1. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). Incorrect v a l v e
(MIL w o r k s O K , no D T C s s e t ) 2. C h e c k t h e idle s p e e d ( s e e p a g e 11 -461). t i m i n g or c l e a r a n c e
3. A d j u s t t h e throttle c a b l e ( s e e p a g e 11-504). adjustment
4. D o t h e c a r b o n a c c u m u l a t i o n c h e c k ( s e e p a g e 11-498).
After w a r m i n g u p , idle s p e e d 1. T r o u b l e s h o o t t h e alternator F R s i g n a l circuit Incorrect v a l v e
is b e l o w s p e c i f i c a t i o n w i t h o u t ( s e e p a g e 11-456). t i m i n g or c l e a r a n c e
load 2. D o t h e c a r b o n a c c u m u l a t i o n c h e c k ( s e e p a g e 11-498). adjustment
(MIL w o r k s O K , n o D T C s s e t )
After w a r m i n g u p , idle s p e e d 1. A d j u s t t h e throttle c a b l e ( s e e p a g e 11-504). Intake air l e a k s
is a b o v e s p e c i f i c a t i o n w i t h o u t 2. T r o u b l e s h o o t t h e a l t e r n a t o r F R s i g n a l circuit
load ( s e e p a g e 11-456).
(MIL w o r k s O K , no D T C s set) 3. I n s p e c t t h e A P P s e n s o r ( s e e p a g e 11-436).
5. T r o u b l e s h o o t t h e E P S s i g n a l circuit ( s e e p a g e 11-458).
11-222
Low power 1. C h e c k the fuel p r e s s u r e ( s e e p a g e 11-477). • Low compression
(MIL w o r k s O K , n o D T C s set) 2. A d j u s t t h e throttle c a b l e ( s e e p a g e 11-504). • Incorrect c a m s h a f t
timing
• I n c o r r e c t e n g i n e oil
level
Engine stalls 1. D o t h e E C M idle learn p r o c e d u r e ( s e e p a g e 11-462). • Intake air l e a k s
(MIL w o r k s O K , n o D T C s set) 2. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-477). • Faulty harness and
3. C h e c k t h e idle s p e e d ( s e e p a g e 11 -461). sensor
4. T r o u b l e s h o o t t h e brake p e d a l p o s i t i o n s w i t c h s i g n a l connections
circuit ( s e e p a g e 11 -460). • Fuel contamination
Difficult to refuel 1. C h e c k t h e fuel v e n t t u b e b e t w e e n t h e E V A P c a n i s t e r Malfunctioning g a s
(MIL w o r k s O K , n o D T C s set) a n d the fuel tank. s t a t i o n filling nozzle.
2. C h e c k the fuel tank v a p o r r e c i r c u l a t i o n t u b e b e t w e e n
t h e fuel pipe a n d t h e fuel tank.
3. R e p l a c e t h e f u e l tank v a p o r c o n t r o l float ( s e e p a g e
11-545).
Fuel overflows during R e p l a c e the fuel tank v a p o r c o n t r o l float ( s e e p a g e 11-545). Malfunctioning g a s
refueling s t a t i o n filling nozzle.
(No D T C s set)
H D S d o e s not c o m m u n i c a t e T r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
w i t h the E C M or t h e v e h i c l e
11-223
System Description
Electronic Control System
T h e fuel a n d e m i s s i o n c o n t r o l s y s t e m s a r e m a n a g e d b y t h e e n g i n e c o n t r o l m o d u l e ( E C M ) .
Self-diagnosis
T h e E C M d e t e c t s a f a i l u r e of a s i g n a l f r o m a s e n s o r o r f r o m a n o t h e r c o n t r o l unit a n d s t o r e s a T e m p o r a r y D T C or a D T C .
D e p e n d i n g o n the f a i l u r e , a D T C is s t o r e d in e i t h e r t h e first o r t h e s e c o n d d r i v e c y c l e . W h e n a D T C is s t o r e d , the E C M
t u r n s o n t h e m a l f u n c t i o n i n d i c a t o r l a m p (MIL) b y s u p p l y i n g g r o u n d to t h e M I L circuit.
• O n e Drive Cycle Detection Method

W h e n a n a b n o r m a l i t y o c c u r s in t h e s i g n a l f r o m a s e n s o r or f r o m a n o t h e r c o n t r o l unit, t h e E C M s t o r e s a D T C a n d
turns on the MIL immediately.
• T w o Drive Cycle Detection Method

W h e n a n a b n o r m a l i t y o c c u r s in t h e s i g n a l f r o m a s e n s o r or f r o m a n o t h e r c o n t r o l unit in the first d r i v e c y c l e , t h e E C M
s t o r e s a T e m p o r a r y D T C . T h e M I L d o e s not c o m e o n at t h i s t i m e . If t h e failure c o n t i n u e s in t h e s e c o n d d r i v e c y c l e ,
t h e E C M s t o r e s a D T C in e r a s a b l e m e m o r y a n d t u r n s o n t h e M I L
Fail-safe Function
W h e n a n a b n o r m a l i t y o c c u r s in t h e s i g n a l f r o m a s e n s o r o r f r o m a n o t h e r c o n t r o l unit, t h e E C M i g n o r e s that s i g n a l a n d
s u b s t i t u t e s a p r e - p r o g r a m m e d v a l u e that a l l o w s the e n g i n e to c o n t i n u e r u n n i n g . T h i s c a u s e s a D T C to be s t o r e d a n d
t h e M I L to c o m e o n .
MIL Bulb Check and Readiness C o d e Condition

W h e n t h e ignition s w i t c h is t u r n e d O N (II), t h e E C M s u p p l i e s g r o u n d to t h e M I L circuit for a b o u t 15 to 20 s e c o n d s to
c h e c k t h e b u l b c o n d i t i o n . If a n y r e a d i n e s s c o d e s a r e not s e t to c o m p l e t e , t h e M I L f l a s h e s five t i m e s . If all r e a d i n e s s
c o d e s a r e s e t to c o m p l e t e , t h e M I L g o e s off.
Self S h u t D o w n (SSD) Mode

After t h e ignition s w i t c h is t u r n e d O F F , t h e E C M s t a y s o n (up to 2 5 m i n u t e s ) . If t h e E C M c o n n e c t o r is d i s c o n n e c t e d
d u r i n g t h i s t i m e , t h e E C M m a y b e d a m a g e d . T o c a n c e l t h i s m o d e , d i s c o n n e c t t h e n e g a t i v e c a b l e f r o m the battery or
j u m p t h e S C S line w i t h t h e H D S after t h e ignition s w i t c h is t u r n e d O F F .
11-224
E C M Electrical Connections
IGNITION COIL
RELAY (IG COIL)
FUEL PUMP
UNDER-HOOD
FUSE/RELAY BOX:
© N o . 41 B A T T E R Y (100 A )
2 N o . 4 2 I G M A I N (40 A )
© N o . 4 6 A C G S (15 A )
4 No. 59 D B W ( 2 0 A )
® N o . 4 7 S T O P (15 A )
MAIN UNDER-DASH
FUSE/RELAY BOX:
© N o . 16 I G C O I L (15 A )
© N o . 2 FUEL PUMP S R S
(15 A )
© N o . 6 A C G (15 A )
© N o . 3 ENGINE START
(7.5 A )
To N o . 2 0 H E A T E R C O N T R O L
COOLING FAN RELAY
(7.5 A )
(0)No. 15 L A F
(20A)*1 (15 A ) * 2
J2 N o . 10 I G P ( L A F ) (7.5 A )
13 N o . 14 D B W (15 A )
14 N o . 11 I G P ( D B W ) (7.5 A )
* 1 : '06-07 m o d e l s
* 2 : '08 m o d e l
(cont'd)
11-225
MAPSENSOR
i
No. 11NJECTOR
B5INJ1
No. 2 INJECTOR
No. 3 INJECTOR
<> B3INJ3
No. 4 INJECTOR
B2INJ4
E27 IMOCD
To IMMOBILIZER UNIT 4"
IAT SENSOR
IAT B17
ECT SENSOR 1
BARO SENSOR
(Built into
the ECM)
KNOCK SENSOR
A6CMP
CMP SENSOR
A7CKP
ECT SENSOR 2
N O
CKP SENSOR
11-226
00 0
AFSHTC A10 <>
AFS+A31 AA/V—'
AFS— A28
EVAP CANISTER A/F SENSOR
PURGE VALVE (SENSOR 1)
E19VSV
EVAP CANISTER
VENT SHUT VALVE
S02SHTC E21
SECONDARY
ALTERNATOR H02S
(SENSOR 2)
-0 BIO ALTL
LG2A8
LG3E3
TO ^—nnwi
SPARK A16IGPLS1
No. 11GNITION COIL
To
SPARK ROCKER ARM OIL
PLUG ICM PRESSURE SWITCH
(VTEC OIL
PRESSURE SWITCH)
No. 2 IGNITION COIL
To
SPARK
ZD
PLUG
No. 3 IGNITION COIL ROCKER ARM OIL

CONTROL SOLENOID
To
SPARK
PLUG ICM
No. 4 IGNITION COIL
OUTPUT SHAFT
(COUNTERSHAFT)
SPEED SENSOR
(cont'd)
11-227
}
To
CRUISE
CONTROL
SET/DECEL,
RESUME/ACCEL,
CANCEL
SWITCH
*3: With A/C
ECM A ECM B ECM D ECM E

(31P) (24P) (17P) (31P)
i
I
/ / / // LZ0
1 2 | 3 | 4 i 5 6 | 7 | |8|9 / | 2 | 3 | 4 | B 6 1 l / l 3|4 | 6 / I T | | 8 | e
10
/ 13 14 15 16
/ /18 20 21 8
/ 10 11 13
/ 11 12 13 14 15 16 17 18 19 20 21
23 24 25 26
/ /28 30 31 17 18 19
///
20 21
TERMINAL LOCATIONS
15 22
/ 24 25
/ 27 28 29 30
/
11-228
1 2 3 4 5 6 7 8 9
KS IGP2 IGP1 PG2 PG1 CMP CKP LG2 LG1
10 13 14 15 16 18 20 21
AFS
IGPLS4 IGPLS3 IGPLS2 IGPLS 1 NC VCC2 VCC1
/
HTC
23 24 25 26 28 30 31
SG2 SG1 APSB APSA AFS- MAP AFS+

number
1 RED/BLU KS (KNOCK S E N S O R ) Detects knock s e n s o r signal With engine knocking: p u l s e s
2 YEL/BLK IGP2 (POWER S O U R C E ) P o w e r s o u r c e for E C M With ignition s w i t c h O N (II): battery voltage
3 YEL/BLK IGP1 ( P O W E R S O U R C E ) P o w e r s o u r c e for E C M With ignition s w i t c h O N (II): battery voltage
4 BLK PG2 (POWER GROUND) G r o u n d circuit for E C M L e s s t h a n 1.0 V at all t i m e s
5 BLK PG1 ( P O W E R G R O U N D ) G r o u n d circuit for E C M L e s s than 1.0 V at all t i m e s
6 GRN CMP (CAMSHAFT Detects C M P s e n s o r signal With engine running: p u l s e s
POSITION S E N S O R ) With ignition s w i t c h O N (II): about 5.0 V
7 BLU CKP (CRANKSHAFT Detects C K P s e n s o r signal With engine running: p u l s e s
POSITION S E N S O R ) With ignition s w i t c h O N (II): about 5.0 V
8 BRN/YEL LG2 (LOGIC GROUND) G r o u n d circuit for E C M L e s s than 1.0 V at all t i m e s
9 BRN/YEL LG1 ( L O G I C G R O U N D ) G r o u n d circuit for E C M L e s s than 1.0 V at all t i m e s
10 GRN A F S H T C (AIR F U E L R A T I O Drives A / F s e n s o r heater With ignition switch O N (II): battery voltage
(A/F) S E N S O R H E A T E R With fully w a r m e d up engine running: about 0 V
CONTROL)
13 WHT/BLU I G P L S 4 (No. 4 I G N I T I O N Drives No. 4 ignition coil With ignition s w i t c h O N (II): about 0 V
COIL PULSE) With engine running: p u l s e s
14 WHT/BLK I G P L S 3 (No. 3 I G N I T I O N Drives No. 3 ignition coil
COIL PULSE)
15 WHT/GRN I G P L S 2 (No. 2 I G N I T I O N Drives No. 2 ignition coil
COIL PULSE)
16 WHT I G P L S 1 (No. 1 I G N I T I O N Drives No. 1 ignition coil
COIL PULSE)
18 BLU/WHT NC (OUTPUT S H A F T Detects output shaft With ignition switch O N (II): about 0 V or 5.0 V
(COUNTERSHAFT) SPEED (countershaft) s p e e d s e n s o r W h i l e driving: about 2.5 V
SENSOR) signal
(cont'd)
11-229
1 2 3 4 5 6 7 8 9
KS IGP2 IGP1 PG2 PG1 CMP CKP LG2 LG1
10 13 14 15 16 18 20 21
AFS
IGPLS4 IGPLS3 IGPLS2 IGPLS 1 NC VCC2 VCC1
HTC
23 24 25 26 28 30 31
SG2 SG1 APSB APSA AFS- MAP AFS+

number
20 YEL/BLU VCC2 (SENSOR VOLTAGE) Provides s e n s o r voltage With ignition s w i t c h O N (II): about 5.0 V
W i t h ignition s w i t c h O F F : about 0 V
21 YEL/RED VCC1 (SENSOR VOLTAGE) Provides s e n s o r voltage With ignition s w i t c h O N (II): about 5.0 V
With ignition switch O F F : about 0 V
23 GRN/YEL SG2 (SENSOR GROUND) Sensor ground L e s s than 1.0 V at all t i m e s
24 GRN/WHT SG1 (SENSOR GROUND) Sensor ground L e s s than 1.0 V at all t i m e s
25 RED/YEL APSB (ACCELERATOR Detects A P P s e n s o r B signal With ignition s w i t c h O N (II) a n d accelerator pedal
P E D A L P O S I T I O N (APP) p r e s s e d : about 2.3 V
S E N S O R B) With ignition s w i t c h O N (II) a n d accelerator pedal
r e l e a s e d : about 0.2 V
26 RED/BLU APSA (ACCELERATOR Detects A P P s e n s o r A signal With ignition s w i t c h O N (II) a n d accelerator pedal
P E D A L P O S I T I O N (APP) p r e s s e d : about 4.5 V
S E N S O R A) With ignition switch O N (II) a n d accelerator pedal
r e l e a s e d : about 0.5 V
28 RED/YEL A F S - (AIR F U E L R A T I O Detects A / F s e n s o r
(A/F) S E N S O R , S E N S O R 1 ( s e n s o r 1) signal
-SIDE)
30 GRN/RED MAP (MANIFOLD Detects M A P s e n s o r s i g n a l With ignition switch O N (II): about 3.0 V
ABSOLUTE PRESSURE A t idle: about 1.0 V (depending on engine s p e e d )
SENSOR)
31 RED A F S + (AIR F U E L R A T I O Detects A / F s e n s o r
(A/F) S E N S O R , S E N S O R 1 ( s e n s o r 1) signal
+SJDE)
11-230

number
2 YEL I N J 4 (No. 4 I N J E C T O R ) D r i v e s No. 4 injector A t idle: duty controlled
3 BLU I N J 3 (No. 3 I N J E C T O R ) D r i v e s No. 3 injector With ignition s w i t c h O N (II): battery voltage
4 RED INJ2 (No. 2 I N J E C T O R ) D r i v e s No. 2 injector
5 BRN INJ1 (No. 1 1 N J E C T O R ) Drives No. 1 injector
6 GRN/YEL V T S (ROCKER A R M OIL D r i v e s rocker a r m oil A t idle: about 0 V
CONTROL SOLENOID control solenoid ( V T E C
(VTEC S O L E N O I D VALVE)) s o l e n o i d valve)
8 RED/WHT ECT1 (ENGINE C O O L A N T Detects E C T s e n s o r 1 s i g n a l With ignition s w i t c h O N (II): about 0.1— 4.8 V
T E M P E R A T U R E S E N S O R 1) (depending o n e n g i n e coolant temperature)
With fully w a r m e d up engine: about 0.5—0.7 V
10 WHT/BLU ALTL (ALTERNATOR L Detects alternator s i g n a l With ignition s w i t c h O N (II): a b o u t 0 V
SIGNAL) With engine running: battery voltage
11 BLU/BLK V T P S W (ROCKER A R M OIL Detects rocker a r m oil With e n g i n e at l o w r p m : about 0 V
P R E S S U R E SWITCH (VTEC p r e s s u r e switch ( V T E C oil W i t h e n g i n e at high r p m : battery voltage
OIL P R E S S U R E SWITCH)) p r e s s u r e switch) s i g n a l
13 WHT/RED A L T F ( A L T E R N A T O R FR Detects alternator FR s i g n a l With e n g i n e running: about 0—5.0 V
SIGNAL) (depending on electrical load)
17 RED/YEL IAT ( I N T A K E A I R Detects IAT s e n s o r s i g n a l With ignition s w i t c h O N (II): a b o u t 0.1—4.8 V
TEMPERATURE SENSOR) (depending o n intake air temperature)
18 WHT/GRN ALTC (ALTERNATOR S e n d s alternator control With fully w a r m e d up e n g i n e running:
CONTROL) signal about 8.0 V
19 GRN SEFD (THROTTLE S e n d s throttle actuator
ACTUATOR CONTROL control serial signal
SERIAL SIGNAL)
20 BLU SEDF (THROTTLE Detects throttle actuator
ACTUATOR CONTROL control serial signal
SERIAL SIGNAL)
21 YEL/BLU PCS (EVAPORATIVE D r i v e s E V A P canister purge With engine r u n n i n g , e n g i n e coolant b e l o w 149 °F
EMISSION CANISTER valve (65 °C): battery voltage
PURGE VALVE) With engine r u n n i n g , e n g i n e coolant a b o v e 149 °F
(65 °C): duty controlled
(cont'd)
11-231
ECM Inputs and Outputs at Connector D (17P)

number
1 LT GRN/RED C C S E T S W (CRUISE Detects c r u i s e S E T switch With c r u i s e S E T s w i t c h O N : about 0 V
CONTROL S E T SWITCH) signal With c r u i s e S E T s w i t c h O F F : battery voltage
4 LTGRN C C M S W (CRUISE Detects c r u i s e M A I N switch With c r u i s e M A I N s w i t c h O N : about 0 V
C O N T R O L MAIN SWITCH) signal With c r u i s e M A I N s w i t c h O F F : battery voltage
7 LT G R N / B L K C C R E S S W (CRUISE Detects c r u i s e R E S s w i t c h With c r u i s e R E S s w i t c h O N : about 0 V
CONTROL R E S SWITCH) signal With c r u i s e R E S s w i t c h O F F : battery voltage
8 GRY B K S W N C (BRAKE PEDAL Detects brake pedal With ignition switch O N (II) a n d brake pedal
POSITION SWITCH) position switch signal r e l e a s e d : battery voltage
With ignition switch O N (II) a n d brake pedal
p r e s s e d : about 5.0 V
9 PNK C C C L S W (CRUISE Detects c r u i s e control clutch With ignition switch O N (II) a n d clutch pedal
CONTROL CLUTCH PEDAL pedal position s w i t c h signal r e l e a s e d : about 5.0 V
POSITION SIGNAL) With ignition switch O N (II) a n d clutch pedal
p r e s s e d : battery voltage
15 BRN E T C S R L Y (THROTTLE Drives throttle actuator With ignition switch O N (II): about 0 V
ACTUATOR CONTROL control m o d u l e relay
MODULE RELAY)
11-232
ECM Inputs and Outputs at Connector E (31P)
1 3 4 5 7 8 9
AFS
ECT2 LG3 SG3 VCC3 MRLY IG1
HTCR
/ 11 12 13
CANH FANC SEFMJ
14
FTP
15
ELD
16
EPSLD
17
IMO
FPR
27
18
ACC
19
VSV
20
SHQ2S
21
S02S
HTC
22 24 25 28 29 30
IMO
BKSW CANL NEP ACS SCS WEN
CD

number
1 BLU ECT2 (ENGINE C O O L A N T Detect E C T s e n s o r 2 signal W i t h ignition s w i t c h O N (II): about 0.1—4.8 V
T E M P E R A T U R E S E N S O R 2) (depending o n engine coolant temperature)
3 GRN/WHT LG3 (LOGIC GROUND) G r o u n d for E C M control L e s s t h a n 1.0 V at all t i m e s
circuit
4 GRN SG3 (SENSOR GROUND) Sensor ground L e s s t h a n 1.0 V at all t i m e s
5 YEL/BLU VCC3 (SENSOR VOLTAGE) Provides s e n s o r voltage W i t h ignition s w i t c h O N (II): about 5.0 V
W i t h ignition s w i t c h O F F : about 0 V
7 GRN M R L Y (PGM-FI M A I N Drives P G M - F I m a i n relay 1 W i t h ignition switch O N (II): about 0 V
R E L A Y 1 (Fl MAIN)) (Fl MAIN) W i t h ignition s w i t c h O F F : battery voltage
P o w e r s o u r c e for D T C
memory
8 ORN A F S H T C R (AIR F U E L R A T I O Drives A / F s e n s o r heater W i t h ignition switch O N (II): about 0 V
(A/F) S E N S O R H E A T E R relay
CONTROL RELAY)
9 BLK/YEL IG1 (IGNITION S I G N A L ) Detects ignition signal W i t h ignition s w i t c h O N (II): battery voltage
W i t h ignition switch O F F : about 0 V
11 RED CANH (CAN Sends communication W i t h ignition s w i t c h O N (II): p u l s e s
COMMUNICATION SIGNAL signal
HIGH)
12 GRN FANC (RADIATOR FAN Drives radiator fan relay W i t h radiator fan running: about 0 V
CONTROL) W i t h radiator fan stopped: battery voltage
13 YEL SEFMJ C o m m u n i c a t e s with With ignition switch O N (II): about 5.0 V
multiplex control unit W i t h e n g i n e running with load: p u l s e s
14 LTGRN FTP ( F U E L T U N K Detects F T P s e n s o r signal With ignition switch O N (II) a n d fuel fill c a p
P R E S S U R E (FTP) S E N S O R ) r e m o v e d : about 2.5 V
15 GRN/RED ELD (ELECTRICAL LOAD Detects E L D signal W i t h ignition switch O N (II): about 0.1—4.8 V
DETECTOR) (depending o n electrical load)
16 BLU/BLK E P S L D (ELECTRICAL P/S Detects P / S load signal At idle with steering w h e e l straight a h e a d : about 0 V
LOAD DETECT) A t idle with steering w h e e l at full lock:
battery voltage
17 GRN/YEL IMOFPR (IMMOBILIZER D r i v e s P G M - F I m a i n relay 2 0 V for 2 s e c o n d s after turning ignition s w i t c h O N
FUEL PUMP RELAY) (FUEL PUMP) (II), t h e n battery voltage
18 RED A C C (A/C C L U T C H R E L A Y ) D r i v e s A / C clutch relay With c o m p r e s s o r O N : about 0 V
W i t h c o m p r e s s o r O F F : battery voltage
19 LT GRN/ VSV (EVAPORATIVE Drives E V A P c a n i s t e r vent W i t h ignition s w i t c h O N (II): battery voltage
WHT E M I S S I O N (EVAP) shut valve
CANISTER VENT SHUT
VALVE)
(cont'd)
11-233
ECM Inputs and Outputs at Connector E (31P)
1
ECT2
11 12 13
3
LG3
4
SG3
14
5
VCC3
15
/ 16
7
MRLY
17
IMO
18 19
8
AFS
HTCR
20
9
IG1
21
S02S
/
CANH FANC SEFMJ FTP ELD EPSLD ACC VSV SHQ2S
FPR HTC
22 24 25 27 28 29 30
IMO
BKSW CANL NEP ACS SCS WEN
CD
N O T E : S t a n d a r d battery voltage is a b o u t 12 V .

number
20 RED SH02S (SECONDARY Detects s e c o n d a r y H 0 2 S With fully w a r m e d up e n g i n e at idle a n d throttle
HEATED O X Y G E N SENSOR ( s e n s o r 2) s i g n a l fully c l o s e d : a b o v e 0.6 V
(SECONDARY H02S), With throttle quickly c l o s e d : b e l o w 0.4 V
S E N S O R 2)
21 BLK/WHT S02SHTC (SECONDARY Drives secondary H 0 2 S With ignition s w i t c h O N (II): battery voltage
HEATED O X Y G E N SENSOR ( s e n s o r 2) heater With fully w a r m e d up e n g i n e running:
(SECONDARY H02S) duty controlled
HEATER CONTROL)
22 WHT/BLK B K S W (BRAKE PEDAL Detects brake pedal With brake pedal r e l e a s e d : about 0 V
POSITION SWITCH) position s w i t c h s i g n a l With brake pedal p r e s s e d : battery voltage
24 WHT C A N L (CAN Sends communication With ignition switch O N (II): p u l s e s
COMMUNICATION SIGNAL signal
LOW)
25 BLU NEP (ENGINE S P E E D Outputs e n g i n e s p e e d pulse With e n g i n e running: p u l s e s
PULSE)
27 RED/BLU IMOCD (IMMOBILIZER Detects immobilizer signal
CODE)
28 BLU/RED A C S (A/C S W I T C H SIGNAL) Detects A / C s w i t c h signal With A / C s w i t c h O N : about 0 V
With A / C s w i t c h O F F : about 5.0 V
29 BRN S C S (SERVICE CHECK Detects s e r v i c e c h e c k signal With s e r v i c e check s i g n a l s h o r t e d u s i n g H D S :
SIGNAL) about 0 V
With s e r v i c e check signal o p e n : about 5.0 V
30 GRN/WHT W E N (WRITE E N A B L E Detects s e r v i c e e n a b l e With ignition switch O N (II): about 0 V
SIGNAL) signal
11-234
Vacuum Hose Routing
(cont'd)
11-235
Vacuum Distribution
® A I R F U E L R A T I O ( A / F ) S E N S O R ( S E N S O R 1) ® FUEL PRESSURE REGULATOR

® SECONDARY HEATED OXYGEN SENSOR ® FUEL PUMP
( S E C O N D A R Y H 0 2 S ) ( S E N S O R 2) ® FUELTANK
® M A N I F O L D A B S O L U T E P R E S S U R E (MAP) S E N S O R dD AIR C L E A N E R
® ENGINE C O O L A N T T E M P E R A T U R E (ECT) S E N S O R 1 ® P O S I T I V E C R A N K C A S E V E N T I L A T I O N (PCV) V A L V E
® I N T A K E A I R T E M P E R A T U R E (IAT) S E N S O R (ID THREE WAY CATALYTIC CONVERTER
(D C R A N K S H A F T P O S I T I O N ( C K P ) S E N S O R ® E V A P O R A T I V E EMISSION (EVAP) CANISTER
® KNOCK SENSOR dD E V A P O R A T I V E EMISSION (EVAP) CANISTER P U R G E V A L V E
® C A M S H A F T POSITION (CMP) S E N S O R ® EVAPORATIVE EMISSION (EVAP) CANISTER
® THROTTLE BODY VENT SHUT VALVE
00) I N J E C T O R (22) F U E L T A N K P R E S S U R E ( F T P ) S E N S O R
dD F U E L P U L S A T I O N D A M P E R ® FUEL TANK VAPOR CONTROL VALVE
® FUEL FILTER
11-236
PGM-FI System Crankshaft Position (CKP) S e n s o r
T h e C K P s e n s o r d e t e c t s c r a n k s h a f t s p e e d a n d is u s e d b y
T h e p r o g r a m m e d fuel injection ( P G M - F I ) s y s t e m is a the E C M to d e t e r m i n e ignition t i m i n g a n d t i m i n g for
s e q u e n t i a l multiport fuel injection s y s t e m . fuel injection of e a c h c y l i n d e r a s w e l l a s d e t e c t i n g
e n g i n e misfire^
Air Conditioning (A/C) C o m p r e s s o r Clutch Relay
W h e n the E C M r e c e i v e s a d e m a n d for c o o l i n g f r o m t h e
A / C s y s t e m , it d e l a y s t h e c o m p r e s s o r f r o m b e i n g
e n e r g i z e d , a n d e n r i c h e s the m i x t u r e to a s s u r e s m o o t h
t r a n s i t i o n to the A / C m o d e .
Air Fuel Ratio (A/F) S e n s o r

T h e A / F s e n s o r o p e r a t e s o v e r a w i d e air/fuel r a n g e . T h e
A / F s e n s o r is installed u p s t r e a m of t h e T W C , a n d s e n d s
s i g n a l s to t h e E C M w h i c h v a r i e s t h e duration of fuel
injection a c c o r d i n g l y .
ZIRCONIA SENSOR
ELEMENT TERMINALS
Engine Coolant Temperature (ECT) Sensor 1 and

Engine Coolant Temperature (ECT) Sensor 2
E C T s e n s o r 1 and E C T s e n s o r 2 are temperature
dependent resistors (thermistors). T h e resistance
d e c r e a s e s a s the engine coolant temperature increases.
HEATER
TERMINALS
Barometric Pressure (BARO) Sensor

T h e B A R O s e n s o r is i n s i d e t h e E C M . It c o n v e r t s
a t m o s p h e r i c p r e s s u r e into a v o l t a g e s i g n a l that is u s e d
b y t h e E C M to modify t h e b a s i c d u r a t i o n of t h e fuel
injection d i s c h a r g e .
C a m s h a f t Position (CMP) S e n s o r
T h e C M P s e n s o r d e t e c t s the position of t h e No. 1
c y l i n d e r a s a r e f e r e n c e for s e q u e n t i a l fuel injection to O-RING
each cylinder.
Ignition T i m i n g C o n t r o l
T h e E C M c o n t a i n s t h e m e m o r y for b a s i c ignition t i m i n g
at v a r i o u s e n g i n e s p e e d s a n d m a n i f o l d a b s o l u t e
p r e s s u r e s . It a l s o a d j u s t s the t i m i n g a c c o r d i n g to e n g i n e
coolant temperature.
O-RING
(cont'd)
11-237

Injector T i m i n g a n d D u r a t i o n M a l f u n c t i o n I n d i c a t o r L a m p (MIL) I n d i c a t i o n (In r e l a t i o n
T h e E C M c o n t a i n s t h e m e m o r y for b a s i c d i s c h a r g e to Readiness Codes)
d u r a t i o n at v a r i o u s e n g i n e s p e e d s a n d m a n i f o l d T h e v e h i c l e h a s c e r t a i n " r e a d i n e s s c o d e s " that a r e part
p r e s s u r e s . T h e b a s i c d i s c h a r g e d u r a t i o n , after b e i n g of t h e o n - b o a r d d i a g n o s t i c s for t h e e m i s s i o n s s y s t e m s .
r e a d out f r o m t h e m e m o r y , is further m o d i f i e d b y If t h e v e h i c l e ' s battery h a s b e e n d i s c o n n e c t e d or g o n e
s i g n a l s s e n t f r o m v a r i o u s s e n s o r s to o b t a i n t h e final d e a d , if the D T C s h a v e b e e n c l e a r e d , or if t h e E C M h a s
discharge duration. b e e n r e s e t , t h e s e c o d e s a r e r e s e t . In s o m e s t a t e s , part
B y m o n i t o r i n g long t e r m fuel t r i m , t h e E C M d e t e c t s l o n g of t h e e m i s s i o n s t e s t i n g i s to m a k e s u r e t h e s e c o d e s a r e
t e r m m a l f u n c t i o n s in t h e fuel s y s t e m a n d s e t s a s e t to c o m p l e t e . If all of t h e m a r e not s e t to c o m p l e t e ,
diagnostic trouble code (DTC). t h e v e h i c l e m a y fail t h e t e s t , or the t e s t c a n n o t be
finished.
I n t a k e A i r T e m p e r a t u r e (IAT) S e n s o r
T h e I A T s e n s o r is a t e m p e r a t u r e d e p e n d e n t r e s i s t o r T o c h e c k if t h e r e a d i n e s s c o d e s a r e s e t to c o m p l e t e ,
(thermistor). T h e r e s i s t a n c e of t h e t h e r m i s t o r d e c r e a s e s t u r n t h e ignition s w i t c h O N (II), but d o not start t h e
a s t h e intake air t e m p e r a t u r e i n c r e a s e s . e n g i n e . T h e M I L w i l l c o m e o n for 1 5 — 2 0 s e c o n d s . If it
t h e n g o e s off, t h e r e a d i n e s s c o d e s a r e c o m p l e t e . If it
f l a s h e s five t i m e s , o n e or m o r e r e a d i n e s s c o d e s a r e not
c o m p l e t e . T o s e t e a c h c o d e , d r i v e t h e v e h i c l e or run t h e
e n g i n e a s d e s c r i b e d in t h e p r o c e d u r e s ( s e e p a g e
11-256).
Manifold A b s o l u t e P r e s s u r e (MAP) S e n s o r
T h e M A P s e n s o r converts manifold absolute pressure
into e l e c t r i c a l s i g n a l s to t h e E C M .
Knock Sensor
T h e knock control s y s t e m a d j u s t s t h e ignition t i m i n g to
m i n i m i z e knock.
Output Shaft (Countershaft) S p e e d S e n s o r

T h i s s e n s o r detects countershaft s p e e d .
MAGNET O-RING
11-238
Secondary Heated Oxygen Sensor (Secondary H 0 2 S ) A c c e l e r a t o r P e d a l P o s i t i o n (APP) S e n s o r
T h e s e c o n d a r y H 0 2 S d e t e c t s t h e o x y g e n c o n t e n t in t h e A s t h e a c c e l e r a t o r p e d a l p o s i t i o n c h a n g e s , the s e n s o r
e x h a u s t g a s d o w n s t r e a m of t h e t h r e e w a y c a t a l y t i c v a r i e s t h e s i g n a l v o l t a g e to t h e E C M .
c o n v e r t e r ( T W C ) , a n d s e n d s s i g n a l s to t h e E C M w h i c h
v a r i e s t h e duration of fuel injection a c c o r d i n g l y . T o APP SENSOR
stabilize its output, t h e s e n s o r h a s a n internal heater.

T h e E C M c o m p a r e s t h e H 0 2 S output w i t h t h e A / F
s e n s o r output to d e t e r m i n e c a t a l y s t efficiency. T h e
s e c o n d a r y H 0 2 S is l o c a t e d o n t h e T W C .
SENSOR
TERMINALS
ZIRCONIA
ELEMENT
BRUSH
HEATER
TERMINALS
Electronic Throttle Control System
T h e throttle is e l e c t r o n i c a l l y c o n t r o l l e d b y t h e e l e c t r o n i c
throttle control s y s t e m . Refer to t h e s y s t e m d i a g r a m to
s e e a functional layout of t h e s y s t e m . TERMINAL
LEVER
Idle control: W h e n t h e e n g i n e is i d l i n g , t h e E C M
c o n t r o l s t h e throttle actuator to m a i n t a i n the p r o p e r idle
s p e e d a c c o r d i n g to e n g i n e l o a d s . Throttle Body
T h e throttle b o d y is a s i n g l e - b a r r e l s i d e draft t y p e . T h e
A c c e l e r a t i o n c o n t r o l : W h e n the a c c e l e r a t o r p e d a l is l o w e r portion of the throttle v a l v e is h e a t e d by e n g i n e
p r e s s e d , t h e E C M o p e n s t h e throttle v a l v e d e p e n d i n g c o o l a n t f r o m the c y l i n d e r h e a d to p r e v e n t icing of t h e
o n t h e a c c e l e r a t o r p e d a l position ( A P P ) s e n s o r s i g n a l . throttle plate.
THROTTLE VALVE
C r u i s e control: T h e E C M c o n t r o l s t h e throttle actuator to
m a i n t a i n s e t s p e e d w h e n the c r u i s e c o n t r o l is o p e r a t i n g .
T h e throttle a c t u a t o r t a k e s the p l a c e of t h e c r u i s e
control actuator.
THROTTLE
POSITION
(TP) S E N S O R
A / B and
THROTTLE
ACTUATOR
(cont'd)
11-239
Idle Control System Fuel Supply System
W h e n t h e e n g i n e is c o l d , t h e A / C c o m p r e s s o r is o n , t h e Fuel Cutoff Control

t r a n s m i s s i o n i s in g e a r , t h e b r a k e p e d a l i s p r e s s e d , t h e D u r i n g d e c e l e r a t i o n w i t h t h e throttle v a l v e c l o s e d ,
p o w e r s t e e r i n g l o a d is h i g h , o r t h e alternator is c u r r e n t to t h e i n j e c t o r s is c u t off to i m p r o v e fuel
c h a r g i n g , t h e E C M s e n d s s i g n a l s to t h e throttle a c t u a t o r e c o n o m y at e n g i n e s p e e d s o v e r 1,050 r p m . F u e l cutoff
to m a i n t a i n t h e c o r r e c t idle s p e e d . control a l s o occurs w h e n the engine s p e e d e x c e e d s
8,200 r p m , r e g a r d l e s s of the position of t h e throttle
Brake Pedal Position S w i t c h v a l v e , to protect t h e e n g i n e f r o m o v e r - r e v v i n g . O n a
T h e brake pedal position s w i t c h s i g n a l s the E C M w h e n c o l d e n g i n e , fuel cut o c c u r s at a l o w e r e n g i n e s p e e d .
the brake pedal is p r e s s e d .
Fuel P u m p Control
Electrical P o w e r Steering (EPS) Signal W h e n t h e ignition is t u r n e d o n , the E C M g r o u n d s
T h e E P S signals the E C M w h e n the power steering load PGM-FI main relay 2 ( F U E L P U M P ) w h i c h feeds current
is h i g h . to the fuel p u m p for 2 s e c o n d s to p r e s s u r i z e the fuel
s y s t e m . W i t h the e n g i n e r u n n i n g , t h e E C M g r o u n d s
Engine Start Switch P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) a n d f e e d s c u r r e n t to
T h e e n g i n e start s w i t c h s i g n a l s t h e E C M w h e n t h e t h e fuel p u m p . W h e n t h e e n g i n e is not r u n n i n g a n d t h e
e n g i n e is c r a n k i n g . ignition i s o n , the E C M c u t s g r o u n d to P G M - F I m a i n
r e l a y 2 ( F U E L P U M P ) w h i c h c u t s c u r r e n t to the fuel
pump.
P G M - F I M a i n R e l a y 1 (Fl M A I N ) a n d 2 ( F U E L P U M P )
P G M - F I m a i n r e l a y 1 (Fl M A I N ) is e n e r g i z e d w h e n e v e r
t h e ignition s w i t c h is O N (II) to s u p p l y battery v o l t a g e to
t h e E C M , p o w e r to t h e i n j e c t o r s , a n d p o w e r for P G M - F I
main relay 2 ( F U E L P U M P ) . PGM-FI main relay 2 ( F U E L
P U M P ) is e n e r g i z e d to s u p p l y p o w e r to the fuel p u m p
for 2 s e c o n d s w h e n t h e ignition s w i t c h is t u r n e d O N (II),
a n d w h e n t h e e n g i n e is c r a n k i n g or r u n n i n g .
11-240
Catalytic Converter System Evaporative Emission (EVAP) Control
System
T W C (Three W a y Catalytic Converter)
T h e T W C c o n v e r t s h y d r o c a r b o n s (HC), c a r b o n R e f e r to t h e s y s t e m d i a g r a m to s e e a f u n c t i o n a l l a y o u t
m o n o x i d e ( C O ) , a n d o x i d e s of nitrogen ( N O x ) in t h e of t h e s y s t e m .
e x h a u s t g a s to c a r b o n d i o x i d e ( C 0 ) , nitrogen (N ), a n d
2 2
water vapor. EVAP Canister

T h e E V A P c a n i s t e r t e m p o r a r i l y s t o r e s fuel v a p o r f r o m
THREE WAY t h e fuel tank until it c a n be p u r g e d f r o m t h e E V A P
c a n i s t e r into t h e e n g i n e a n d b u r n e d .
E V A P Canister Purge Valve

W h e n t h e e n g i n e c o o l a n t t e m p e r a t u r e is b e l o w 149 °F
(65 °C), t h e E C M t u r n s off t h e E V A P c a n i s t e r p u r g e v a l v e
w h i c h c u t s v a c u u m to t h e E V A P c a n i s t e r .
F u e l T a n k P r e s s u r e (FTP) S e n s o r
T h e F T P s e n s o r c o n v e r t s fuel t a n k a b s o l u t e p r e s s u r e
into a n e l e c t r i c a l input to t h e E C M .
S E N S O R UNIT
Positive Crankcase Ventilation (PCV) System
T h e P C V valve prevents blow-by gases from escaping

into t h e a t m o s p h e r e b y v e n t i n g t h e m into t h e intake
manifold.
PCVVALVE PCV HOSE .BREATHER
O-RING
(cont'd)
11-241
EVAP Canister Vent Shut Valve

T h e E V A P c a n i s t e r v e n t s h u t v a l v e is o n the E V A P
canister.
T h e E V A P canister vent shut valve controls the venting
of the E V A P c a n i s t e r .
O-RING
VALVE TERMINAL
11-242
Fuel Cap Warning Message To make the message go off (Without the
HDS) ('06-07 models)
T h e E C M d e t e c t s a l o o s e or m i s s i n g fuel fill c a p a s a n
e v a p o r a t i v e s y s t e m leak a n d alerts the d r i v e r by Procedure
s h o w i n g a w a r n i n g m e s s a g e in the g a u g e d i s p l a y .
1. T i g h t e n the fuel fill c a p until it c l i c k s .
First drive cycle
T h e first t i m e a leak is d e t e c t e d a " C H E C K F U E L C A P " 2. T h e m e s s a g e s h o u l d g o off after s e v e r a l d a y s of
m e s s a g e a p p e a r s in the g a u g e d i s p l a y (A). T o s c r o l l to normal driving.
a n o t h e r m e s s a g e , p r e s s t h e s e l e c t / r e s e t button.
T h e " C H E C K F U E L C A P " m e s s a g e will a p p e a r e a c h t i m e To make the message go off (Without the
y o u restart t h e e n g i n e until t h e s y s t e m t u r n s the HDS)
m e s s a g e off. T u r n t h e e n g i n e off t h e n r e p l a c e or tighten
t h e fuel fill c a p until it c l i c k s at least o n c e . Procedure
1. T i g h t e n the fuel fill c a p until it c l i c k s .
2. S t a r t t h e e n g i n e , t h e n t u r n t h e ignition s w i t c h O F F .
3. R e p e a t s t e p 2 t w o m o r e t i m e s .
Shows "CHECK FUEL CAP"

in t h e g a u g e d i s p l a y
To make the message go off (With the HDS)
Procedure
1. T i g h t e n t h e fuel fill c a p until it c l i c k s .
2. C l e a r t h e T e m p o r a r y D T C w i t h t h e H D S .
3. Verify t h e r e is n o leak by d o i n g t h e E V A P
F U N C T I O N T E S T in t h e I N S P E C T I O N M E N U with
the H D S .
(cont'd)
11-243
Electronic Throttle Control System Diagram
T h e e l e c t r o n i c throttle control s y s t e m c o n s i s t s of t h e throttle actuator, throttle position (TP) s e n s o r A / B , a c c e l e r a t o r

p e d a l position (APP) s e n s o r A / B , t h e throttle a c t u a t o r c o n t r o l m o d u l e , a n d the E C M .
APP
From
SENSOR A <4 THROTTLE ACTUATOR
YEL/RED
RED/BLU CONTROL MODULE RELAY
GRN/WHT
APP THROTTLE ACTUATOR
SENSOR B CONTROL MODULE
YEL/BLU
RED/YEL
GRN —
From
THROTTLE
YEL/GRN • I ACTUATOR
1
CONTROL
MODULE
RELAY
BLK
11-244
Evaporative Emission (EVAP) Control Diagram
T h e E V A P c o n t r o l s m i n i m i z e t h e a m o u n t of fuel v a p o r e s c a p i n g to t h e a t m o s p h e r e . V a p o r f r o m t h e fuel t a n k is
t e m p o r a r i l y s t o r e d in t h e E V A P c a n i s t e r until it c a n b e p u r g e d f r o m t h e c a n i s t e r into t h e e n g i n e a n d b u r n e d .
T h e E V A P c a n i s t e r is p u r g e d b y d r a w i n g f r e s h air t h r o u g h it a n d into a port o n t h e intake m a n i f o l d .

T h e p u r g i n g v a c u u m is c o n t r o l l e d by t h e E V A P c a n i s t e r p u r g e v a l v e , w h i c h o p e r a t e s w h e n e v e r e n g i n e c o o l a n t
t e m p e r a t u r e is a b o v e 149 °F (65 *€).
VARIOUS
SENSORS
F U E L FILLER V A P O R
RECIRCURATIOIM T U B E
^ From
<4 A / F S E N S O R
R E L A Y (LAF)
FUEL FILLER
^ F r o m No. 6
4 A C G (15 A )
FUSE
(cont'd)
11-245
E C M Circuit Diagram
ECM 20P JUNCTION

CONNECTOR
I IIIIIIII
-YEL/BLK •
'—c INJ1
No. 11NJECTOR
1
-YEL/BLK •
-RED •
No. 2 INJECTOR
1 r —
-YEL/BLK •
1
No. 3 INJECTOR
-YEL/BLK •
INJ4
-YEL 1
No. 4 INJECTOR
-YEL/BLK •
IGP1
A2
-YEL/BLK •
12V
5V
-YEL/BLK
-GRN -
-BRN/YEL-
CMP SENSOR
-YEL/BLK
3 1 A7
CKP
-BLU •
YEL/ -BRN/YEL
BLK
C105 CKP SENSOR
C101
11-246
ROCKER ARM OIL
PRESSURE SWITCH
(VTEC OIL
PRESSURE SWITCH)
3 VTPSW
-BLU/BLK
-BRN/YEL
1
-GRN/YEL •
ROCKER ARM OIL

CONTROL SOLENOID
(VTEC SOLENOID ,
VALVE) -i
A21
-YEL/RED
MAP
-GRN/RED I MAP SENSOR
A24
-GRN/WHT•
KNOCKSENSOR
A1
TRED/BLU : TRED/BLU •
-RED/BLU -RED/BLU • To IMMOBILIZER UNIT
C404
(cont'd)
11-247
-GRN/YEL • -GRN/YEL -
SG2
B17
-RED/YEL RED/YEL -RED/YEL
IAT
C101 IAT SENSOR
-GRN/YEL
-RED/WHT • -RED/WHT
ECT1
d
1
ECT SENSOR 1
a
C102
GRN/
WHT
d
>3L C304
GRN/
-GRN -
-BLU -
ECT SENSOR 2
WHT
- BRN/YEL -BRN/YEL
LG1
A8 20P
• BRN/YEL -BRN/YEL JUNCTION
CONNECTOR
-BRN/YEL
- BRN/YEL
G101
11-248
C301
9
-BLK/YEL 4J BLK/YEL -
C101
-YEL/BLU
Hi— RED/YEL • -RED/YEL
EVAP CANISTER
PURGE VALVE
C404 C101
-BLK/YEL -BLK/YEL -BLK/YEL -
B10
w- -WHT/BLU -WHT/BLU
-WHT/RED
-WHT/GRN •
B13
-WHT/RED
ALTF 20P
JUNCTION ALTERNATOR
B18 CONNECTOR
"id* ALTC
-WHT/GRN •
rrm
X 15
-BLK/YEL
1
—nnrs
" SPARK
No. 11GNITION COIL
-BLK/YEL *^To
SPARK
-WHT/GRN •
IGPLS2
-BLK •
No. 2 IGNITION COIL
-BLK/YEL r
44- ffiP—•To
SPARK
-WHT/BLK PLUG
IGPLS3 ICM
No. 3 IGNITION COIL
X j -WHT/BLU -
-BLK/YEL
•|4-^-^To
PLUG
SPARK
-BLK •
BLK/
YEL
1—<Wn
No. 4 IGNITION COIL
il
cioi l - H
GRN/
YEL
A
(cont'd)
11-249
APP SENSOR A
C102 -YEL/RED
A26
-RED/BLU -RED/BLU -RED/BLU
APSA
^7 A20
VCC2
-YEL/BLU - YEL/RED
-GRN/WHT •
-YEL/BLU "
APPSENSORB
A25
APSB
-RED/YEL -RED/YEL
-RED/YEL •
3
APP SENSOR
-YEL/GRN
SEFD
B20
-WHT/BLU • —GRN——
-WHT/BLK • —BLU
TYEL/ -RED/BLK
— RED/BLU
— RED/BLK
GRN
-GRN - —GRN •
-BLU • —BLU •
-BLK • — BLK -
THROTTLE ACTUATOR
CONTROL MODULE
.BLU
-RED/BLK •
-RED
-WHT/BLK -
-WHT/BLU -
THROTTLE
ACTUATOR
BARO SENSOR
(Buitt into the ECM) THROTTLE BODY
11-250
A31
• RED - -RED
AFS+
A28 -RED/YEL
AFS—
• RED/YEL
-GRN - -wv j
A10 -WHT/BLK
-GRN
A/F SENSOR
C101 (SENSOR 1)
-GRN/WHT
LG3
E20
SH02S
5
WHT --3W*H*|
11 -GRN/YEL -
|-HC404 - BLK/WHT •
-BLK/YEL -
- BLK/WHT
SECONDARY
H02S (SENSOR 2)
-BLU/BLK - BLU/BLK
EPSLD "1*1
I 12P JUNCTION EPS CONTROL
J CONNECTOR UNIT
Jf
"BLU- 3 TEST
TACHOMETER
CONNECTOR
r "i
GAUGE ASSEMBLY
B26
- YEL • -YEL
30P CONNECTOR
-WHT/BLK - WHT/BLK —
BKSW
D8
C403
C453
| WHT/GRN —
2
^3 Brake pedal pressed: closed
Brake pedal released: open
BKSWNC
D4
-GRY-
-HP •GRY- -GRY-
Brake pedal pressed: open
"Brake pedal
• •released:
• l:clos«
closed
- LTGRN •
BRAKE PEDAL
To POSITION SWITCH
CRUISE
• CONTROL
MAIN
SWITCH
To
D1 CRUISE
-LT GRN/RED — -LT GRN/RED CONTROL
CCSETSW
- SET/DECEL,
D7 9 RESUME/ACCEL,
-LTGRN/BLK -LT GRN/RED CANCEL
CCRESSW SWITCH
C404
(cont'd)
11-251
E C M Circuit Diagram (cont'd)
*1
I 12P JUNCTION I
10
i i 8
1 r
1 —BRN -BRN
C404 -WHT/GRN -
-GRN/WHT •
DATA LINK
CONNECTOR
-GRN/WHT •
-ft
C453
-GRN/WHT •
-RED
14
-WHT •
-Q-
G401
12P JUNCTION
CONNECTOR
rrn rrn
iL
-RED •
CANH
^ VSA MODULATOR-
E24 ^ CONTROL UNIT
•WHT • -WHT •
4 CANL
^
STEERING ANGLE
SENSOR
_w VSA MODULATOR-
CONTROL UNIT
> 3 . ft PNK -
I
C453 BLK
CRUISE CLUTCH PEDAL
POSITION SWITCH
G401
EVAP CANISTER
VENT SHUT VALVE
* 1 : '08 m o d e l
11-252
i
' f
i YEL/BLU — — -
-BLU/WHT
Q M GRN/YEL
2
f§gl
OUTPUT SHAFT
(COUNTERSHAFT)
A5 SPEED SENSOR
-BLK •
-BLK •
G10
r 3
YEL/GRN
BLK—
G601
-BLK/YEL BLK/YEL C403 -YEL/GRN •

IG1
-BLK/YEL -
E17
-GRN/YEL -GRN/YEL •
IMOFPR
-YEL/BLK •
PGM-FI
MAIN RELAY 2
(FUEL PUMP)
-YEL/BLK
E7 HQ-
-WHT/GRN -
-GRN
-WHT/GRN-
5?
C453
PGM-FI
MAIN RELAY 1
(Fl MAIN)
-YEL/GRN -
- BLU/WHT - «-0"j-T>ji
-BRN •
C453 -YEL/GRN -
THROTTLE
AC ACTUATOR
CONTROL
MODULE RELAY
- WHT/RED- JLr~
2
E8
-ORN
ft -YEL/BLU
A/F SENSOR
RELAY (LAF)
T GRN/YEL-
C453 It
-BLK/YEL -
- GRN/YEL -
-GRN —
-BLK/YEL -
IGNITION COIL
RELAY
(IG COIL)
(cont'd)
11-253
E28
-BLU/RED -BLU/RED •
-BLU/WHT •
A/C PRESSURE
C204 SWITCH
UNDER-HOOD FUSE/RELAY BOX

7P CONNECTOR
-WHT/GRN H]— WHT/GRN —
C201
16P CONNECTOR
E18 11
-RED -
ACC
F "" A/C COMPRESSOR
CLUTCH RELAY
J12P JUNCTION |
{CONNECTOR
i
E12
RADIATOR
FAN RELAY
i—nnp ,
CONDENSOR
FAN RELAY
-BLK/YEL
YEL
3P CONNECTOR
WHT
18P CONNECTOR L
WHT/GRN -O—O-
C201 3P CONNECTOR
0
BLK/YEL -
-GRN/RED - GRN/RED -
—BLK — -
UNDER-HOOD FUSE/RELAY BOX

0 N o . 47 S T O P (15 A )
2 N o . 5 9 D B W (20 A )
( D N o . 4 2 I G 1 M A I N (40 A )
4 N o . 4 6 A C G S (15 A )
® N o . 41 B A T T E R Y ( 1 0 0 A )
C201 IC201 E
X— ®"
*1:'08 model
*3: with A / C Jk Jk JL
AG AH Al rA,
AJ
" CATTED
11-254
Al AH AG J Z [V] AB [AE]
MAIN UNDER-DASH FUSE/RELAY BOX
MAIN UNDER-DASH
FUSE/RELAY BOX:
© N o . 6 A C G (15 A )
1 N o . 2 F U E L P U M P S R S (15 A )
3 N o . 11 I G P ( D B W ) (7.5 A )
4 N o . 10 I G P ( L A F ) (7.5 A )
( D N o . 15 L A F (20 A ) * 2 (15 A ) *1
6 N o . 14 D B W (15 A )
(DNo. 16 I G C O I L (15 A )
8 N o . 3 E N G I N E S T A R T (7.5 A )
(DNo. 20 H E A T E R C O N T R O L
C O O L I N G F A N R E L A Y (7.5 A )
*1:'08 model
* 2 : '06-07 m o d e l s
11-255
How to Set Readiness Codes
Malfunction Indicator Lamp (MIL) Indication Catalytic Converter Monitor and Readiness
(In relation to Readiness Codes) Code
T h e v e h i c l e h a s c e r t a i n " r e a d i n e s s c o d e s " that a r e part NOTE:

of the o n - b o a r d d i a g n o s t i c s for t h e e m i s s i o n s s y s t e m s . • D o not turn the ignition s w i t c h off d u r i n g the
If the v e h i c l e ' s battery h a s b e e n d i s c o n n e c t e d or g o n e procedure.
d e a d , if t h e D T C s h a v e b e e n c l e a r e d , or if the E C M h a s • A l l r e a d i n e s s c o d e s a r e c l e a r e d w h e n the battery is
b e e n r e s e t , t h e s e r e a d i n e s s c o d e s a r e r e s e t to d i s c o n n e c t e d , if the D T C s h a v e b e e n c l e a r e d , or if the
i n c o m p l e t e . In s o m e s t a t e s , part of the e m i s s i o n s E C M is r e s e t w i t h the H D S .
t e s t i n g is to m a k e s u r e t h e s e c o d e s a r e s e t to c o m p l e t e . • L o w a m b i e n t t e m p e r a t u r e s or e x c e s s i v e s t o p - a n d - g o
If all of t h e m a r e not s e t to c o m p l e t e , the v e h i c l e m a y traffic m a y i n c r e a s e the drive t i m e n e e d e d to s w i t c h
fail the e m i s s i o n t e s t , or t h e t e s t c a n n o t be f i n i s h e d . t h e r e a d i n e s s c o d e f r o m i n c o m p l e t e to c o m p l e t e .
• T h e r e a d i n e s s c o d e will not s w i t c h to c o m p l e t e until
T o c h e c k if t h e r e a d i n e s s c o d e s a r e s e t to c o m p l e t e , all t h e e n a b l e criteria a r e met.
turn t h e ignition s w i t c h O N (II), but d o not start the • If a fault in t h e s e c o n d a r y H 0 2 S s y s t e m c a u s e d the
e n g i n e . T h e M I L w i l l c o m e o n for 1 5 — 2 0 s e c o n d s . If it M I L to c o m e o n , the r e a d i n e s s c o d e c a n n o t be s e t to
t h e n g o e s off, t h e r e a d i n e s s c o d e s a r e c o m p l e t e . If it c o m p l e t e until y o u c o r r e c t the fault.
f l a s h e s f i v e t i m e s , o n e or m o r e r e a d i n e s s c o d e s a r e not
s e t to c o m p l e t e . T o s e t r e a d i n e s s c o d e s f r o m E n a b l e Criteria
i n c o m p l e t e to c o m p l e t e , d o t h e p r o c e d u r e for the
appropriate code. • E C T S E N S O R 1 at 158 °F (70 °C) or m o r e .
• I A T S E N S O R at 20 °F ( - 7 °C) or m o r e .
T o c h e c k t h e s t a t u s of a s p e c i f i c D T C s y s t e m , c h e c k the • V S S r e a d s m o r e t h a n 2 5 m p h (40 k m / h ) .
O B D s t a t u s in t h e D T C M E N U w i t h the H D S ( s e e p a g e
11-218). T h i s s c r e e n d i s p l a y s t h e c o d e , t h e c u r r e n t d a t a Procedure
list of t h e e n a b l e c r i t e r i a , a n d t h e s t a t u s of the r e a d i n e s s
testing. 1. C o n n e c t the H D S to the v e h i c l e ' s data link
c o n n e c t o r ( D L C ) , a n d bring up t h e R E A D I N E S S
C O D E s s c r e e n for C a t a l y s t in the D T C s M E N U .
3. T e s t - d r i v e the v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . After a b o u t
5 m i l e s (8 k m ) , the r e a d i n e s s c o d e s h o u l d s w i t c h to
completed.
4. If t h e r e a d i n e s s c o d e is still not s e t to c o m p l e t e ,
c h e c k for a T e m p o r a r y D T C w i t h the H D S . If t h e r e is
n o D T C , o n e or m o r e of the e n a b l e criteria w e r e
p r o b a b l y not m e t ; r e p e a t the p r o c e d u r e .
11-256
4*
Evaporative Emission (EVAP) Control Air Fuel Ratio (A/F) Sensor Monitor and
System Monitor and Readiness Code Readiness Code
N O T E : All r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery NOTE:

is d i s c o n n e c t e d , if the D T C s h a v e b e e n c l e a r e d , or if t h e • D o not t u r n t h e ignition s w i t c h off d u r i n g the
E C M is r e s e t w i t h the H D S . procedure.
• AH r e a d i n e s s c o d e s a r e c l e a r e d w h e n the battery i s
Enable Criteria d i s c o n n e c t e d , if t h e D T C s h a v e b e e n c l e a r e d , o r if the
E C M is r e s e t w i t h t h e H D S .
• Battery v o l t a g e is h i g h e r t h a n 10.5 V .
• E n g i n e at idle. Enable Criteria
• E C T S E N S O R 1 a n d S E N S O R 2 b e t w e e n 176 °F (80 <€)
a n d 2 1 2 °F (100 <€). E C T S E N S O R 1 at 140 °F (60 °C) or m o r e .
• M A P s e n s o r l e s s t h a n 46.6 kPa (14 i n . H g , 3 5 0 m m H g ) .
• V S S 0 m p h (0 k m / h ) . Procedure
• I A T S E N S O R b e t w e e n 32 °F (0 °Z) a n d 2 1 2 °F (100 <€). 1. Start t h e e n g i n e .
Procedure 2. T e s t - d r i v e t h e v e h i c l e u n d e r s t o p - a n d - g o c o n d i t i o n s
1. C o n n e c t the H D S to the v e h i c l e ' s data link w i t h s h o r t p e r i o d s of s t e a d y c r u i s e . D u r i n g t h e
connector (DLC). d r i v e , d e c e l e r a t e (with t h e throttle fully c l o s e d ) for
5 s e c o n d s . After a b o u t 3.5 m i l e s (5.6 k m ) , the
2. S t a r t the e n g i n e . r e a d i n e s s c o d e s h o u l d s w i t c h f r o m i n c o m p l e t e to
complete.
3. S e l e c t E V A P T E S T in the I N S P E C T I O N M E N U w i t h
the H D S , t h e n s e l e c t t h e F U N C T I O N T E S T in the 3. C h e c k t h e r e a d i n e s s c o d e s s c r e e n for t h e A I R F U E L
EVAP T E S T MENU. R A T I O (A/F) S E N S O R in t h e D T C s M E N U w i t h t h e
HDS.
• If the result is a r e n o r m a l , r e a d i n e s s is c o m p l e t e .
• If t h e result is a r e not n o r m a l , g o to t h e next s t e p . • If the s c r e e n s h o w s c o m p l e t e , r e a d i n e s s is
complete.
4. C h e c k for a T e m p o r a r y D T C . If t h e r e is n o D T C , o n e • If t h e s c r e e n s h o w s not c o m p l e t e , g o to t h e next
or m o r e of the e n a b l e criteria w e r e p r o b a b l y not step.
m e t ; r e p e a t the p r o c e d u r e .
4. C h e c k for a T e m p o r a r y D T C . If t h e r e i s no D T C , t h e
e n a b l e criteria w a s p r o b a b l y not met. S e l e c t the
D A T A L I S T M e n u . C h e c k the E C T S E N S O R 1 in t h e
A L L D A T A L I S T w i t h the H D S . If E C T S E N S O R 1 is
l o w e r t h a n 140 °F (60 °C), run t h e e n g i n e until it is
h i g h e r t h a n 140 °F (60 °C), t h e n r e p e a t the
procedure.
(cont'd)
11-257
How to Set Readiness Codes (cont'd)
Air Fuel Ratio (A/F) Sensor Heater Monitor
Readiness Code
N O T E : A l l r e a d i n e s s c o d e s a r e c l e a r e d w h e n t h e battery
is d i s c o n n e c t e d , if t h e D T C s h a v e b e e n c l e a r e d , or if the
E C M is r e s e t w i t h t h e H D S .
Procedure
1. Start t h e e n g i n e , a n d let it idle for 1 m i n u t e . T h e

complete.
2 . If the r e a d i n e s s c o d e is still not s e t to c o m p l e t e ,

c h e c k for a T e m p o r a r y D T C . If t h e r e is n o D T C ,
repeat t h e p r o c e d u r e .
Misfire Monitor and Readiness Code

• T h i s r e a d i n e s s c o d e i s a l w a y s s e t to a v a i l a b l e
b e c a u s e m i s f i r i n g is c o n t i n u o u s l y m o n i t o r e d .
• M o n i t o r i n g p a u s e s , a n d the m i s f i r e c o u n t e r r e s e t s , if
the vehicle is driven o v e r a rough road.
• Monitoring a l s o p a u s e s , a n d the misfire counter
. h o l d s at its c u r r e n t v a l u e , if t h e throttle position
c h a n g e s m o r e t h a n a p r e d e t e r m i n e d v a l u e , o r if
d r i v i n g c o n d i t i o n s fall o u t s i d e the r a n g e of a n y
related e n a b l e criteria.
Fuel System Monitor and Readiness Code
• T h i s r e a d i n e s s c o d e i s a l w a y s s e t to a v a i l a b l e
b e c a u s e t h e fuel s y s t e m is c o n t i n u o u s l y m o n i t o r e d
during c l o s e d loop operation.
• Monitoring p a u s e s w h e n the catalytic converter,
E V A P control s y s t e m , a n d A / F s e n s o r m o n i t o r s a r e
active.
• M o n i t o r i n g a l s o p a u s e s w h e n a n y related e n a b l e
criteria a r e not b e i n g m e t . M o n i t o r i n g r e s u m e s w h e n
the e n a b l e criteria is a g a i n b e i n g m e t .
Comprehensive Component Monitor and

Readiness Code
T h i s r e a d i n e s s c o d e is a l w a y s s e t t o a v a i l a b l e b e c a u s e
the c o m p r e h e n s i v e c o m p o n e n t m o n i t o r is c o n t i n u o u s l y
r u n n i n g w h e n e v e r t h e e n g i n e is c r a n k i n g or r u n n i n g .
11-258
PGM-FI System
E L E C T R I C A L L O A D D E T E C T O R (ELD)
C A M S H A F T POSITION
(CMP) S E N S O R
R e p l a c e m e n t p a g e 11-387
ENGINE COOLANT
TEMPERATURE
(ECT) S E N S O R 1
KNOCK SENSOR
MANIFOLD ABSOLUTE
P R E S S U R E (MAP) S E N S O R
INTAKE AIR T E M P E R A T U R E
(IAT) S E N S O R
CRANKSHAFT POSITION
(CKP) S E N S O R
(ECT) S E N S O R 2
(cont'd)
11-259
PGM-FI System
ENGINE C O N T R O L M O D U L E (ECM) D A T A LINK C O N N E C T O R (DLC)

General Troubleshooting General Troubleshooting
Information, page 11-213 Information, page 11-213
Updating, page 11-216 Troubleshooting, page 11-367
Substitution, page 11-217
Replacement, page 11-389
11-260
DTC Troubleshooting
DTC P0107: MAP Sensor Circuit Low Voltage 7. M e a s u r e v o l t a g e b e t w e e n M A P s e n s o r 3 P

c o n n e c t o r t e r m i n a l s N o . 1 a n d N o . 3.
a n d a n y on-board s n a p s h o t , and r e v i e w the general MAP S E N S O R 3P C O N N E C T O R
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213).
1. T u r n the ignition s w i t c h O N (II). VCC1

(YEL/RED)
1 2 3
2. C h e c k t h e M A P S E N S O R in t h e D A T A L I S T w i t h t h e SG1
HDS. (GRN/WHT)

less indicated?
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s Is there about 5 V?
at the M A P s e n s o r a n d t h e E C M . •
NO—Goto step8.
4. D i s c o n n e c t t h e M A P s e n s o r 3 P c o n n e c t o r .
5. T u r n the ignition s w i t c h O N (II). t e r m i n a l s A21 a n d A 2 4 .
6. C h e c k t h e M A P S E N S O R in t h e D A T A L I S T w i t h t h e
HDS.

less indicated? 1 | 2 3 4 | 5 6 | 7 | 8 | 9 VCC1
(YEL/RED)
10
// 13 14 15 16
/ / 18 20 21
SGI
/ 23 24 25 26
/ / 28 30 31
N O — G o to s t e p 7. (GRN/WHT)
Is thereabouts V?
(A21) a n d t h e M A P s e n s o r , t h e n g o to s t e p 15.
(cont'd)
11-261
PGM-FI System
9. T u r n the ignition s w i t c h O F F . 19. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
10. J u m p t h e S C S line w i t h t h e H D S . Is DTC P0107 indicated?
11. D i s c o n n e c t E C M c o n n e c t o r A (31P). Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

t e r m i n a l s at t h e M A P s e n s o r a n d t h e E C M , t h e n g o
12. C h e c k for continuity b e t w e e n M A P s e n s o r 3 P to s t e p 1.
N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
indicated D T C s troubleshooting. •
MAP 2 1 . R e c o n n e c t all c o n n e c t o r s .
(GRN/RED)
2 2 . U p d a t e t h e E C M if it d o e s not h a v e the latest
g o o d E C M ( s e e p a g e 11-217).
W i r e s i d e of f e m a l e t e r m i n a l s 2 3 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .

Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M t e r m i n a l s at t h e M A P s e n s o r a n d t h e E C M . If t h e
(A30) a n d t h e M A P s e n s o r , t h e n g o to s t e p 15. E C M w a s updated, substitute a known-good E C M
( s e e p a g e 11-217), t h e n r e c h e c k . If t h e E C M w a s
N O — G o to s t e p 2 1 . s u b s t i t u t e d , g o to s t e p 1.
13. T u r n t h e ignition s w i t c h O F F . N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
14. R e p l a c e t h e M A P s e n s o r ( s e e p a g e 11-384). original E C M ( s e e p a g e 11-389). If a n y other
15. R e c o n n e c t all c o n n e c t o r s . indicated D T C s troubleshooting. •
17. R e s e t the E C M w i t h t h e H D S .
18. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
11-262
DTC P0108: MAP Sensor Circuit High Voltage 8. R e m o v e t h e j u m p e r w i r e f r o m t h e M A P s e n s o r 3 P
connector.
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l 9. M e a s u r e v o l t a g e b e t w e e n M A P s e n s o r 3 P
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). c o n n e c t o r t e r m i n a l s N o . 1 a n d N o . 3.
HDS. VCC1 A.
(YEL/RED) . — A
1 2 3
Is about 160 kPa (47.1 in.Hg, 1,197 mmHg), or
4.49 V or more indicated? SGI
(GRN/WHT)
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
at t h e M A P s e n s o r a n d t h e E C M . •
3. T u r n t h e ignition s w i t c h O F F . Is there about 5 V?
4. D i s c o n n e c t t h e M A P s e n s o r 3 P c o n n e c t o r . Y E S — G o to s t e p 15.
5. C o n n e c t t h e M A P s e n s o r 3 P c o n n e c t o r t e r m i n a l s N O — G o to s t e p 10.
No. 2 a n d N o . 3 w i t h a j u m p e r w i r e .
11. J u m p t h e S C S line w i t h t h e H D S .
I 1 (z\ 3|
MAP SGI 13. C o n n e c t M A P s e n s o r 3 P c o n n e c t o r t e r m i n a l N o . 3
(GRN/RED) (GRN/WHT) to b o d y g r o u n d w i t h a j u m p e r w i r e .
JUMPER WIRE M A P S E N S O R 3P C O N N E C T O R
vv
1[2|3l
SGI
(GRN/WHT)
7. C h e c k t h e M A P S E N S O R in t h e D A T A L I S T w i t h t h e JUMPER WIRE
HDS.
Is about 160 kPa (47.1 in.Hg, 1,197 mmHg), or W i r e s i d e of f e m a l e t e r m i n a l s

4.49 V or more indicated?
(cont'd)
11-263
PGM-FI System
14. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 17. T u r n t h e ignition s w i t c h O N (II).

HDS.
Is about 160 kPa (47.1 in.Hg, 1,197 mmHg), or

1 I2 | 3 | 4 | 5 6 | 7 | 8 | 9 4.49 V or more indicated?
10
/ 13 14 15 16 18
/ / 20 21
SGI
23 24 25 26
/ / 28 30 31 Y E S — G o to s t e p 2 6 .
(GRN/WHT) N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
(A30) a n d t h e M A P s e n s o r , t h e n g o to s t e p 2 1 .
20. R e p l a c e t h e M A P s e n s o r ( s e e p a g e 11-384).
Is there continuity? 2 1 . R e c o n n e c t all c o n n e c t o r s .
Y E S — G o to s t e p 2 7 . 2 2 . T u r n t h e ignition s w i t c h O N (II).
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M 23. R e s e t the E C M with the H D S .

(A24) a n d t h e M A P s e n s o r , t h e n g o to s t e p 2 1 .
2 5 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h H D S .
16. C o n n e c t E C M c o n n e c t o r t e r m i n a l s A 2 4 a n d A 3 0
with a j u m p e r wire. Is DTC P0108 indicated?
t e r m i n a l s at t h e M A P s e n s o r a n d the E C M , t h e n g o
to s t e p 1.
2 J3 4 5 8 J9 N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
10 13 14 15 16 18 20 21 T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
23 24 25 26 28 30 31 indicated D T C s troubleshooting. •
SG1 MAP
(GRN/WHT) (GRN/RED)
JUMPER WIRE
11-264
2 7 . R e c o n n e c t all c o n n e c t o r s .
2 8 . U p d a t e t h e E C M if it d o e s not h a v e t h e latest
s o f t w a r e ( s e e p a g e 11-216), o r s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
2 9 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
t e r m i n a l s at t h e M A P s e n s o r a n d t h e E C M . If t h e
E C M w a s updated, substitute a known-good E C M
s u b s t i t u t e d , g o to s t e p 1.
N O — I f the E C M w a s updated, troubleshooting is

original E C M ( s e e p a g e 11-389). If a n y o t h e r
T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to t h e
PGM-FI System
DTC P0111: IAT Sensor Circuit Range/ 12. C h e c k t h e I A T S E N S O R in the D A T A L I S T w i t h the

Performance Problem HDS.
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data Does the IAT SENSOR change 58 °F (32 °C) or

a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l more?
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213).
Y E S — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at this
1. C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
E C T s e n s o r 1, E C T s e n s o r 2 , a n d the I A T s e n s o r . at the I A T s e n s o r a n d t h e E C M . •
Are the connections and terminals OK ? N O — G o to s t e p 13.
Y E S — G o to s t e p 2. 13. T u r n the ignition s w i t c h O F F .
N O — R e p a i r the connections or terminals, then go 14. R e p l a c e the I A T s e n s o r ( s e e p a g e 11-384).

to s t e p 15.
2 . R e m o v e the I A T s e n s o r ( s e e p a g e 11-384).
3. A l l o w t h e I A T s e n s o r to c o o l to a m b i e n t
temperature. 17. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
4. Note the a m b i e n t t e m p e r a t u r e . 18. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
5. C o n n e c t I A T s e n s o r to its 2 P c o n n e c t o r , but d o not Is DTC P0111 indicated?

install it o n the intake air d u c t .
Y E S — C h e c k for poor c o n n e c t i o n s or l o o s e
6. T u r n t h e ignition s w i t c h O N (II). t e r m i n a l s at t h e I A T s e n s o r a n d t h e E C M , t h e n g o to
s t e p 1.
7. Note the v a l u e of t h e I A T S E N S O R q u i c k l y in t h e
D A T A L I S T w i t h the H D S . N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to the
8. C o m p a r e the v a l u e of t h e I A T S E N S O R a n d t h e indicated D T C s troubleshooting. •
ambient temperature.
Does the value of the IAT SENSOR differ 5.4 °F

(3 °C) or more?
9. D i s c o n n e c t t h e I A T s e n s o r f r o m t h e 2 P c o n n e c t o r .
10. U s i n g a h e a t g u n , b l o w hot air o n t h e I A T s e n s o r for

a f e w s e c o n d s . D o not a p p l y t h e h e a t l o n g e r t h a n a
f e w s e c o n d s or y o u w i l l d a m a g e t h e s e n s o r .
11. C o n n e c t t h e I A T s e n s o r to its 2 P c o n n e c t o r , but d o

not install it o n the intake air d u c t .
11-266
DTC P0112: IAT Sensor Circuit Low Voltage 10. C h e c k f o r c o n t i n u i t y b e t w e e n I A T s e n s o r 2 P
a n d a n y on-board s n a p s h o t , and review the general
2. C h e c k t h e I A T S E N S O R in t h e D A T A L I S T w i t h t h e IAT
HDS. (RED/YEL)
Is about 356 °F (180 °C) or higher, or 0.08 V or

less indicated?
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s Is there continuity?
at t h e I A T s e n s o r a n d t h e E C M . •
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e I A T
3. T u r n the ignition s w i t c h O F F . s e n s o r a n d t h e E C M (B17), t h e n g o to s t e p 13.
4. D i s c o n n e c t the I A T s e n s o r 2 P c o n n e c t o r . N O — G o to s t e p 18.
5. T u r n the ignition s w i t c h O N (II). 11. T u r n t h e ignition s w i t c h O F F .
6. C h e c k t h e I A T S E N S O R in t h e D A T A L I S T w i t h t h e 12. R e p l a c e t h e I A T s e n s o r ( s e e p a g e 11-384).
HDS.
13. R e c o n n e c t all c o n n e c t o r s .
less indicated? 14. T u r n t h e ignition s w i t c h O N (II).
Y E S — G o to s t e p 7. 15. R e s e t t h e E C M w i t h t h e H D S .
N O — G o to s t e p 11. 16. D o t h e E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
8. J u m p t h e S C S line w i t h the H D S .
(cont'd)
11-267
PGM-FI System
17. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
t e r m i n a l s at t h e I A T s e n s o r a n d t h e E C M , t h e n g o to
s t e p 1.
N O — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y o t h e r
19. U p d a t e the E C M if it d o e s not h a v e t h e latest

g o o d E C M ( s e e p a g e 11-217).
Is DTCP0112 indicated?
t e r m i n a l s at t h e I A T s e n s o r a n d t h e E C M . If t h e E C M
w a s updated, substitute a known-good E C M
N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
11-268
DTC P0113: IAT Sensor Circuit High Voltage 8. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a 9. R e m o v e t h e j u m p e r w i r e f r o m t h e IAT s e n s o r 2 P
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l connector.
11. M e a s u r e v o l t a g e b e t w e e n I A T s e n s o r 2 P c o n n e c t o r
2. C h e c k t h e I A T S E N S O R in t h e D A T A L I S T w i t h t h e terminal No. 1 a n d body ground.
HDS.
Is about -40°F( -40 °C) or less, or 4.92 V or
more Indicated?
IAT
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s (RED/YEL)
at t h e I A T s e n s o r a n d the E C M . •
4. D i s c o n n e c t the I A T s e n s o r 2 P c o n n e c t o r .
5. C o n n e c t I A T s e n s o r 2 P c o n n e c t o r t e r m i n a l s No. 1 Is there about 5 V?

a n d No. 2 with a j u m p e r wire.
TTgl 13. J u m p t h e S C S line w i t h t h e H D S .

IAT SG3
(RED/YEL) (GRN)
JUMPER WIRE
15. C o n n e c t I A T s e n s o r 2 P c o n n e c t o r t e r m i n a l No. 2 to
7. C h e c k t h e I A T S E N S O R in t h e D A T A L I S T w i t h t h e
HDS.
SG3
(GRN)
Is about - 40 °F ( -40 °C) or less, or 4.92 V or
JUMPER WIRE
more indicated?
(cont'd)
11-269
PGM-FI System
16. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 18. T u r n t h e ignition s w i t c h O F F .
terminal E 4 and body ground.
19. R e p l a c e t h e I A T s e n s o r ( s e e p a g e 11-384).
S G 3 (GRN) f
1
1 X 3 | 4 | 5
22. R e s e t the E C M with the H D S .
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 2 7 28 2 9 30
/ 2 3 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 4 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
W i r e s i d e of f e m a l e t e r m i n a l s Is DTC P0113 indicated?
Is there continuity? t e r m i n a l s at t h e I A T s e n s o r a n d t h e E C M , t h e n g o to
s t e p 1.
Y E S — G o to s t e p 2 6 .
N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M (E4) T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
a n d t h e I A T s e n s o r , t h e n g o to s t e p 2 0 . indicated D T C s troubleshooting. •
17. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 2 5 . T u r n t h e ignition s w i t c h O F F .
B17 and body ground.
/ 2 | 3 4 | 5 g o o d E C M ( s e e p a g e 11-217).
8
/ 10 11
/ ///
13
17 18 19
///
20 21
IAT ( R E D / Y E L )
t e r m i n a l s at t h e I A T s e n s o r a n d t h e E C M . If t h e E C M
W i r e s i d e of f e m a l e t e r m i n a l s w a s updated, substitute a known-good E C M
Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
(B17) a n d t h e I A T s e n s o r , t h e n g o to s t e p 2 0 . original E C M ( s e e p a g e 11-389). If a n y o t h e r
N O — G o to s t e p 2 5 . indicated D T C s troubleshooting. •
11-270
DTC P0116: ECT Sensor 1 Circuit Range/ 10. C h e c k E C T S E N S O R 1 in the D A T A L I S T w i t h the
Performance Problem HDS.
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data Does ECT SENSOR 1 change 18 °F (10 °C) or

a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l more?
Y E S — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s
1. T u r n the ignition s w i t c h O N (II). t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
at E C T s e n s o r 1 a n d the E C M . •
2. C h e c k E C T S E N S O R 1 in t h e D A T A L I S T w i t h the
HDS. N O — G o to s t e p 11.
Is about 176 °F (80 °C) or higher, or 0.78 V or less 11. T u r n the ignition s w i t c h O F F .
indicated?
12. R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385).
14. R e s e t t h e E C M w i t h t h e H D S .
3. Note the v a l u e of E C T S E N S O R 1 in the D A T A L I S T
w i t h the H D S . 15. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
4. Start the e n g i n e . Hold the e n g i n e s p e e d at 16. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .

radiator f a n c o m e s o n , t h e n let it idle. Is DTC P0116 indicated?
5. C h e c k E C T S E N S O R T i n the D A T A L I S T w i t h the Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

HDS. t e r m i n a l s at E C T s e n s o r 1 a n d the E C M , t h e n go to
s t e p 1.
Does ECT SENSOR 1 change 18 °F (10 °C) or
more? N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
T e m p o r a r y D T C s or D T C s are i n d i c a t e d , g o to the
Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s indicated D T C s troubleshooting. •
6. Note the v a l u e of E C T S E N S O R 1 in t h e D A T A L I S T
w i t h the H D S .
8. O p e n the e n g i n e h o o d , a n d let t h e e n g i n e c o o l for

3 hours.
11-271
PGM-FI System
DTC P0117: ECT Sensor 1 Circuit Low Voltage 10. C h e c k for continuity b e t w e e n E C T s e n s o r 1 2 P
and any on-board s n a p s h o t , a n d review the general
E C T S E N S O R 1 2P C O N N E C T O R
2. C h e c k E C T S E N S O R 1 in t h e D A T A L I S T w i t h t h e d&i
HDS.
ECT1 I
(RED/WHT)I

less indicated?
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s Is there continuity?
at E C T s e n s o r 1 a n d t h e E C M . •
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n E C T s e n s o r
3. T u r n t h e ignition s w i t c h O F F . 1 a n d t h e E C M ( B 8 ) , t h e n g o to s t e p 13.
4. D i s c o n n e c t t h e E C T s e n s o r 1 2 P c o n n e c t o r . N O — G o to s t e p 18.
6. C h e c k E C T S E N S O R 1 in t h e D A T A L I S T w i t h t h e 12. R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385).
HDS.
less indicated? 14. T u r n the ignition s w i t c h O N (II).
Y E S — G o to s t e p 7. 15. R e s e t the E C M w i t h the H D S .
N O — G o to s t e p 11. 16. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
11-272
t e r m i n a l s at E C T s e n s o r 1 a n d t h e E C M , t h e n g o to
s t e p 1.
indicated D T C s t r o u b l e s h o o t i n g . •

g o o d E C M ( s e e p a g e 11-217).
Y E S — C h e c k f o r p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at E C T s e n s o r 1 a n d t h e E C M . If t h e E C M
( s e e p a g e 11-217), t h e n r e c h e c k . If the E C M w a s
NO—If the E C M w a s updated, troubleshooting is

original E C M ( s e e p a g e 11-389). If a n y other
PGM-FI System
DTC P0118: ECT Sensor 1 Circuit High 8. T u r n t h e ignition s w i t c h O F F .

Voltage
9. R e m o v e t h e j u m p e r w i r e f r o m E C T s e n s o r 1 2 P
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a connector.
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). 10. T u r n t h e ignition s w i t c h O N (II).
1. T u r n t h e ignition s w i t c h O N (II). 11. M e a s u r e v o l t a g e b e t w e e n E C T s e n s o r 1 2 P

2 . C h e c k E C T S E N S O R 1 in t h e D A T A L I S T w i t h t h e
HDS.
Is about ~40°F ( -40 °C) or less, or 4.92 V or

more indicated?
Y E S — G o to s t e p 3. ECT1
(RED/WHT)
3. T u r n t h e ignition s w i t c h O F F . W i r e s i d e of f e m a l e t e r m i n a l s
4. D i s c o n n e c t t h e E C T s e n s o r 1 2 P c o n n e c t o r .
Is there about 5 V?
5. C o n n e c t E C T s e n s o r 1 2 P c o n n e c t o r t e r m i n a l s N o . 1
and No. 2 with a jumper wire. YES-Gotostep12.
N O ^ G o t o s t e p 17.
1 2
ECT1 SG2
(RED/WHT) (GRN/YEL) 14. D i s c o n n e c t E C M c o n n e c t o r A (31P).
JUMPER WIRE 15. C o n n e c t E C T s e n s o r 1 2 P c o n n e c t o r t e r m i n a l No. 2

W i r e s i d e of f e m a l e t e r m i n a l s E C T S E N S O R 1 2P C O N N E C T O R
1 2
7. C h e c k E C T S E N S O R 1 in t h e D A T A L I S T w i t h t h e
SG2 (GRN/YEL)
HDS.
JUMPER WIRE
Is about -40°F ( -40 °C) or less, or 4.92 V or

more indicated?
11-274
16. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 18. T u r n t h e ignition s w i t c h O F F .
1 2 3 4 | 5 6 7| 8 | 9 2 1 . T u r n t h e ignition s w i t c h O N (II).
10
// 13 14 15 16
/ /18 20 21
22. Reset the E C M with the H D S .
/ 23 24
SG2
25 26
/ /28 30 31
1 (GRN/YEL) 2 3 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 4 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
Is there continuity? t e r m i n a l s at E C T s e n s o r 1 a n d t h e E C M , t h e n g o to
s t e p 1.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to the
(A23) a n d E C T s e n s o r 1, t h e n g o to s t e p 2 0 . indicated D T C s troubleshooting. •
17. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 2 5 . T u r n t h e ignition s w i t c h O F F .
B8 and body ground.
/ 2 |3 4 5 / 6 g o o d E C M ( s e e p a g e 11-217).
8 / 10 11 / / / /
13
M 18 19 20 21 / / / 2 8 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
ECT1 (RED/WHT)
W i r e s i d e of f e m a l e t e r m i n a l s w a s u p d a t e d , substitute a k n o w n - g o o d E C M
Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
(B8) a n d E C T s e n s o r 1, t h e n g o to s t e p 2 0 . original E C M ( s e e p a g e 11-389). If a n y o t h e r
N O — G o to s t e p 25. indicated D T C s troubleshooting. •
11-275
PGM-FI System
DTC P0125: ECT Sensor 1 Malfunction/Slow 9. T u r n t h e ignition s w i t c h O F F .

Response
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l 11. T u r n t h e ignition s w i t c h O N (II).
1. S t a r t t h e e n g i n e , a n d let it idle for 5 m i n u t e s or
more. 13. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2. C h e c k E C T S E N S O R 1 in the D A T A L I S T w i t h t h e 14. A l l o w the e n g i n e to c o o l to a m b i e n t t e m p e r a t u r e .

HDS.
15. S t a r t the e n g i n e , a n d let it idle for 20 m i n u t e s .
Is about 10°F( —12 °C) or less, or 4.45 V or more
indicated? 16. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
Y E S — G o to s t e p 9. Is DTC P0125 indicated?
N O — G o to s t e p 3. Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at E C T s e n s o r 1, E C T s e n s o r 2 , a n d the
3. A l l o w the e n g i n e to c o o l to 104 °F (40 °C) or l e s s . E C M , t h e n g o to s t e p 1.
4. Note the v a l u e of E C T S E N S O R 1 a n d E C T S E N S O R N O — G o to s t e p 17.

2 in t h e D A T A L I S T w i t h t h e H D S .
17. M o n i t o r t h e O B D S T A T U S for D T C P 0 1 2 5 in t h e
5. S t a r t t h e e n g i n e , a n d let it idle. D T C s M E N U with the H D S .
6. Let t h e e n g i n e idle until E C T S E N S O R 1 g o e s up Does the screen indicate PASSED?

49 °F (27 °C) o r m o r e f r o m the r e c o r d e d
temperature. Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 16,
7. Note t h e v a l u e of E C T S E N S O R 2 in t h e D A T A L I S T g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
with the H D S .
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
8. C o m p a r e E C T S E N S O R 2 a n d t h e r e c o r d e d c o n n e c t i o n s or l o o s e t e r m i n a l s at E C T s e n s o r 1,
temperature. E C T s e n s o r 2 , a n d t h e E C M , t h e n g o to s t e p 1. If t h e
s c r e e n i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 14.
Did ECT SENSOR 2 change 17 °F (9.5 °C) or
more?
at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e E C M . •
N O — C h e c k t h e t h e r m o s t a t ( s e e p a g e 10-7). If t h e
t h e r m o s t a t is O K , g o to s t e p 9. If t h e t h e r m o s t a t is
faulty, r e p l a c e it ( s e e p a g e 10-11), t h e n g o to s t e p
11-276
DTC P0128: Cooling System Malfunction 11. C o m p a r e t h e v a l u e of r e c o r d e d E C T S E N S O R 2 a n d
t h e v a l u e of p r e s e n t E C T S E N S O R 2.
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l Did temperature rise 17 °F (9.5 °C) or more?
Y E S — I n t e r m i t t e n t f ailu r e, t h e s y s t e m is O K at t h i s
1. T u r n t h e ignition s w i t c h O N (II). t i m e . C h e c k for poor c o n n e c t i o n s or l o o s e t e r m i n a l s
at E C T s e n s o r 1, E C T s e n s o r 2 , a n d the E C M . B
2. C l e a r t h e D T C with the H D S .
N O — T e s t t h e t h e r m o s t a t ( s e e p a g e 10-7), t h e n g o
3. T u r n the b l o w e r s w i t c h O F F . to s t e p 12.
4. C h e c k the F A N C T R L in the D A T A L I S T w i t h t h e 12. T u r n t h e ignition s w i t c h O N (II).

HDS.
13. R e s e t the E C M with t h e H D S .
Is it OFF?
14. Let t h e e n g i n e c o o l until the c o o l a n t t e m p e r a t u r e is
Y E S — G o to s t e p 5. b e t w e e n 21 °F ( - 6 °C) a n d 104 °F (40 °C).
N O — W a i t until the F A N C T R L is off, t h e n g o to s t e p 15. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).

5.
16. T e s t - d r i v e at a s t e a d y s p e e d b e t w e e n 1 5 — 7 5 m p h
5. C h e c k the radiator fan o p e r a t i o n . _(24—120 k m / h ) for 10 m i n u t e s .
Does the radiator fan keep running? 17. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
Y E S — C h e c k the radiator f a n circuit ( s e e p a g e Is DTC P0128 indicated?

10-20). If the circuits a n d t h e s w i t c h a r e O K , g o to
s t e p 19. Y E S — C h e c k the c o o l i n g s y s t e m , t h e n g o to s t e p 1.
N O — G o to s t e p 6. N O — G o to s t e p 18.
6. Let t h e e n g i n e c o o l until the c o o l a n t t e m p e r a t u r e is 18. Monitor t h e O B D S T A T U S for D T C P 0 1 2 8 in the

104 °F (40 °C) or l e s s . D T C s M E N U with the H D S .
7. Note t h e v a l u e of E C T S E N S O R 1 a n d E C T S E N S O R Does the screen indicate PASSED?

2 in t h e D A T A L I S T w i t h t h e H D S .
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
8. Start the e n g i n e , a n d let it idle. T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 17,
g o to t h e indicated D T C s t r o u b l e s h o o t i n g . •
9. Let t h e e n g i n e idle until E C T S E N S O R 1 g o e s up
49 °F (27 °C) or m o r e f r o m t h e r e c o r d e d N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k the
temperature. c o o l i n g s y s t e m , t h e n g o to s t e p 1. If the s c r e e n
i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 14.
HDS.
(cont'd)
11-277
PGM-FI System

g o o d E C M ( s e e p a g e 11-217).
2 0 . Let t h e e n g i n e c o o l until t h e c o o l a n t t e m p e r a t u r e is
b e t w e e n 21 °F (—6 *€) a n d 104 °F (40 °C).
2 1 . Start t h e e n g i n e . Hold t h e e n g i n e s p e e d at
2 2 . T e s t - d r i v e at a s t e a d y s p e e d b e t w e e n 1 5 — 7 5 m p h
( 2 4 — 1 2 0 k m / h ) for 10 m i n u t e s .
2 3 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
t e r m i n a l s at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e
E C M . If t h e E C M w a s u p d a t e d , s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 2 0 . If
t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
N O — G o to s t e p 2 4 .
24. M o n i t o r t h e O B D S T A T U S f o r D T C P 0 1 2 8 in the
D T C s M E N U w i t h the H D S .
Does the screen indicate PASSED?
Y E S — I f the E C M w a s updated, troubleshooting is

T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 2 3 ,
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
c o n n e c t i o n s or l o o s e t e r m i n a l s at E C T s e n s o r 1,
E C T s e n s o r 2 , a n d t h e E C M . If t h e E C M w a s u p d a t e d ,
s u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-217),
t h e n g o to s t e p 20. If the E C M w a s s u b s t i t u t e d , g o
to s t e p 1. If t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D ,
g o to s t e p 20 a n d r e c h e c k .
11-278
DTC P0133: A/F Sensor (Sensor 1) 10. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
Malfunction/Slow Response
11. S t a r t the e n g i n e . Hold the e n g i n e s p e e d at
NOTE: 3 , 0 0 0 r p m w i t h o u t l o a d (in neutral) until the
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d radiator f a n c o m e s o n , t h e n let it idle.
any on-board s n a p s h o t , and review the general
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). 12. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
• If D T C P0139 is s t o r e d at the s a m e t i m e a s D T C P 0 1 3 3 ,
t r o u b l e s h o o t D T C P 0 1 3 9 first, t h e n r e c h e c k for D T C • E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)
P0133. a b o v e 176 °F ( 8 0 * 0
1. T u r n the ignition s w i t c h O N (II). • D r i v e t h e v e h i c l e at 2 5 m p h (40 k m / h ) or l e s s for
5 m i n u t e s , t h e n d r i v e at s t e a d y s p e e d b e t w e e n
2. C l e a r t h e D T C w i t h the H D S . 2 6 - 8 1 mph ( 4 1 - 1 3 0 km/h).
3. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 13. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .

radiator f a n c o m e s o n , t h e n let it idle. Is DTC P0133 indicated?
4. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : Y E S — C h e c k for p o o r c o n n e c t i o n s o r l o o s e
t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1) a n d the E C M ,
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) t h e n g o to s t e p 1.
a b o v e 176 °F (80 <€)
• T r a n s m i s s i o n in 4th g e a r N O — G o to s t e p 14.
• Drive t h e v e h i c l e at 2 5 m p h (40 km/h) or l e s s for
5 m i n u t e s , t h e n drive at s t e a d y s p e e d b e t w e e n 14. M o n i t o r t h e O B D S T A T U S for D T C P 0 1 3 3 in the
2 6 - 8 1 mph ( 4 1 - 1 3 0 km/h). D T C s M E N U w i t h the H D S .
5. Monitor the O B D S T A T U S for D T C P 0 1 3 3 in the Does the screen indicate PASSED?

D T C s M E N U with the H D S .
Does the screen indicate FAILED? T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 13,
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for poor
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e A / F s e n s o r
failure, t h e s y s t e m is O K at this t i m e . C h e c k for ( S e n s o r 1) a n d the E C M , t h e n g o to s t e p 1. If the
p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e A / F s c r e e n i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until a
s e n s o r ( S e n s o r 1) a n d the E C M . If t h e s c r e e n r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
i n d i c a t e s E X E C U T I N G , keep d r i v i n g until a result C O N D I T I O N , g o t o s t e p 11.
c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
C O N D I T I O N , g o to s t e p 3 a n d r e c h e c k .
7. R e p l a c e the A / F s e n s o r ( S e n s o r 1) ( s e e p a g e
11-386).
11-279
PGM-FI System
DTC P0134: A/F Sensor (Sensor 1) Heater 11. M o n i t o r the O B D S T A T U S for D T C P 0 1 3 4 in t h e

System Malfunction D T C s M E N U with the H D S .
NOTE: Does the screen indicate PASSED?

• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data a n d
a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 10,
• If D T C P 0 1 3 5 i s s t o r e d at t h e s a m e t i m e a s D T C P 0 1 3 4 , g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
t r o u b l e s h o o t D T C P 0 1 3 5 first, t h e n r e c h e c k for D T C
P0134. N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e A / F s e n s o r
1. T u r n t h e ignition s w i t c h O N (II). ( S e n s o r 1), the A / F s e n s o r relay ( L A F ) , a n d the E C M ,
t h e n g o to s t e p 1. If t h e s c r e e n i n d i c a t e s N O T
2. Clear the D T C with the H D S . C O M P L E T E D , k e e p idling until a result c o m e s o n .
4. C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
at t h e A / F s e n s o r ( S e n s o r 1), t h e A / F s e n s o r relay
( L A F ) , a n d the E C M . B
11-386).
10. C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1), the A / F
s e n s o r r e l a y ( L A F ) , a n d t h e E C M , t h e n g o to s t e p 1.
11-280
DTC P0135: A/F Sensor (Sensor 1) Heater 7. D i s c o n n e c t t h e A / F s e n s o r ( S e n s o r 1) 4P c o n n e c t o r .
Circuit Malfunction
8. A t the A / F s e n s o r s i d e , m e a s u r e r e s i s t a n c e b e t w e e n
N O T E : Before y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r t e r m i n a l s No. 3
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l a n d N o . 4.
A / F S E N S O R ( S E N S O R 1) 4 P C O N N E C T O R
2. C l e a r the D T C w i t h the H D S .
1 2
+B AFSHTC
3. Start the e n g i n e . Hold t h e e n g i n e s p e e d at o A
O 4
Is DTC P0135 indicated? T e r m i n a l s i d e of m a l e t e r m i n a l s
Is there 2.1—2.9 Q at room temperature?
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s Y E S — G o to s t e p 9.
at the A / F s e n s o r ( S e n s o r 1), the A / F s e n s o r r e l a y
(LAF), and the E C M . H N O — G o to s t e p 2 2 .
5. T u r n the ignition s w i t c h O F F . 9. A t the A / F s e n s o r s i d e , c h e c k for continuity

b e t w e e n A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r
6. C h e c k t h e s e f u s e s : t e r m i n a l No. 2 a n d A / F s e n s o r ( S e n s o r 1) 4 P
c o n n e c t o r t e r m i n a l s No. 3 a n d No. 4 individually.
• No. 15 L A F ('06-07 m o d e l s : 20 A , '08 m o d e l :
15 A) f u s e in t h e u n d e r - d a s h f u s e / r e l a y box. A / F S E N S O R ( S E N S O R 1) 4 P C O N N E C T O R
• No. 1 0 I G P ( L A F ) (7.5 A ) f u s e in t h e u n d e r - d a s h
f u s e / r e l a y box.
• No. 59 D B W (20 A ) f u s e in t h e u n d e r - h o o d f u s e /
relay box.
Are any of the above fuses blown?
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the A / F AFSHTC
s e n s o r relay ( L A F ) a n d the f u s e s . A l s o r e p l a c e t h e
b l o w n f u s e ( s ) , t h e n g o to s t e p 2 3 .
Y E S — G o to s t e p 2 2 .
(cont'd)
11-281
PGM-FI System

10. J u m p t h e S C S line w i t h the H D S . 14. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
AFSHTC
(GRN)
1 2 3 4 | 5 6 I 7 8 9
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 28 30 31
AFSHTC 1 | 2 3 4 | 5 6 | 7 8 | 9
(GRN)
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 28 30 31
Is there continuity? N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M

(A10) a n d the A / F s e n s o r ( S e n s o r 1), t h e n g o to s t e p
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M 23.
(A10) a n d the A / F s e n s o r ( S e n s o r 1), t h e n g o to s t e p
23. 15. R e m o v e t h e A / F s e n s o r r e l a y ( L A F ) (A).
A
13. C o n n e c t A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r
1 2 AFSHTC
(GRN)
3 4
JUMPER WIRE
11-282
4fi
16. C o n n e c t A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r 19. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
t e r m i n a l No. 3 to b o d y g r o u n d w i t h a j u m p e r w i r e . terminal E 8 and body ground.
A / F S E N S O R ( S E N S O R 1) 4 P C O N N E C T O R E C M C O N N E C T O R E (31P)
A F S H T C R (ORN)
+B
1 2 1 \/ 3 4 | 5 1 XI
8 | 9
(WHT/BLK)
3 4 / 11 12 13 14 15 16 17 18 19 20 21
JUMPER WIRE
22
/24 25
/
27 28 29 30
/
17. C h e c k for continuity b e t w e e n A / F s e n s o r relay Is there continuity?

( L A F ) 4 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y g r o u n d .
Y E S — R e p a i r o p e n in the w i r e b e t w e e n E C M (E8)
a n d t h e A / F s e n s o r r e l a y ( L A F ) , t h e n g o to s t e p 2 3 .
A/F SENSOR RELAY
(LAF) 4P C O N N E C T O R
+B 2 0 . C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
(WHT)
terminal E 8 a n d A / F s e n s o r relay (LAF) 4P
c o n n e c t o r t e r m i n a l No. 3.
A F S H T C R (ORN)
1 | / | 3 | 4 | 5 7 | /I
8 | 9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/24 25
/
27 28 29 30
/
Is there continuity? A/F SENSOR RELAY
(LAF) 4P C O N N E C T O R
Y E S — G o to s t e p 18. AFSHTCR
1
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e A / F
2
s e n s o r ( S e n s o r 1) a n d t h e A / F s e n s o r r e l a y ( L A F ) ,
t h e n g o to s t e p 2 3 .
3
X 4
Y E S — G o t o step 21.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M (E8)
a n d t h e A / F s e n s o r r e l a y ( L A F ) , t h e n g o to s t e p 2 3 .
(cont'd)
11-283
PGM-FI System
2 1 . C h e c k t h e A / F s e n s o r r e l a y ( L A F ) ( s e e p a g e 22-48). 2 9 . R e c o n n e c t all c o n n e c t o r s .
Is the A/F sensor relay (LAF) OK ? 30. U p d a t e t h e E C M if it d o e s not h a v e the latest

Y E S — G o to s t e p 2 9 . g o o d E C M ( s e e p a g e 11-217).
N O — R e p l a c e t h e A / F s e n s o r r e l a y ( L A F ) , t h e n g o to 3 1 . S t a r t the e n g i n e .
step 23.
2 2 . R e p l a c e t h e A / F s e n s o r ( S e n s o r 1) ( s e e p a g e Is DTC P0135 indicated?

11-386).
2 3 . R e c o n n e c t all c o n n e c t o r s . t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1), t h e A / F
s e n s o r r e l a y ( L A F ) , a n d t h e E C M . If t h e E C M w a s
24. T u r n t h e ignition s w i t c h O N (II). u p d a t e d , substitute a k n o w n - g o o d E C M ( s e e p a g e
11-217), t h e n g o to s t e p 3 1 . If t h e E C M w a s
25. Reset the E C M with the H D S . s u b s t i t u t e d , g o to s t e p 1.
2 6 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). N O — G o to s t e p 3 3 .
2 7 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 3 3 . Monitor t h e O B D S T A T U S for D T C P 0 1 3 5 in the

t e r m i n a l s at the A / F s e n s o r ( S e n s o r 1) a n d t h e E C M , Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
t h e n g o to s t e p 1. c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
N O — G o to s t e p 2 8 . T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 3 2 ,
g o to the i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
2 8 . M o n i t o r t h e O B D S T A T U S for D T C P 0 1 3 5 in the
D T C s M E N U with the H D S . N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
Does the screen indicate PASSED? ( S e n s o r 1), t h e A / F s e n s o r r e l a y ( L A F ) , a n d t h e E C M .
If t h e E C M w a s u p d a t e d , s u b s t i t u t e a k n o w n - g o o d
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If the E C M
T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 2 7 , w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • N O T C O M P L E T E D , k e e p idling until a result c o m e s
on.
( S e n s o r 1) a n d t h e E C M , t h e n g o to s t e p 1. If t h e
s c r e e n i n d i c a t e s N O T C O M P L E T E D , k e e p idling
until a r e s u l t c o m e s o n .
11-284
DTC P0137: Secondary H02S (Sensor 2) 12. C h e c k for continuity b e t w e e n s e c o n d a r y H 0 2 S
Circuit Low Voltage ( S e n s o r 2) 4 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
ground.
a n d a n y on-board s n a p s h o t , a n d review the general
S E C O N D A R Y H 0 2 S ( S E N S O R 2)
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). 4P C O N N E C T O R
1 ? -
S H 0 2 S (WHT)
2. C l e a r t h e D T C w i t h the H D S .
3 4
3. S t a r t t h e e n g i n e , a n d let it idle w i t h o u t l o a d (in
neutral) until t h e radiator f a n c o m e s o n .
4. C h e c k t h e H 0 2 S S 2 in t h e D A T A L I S T w i t h t h e H D S .
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s (E20) a n d the s e c o n d a r y H 0 2 S ( S e n s o r 2), t h e n g o
at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d at t h e to s t e p 15.
ECM.B
connector. 14. R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2) ( s e e p a g e
11-386).
19. S t a r t t h e e n g i n e , a n d let it idle without l o a d (in
9. T u r n t h e ignition s w i t c h O F F . neutral) until the radiator f a n c o m e s o n .
(cont'd)
11-285
PGM-FI System
20. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : 26. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) • E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)
a b o v e 176 °F (80 <€) a b o v e 176 °F (80 <€)
• T r a n s m i s s i o n in 4th g e a r • T r a n s m i s s i o n in 4th g e a r
• E n g i n e s p e e d at 1 , 5 0 0 — 3 , 0 0 0 r p m • E n g i n e s p e e d at 1,500—3,000 r p m
• Drive about 1 minute or more • D r i v e a b o u t 1 m i n u t e or m o r e
2 1 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 2 7 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
Is DTC P0137 indicated? Is DTC P0137 indicated?
Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
t h e E C M , t h e n g o to s t e p 1. t h e E C M . If t h e E C M w a s u p d a t e d , s u b s t i t u t e a
k n o w n - g o o d E C M ( s e e p a g e 11-217), t h e n g o to
N O — G o to s t e p 2 2 . s t e p 26. If t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
2 2 . M o n i t o r t h e O B D S T A T U S for D T C P 0 1 3 7 in t h e N O — G o to s t e p 2 8 .
2 8 . M o n i t o r t h e O B D S T A T U S for D T C P0137 in t h e
Does the screen indicate PASSED? D T C s M E N U w i t h the H D S .
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r Does the screen indicate PASSED?

g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r o r i g i n a l E C M ( s e e p a g e 11-389). If a n y other
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e s e c o n d a r y T e m p o r a r y D T C s o r D T C s w e r e indicated in s t e p 2 7 ,
H 0 2 S ( S e n s o r 2) a n d t h e E C M , t h e n g o to s t e p 1. If g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until
a result c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
C O N D I T I O N , g o to s t e p 2 0 . c o n n e c t i o n s or l o o s e t e r m i n a l s at the s e c o n d a r y
H 0 2 S ( S e n s o r 2) a n d t h e E C M . If the E C M w a s
2 3 . R e c o n n e c t all c o n n e c t o r s . updated, substitute a known-good E C M (see page
2 4 . U p d a t e t h e E C M if it d o e s not h a v e t h e latest s u b s t i t u t e d , g o to s t e p 1. If the s c r e e n i n d i c a t e s
s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n - E X E C U T I N G , k e e p d r i v i n g until a result c o m e s o n . If
g o o d E C M ( s e e p a g e 11-217). t h e s c r e e n i n d i c a t e s O U T O F C O N D I T I O N , g o to
step 26.
2 5 . S t a r t t h e e n g i n e , a n d let it idle w i t h o u t l o a d (in
11-286
9. C h e c k t h e H 0 2 S S 2 in t h e D A T A L I S T w i t h the H D S .
and any on-board snapshot, and review the general Does the voltage stay at 1.27 V or more?
3. S t a r t the e n g i n e , a n d let it idle w i t h o u t load (in
neutral) until t h e radiator f a n c o m e s o n . 11. R e m o v e t h e j u m p e r w i r e f r o m t h e s e c o n d a r y H 0 2 S
( S e n s o r 2) 4 P c o n n e c t o r ,
4. C h e c k t h e H 0 2 S S 2 in the D A T A L I S T w i t h t h e H D S .
Does the voltage stay at 1.27 V or more? t e r m i n a l No. 2 to b o d y g r o u n d w i t h a j u m p e r w i r e .
time. C h e c k for poor connections or loose terminals
1 2 -
at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d t h e E C M . • S H 0 2 S (WHT)
5. T u r n the ignition s w i t c h O F F . 3 4
JUMPER WIRE
connector.
7. C o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r T e r m i n a l s i d e of m a l e t e r m i n a l s
t e m r i n a l s N o . 1 a n d No. 2 w i t h a j u m p e r w i r e .

JUMPER WIRE
SG2 (GRN/YEL)
1 2 - SH02S (WHT)
3 4 N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
(A23) a n d t h e s e c o n d a r y H 0 2 S ( S e n s o r 2), t h e n g o
to s t e p 2 1 .
(cont'd)
11-287
PGM-FI System
15. T u r n the ignition s w i t c h O F F . 26. Test-drive under these conditions:
16. J u m p the S C S line w i t h t h e H D S . • E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)

a b o v e 176 °F (80 °C)
17. D i s c o n n e c t E C M c o n n e c t o r E (31P). • T r a n s m i s s i o n in 4th g e a r
• E n g i n e s p e e d at 1,500—3,000 r p m
18. C h e c k for continuity b e t w e e n E C M c o n n e c t o r • Drive 1 minute or more
terminal E20 and body ground.
2 7 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
1 /' 3 4 | 5 / \ 7 I8 i 9
Y E S — C h e c k for p o o r c o n n e c t i o n s o r l o o s e
/ 11 12 13 14 15 16 17 18 19 20 21 t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
22 24 25
/ 27 28 29 3D
S H 0 2 S (RED)
/ the E C M , t h e n g o s t e p 1.
N O — G o to s t e p 2 8 .
2 8 . M o n i t o r t h e O B D S T A T U S for D T C P 0 1 3 8 in t h e
Is there continuity? Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other

Y E S — G o to s t e p 2 9 . g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
(E20) a n d the s e c o n d a r y H 0 2 S ( S e n s o r 2 ) , t h e n g o c o n n e c t i o n s o r l o o s e t e r m i n a l s at t h e s e c o n d a r y
to s t e p 2 1 . H 0 2 S ( S e n s o r 2) a n d t h e E C M , t h e n g o t o s t e p 1. If
t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until
19. T u r n t h e ignition s w i t c h O F F . a r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
C O N D I T I O N , g o to s t e p 26.
20. R e p l a c e t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) ( s e e p a g e
11-386).
2 3 . R e s e t t h e E C M w i t h the H D S .

11-288

g o o d E C M ( s e e p a g e 11-217).
3 1 . S t a r t the e n g i n e , a n d let it idle w i t h o u t load (in

32. Test-drive under these conditions:
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)
a b o v e 176 °F (80 °C)
• E n g i n e s p e e d at 1,500—3,000 r p m
• Drive 1 m i n u t e or m o r e
t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
t h e E C M . If t h e E C M w a s u p d a t e d , s u b s t i t u t e a
s t e p 3 2 . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
34. Monitor the O B D S T A T U S for D T C P 0 1 3 8 in the

Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e s e c o n d a r y
H 0 2 S ( S e n s o r 2) a n d the E C M . If t h e E C M w a s
u p d a t e d , substitute a k n o w n - g o o d E C M ( s e e p a g e
11-217), t h e n g o to s t e p 3 2 . If the E C M w a s
s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
E X E C U T I N G , k e e p driving until a result c o m e s o n . If
t h e s c r e e n i n d i c a t e s O U T O F C O N D I T I O N , g o to
step 32.
11-289
PGM-FI System
DTC P0139: Secondary H02S (Sensor 2) Slow 12. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
Response
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a b o v e 176 °F (80 °C)
a n d any on-board s n a p s h o t , and review the general • T r a n s m i s s i o n in 4th g e a r
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). • V e h i c l e s p e e d at 3 5 m p h (56 k m / h ) or m o r e
• D r i v e 50 s e c o n d s
neutral) until t h e radiator f a n c o m e s o n . Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
4. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : t h e E C M , t h e n g o to s t e p 1.
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) N O — G o to s t e p 14.
a b o v e 176 °F (80 °C)
• T r a n s m i s s i o n in 4th g e a r 14. M o n i t o r t h e O B D S T A T U S for D T C P 0 1 3 9 in t h e
• V e h i c l e s p e e d at 3 5 m p h (56 k m / h ) o r m o r e D T C s M E N U w i t h the H D S .
• D r i v e 50 s e c o n d s
D T C s M E N U with the H D S . Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 13,
Does the screen indicate FAILED? g o t o the indicated D T C s t r o u b l e s h o o t i n g . *
Y E S — G o to s t e p 6. N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at the s e c o n d a r y
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent H 0 2 S ( S e n s o r 2) a n d t h e E C M . If t h e s c r e e n
f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . C h e c k f o r i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until a result
p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at the c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d t h e E C M . If t h e C O N D I T I O N , g o to s t e p 12,
s c r e e n i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until a
result c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
11-386).

11-290
DTC P0141: Secondary H02S (Sensor 2) 8. A t the s e c o n d a r y H 0 2 S ( S e n s o r 2) s i d e , m e a s u r e
Heater Circuit Malfunction r e s i s t a n c e b e t w e e n s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P
c o n n e c t o r t e r m i n a l s N o . 3 a n d No. 4.
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). 4P C O N N E C T O R
2. C l e a r t h e D T C w i t h the H D S . r 2
3 4
Is DTC P0141 indicated? W i r e s i d e of f e m a l e t e r m i n a l s
Is there 5.0— 6.4 0, at room temperature?
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s Y E S — G o t o s t e p 9.
at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d t h e E C M . B
N O - G o to s t e p 2 2 .
9. A t the s e c o n d a r y H 0 2 S ( S e n s o r 2) s i d e , c h e c k for
6. C h e c k t h e No. 6 A C G (15 A ) f u s e in the u n d e r - d a s h continuity b e t w e e n b o d y g r o u n d a n d s e c o n d a r y
f u s e / r e l a y box. H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r t e r m i n a l s N o . 3 a n d
No. 4 i n d i v i d u a l l y .
Is the fuse OK?
Y E S — G o to s t e p 6. 4P C O N N E C T O R
N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e
s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d the N o . 6 A C G
(15 A ) f u s e , t h e n g o to s t e p 2 3 .
connector.
Y E S — G o to s t e p 2 2 .
(cont'd)
11-291
PGM-FI System
10. T u r n t h e ignition s w i t c h O N (II). 16. M e a s u r e v o l t a g e b e t w e e n s e c o n d a r y H 0 2 S

( S e n s o r 2) 4 P c o n n e c t o r t e r m i n a l N o . 4 a n d b o d y
11. M e a s u r e v o l t a g e b e t w e e n s e c o n d a r y H 0 2 S ( S e n s o r ground.
2) 4 P c o n n e c t o r t e r m i n a l s N o . 3 a n d N o . 4.
IG1
S02S (BLK/YEL)
HTC 1 2 . IG1
(BLK/WHT) (BLK/YEL)
- 3 4 -

N O — C h e c k t h e N o . 6 A C G (15 A ) f u s e in t h e u n d e r -
N O — G o to s t e p 16. d a s h f u s e / r e l a y b o x . If the f u s e is O K , repair o p e n in
t h e w i r e b e t w e e n t h e s e c o n d a r y H 0 2 S ( S e n s o r 2)
12. T u r n t h e ignition s w i t c h O F F . a n d t h e No. 6 A C G (15 A ) f u s e , t h e n g o to s t e p . 2 3 .
13. J u m p t h e S C S line w i t h t h e H D S . 17. T u r n t h e ignition s w i t c h O F F .
14. D i s c o n n e c t E C M c o n n e c t o r E (31P). 18. J u m p t h e S C S line w i t h t h e H D S .
15. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 19. D i s c o n n e c t E C M c o n n e c t o r E (31P).

t e r m i n a l E21 a n d b o d y g r o u n d .
2 0 . C o n n e c t s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P c o n n e c t o r
t e r m i n a l No. 3 to b o d y g r o u n d w i t h a j u m p e r w i r e .
1 / 3 4 | 5 7 | XI 8 9
S02SHTC
(BLK/WHT)
/ 11 12 13 14 15 16 17 18 19 20 21
1 2
22
/ 24 25
/ 27 28 29 30
/ 3 4
S 0 2 S H T C (BLK/WHT)
JUMPER WIRE
(E21) a n d t h e s e c o n d a r y H 0 2 S ( S e n s o r 2 ) t h e n g o
#
to s t e p 2 3 .
11-292
2 1 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r 2 8 . M o n i t o r t h e O B D S T A T U S for D T C P0141 in the
t e r m i n a l E21 a n d b o d y g r o u n d . D T C s M E N U with the H D S .

/\ I
7 S02SHTC
1 .1/ 3 4 |5 8 | 9 (BLK/WHT)
/ 11 12 13 14 15 16 17 18 19 20 21 g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
22
/ 24 25
/ 27 28 29 30
/ N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
H 0 2 S ( S e n s o r 2) a n d t h e E C M , t h e n g o to s t e p 1. If
t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D , k e e p idling
until a result c o m e s o n .
Is there continuity? 3 0 . U p d a t e t h e E C M if it d o e s not h a v e t h e latest

Y E S — G o to s t e p 29. g o o d E C M ( s e e p a g e 11-217).
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M 3 1 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
(E21) a n d the s e c o n d a r y H 0 2 S ( S e n s o r 2), t h e n g o
to s t e p 23. Is DTC P0141 indicated?
2 2 . R e p l a c e the s e c o n d a r y H 0 2 S ( S e n s o r 2) ( s e e p a g e Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
11-386). t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
t h e E C M . If t h e E C M w a s u p d a t e d , substitute a
2 3 . R e c o n n e c t all c o n n e c t o r s . k n o w n - g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k .
If t h e E C M w a s s u b s t i t u t e d , go to s t e p 1.
N O — G o to s t e p 3 2 .
2 5 . R e s e t the E C M w i t h t h e H D S .
3 2 . M o n i t o r t h e O B D S T A T U S for D T C P0141 in the
26. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). D T C s M E N U with the H D S .
27. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . Does the screen indicate PASSED?
Is DTC P0141 indicated? Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is

Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e original E C M ( s e e p a g e 11-389). If a n y other
t e r m i n a l s at the s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 3 1 ,
t h e E C M , t h e n g o to s t e p 1. g o to t h e indicated D T C s t r o u b l e s h o o t i n g . •
N O — G o to s t e p 28. N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r

H 0 2 S ( S e n s o r 2) a n d t h e E C M . If the E C M w a s
11-217), t h e n r e c h e c k . If t h e E C M w a s s u b s t i t u t e d ,
g o to s t e p 1. If the s c r e e n i n d i c a t e s N O T
C O M P L E T E D , k e e p idling until a result c o m e s o n .
11-293
PGM-FI System
DTC P0171: Fuel System Too Lean 2. T u r n t h e ignition s w i t c h O N (II).
DTC P0172: Fuel System Too Rich 3. R e s e t t h e E C M w i t h t h e H D S .
NOTE: 4. Do t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

a n y on-board s n a p s h o t , a n d r e v i e w the general 5. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). 3,000 r p m w i t h o u t l o a d (in neutral) until the
• If s o m e of the D T C s listed b e l o w a r e s t o r e d at t h e radiator f a n c o m e s o n , t h e n let it idle.
s a m e t i m e a s D T C P0171 a n d / o r P 0 1 7 2 , t r o u b l e s h o o t
t h o s e D T C s first, t h e n r e c h e c k for P0171 a n d / o r P 0 1 7 2 . 6. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
P0107, P0108, P1128, P1129: Manifold absolute • E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)

pressure (MAP) s e n s o r a b o v e 158 °F (70 <€)
P 0 1 3 3 , P 1 1 5 7 , P 2 1 9 5 , P 2 2 3 8 , P 2 2 5 2 , P 2 A 0 0 : A i r fuel • T r a n s m i s s i o n in 5th g e a r
ratio (A/F) s e n s o r ( S e n s o r 1) • Drive at a s t e a d y s p e e d b e t w e e n 1 5 — 7 5 m p h
P 0 1 3 4 , P0135: A i r fuel ratio ( A / F ) s e n s o r ( S e n s o r 1) ( 2 4 - 1 2 0 km/h)
heater
P 0 1 3 7 , P 0 1 3 8 , P 0 1 3 9 : S e c o n d a r y H 0 2 S ( S e n s o r 2) N O T E : D T C P0171 a n d / o r P 0 1 7 2 m a y take up to
P 0 1 4 1 : S e c o n d a r y H 0 2 S ( S e n s o r 2) h e a t e r 80 m i n u t e s of t e s t d r i v i n g to s e t . U s i n g t h e H D S ,
P 0 4 4 3 , P0496: E V A P c a n i s t e r p u r g e v a l v e m o n i t o r the air fuel f e e d b a c k a v e r a g e ( A F F B A V E ) .
P2646, P2647, P2648, P2649: V T E C s y s t e m If the A F F B A V E s t a y s w i t h i n 0 . 8 — 1 . 2 5 , t h e r e is n o
P 2 2 7 9 : Intake air l e a k a g e p r o b l e m at t h i s t i m e .
1. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11-477). 7. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
Is the fuel pressure OK? Is DTC P0171 or P0172 indicated?
Y E S — C h e c k the e n g i n e v a l v e c l e a r a n c e s a n d a d j u s t Y E S — G o to s t e p 1.
if n e c e s s a r y ( s e e p a g e 6-10). If t h e v a l v e c l e a r a n c e s
a r e O K , r e p l a c e t h e i n j e c t o r s ( s e e p a g e 11-382), N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
t h e n g o to s t e p 2. T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
N O -
• If t h e p r e s s u r e is t o o h i g h , r e p l a c e t h e fuel
p r e s s u r e regulator ( s e e p a g e 11-486), t h e n g o to
s t e p 2.
• If t h e p r e s s u r e is too l o w , c h e c k t h e fuel p u m p
( s e e p a g e 11-470) a n d t h e f u e l f e e d line ( s e e p a g e
11-478), t h e n g o to s t e p 2.
11-294
DTC P0300: Random Misfire and Any 1. T u r n t h e ignition s w i t c h O N (II).
Combination of the Following:
3. S t a r t t h e e n g i n e (in neutral), t h e n let it idle w i t h o u t
DTC P0302: No. 2 Cylinder Misfire Detected load.
DTC P0303: No. 3 Cylinder Misfire Detected 4. M o n i t o r t h e O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,

P 0 3 0 3 , or P 0 3 0 4 in t h e D T C s M E N U w i t h the H D S .
Does the screen indicate FAILED?
• Pressure gauge adapter 07NAJ-P07010A Y E S — G o to s t e p 9.
• A / T low p r e s s u r e g a u g e w / p a n e l 07406-0070301
• A / T p r e s s u r e h o s e 07406-0020201 N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , g o to s t e p 5. If
• A / T p r e s s u r e h o s e , 2,210 m m 0 7 M A J - P Y 4 0 1 1 A the s c r e e n i n d i c a t e s E X E C U T I N G , k e e p driving until
• A / T pressure hose, adapter 0 7 M A J - P Y 4 0 1 2 0 a r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
C O N D I T I O N , w a i t for s e v e r a l m i n u t e s , a n d r e c h e c k .
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d 5. C h e c k t h e C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3
any on-board s n a p s h o t , and review the general M I S F I R E , a n d / o r C Y L 4 M I S F I R E in t h e D A T A L I S T
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). for 10 m i n u t e s w i t h t h e H D S .
• If the m i s f i r e is f r e q u e n t e n o u g h to trigger detection
of i n c r e a s e d e m i s s i o n s d u r i n g 2 c o n s e c u t i v e driving Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3
c y c l e s , t h e M I L w i l l c o m e o n , a n d D T C P 0 3 0 0 (and MISFIRE, and/or CYL4 MISFIRE show misfire
s o m e c o m b i n a t i o n of P0301 t h r o u g h P0304) w i l l be counts?
stored.
• If t h e m i s f i r e is f r e q u e n t e n o u g h to d a m a g e the Y E S — G o to s t e p 9.
c a t a l y s t , the M I L will f l a s h w h e n e v e r t h e m i s f i r e
o c c u r s , a n d D T C P 0 3 0 0 (and s o m e c o m b i n a t i o n of N O — G o to s t e p 6.
P0301 t h r o u g h P0304) will be s t o r e d . W h e n t h e
m i s f i r e s t o p s , t h e M I L will r e m a i n o n . 6. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in t h e
• T r o u b l e s h o o t t h e f o l l o w i n g D T C s first, if a n y of t h e m r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s :
w e r e s t o r e d a l o n g w i t h the r a n d o m m i s f i r e D T C ( s ) :
• ENGINE SPEED
P0107, P0108, P1128, P1129: Manifold absolute • VSS
p r e s s u r e (MAP) s e n s o r • REL TP SENSOR
P0171, P0172: Fuel s y s t e m • C L V (calculated load value)
P 0 3 3 5 , P0339: C r a n k s h a f t position ( C K P ) s e n s o r
P 0 3 6 5 , P0369: C a m s h a f t p o s i t i o n ( C M P ) s e n s o r 7. M o n i t o r the O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,
P 0 5 0 6 , P0507: Idle control s y s t e m P 0 3 0 3 , or P0304 in t h e D T C s M E N U w i t h the H D S .
P 2 6 4 6 , P 2 6 4 7 , P 2 6 4 8 , P2649: V T E C s y s t e m
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , g o to s t e p 8. If
t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p driving until
a r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
C O N D I T I O N , go to s t e p 6 a n d r e c h e c k .
(cont'd)
11-295
PGM-FI System
8. C h e c k t h e C Y L 1 M I S F I R E / C Y L 2 M I S F I R E , C Y L 3 14. C h e c k t h e fuel p r e s s u r e ( s e e p a g e 11 -477).

M I S F I R E , a n d / o r C Y L 4 M I S F I R E In t h e D A T A L I S T
for 10 m i n u t e s w i t h the H D S . Is the fuel pressure OK ?
Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3 Y E S — G o to s t e p 15.

MISFIRE, and/or CYL4 MISFIRE show misfire
counts? NO-
• If the p r e s s u r e is t o o h i g h , r e p l a c e the fuel
Y E S — G o to s t e p 9. p r e s s u r e regulator ( s e e p a g e 11-486), t h e n g o to
s t e p 20.
N O — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s • If t h e p r e s s u r e is t o o l o w , c h e c k the fuel p u m p ,
time.B the fuel f e e d p i p e , a n d the fuel filter. If t h e y a r e
O K , r e p l a c e t h e fuel p r e s s u r e regulator ( s e e p a g e
9. T u r n t h e ignition s w i t c h O F F . 11 -486), t h e n g o to s t e p 20.
10. C h e c k the fuel quality. 15. T u r n t h e ignition s w i t c h O F F .
Is the quality good? 16. R e m o v e t h e rocker a r m oil p r e s s u r e s w i t c h ( V T E C

oil p r e s s u r e s w i t c h ) (A), a n d install t h e s p e c i a l t o o l s
Y E S — G o to s t e p 11. a s s h o w n , t h e n attach the rocker a r m oil p r e s s u r e
s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) (A) to the
N O — D r a i n the tank a n d fill w i t h k n o w n - g o o d f u e l , p r e s s u r e g a u g e a d a p t e r (B).
t h e n g o to s t e p 20.
N O T E : Install t h e parts in the r e v e r s e o r d e r of
11. I n s p e c t t h e s p a r k p l u g s ( s e e p a g e 4-28). If the s p a r k removal with a n e w O-ring.
plugs are fouled or w o r n , replace t h e m .
12. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in t h e

r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s :
• ENGINE SPEED
• VSS
• REL TP SENSOR
• C L V (calculated load value)
13. C h e c k t h e C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3
M I S F I R E , a n d / o r C Y L 4 M I S F I R E in t h e D A T A L I S T
for 10 m i n u t e s w i t h t h e H D S .
(2.2 kgf m , 1 6 Ibf ft)
Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3
MISFIRE, and/or CYL4 MISFIRE show misfire 17. R e c o n n e c t the rocker a r m oil p r e s s u r e s w i t c h
counts? ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r .
Y E S — G o to s t e p 14. 18. Start the e n g i n e . Hold the e n g i n e s p e e d at

N O — G o to s t e p 20. radiator f a n c o m e s o n , t h e n let it idle.
11-296
19. C h e c k t h e oil p r e s s u r e at e n g i n e s p e e d s of 1,000 2 7 . M o n i t o r t h e O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,
a n d 2,000 r p m . P 0 3 0 3 , or P 0 3 0 4 in the D T C s M E N U w i t h the H D S .
Is the oil pressure below 49 kPa (0.5 kgf/crrf, Does the screen indicate PASSED?
7 psi)?
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
Y E S — C h e c k for air in the fuel line, t h e n g o to s t e p T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 2 6 ,
20. g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
N O — I n s p e c t t h e V T E C s y s t e m , t h e n g o to s t e p 2 0 . N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , g o to s t e p 1
a n d r e c h e c k . If t h e s c r e e n i n d i c a t e s E X E C U T I N G ,
20. T u r n t h e ignition s w i t c h O N (II). k e e p d r i v i n g until a result c o m e s o n . If the s c r e e n
i n d i c a t e s O U T O F C O N D I T I O N , g o to s t e p 2 5 .
2 1 . R e s e t the E C M w i t h the H D S .
2 2 . C l e a r the C K P pattern w i t h the H D S .
2 3 . D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
24. D o the C K P pattern learn p r o c e d u r e ( s e e p a g e

11-214).
2 5 . T e s t - d r i v e t h e v e h i c l e for s e v e r a l m i n u t e s in t h e
r a n g e of t h e s e r e c o r d e d f r e e z e data p a r a m e t e r s :
• ENGINE S P E E D
• VSS
• RELTPSENSOR
• C L V ( c a l c u l a t e d load v a l u e )
Is DTC P0300, P0301, P0302, P0303, or P0304

indicated?
t e r m i n a l s at the ignition c o i l , the injector, a n d t h e
E C M , t h e n g o to D T C P0301, P0302, P0303, or P0304
troubleshooting ( s e e p a g e 11-298).
11-297
PGM-FI System
DTC P0301: No. 1 Cylinder Misfire Detected 7. M o n i t o r t h e O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,

P 0 3 0 3 , or P 0 3 0 4 in the D T C s M E N U w i t h t h e H D S .
N O — I f t h e s c r e e n indicate P A S S E D , g o to s t e p 8. If
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p driving until
and a n y on-board s n a p s h o t , a n d review the general a result c o m e s o n . If the s c r e e n i n d i c a t e s O U T O F
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). C O N D I T I O N , g o to s t e p 6 a n d r e c h e c k .
1. T u r n t h e ignition s w i t c h O N (II). 8. C h e c k t h e C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3
M I S F I R E , a n d / o r C Y L 4 M I S F I R E in the D A T A L I S T
2. C l e a r the D T C w i t h t h e H D S . for 10 m i n u t e s w i t h the H D S .
3. S t a r t t h e e n g i n e , t h e n let it idle w i t h o u t l o a d Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3

(in neutral). MISFIRE, and/or CYL4 MISFIRE show misfire
counts?
4. M o n i t o r t h e O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,
P 0 3 0 3 , or P 0 3 0 4 in t h e D T C s M E N U w i t h t h e H D S . Y E S — G o to s t e p 9.
Does the screen indicate FAILED? N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s

t i m e . C h e c k for l o o s e w i r e s or p o o r c o n n e c t i o n s in
Y E S — G o to s t e p 9. t h e fuel s y s t e m c i r c u i t s
N O — I f t h e s c r e e n i n d i c a t e P A S S E D , g o to s t e p 5. If 9. T u r n t h e ignition s w i t c h O F F .
t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling until
a r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F 10. R e m o v e the fuel rail c o v e r .
C O N D I T I O N , w a i t for s e v e r a l m i n u t e s , a n d r e c h e c k .
11. S t a r t the e n g i n e , a n d listen for a c l i c k i n g s o u n d at
5. C h e c k t h e C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3 t h e injector of t h e p r o b l e m c y l i n d e r .
M I S F I R E a n d / o r C Y L 4 M I S F I R E in the D A T A L I S T f o r
10 m i n u t e s w i t h t h e H D S . Does the injector click?
Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3 Y E S — G o to s t e p 12.

MISFIRE and/or CYL4 MISFIRE show misfire
counts? N O — G o to s t e p 43.
N O — G o to s t e p 6. 13. E x c h a n g e t h e ignition coil f r o m the p r o b l e m

cylinder with one from another cylinder.
6. T e s t - d r i v e t h e v e h i c l e for s e v e r a l m i n u t e s in t h e
r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s : 14. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in t h e
• ENGINE SPEED
• VSS • ENGINE SPEED
• REL TP SENSOR • VSS
• C L V (calculated load value) • REL TP SENSOR
11-298
15. C h e c k the C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3 21. Determine w h i c h cylinder had the misfire.
for 10 m i n u t e s w i t h the H D S . Does the misfire occur in the cylinder where the
spark plug was moved?
MISFIRE, and/or CYL4 MISFIRE show misfire Y E S — R e p l a c e the faulty s p a r k p l u g , t h e n g o to
counts? step 63.
Y E S — G o to s t e p 16. N O — G o to s t e p 2 2 .
N O — I n t e r m i t t e n t m i s f i r e d u e to p o o r c o n t a c t at the 2 2 . T u r n the ignition s w i t c h O F F .

ignition coil c o n n e c t o r (no m i s f i r e at t h i s t i m e ) .
M a k e s u r e the coil c o n n e c t i o n s a r e s e c u r e . • 2 3 . E x c h a n g e t h e injector f r o m t h e p r o b l e m c y l i n d e r
w i t h o n e f r o m the a n o t h e r c y l i n d e r .
16. D e t e r m i n e w h i c h c y l i n d e r h a d the m i s f i r e .
24. Start the e n g i n e , a n d let it idle for 2 m i n u t e s .
Does the misfire occur in the cylinder where the
ignition coil was exchanged? 2 5 . T e s t - d r i v e t h e v e h i c l e for s e v e r a l m i n u t e s in the
Y E S — R e p l a c e the faulty ignition coil ( s e e p a g e
4-25), t h e n g o to s t e p 6 3 . • ENGINE SPEED
• VSS
N O — G o to s t e p 17. • R E L TP SENSOR
• C L V ( c a l c u l a t e d load v a l u e )
26. C h e c k the C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3
18. E x c h a n g e t h e s p a r k plug f r o m t h e p r o b l e m c y l i n d e r M I S F I R E , a n d / o r C Y L 4 M I S F I R E in the D A T A L I S T
with one from another cylinder. for 10 m i n u t e s w i t h the H D S .
19. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in the Does CYL1 MISFIRE, CYL2 MISFIRE, CYL3
r a n g e of t h e s e r e c o r d e d f r e e z e data p a r a m e t e r s : MISFIRE, and/or CYL4 MISFIRE show misfire
counts?
•ENGINE SPEED
• VSS Y E S — G o to s t e p 27.
• REL TP SENSOR
• C L V (calculated load value) N O — I n t e r m i t t e n t misfire d u e to b a d c o n t a c t in the
injector c o n n e c t o r (no m i s f i r e at t h i s t i m e ) . C h e c k
20. C h e c k t h e C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3 for poor c o n n e c t i o n s or l o o s e t e r m i n a l s at the
M I S F I R E , a n d / o r C Y L 4 M I S F I R E in the D A T A L I S T injector.!
2 7 . D e t e r m i n e w h i c h c y l i n d e r h a d the m i s f i r e .
MISFIRE, and/or CYL4 MISFIRE show misfire Does the misfire occur in the cylinder where the
counts? injector was exchanged?
Y E S — G o to s t e p 2 1 . Y E S — R e p l a c e the faulty injector ( s e e p a g e 11-382),

N O — I n t e r m i t t e n t m i s f i r e d u e to s p a r k plug fouling
(no m i s f i r e at t h i s t i m e ) . • N O — G o to s t e p 2 8 .
(cont'd)
11-299
PGM-FI System
2 9 . D i s c o n n e c t t h e ignition coil 3 P c o n n e c t o r f r o m t h e 34. T u r n t h e ignition s w i t c h O F F .
problem cylinder.
3 5 . J u m p t h e S C S line w i t h t h e H D S .
3 1 . M e a s u r e v o l t a g e b e t w e e n ignition coil 3 P
connector terminal No. 3 a n d body g r o u n d . 37. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e
appropriate E C M connector terminal (see table).
No. 1 P0301 A16 WHT
1
IG
No. 2 P0302 A15 WHT/GRN
(BLK/YEL) No. 3 P0303 A14 WHT/BLK
No. 4 P0304 A13 WHT/BLU
IGPLS4 (WHT/BLU) IGPLS1 (WHT)
1 | 2 3 4 5 6 | 7 | 8.| 9
10
/ 13 14 15 16
/ // 18 20 21

IGPLS3
23 24 25 26
/
IGPLS2
28 30 31
_ (WHT/BLK) , . (WHT/GRN)
Y E S — G o to s t e p 3 2 .
© ©
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e ignition
coil a n d t h e ignition coil r e l a y , t h e n g o to s t e p 6 3 . W i r e s i d e of f e m a l e t e r m i n a l s
3 3 . C h e c k for continuity b e t w e e n ignition coil 3 P
connector terminal No. 2 a n d body ground. Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the E C M
a n d t h e ignition c o i l , t h e n g o to s t e p 6 3 .
1 GND
(BLK)
Wire side of f e m a l e t e r m i n a l s
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e ignition
coil a n d G 1 0 1 , t h e n g o to s t e p 6 3 .
11-300
38. C o n n e c t a p p r o p r i a t e ignition coil 3 P c o n n e c t o r 39. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d t h e
t e r m i n a l No. 1 to b o d y g r o u n d w i t h a j u m p e r w i r e a p p r o p r i a t e E C M c o n n e c t o r t e r m i n a l ( s e e table).
( s e e table).
PROBLEM DTC WIRE CYLINDER TERMINAL COLOR
CYLINDER COLOR No. 1 P0301 A16 WHT
No. 1 P0301 WHT No. 2 P0302 A15 WHT/GRN
No. 2 P0302 WHT/GRN No. 3 P0303 A14 WHT/BLK
No. 3 P0303 WHT/BLK No. 4 P0304 A13 WHT/BLU
No. 4 P0304 WHT/BLU
IGNITION COIL 3P C O N N E C T O R IGPLS4 (WHT/BLU) IGPLS1 (WHT)
1 I
1 | 2 | 3 4 |.5 6 | 7 | 8 9
1
IGPLS 10
/ 13 14 15 16
/ / 18 20 21
JUMPER WIRE IGPLS3

23 2 4 25 26
/ /
IGPLS2
28 30 31
^ (WHT/BLK) . (WHT/GRN)
1$ there continuity?
t h e ignition c o i l , t h e n g o to s t e p 6 3 .
40. R e c o n n e c t t h e ignition coil 3 P c o n n e c t o r a n d E C M

c o n n e c t o r A (31P).
41. D o a n e n g i n e c o m p r e s s i o n a n d a c y l i n d e r l e a k d o w n
t e s t ( s e e p a g e 6-7).
Did the engine pass both tests?
N O — R e p a i r the e n g i n e , t h e n go to s t e p 6 3 .
(cont'd)
11-301
PGM-FI System
4 2 . D o t h e V T E C r o c k e r a r m t e s t ( s e e p a g e 6-8). 4 8 . T u r n t h e ignition s w i t c h O F F .
Did the VTEC rocker arm pass the test? 4 9 . R e m o v e t h e fuel rail c o v e r .
Y E S — G o to s t e p 7 2 . 5 0 . D i s c o n n e c t t h e injector 2 P c o n n e c t o r f r o m t h e
problem cylinder.
N O — R e p a i r a s n e c e s s a r y / t h e n g o to s t e p 6 3 .
5 2 . M e a s u r e v o l t a g e b e t w e e n injector 2 P c o n n e c t o r
44. J u m p t h e S C S line w i t h t h e H D S . terminal No. 1 and body ground.
47. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d t h e
a p p r o p r i a t e E C M c o n n e c t o r t e r m i n a l ( s e e table). IGP
(YEL/BLK)

No. 1 P0301 B5 BRN
No. 2 P0302 B4 RED
No. 3 P0303 B3 BLU W i r e side of f e m a l e terminals
No. 4 P0304 B2 YEL
It there battery voltage?

INJ3 (BLU) INJ2 (RED) Y E S — G o to s t e p 5 3 .
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e injector
a n d P G M - F I m a i n relay 1 (Fl M A I N ) , t h e n g o to s t e p
63.
11-302
54. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d t h e 5 5 . C o n n e c t a p p r o p r i a t e injector 2 P c o n n e c t o r t e r m i n a l
a p p r o p r i a t e E C M c o n n e c t o r t e r m i n a l ( s e e table). N o . 2 to b o d y g r o u n d w i t h a j u m p e r w i r e ( s e e table).
PROBLEM DTC ECM WIRE PROBLEM DTC WIRE

CYLINDER TERMINAL COLOR CYLINDER COLOR
No. 1 P0301 B5 BRN No. 1 P0301 BRN
No. 2 P0302 B4 RED No. 2 P0302 RED
No. 3 P0303 B3 BLU No. 3 P0303 BLU
No. 4 P0304 B2 YEL No. 4 P0304 YEL
E C M C O N N E C T O R B (24P) INJECTOR 2P C O N N E C T O R
1NJ3 ( B L U ) INJ2 (RED)
INJ4 (YEL) INJ1 (BRN)
INJ
/ | 2 | 3 | 4 5
8
/ 10 11
/ / 13
/
JUMPER WIRE
17 18 19 20 21
/
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M
a n d t h e injector, t h e n g o to s t e p 6 3 .
(cont'd)
11-303
PGM-FI System
56. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e 57. A t t h e injecotor s i d e , m e a s u r e r e s i s t a n c e b e t w e e n
appropriate E C M connector terminal (see table). injector 2 P c o n n e c t o r t e r m i n a l s N o . 1 a n d N o . 2.

INJECTOR 2P CONNECTOR
No. 1 P0301 B5 BRN
No. 2 P0302 B4 RED
No. 3 P0303 B3 BLU 1 2
No. 4 P0304 B2 YEL
INJ
IGP
INJ3 (BLU) INJ2(RED)
INJ4 (YEL) INJ1 (BRN)

T e r m i n a l side of m a l e t e r m i n a l s
H2|3|4|5
10 1.3
Is there 10- 13 0,?
18 19 20 21
W i r e s i d e of f e m a l e t e r m i n a l s N O — R e p l a c e t h e injector ( s e e p a g e 11-382), t h e n
g o to s t e p 6 3 .
Is there continuity? 5 8 . S u b s t i t u t e a k n o w n - g o o d injector into t h e p r o b l e m

cylinder.
Y E S — G o to s t e p 5 7 .
t h e i n j e c t o r , t h e n g o to s t e p 6 3 . 6 0 . S t a r t t h e e n g i n e , a n d let it idle for 2 m i n u t e s .
• ENGINE SPEED
• VSS
• RELTP SENSOR
62. C h e c k the C Y L 1 M I S F I R E , C Y L 2 M I S F I R E , C Y L 3

MISFIRE, and/or CYL4 MISFIRE show misfire
counts?
Y E S — G o to s t e p 7 2 .
N O — R e p l a c e t h e original injector ( s e e p a g e 11-382),

11-304
6 3 . R e c o n n e c t all c o n n e c t o r s . 7 2 . U p d a t e t h e E C M if it d o e s not h a v e the latest
64. T u r n t h e ignition s w i t c h O N (II). g o o d E C M ( s e e p a g e 11-217).
6 5 . R e s e t the E C M w i t h t h e H D S . 7 3 . T e s t - d r i v e t h e v e h i c l e for s e v e r a l m i n u t e s in t h e
66. C l e a r the C K P pattern w i t h t h e H D S .
• ENGINE SPEED
6 7 . D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462). • VSS
• RELTP SENSOR
6 8 . D o the C K P pattern l e a r n p r o c e d u r e ( s e e p a g e • C L V ( c a l c u l a t e d load v a l u e )
11-214).
r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s : Is DTC P0301, P0302, P0303, or P0304
indicated?
• ENGINE SPEED
• VSS Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
• REL TP SENSOR t e r m i n a l s at t h e injector, t h e ignition c o i l , a n d t h e
' • C L V ( c a l c u l a t e d load v a l u e ) E C M . If t h e E C M w a s u p d a t e d , substitute a k n o w n -
70. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
Is DTC P0301, P0302, P0303, or P0304 N O — G o to s t e p 7 5 .

indicated?
7 5 . M o n i t o r t h e O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 ,
Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e P 0 3 0 3 , or P 0 3 0 4 in t h e D T C s M E N U w i t h the H D S .
t e r m i n a l s at t h e ignition c o i l , t h e injector, a n d t h e
E C M , t h e n g o to D T C P 0 3 0 0 , P 0 3 0 1 , P 0 3 0 2 , P 0 3 0 3 , Does the screen indicate PASSED?
or P 0 3 0 4 t r o u b l e s h o o t i n g ( s e e p a g e 11-295).
Y E S — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
N O — G o to s t e p 7 1 . c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
o r i g i n a l E C M ( s e e p a g e 11-389). If a n y other
7 1 . Monitor the O B D S T A T U S for D T C P 0 3 0 1 , P 0 3 0 2 , T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 7 4 ,
P 0 3 0 3 , o r P 0 3 0 4 in the D T C s M E N U w i t h t h e H D S . g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Does the screen indicate FAILED? N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r

c o n n e c t i o n s or l o o s e t e r m i n a l s at the ignition c o i l ,
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other t h e injector, a n d the E C M . If t h e E C M w a s u p d a t e d ,
T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 7 0 , s u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-217),
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • t h e n g o to s t e p 7 3 . If t h e E C M w a s s u b s t i t u t e d , g o
to s t e p 1. If the s c r e e n i n d i c a t e s E X E C U T I N G , k e e p
N O — I f t h e s c r e e n indicate F A I L E D , g o to s t e p 1 a n d d r i v i n g until a result c o m e s o n . If the s c r e e n
r e c h e c k . If t h e s c r e e n i n d i c a t e d E X E C U T I N G , k e e p i n d i c a t e s O U T O F C O N D I T I O N , g o to s t e p 7 3 .
driving until a result c o m e s o n . If the s c r e e n
i n d i c a t e s O U T O F C O N D I T I O N , go to s t e p 6 9 .
11-305
PGM-FI System
DTC P0325: Knock Sensor Circuit Malfunction 10. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
t e r m i n a l A1 a n d b o d y g r o u n d .
a n d a n y on-board s n a p s h o t , a n d r e v i e w the general
KS
1. T u r n t h e ignition s w i t c h O N (II). (RED/BLU)
1 2 3 4 | 5 6 | 7 | | 8 | 9
2. C l e a r t h e D T C w i t h t h e H D S . 10
// 13 14 15 16
/ / 18 20 21
/ 23 24 25 26
/ / 28 30 31

4. Hold t h e e n g i n e s p e e d b e t w e e n 3 , 0 0 0 — 4 , 0 0 0 r p m W i r e s i d e of f e m a l e t e r m i n a l s
for at l e a s t 10 s e c o n d s .
5. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . Is there continuity ?
Is DTC P0325 indicated? Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M

(A1) a n d t h e knock s e n s o r , t h e n g o to s t e p 14.
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s 11. C o n n e c t t h e knock s e n s o r 1P c o n n e c t o r t e r m i n a l to
at t h e k n o c k s e n s o r a n d t h e E C M . • body ground with a jumper wire.
K N O C K S E N S O R 1P C O N N E C T O R
7. J u m p the S C S line w i t h t h e H D S .
8. D i s c o n n e c t t h e knock s e n s o r 1P c o n n e c t o r . 1
KS (RED/BLU)
JUMPER WIRE
11-306
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 2 0 . M o n i t o r t h e O B D S T A T U S f o r D T C P 0 3 2 5 in t h e
t e r m i n a l A1 a n d b o d y g r o u n d . D T C s M E N U w i t h the H D S .

KS
(RED/BLU) T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 19,
1 | 2 3 4 5 6 7 | | 8 | 9 g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 28 30 31 N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for poor
c o n n e c t i o n s or l o o s e t e r m i n a l s at the k n o c k s e n s o r
a n d t h e E C M , t h e n go to s t e p 1. If the s c r e e n
W i r e s i d e of f e m a l e t e r m i n a l s 2 1 . U p d a t e t h e E C M if it d o e s not h a v e the latest

s o f t w a r e ( s e e p a g e 11-216), o r substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
2 2 . Hold t h e e n g i n e s p e e d b e t w e e n 3 , 0 0 0 — 4 , 0 0 0 r p m
Y E S — G o to s t e p 13. for at l e a s t 10 s e c o n d s .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M (A1) 2 3 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
a n d t h e knock s e n s o r , t h e n g o to s t e p 14.
13. R e p l a c e t h e knock s e n s o r ( s e e p a g e 11-388).
14. R e c o n n e c t all c o n n e c t o r s . t e r m i n a l s at t h e knock s e n s o r a n d the E C M . If the
15. T u r n t h e ignition s w i t c h O N (II). ( s e e p a g e 11-217), t h e n g o to s t e p 22. If t h e E C M
w a s s u b s t i t u t e d , g o to s t e p 1.
16. R e s e t t h e E C M with t h e H D S .
18. Hold t h e e n g i n e s p e e d b e t w e e n 3 , 0 0 0 — 4 , 0 0 0 r p m D T C s M E N U w i t h the H D S .
for at l e a s t 10 s e c o n d s .
Is DTC P0325 indicated? c o m p l e t e . If the E C M w a s s u b s t i t u t e d , r e p l a c e t h e
YES-Gotostep21. T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 2 3 ,
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e knock s e n s o r
a n d t h e E C M . If the E C M w a s u p d a t e d , s u b s t i t u t e a
s t e p 2 2 . If the E C M w a s s u b s t i t u t e d , g o to s t e p 1. If
t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D , g o to s t e p
22.
11-307
PGM-FI System
DTC P0335: CKP Sensor No Signal 9. M e a s u r e v o l t a g e b e t w e e n C K P s e n s o r 3 P c o n n e c t o r

a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l
CKP S E N S O R 3P C O N N E C T O R
Is DTC P0335 indicated? Wire side of f e m a l e terminals
Is there about 5 V?
at t h e C K P s e n s o r a n d the E C M . •
10. M e a s u r e v o l t a g e b e t w e e n C K P s e n s o r 3 P c o n n e c t o r
6. D i s c o n n e c t t h e C K P s e n s o r 3 P c o n n e c t o r . t e r m i n a l s No. 2 a n d N o . 3.

CKP S E N S O R 3P C O N N E C T O R
8. M e a s u r e v o l t a g e b e t w e e n C K P s e n s o r 3 P c o n n e c t o r
1 2 3
C K P S E N S O R 3P C O N N E C T O R
LG IGP
(BRN/YEL) (YEL/BLK)
IGP
(YEL/BLK)
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — G o to s t e p 16.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e C K P
Is there battery voltage? s e n s o r a n d G 1 0 1 , t h e n g o to s t e p 18.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e C K P
s e n s o r a n d P G M - F I m a i n r e l a y 1 (Fl M A I N ) , t h e n g o
to s t e p 18.
11-308
11. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 16. T u r n t h e ignition s w i t c h O F F .
A7 and body ground.
17. R e p l a c e the C K P s e n s o r ( s e e p a g e 11-387).
1 1 CKP (BLU) 19. T u r n t h e ignition s w i t c h O N (II).

1 2 3 4 5 6
I 18I
8 9
10
// 13 14 15 16
/ / 20 21
/ 23 2 4 25 2 6
/ / 28 30 31
X
2 1 . C l e a r t h e C K P pattern w i t h the H D S .
W i r e s i d e of f e m a l e t e r m i n a l s 2 3 . D o t h e C K P pattern l e a r n p r o c e d u r e ( s e e p a g e
11-214).
Is there about 5 V? 24. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M Is DTC P0335 indicated?

(A7) a n d the C K P s e n s o r , t h e n g o to s t e p 18.
N O — G o to s t e p 12. t e r m i n a l s at t h e C K P s e n s o r a n d t h e E C M , t h e n go
to s t e p 1.
13. J u m p t h e S C S line w i t h the H D S . T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to the
terminal A7 and body ground. 26. U p d a t e the E C M if it d o e s not h a v e t h e latest
g o o d E C M ( s e e p a g e 11-217).
I I CKP (BLU)
1 2 5 6
I 18 8 9
// /
A //
10 13 14 15 16 20 21
/ 23 2 4 25 26 28 30 31
t e r m i n a l s at t h e C K P s e n s o r a n d the E C M . If t h e
E C M w a s u p d a t e d , substitute a k n o w n - g o o d E C M
c o m p l e t e . If the E C M w a s s u b s t i t u t e d , r e p l a c e the
Is there continuity? original E C M ( s e e p a g e 11-389). If a n y other
T e m p o r a r y D T C s or D T C s are i n d i c a t e d , g o to the
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the E C M indicated D T C s troubleshooting. •
(A7) a n d t h e C K P s e n s o r , t h e n g o to s t e p 18.
N O — G o to s t e p 2 5 .
11-309
PGM-FI System
DTC P0339: CKP Sensor Circuit Intermittent 8. R e m o v e t h e c a m c h a i n c a s e ( s e e p a g e 6-13), a n d

Interruption c h e c k the C K P s e n s o r p u l s e plate for d a m a g e .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a Is the pulse plate damaged?

and any on-board snapshot, and review the general
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). Y E S — R e p l a c e t h e C K P s e n s o r p u l s e plate ( s e e p a g e
6-19), t h e n g o t o s t e p 11.
3. S t a r t t h e e n g i n e , a n d let it idle for 10 s e c o n d s .
10. R e p l a c e t h e C K P s e n s o r ( s e e p a g e 11-387).
4. C h e c k t h e C K P N O I S E in t h e D A T A L I S T w i t h t h e
HDS. 11. T u r n t h e ignition s w i t c h O N (II).
Are 0 counts indicated? 12. R e s e t the E C M w i t h t h e H D S .
Y E S — G o to s t e p 7. 13. C l e a r t h e C K P pattern w i t h the H D S .
N O — G o to s t e p 5. 14. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
5. T e s t - d r i v e t h e v e h i c l e for s e v e r a l m i n u t e s in t h e 15. D o t h e C K P pattern l e a r n p r o c e d u r e ( s e e p a g e

r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s : 11-214).
• ENGINE SPEED 16. S t a r t t h e e n g i n e , a n d let it idle for 10 s e c o n d s .

• VSS
17. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
6. C h e c k t h e C K P N O I S E in the D A T A L I S T w i t h t h e
HDS. Is DTC P0339 indicated?
Are 0 counts indicated ? Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

t e r m i n a l s at t h e C K P s e n s o r a n d t h e E C M , t h e n g o
Y E S — G o to s t e p 7. to s t e p 1.
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
at the C K P s e n s o r a n d t h e E C M . • indicated D T C s troubleshooting. •
7. C h e c k for p o o r or l o o s e c o n n e c t i o n s a n d t e r m i n a l s
at t h e s e l o c a t i o n s :
• CKP sensor
• ECM
• Engine ground
• Body ground
Are the connections and terminals OK?
N O — R e p a i r t h e c o n n e c t o r s or t e r m i n a l s , t h e n g o to
s t e p 11.
11-310
DTC P0365: CMP Sensor No Signal 9. M e a s u r e v o l t a g e b e t w e e n C M P s e n s o r 3 P
C M P S E N S O R 3P C O N N E C T O R
1 2 3
2. C l e a r t h e D T C w i t h the H D S . CMP
. (GRN)
Is DTC P0365 indicated? W i r e s i d e of f e m a l e t e r m i n a l s
Is there about 5 V?
at t h e C M P s e n s o r a n d the E C M . •
10. M e a s u r e v o l t a g e b e t w e e n C M P s e n s o r 3 P
6. D i s c o n n e c t the C M P s e n s o r 3 P c o n n e c t o r . c o n n e c t o r t e r m i n a l s N o . 2 a n d N o . 3.

C M P S E N S O R 3P C O N N E C T O R
8. M e a s u r e v o l t a g e b e t w e e n C M P s e n s o r 3 P
c o n n e c t o r t e r m i n a l No. 3 a n d b o d y g r o u n d . IGP
(YEL/BLK)
1 2 3
CMP S E N S O R 3P C O N N E C T O R LG
(BRN/YEL)
IGP
(YEL/BLK)
1 2 3
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e C M P
Is there battery voltage? s e n s o r a n d G 1 0 1 , t h e n g o to s t e p 18.
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e C M P
s e n s o r a n d P G M - F I m a i n r e l a y 1 (Fl M A I N ) , t h e n g o
to s t e p 18.
(cont'd)
11-311
PGM-FI System

A 6 and body ground.
17. R e p l a c e t h e C M P s e n s o r ( s e e p a g e 11-387).
1 C M P (GRN) 19. T u r n t h e ignition s w i t c h O N (II).

1 | 2 | 3 4 | 5 6 | 7 | 8 | 9
10
/ 13 14 15 16
/ /
18 20 21
23 24 25 26
/ /
28 30 31
X
Is there about 5 V? t e r m i n a l s at t h e C M P s e n s o r a n d t h e E C M , t h e n g o
to s t e p 1.
(A6) a n d t h e C M P s e n s o r , t h e n g o to s t e p 18. N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
12. T u r n t h e ignition s w i t c h O F F . 2 3 . R e c o n n e c t all c o n n e c t o r s .
13. J u m p t h e S C S line w i t h t h e H D S . 24. U p d a t e the E C M if it d o e s not h a v e t h e latest

14. D i s c o n n e c t E C M c o n n e c t o r A (31P). g o o d E C M ( s e e p a g e 11-217).
15. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 2 5 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .

terminal A 6 and body ground.
t e r m i n a l s at t h e C M P s e n s o r a n d t h e E C M . If the
I— " 1 C M P (GRN) E C M w a s updated, substitute a known-good E C M
1 | 2 3 4 5 6 7 | 8 9 ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e E C M w a s
10
/ 13 14 15 16
/ /
18 20 21
23 24 25 26
/ /
28 30 31
W i r e s i d e of f e m a l e t e r m i n a l s indicated D T C s troubleshooting. •
(A6) a n d t h e C M P s e n s o r , t h e n g o to s t e p 19.
N O — G o to s t e p 2 3 .
11-312
DTC P0369: CMP Sensor Circuit Intermittent 8. C h e c k for d a m a g e o n t h e C M P p u l s e plate
Interruption ( s e e p a g e 6-34).
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data Is the plate damaged?

t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). Y E S — R e p l a c e t h e C M P p u l s e plate ( s e e p a g e 6-34),
3. S t a r t t h e e n g i n e , a n d let it idle for 10 s e c o n d s .
10. R e p l a c e t h e C M P s e n s o r ( s e e p a g e 11-387).
4. C h e c k t h e C M P N O I S E in t h e D A T A L I S T w i t h t h e
Are 0 counts indicated? 12. R e s e t t h e E C M w i t h t h e H D S .
Y E S - G o to s t e p 7. 13. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
N O — G o to s t e p 5. 14. S t a r t t h e e n g i n e , a n d let it idle for 10 s e c o n d s .
5. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in t h e 15. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .

• ENGINE SPEED
• VSS Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e C M P s e n s o r a n d the E C M , t h e n g o
6. C h e c k t h e C M P N O I S E in t h e D A T A L I S T w i t h t h e to s t e p 1.
HDS.
Are 0 counts indicated? T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
at t h e C M P s e n s o r a n d t h e E C M . •
7. C h e c k for p o o r or l o o s e c o n n e c t i o n s a n d t e r m i n a l s
at t h e s e l o c a t i o n s :
• CMP sensor
• ECM
• Engine ground
• Body ground
N O — R e c o n n e c t the c o n n e c t o r s or t e r m i n a l s , t h e n
g o to s t e p 11.
11-313
PGM-FI System
DTC P0563: ECM Power Source Circuit 10. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l

Unexpected Voltage E7 and body ground.
M R L Y (GRN)
1 1
1 M 3 | 4 | 5 y\i
8 9
2. C l e a r t h e D T C w i t h t h e H D S . / 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/
4. W a i t 10 s e c o n d s .
6. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . Is there battery voltage?
Is DTC P0563 indicated? Y E S — G o t o s t e p 13.
Y E S — G o t o s t e p 7. N O — G o to s t e p 11.
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 11. R e m o v e P G M - F I m a i n r e l a y 1 (Fl M A I N ) (A).

at t h e N o . 46 A C G S (15 A ) f u s e in t h e u n d e r - h o o d A
f u s e / r e l a y b o x , P G M - F I m a i n r e l a y 1 (Fl M A I N ) , a n d
the E C M . B
11-314
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 16. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M
terminal E7 and body ground. c o n n e c t o r t e r m i n a l s A 3 a n d A 2 individually.
E C M C O N N E C T O R E (31P) E C M C O N N E C T O R A (31P)
IGP2 IGP1
M R L Y (GRN) (YEL/BLK) (YEL/BLK)
1 / 3 | 4| 5 / | 7 8 9
1 | 2 | 3 | 4 | 5 6 | 7 | 8 | 9
/ 11 12 13 14 15 16 17 18 19 20 21
10
/ 13 14 15 16
/ / 18 20 21
22
/ 24 25
/ 27 28 29 30
/ 23 24 25 26
/ / 28 30 31
Is there continuity? Is there battery voltage?
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the E C M Y E S — G o t o s t e p 17.

(E7) a n d P G M - F I m a i n r e l a y 1 (Fl M A I N ) , t h e n g o to
s t e p 20. N O — G o to s t e p 2 7 .
N O — G o to s t e p 19. 17. R e m o v e P G M - F I m a i n r e l a y 1 (Fl M A I N ) (A).
13. R e c o n n e c t E C M c o n n e c t o r E (31P). A
E7 and body ground.
M R L Y (GRN)
1 / 3 | 4 | 5 / | 7 8 9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/
N O — G o to s t e p 2 7 .
(cont'd)
11-315
PGM-FI System
18. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d E C M 2 5 . W a i t 10 s e c o n d s .
connector terminals A 3 a n d A 2 individually.
IGP2 IGP1
(YEL/BLK) (YEL/BLK)
t e r m i n a l s at P G M - F I m a i n r e l a y 1 (Fl M A I N ) a n d the
1 | 2 | 3 | 4 | 5 6 | 7 8 | 9 E C M , t h e n g o to s t e p 1.
10
// 13 14 15 16
/ / 18 20 21
/ 23 24 25 26
/ / 28 30 31 N O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
W i r e s i d e of f e m a l e t e r m i n a l s 2 7 . R e c o n n e c t all c o n n e c t o r s .
Is there battery voltage? s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
t h e E C M ( A 2 , A 3 ) a n d P G M - F I m a i n r e l a y 1 (Fl 2 9 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
M A I N ) , t h e n g o to s t e p 20.
19. T e s t P G M - F I m a i n r e l a y 1 (Fl M A I N ) ( s e e p a g e t e r m i n a l s at P G M - F I m a i n r e l a y 1 (Fl M A I N ) a n d the
22-48). E C M , t h e n g o to s t e p 1. If the E C M w a s u p d a t e d ,
Is PGM-FI main relay 1 (Fl MAIN) OK? t h e n r e c h e c k . If the E C M w a s s u b s t i t u t e d , g o to s t e p
1.
Y E S — G o to s t e p 2 7 .
N O — R e p l a c e t h e P G M - F I m a i n r e l a y 1 (Fl M A I N ) , c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
t h e n g o to s t e p 20. original E C M ( s e e p a g e 11-389). If a n y o t h e r
2 0 . R e c o n n e c t all c o n n e c t o r s . indicated D T C s troubleshooting. •
2 3 . Do t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
11-316
DTC P0600: Serial Communication Link DTC P0602: ECM Programming Error
Malfunction
NOTE:
NOTE: • B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d any on-board snapshot, and r e v i e w the general
a n y on-board s n a p s h o t , and review the general t r o u b l e s h o o t i n g information ( s e e p a g e 11-213).
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). • T h i s D T C is i n d i c a t e d w h e n t h e E C M u p d a t e is not
• T h i s D T C is s t o r e d w h e n t h e r e is a p r o b l e m in t h e completed.
s e r i a l c o m m u n i c a t i o n s y s t e m . G o to the g a u g e • D o not turn t h e ignition s w i t c h O F F w h i l e updating
a s s e m b l y troubleshooting. t h e E C M . If y o u t u r n the ignition s w i t c h O F F before
completion, the E C M c a n be d a m a g e d .
1. D o t h e E C M u p d a t e p r o c e d u r e ( s e e p a g e 11-216).
Y E S — R e p l a c e t h e original E C M ( s e e p a g e 11-389).
N O — U p d a t i n g i s c o m p l e t e . If a n y other T e m p o r a r y
D T C s o r D T C s a r e i n d i c a t e d , g o to the indicated
D T C s troubleshooting. •
11-317
PGM-FI System
DTC P0603: ECM Internal Control Module DTC P0606: ECM Processor Malfunction
Keep Alive Memory (KAM) Error
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d a n y on-board s n a p s h o t , a n d review the general
a n d a n y on-board s n a p s h o t , a n d review the general t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213).
2. Clear the D T C with the H D S .
5. W a i t 40 s e c o n d s .
time.B Is DTC P0606 indicated?
4. U p d a t e t h e E C M if it d o e s not h a v e t h e latest Y E S — G o to s t e p 7.
g o o d E C M ( s e e p a g e 11-217). N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s
time.H
7. U p d a t e t h e E C M if it d o e s not h a v e t h e latest
Is DTC P0603 indicated? s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
Y E S — I f the E C M w a s updated, substitute a known-
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e 8. T u r n t h e ignition s w i t c h O F F .
E C M w a s s u b s t i t u t e d , g o to s t e p 1.
c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e 10. W a i t 40 s e c o n d s .
T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e 11. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
indicated D T C s t r o u b l e s h o o t i n g . !
Y E S — I f the E C M w a s u p d a t e d / s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 8. If
N O — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e the
11-318
DTC P0630: VIN Not Programmed or 8. C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
Mismatch
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d Y E S — G o to s t e p 9.
any on-board snapshot, and review the general
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at this
• T h i s D T C is s t o r e d o n l y w h e n t h e E C M d o e s not h a v e t i m e . If a n y other T e m p o r a r y D T C s or D T C s a r e
t h e V I N i n f o r m a t i o n of the v e h i c l e . U s e t h e H D S to i n d i c a t e d , g o to t h e i n d i c a t e d D T C s
input t h e m i s s i n g V I N i n f o r m a t i o n . troubleshooting. •
1. T u r n t h e ignition s w i t c h O N (II). 9. U p d a t e t h e E C M if it d o e s not h a v e t h e latest

2. C h e c k t h e V I N w i t h the H D S . g o o d E C M ( s e e p a g e 11-217).
Does the HDS show the vehicle's VIN? 10. C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
Y E S — G o to s t e p 5. Is DTC P0630 indicated?
N O — G o to s t e p 3. Y E S — I f the E C M w a s updated, substitute a known-

3. Input t h e V I N to the E C M w i t h t h e H D S . E C M w a s s u b s t i t u t e d , g o to s t e p 1.
Does the screen show COMPLETE? N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is

Y E S — G o to s t e p 5. original E C M ( s e e p a g e 11-389). If a n y other
4. C h e c k for D T C s w i t h the H D S .
Y E S — G o to t h e D T C P 0 6 0 3 t r o u b l e s h o o t i n g . •
7. T u r n the ignition s w i t c h O N (II), a n d w a i t 5 s e c o n d s .
11-319
PGM-FI System
DTC P0685: ECM Power Control Circuit/ 15. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .

Internal Circuit Malfunction
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a n d Y E S — I f the E C M w a s updated, substitute a known-
any on-board snapshot, and review the general g o o d E C M ( s e e p a g e 11-217), t h e n g o t o s t e p 10. If
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
• If t h e p r o b l e m d o e s n ' t return after y o u c l e a r t h e D T C ,
o r if t h i s D T C is s t o r e d intermittently, c h e c k f o r l o o s e N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
t e r m i n a l s at t h e I G P line c o n n e c t o r s b e f o r e r e p l a c i n g c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
the E C M . original E C M ( s e e p a g e 11-389). If a n y o t h e r
1. T u r n t h e ignition s w i t c h O N (II). indicated D T C s troubleshooting. •
3. S t a r t t h e e n g i n e , t h e n let it idle f o r 3 0 s e c o n d s .
t i m e . If a n y other T e m p o r a r y D T C s or D T C s a r e
i n d i c a t e d , g o to t h e indicated D T C s
troubleshooting.!

g o o d E C M ( s e e p a g e 11-217).
12. S t a r t t h e e n g i n e , t h e n let it idle for 3 0 s e c o n d s .
11-320
DTC P0720: Output Shaft (Countershaft) 7. M e a s u r e v o l t a g e b e t w e e n output s h a f t
Speed Sensor Circuit Malfunction (countershaft) s p e e d s e n s o r 3 P connector terminal
No. 1 a n d b o d y g r o u n d .
and a n y on-board s n a p s h o t , a n d review the general
OUTPUT SHAFT (COUNTERSHAFT)
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). S P E E D S E N S O R 3P C O N N E C T O R
3,000 r p m without load (in neutral) until t h e
radiator f a n c o m e s o n , t h e n let it idle. VCC2
(YEL/BLU)
2. T e s t - d r i v e s e v e r a l m i l e s .
3. C h e c k t h e C S H A F T S P D in t h e D A T A L I S T w i t h t h e
HDS.
Is any vehicle speed indicated?
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Is there about 5 V?
t i m e . C h e c k for poor c o n n e c t i o n s or l o o s e t e r m i n a l s
at t h e output shaft (countershaft) s p e e d s e n s o r a n d Y E S — G o to s t e p 8.
the E C M . B
N O — G o to s t e p 4. (A20) a n d t h e output s h a f t (countershaft) s p e e d
s e n s o r , t h e n g o to s t e p 17.
8. M e a s u r e v o l t a g e b e t w e e n output s h a f t
5. D i s c o n n e c t t h e output s h a f t (countershaft) s p e e d (countershaft) s p e e d s e n s o r 3 P c o n n e c t o r t e r m i n a l
sensor 3P connector. No. 2 a n d b o d y g r o u n d .
S P E E D S E N S O R 3P C O N N E C T O R
1 2 3
NC
(BLU/WHT)
Is there about 5 V?
(cont'd)
11-321
PGM-FI System
9. M e a s u r e v o l t a g e b e t w e e n output s h a f t 11. T u r n the ignition s w i t c h O F F .
(countershaft) s p e e d s e n s o r 3 P c o n n e c t o r t e r m i n a l s
No. 1 a n d N o . 3. 12. J u m p the S C S line w i t h the H D S .
1 .2 3
VCC2 SG2 E C M C O N N E C T O R A (31P)
(YEL/BLU) (GRN/YEL)
1
kg)- 1 3 5 6
I 8J 9
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 23
NC
30 31
(BLU/WHT)
Is there about 5 V?
(A23) a n d the output s h a f t (countershaft) s p e e d Is there continuity?
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the E C M
10. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l (A18) a n d t h e output shaft (countershaft) s p e e d
A18 and body ground. s e n s o r , t h e n g o to s t e p 17.
1 | 2 | 3 | 4 | B 6 IT 8 | 9
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 23
NC
30 31
(BLU/WHT)
Is there about 5 V?
(A18) a n d t h e output s h a f t (countershaft) s p e e d
11-322
15. T u r n the ignition s w i t c h O F F . 24. R e c o n n e c t all c o n n e c t o r s .
16. R e p l a c e the output shaft (countershaft) s p e e d 2 5 . U p d a t e the E C M if it d o e s not h a v e t h e latest

s e n s o r ( s e e p a g e 11 -388). s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
19. R e s e t the E C M w i t h t h e H D S . a b o v e 158 °F (70 °C)
20. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462). • E n g i n e s p e e d at 2 , 0 0 0 — 3 , 0 0 0 r p m
• D r i v e for s e v e r a l m i n u t e s , t h e n d e c e l e r a t e (with
21. Test-drive under these conditions: the throttle fully c l o s e d ) for 8 s e c o n d s
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) 2 7 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
a b o v e 158 °F (70 °C)
• T r a n s m i s s i o n in 5th g e a r Is DTC P0720 indicated?
• E n g i n e s p e e d at 2 , 0 0 0 — 3 , 0 0 0 r p m
• D r i v e for s e v e r a l m i n u t e s , t h e n d e c e l e r a t e (with Y E S — C h e c k for p o o r c o n n e c t i o n s o r l o o s e
t h e throttle fully c l o s e d ) for 8 s e c o n d s t e r m i n a l s at t h e output shaft (countershaft) s p e e d
s e n s o r and the E C M .
t e r m i n a l s at the output shaft (countershaft) s p e e d
s e n s o r a n d t h e E C M , t h e n g o to s t e p 1.
N O — G o to s t e p 2 3 .
2 3 . M o n i t o r the O B D S T A T U S for D T C P0720 in the

g o to the indicated D T C s t r o u b l e s h o o t i n g . !
N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at the output shaft
(countershaft) s p e e d s e n s o r a n d the E C M , t h e n g o
to s t e p 1. If the s c r e e n i n d i c a t e s N O T C O M P L E T E D ,
(cont'd)
11-323
PGM-FI System

28. M o n i t o r t h e O B D S T A T U S for D T C P 0 7 2 0 in t h e DTC P1109: BARO Sensor Circuit Out of
D T C s M E N U w i t h the H D S . Range High
Does the screen indicate PASSED? N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data

a n d any on-board s n a p s h o t , and review the general
Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213).
original E C M ( s e e p a g e 11-389). If a n y o t h e r 1. T u r n t h e ignition s w i t c h O N (II).
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • 2. R e s e t t h e E C M w i t h t h e H D S .
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r 3. S t a r t t h e e n g i n e .
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e o u t p u t s h a f t
(countershaft) s p e e d s e n s o r a n d t h e E C M . If t h e 4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
( s e e p a g e 11-217), t h e n g o to s t e p 26. If t h e E C M Is DTC P1109 indicated?
w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
N O T C O M P L E T E D , g o to s t e p 2 6 . Y E S — G o to s t e p 5.
N O - H n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
t i m e . If a n y o t h e r T e m p o r a r y D T C s or D T C s a r e
i n d i c a t e d , g o to t h e i n d i c a t e d D T C s
g o o d E C M ( s e e p a g e 11-217).
Y E S — I f t h e E C M w a s u p d a t e d , substitute a k n o w n -
11-324
DTC P1116: ECT Sensor 1 Circuit Range/ 9. A l l o w E C T s e n s o r 1 to c o o l to a m b i e n t t e m p e r a t u r e .
Performance Problem
10. Note the a m b i e n t t e m p e r a t u r e .
NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data a n d 11. C o n n e c t E C T s e n s o r 1 to t h e 2 P c o n n e c t o r , but d o
any on-board snapshot, and review the general not install s e n s o r o n t h e e n g i n e .
• If D T C P0111 is s t o r e d at t h e s a m e t i m e a s D T C P 1 1 1 6 , 12. T u r n the ignition s w i t c h O N (II).
t r o u b l e s h o o t D T C P0111 first, t h e n r e c h e c k for D T C
P1116. 13. Note the v a l u e of E C T S E N S O R 1 q u i c k l y in t h e
D A T A L I S T with the H D S .
1. C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at
E C T s e n s o r 1 a n d E C T s e n s o r 2. 14. C o m p a r e t h e v a l u e of E C T S E N S O R 1 a n d t h e
ambient temperature.
Does the value of ECT SENSOR 1 differ 5.4 °F
Y E S — G o to s t e p 2. (3 °C) or more?
N O — R e p a i r the c o n n e c t o r s or t e r m i n a l s , t h e n g o to Y E S — R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385), t h e n
s t e p 27. g o to s t e p 27.
2. T u r n t h e ignition s w i t c h O N (II). N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
3. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e E C M . a
Are DTC P1116 and P2183 indicated at the same 15. S t a r t the e n g i n e , a n d let it idle for 10 m i n u t e s .
time?
Y E S — G o to s t e p 15. HDS.
N O — G o to s t e p 4. Is about 113 °F (45 °C) or less indicated?
4. Start t h e e n g i n e , a n d let it idle for 10 m i n u t e s . Y E S — R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385), t h e n

g o to s t e p 27.
HDS. N O — G o to s t e p 17.
Is about 113 °F (45 °C) or less indicated? 17. L e t t h e e n g i n e idle for 10 m i n u t e s .
Y E S — R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385), t h e n 18. C h e c k E C T S E N S O R 2 in t h e D A T A L I S T w i t h t h e
g o to s t e p 2 7 . HDS.
N O — G o to s t e p 6. Is about 113 °F (45 °C) or less indicated?
6. T u r n the ignition s w i t c h O F F . Y E S — R e p l a c e E C T s e n s o r 2 ( s e e p a g e 11-385), t h e n

g o t o s t e p 27.
7. Drain t h e c o o l a n t ( s e e p a g e 10-9).
8. R e m o v e E C T s e n s o r 1 ( s e e p a g e 11-385).
(cont'd)
11-325
PGM-FI System
19. T u r n t h e ignition s w i t c h O F F . 2 7 . T u r n t h e ignition s w i t c h O N (II).
2 0 . D r a i n t h e c o o l a n t ( s e e p a g e 10-9). 2 8 . R e s e t t h e E C M w i t h the H D S .
2 1 . R e m o v e E C T s e n s o r 1 ( s e e p a g e 11-385) a n d E C T 2 9 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

s e n s o r 2 ( s e e p a g e 11 -385).
2 2 . A l l o w t h e s e n s o r s to c o o l to a m b i e n t t e m p e r a t u r e .
2 3 . Note t h e a m b i e n t t e m p e r a t u r e .
2 4 . C o n n e c t E C T s e n s o r 1 to t h e 2 P c o n n e c t o r , a n d E C T t e r m i n a l s at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e
s e n s o r 2 to the 2 P c o n n e c t o r , but d o not install E C M , t h e n g o to s t e p 1.
t h e m on the engine.
2 5 . Note t h e v a l u e of E C T S E N S O R 1 a n d E C T S E N S O R T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to t h e
2 q u i c k l y in the D A T A L I S T w i t h t h e H D S . indicated D T C s troubleshooting. •
2 6 . C o m p a r e t h e v a l u e of E C T S E N S O R 1 a n d t h e
a m b i e n t t e m p e r a t u r e , a n d the v a l u e of E C T
S E N S O R 2 a n d the a m b i e n t t e m p e r a t u r e
individually.
Does one of the sensors differ more than 5.4 °F

(3 °C) from the ambient temperature?
Y E S — R e p l a c e t h e s e n s o r that differed m o r e t h a n
5.4 °F (3 *€) f r o m t h e a m b i e n t t e m p e r a t u r e , t h e n g o
to s t e p 2 7 .
at E C T s e n s o r 1, E C T s e n s o r 2 , a n d the E C M . H
11-326
DTC P1128: MAP Sensor Signal Lower Than 8. T u r n t h e ignition s w i t c h O F F .
Expected
9. R e p l a c e t h e M A P s e n s o r ( s e e p a g e 11-384).
a n d a n y on-board s n a p s h o t , a n d r e v i e w the general 10. T u r n t h e ignition s w i t c h O N (II).
1. I n s p e c t t h e air c l e a n e r e l e m e n t ( s e e p a g e 11-505).
12. Do t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
Is there damage or clogging?
Y E S — R e p l a c e the air c l e a n e r e l e m e n t ( s e e p a g e 3,000 r p m w i t h o u t l o a d (in neutral) until t h e
11-505). T h e n c l e a r the D T C w i t h the H D S , a n d g o to radiator f a n c o m e s o n , t h e n let it idle.
s t e p 13.
2. T u r n t h e ignition s w i t c h O N (II). a b o v e 1 5 8 ° F ( 7 0 °C)
• T r a n s m i s s i o n in 3 r d g e a r
3. C h e c k t h e M A P S E N S O R in t h e D A T A L I S T w i t h the • V e h i c l e s p e e d at 15 m p h (24 k m / h ) or m o r e , a n d
HDS. e n g i n e s p e e d b e t w e e n 1,300 r p m a n d 7,600 r p m
for 2 s e c o n d s or m o r e .
Is less than 54.1 kPa (16.0 in.Hg, 406 mmHg), or
1.61 V held for more than 5 seconds? 15. C h e c k for T e m p o r a r y D T C s or D T C s with t h e H D S .
Y E S — G o to s t e p 8. IsDTCP1128 indicated?
N O — G o to s t e p 4. Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e M A P s e n s o r a n d t h e E C M , t h e n g o
4. C l e a r t h e D T C with the H D S . to s t e p 1.
5. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at N O — G o to s t e p 16.
radiator f a n c o m e s o n , t h e n let it idle. 16. M o n i t o r t h e O B D S T A T U S for D T C P1128 in the
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) Does the screen indicate PASSED?
a b o v e 158 T (70 °C)
• T r a n s m i s s i o n in 3rd g e a r Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
• V e h i c l e s p e e d at 15 m p h (24 k m / h ) or m o r e , a n d T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 15,
e n g i n e s p e e d b e t w e e n 1,300 r p m a n d 7,600 r p m g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
for 2 s e c o n d s or m o r e .
7. M o n i t o r the O B D S T A T U S for D T C P 1 1 2 8 in the c o n n e c t i o n s or l o o s e t e r m i n a l s at the M A P s e n s o r
D T C s M E N U with the H D S . a n d t h e E C M , t h e n go to s t e p 1. If t h e s c r e e n
Does the screen indicate FAILED ?
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent
f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . C h e c k for
p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e M A P
s e n s o r a n d t h e E C M . If t h e s c r e e n i n d i c a t e s N O T
C O M P L E T E D , g o to s t e p 5 a n d r e c h e c k .
11-327
PGM-FI System
DTC P1129: MAP Sensor Signal Higher Than 6. M o n i t o r the O B D S T A T U S for D T C P 1 1 2 9 in the
Expected D T C s M E N U w i t h the H D S .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data Does the screen indicate FAILED?

and a n y on-board s n a p s h o t , and review the general
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). Y E S — G o to s t e p 7.
1. C h e c k for v a c u u m l e a k s in t h e s e p a r t s . N O — I f the s c r e e n i n d i c a t e s P A S S E D , intermittent

f a i l u r e , the s y s t e m is O K at t h i s t i m e . C h e c k for
• PCV valve p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s at the M A P
• PCV hose s e n s o r a n d the E C M . If the s c r e e n i n d i c a t e s N O T
• E V A P canister purge valve C O M P L E T E D , g o to s t e p 5 a n d r e c h e c k .
• Brake booster hose 7. T u r n t h e ignition s w i t c h O F F .
8. R e p l a c e the M A P s e n s o r ( s e e p a g e 11-384).
Are there any vacuum leaks?
Y E S — R e p a i r or r e p l a c e parts w i t h v a c u u m l e a k s ,
t h e n g o to s t e p 9. 10. R e s e t t h e E C M w i t h the H D S .
N O — G o to s t e p 2. 11. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 . S t a r t the e n g i n e . Hold the e n g i n e s p e e d at 12. S t a r t the e n g i n e . Hold the e n g i n e s p e e d at

3.000 r p m w i t h o u t l o a d (in neutral) until the 3,000 r p m w i t h o u t l o a d (in neutral) until the
radiator f a n c o m e s o n , t h e n let it idle. radiator f a n c o m e s o n , t h e n let it idle.
3. C h e c k t h e M A P S E N S O R in t h e D A T A L I S T w i t h t h e 13. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
HDS.
Is more than 36.9 kPa (11.0 in.Hg, 277 mmHg), or a b o v e 158 °F (70<€)
1.1 V held for more than for 5 seconds? • Vehicle s p e e d between 55—75 m p h (88—
121 k m / h ) for 10 s e c o n d s
Y E S — G o to s t e p 7. • V e h i c l e s p e e d d e c e l e r a t e d w i t h throttle fully
c l o s e d for at l e a s t 2 s e c o n d s for m o r e
4. C l e a r the D T C w i t h t h e H D S .
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
a b o v e 158 T ( 7 0 * 0 t e r m i n a l s at the M A P s e n s o r a n d t h e E C M , t h e n g o
• T r a n s m i s s i o n in 5th g e a r to s t e p 1.
• Vehicle s p e e d between 55—75 mph (88—
121 k m / h ) for 10 s e c o n d s N O — G o to s t e p 15.
• V e h i c l e s p e e d d e c e l e r a t e d w i t h throttle fully
c l o s e d for at l e a s t 2 s e c o n d s for m o r e
11-328
15. M o n i t o r t h e O B D S T A T U S for D T C P 1 1 2 9 in the
Y E S — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y other
c o n n e c t i o n s o r l o o s e t e r m i n a l s at the M A P s e n s o r
a n d t h e E C M , t h e n g o to s t e p 1. If t h e s c r e e n
PGM-FI System
DTC P1157: A/F Sensor (Sensor 1) A F S Circuit 10. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

High Voltage t e r m i n a l A31 a n d b o d y g r o u n d .
1 | 2 | 3 | 4 | 5 6 | 7 | | 8 | 9
/// // //
10 13 14 15 16 18 20 21
23 24 25 26 28 30 31
2. C l e a r t h e D T C w i t h t h e H D S . A F S + (RED)
3. S t a r t t h e e n g i n e , a n d w a i t 20 s e c o n d s .
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Y E S — G o to s t e p 11.
at t h e A / F s e n s o r ( S e n s o r 1) a n d t h e E C M . • N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E C M
(A31) a n d t h e A / F s e n s o r ( S e n s o r 1), t h e n go to s t e p
5. T u r n t h e ignition s w i t c h O F F . 15.
6. J u m p t h e S C S line w i t h t h e H D S . 11. R e m o v e the j u m p e r w i r e f r o m the A / F s e n s o r

( S e n s o r 1) 4 P c o n n e c t o r .
7. D i s c o n n e c t t h e A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r .
8. D i s c o n n e c t E C M c o n n e c t o r A (31P). t e r m i n a l N o . 2 to b o d y g r o u n d w i t h a j u m p e r w i r e .
A F S - (RED/YEL)
A / F S E N S O R ( S E N S O R 1) 4 P C O N N E C T O R 1 2
3 4
A F S + (RED) JUMPER WIRE
1 2
3 4
JUMPER WIRE
11-330
13. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 20. M o n i t o r t h e O B D S T A T U S for D T C P 1 1 5 7 in t h e
terminal A 2 8 and body ground. D T C s M E N U with the HDS.
1 2 | 3 | 4 | 5 6 | 7 8 | 9 T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 19,
10
/
23 24
13 14 15 16
25 26 // // 18
28
20 21
30 31
A F S — (RED/YEL)
( S e n s o r 1) a n d t h e E C M , t h e n g o to s t e p 1. If t h e
until a r e s u l t c o m e s o n .
2 1 . U p d a t e the E C M if it d o e s not h a v e t h e latest
Is there continuity ? g o o d E C M ( s e e p a g e 11-217).
Y E S — G o to s t e p 14. 2 2 . S t a r t t h e e n g i n e , a n d let it idle.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M 2 3 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
(A28) a n d t h e A / F s e n s o r ( S e n s o r 1), t h e n g o to s t e p
15. Is DTC P1157 indicated?
14. R e p l a c e t h e A / F s e n s o r ( S e n s o r 1) ( s e e p a g e Y E S — I f the E C M w a s updated, substitute a known-

11-386). g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 2 2 . If
t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1) a n d t h e E C M ,
t h e n g o to s t e p 1. If t h e c o n n e c t o r a n d t e r m i n a l fits
a r e O K , g o to s t e p 2 1 .
(cont'd)
11-331
PGM-FI System

o r i g i n a l E C M ( s e e p a g e 11-389). If a n y o t h e r
T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 2 3 ,
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , g o to s t e p 1. If
the E C M w a s updated, substitute a known-good
E C M ( s e e p a g e 11-217), t h e n g o to s t e p 2 2 . If t h e
E C M w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n
i n d i c a t e s N O T C O M P L E T E D , k e e p idling until a
result c o m e s on.
11-332
DTC P1172: A/F Sensor (Sensor 1) Circuit Out 11. C h e c k for T e m p o r a r y D T C s or D T C s with t h e H D S .
of Range High
a n d a n y on-board s n a p s h o t , and r e v i e w the general Y E S — C h e c k f o r p o o r c o n n e c t i o n s or l o o s e
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1) a n d the E C M ,
12. Monitor t h e O B D S T A T U S for D T C P 1 1 7 2 in the
3. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at D T C s M E N U with the H D S .
radiator f a n c o m e s o n , t h e n let it idle. Does the screen indicate PASSED?
4. Monitor the O B D S T A T U S for D T C P 1 1 7 2 in t h e Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other

D T C s M E N U with the H D S . T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 11,
Y E S — G o to s t e p 5. c o n n e c t i o n s or l o o s e t e r m i n a l s at the A / F s e n s o r
( S e n s o r 1) a n d the E C M , t h e n g o to s t e p 1. If the
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling until a
failure, t h e s y s t e m is O K at t h i s t i m e . C h e c k for result c o m e s o n . If the s c r e e n i n d i c a t e s O U T O F
poor c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e A / F C O N D I T I O N , g o to s t e p 10.
s e n s o r ( S e n s o r 1) a n d the E C M . If t h e s c r e e n
i n d i c a t e s E X E C U T I N G , k e e p idling until a r e s u l t
6. R e p l a c e t h e A / F s e n s o r ( S e n s o r 1) ( s e e p a g e
11-386).
9. Do the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
10. Start the e n g i n e . Hold t h e e n g i n e s p e e d at

11-333
PGM-FI System
DTC P1297: ELD Circuit Low Voltage 10. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

terminal E 1 5 and body ground.
and any on-board s n a p s h o t , and review the general E C M C O N N E C T O R E (31P)
1. T u r n t h e ignition s w i t c h O N (II). ~7_1 8 9

1 1 12 13 14 15 16 17 18 19 20 21
2. C h e c k the E L D in t h e D A T A L I S T w i t h t h e H D S . //
22 24 25 /
ELD
27 28 29 30
/
Is72 A or more indicated? (GRN/RED)
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s W i r e s i d e of f e m a l e t e r m i n a l s
at the E L D a n d t h e E C M . •
is there continuity?
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n the E C M
4. D i s c o n n e c t the E L D 3 P c o n n e c t o r . (E15) a n d t h e E L D , t h e n g o to step-13.
5. T u r n t h e ignition s w i t c h O N (II). N O — G o to s t e p 2 0 .
6. C h e c k the E L D in t h e D A T A L I S T w i t h t h e H D S . 11. T u r n t h e ignition s w i t c h O F F .
is 72 A or more indicated? 12. R e p l a c e t h e u n d e r - h o o d f u s e / r e l a y box.
Y E S — G o to s t e p 7. 13. R e c o n n e c t all c o n n e c t o r s .
N O — G o to s t e p 11. 14. T u r n the ignition s w i t c h O N (II).
7. T u r n the ignition s w i t c h O F F . 15. R e s e t t h e E C M w i t h the H D S .
8. J u m p the S C S line w i t h the H D S . 16. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
9. D i s c o n n e c t E C M c o n n e c t o r E (31P). 17. S t a r t the e n g i n e .
18. T u r n o n t h e h e a d l i g h t s .
t e r m i n a l s at t h e E L D a n d the E C M , t h e n g o to s t e p
1.
T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to the
11-334
2 1 . U p d a t e the E C M if it d o e s not h a v e the latest

g o o d E C M ( s e e p a g e 11-217).
2 2 . S t a r t the e n g i n e .
23. T u r n on the headlights.
24. C h e c k for T e m p o r a r y D T C s or D T C s with the H D S .
t e r m i n a l s at the E L D a n d the E C M . If the E C M w a s
11-217), t h e n go to s t e p 2 2 . If the E C M w a s
N O — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
PGM-FI System
DTC P1298: ELD Circuit High Voltage 7. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a 8. C o n n e c t E L D 3 P c o n n e c t o r t e r m i n a l N o . 3 to b o d y
a n d a n y on-board s n a p s h o t , and review the general ground with a jumper wire.
1. S t a r t the e n g i n e , a n d let it idle.
2. C h e c k the E L D in t h e D A T A L I S T w i t h t h e H D S .
Is 0.2 A or less indicated? ELD

(GRN/RED)
JUMPER WIRE
at t h e E L D a n d t h e E C M . • Wire s i d e of f e m a l e terminals
4. D i s c o n n e c t t h e E L D 3 P c o n n e c t o r .
6. M e a s u r e v o l t a g e b e t w e e n E L D 3 P c o n n e c t o r terminal E 1 5 and body ground.
1 / 3 4 5 X 7 8 9
IG1
(BLK/YEL)
/ 11 12 13 14 15 16 17 18 19 20 21
/
22
/ 24 25
/
ELD
2 7 28 29 30
(GRN/RED)
/
N O — C h e c k t h e N o . 6 A C G (15 A ) f u s e in t h e m a i n (E15) a n d t h e E L D , t h e n g o to s t e p 14.
u n d e r - d a s h f u s e / r e l a y b o x . If t h e f u s e is O K , r e p a i r
o p e n in t h e w i r e b e t w e e n t h e N o . 6 A C G (15 A ) f u s e
a n d t h e E L D , t h e n g o to s t e p 14.
11-336
12, C h e c k for c o n t i n u i t y b e t w e e n E L D 3 P c o n n e c t o r 19. U p d a t e t h e E C M if it d o e s not h a v e t h e latest
terminal No. 2 and body ground. s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
GND Y E S — C h e c k for poor c o n n e c t i o n s or l o o s e

(BLK)
t e r m i n a l s at the E L D a n d t h e E C M . If t h e E C M w a s
11-217), t h e n r e c h e c k . If the E C M w a s s u b s t i t u t e d ,
g o to s t e p 1.
W i r e s i d e of f e m a l e t e r m i n a l s N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
c o m p l e t e . If the E C M w a s s u b s t i t u t e d , r e p l a c e t h e
Is there continuity ? T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to the
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E L D a n d
G 2 0 1 , t h e n g o to s t e p 14.
13. R e p l a c e the u n d e r - h o o d f u s e / r e l a y b o x .
17. D o t h e E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
11-337
PGM-FI System
DTC P2183: ECT Sensor 2 Circuit Range/ 11. C o n n e c t E C T s e n s o r 2 to t h e 2 P c o n n e c t o r , but d o

Performance Problem not install it o n t h e e n g i n e .
NOTE: 12. T u r n the ignition s w i t c h O N (II).

any o n b o a r d snapshot, and review the general 13. Note the v a l u e of E C T S E N S O R 2 q u i c k l y in the
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). D A T A L I S T with the H D S .
• If D T C P0111 is s t o r e d at t h e s a m e t i m e a s D T C P 2 1 8 3 ,
t r o u b l e s h o o t D T C P0111 first, t h e n r e c h e c k for D T C 14. C o m p a r e the v a l u e of E C T S E N S O R 2 a n d t h e
P2183. ambient temperature.
1. C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at Does ECT SENSOR 2 differ 5.4 °F (3 °C) or

E C T s e n s o r 1 a n d E C T s e n s o r 2. more?
Are the connections and terminals OK? Y E S — R e p l a c e E C T s e n s o r 2 ( s e e p a g e 11-385), t h e n

g o to s t e p 27.
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at this
N O — R e p a i r t h e c o n n e c t o r s o r t e r m i n a l s , t h e n g o to t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
s t e p 27. at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e E C M . B
2 . T u r n t h e ignition s w i t c h O N (II). 15. S t a r t t h e e n g i n e , a n d let it idle for 10 m i n u t e s .
3. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S . 16. C h e c k E C T S E N S O R 1 in the D A T A L I S T w i t h the

HDS.
Are DTC P1116 and P2183 indicated at the same
time? Is about 129 °F (54 °C) or less indicated?
Y E S — G o to s t e p 15. Y E S — R e p l a c e E C T s e n s o r 1 ( s e e p a g e 11-385), t h e n
g o to s t e p 27.
4. S t a r t t h e e n g i n e , a n d let it idle for 10 m i n u t e s .
17. Let the e n g i n e idle for 10 m i n u t e s .
5. C h e c k E C T S E N S O R 2 in the D A T A L I S T w i t h t h e
HDS. 18. C h e c k E C T S E N S O R 2 in the D A T A L I S T w i t h the
HDS.
Is about 129 °F (54 °C) or less indicated?
Is about 129 °F (54 °C) or less indicated?
Y E S — R e p l a c e E C T s e n s o r 2 ( s e e p a g e 11-385), t h e n
g o to s t e p 2 7 . Y E S — R e p l a c e E C T s e n s o r 2 ( s e e p a g e 11-385), t h e n
g o to s t e p 27.
7. D r a i n t h e c o o l a n t ( s e e p a g e 10-9).
8. R e m o v e E C T s e n s o r 2 ( s e e p a g e 11-385).
9. A l l o w E C T s e n s o r 2 to c o o l to a m b i e n t t e m p e r a t u r e .
10. Note the a m b i e n t t e m p e r a t u r e .
11-338
19. T u r n t h e ignition s w i t c h O F F . 27. T u r n t h e ignition s w i t c h O N (II).
20. D r a i n t h e c o o l a n t ( s e e p a g e 10-9). 28. R e s e t the E C M with the H D S .
2 1 . R e m o v e E C T s e n s o r 1 ( s e e p a g e 11-385) a n d E C T 2 9 . D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

s e n s o r 2 ( s e e p a g e 11-385).
2 2 . A l l o w t h e s e n s o r s to c o o l to a m b i e n t t e m p e r a t u r e .
2 3 . Note t h e a m b i e n t t e m p e r a t u r e .
2 4 . C o n n e c t E C T s e n s o r 1 to 2 P c o n n e c t o r , a n d E C T t e r m i n a l s at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e
s e n s o r 2 to t h e 2 P c o n n e c t o r , but d o not install E C M , t h e n g o to s t e p 1.
t h e m into t h e e n g i n e .
2 5 . Note t h e v a l u e of E C T S E N S O R 1 a n d E C T S E N S O R T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to the
2 q u i c k l y in t h e D A T A L I S T w i t h t h e H D S . indicated D T C s troubleshooting. B
2 6 . C o m p a r e t h e v a l u e of E C T S E N S O R 1 a n d t h e
a m b i e n t t e m p e r a t u r e , a n d t h e v a l u e of E C T
S E N S O R 2 a n d the ambient temperature
individually.
Does one of the sensors differ more than 5.4 °F

(3 °C) from the ambient temperature?
Y E S — R e p l a c e t h e s e n s o r that differed m o r e t h a n
5.4 °F (3 °C) f r o m t h e a m b i e n t t e m p e r a t u r e , t h e n g o
to s t e p 27.
at E C T s e n s o r 1, E C T s e n s o r 2 , a n d t h e E C M . B
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PGM-FI System
DTC P2184: ECT Sensor 2 Circuit Low Voltage 7. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a 8. J u m p t h e S C S line w i t h t h e H D S .
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). 9. D i s c o n n e c t E C M c o n n e c t o r E (31P).
1. T u r n t h e ignition s w i t c h O N (II). 10. C h e c k for continuity b e t w e e n E C T s e n s o r 2 2 P

HDS. E C T S E N S O R 2 2P C O N N E C T O R
Is about 356 °F (180 °C) or more, or 0.08 V or less

indicated?
ECT2
JBLU)
at E C T s e n s o r 2 a n d t h e E C M . B
4. D i s c o n n e c t t h e E C T s e n s o r 2 2 P c o n n e c t o r .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n E C T s e n s o r
6. C h e c k E C T S E N S O R 2 in t h e D A T A L I S T w i t h t h e 2 a n d t h e E C M ( E l ) , t h e n g o t o s t e p 13.
HDS.
Is about 356 °F (180 °C) or more, or 0.08 V or less
indicated? 11. T u r n t h e ignition s w i t c h O F F .
Y E S — G o to s t e p 7. 12. R e p l a c e E C T s e n s o r 2 ( s e e p a g e 11-385).
N O — G o to s t e p 11. 13. R e c o n n e c t all c o n n e c t o r s .
11-340
s t e p 1.
N O — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y other

g o o d E C M ( s e e p a g e 11-217).
N O — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g i s
PGM-FI System
DTC P2185: ECT Sensor 2 Circuit High 6 . T u r n t h e ignition s w i t c h O N (II).
Voltage
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a HDS.
and any on-board s n a p s h o t , and r e v i e w the general
troubleshooting information (see page 1 1 - 2 1 3 ) . Is about -40°F(-40 °C) or less, or 4.92 V or
more indicated?
HDS. N O — G o to s t e p 1 8 .
Is about -40°F ( -40 °C) or less, or 4.92 V or 8 . T u r n t h e ignition s w i t c h O F F .

more indicated?
9 . R e m o v e the j u m p e r w i r e f r o m E C T s e n s o r 2 2 P
Y E S — G o t o step 3 . connector.
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s 1 0 . T u r n t h e ignition s w i t c h O N (II).
at E C T s e n s o r 2 a n d t h e E C M . • 11. M e a s u r e voltage between E C T s e n s o r 2 2 P
3 . T u r n t h e ignition s w i t c h O F F .
ECT SENSOR 2 2P CONNECTOR

4. Disconnect the E C T s e n s o r 2 2 P connector.
5 . C o n n e c t EECT s e n s o r 2 2 P c o n n e c t o r t e r m i n a l s N o . 1
and No. 2 with a j u m p e r wire.
Viz]
ECT2
ECT S E N S O R 2 2P CONNECTOR (BLU)
l 1 [2
ECT2 SG3
(BLU) (GRN)
JUMPER WIRE Is there about 5 V?
Y E S — G o to s t e p 1 2 .
N O — G o to s t e p 1 7 .
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12. T u r n t h e ignition s w i t c h O F F . 17. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l
E1 a n d b o d y g r o u n d .
15. C o n n e c t E C T s e n s o r 2 2 P c o n n e c t o r t e r m i n a l N o . 2 ECT2
(BLU)
to b o d y g r o u n d w i t h a j u m p e r w i r e . H7T3 4 | 5
11 12 13 14 15 16 17 18 19 20 21
ECT S E N S O R 2 2P C O N N E C T O R 22 25 27 28 29 30 \ /
.A.
1 2
SG3
(GRN)
JUMPER WIRE
Is there about 5 V?
W i r e s i d e of f e m a l e t e r m i n a l s (E1) a n d E C T s e n s o r 2 , t h e n g o to s t e p 20.
N O — G o to s t e p 2 5 .
terminal E 4 and body ground. 18. T u r n t h e ignition s w i t c h O F F .
1 / 3 4 | 5 / | 7 8 9 2 1 . T u r n t h e ignition s w i t c h O N (II).
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
2 3 . Do the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
a n d E C T s e n s o r 2, t h e n g o to s t e p 20.
(cont'd)
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PGM-FI System
s t e p 1.
g o o d E C M ( s e e p a g e 11-217).
11-344
DTC P2195: A/F Sensor (Sensor 1) Signal 6. T u r n t h e ignition s w i t c h O F F .
Stuck Lean
7. R e i n s t a l l t h e A / F s e n s o r ( S e n s o r 1) ( s e e p a g e
NOTE: 11-386).
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d
a n y on-board s n a p s h o t , a n d review the general 8. T u r n t h e ignition s w i t c h O N (II).
• If t h e v e h i c l e w a s out of fuel a n d t h e e n g i n e s t a l l e d 9. R e s e t t h e E C M w i t h t h e H D S .
before t h i s D T C w a s s t o r e d , refuel, t h e n c l e a r t h e D T C
with the H D S . 10. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
• If D T C P 2 1 0 1 , P 2 1 1 8 , P 2 1 3 5 , P 2 1 3 8 , P 2 1 7 6 , or a
c o m b i n a t i o n of P2122 a n d P 2 1 2 7 , P 2 1 2 2 a n d P 2 1 3 8 , 11. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
or P2127 a n d P 2 1 3 8 is s t o r e d at the s a m e t i m e ,
t r o u b l e s h o o t t h e m first, t h e n r e c h e c k for D T C P 2 1 9 5 . Is DTC P2195 indicated?
1. C h e c k t h e installation of t h e A / F s e n s o r ( S e n s o r 1). Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

Is the A/F sensor loose or disconnected from the t h e n g o to s t e p 1.
exhaust pipe?
N O — G o to s t e p 2. D T C s M E N U with the H D S .
2. T u r n t h e ignition s w i t c h O N (II). Does the screen indicate PASSED?
3. C l e a r t h e D T C w i t h t h e H D S . Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
4. S t a r t t h e e n g i n e , t h e n let it idle. g o to t h e indicated D T C s t r o u b l e s h o o t i n g . •
5. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at the A / F s e n s o r
Are any Temporary DTCs or DTCs indicated? ( S e n s o r 1) a n d t h e E C M , t h e n g o to s t e p 1. If t h e
s c r e e n i n d i c a t e d N O T C O M P L E T E D , k e e p idling
Y E S — I f D T C P 2 1 9 5 is i n d i c a t e d , c h e c k for p o o r until a r e s u l t c o m e s o n .
( S e n s o r 1) a n d the E C M , t h e n g o to s t e p 13. If a n y
o t h e r T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to
the indicated D T C s troubleshooting.
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at this
at t h e A / F s e n s o r ( S e n s o r 1) a n d t h e E C M . •
(cont'd)
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PGM-FI System

g o o d E C M ( s e e p a g e 11-217).
14. S t a r t t h e e n g i n e , t h e n let it idle.
t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1) a n d t h e E C M .
If t h e E C M w a s u p d a t e d , s u b s t i t u t e a k n o w n - g o o d
E C M ( s e e p a g e 11-217), t h e n g o to s t e p 14. If t h e
T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 15,
( S e n s o r 1) a n d t h e E C M . If the E C M w a s u p d a t e d ,
t h e n g o to s t e p 14. If the E C M w a s s u b s t i t u t e d , g o
to s t e p 1. If the s c r e e n i n d i c a t e s N O T C O M P L E T E D ,
k e e p idling until a r e s u l t c o m e s o n .
11-346
DTC P2227: BARO Sensor Circuit Range/ 7. M o n i t o r t h e O B D S T A T U S for D T C P 2 2 2 7 in the
Performance Problem D T C s M E N U with the H D S .
NOTE: Does the screen indicate FAILED?

a n y on-board snapshot, and review the general Y E S — G o to s t e p 8.
• If D T C P 0 1 0 7 , P 0 1 0 8 , P 1 1 2 8 , a n d / o r P 1 1 2 9 a r e s t o r e d N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent
at t h e s a m e t i m e a s D T C P 2 2 2 7 , t r o u b l e s h o o t t h o s e f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . If t h e s c r e e n
D T C s first, t h e n r e c h e c k for D T C P 2 2 2 7 . i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 5 a n d
recheck.
1. I n s p e c t t h e air c l e a n e r e l e m e n t ( s e e p a g e 11-505).
Is there damage or clogging? s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
Y E S — R e p l a c e t h e air c l e a n e r e l e m e n t ( s e e p a g e
11-505). C l e a r t h e D T C w i t h t h e H D S , t h e n g o to 9. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
s t e p 9. 3,000 r p m w i t h o u t load (in neutral) until the
2 . T u r n t h e ignition s w i t c h O N (II), a n d w a i t 2 s e c o n d s .
3. C h e c k t h e B A R O S E N S O R in t h e D A T A L I S T w i t h a b o v e 158 °F (70 <€)
the H D S . • T r a n s m i s s i o n in 4th g e a r
• R E L T P S E N S O R b e t w e e n 11 d e g a n d 2 3 d e g for
Is about 101 kPa (29.9 in.Hg, 760 mmHg), or about 3 s e c o n d s or m o r e
2.9 V at sea level indicated?
4. C l e a r t h e D T C w i t h the H D S . t e r m i n a l s at the E C M , t h e n g o to s t e p 1. If t h e E C M
w a s u p d a t e d , substitute a k n o w n - g o o d E C M
5. S t a r t t h e e n g i n e . Hold the e n g i n e s p e e d at ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e E C M w a s
3,000 r p m without load (in neutral) until the s u b s t i t u t e d , g o to s t e p 1.
6. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s , t h e n c o n n e c t t h e
HDS.
a b o v e 158 °F (70 °C)
• R E L T P S E N S O R A b e t w e e n 11 d e g a n d 2 3 d e g
for 3 s e c o n d s or m o r e
(cont'd)
11-347
PGM-FI System

c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E C M . If t h e
( s e e p a g e 11-217), t h e n g o to s t e p 10. If t h e E C M
w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
N O T C O M P L E T E D , g o to s t e p 10.
11-348
DTC P2228: BARO Sensor Circuit Low Voltage DTC P2229: BARO Sensor Circuit High
Voltage
and any on-board snapshot, and review the general N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l
2 . C h e c k t h e B A R O S E N S O R in t h e D A T A L I S T w i t h
the H D S . 2 . C h e c k t h e B A R O S E N S O R in t h e D A T A L I S T w i t h
the H D S .
Is about 53 kPa (15.6 in.Hg, 397 mmHg), or 1.58 V
or less indicated? Is about 160 kPa (47.2 in.Hg, 1,200 mmHg), or
4.49 V or more indicated?
time.l N O — I ntermitte nt fai I u re, the s y s t e m i s O K at th is
time.B
s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n - 3 . U p d a t e t h e E C M if it d o e s not h a v e t h e latest
g o o d E C M ( s e e p a g e 11-217). s o f t w a r e ( s e e p a g e 11-216), o r s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
4 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
4 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
Y E S — C h e c k for poor connections or loose
t e r m i n a l s at t h e E C M . If the E C M w a s u p d a t e d , Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
substitute a k n o w n - g o o d E C M ( s e e p a g e 11-217), t e r m i n a l s at t h e E C M . If the E C M w a s u p d a t e d ,
t h e n r e c h e c k . If the E C M w a s s u b s t i t u t e d , g o to s t e p s u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-217),
1. t h e n r e c h e c k . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p
1.
c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e NO—If the E C M w a s updated, troubleshooting is
original E C M ( s e e p a g e 11-389). If a n y o t h e r c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e o r i g i n a l E C M ( s e e p a g e 11-389). If a n y other
indicated D T C s troubleshooting. • T e m p o r a r y D T C s or D T C s are indicated, go to the
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PGM-FI System
DTC P2238: A/F Sensor (Sensor 1) A F S + 9. R e p l a c e t h e A / F s e n s o r ( S e n s o r 1) ( s e e p a g e
Circuit Low Voltage 11-386).
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a 10. R e c o n n e c t all c o n n e c t o r s .

and a n y on-board s n a p s h o t a n d review the general
1. T u r n t h e ignition s w i t c h O N (II). 12. R e s e t t h e E C M w i t h the H D S .
2. C l e a r t h e D T C w i t h t h e H D S . 13. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
3. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 14. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
Y E S — G o to s t e p 4. Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s t h e n g o to s t e p 1. If the c o n n e c t o r a n d t e r m i n a l fits
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s a r e O K , g o to s t e p 16.
5. J u m p t h e S C S line w i t h t h e H D S . D T C s M E N U with the H D S .
6. D i s c o n n e c t t h e A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r . Does the screen indicated PASSED?
7. D i s c o n n e c t E C M c o n n e c t o r A (31P). Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
8. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r g o to the i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
( S e n s o r 1) a n d t h e E C M , t h e n g o t o s t e p 1. If t h e
1 | 2 | 3 | 4 | 5 6 | 7 | | 8 | 9 until a result c o m e s o n .
10
/
23 24
13 14 15 16
25 26 // // 18
28
20 21
30 31
AFS+
(RED)
11.
11-350
16. U p d a t e the E C M if it d o e s not h a v e the latest
g o o d E C M ( s e e p a g e 11-217).
19. Monitor the O B D S T A T U S for D T C P 2 2 3 8 in t h e

t h e E C M w a s u p d a t e d , substitute a k n o w n - g o o d
result c o m e s o n .
PGM-FI System
DTC P2252: A/F Sensor (Sensor 1) A F S — 10. R e p l a c e the A / F s e n s o r ( S e n s o r 1) ( s e e p a g e

Circuit Low Voltage 11-386).
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a 11. R e c o n n e c t all c o n n e c t o r s .

t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). 12. T u r n the ignition s w i t c h O N (II).
1. T u r n t h e ignition s w i t c h O N (II). 13. R e s e t t h e E C M w i t h the H D S .
2. C l e a r t h e D T C w i t h the H D S . 14. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
3. S t a r t t h e e n g i n e . 15. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . Is DTC P2252 indicated?
Is DTC P2252 Indicated? Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

Y E S — G o to s t e p 5. t h e n g o to s t e p 1. If t h e c o n n e c t o r s a n d t e r m i n a l fits
a r e O K , g o to s t e p 17.
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s N O — G o to s t e p 16.
5. T u r n t h e ignition s w i t c h O F F . D T C s M E N U w i t h the H D S .
6. J u m p the S C S line w i t h t h e H D S . Does the screen indicate PASSED?
7. D i s c o n n e c t t h e A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r . Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
8. D i s c o n n e c t E C M c o n n e c t o r A (31P). g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
9. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r

terminals A28 and body ground. c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e A / F s e n s o r
( S e n s o r 1) a n d t h e E C M , t h e n g o to s t e p 1. If the
1 | 2 | 3 | 4 | 5 6 | 7 | 8 | 9
/// // //
10 13 14 15 16 18 20 21
23 24 25 26 28 30 31
AFS—
XjRED/YEL)
11.
11-352
17. U p d a t e t h e E C M if it d o e s not h a v e t h e latest *
g o o d E C M ( s e e p a g e 11-217).

t h e E C M w a s s u b s t i t u t e d , go to s t e p 1.
g o t o t h e indicated D T C s t r o u b l e s h o o t i n g . •
t h e E C M w a s u p d a t e d , substitute a k n o w n - g o o d
result c o m e s on.
PGM-FI System
DTC P2270: Secondary H02S (Sensor 2) 11. S t a r t the e n g i n e , a n d let it idle w i t h o u t l o a d (in
Circuit Signal Stuck Lean neutral) until t h e radiator f a n c o m e s o n .
DTC P2271: Secondary H02S (Sensor 2) 12. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :

Circuit Signal Stuck Rich
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a a b o v e 1 7 6 ° F ( 8 0 <€)
and any on-board snapshot, and review the general • V e h i c l e s p e e d at 3 5 m p h (56 k m / h ) or m o r e
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). • D r i v e 2 6 s e c o n d s or m o r e
1. T u r n t h e ignition s w i t c h O N (II). 13. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
2. C l e a r t h e D T C w i t h t h e H D S . lsDTCP2270orP2271 indicated?
3. S t a r t t h e e n g i n e , a n d let it idle w i t h o u t l o a d (in Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

neutral) until t h e radiator f a n c o m e s o n . t e r m i n a l s at t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d
t h e E C M , t h e n g o to s t e p 1.
a b o v e 176 °F (80 °C) 14. M o n i t o r t h e O B D S T A T U S for D T C P 2 2 7 0 or P2271
• V e h i c l e s p e e d at 3 5 m p h (56 k m / h ) or m o r e in t h e D T C s M E N U with the H D S .
• D r i v e 2 6 s e c o n d s or m o r e
5. M o n i t o r t h e O B D S T A T U S for D T C P 2 2 7 0 or P2271
in t h e D T C s M E N U w i t h t h e H D S . Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
Does the screen indicate FAILED? g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Y E S — G o to s t e p 6. N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent H 0 2 S ( S e n s o r 2) a n d t h e E C M , t h e n g o to s t e p 1. If
f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . C h e c k for t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p driving until
p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e a r e s u l t c o m e s o n . If the s c r e e n i n d i c a t e s O U T O F
s e c o n d a r y H 0 2 S ( S e n s o r 2) a n d t h e E C M . If t h e C O N D I T I O N , g o to s t e p 12.
s c r e e n i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until a
r e s u l t c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
11-386).
11-354
DTC P2610: ECM Ignition Off Internal Timer
Performance Problem
and a n y on-board snapshot, and review the general
time.H

g o o d E C M ( s e e p a g e 11-217).

11-355
PGM-FI System
DTC P2A00: A/F Sensor (Sensor 1) Circuit 10. D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
Range/Performance Problem
11. S t a r t t h e e n g i n e . H o l d the e n g i n e s p e e d at
N O T E : B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a 3,000 r p m w i t h o u t l o a d (in neutral) until the
and any on-board s n a p s h o t , and review the general radiator f a n c o m e s o n , t h e n let it idle.
2. C l e a r t h e D T C w i t h t h e H D S . a b o v e 158 °F (70 X )
• T r a n s m i s s i o n in 3 r d g e a r
3. S t a r t the e n g i n e . Hold t h e e n g i n e s p e e d at • Drive first t h e v e h i c l e b e t w e e n 2 5 — 5 5 m p h ( 4 0 —
3,000 r p m w i t h o u t l o a d (in neutral) until the 88 k m / h ) for 5 m i n u t e s .
radiator f a n c o m e s o n , t h e n let it idle. • Drive at s t e a d y s p e e d b e t w e e n 5 5 — 7 5 m p h ( 8 8 —
120 k m / h ) for 10 m i n u t e s , t h e n s l o w d o w n w i t h
4. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : t h e throttle c o m p l e t e l y c l o s e d for 4 s e c o n d s .
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) 13. C h e c k for T e m p o r a r y D T C s or D T C s with t h e H D S .

<
above 1 5 8 ° F ( 7 0 C )
• T r a n s m i s s i o n in 3 r d g e a r Is DTC P2A00 indicated?
• Drive t h e v e h i c l e b e t w e e n 2 5 — 5 5 m p h (40 —
8 8 k m / h ) for 5 m i n u t e s . Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
• Drive at a s t e a d y s p e e d b e t w e e n 5 5 — 7 5 m p h t e r m i n a l s at t h e A / F s e n s o r ( S e n s o r 1) a n d t h e E C M ,
( 8 8 — 1 2 0 k m / h ) for 10 m i n u t e s , t h e n s l o w d o w n t h e n g o to s t e p 1.
with the throttle c o m p l e t e l y c l o s e d for 4 s e c o n d s .
5. Monitor t h e O B D S T A T U S for D T C P 2 A 0 0 in t h e
D T C s M E N U with the H D S . 14. M o n i t o r t h e O B D S T A T U S for D T C P 2 A 0 0 in t h e
N O — I f the s c r e e n i n d i c a t e s P A S S E D , intermittent T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 13,
failure, the s y s t e m is O K at t h i s t i m e . C h e c k for g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
p o o r c o n n e c t i o n s or l o o s e at t h e A / F s e n s o r
( S e n s o r 1) a n d the E C M . If t h e s c r e e n i n d i c a t e s N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
E X E C U T I N G , k e e p d r i v i n g until a r e s u l t c o m e s o n . If c o n n e c t i o n s or l o o s e t e r m i n a l s at the A / F s e n s o r
t h e s c r e e n i n d i c a t e s O U T O F C O N D I T I O N , go to ( S e n s o r 1) a n d t h e E C M , t h e n go to s t e p 1. If t h e
step 3 and recheck. s c r e e n i n d i c a t e s E X E C U T I N G , k e e p driving until a
result c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
6. T u r n t h e ignition s w i t c h O F F . C O N D I T I O N , g o to s t e p 12.
11-386).
11-356
DTC U0122: F-CAN Malfunction (ECM-VSA 9. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r
Modulator-Control Unit) t e r m i n a l N o . 11 to b o d y g r o u n d w i t h a j u m p e r w i r e .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data V S A M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R

1 C A N H (RED)
1 | 2 | / U M e L / M 9 M n M i 3 M i 5 | 16
1. T u r n the ignition s w i t c h O N (II). 17|/|/|/|/|/|/|yl25|/j27|/|29|/|31
32 47
|33|34|35|36|37|/|/|/1/l42|43|44|45|46|
JUMPER WIRE
Is DTC U0122 Indicated?

N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at t h i s 10. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s t e r m i n a l E11 a n d b o d y g r o u n d .
at t h e V S A m o d u l a t o r - c o n t r o l unit a n d t h e E C M . •
4. C h e c k for a D T C s in t h e D T C s M E N U w i t h t h e H D S .
VSA DTC 86 Indicated? t | / | 3 | 4 | 5 7 | /I| 8 | 9
Y E S — G o to s t e p 5. //
22
11 12 13 14 15 16 17 18 19 20 21
24 25
C A N H (RED) / 27 28 29 30
/
6. J u m p t h e S C S line w i t h the H D S . W i r e s i d e of f e m a l e t e r m i n a l s
7. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P
c o n n e c t o r ( s e e p a g e 19-127). Is there continuity?
8. D i s c o n n e c t E C M c o n n e c t o r E (31P). Y E S — G o to s t e p 11.
(E11) a n d t h e V S A m o d u l a t o r - c o n t r o l unit, t h e n g o
to s t e p 13.
(cont'd)
11-357
PGM-FI System
11. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit c o n n e c t o r 13. R e c o n n e c t all c o n n e c t o r s .
V S A M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R
C A N H (WHT) f
1 UI/UMeL/M9|/|ii|/|i3Mi5| 16
M\AAAAAAA2s\An\/\2B\/\*
32 |33|34|35|36|37|ylX|/|Xl42|43|44|46|46| 47 17. C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
JUMPER WIRE Is DTC U0122 Indicated?
t e r m i n a l s at t h e V S A m o d u l a t o r - c o n t r o l unit a n d
Wire side of female terminals t h e E C M , t h e n g o t o s t e p 1.
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r T e m p o r a r y D T C s or D T C s are indicated, go to the
terminal E24 and body ground. indicated D T C s troubleshooting. •
1 l / l 3 | 4 | 5 /I 7 8 |9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/
C A N L (WHT)
27 28 29 30
/
Y E S — S u b s t i t u t e a known-good V S A modulator-
control unit ( s e e p a g e 19-127), t h e n g o to s t e p 13
a n d r e c h e c k . if D T C U 0 1 2 2 i s not i n d i c a t e d , r e p l a c e
t h e original V S A m o d u l a t o r - c o n t r o l unit ( s e e p a g e
19-127), t h e n g o to s t e p 13.
( E 2 4 ) a n d t h e V S A m o d u l a t o r - c o n t r o l unit, t h e n g o
to s t e p 13.
11-358
DTC U1102: F-CAN Malfunction (BUS-OFF)
Is DTC U1102 Indicated?
time.B

g o o d E C M ( s e e p a g e 11-217).
6. C h e c k f o r T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
lsDTCL/1102 indicated?
PGM-FI System
F-CAN Circuit Troubleshooting
N O T E : I n f o r m a t i o n m a r k e d w i t h a n a s t e r i s k (*) a p p l i e s 6. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P
to the C A N L line. connector.
1. T u r n the ignition s w i t c h O F F . 7. D i s c o n n e c t the s t e e r i n g a n g l e s e n s o r 5 P c o n n e c t o r .
2. J u m p t h e S C S line w i t h the H D S . 8. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

terminal E l l and E 2 4 \
E C M C O N N E C T O R E (3IP)
4. D i s c o n n e c t H D S f r o m the D L C .
5. M e a s u r e r e s i s t a n c e b e t w e e n E C M c o n n e c t o r
1 l/l 3 | 4 | 5 / \ 7 I 8| 9
t e r m i n a l s E11 a n d E 2 4 \ 11 12 13 14 15 16 17 18 19 20 21
/22
/
24 25
/ 2 7 2 8 2 9 30
/
C A N H (RED) C A N L (WHT)
1 l / l 3 | 4 | 5 / I T | |a 9
11 12 13 14 15 16 17 18 19 20 21
//
22 24 25 27 28 29 30
C A N H (RED) jCANL /(WHT) /

Y E S — R e p a i r s h o r t in t h e w i r e s b e t w e e n the E C M
W i r e s i d e of f e m a l e terminals c o n n e c t o r t e r m i n a l s E11 a n d E 2 4 \ B
Is there about 108- 132 & ?
11-360
9. C o n n e c t E C M c o n n e c t o r t e r m i n a l E11 to b o d y 11. C h e c k for continuity b e t w e e n s t e e r i n g a n g l e s e n s o r
ground with a j u m p e r wire. 5P connector terminal No. 4 and body ground.
E C M C O N N E C T O R E (31P) S T E E R I N G A N G L E S E N S O R 5P C O N N E C T O R
c,
I
/
1 / 1 3 1 4 5
/ 7 l S | 9
1 2 4 5
/ 11 12 13 14 15 16 17 18 19 20 21
22
/
24
CANH (RED)
25
/ 27 28 29 30
/ CANH
(RED).
JUMPER WIRE
W i r e s i d e of f e m a l e t e r m i n a l s Wire side of f e m a l e terminals
10. C h e c k for c o n t i n u i t y b e t w e e n V S A m o d u l a t o r - Is there continuity?

control unit 4 7 P c o n n e c t o r t e r m i n a l N o . 11 a n d
body ground. Y E S — G o to s t e p 12.
(E11) a n d t h e s t e e r i n g a n g l e s e n s o r . •
CANH
12. R e m o v e t h e j u m p e r w i r e f r o m E C M c o n n e c t o r E
(RED)
(31P).
l33l34|35|36|37|/|/lXl^42l^|44|45T4^
( E l 1) a n d the V S A m o d u l a t o r - c o n t r o l u n i t . H
(cont'd)
11-361
PGM-FI System
F-CAN Circuit Troubleshooting (cont'd)
13. C o n n e c t E C M c o n n e c t o r t e r m i n a l E 2 4 to b o d y 15. C h e c k for continuity b e t w e e n s t e e r i n g a n g l e s e n s o r
ground with a jumper wire. 5P connector terminal No. 2 and body ground.
E C M C O N N E C T O R E (31P) S T E E R I N G A N G L E S E N S O R 5P C O N N E C T O R
M 1 1A
/
1 3 4 5 7 8 | 9
11 12 13 14 15 16 17 18 19 20 21
I
1 2 / 4 5
22
/ 24 25
/
C A N L (WHT)
27 28 29 30
/ CANL
,(WHT)
JUMPER WIRE
14. C h e c k for c o n t i n u i t y b e t w e e n V S A m o d u l a t o r - 1$ there continuity?

body ground. Y E S — R e p l a c e t h e V S A m o d u l a t o r - c o n t r o l unit
( s e e p a g e 19-127).
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E C M
(E24) a n d t h e s t e e r i n g a n g l e s e n s o r . •
CANL
(WHT)
|33|34|35|36|37|/|/|XIXl42|43|44|45|46l
(E24) a n d the V S A modulator-control u n i t . B
11-362
16. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P 19. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
connector. terminal E24 and body ground.
17. D i s c o n n e c t the s t e e r i n g a n g l e s e n s o r 5 P c o n n e c t o r . E C M C O N N E C T O R E (31P)

t e r m i n a l E11 a n d b o d y g r o u n d . 1 \/ 12 3 | 4 5 / \ 7 8 9 I
//
22
11
24
13 14 15 16 17 18 19 20 21
25
/ 27 28 29 30
/
C A N L (WHT)
1 / 3 4 l 5 7 XI
| 8 9
/ /
11 12 13 14 15 16 17 18 19 20 21
22 / 24 25
/
27 28 29 30
/ W i r e s i d e of f e m a l e t e r m i n a l s
C A N H (RED)
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M
c o n n e c t o r t e r m i n a l E 2 4 a n d t h e V S A modulator-
c o n t r o l unit, t h e s t e e r i n g a n g l e s e n s o r , or the
Is there continuity ? DLC.B
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M N O — G o to s t e p 20.
c o n n e c t o r t e r m i n a l s E11 a n d t h e V S A m o d u l a t o r -
control unit, the s t e e r i n g a n g l e s e n s o r , or the
DLC.B
(cont'd)
11-363
PGM-FI System
F-CAN Circuit Troubleshooting (cont'd)
2 0 . C h e c k for continuity b e t w e e n V S A m o d u l a t o r - 2 1 . C h e c k for continuity b e t w e e n s t e e r i n g a n g l e s e n s o r
c o n t ro l unit 4 7 P c o n n e c t o r t e r m i n a l N o . 47 a n d 5P connector terminal No. 1 and body ground.
body ground.
S T E E R I N G A N G L E S E N S O R 5P C O N N E C T O R
17 IXIÎXIXLÎXIXI 251>| 271>| 29l>TiT16

1 2
GND
/ 4 5
3 2
1 |33|34|35|36|37MXMXl42|43|44|45|46| | 4 7
(BLK)
GND
(BLK),
Y E S — G o to s t e p 2 2 .
Y E S — G o to s t e p 2 1 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e s t e e r i n g
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A a n g l e s e n s o r (No. 1) a n d b o d y g r o u n d ( G 4 0 D . B
m o d u l a t o r - c o n t r o l unit (No. 47) a n d b o d y g r o u n d
(G303).B 2 2 . R e c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P
connector.
2 3 . C o n n e c t t h e H D S ( s e e p a g e 11-213).
24. T u r n t h e ignition s w i t c h O N (II), a n d r e a d t h e H D S .
Does the HDS identify the vehicle?
Y E S — R e p l a c e the steering angle s e n s o r (see page

19-124). •
N O — G o to s t e p 2 5 .
11-364
2 5 . S u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e 11-217).
2 6 . T u r n the ignition s w i t c h O N (II), a n d r e a d t h e H D S .
Does the HDS identify the vehicle ?
Y E S — S y s t e m is O K at t h i s t i m e . R e p l a c e t h e
original E C M ( s e e p a g e 1 1 - 3 8 9 ) . H
N O — R e p l a c e the V S A m o d u l a t o r - c o n t r o l unit
( s e e p a g e 19-127). •
PGM-FI System
MIL Circuit Troubleshooting
2. D o t h e g a u g e s e l f - d i a g n o s t i c f u n c t i o n ( s e e p a g e
22-60). E C M C O N N E C T O R E (31P)
Does the MIL indicator flash?

1 / 3 4 | 5 / I 7 I8 I 9
NO—Substitute a known-good gauge assembly,

//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
S C S (BRN)
a n d r e c h e c k . If t h e M I L circuit is O K , r e p l a c e t h e
original g a u g e a s s e m b l y ( s e e p a g e 22-89). •
3. C o n n e c t t h e H D S to t h e D L C ( s e e p a g e 11-213).
4. C h e c k t h e S C S in t h e D A T A L I S T w i t h t h e H D S .
Is a short indicated? Is there continuity?
(E29) a n d t h e S R S unit, t h e E P S control unit, t h e
N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest DLC. •
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest
symptom/indication g o e s a w a y with a known-good s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n -
E C M , r e p l a c e t h e original E C M ( s e e p a g e 11-389). • g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e
5. T u r n t h e ignition s w i t c h O F F . E C M , r e p l a c e t h e original E C M ( s e e p a g e 1 1 - 3 8 9 ) . H
6. D i s c o n n e c t E C M c o n n e c t o r E (31P), t h e n d i s c o n n e c t
the H D S .
11-366
DLC Circuit Troubleshooting
N O T E : Before you begin, make s u r e the H D S a n d the 8. T u r n the ignition s w i t c h O N (II), a n d w a t c h the V S A
D L C c a b l e a r e w o r k i n g properly. indicator.
1. T u r n t h e ignition s w i t c h O F F . Does the VSA indicator stay ON?
2. C o n n e c t the H D S to the D L C ( s e e p a g e 11-213). Y E S — G o to the V S A s y s t e m ' s g e n e r a l

troubleshooting information (see page 1 9 - 6 9 ) . •
N O T E : M a k e s u r e the H D S is p r o p e r l y c o n n e c t e d to
the D L C . N O — G o to s t e p 9.
3. T u r n t h e ignition s w i t c h O N (II), a n d r e a d t h e H D S . 9. T u r n the ignition s w i t c h O F F .
Does the HDS identify the vehicle? 10. T u r n the ignition s w i t c h O N (II), a n d w a t c h the
i m m o b i l i z e r indicator.
Does the immobilizer indicator stay on?
N O — G o to s t e p 2 2 .
Y E S — G o to t h e i m m o b i l i z e r s y s t e m c h e c k
4. C h e c k the T e m p o r a r y D T C s or D T C s in the P G M - F I ( s e e p a g e 22-213). •
s y s t e m w i t h the H D S .
Y E S — G o to the i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
12. S t a r t the e n g i n e , a n d w a t c h t h e E P S indicator.
Does the EPS indicator stay on?
Y E S — G o to the E P S s y s t e m ' s g e n e r a l
6. T u r n the ignition s w i t c h O N (II), a n d w a t c h t h e S R S t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 17-17). •
indicator.
NO-
Does the SRS indicator stay ON ? • W i t h T P M S : g o to s t e p 13.
• W i t h o u t T P M S : g o to s t e p 15.
Y E S — G o to the S R S s y s t e m ' s g e n e r a l
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 23-24). •
(cont'd)
11-367
PGM-FI System
DLC Circuit Troubleshooting (cont'd)
19. C o n t i n u e to c h e c k for continuity b e t w e e n D L C
13. T u r n t h e ignition s w i t c h O F F . terminals No. 1 and No. 7 and body ground
individually, while disconnecting t h e s e parts, one
14. S t a r t t h e e n g i n e , a n d w a t c h t h e T P M S indicator. at a t i m e :
Does the TPMS indicator stay ON? • E P S c o n t r o l unit (14P) c o n n e c t o r

• I m m o b i l i z e r control u n i t - r e c e i v e r (7P) c o n n e c t o r
Y E S — G o to t h e T P M S ' s g e n e r a l t r o u b l e s h o o t i n g • S R S unit c o n n e c t o r A (28P)
information (see page 1 8 - 5 D . B • V S A m o d u l a t o r - c o n t r o l unit (47P) c o n n e c t o r
• G a u g e a s s e m b l y A (22P) c o n n e c t o r
N O — G o to s t e p 15. • T P M S c o n t r o l unit (20P) c o n n e c t o r (with T P M S )
15. D o t h e g a u g e s e l f - d i a g n o s t i c f u n c t i o n w i t h o u t t h e
H D S ( s e e p a g e 22-60).
Are all the indicator flashing? DIAG-H K-LINE

(LT BLU) (GRY)
12 14
N O — T r o u b l e s h o o t the g a u g e a s s e m b l y .
17. D i s c o n n e c t t h e H D S f r o m t h e D L C . T e r m i n a l s i d e of f e m a l e t e r m i n a l s
18. C h e c k for c o n t i n u i t y b e t w e e n D L C t e r m i n a l s N o . 1
and No. 7 and body ground individually. Does continuity go away when one of the above
components is disconnected ?
Y E S — R e p l a c e t h e part that c a u s e d a n o p e n w h e n it
w a s disconnected. •
DIAG-H KLINE
(LT BLU) (GRY) N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e D L C
( D I A G - H ) a n d t h e E P S control unit or t h e
12 14 i m m o b i l i z e r c o n t r o l u n i t - r e c e i v e r or the D L C (K-line)
a n d t h e g a u g e a s s e m b l y , t h e S R S unit, t h e V S A
m o d u l a t o r - c o n t r o l unit, a n d the T P M S control unit
(with T P M S ) . •
11-368
20. C o n n e c t D L C t e r m i n a l s N o . 1 a n d N o . 7 to b o d y 2 2 . T u r n t h e ignition s w i t c h O F F .
ground with a j u m p e r wire.
23. Disconnect the H D S from the D L C .
24. M e a s u r e v o l t a g e b e t w e e n D L C t e r m i n a l N o . 16 a n d
body ground.
DIAG-H K-LINE
(LT B L U ) (GRY)
I_77a JL_I
V //
5
9 v
12 / 1
14
— • t__lj —
1 4 5 6 7
JUMPER
WIRE
JUMPER
WIRE \ Kk1 l J l .K/
\ 9 | / | / | 1 2 | / | 1 4 | / | 1 6 /
+B
(WHT/GRN)/
Terminal side of female terminals
2 1 . C h e c k f o r continuity b e t w e e n b o d y g r o u n d a n d
these connector terminals: T e r m i n a l s i d e of f e m a l e t e r m i n a l s
Connector Unit DLC

Terminal Terminal Is there battery voltage?
S R S unitA(28P) No. 2 4 No. 7
(GRY) (GRY) Y E S — G o to s t e p 2 5 .
Gauge assembly A No. 11 No. 7
(22P) (GRY) (GRY) N O — R e p a i r o p e n in t h e w i r e b e t w e e n D L C t e r m i n a l
V S A modulator- No. 2 No. 7 No. 16 a n d t h e N o . 4 6 A C G S (15 A ) f u s e in t h e
control unit (47 P) (GRY) (GRY) under-hood fuse/relay box.H
T P M S control unit No. 7 No. 7
(20P) (GRY) (GRY)
I m m o b i l i z e r control No. 3 No. 1
u n i t - r e c e i v e r (7P) (LT B L U ) (LT B L U )
E P S control unit No. 14 No. 1
(HP) (LT B L U ) (LT BLU)
Is there continuity between the DLC terminal and

each of the terminals in the chart?
Y E S — R e p l a c e t h e control unit that d o e s not

communicated with the HDS. •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e D L C (K-
line o r D I A G H) a n d t h e a p p r o p r i a t e c o n n e c t o r . •
(cont'd)
11-369
PGM-FI System
25. M e a s u r e voltage between D L C terminals No. 4 a n d 30. C o n n e c t D L C t e r m i n a l N o . 6 to b o d y g r o u n d w i t h a

N o . 16. jumper wire.
D A T A LINK C O N N E C T O R (DLC) D A T A LINK C O N N E C T O R (DLC)
CANH
(RED)
m
G N D (BLK)
1 4 I5I6I7
9 L/|/112L/|14L/|16
JUMPER
+B (WHT/GRN) WIRE
T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s
Is there battery voltage? 3 1 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r

t e r m i n a l E11 a n d b o d y g r o u n d .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e D L C
t e r m i n a l (No. 4) a n d b o d y g r o u n d ( G 4 0 1 ) .
1 l/l 3 | 4 | 5 X I 7 8 | 9
26. C o n n e c t t h e H D S to t h e D L C ( s e e p a g e 11-213).
/ 11 12 13 14 15 16 17 18 19 20 21
22 / 24
/ 25
/
27 28 29 30
/
C A N H (RED)
2 8 . D i s c o n n e c t E C M c o n n e c t o r E (31P).
29. Disconnect the H D S from the D L C .

Y E S — G o to s t e p 3 2 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M
( E l l ) a n d D L C t e r m i n a l N o . 6. •
11-370
3 2 . D i s c o n n e c t the j u m p e r w i r e . 3 5 . T r y to start the e n g i n e .
3 3 . C o n n e c t D L C t e r m i n a l N o . 14 to b o d y g r o u n d w i t h a Does the engine start and idle smoothly?

jumper wire.
Y E S — G o t o F - C A N circuit t r o u b l e s h o o t i n g
( s e e p a g e 11-360).
DATA LINK CONNECTOR (DLC)
N O — G o to s t e p 3 6 .
\
\«
1
// 4 5 i5 7
// 12 / 1
*/ 16/
CANL (WHT) 3 7 . I n s p e c t the N o . 42 IG1 M A I N (40 A ) f u s e in the

JUMPER WIRE under-hood fuse/relay box.
Is the fuse OK?
T e r m i n a l s i d e of f e m a l e t e r m i n a l s Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the N o . 42
IG1 M A I N (40 A ) f u s e a n d the ignition s w i t c h . If t h e
w i r e is O K , g o to s t e p 3 8 .
terminal E24 and body ground. N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e No. 42
IG1 M A I N (40 A ) f u s e a n d the u n d e r - h o o d f u s e /
r e l a y box. A l s o r e p l a c e t h e No. 42 IG1 M A I N (40 A )
ECM CONNECTOR E (31P)
fuse.H
1 1 / 3 4 5
7. | /I
| 8
9 3 8 . I n s p e c t the N o . 4 6 A C G S (15 A ) f u s e in t h e u n d e r -
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
Is the fuse OK?

CANL (WHT)
Y E S — G o to s t e p 4 5 .
N O — G o to s t e p 3 9 .
Y E S — G o to s t e p 3 5 .
N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M
(E24) a n d D L C t e r m i n a l No. 14.
(cont'd)
11-371
PGM-FI System
3 9 . R e m o v e the b l o w n No. 46 A C G S (15 A ) f u s e In t h e 4 2 . D i s c o n n e c t e a c h of t h e c o m p o n e n t s o r t h e
under-hood fuse/relay box. c o n n e c t o r s b e l o w , o n e at a t i m e , a n d c h e c k for
continuity b e t w e e n P G M - F I m a i n r e l a y 1 (Fl M A I N )
40. R e m o v e P G M - F I m a i n r e l a y 1 (Fl M A I N ) (A). 4P connector terminal No. 2 and body ground.
A • PGM-FI main relay 2 ( F U E L PUMP)

• E C M c o n n e c t o r A (31P)
• E a c h injector 2 P c o n n e c t o r
• C a m s h a f t position (CMP) s e n s o r 3P connector
• C r a n k s h a f t position ( C K P ) s e n s o r 3 P c o n n e c t o r
P G M - F I M A I N R E L A Y 1 (Fl M A I N )
IGP
(YEL/BLK)
4 1 . C h e c k for continuity b e t w e e n b o d y g r o u n d a n d
P G M - F I m a i n r e l a y 1 (Fl M A I N ) 4 P c o n n e c t o r
t e r m i n a l s No. 1 a n d N o . 4 i n d i v i d u a l l y .
W i r e s i d e of f e m a l e t e r m i n a I s
Does continuity go away when one of the above
+B
(WHT/GRN) components is disconnected?
Y E S — R e p l a c e t h e part t h a t m a d e continuity to
b o d y g r o u n d g o a w a y w h e n d i s c o n n e c t e d . If t h e
i t e m is the E C M , u p d a t e t h e E C M if it d o e s not h a v e
t h e latest s o f t w a r e ( s e e p a g e 11-216), or substitute
a k n o w n - g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k .
If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y w i t h a k n o w n -
W i r e s i d e of f e m a l e t e r m i n a l s 11-389).
A l s o r e p l a c e t h e No. 46 A C G S (15 A ) f u s e . B
N O — G o to s t e p 4 3 .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e N o . 46
A C G S (15 A ) f u s e a n d P G M - F I m a i n r e l a y 1 (Fl 43. D i s c o n n e c t t h e c o n n e c t o r s f r o m t h e s e c o m p o n e n t s :
M A I N ) . A l s o r e p l a c e t h e N o . 46 A C G S (15 A ) f u s e . l
• PGM-FI m a i n relay 2 ( F U E L PUMP)
N O — G o to s t e p 42. • E C M c o n n e c t o r A (31P)
• Injectors
• CMP sensor
• CKP sensor
11-372
44. C h e c k for c o n t i n u i t y b e t w e e n P G M - F I m a i n r e l a y 1 49. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
(Fl M A I N ) 4 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y terminal E 9 and body ground.
ground.
IG1
IGP 1 1/ 3 | 4| 5 /\ 7
I 8 9
(YEL/BLK)
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
Y E S — G o to s t e p 5 0 .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n P G M - F I
m a i n r e l a y 1 (Fl M A I N ) a n d e a c h i t e m . A l s o r e p l a c e N O - R e p l a c e t h e N o . 2 F U E L P U M P S R S (15 A )
the N o . 46 A C G S (15 A ) f u s e . • f u s e , a n d u p d a t e t h e E C M if it d o e s not h a v e t h e
latest s o f t w a r e ( s e e p a g e 11-216), o r substitute a
N O — R e p l a c e P G M - F I m a i n r e l a y 1 (Fl M A I N ) . A l s o k n o w n - g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k .
r e p l a c e t h e No. 46 A C G S (15 A ) f u s e o r the f u s e . • If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y w i t h a k n o w n -
45. I n s p e c t t h e N o . 2 F U E L P U M P S R S (15 A ) f u s e in t h e 11-389). •
under-dash fuse/relay box.
5 0 . R e m o v e P G M - F I m a i n relay 2 ( F U E L P U M P ) (A).
Is the fuse OK?
46. R e m o v e t h e b l o w n No. 2 F U E L P U M P S R S (15 A )

f u s e in t h e u n d e r - d a s h f u s e / r e l a y box.
(cont'd)
11-373
PGM-FI System
5 1 . C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 5 6 . R e i n s t a l l P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) (A).
IG1
1 l/l 3 | 4 | 5 / 1 7 | 1819
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
Is there continuity? 5 7 . C h e c k for continuity b e t w e e n f u e l p u m p 5 P

Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e N o . 2
F U E L P U M P S R S (15 A ) f u s e , t h e E C M ( E 9 ) , a n d F U E L P U M P 5P C O N N E C T O R
PGM-FI main relay 2 ( F U E L P U M P ) . A l s o replace the
/5/
N o . 2 F U E L P U M P (15 A ) f u s e . •
N O — G o to s t e p 5 2 . 1 2 FUEL PUMP
(YEL/GRN)
52. R e m o v e the rear tray (see page 20-73). V
5 3 . R e m o v e the a c c e s s p a n e l f r o m t h e floor.
54. D i s c o n n e c t t h e f u e l p u m p 5 P c o n n e c t o r .
55. C h e c k for c o n t i n u i t y b e t w e e n f u e l p u m p 5 P
F U E L P U M P 5P C O N N E C T O R
Y E S - R e p l a c e PGM-FI m a i n relay 2 ( F U E L P U M P ) .
1 2 / FUEL PUMP
A l s o r e p l a c e t h e N o . 2 F U E L P U M P S R S (15 A )
fuse.B
V 5/
(YEL/GRN)
N O — C h e c k t h e fuel p u m p , a n d r e p l a c e it if
n e c e s s a r y . A l s o replace the No. 2 F U E L P U M P S R S
(15 A ) f u s e . •

5 9 . D i s c o n n e c t E C M c o n n e c t o r E (31P).
Is there continuity? 6 0 . T u r n t h e ignition s w i t c h O N (II).
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e f u e l
p u m p and PGM-FI main relay 2 ( F U E L PUMP). Also
r e p l a c e t h e N o . 2 F U E L P U M P S R S (15 A ) f u s e . B
11-374
61. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r t e r m i n a l 64. R e m o v e P G M - F I m a i n r e l a y 1 (Fl M A I N ) (A).
E9 and body ground.
A
IG1
]_(BLK/YEL)
1 IXi3l4|5|7 n ? r
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/
27 28 29 30
/
65. M e a s u r e v o l t a g e b e t w e e n P G M - F I m a i n r e l a y 1 (Fl
Is there battery voltage? MAIN) 4P connector terminal No. 4 and body
ground.
Y E S — G o to s t e p 6 2 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 2 4P C O N N E C T O R
F U E L P U M P S R S (15 A ) f u s e a n d t h e E C M (E9). •
E7 a n d body ground.
M R L Y (GRN) I
1 / 3 | 4 | 5 7 | XI
8 9 W i r e s i d e of f e m a l e t e r m i n a l s
/ 11 12 13 14 15 16 17 18 19 20 21
22
/24 25
/
27 28 29 30
/ Is there battery voltage?
Y E S — G o to s t e p 6 6 .
A C G S (15 A ) f u s e a n d P G M - F I m a i n r e l a y 1 (Fl
Is there battery voltage? MAIN).B
Y E S — G o to s t e p 6 7 .
N O — G o to s t e p 6 3 .
(cont'd)
11-375
PGM-FI System
66. C h e c k for c o n t i n u i t y b e t w e e n P G M - F I m a i n r e l a y 1 69. M e a s u r e voltage between body ground a n d E C M

(Fl M A I N ) 4 P c o n n e c t o r t e r m i n a l N o . 3 a n d E C M c o n n e c t o r t e r m i n a l s A 2 a n d A 3 individually.
connector terminal E 7 .
PGM-FI MAIN
RELAY 1 IGP2 IGP1
(Fl M A I N ) (YEL/BLK) (YEL/BLK)
1 | 2 3 4 | 5 6 | 7 8 9
Wire side of
female terminals
10
/
2 3 24
13 14 15 16
25 26 // // 18
28
20 21
30 31
1 / 3 4 | 5 7
/I 1
8 9 W i r e s i d e of f e m a l e t e r m i n a l s
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/ Is there battery voltage?
Is there continuity? Y E S — G o to s t e p 7 6 .
Y E S - T e s t P G M - F I m a i n r e l a y 1 (Fl M A I N ) N O — G o to s t e p 7 0 .
( s e e p a g e 22-48). If t h e r e l a y is O K , u p d a t e t h e E C M
if it d o e s not h a v e t h e latest s o f t w a r e ( s e e p a g e 7 0 . T u r n t h e ignition s w i t c h O F F .
11-216), o r s u b s t i t u t e a k n o w n - g o o d E C M ( s e e p a g e
11-217), t h e n r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n 7 1 . R e m o v e P G M - F I m a i n r e l a y 1 (Fl M A I N ) (A).
goes a w a y with a known-good E C M , replace the
original E C M ( s e e p a g e 11-389). • A
N O — R e p a i r o p e n in t h e w i r e b e t w e e n P G M - F I m a i n
r e l a y 1 (Fl M A I N ) a n d t h e E C M ( E 7 ) . B
67. R e c o n n e c t E C M c o n n e c t o r E (31P).
11-376
7 3 . M e a s u r e v o l t a g e b e t w e e n P G M - F I m a i n r e l a y 1 (Fl 7 5 . C h e c k f o r continuity b e t w e e n P G M - F I m a i n r e l a y 1
MAIN) 4P connector terminal No. 1 a n d body (Fl M A I N ) 4 P c o n n e c t o r t e r m i n a l N o . 2 a n d E C M
ground. connector terminals A 2 a n d A 3 individually.
P G M - F I M A I N R E L A Y 1 (Fl M A I N ) 4 P C O N N E C T O R
+B
(WHT/GRN)
W i r e s i d e of f e m a l e t e r m i n a l s IGP2 IGP1 ( Y E L / B L K )
(YEL/BLK)
1 I2 3 4 5 6 | 7 | 8 9
/// // //
Is there battery voltage? 10 13 14 15 16 18 20 21
23 24 25 26 28 30 31
Y E S — G o to s t e p 7 4 . Wire side of f e m a l e t e r m i n a l s
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 46 Is there continuity ?
A C G S (15 A ) f u s e a n d P G M - F I m a i n r e l a y 1 (Fl
MAIN).B Y E S - R e p l a c e P G M - F I m a i n relay 1 (Fl M A I N ) . B
7 4 . T u r n t h e ignition s w i t c h O F F . N O — R e p a i r o p e n in t h e w i r e b e t w e e n P G M - F I m a i n
r e l a y 1 (Fl M A I N ) a n d t h e E C M ( A 2 , A 3 ) . B
(cont'd)
11-377
PGM-FI System
76. M e a s u r e voltage between body ground and E C M 77. M e a s u r e voltage between body ground and E C M
connector terminals A4, A 5 , A8, A 9 , and E 3 connector terminal A21.
individually.
E C M C O N N E C T O R A (3IP)
PG1 LG2
(BLK) (BRN/ LG1
P G 2 (BLK) r (BRN/ 1 2 | 3 4 | 5 6 | 7 8 | 9 VCC1
I
YEL) (YEL/RED)
1 | 2 | 3 | 4 | 5 6 | 7 |
/
8 9 10
/ 13 14 15 16
// // 18 20 21
// /
10 13 14 15 16 18 20 21 23 24 25 26 28 30 31
23 24 25 26 28 30 31
E C M C O N N E C T O R E (31P) W i r e s i d e of f e m a l e t e r m i n a l s
LG3 (GRN/WHT)
1 1
1 / 3 4 I 5 / t \ 8 9 Is there about 5 V?
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
Y E S — G o to s t e p 8 3 .
N O — G o to s t e p 7 8 .
W i r e s i d e of f e m a l e t e r m i n a l s 78. Disconnect the M A P s e n s o r 3P connector, a n d

m e a s u r e voltage between body ground and E C M
Is there less than 1.0 V? c o n n e c t o r t e r m i n a l A21 w i t h t h e ignition s w i t c h
O N (II).
Y E S — G o to s t e p 7 7 .
N O — R e p a i r o p e n in t h e w i r e ( s ) that h a d m o r e t h a n
1.0 V b e t w e e n G 1 0 1 a n d the E C M (A4, A 5 , A 8 , A 9 ,
E3)M VCC1
1 | 2 3 | 4 | 5 6 | 7 8 | 9
(YEL/RED)
10
23 24/ 13 14 15 16
25 26 // // 18
28
20 21
30 31
Is there about 5 V?
Y E S — R e p l a c e t h e M A P s e n s o r ( s e e p a g e 11-384).
N O — G o to s t e p 7 9 .
11-378
79. T u r n t h e ignition s w i t c h O F F . 83. Measure voltage between body ground and E C M
8 2 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r 1 | 2 | 3 | 4.1.5 6 | 7 8 | 9

t e r m i n a l A21 a n d b o d y g r o u n d . 10
// 13 14 15 16
/ / 18 20 21
23 24 25 26
VCC2/ /
(YEL/BLU)
28 33 31
1 | 2 | 3 | 4 | 5 6 | 7 8 | 9 VCC1
(YEL/RED)
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 26
/ / 28 30 31
Is there about 5 V?
YES-Gotostep91.
N O — G o to s t e p 8 4 .
Is there continuity? 8 4 . T u r n t h e ignition s w i t c h O F F .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M 8 5 . D i s c o n n e c t t h e c o n n e c t o r f r o m e a c h of t h e s e
(A21) a n d t h e M A P s e n s o r . • s e n s o r s , o n e at a t i m e , a n d m e a s u r e v o l t a g e
between body ground and E C M connector terminal
N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest A 2 0 w i t h t h e ignition s w i t c h O N (II).
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e • A c c e l e r a t o r p e d a l position (APP) s e n s o r A
symptom/indication g o e s a w a y with a known-good • O u t p u t s h a f t (countershaft) s p e e d s e n s o r
1 2 | 3 | 4 | 5 6 | 7 | | 8 9
10
/
23 24
13 14 15 16
25 26 // // 18
28
20 21
33 31
VCC2
(YEL/BLU)
Is there about 5 V?
Y E S — R e p l a c e t h e s e n s o r that r e s t o r e d 5 V w h e n
disconnected. •
(cont'd)
11-379
PGM-FI System
8 6 . T u r n the ignition s w i t c h O F F . 91. M e a s u r e voltage between body ground and E C M

connector terminal E 5 .
8 7 . J u m p t h e S C S line w i t h the H D S .
88. Disconnect the connector from these s e n s o r s :
• Accelerator pedal position (APP) s e n s o r A VCC3 (YEL/BLU)

1 1
• Output s h a f t (countershaft) s p e e d s e n s o r
1 / 3 | 4 | 57 /I8 | 9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/
E C M C O N N E C T O R A (31P) W i r e s i d e of f e m a l e t e r m i n a l s
1 2 3 | 4 | 5 6 | 7 8 9 Is there about 5 V?
10
/ 13 14 15 16
/ / 18 20 21
23 24 25 2 6
VCC2/ /
(YEL/BLU)
28 3 3 31 Y E S — U p d a t e t h e E C M if it d o e s not h a v e t h e latest
E C M , r e p l a c e t h e original E C M ( s e e p a g e 1 1 - 3 8 9 ) . B
W i r e s i d e of f e m a l e t e r m i n a l s N O — G o to s t e p 9 2 .
(A20) a n d A P P s e n s o r A or output s h a f t
(countershaft) s p e e d s e n s o r . •
N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest
symptom/indication goes a w a y with a known-good
E C M , r e p l a c e t h e o r i g i n a l E C M ( s e e p a g e 11-389). •
11-380
9 3 . D i s c o n n e c t the c o n n e c t o r f r o m e a c h of t h e s e 96. Disconnect the connector from these s e n s o r s :
s e n s o r s , o n e at t i m e , a n d m e a s u r e v o l t a g e b e t w e e n
body ground and E C M connector terminal E 5 with • Fuel tank pressure (FTP) s e n s o r
t h e ignition s w i t c h O N (II). • A c c e l e r a t o r p e d a l p o s i t i o n (APP) s e n s o r B
• F u e l tank p r e s s u r e (FTP) s e n s o r 9 7 . D i s c o n n e c t E C M c o n n e c t o r E (31P).

• A c c e l e r a t o r p e d a l position (APP) s e n s o r B
9 8 . C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
VCC3 (YEL/BLU)
1 / 3 4 | 5 / 7 | 8 9
" VCC3 (YEL/BLU)
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
/I—
1 | / | 3 | 4 | 5
1
7 /I
8 | 9 I
//
22
11 12 13 14 15 16 17 18 19 20 21
24 25
/ 27 28 29 30
/
Is there about 5 V?
Y E S — R e p l a c e the s e n s o r that r e s t o r e d 5 V w h e n Is there continuity?

disconnected. •
N O — G o to s t e p 9 4 . (E5) a n d t h e F T P s e n s o r or A P P s e n s o r B. •
94. T u r n t h e ignition s w i t c h O F F . N O — U p d a t e t h e E C M if it d o e s not h a v e t h e latest

9 5 . J u m p t h e S C S line w i t h t h e H D S . g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e
11-381
PGM-FI System
Injector Replacement
2 . R e m o v e t h e fuel rail c o v e r (A).
3. D i s c o n n e c t t h e c o n n e c t o r s (B) f r o m t h e i n j e c t o r s , t h e n r e m o v e t h e h a r n e s s h o l d e r (C) f r o m the fuel rail (D).
4. D i s c o n n e c t t h e q u i c k - c o n n e c t fitting (E) f r o m the fuel rail.
5. R e m o v e t h e retainer nuts (F) a n d bolts (G) f r o m t h e fuel rail.
6. D i s c o n n e c t the fuel rail f r o m t h e intake m a n i f o l d (H).
7. R e m o v e t h e injector c l i p s (I) f r o m t h e f u e l rail.
8. R e m o v e the i n j e c t o r s (J) f r o m t h e fuel rail.
9. R e m o v e t h e O - r i n g s (K) f r o m t h e injector.
11-382
10. C o a t n e w 0 - r i n g s (A) w i t h c l e a n e n g i n e oil, a n d put t h e m o n t h e i n j e c t o r s (B).
11. Insert t h e injectors into t h e fuel rail (C).
12. Install t h e injector c l i p s (D).
13. Install the injectors in t h e intake m a n i f o l d ( E ) .
14. Install a n d tighten t h e retainer n u t s a n d bolts.
15. C o n n e c t t h e q u i c k - c o n n e c t fitting (F) ( s e e p a g e 11-483).
16. C o n n e c t t h e injector c o n n e c t o r s a n d t h e h a r n e s s h o l d e r .
17. Install the injector c o v e r (G).
18. T u r n the ignition s w i t c h O N (II), but d o not o p e r a t e t h e starter. After t h e fuel p u m p r u n s for a b o u t 2 s e c o n d s , t h e
fuel p r e s s u r e in t h e fuel line r i s e s . R e p e a t this 2 o r 3 t i m e s , t h e n c h e c k for fuel l e a k a g e .
11-383
PGM-FI System
MAP Sensor Replacement IAT Sensor Replacement
1. D i s c o n n e c t t h e M A P s e n s o r 3 P c o n n e c t o r (A). 1. D i s c o n n e c t the I A T s e n s o r 2 P c o n n e c t o r (A).
2 . R e m o v e the clip (B) a n d t h e I A T s e n s o r ( C ) .
3. Install t h e parts in the r e v e r s e o r d e r of r e m o v a l .
2. R e m o v e the bolt (B).
3. R e m o v e the M A P s e n s o r ( C ) .
4. Install t h e parts in the r e v e r s e o r d e r of r e m o v a l

w i t h a n e w O - r i n g (D).
11-384
ECT Sensor 1 Replacement ECT Sensor 2 Replacement
1. Drain the e n g i n e c o o l a n t ( s e e p a g e 10-9). 1. D r a i n t h e e n g i n e c o o l a n t ( s e e p a g e 10-9).
2. D i s c o n n e c t t h e E C T s e n s o r 1 2 P c o n n e c t o r (A). 2. R e m o v e the s p l a s h shield.
3. D i s c o n n e c t t h e E C T s e n s o r 2 2 P c o n n e c t o r (A), t h e n
r e m o v e E C T s e n s o r 2 (B).
3. R e m o v e E C T s e n s o r 1 (B).
4. Install t h e p a r t s in the r e v e r s e o r d e r of r e m o v a l 4. Install E C T s e n s o r 2 w i t h a n e w O - r i n g (C).

w i t h a n e w O - r i n g (C).
5. Install the s p l a s h s h i e l d .
5. Refill the radiator with e n g i n e c o o l a n t ( s e e p a g e
10-9). 6. Refill the radiator w i t h e n g i n e c o o l a n t ( s e e p a g e
10-9).
11-385
PGM-FI System
A / F Sensor Replacement Secondary H02S Replacement
0 2 s e n s o r w r e n c h , S n a p - o n Y A 8 8 7 5 or S W R 2 , or 0 2 s e n s o r w r e n c h , S n a p - o n Y A 8 8 7 5 or S W R 2 , o r
equivalent, commercially available equivalent, commercially available
1. D i s c o n n e c t t h e A / F s e n s o r ( S e n s o r 1) 4 P c o n n e c t o r 1. D i s c o n n e c t t h e s e c o n d a r y H 0 2 S ( S e n s o r 2) 4 P
(A). c o n n e c t o r (A).
2. R e m o v e the s e c o n d a r y H 0 2 S ( S e n s o r 2) (A).
A
44 N-m
(4.5 kgf m , 3 3 Ibf-ft)
3. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l . 3. Install the p a r t s in the r e v e r s e o r d e r of r e m o v a l .
11-386
CMP Sensor Replacement CKP Sensor Replacement
N O T E : T h e C M P s e n s o r is o n t h e e x h a u s t s i d e of the 1. R e m o v e the C K P s e n s o r (A).
cylinder head.
1. D i s c o n n e c t the C M P s e n s o r 3 P c o n n e c t o r (A).
2. D i s c o n n e c t the C K P s e n s o r 3 P c o n n e c t o r (B).
2. R e m o v e t h e C M P s e n s o r (B) f r o m the e x h a u s t 3. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l

c a m s h a f t s i d e of t h e c y l i n d e r h e a d . w i t h a n e w O - r i n g (C).
3. Install t h e parts in the r e v e r s e o r d e r of r e m o v a l 4. D o t h e c r a n k ( C K P ) pattern clear/pattern l e a r n

w i t h a n e w O - r i n g (C). p r o c e d u r e ( s e e p a g e 11-214).
11-387
PGM-FI System
Output Shaft (Countershaft) Speed Knock Sensor Replacement
Sensor Replacement
1. R e m o v e t h e intake m a n i f o l d ( s e e p a g e 9-3).
1. D i s c o n n e c t t h e output s h a f t ( c o u n t e r s h a f t ) s p e e d 2. D i s c o n n e c t the knock s e n s o r 1P c o n n e c t o r (A).
s e n s o r (B).
3. R e m o v e t h e knock s e n s o r (B).
3 . Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w O - r i n g (C). 4 . Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l .
11-388
ECM Replacement
Special Tools Required 3. M a k e s u r e the H D S c o m m u n i c a t e s w i t h t h e E C M

• Honda diagnostic s y s t e m (HDS) tablet tester a n d o t h e r v e h i c l e s y s t e m s . If it d o e s n ' t , g o to t h e
• H o n d a interface m o d u l e (HIM) a n d a n iN w o r k s t a t i o n D L C circuit t r o u b l e s h o o t i n g ( s e e p a g e 11-367). If
with H D S and C M update software y o u a r e returning f r o m D L C circuit t r o u b l e s h o o t i n g ,
• H D S pocket tester s k i p s t e p s 4 t h r o u g h 7 , 1 7 t h r o u g h 19, a n d 22
• G N A - 6 0 0 a n d a n iN w o r k s t a t i o n w i t h H D S a n d C M t h r o u g h 2 3 , a n d d o t h i s after r e p l a c i n g t h e E C M :
update software
U s e a n y o n e of t h e s e u p d a t e t o o l s . • R e p l a c e the e n g i n e oil ( s e e p a g e 8-6) a n d t h e
e n g i n e oil filter ( s e e p a g e 8-7).
NOTE:
• M a k e s u r e the H D S is l o a d e d with t h e latest s o f t w a r e • C l e a n t h e throttle b o d y ( s e e p a g e 11-499).
version.
• If y o u a r e r e p l a c i n g t h e E C M after s u b s t i t u t i n g a 4. S e l e c t t h e P G M - F I s y s t e m with the H D S .
k n o w n - g o o d E C M , reinstall the original E C M , t h e n d o
this procedure. 5. S e l e c t t h e I N S P E C T I O N M E N U with t h e H D S .
• D u r i n g t h e p r o c e d u r e , if a n y R E A D D A T A , W R I T E 6. S e l e c t t h e E T C S T E S T , t h e n s e l e c t t h e T P P O S I T I O N
D A T A , or other data c h e c k s fail, note t h e failure, t h e n C H E C K , and follow the s c r e e n prompts.
continue.
N O T E : If t h e T P P O S I T I O N C H E C K i n d i c a t e s F A I L E D ,
1. C o n n e c t the H D S to t h e data link c o n n e c t o r ( D L C ) c o n t i n u e with t h i s p r o c e d u r e .
(A) l o c a t e d u n d e r t h e d r i v e r ' s s i d e of front c o n s o l e .
7. S e l e c t t h e R E P L A C E E C M M E N U , t h e n s e l e c t R E A D
D A T A , a n d f o l l o w the s c r e e n p r o m p t s .
NOTE:
• D o i n g t h i s s t e p c o p i e s ( R E A D S ) t h e e n g i n e oil life
data f r o m the original E C M s o y o u c a n later
d o w n l o a d ( W R I T E S ) it into t h e n e w E C M .
• If R E A D D A T A i n d i c a t e s F A I L E D , c o n t i n u e w i t h
this procedure.
10. R e m o v e the left s i d e kick p a n e l ( s e e p a g e 20-71) to

2. T u r n t h e ignition s w i t c h O N (II). e x p o s e the E C M .
(cont'd)
11-389
PGM-FI System
ECM Replacement (cont'd)
11. D i s c o n n e c t the E C M c o n n e c t o r s (A). 2 2 . If the T P P O S I T I O N C H E C K failed in s t e p 6 c l e a n the
throttle b o d y ( s e e p a g e 11-499), t h e n g o to s t e p 23.
2 3 . If the R E A D D A T A f a i l e d in s t e p 7 or the W R I T E
D A T A failed in s t e p 19, r e p l a c e the e n g i n e oil
( s e e p a g e 8-6) a n d e n g i n e oil filter ( s e e p a g e 8-7),
24. S e l e c t the P G M - F I s y s t e m , a n d r e s e t the E C M w i t h

the H D S .

s o f t w a r e ( s e e p a g e 11-216).
26. Do the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
2 7 . Do the C K P pattern l e a r n p r o c e d u r e ( s e e p a g e
11-214).
12. R e m o v e t h e bolts (B) t h e n r e m o v e t h e E C M ( C ) .
13. Install t h e E C M in the r e v e r s e o r d e r of r e m o v a l .
14. O p e n t h e S C S w i t h the H D S .
16. M a n u a l l y input the V I N to the E C M w i t h the H D S .
N O T E : D T C P 0 6 3 0 " V I N Not P r o g r a m m e d or
M i s m a t c h " m a y be s t o r e d b e c a u s e the V I N h a s not
b e e n p r o g r a m m e d into t h e E C M ; i g n o r e it, a n d
17. If R E A D D A T A failed in s t e p 7, g o to s t e p 2 0 ,
o t h e r w i s e to s t e p 18.
18. S e l e c t the P G M - F I s y s t e m w i t h the H D S .
19. S e l e c t the R E P L A C E E C M M E N U , t h e n s e l e c t W R I T E
D A T A , a n d f o l l o w the s c r e e n p r o m p t s .
N O T E : If t h e W R I T E D A T A i n d i c a t e s F A I L E D ,
continue with this procedure.
20. S e l e c t the IMMOBI s y s t e m with the H D S .
2 1 . E n t e r the i m m o b i l i z e r c o d e w i t h t h e E C M
r e p l a c e m e n t p r o c e d u r e in the H D S ; it a l l o w s y o u to
start the e n g i n e .
11-390
C o m p o n e n t Location Index
ENGINE C O N T R O L M O D U L E (ECM)
Updating, p a g e 11-216
S u b s t i t u t i o n , p a g e 11-217
11-391
DTC Troubleshooting
DTC P0122: TP Sensor A Circuit Low Voltage 8. C h e c k for continuity b e t w e e n throttle b o d y 6 P
and any on-board snapshot, and review the general T H R O T T L E B O D Y 6P C O N N E C T O R
1 2 3 4 5 6
TPSA (RED/BLK)
3. C h e c k T P S E N S O R A in t h e D A T A L I S T w i t h t h e
HDS.
Is there about 0.3 V or less?

N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s Is there continuity?
at t h e throttle b o d y a n d t h e throttle a c t u a t o r control Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e throttle
module. • b o d y a n d t h e throttle a c t u a t o r control m o d u l e
( T P S A line), t h e n g o to s t e p 17.
N O — S u b s t i t u t e a k n o w n - g o o d throttle a c t u a t o r
Are DTC P0122 and P0222 indicated at the same control m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
time? 17 a n d r e c h e c k . If D T C P 0 1 2 2 i s not i n d i c a t e d ,
r e p l a c e t h e original throttle a c t u a t o r c o n t r o l
Y E S — G o to s t e p 9. m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 17. If
D T C P 0 1 2 2 is i n d i c a t e d , g o to s t e p 15.
6. D i s c o n n e c t the throttle b o d y 6 P c o n n e c t o r .
7. D i s c o n n e c t t h e throttle a c t u a t o r control m o d u l e 16P

connector.
11-392
9. M e a s u r e v o l t a g e b e t w e e n throttle b o d y 6 P 14. C h e c k for c o n t i n u i t y b e t w e e n throttle actuator
connector terminal No. 2 and body ground. c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 11 a n d
body ground.
T H R O T T L E B O D Y 6P C O N N E C T O R
T H R O T T L E A C T U A T O R C O N T R O L M O D U L E 16P
CONNECTOR
1 2 3 4 5 6
1 2 /// 6 7 8
V C C (BLU)
9 10 11 12 / //VCC
14
(BLU)
Is there about 5 V?
Y E S — S u b s t i t u t e a k n o w n - g o o d throttle a c t u a t o r
N O — G o to s t e p 10. c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
17 a n d r e c h e c k . If D T C P 0 1 2 2 is not i n d i c a t e d ,
10. T u r n the ignition s w i t c h O F F . r e p l a c e t h e o r i g i n a l throttle a c t u a t o r control
m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 17. If
11. D i s c o n n e c t t h e throttle a c t u a t o r control m o d u l e 16P D T C P 0 1 2 2 is i n d i c a t e d , g o to s t e p 15.
c o n n e c t o r ( s e e p a g e 11-437).
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e throttle
12. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r . b o d y a n d t h e throttle actuator c o n t r o l m o d u l e
( V C C line), t h e n g o to s t e p 17.
13. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l N o . 2
1 2 3 4 5 6
JUMPERWIRE V C C (BLU)
(cont'd)
11-393
16. R e p l a c e t h e throttle b o d y ( s e e p a g e 11-500).
t e r m i n a l s at t h e throttle b o d y a n d t h e throttle
a c t u a t o r c o n t r o l m o d u l e , t h e n g o to s t e p 1.
I M O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
11-394
DTC P0123: TP Sensor A Circuit High Voltage 8. M e a s u r e v o l t a g e b e t w e e n throttle b o d y 6 P
1 2 3 4 5 6 -^X
2. C l e a r t h e D T C w i t h t h e H D S . TPSA (RED/BLK)
3. C h e c k T P S E N S O R A in t h e D A T A L I S T w i t h t h e
HDS.
Is there about 4.8 V or more?

N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s Is there about 5 V?
at t h e throttle b o d y a n d t h e throttle a c t u a t o r control Y E S — G o to s t e p 18.
module. •
time? 10. D i s c o n n e c t t h e throttle a c t u a t o r control m o d u l e 16P
N O — G o to s t e p 5. to b o d y g r o u n d w i t h a j u m p e r w i r e .
THROTTLE B O D Y 6P C O N N E C T O R
6. D i s c o n n e c t the throttle b o d y 6 P c o n n e c t o r .
7. T u r n t h e ignition s w i t c h O N (II). ^X
2 3 4 5 6
JUMPER WIRE TPSA (RED/BLK)
(cont'd)
11-395

12. C h e c k for continuity b e t w e e n throttle a c t u a t o r 16. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l No. 4
control m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 10 a n d to b o d y g r o u n d w i t h a j u m p e r w i r e .
body ground.
CONNECTOR
1 2 /// 6 7 8 1 2 3 5 6
9 10 11 12 / //
TPSA
14 JUMPER WIRE S G (GRN)
(RED/BLK)
17. C h e c k for continuity b e t w e e n throttle a c t u a t o r

Is there continuity? control m o d u l e 16P c o n n e c t o r t e r m i n a l No. 9 a n d
body ground.
c o n t ro l m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
18 a n d r e c h e c k . If D T C P 0 1 2 3 i s not i n d i c a t e d , CONNECTOR
r e p l a c e t h e o r i g i n a l throttle a c t u a t o r c o n t r o l
m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 2 0 . If
1 2 /// 6 7 8
9 10 11 12
SG
/ // 14
b o d y a n d t h e throttle a c t u a t o r c o n t rol m o d u l e (GRN)
( T P S A line), t h e n g o to s t e p 2 0 .
14. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r .
15. D i s c o n n e c t t h e throttle a c t u a t o r c o n t r o l m o d u l e 16P Is there continuity?

control m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
2 0 a n d r e c h e c k . If D T C P 0 1 2 3 is not i n d i c a t e d ,
r e p l a c e t h e original throttle a c t u a t o r control
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e throttle
b o d y a n d the throttle a c t u a t o r control m o d u l e
( S G line), t h e n g o t o s t e p 2 0 .
11-396
19. R e p l a c e the throttle b o d y ( s e e p a g e 11-500).
20. R e c o n n e c t a l l c o n n e c t o r s .
2 2 . R e s e t t h e E C M with t h e H D S .
2 3 . D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
a c t u a t o r control m o d u l e , t h e n g o to s t e p 1.
T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o t o the
DTC P0222: TP Sensor B Circuit Low Voltage 8. C h e c k f o r continuity b e t w e e n throttle b o d y 6 P

1 2 3 4 5 6
T P S B (RED)
3. C h e c k T P S E N S O R B in t h e D A T A L I S T w i t h t h e
HDS.

N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m i s O K at t h i s Is there continuity?
at t h e throttle b o d y a n d t h e throttle a c t u a t o r c o n t r o l Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e throttle
module. • b o d y a n d t h e throttle actuator control m o d u l e
( T P S B line), t h e n g o to s t e p 17.
4. C h e c k f o r T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
N O — S u b s t i t u t e a k n o w n - g o o d throttle a c t u a t o r
Are DTC P0122 and P0222 indicated at the same c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
time? 17 a n d r e c h e c k . If D T C P 0 2 2 2 is not i n d i c a t e d ,
r e p l a c e t h e o r i g i n a l throttle a c t u a t o r control
Y E S — G o to s t e p 9. m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 17. If
D T C P 0 2 2 2 i s i n d i c a t e d , g o to s t e p 15.

11-398
9. M e a s u r e v o l t a g e b e t w e e n throttle b o d y 6 P 14. C h e c k for continuity b e t w e e n throttle a c t u a t o r
connector terminal No. 2 and body ground. c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 11 a n d
body ground.
CONNECTOR
1 2 3 4 5 6
V C C (BLU)
1 2
/ / / 146 7 8
9 10 11 12
/ //
VCC
JBLU)
Is there about 5 V?
Y E S — S u b s t i t u t e a k n o w n - g o o d throttle actuator
N O — G o to s t e p 10. c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o t o s t e p
17 a n d r e c h e c k . If D T C P 0 2 2 2 is not i n d i c a t e d ,
10. T u r n t h e ignition s w i t c h O F F . r e p l a c e t h e original throttle a c t u a t o r c ontr ol
11. D i s c o n n e c t t h e throttle actuator c ont rol m o d u l e 16P D T C P 0 2 2 2 is i n d i c a t e d , g o to s t e p 15.
12. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r . b o d y a n d the throttle a c t u a t o r c o n t r o l m o d u l e
( V C C line), t h e n g o to s t e p 17.
3 4 5 6
JUMPER WIRE V C C (BLU)
(cont'd)
11-399
t e r m i n a l s at the throttle b o d y a n d t h e throttle
11-400
DTC P0223: TP Sensor B Circuit High Voltage 8. M e a s u r e v o l t a g e b e t w e e n throttle b o d y 6 P
a n d a n y on-board s n a p s h o t , and review the general
1 2 3 4 5 6
T P S B (RED)
3. C h e c k T P S E N S O R B in the D A T A L I S T w i t h t h e
HDS.

N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Is there about 5 V?
at t h e throttle b o d y a n d the throttle actuator control Y E S — G o t o s t e p 18.
module. •
4. C h e c k for T e m p o r a r y D T C s or D T C s with t h e H D S .
time? 10. D i s c o n n e c t t h e throttle actuator c o n t r o l m o d u l e 16P
11. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l No. 3
N O — G o to s t e p 5. to b o d y g r o u n d w i t h a j u m p e r w i r e .
7. T u r n the ignition s w i t c h O N (II). 1 2 3 4 5 6

JUMPER WIRE T P S B (RED)
(cont'd)
11-401
12. C h e c k for c o n t i n u i t y b e t w e e n throttle a c t u a t o r 16. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l No. 4
c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 12 a n d to b o d y g r o u n d w i t h a j u m p e r w i r e .
body ground.
THROTTLE B O D Y 6P C O N N E C T O R
CONNECTOR
1 2 /// 6 7 8 1 2 3 5 6
9 10 11 12 / // TPSB
14 JUMPER WIRE S G (GRN)
(RED/BLU)
17. C h e c k for c o n t i n u i t y b e t w e e n throttle a c t u a t o r

Is there continuity ? control m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 9 a n d
body ground.
c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o to
s t e p 20 a n d r e c h e c k . If D T C P 0 2 2 3 is not i n d i c a t e d , CONNECTOR
r e p l a c e the o r i g i n a l throttle a c t u a t o r c o n t r o l
1 2 /// 6 7 8
9 10 11 12
SG
/ // 14
b o d y a n d the throttle a c t u a t o r c o n t r ol m o d u l e (GRN)
( T P S B line), t h e n g o to s t e p 20.
15. D i s c o n n e c t t h e throttle a c t u a t o r c o n tro l m o d u l e 16P Is there continuity?

control m o d u l e ( s e e p a g e 11-437), t h e n g o to
s t e p 20 a n d r e c h e c k . If D T C P 0 2 2 3 is not i n d i c a t e d ,
r e p l a c e t h e o r i g i n a l throttle a c t u a t o r co nt r ol
D T C P 0 2 2 3 i s i n d i c a t e d , g o to s t e p 18.
b o d y a n d t h e throttle a c t u a t o r control m o d u l e
( S G line), t h e n g o to s t e p 20.
11-402
actuator control m o d u l e , t h e n g o to s t e p 1.
DTC P1683: Throttle Valve Default Position 9. P u s h t h e throttle v a l v e to c l o s e d a s s h o w n .

Spring Performance Problem
ACAUTION
Do not i n s e r t y o u r f i n g e r s into t h e i n s t a l l e d throttle
b o d y w h e n y o u turn t h e ignition s w i t c h O N (II) o r
w h i l e t h e ignition s w i t c h is O N (II). If y o u d o , y o u
will s e r i o u s l y injure y o u r f i n g e r s if t h e throttle v a l v e
is a c t i v a t e d .
1. T u r n t h e ignition s w i t c h O N (II). 10. R e l e a s e t h e throttle v a l v e .
2. C l e a r the D T C w i t h the H D S . Does the throttle valve return?
3. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at Y E S — C l e a n t h e throttle b o d y ( s e e p a g e 11-499),

3,000 r p m w i t h o u t l o a d (in neutral) until the t h e n g o to s t e p 13 a n d r e c h e c k . If D T C P 1 6 8 3 is
radiator f a n c o m e s o n , t h e n let it idle. i n d i c a t e d , g o to s t e p 11.
4. T u r n t h e ignition s w i t c h O F F , a n d w a i t 10 s e c o n d s . N O — G o to s t e p 11.
6. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 12. R e p l a c e t h e throttle b o d y ( s e e p a g e 11-500).
Is DTC P1683 indicated? 13. T u r n t h e ignition s w i t c h O N (II).
Y E S — G o to s t e p 7. 14. R e s e t t h e E C M w i t h the H D S .
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 15. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

at t h e throttle b o d y a n d t h e throttle a c t u a t o r c o n t r o l 16. T u r n t h e ignition s w i t c h O F F , a n d w a i t 10 s e c o n d s .
module. •
8. D i s c o n n e c t t h e intake air d u c t f r o m t h e throttle
body. Is DTC P1683 indicated?
11-404
DTC P1684: Throttle Valve Return Spring 9. P u s h t h e throttle v a l v e o p e n a s s h o w n .
Performance Problem
ik CAUTION
D o not insert y o u r f i n g e r s into t h e installed throttle
b o d y w h e n y o u turn t h e ignition s w i t c h O N (II) or
and a n y on-board snapshot, and review the general
1. T u r n t h e ignition s w i t c h O N (II). 10. R e l e a s e t h e throttle v a l v e .
2. C l e a r t h e D T C with t h e H D S . Does the throttle valve return?
3. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at Y E S — C l e a n t h e throttle b o d y ( s e e p a g e 11-499),

3,000 r p m w i t h o u t l o a d (in neutral) until the t h e n g o to s t e p 13 a n d r e c h e c k . If D T C P 1 6 8 4 is
radiator f a n c o m e s o n , t h e n let it idle. i n d i c a t e d , g o to s t e p 11.
4. T u r n t h e ignition s w i t c h O F F , a n d w a i t 10 s e c o n d s . N O — G o to s t e p 11.
6. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 12. R e p l a c e t h e throttle b o d y ( s e e p a g e 11-500).
Is DTC P1684 indicated? 13. T u r n t h e ignition s w i t c h O N (II).
Y E S — G o to s t e p 7. 14. R e s e t t h e E C M w i t h t h e H D S .
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s 15. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

at t h e throttle b o d y a n d the throttle actuator control 16. T u r n t h e ignition s w i t c h O F F , a n d w a i t 10 s e c o n d s .
module. •
8. D i s c o n n e c t the intake air duct f r o m t h e throttle
body. Is DTC P1684 indicated?
t e r m i n a l s at t h e throttle b o d y a n d the throttle
11-405
DTC P2101: Throttle Actuator System 7. T u r n t h e ignition s w i t c h O F F .

Malfunction
8. D i s c o n n e c t t h e intake air duct f r o m the throttle
body.
ACAUTION
Do not insert y o u r f i n g e r s into t h e i n s t a l l e d throttle 9. T u r n the ignition s w i t c h O N (H).
b o d y w h e n y o u t u r n t h e ignition s w i t c h O N (II) o r
w h i l e the ignition s w i t c h is O N (II). If y o u d o , y o u 10. C l e a r the D T C w i t h the H D S .
will s e r i o u s l y i n j u r e y o u r f i n g e r s if the throttle v a l v e
is a c t i v a t e d . 11. V i s u a l l y c h e c k t h e throttle v a l v e o p e r a t i o n w h i l e
d o i n g t h e E T C S T E S T in the I N S P E C T I O N M E N U
with the H D S .
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l Does the throttle valve operate smoothly?
Y E S — C l e a n t h e throttle b o d y ( s e e p a g e 11-499),
1. T u r n the ignition s w i t c h O N (II). t h e n g o to s t e p 19 a n d r e c h e c k . If D T C P2101 is
i n d i c a t e d , t h e n g o to s t e p 17.
3. Do the E T C S T E S T in t h e I N S P E C T I O N M E N U w i t h
the H D S . 12. T u r n t h e ignition s w i t c h O F F .
4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S . 13. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r .
Is DTC P2101 indicated? 14. D i s c o n n e c t the throttle actuator control m o d u l e 16P

15. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l s N o . 5
N O — G o to s t e p 5. a n d N o . 6 with a j u m p e r w i r e .
5. T e s t - d r i v e the v e h i c l e for s e v e r a l m i n u t e s in the

•ENGINE SPEED
• VSS
1 2 3 4 5 6
• A P P SENSOR M - (WHT/BLU) M+ (WHT/BLK)
6. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S . JUMPER WIRE

at the throttle b o d y a n d t h e throttle a c t u a t o r control
m o d u l e , t h e n c l e a n t h e throttle b o d y ( s e e p a g e
11-499).B
11-406
16. C h e c k for continuity b e t w e e n throttle actuator 2 3 . T e s t - d r i v e the v e h i c l e f o r s e v e r a l m i n u t e s in t h e
c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l s No. 1 a n d r a n g e of t h e s e r e c o r d e d f r e e z e d a t a p a r a m e t e r s :
N o . 8.
• ENGINE SPEED
•VSS
CONNECTOR
• A P P SENSOR
M+ (BLU) M - (GRN)
1 2 /// 6 7 8 Is DTC P2101 indicated?
9 10 11 12 / // 14 Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
a c t u a t o r control m o d u l e , c l e a n t h e throttle b o d y
Is there continuity? indicated D T C s troubleshooting. •
s t e p 19 a n d r e c h e c k . If D T C P2101 is not i n d i c a t e d ,
r e p l a c e the original throttle actuator control
D T C P2101 is i n d i c a t e d , g o to s t e p 17.
N O — R e p a i r o p e n in t h e w i r e s b e t w e e n t h e throttle
b o d y a n d t h e throttle actuator control m o d u l e
(motor drive l i n e s ) , t h e n g o to s t e p 19.
2 1 . R e s e t the E C M with t h e H D S .
2 2 . D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
11-407
DTC P2108: Throttle Actuator Control Module

Problem
and any on-board s n a p s h o t , and review the general
control m o d u l e ( s e e p a g e 11-437), a n d r e c h e c k . If
D T C P 2 1 0 8 is not i n d i c a t e d , r e p l a c e t h e o r i g i n a l
throttle a c t u a t o r c o n t r o l m o d u l e ( s e e p a g e 11-437).
at t h e throttle b o d y , t h e throttle a c t u a t o r c o n t r o l
m o d u l e , a n d the E C M . B
11-408
DTC P2118: Throttle Actuator Current Range/ 4. A t throttle b o d y s i d e , m e a s u r e r e s i s t a n c e b e t w e e n
Performance Problem throttle b o d y 6 P c o n n e c t o r t e r m i n a l s N o . 5 a n d
N o . 6 w i t h t h e throttle fully c l o s e d .
and a n y on-board s n a p s h o t , and review the general T H R O T T L E B O D Y 6P C O N N E C T O R

1 2 3 4 5 6
2. M e a s u r e r e s i s t a n c e b e t w e e n throttle actuator
M - M+
control m o d u l e 16P c o n n e c t o r t e r m i n a l s N o . 1 a n d
No. 8.
CONNECTOR T e r m i n a l s i d e of m a l e t e r m i n a l s
Is there about 1.0 0, or less?

M+ (BLU) M - (GRN)
1 2 /// 6 7 8 Y E S — G o to s t e p 5.
9 10 11 12 / // 14
N O — R e p a i r s h o r t in t h e w i r e s b e t w e e n t h e throttle
b o d y a n d t h e throttle actuator c o n t r o l m o d u l e
(motor d r i v e l i n e s ) , t h e n g o to s t e p 6.
Is there about 1.0 0, or less? 6. R e c o n n e c t all c o n n e c t o r s .
Y E S — G o to s t e p 3. 7. T u r n t h e ignition s w i t c h O N (II).
N O — S u b s t i t u t e a k n o w n - g o o d throttle actuator 8. R e s e t the E C M w i t h t h e H D S .

control m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 6
a n d r e c h e c k . If D T C P 2 1 1 8 i s not i n d i c a t e d , r e p l a c e 9. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
t h e o r i g i n a l throttle actuator control m o d u l e
(see p a g e 11-437), t h e n g o to s t e p 6. 10. T u r n the ignition s w i t c h O F F .
3. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r . 11. T u r n the ignition s w i t c h O N (II).
12. S l o w l y p r e s s t h e a c c e l e r a t o r p e d a l to t h e floor.
(cont'd)
11-409
11-410
DTC P2122: APP Sensor A (TP Sensor D) 7. T u r n t h e ignition s w i t c h O F F .
Circuit Low Voltage
and any on-board s n a p s h o t , and review the general 9. D i s c o n n e c t E C M c o n n e c t o r A (31P).
10. C h e c k for continuity b e t w e e n A P P s e n s o r 6 P
1. T u r n t h e ignition s w i t c h O N (II). connector terminal No. 4 a n d body ground.
2. C h e c k A P P S E N S O R A in the D A T A L I S T w i t h t h e
A P P S E N S O R 6P C O N N E C T O R
HDS.
Y E S — G o t o s t e p 3. APSA (RED/BLU)
at A P P s e n s o r A a n d t h e E C M . •
4. D i s c o n n e c t the A P P s e n s o r 6 P c o n n e c t o r .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n A P P s e n s o r
6. M e a s u r e v o l t a g e b e t w e e n A P P s e n s o r 6 P c o n n e c t o r A a n d t h e E C M (A26), t h e n g o to s t e p 2 0 .
APP S E N S O R 6P C O N N E C T O R
11. C o n n e c t A P P s e n s o r 6 P c o n n e c t o r t e r m i n a l N o . 4 to
1 2 3 4 5 6
VCC2 (YEL/RED) SG2 (GRN/WHT)
1 2 3 5 6
APSA (RED/BLU)
JUMPER WIRE
Is there about 5 V?
(cont'd)
11-411
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 15. T u r n t h e ignition s w i t c h O N (II).

16. C h e c k A P P S E N S O R A in the D A T A L I S T w i t h the
HDS.

1 | 2 3 4 | 5 6 | 7 | IS | 9
Y E S — G o to s t e p 2 5 .
10
/ 13 14 15 16
/ /
18 20 21
23 2 4 25 26
/ / 28
APSA (RED/BLU)
30 31
terminals A20 and A23.
W i r e s i d e of f e m a l e t e r m i n a l s E C M C O N N E C T O R A (31P)
4 5
13 14 15 16
6 7
18
un 20 21
24 25 26 28 33
N O — R e p a i r o p e n in the w i r e b e t w e e n A P P s e n s o r SG2 VCC2
(GRN/YEL) (YEL/BLU)
A a n d t h e E C M (A26), t h e n g o to s t e p 2 0 .
13. R e c o n n e c t E C M c o n n e c t o r A (31P).
14. C o n n e c t A P P s e n s o r 6 P c o n n e c t o r t e r m i n a l s N o . 4
and No. 5 with a jumper wire.
Is there about 5 V?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n A P P s e n s o r
A a n d the E C M (A20), t h e n g o to s t e p 20.
N O — G o to s t e p 2 5 .
1 2 3 i 5 6
APSA (RED/BLU) VCC2 (YEL/RED)
JUMPER WIRE
11-412
19. R e p l a c e t h e A P P s e n s o r ( s e e p a g e 11-437).
2 2 . R e s e t the E C M w i t h t h e H D S .
t e r m i n a l s at A P P s e n s o r A a n d the E C M , t h e n g o to
s t e p 1.

g o o d E C M ( s e e p a g e 1-1-217).
t e r m i n a l s at A P P s e n s o r A a n d the E C M . If the E C M
DTC P2123: APP Sensor A (Throttle Position 7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r

Sensor D) Circuit High Voltage terminals A20 and A23.
a n d any on-board s n a p s h o t , and review the general
4 | 5
III
10 13 14 15
16 / 2 8 / 2 0 21
23 24 25 26 31
2 . C h e c k A P P S E N S O R A in t h e D A T A L I S T w i t h t h e
HDS. SG2 VCC2
(GRN/YEL) (YEL/BLU)
at t h e A P P s e n s o r a n d t h e E C M . •
3. T u r n t h e ignition s w i t c h O F F . (A23) a n d the A P P s e n s o r , t h e n g o to s t e p 10.
4. D i s c o n n e c t t h e A P P s e n s o r 6 P c o n n e c t o r . N O — G o to s t e p 15.
6. M e a s u r e v o l t a g e b e t w e e n A P P s e n s o r 6 P c o n n e c t o r 9. R e p l a c e t h e A P P s e n s o r ( s e e p a g e 11-437).
1 2 3 4 5 6 13. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

VCC2 (YEL/RED) S G 2 (GRN/WHT)
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e A P P s e n s o r a n d t h e E C M , t h e n g o
to s t e p 1.
Is there about 5 V?
Y E S — G o t o step8. T e m p o r a r y D T C s o r D T C s a r e i n d i c a t e d , g o to t h e
11-414

g o o d E C M ( s e e p a g e 11-217).
t e r m i n a l s at t h e A P P s e n s o r a n d t h e E C M . If t h e
NO—If the E C M w a s updated, troubleshooting is

DTC P2127: APP Sensor B (TP Sensor E) 7. T u r n t h e ignition s w i t c h O F F .

Circuit Low Voltage
and any on-board s n a p s h o t , and review the general 9. D i s c o n n e c t E C M c o n n e c t o r A (31P).
10. C h e c k for c o n t i n u i t y b e t w e e n A P P s e n s o r 6 P
1. T u r n t h e ignition s w i t c h O N (II). connector terminal No. 3 and body ground.
2. C h e c k A P P S E N S O R B in t h e D A T A L I S T w i t h t h e
HDS.

12 3 4 5 6
Y E S — G o t o s t e p 3. APSB (RED/YEL)
at A P P s e n s o r B a n d t h e E C M . •
4. D i s c o n n e c t t h e A P P s e n s o r 6 P c o n n e c t o r .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n A P P s e n s o r
6. M e a s u r e v o l t a g e b e t w e e n A P P s e n s o r 6 P c o n n e c t o r B a n d t h e E C M ( A 2 5 ) , t h e n g o to s t e p 20.
11. C o n n e c t A P P s e n s o r 6 P c o n n e c t o r t e r m i n a l N o . 3 to
1 2 3 4 5 6 APP S E N S O R 6P C O N N E C T O R
VCC3 (YEL/BLU) S G 3 (GRN)
1 2 3 4 5 6
APSB (RED/YEL)
JUMPER WIRE
Is there about 5 V?
11-416
12. C h e c k for continuity b e t w e e n E C M c o n n e c t o r 15. T u r n t h e ignition s w i t c h O N (II).
16. C h e c k A P P S E N S O R B in t h e D A T A L I S T w i t h t h e
HDS.

1 | 2 | 3 | 4 | 5 6 | 7 8 9
10
/ 13 14 15 16
/ / 18 20 21 Y E S — G o to s t e p 2 5 .
23 24 25 26
/ /
APSB (RED/YEL)
28 30 31
terminals E4 and E5.
W i r e s i d e of f e m a l e t e r m i n a l s E C M C O N N E C T O R E (31P)
VCC3 (YEL/BLU)
1 1/ 3 | 4 | 5 / | 7 | | 8 | 9
N O — R e p a i r o p e n in the w i r e b e t w e e n A P P s e n s o r
/ 11 12 13 14 15 16 17 18 19 20 21
B a n d t h e E C M (A25), t h e n g o to s t e p 20. 22
/ 24 25
/ 2 7 28 29 30
/
13. R e c o n n e c t E C M c o n n e c t o r A (31P).
14. C o n n e c t A P P s e n s o r 6 P c o n n e c t o r t e r m i n a l s N o . 1
a n d No. 3 w i t h a j u m p e r w i r e .
Is there about 5 V?
Y E S — R e p a i r o p e n in the w i r e b e t w e e n A P P s e n s o r
B a n d the E C M ( E 5 ) , t h e n g o to s t e p 20.
2 3 4 5 6
VCC3 (YEL/BLU) APSB (RED/YEL)
JUMPER WIRE
(cont'd)
11-417
19. R e p l a c e t h e A P P s e n s o r ( s e e p a g e 11-437).
t e r m i n a l s at A P P s e n s o r B a n d t h e E C M , t h e n g o to
s t e p 1.
g o o d E C M ( s e e p a g e 11-217).
t e r m i n a l s at A P P s e n s o r B a n d t h e E C M . If t h e E C M
11-418
DTC P2128: APP Sensor B (Throttle Position 7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r
Sensor E) Circuit High Voltage terminals E4 and E 5 .
1. T u r n the ignition s w i t c h O N (II). VCC3 (YEL/BLU)
2 . C h e c k A P P S E N S O R B in t h e D A T A L I S T w i t h t h e 1 M 3 | 4 | 5 T | XI 1 a|»
HDS.
/ 11 12 13 14 15 16 17 18 19 20 21
Is there about 4.0 V or higher?

22
/24 25
/
27 28 29 30
/
at A P P s e n s o r B a n d the E C M . B
3. T u r n t h e ignition s w i t c h O F F . (E4) a n d t h e A P P s e n s o r , t h e n go to s t e p 10.
4. D i s c o n n e c t t h e A P P s e n s o r 6 P c o n n e c t o r . N O — G o to s t e p 15.
6. M e a s u r e v o l t a g e b e t w e e n A P P s e n s o r 6 P c o n n e c t o r 9. R e p l a c e t h e A P P s e n s o r ( s e e p a g e 11-437).
t e r m i n a l s No. 1 a n d No. 2.
1 2 3 4 5 6 13. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).

VCC3 SG3
(YEL/BLU) (GRN) 14. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at A P P s e n s o r B a n d the E C M , t h e n g o to
stepl.
Is thereabouts V?
Y E S — G o t o s t e p 8. T e m p o r a r y D T C s or D T C s a r e i n d i c a t e d , g o to t h e
(cont'd)
11-419
16. R e c o n n e c t ail c o n n e c t o r s .

g o o d E C M ( s e e p a g e 11-217).
11-420
4ft
DTC P2135: TP Sensor A/B Incorrect Voltage 9. T u r n t h e ignition s w i t c h O F F .
Correlation
10. D i s c o n n e c t t h e throttle a c t u a t o r c o n t r o l m o d u l e 16P
ACAUTION
Do not insert y o u r f i n g e r s into the i n s t a l l e d throttle 11. C h e c k for c o n t i n u i t y b e t w e e n throttle a c t u a t o r
b o d y w h e n y o u turn t h e ignition s w i t c h O N (II) o r c o n t r o l m o d u l e 1 6 P c o n n e c t o r t e r m i n a l s N o . 10 a n d
w h i l e t h e ignition s w i t c h is O N (II). if y o u d o , y o u N o . 12.
is a c t i v a t e d . T H R O T T L E A C T U A T O R C O N T R O L M O D U L E 16P
CONNECTOR
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l 1 2 /// 6 7 8
1. T u r n the ignition s w i t c h O N (II). TPSA

9 10 11 12 / // 14
(RED/BLK)
3. D o t h e E T C S T E S T in the I N S P E C T I O N M E N U w i t h W i r e s i d e of f e m a l e t e r m i n a l s
the H D S .
4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . Is there continuity?
Y E S — G o to s t e p 5. N O — S u b s t i t u t e a k n o w n - g o o d throttle actuator
c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
N O — I n t e r m i t t e n t failure, the s y s t e m is O K at t h i s 16 a n d r e c h e c k . If D T C P 2 1 3 5 is not i n d i c a t e d ,
t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s r e p l a c e t h e original throttle a c t u a t o r c o n t r o l
at t h e throttle b o d y a n d the throttle actuator c o n t r o l m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 16.
module. •

body.
8. V i s u a l l y c h e c k t h e throttle v a l v e o p e r a t i o n w h i l e
y o u c l e a n t h e D T C w i t h the H D S .
Does the valve temporarily move to the fully

closed position?
(cont'd)
11-421
13. C h e c k for c o n t i n u i t y b e t w e e n throttle a c t u a t o r

control m o d u l e 16P c o n n e c t o r t e r m i n a l s No. 10 a n d
N o . 12.
CONNECTOR
1 2 /// 6 7 8
TPSA
9 10 11 12 / // 14
(RED/BLK)
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e T P S A
line a n d the T P S B line, t h e n g o to s t e p 16.
i n d i c a t e d D T C s t r o u b l e s h o o t i n g . If a n y other
11-422
DTC P2138: APP Sensor A/B (TP Sensor D/E) 10. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r
Incorrect Voltage Correlation terminals A25 and A26.
1 | 2 | 3 | 4 | 5 6 | 7 | 8 | 9
10
/ 13 14 15 16
/ / 18 20 21
23 24
APSB (RED/YEL)
25 2 6
/ / 28
APSA (RED/BLU)
30 31
3. P r e s s the a c c e l e r a t o r p e d a l to t h e floor.
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M
t i m e . C h e c k f o r p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s t e r m i n a l s ( A 2 5 , A 2 6 ) , t h e n g o to s t e p 13.
at t h e A P P s e n s o r a n d t h e E C M . •
N O — G o to s t e p 2 1 .
5. C h e c k A P P S E N S O R A a n d A P P S E N S O R B in t h e
D A T A L I S T with the H D S . 11. T u r n t h e ignition s w i t c h O F F .
Are they the same voltage? 12. R e p l a c e t h e A P P s e n s o r ( s e e p a g e 11-437).
Y E S — G o to s t e p 6. 13. R e c o n n e c t all c o n n e c t o r s .
N O — G o to s t e p 11. 14. T u r n t h e ignition s w i t c h O N (II).
6. T u r n t h e ignition s w i t c h O F F . 15. R e s e t t h e E C M w i t h t h e H D S .
7. J u m p t h e S C S line w i t h t h e H D S . 16. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
8. D i s c o n n e c t t h e A P P s e n s o r 6 P c o n n e c t o r . 17. T u r n t h e ignition s w i t c h O F F .
9. D i s c o n n e c t E C M c o n n e c t o r A (31P). 18. T u r n t h e ignition s w i t c h O N (II).
19. P r e s s t h e a c c e l e r a t o r p e d a l to t h e floor.
(cont'd)
11-423
t e r m i n a l s at t h e A P P s e n s o r a n d t h e E C M , t h e n g o
to s t e p 1.
I M O — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
g o o d E C M ( s e e p a g e 11-217).
2 5 . P r e s s t h e a c c e l e r a t o r p e d a l to t h e floor.
7 s DTC P2138 indicated?
( s e e p a g e 11-217), t h e n g o to s t e p 2 3 . If t h e E C M
11-424
DTC P2176: Throttle Actuator Control System 10. V i s u a l l y c h e c k t h e throttle v a l v e o p e r a t i o n w h i l e
Idle Position Not Learned p e r f o r m i n g t h e E T C S T E S T in t h e I N S P E C T I O N
M E N U with the HDS.
ACAUTION Does the throttle valve move to its fully closed

D o not insert y o u r f i n g e r s into t h e installed throttle position?
w h i l e t h e ignition s w i t c h i s O N (II). If y o u d o , y o u Y E S — G o to s t e p 11.
will s e r i o u s l y i n j u r e y o u r f i n g e r s if the throttle v a l v e
is a c t i v a t e d . N O — G o to s t e p 12.
11. C h e c k for s l u d g e o r c a r b o n o n t h e throttle v a l v e .

NOTE:
• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d Is there sludge or carbon on the throttle valve?
a n y on-board s n a p s h o t , a n d review the general
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). Y E S — C l e a n t h e throttle b o d y ( s e e p a g e 11-499),
• If D T C P 2 1 3 5 i s s t o r e d at t h e s a m e t i m e a s D T C P 2 1 7 6 , t h e n g o to s t e p 20 a n d r e c h e c k .
t r o u b l e s h o o t D T C P 2 1 3 5 first, t h e n r e c h e c k for D T C
P2176. N O — G o to s t e p 19.
1. T u r n the ignition s w i t c h O N (II). 12. T u r n t h e ignition s w i t c h O F F .
2. C l e a r the D T C w i t h the H D S . 13. D i s c o n n e c t t h e throttle b o d y 6 P c o n n e c t o r .
3. T u r n the ignition s w i t c h O F F . 14. D i s c o n n e c t t h e throttle a c t u a t o r control m o d u l e 16P

4. T u r n the ignition s w i t c h O N (II), a n d w a i t
10 s e c o n d s . 15. C o n n e c t throttle b o d y 6 P c o n n e c t o r t e r m i n a l s N o . 5
and No. 6 with a j u m p e r wire.
THROTTLE BODY 6P CONNECTOR

1 2 3 4 5 6
M— ( W H T / B L U ) M+ (WHT/BLK)
at t h e throttle b o d y a n d t h e throttle a c t u a t o r control
JUMPER WIRE
m o d u l e , t h e n c l e a n t h e throttle b o d y ( s e e p a g e
11-499). •
7. D i s c o n n e c t the intake air d u c t f r o m the throttle

body.
(cont'd)
11-425
16. C h e c k for c o n t i n u i t y b e t w e e n throttle a c t u a t o r 2 5 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
control m o d u l e 16P c o n n e c t o r t e r m i n a l s N o . 1 a n d
N o . 8. Is DTC P2176 indicated?
CONNECTOR t e r m i n a l s at t h e throttle b o d y a n d the throttle
a c t u a t o r control m o d u l e , c l e a n t h e throttle b o d y
M+ (BLU) M - (GRN)
1 2 /// 6 7 8
9 10 11 12 / // 14 indicated D T C s troubleshooting. •
control m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p
19 a n d r e c h e c k . If D T C P 2 1 7 6 i s not i n d i c a t e d ,
r e p l a c e t h e original throttle a c t u a t o r control
m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 19.
N O — R e p a i r o p e n in the w i r e s b e t w e e n t h e throttle
b o d y a n d t h e throttle a c t u a t o r c o n t r o l m o d u l e
(motor d r i v e l i n e s ) , t h e n g o to s t e p 19.
2 4 . T u r n t h e ignition s w i t c h O N (II), a n d w a i t
10 s e c o n d s .
11-426
4ft
DTC P2552: Throttle Actuator Control Module 6. T e s t t h e throttle actuator control m o d u l e relay
Relay Malfunction ( s e e p a g e 22-48).
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data Is the relay OK ?

t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). Y E S — G o to s t e p 7.
1. T u r n the ignition s w i t c h O N (II). N O — R e p l a c e t h e throttle a c t u a t o r control m o d u l e

r elay, t h e n g o to s t e p 10.
3. D o the E T C S T E S T in the I N S P E C T I O N M E N U w i t h
the H D S . 8. D i s c o n n e c t E C M c o n n e c t o r D ( 1 7 P ) .
Is the RELAY circuit OK? 9. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

terminal D15 and body ground.
Y E S — I n t e r m i t t e n t failure, t h e s y s t e m is O K at this
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s E C M C O N N E C T O R D (17P)
at t h e throttle actuator control m o d u l e relay, the
throttle actuator control m o d u l e , a n d the E C M . H I I
20
15
4. T u r n the ignition s w i t c h O F F . ETCSRLY
.(BRN)
5. R e m o v e t h e throttle actuator control m o d u l e
r e l a y (A).
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the throttle
actuator control m o d u l e r e l a y a n d the E C M (D15),
t h e n g o t o s t e p 10.
(cont'd)
11-427
10. R e c o n n e c t E C M c o n n e c t o r D ( 1 7 P ) .
15. T u r n t h e ignition s w i t c h O N (II), a n d w a i t

10 s e c o n d s .
t e r m i n a l s at t h e throttle a c t u a t o r c o n t r o l m o d u l e
r e l a y , t h e throttle a c t u a t o r c o n t r o l m o d u l e , a n d t h e
E C M , t h e n g o to s t e p 1.
N O — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y o t h e r

g o o d E C M ( s e e p a g e 11-217).
20. T u r n t h e ignition s w i t c h O N (II), a n d w a i t

10 s e c o n d s .
t e r m i n a l s at t h e throttle a c t u a t o r control m o d u l e
r e l a y , the throttle a c t u a t o r c o n t r o l m o d u l e , a n d t h e
the E C M w a s s u b s t i t u t e d , g o to s t e p 1.
11-428
DTC U0107: Lost Communication With 11. C h e c k t h e throttle v a l v e o p e r a t i o n .
Throttle Actuator Control Module
Does it open after it closes?
and any on-board snapshot, and review the general Y E S — G o t o s t e p 12.
12. C h e c k t h e throttle v a l v e a g a i n .
Does the throttle valve open fully?
Is DTC U0107 indicated?
t e r m i n a l s at t h e throttle b o d y , t h e throttle actuator 13. T u r n t h e ignition s w i t c h O F F .
control m o d u l e , a n d the E C M , t h e n g o to s t e p 50. If
t h e c o n n e c t i o n s a r e O K , g o to s t e p 6. 14. D i s c o n n e c t the throttle actuator control m o d u l e 16P
connector.
15. C h e c k for continuity b e t w e e n throttle actuator
4. S t a r t t h e e n g i n e . c o n t r o l m o d u l e 16P c p n n e c t o r t e r m i n a l N o . 7 a n d
body ground.
Is DTC U0107 indicated? CONNECTOR
G N D (BLK)
1 2
/// 6 7 8
at t h e throttle b o d y , t h e throttle a c t u a t o r control
m o d u l e r e l a y , t h e throttle a c t u a t o r control m o d u l e ,
9 10 11 12
/ // 14
a n d the E C M . •
6. C l e a r t h e D T C w i t h t h e H D S . W i r e s i d e of f e m a l e t e r m i n a l s
body. Y E S — G o to s t e p 16.
9. P r e s s the a c c e l e r a t o r p e d a l to t h e floor. N O — R e p a i r o p e n in t h e w i r e b e t w e e n the throttle

b o d y , t h e throttle actuator control m o d u l e , a n d
10. T u r n t h e ignition s w i t c h O N (II), G 1 0 1 , t h e n g o to s t e p 50.
(cont'd)
11-429
16. R e m o v e t h e throttle a c t u a t o r control m o d u l e r e l a y 19. Install t h e throttle a c t u a t o r control m o d u l e relay.

(A).
2 1 . M e a s u r e v o l t a g e b e t w e e n throttle a c t u a t o r control
m o d u l e 16P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
ground.
CONNECTOR
+ B (YEL/GRN)
1 2 /// 6 7 8
9 10 11 12 / // 14
17. M e a s u r e v o l t a g e b e t w e e n throttle a c t u a t o r c o n t r o l
module relay 4P connector terminal No. 2 a n d body W i r e s i d e of f e m a l e t e r m i n a l s
ground.
Is there battery voltage for about 2 seconds?

THROTTLE ACTUATOR CONTROL MODULE RELAY
+B
s t e p 50 a n d r e c h e c k . If D T C U 0 1 0 7 i s not i n d i c a t e d ,
(BLU/WHT)
r e p l a c e t h e o r i g i n a l throttle a c t u a t o r control
m o d u l e ( s e e p a g e 11-437), t h e n g o to s t e p 50.
N O — G o to s t e p 2 2 .
23. R e m o v e t h e throttle a c t u a t o r control m o d u l e r e l a y
(A).
18. C h e c k t h e N o . 14 D B W (15 A ) f u s e in t h e u n d e r -
d a s h fuse/relay box.
Is the fuse OK?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e throttle
a c t u a t o r c o n t r o l m o d u l e r e l a y ( + B line) a n d t h e
N o . 14 D B W (15 A ) f u s e , t h e n g o to s t e p 50.
N O — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e throttle
a c t u a t o r c o n t r o l m o d u l e r e l a y ( + B line) a n d t h e
No. 14 D B W (15 A ) f u s e . A l s o r e p l a c e t h e f u s e , t h e n
g o to s t e p 50.
11-430
24. C h e c k t h e throttle a c t u a t o r control m o d u l e r e l a y 3 0 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r
(see p a g e 22-48). t e r m i n a l D 1 5 a n d throttle a c t u a t o r c o n t r o l m o d u l e
r e l a y 4 P c o n n e c t o r t e r m i n a l N o . 3.
Is the throttle actuator control module relay OK?
E C M C O N N E C T O R D (17P)
E
N O — R e p l a c e t h e throttle a c t u a t o r control m o d u l e
15
relay, t h e n g o to s t e p 50.
E T C S R L Y (BRN)
25. T u r n t h e ignition s w i t c h O N (II). THROTTLE ACTUATORCONTROL MODULE RELAY

2 6 . M e a s u r e v o l t a g e b e t w e e n throttle a c t u a t o r control
m o d u l e r e l a y 4 P c o n n e c t o r t e r m i n a l No. 4 a n d b o d y 4) 1
2
ground.
•3-.SLI
ETCSRLY
THROTTLE ACTUATORCONTROLMODULE RELAY (BRN)
W i r e s i d e of female t e r m i n a l s
Y E S — G o to s t e p 3 1 .
(D15) a n d t h e throttle a c t u a t o r c o n t r o l m o d u l e r e l a y ,
3 1 . C h e c k for continuity b e t w e e n throttle actuator
c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l No. 2 a n d
Is there battery voltage? body ground.
CONNECTOR
actuator c o n t ro l m o d u l e r e l a y a n d P G M - F I m a i n
r e l a y 1 (Fl M A I N ) , t h e n g o to s t e p 50. + B (YEL/GRN)
2 7 . T u r n t h e ignition s w i t c h O F F ,
1 2
/ / // 6 7 8
2 8 . J u m p the S C S line w i t h t h e H D S .
9 10 11 12 14
//
29. D i s c o n n e c t E C M c o n n e c t o r D ( 1 7 P ) .
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e throttle
a c t u a t o r control m o d u l e a n d t h e throttle a c t u a t o r
c o n t r o l m o d u l e r e l a y ( + B line), t h e n g o to s t e p 50.
N O — G o t o step 32.
(cont'd)
11-431
3 2 . C o n n e c t throttle a c t u a t o r control m o d u l e r e l a y 4 P 3 4 . T u r n t h e ignition s w i t c h O F F .

c o n n e c t o r t e r m i n a l N o . 1 to b o d y g r o u n d w i t h a
jumper wire. 3 5 . J u m p t h e S C S line w i t h t h e H D S .
THROTTLE ACTUATOR CONTROL MODULE RELAY 3 6 . D i s c o n n e c t t h e throttle a c t u a t o r control m o d u l e 16P

4P C O N N E C T O R c o n n e c t o r ( s e e p a g e 11-437).
+B
(YEL/GRN) 3 7 . D i s c o n n e c t E C M c o n n e c t o r B (24P).
/ / / 1
2 3 8 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r
JUMPER
4 WIRE terminal B19 and body ground.
W i r e s i d e of f e m a l e t e r m i n a l s / 2 | 3 | 4 | 5 6
/
8
/ 10 11
/ ///13
3 3 . C h e c k for continuity b e t w e e n throttle a c t u a t o r

17 18 19
///
20 21
S E F D (GRN)
c o n t r o l m o d u l e 16P c o n n e c t o r t e r m i n a l N o . 2 a n d
body ground.
CONNECTOR W i r e s i d e of f e m a l e t e r m i n a l s
+B (YEL/GRN) Is there continuity?
1 2 /// 6 7 8
9 10 11 12 / // 14
(B19) a n d t h e throttle a c t u a t o r control m o d u l e , t h e n
g o to s t e p 50.
N O — G o to s t e p 3 9 .
a c t u a t o r c o n t r o l m o d u l e a n d t h e throttle a c t u a t o r
control m o d u l e r e l a y ( + B line), t h e n g o to s t e p 50.
11-432
3 9 . C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 4 0 . T u r n t h e ignition s w i t c h O F F .
t e r m i n a l B 1 9 a n d throttle a c t u a t o r control m o d u l e
16P c o n n e c t o r t e r m i n a l N o . 6. 4 1 . J u m p t h e S C S line with the H D S .
4 2 . D i s c o n n e c t t h e throttle a c t u a t o r c o n t r o l m o d u l e 16P
/ 2 | 3 | 4 | 5 h / connector.
8
/ 10 11
/ /// 13
17 18 19
///
20 21
S E F D (GRN)
^— 44. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
THROTTLE ACTUATORCONTROL MODULE
16P C O N N E C T O R ' S E F D (GRN)
1 2 /// 6 7 8
9 10 11 12 A 14 // / 2 | 3 | 4 5 | B /
W i r e s i d e of f e m a l e t e r m i n a l s 8
/ 10 11
/ ///13
17 18 19
///
20 21
S E D F (BLU)
s t e p 50 a n d r e c h e c k . If D T C U 0 1 0 7 is not i n d i c a t e d ,
r e p l a c e the original throttle actuator c ontrol W i r e s i d e of f e m a l e t e r m i n a l s
m o d u l e ( s e e p a g e 11-437), t h e n go to s t e p 5 0 . If
D T C U 0 1 0 7 is i n d i c a t e d , g o to s t e p 56.
(B19) a n d t h e throttle a c t u a t o r control m o d u l e , t h e n Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
g o to s t e p 50. (B20) a n d t h e throttle a c t u a t o r control m o d u l e , t h e n
N O — G o to s t e p 4 5 .
(cont'd)
11-433
45. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r 46. T u r n t h e ignition s w i t c h O F F .
t e r m i n a l B 2 0 a n d throttle a c t u a t o r control m o d u l e
16P c o n n e c t o r t e r m i n a l N o . 14. 4 7 . J u m p t h e S C S line w i t h t h e H D S .
/ | 2 | 3 | 4 | 6
/ 6
49. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d
8
/ 10 11
/ ///13
E C M connector terminals A 8 and A 9 individually.
17 18 19
///
20 21
S E D F (BLU)
THROTTLE ACTUATOR CONTROL MODULE
16P C O N N E C T O R LG2 LG1
1 2 /// 6 7 8 (BRN/YEL) (BRN/YEL)
9 10 11 12 / // 14
S E D F (BLU)
1 | 2 | 3 | 4 | 5 6 | 7 | |8 9
10
/ 13 14 15 16
/ / 18 20 21
W i r e s i d e of f e m a l e t e r m i n a l s 23 24 25 26
/ / 28 30 31
Y E S — S u b s t i t u t e a k n o w n - g o o d throttle a c t u a t o r W i r e s i d e of f e m a l e t e r m i n a l s
s t e p 50 a n d r e c h e c k . If D T C U 0 1 0 7 is not i n d i c a t e d ,
r e p l a c e t h e o r i g i n a l throttle a c t u a t o r c o n t r o l Is there continuity?
D T C U 0 1 0 7 is i n d i c a t e d , g o to s t e p 56. Y E S — C h e c k for p o o r c o n n e c t i o n s o r l o o s e
t e r m i n a l s at t h e throttle b o d y , t h e throttle a c t u a t o r
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M control m o d u l e r e l a y , t h e throttle actuator control
(B20) a n d t h e throttle a c t u a t o r control m o d u l e , t h e n m o d u l e , a n d t h e E C M , t h e n go to s t e p 1.
g o to s t e p 50.
N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M ( A 8 ,
A 9 ) a n d G 1 0 1 , t h e n g o to s t e p 50.
11-434
4ft
t e r m i n a l s at t h e throttle b o d y , t h e throttle a c t u a t o r
c o n t r o l m o d u l e r e l a y , t h e throttle actuator control
m o d u l e , a n d t h e E C M , t h e n g o to s t e p 1.

g o o d E C M ( s e e p a g e 11-217).
t e r m i n a l s at t h e throttle b o d y , the throttle actuator
control m o d u l e r e l a y , t h e throttle a c t u a t o r control
m o d u l e , a n d t h e E C M . If t h e E C M w a s u p d a t e d ,
t h e n r e c h e c k . If the E C M w a s s u b s t i t u t e d , g o to s t e p
1.
11-435
APP Sensor Signal Inspection
NOTE: 5. M a k e s u r e t h e a c c e l e r a t o r p e d a l i s not p r e s s e d ,
• T h i s p r o c e d u r e c h e c k s t h e A P P s e n s o r in its fully t h e n c h e c k t h e A P P S E N S O R in t h e D A T A L I S T with
c l o s e d p o s i t i o n . In a n y o t h e r p o s i t i o n , t h e A P P s e n s o r the H D S .
s t o r e s D T C s w h i c h a r e c o v e r e d in o t h e r
troubleshooting procedures. • If it is b e l o w 2 % , the A P P s e n s o r i s O K .
• C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S • If it is a b o v e 2 % , update t h e E C M if it d o e s not
b e f o r e d o i n g this p r o c e d u r e . If a n y D T C s a r e h a v e the latest s o f t w a r e , or s u b s t i t u t e a k n o w n -
i n d i c a t e d , t r o u b l e s h o o t t h e m first, t h e n d o t h i s g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 6.
procedure.
• P r e s s t h e a c c e l e r a t o r p e d a l s e v e r a l t i m e s to c h e c k its 6. M a k e s u r e t h e a c c e l e r a t o r p e d a l is not p r e s s e d ,
o p e r a t i o n . If it d o e s not o p e r a t e p r o p e r l y , c h e c k t h e t h e n c h e c k t h e A P P S E N S O R in t h e D A T A L I S T with
p e d a l , t h e throttle c a b l e , a n d t h e A P P s e n s o r the H D S .
i n d i v i d u a l l y . If y o u find a p r o b l e m in o n e of t h e m ,
r e p l a c e t h e part(s) that c a u s e d t h e p r o b l e m . • If it is b e l o w 2 % , the A P P s e n s o r is O K .
• If it is a b o v e 2 % , r e p l a c e t h e A P P s e n s o r
1. C o n n e c t the H D S to t h e d a t a link c o n n e c t o r ( D L C ) ( s e e p a g e 11-437), t h e n g o to s t e p 1.
(A) located b e h i n d the d r i v e r ' s s i d e of t h e front
console.
3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M . If
it d o e s n ' t , g o to t h e D L C circuit t r o u b l e s h o o t i n g
( s e e p a g e 11-367).
4. M a k e s u r e the a c c e l e r a t o r p e d a l is not p r e s s e d ,
t h e n c h e c k t h e A P P S E N S O R in t h e D A T A L I S T w i t h
the H D S .
• If it is b e l o w 2 % , the A P P s e n s o r is O K .
• If it is a b o v e 2 % , a d j u s t t h e throttle c a b l e
11-436
APP Sensor Replacement Throttle Actuator Control Module
Replacement
1. R e m o v e the throttle c a b l e c o v e r ( s e e p a g e 11-504).
2. R e m o v e the throttle c a b l e ( s e e p a g e 11-503). 1. R e m o v e t h e p a s s e n g e r ' s d a s h b o a r d l o w e r c o v e r

( s e e p a g e 20-86).
3. D i s c o n n e c t the a c c e l e r a t o r p e d a l position (APP)
s e n s o r 6 P c o n n e c t o r (A). 2 . P u s h t h e t a b (A), a n d d i s c o n n e c t the throttle
a c t u a t o r control m o d u l e 16P c o n n e c t o r (B).
3. R e m o v e the nuts (C) a n d the throttle actuator

4. R e m o v e the bolts (B) a n d the A P P s e n s o r (C). c o n t r o l m o d u l e (D).
5. Install the parts in the r e v e r s e o r d e r of r e m o v a l . 4. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l .
11-437
VTEC
11-438
DTC Troubleshooting
DTC P2646: Rocker Arm Oil Pressure Switch 8. C h e c k the V T E C P R E S S W in the D A T A L I S T w i t h

(VTEC Oil Pressure Switch) Circuit Low the H D S .
Voltage
Is switch ON indicated?
• Pressure gauge adapter 07NAJ-P07010A Y E S — G o t o s t e p 15.
• A / T l o w p r e s s u r e g a u g e w / p a n e l 07406-0070301
• A / T p r e s s u r e h o s e 07406-0020201 N O — G o to s t e p 9.
• A / T p r e s s u r e h o s e , 2,210 m m 0 7 M A J - P Y 4 0 1 1 A
• A / T pressure h o s e , adapter 07MAJ-PY40120 9. T u r n the ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a 10. R e m o v e t h e r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C

a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l oil p r e s s u r e s w i t c h ) (A) a n d install t h e s p e c i a l t o o l s
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). a s s h o w n , t h e n install the rocker a r m oil p r e s s u r e
s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) (A) to the oil
1. C h e c k t h e e n g i n e oil l e v e l . p r e s s u r e g a u g e a d a p t e r (B).
Is the engine oil level OK? N O T E : Install t h e parts in the r e v e r s e o r d e r of

r e m o v a l w i t h a n e w O-ring.
N O — A d j u s t t h e e n g i n e oil to t h e proper l e v e l , t h e n
4. Do t h e V T E C T E S T in the I N S P E C T I O N M E N U w i t h
the H D S .
Is the result OK?

(2.2 k g f . m , 16 Ibf-ft)
t i m e . C h e c k for poor c o n n e c t i o n s or l o o s e t e r m i n a l s 11. R e c o n n e c t t h e r o c k e r a r m oil p r e s s u r e s w i t c h
at the rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r .
p r e s s u r e s w i t c h ) , t h e rocker a r m oil control
s o l e n o i d ( V T E C s o l e n o i d v a l v e ) , a n d the E C M . B
6. D i s c o n n e c t the rocker a r m oil p r e s s u r e s w i t c h

(cont'd)
11-439
VTEC
12. S t a r t the e n g i n e . 19. R e c o n n e c t all c o n n e c t o r s .
13. D o the V T E C T E S T in the I N S P E C T I O N M E N U w i t h 20. T u r n t h e ignition s w i t c h O N (II).

the H D S .
14. C h e c k the V E T C oil p r e s s u r e .
Does the oil pressure increase at least 392 kPa
(4.0 kgf/cnf, 56.9 psi)? 2 3 . D o t h e V T E C T E S T in t h e I N S P E C T I O N M E N U w i t h
the H D S .
Y E S — R e p l a c e the r o c k e r a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) ( s e e p a g e 11-449), t h e n 24. C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
g o to s t e p 20.
N O — I n s p e c t the V T E C s y s t e m . If is O K , r e p l a c e t h e
rocker a r m oil control v a l v e ( V T E C s o l e n o i d v a l v e ) Y E S — C h e c k for poor c o n n e c t i o n s o r l o o s e
( s e e p a g e 11-449), t h e n g o to s t e p 20. t e r m i n a l s at t h e rocker a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) , the r o c k e r a r m oil
15. T u r n the ignition s w i t c h O F F . control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) , a n d the
ECM.
18. C h e c k for continuity b e t w e e n E C M c o n n e c t o r D T C s M E N U w i t h the H D S .
t e r m i n a l B11 a n d b o d y g r o u n d .
g o to the indicated D T C s t r o u b l e s h o o t i n g . •
c o n n e c t i o n s o r l o o s e t e r m i n a l s at the r o c k e r a r m oil
VTPSW (BLU/BLK)
p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) , t h e
rocker a r m oil control s o l e n o i d ( V T E C s o l e n o i d
v a l v e ) , a n d the E C M , t h e n g o to s t e p 1. If t h e s c r e e n
i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 2 3 .
I n s p e c t t h e f o l l o w i n g i t e m s . If t h e y a r e O K , r e p l a c e
t h e rocker a r m oil control v a l v e ( s e e p a g e 11-449),
Is there continuity? t h e n g o to s t e p 19.
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E C M • V T E C s y s t e m ' s oil line

(B11) a n d t h e rocker a r m oil p r e s s u r e s w i t c h ( V T E C • O p e r a t i o n of t h e rocker a r m ( s e e p a g e 6-8)
oil p r e s s u r e s w i t c h ) , t h e n g o to s t e p 19.
N O — G o to s t e p 2 7 .
11-440
27. U p d a t e the E C M if it d o e s not h a v e the latest

g o o d E C M ( s e e p a g e 11-217).
28. D o the V T E C T E S T in the I N S P E C T I O N M E N U w i t h

the H D S .
29. C h e c k for T e m p o r a r y D T C s or D T C s with t h e H D S .
t e r m i n a l s at t h e rocker a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) , t h e rocker a r m oil
control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) , a n d the
E C M . If t h e E C M w a s u p d a t e d , substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217), t h e n go to s t e p 2 8 . If
30. M o n i t o r the O B D S T A T U S for D T C P 2 6 4 6 in t h e

c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e r o c k e r a r m oil
p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) , t h e
v a l v e ) , a n d the E C M . If t h e E C M w a s u p d a t e d ,
substitute a k n o w n - g o o d E C M ( s e e p a g e 11-217),
t h e n g o to s t e p 2 8 . If t h e E C M w a s s u b s t i t u t e d , g o
to s t e p 1. If t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D ,
g o to s t e p 28.
VTEC
(VTEC Oil Pressure Switch) Circuit High
Voltage 7. D i s c o n n e c t t h e rocker a r m oil p r e s s u r e s w i t c h
and any on-board snapshot, and review the general 8. A t t h e rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). p r e s s u r e s w i t c h ) s i d e , c h e c k for continuity b e t w e e n
r o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e
1. C h e c k the e n g i n e oil l e v e l . s w i t c h ) 2 P c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 2.
Is the engine oil level OK?

(VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R
N O — A d j u s t t h e e n g i n e oil to t h e p r o p e r l e v e l , t h e n VTPSW
g o to s t e p 14.
4. D o the V T E C T E S T in the I N S P E C T I O N M E N U w i t h T e r m i n a l s i d e of m a l e t e r m i n a l s
the H D S .
Is the result OK? Is there continuity?
Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at this Y E S — G o to s t e p 9.

at t h e rocker a r m oil p r e s s u r e s w i t c h ( V T E C oil N O — R e p l a c e the rocker a r m oil p r e s s u r e s w i t c h
p r e s s u r e s w i t c h ) a n d the E C M . B ( V T E C oil p r e s s u r e s w i t c h ) ( s e e p a g e 11-449), t h e n
g o to s t e p 13.
5. C h e c k the result of s t e p 4.
• VTEC Switch Failure

• VTEC Switch Open
• VTEC Switch S I G Line Open
• VTEC Switch G N D Line Open
Is the test result any of these?
N O — C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s
p r e s s u r e s w i t c h ) . If it is O K , r e p l a c e t h e r o c k e r a r m
oil control v a l v e ( V T E C s o l e n o i d v a l v e ) ( s e e p a g e
11-449), t h e n g o to s t e p 14.
11-442
10. M e a s u r e voltage b e t w e e n rocker a r m oil p r e s s u r e 12. T u r n t h e ignition s w i t c h O F F .
t e r m i n a l No. 1 a n d b o d y g r o u n d . 13. R e c o n n e c t the r o c k e r a r m oil p r e s s u r e s w i t c h
(VTEC OIL P R E S S U R E SWITCH) 2P C O N N E C T O R 14. T u r n t h e ignition s w i t c h O N (II).
VTPSW 15. R e s e t t h e E C M w i t h t h e H D S .
(BLU/BLK)
W i r e s i d e of f e m a l e terminals Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at the r o c k e r a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) a n d the E C M , t h e n g o to
Is there battery voltage? s t e p 1.
Y E S — R e p a i r o p e n in the w i r e b e t w e e n t h e rocker N O — G o to s t e p 18.

a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h )
a n d G 1 0 1 , t h e n g o to s t e p 12. 18. M o n i t o r t h e O B D S T A T U S for D T C P2647 in the
B11 a n d b o d y g r o u n d . Y E S — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y other
T e m p o r a r y D T C s o r D T C s w e r e indicated in s t e p 17,
/ \ 2 I 3 | 4 | 5 6 c o n n e c t i o n s or l o o s e t e r m i n a l s at the rocker a r m oil
p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) a n d the
8
/ 10 11
/ ///
13
E C M , t h e n g o to s t e p 1. If the s c r e e n i n d i c a t e s N O T
17 18 19
///
20 21
VTPSW (BLU/BLK)
C O M P L E T E D , go to s t e p 16 a n d r e c h e c k .
(B11) a n d the rocker a r m oil p r e s s u r e s w i t c h ( V T E C
oil p r e s s u r e s w i t c h ) , t h e n g o to s t e p 12.
(cont'd)
11-443
VTEC

g o o d E C M ( s e e p a g e 11-217).
2 2 . S t a r t the e n g i n e , a n d let it idle.
t e r m i n a l s at t h e r o c k e r a r m oil p r e s s u r e s w i t c h
( V T E C oil p r e s s u r e s w i t c h ) a n d t h e E C M . If t h e E C M
( s e e p a g e 11-217), t h e n go to s t e p 2 2 . If t h e E C M
24. Monitor t h e O B D S T A T U S for D T C P2647 in t h e


p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) a n d t h e
t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n
11-444
DTC P2648: Rocker Arm Oil Control Solenoid 8. D i s c o n n e c t E C M c o n n e c t o r B (24P).
(VTEC Solenoid Valve) Circuit Low Voltage
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e data terminal B6 and body ground.

V T S (GRN/YEL)
A* |3
V I- 5 6
A
8
/ 10 11
/ /// 13
the H D S .
17 18 19
///
20 21
Is the result OK?
Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at this W i r e s i d e of f e m a l e t e r m i n a l s

at the rocker a r m oil control s o l e n o i d ( V T E C
s o l e n o i d v a l v e ) a n d the E C M . B Is there continuity?
N O — G o to s t e p 4. Y E S — R e p a i r s h o r t in the w i r e b e t w e e n t h e E C M
(B6) a n d the rocker a r m oil control s o l e n o i d ( V T E C
4. T u r n the ignition s w i t c h O F F . s o l e n o i d v a l v e ) , t h e n g o to s t e p 11.
5. D i s c o n n e c t the rocker a r m oil control s o l e n o i d N O — G o to s t e p 18.

(VTEC solenoid valve) I P connector.
10. R e p l a c e the rocker a r m oil control v a l v e ( V T E C
6. A t the v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n t h e s o l e n o i d v a l v e ) ( s e e p a g e 11-449).
v a l v e ) 1P c o n n e c t o r t e r m i n a l a n d b o d y g r o u n d . 11. R e c o n n e c t all c o n n e c t o r s .

R O C K E R A R M OIL C O N T R O L S O L E N O I D
( V T E C S O L E N O I D V A L V E ) 1P C O N N E C T O R

the H D S .
T e r m i n a l s i d e of m a l e t e r m i n a l s Is DTC P2648 indicated?
Is there 14—30 Q at room temperature? t e r m i n a l s at the rocker a r m oil control s o l e n o i d
( V T E C s o l e n o i d v a l v e ) a n d the E C M , t h e n g o to s t e p
Y E S — G o to s t e p 7. 1.
N O — G o to s t e p 10. N O — G o to s t e p 17.
(cont'd)
11-445
VTEC
17. M o n i t o r t h e O B D S T A T U S for D T C P 2 6 4 8 in t h e 2 2 . M o n i t o r t h e O B D S T A T U S for D T C P 2 6 4 8 in t h e

D T C s M E N U w i t h the H D S . D T C s M E N U w i t h the H D S .
Does the screen indicate PASSED? Does the screen indicate PASSED?
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r Y E S — I f the E C M w a s updated, troubleshooting is

T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 16, c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • o r i g i n a l E C M ( s e e p a g e 11-389). If a n y other
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) a n d t h e N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
E C M , t h e n g o to s t e p 1. If t h e s c r e e n i n d i c a t e s N O T c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e r o c k e r a r m oil
C O M P L E T E D , g o to s t e p 15. control solenoid ( V T E C solenoid valve) a n d the
E C M . If t h e E C M w a s u p d a t e d , substitute a k n o w n -
18. R e c o n n e c t all c o n n e c t o r s . g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 20. If
t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n
19. U p d a t e t h e E C M if it d o e s not h a v e t h e latest i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 20.
g o o d E C M ( s e e p a g e 11-217).
20. D o t h e V T E C T E S T in t h e I N S P E C T I O N M E N U w i t h
the H D S .
t e r m i n a l s at t h e r o c k e r a r m oil c o n t r o l s o l e n o i d
( V T E C s o l e n o i d v a l v e ) a n d the E C M . If t h e E C M w a s
updated, substitute a known-good E C M (see page
11-217), t h e n go to s t e p 20. If t h e E C M w a s
N O — G o to s t e p 2 2 .
11-446
4*
DTC P2649: Rocker Arm Oil Control Solenoid 8. J u m p t h e S C S line w i t h t h e H D S .
(VTEC Solenoid Valve) Circuit High Voltage
a n d a n y o n - b o a r d s n a p s h o t , a n d r e v i e w the g e n e r a l 10. C o n n e c t t h e r o c k e r a r m oil control s o l e n o i d ( V T E C
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). s o l e n o i d v a l v e ) I P c o n n e c t o r t e r m i n a l to b o d y
2. C l e a r the D T C w i t h the H D S . (VTEC SOLENOID VALVE) IP CONNECTOR
4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . JUMPER WIRE
N O — I n t e r m i t t e n t failure, the s y s t e m is O K at this

t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s 11. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
at t h e r o c k e r a r m oil control s o l e n o i d ( V T E C terminal B6 and body ground.
s o l e n o i d v a l v e ) a n d the E C M . •
6. D i s c o n n e c t the rocker a r m oil control s o l e n o i d V T S ( G R N / YE L )

| — T"
( V T E C s o l e n o i d v a l v e ) 1P c o n n e c t o r .
XI 2 | 3 4 | 5 /
7. A t the v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n the
8
/ 10 11
/
13
/ /
v a l v e ) 1P c o n n e c t o r t e r m i n a l a n d b o d y g r o u n d .
17 18 19 20 21
///
( V T E C S O L E N O I D V A L V E ) 1P C O N N E C T O R W i r e s i d e of f e m a l e t e r m i n a l s
N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M (B6)

a n d the r o c k e r a r m oil control s o l e n o i d ( V T E C
s o l e n o i d v a l v e ) , t h e n g o to s t e p 13.
Is there 14—30 0. at room temperature?
(cont'd)
11-447
VTEC
12. R e p l a c e t h e r o c k e r a r m oil c o n t r o l v a l v e ( V T E C 2 2 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .

s o l e n o i d v a l v e ) ( s e e p a g e 11-449).
14. T u r n t h e ignition s w i t c h O N (II). t e r m i n a l s at t h e r o c k e r a r m oil control s o l e n o i d
( V T E C s o l e n o i d v a l v e ) a n d the E C M . If t h e E C M w a s
15. R e s e t t h e E C M w i t h t h e H D S . updated, substitute a known-good E C M (see page
16. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). s u b s t i t u t e d , g o to s t e p 1.
17. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . N O — G o to s t e p 2 3 .
Is DTC P2649 indicated? 2 3 . M o n i t o r t h e O B D S T A T U S for D T C P 2 6 4 9 in t h e

t e r m i n a l s at t h e r o c k e r a r m oil c o n t r o l s o l e n o i d Does the screen indicate PASSED?
( V T E C s o l e n o i d v a l v e ) a n d t h e E C M , t h e n g o to s t e p
1. Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
N O — G o to s t e p 18. original E C M ( s e e p a g e 11-389). If a n y other
18. M o n i t o r t h e O B D S T A T U S for D T C P 2 6 4 9 in t h e g o to the i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Does the screen indicate PASSED? c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e r o c k e r a r m oil
control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) a n d t h e
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r E C M . If t h e E C M w a s u p d a t e d , substitute a k n o w n -
T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 17, g o o d E C M ( s e e p a g e 11-217), t h e n g o to s t e p 2 1 . If
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • the E C M w a s s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r result c o m e s o n .
control s o l e n o i d ( V T E C s o l e n o i d v a l v e ) a n d t h e
E C M , t h e n g o to s t e p 1. If t h e s c r e e n i n d i c a t e s N O T
C O M P L E T E D , k e e p idling until a r e s u l t c o m e s o n .

g o o d E C M ( s e e p a g e 11-217).
2 1 . S t a r t t h e e n g i n e , a n d let it idle.
11-448
Rocker Arm Oil Control Valve (VTEC Rocker Arm Oil Pressure Switch
Solenoid Valve) Removal/ (VTEC Oil Pressure Switch)
Installation Removal/Installation
1. D i s c o n n e c t the rocker a r m oil control v a l v e ( V T E C 1. D i s c o n n e c t t h e rocker a r m oil p r e s s u r e s w i t c h

s o l e n o i d v a l v e ) 1 P c o n n e c t o r a n d rocker a r m oil ( V T E C oil p r e s s u r e s w i t c h ) 2 P c o n n e c t o r (A).
p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) 2 P
connector.
2 . R e m o v e the bolts (A).
2 . R e m o v e t h e rocker a r m oil p r e s s u r e s w i t c h ( V T E C
oil p r e s s u r e s w i t c h ) (B).
3 . R e m o v e the rocker a r m oil control v a l v e ( V T E C
s o l e n o i d v a l v e ) (B). 3 . install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l
with a n e w O-ring (C).
4 . Install the parts in the r e v e r s e o r d e r of r e m o v a l
w i t h a n e w filter (C).
11-449
Idle Control System
BRAKE PEDAL POSITION SWITCH

Circuit T r o u b l e s h o o t i n g , page 11-460
11-450
DTC Troubleshooting
DTC P0506: Idle Control System RPM Lower 7. C h e c k for dirt, c a r b o n , or d a m a g e in t h e throttle
Than Expected bore.
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze data Is there dirt, carbon, or damage in the throttle

and a n y on-board s n a p s h o t , and review the general bore?
Y E S — I f t h e r e is dirt or c a r b o n , c l e a n t h e throttle
1. T u r n t h e ignition s w i t c h O N (II). b o d y ( s e e p a g e 11-499). A l s o c h e c k for d a m a g e at
t h e air c l e a n e r e l e m e n t ( s e e p a g e 11-505), t h e n g o
2. C l e a r t h e D T C w i t h t h e H D S . to s t e p 9. If t h e r e is d a m a g e in t h e throttle b o r e , g o
to s t e p 8.
3 , 0 0 0 r p m w i t h o u t l o a d (in neutral) until t h e N O — C h e c k the A / C s y s t e m or p o w e r s t e e r i n g
radiator f a n c o m e s o n , t h e n let it idle. s y s t e m , t h e n g o to s t e p 17.
4. C h e c k t h i s data in t h e D A T A L I S T w i t h t h e H D S . 8. R e p l a c e t h e throttle b o d y ( s e e p a g e 11-500).
• E C T S E N S O R 1 a b o v e 158 °F (70° C ) 9. R e s e t t h e E C M w i t h t h e H D S .
• I A T S E N S O R a b o v e 3 2 °F (0 °C)
• V S S is 0 m p h (0 k m / h ) 10. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
• S T F U E L T R I M b e t w e e n 0.69 a n d 1.47
• F S S is C L O S E D 11. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
5. M o n i t o r the O B D S T A T U S for D T C P 0 5 0 6 in t h e radiator f a n c o m e s o n , t h e n let it idle.
D T C s M E N U with t h e H D S .
12. C h e c k t h i s d a t a in t h e D A T A L I S T w i t h t h e H D S .
• E C T S E N S O R 1 a b o v e 158 °F (70 °C)
Y E S — G o to s t e p 6. • I A T S E N S O R a b o v e 3 2 °F (0 °C)
• V S S is 0 m p h (0 k m / h )
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , g o t o s t e p 15. • S T F U E L T R I M b e t w e e n 0.69 a n d 1.47
If t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling • F S S is C L O S E D
until a result c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T
O F C O N D I T I O N , g o to s t e p 4 a n d r e c h e c k . 13. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
6. R e m o v e t h e intake air d u c t f r o m t h e throttle b o d y . Is DTC P0506 indicated?
(cont'd)
11-451
Idle Control System
14. M o n i t o r the O B D S T A T U S for D T C P 0 5 0 6 in the 19. U p d a t e the E C M if it d o e s not h a v e the latest
D T C s M E N U with the H D S . s o f t w a r e ( s e e p a g e 11-216), or substitute a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
2 0 . Start t h e e n g i n e . Hold t h e e n g i n e s p e e d at
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r 3,000 r p m w i t h o u t l o a d (in neutral) until the
T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 13, radiator f a n c o m e s o n , t h e n let it idle.
2 1 . C h e c k the data in the D A T A L I S T with the H D S .
N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k t h e A / C
s y s t e m a n d / o r p o w e r s t e e r i n g s y s t e m , t h e n g o to • E C T S E N S O R 1 a b o v e 156 °F (70 °C)
s t e p 19. If the s c r e e n i n d i c a t e s E X E C U T I N G , k e e p • I A T S E N S O R a b o v e 3 2 °F (0 °C)
idling until a result c o m e s o n . If the s c r e e n • V S S is 0 m p h (0 k m / h )
i n d i c a t e s O U T O F C O N D I T I O N , g o to s t e p 12. • S T F U E L T R I M b e t w e e n 0.69 a n d 1.47
• F S S is C L O S E D
15. R e m o v e the intake a i r duct f r o m the throttle b o d y .
16. C h e c k for dirt, c a r b o n , or d a m a g e in t h e throttle
bore. Is DTC P0506 indicated?
Is there dirt, carbon, or damage in the throttle Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

bore? t e r m i n a l s at the throttle b o d y a n d the E C M . If the
Y E S — I f t h e r e is dirt or c a r b o n , c l e a n t h e throttle ( s e e p a g e 11-217), t h e n g o to s t e p 20. If t h e E C M
b o d y ( s e e p a g e 11-499). A l s o c h e c k for d a m a g e at w a s s u b s t i t u t e d , g o to s t e p 1.
the air c l e a n e r e l e m e n t ( s e e p a g e 11-505), t h e n g o
to s t e p 9. If t h e r e is d a m a g e in t h e throttle b o r e , g o N O — G o to s t e p 2 3 .
to s t e p 8.
N O — G o to s t e p 17. D T C s M E N U with the H D S .
17. R e c h e c k w i t h different load c o n d i t i o n s (turn o n the Does the screen indicate PASSED?
headlights, blower motor, rear w i n d o w defogger
a n d / o r A / C , c h a n g i n g the g e a r p o s i t i o n , etc.). Y E S — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
18. M o n i t o r t h e O B D S T A T U S for D T C P 0 5 0 6 in t h e original E C M ( s e e p a g e 11-389). If a n y other
D T C s M E N U w i t h the H D S . T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 2 2 ,
g o to the indicated D T C s t r o u b l e s h o o t i n g . *
N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k for poor
Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s c o n n e c t i o n s or l o o s e t e r m i n a l s at the throttle b o d y
time.B a n d t h e E C M . If t h e E C M w a s u p d a t e d , substitute a
N O — I f the s c r e e n i n d i c a t e s F A I L E D , c h e c k the A / C s t e p 20. If the E C M w a s s u b s t i t u t e d , g o to s t e p 1. If
s y s t e m a n d / o r p o w e r s t e e r i n g s y s t e m , t h e n g o to the s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling until
s t e p 1. If the s c r e e n i n d i c a t e s E X E C U T I N G , k e e p a result c o m e s o n . If the s c r e e n i n d i c a t e s O U T O F
idling until a r e s u l t c o m e s o n . If t h e s c r e e n C O N D I T I O N , g o to s t e p 20.
i n d i c a t e s O U T O F C O N D I T I O N , g o to s t e p 12.
11-452
DTC P0507: Idle Control System RPM Higher 6. T u r n the ignition s w i t c h O N (II).
Than Expected
and any on-board snapshot, and review the general 8. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
1. T u r n the ignition s w i t c h O N (II). 3,000 r p m w i t h o u t l o a d (in neutral) until the
2. C l e a r t h e D T C with the H D S .
10. C h e c k for T e m p o r a r y D T C s or D T C s with the H D S .
3,000 r p m w i t h o u t load (in neutral) until the Is DTC P0507 indicated?
4. Monitor the O B D S T A T U S for D T C P0507 in t h e
D T C s M E N U with the H D S . N O — G o to s t e p 11.
Does the screen indicate FAILED? 11. M o n i t o r t h e O B D S T A T U S for D T C P0507 in t h e

f a i l u r e , the s y s t e m is O K at t h i s t i m e . If the s c r e e n Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other
i n d i c a t e s E X E C U T I N G , k e e p idling until a result T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 10,
c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F g o t o the indicated D T C s troubleshooting. •
C O N D I T I O N , r e c h e c k w i t h different load c o n d i t i o n s
(turn o n the h e a d l i g h t s , b l o w e r m o t o r , or A / C ; N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , g o to s t e p 12. If
c h a n g e t h e g e a r p o s i t i o n , etc.), t h e n g o to s t e p 3. t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling until
a result c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
5. C h e c k for v a c u u m l e a k s at t h e s e parts: C O N D I T I O N , r e c h e c k with different load c o n d i t i o n s
(turn o n t h e h e a d l i g h t s , b l o w e r m o t o r , or A / C ;
• PCV valve c h a n g e t h e g e a r p o s i t i o n , etc.), t h e n g o to s t e p 9.
• PCV hose
• E V A P canister purge valve
Are there any leaks?
Y E S — R e p a i r or r e p l a c e faulty parts, t h e n g o to
s t e p 6.
(cont'd)
11-453
Idle Control System
g o o d E C M ( s e e p a g e 11-217).
t e r m i n a l s at t h e throttle b o d y a n d t h e E C M . If t h e
15. Monitor t h e O B D S T A T U S for D T C P 0 5 0 7 in t h e

c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e throttle b o d y
a n d t h e E C M . If t h e E C M w a s u p d a t e d , s u b s t i t u t e a
s t e p 13. If t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1. If
t h e s c r e e n i n d i c a t e s E X E C U T I N G , k e e p idling until
a result c o m e s o n . If the s c r e e n i n d i c a t e s O U T O F
11-454
A / C Signal Circuit Troubleshooting
1. S t a r t t h e e n g i n e , a n d let it idle. 9. M o m e n t a r i l y c o n n e c t u n d e r - h o o d f u s e / r e l a y b o x
16P c o n n e c t o r t e r m i n a l N o . 11 to b o d y g r o u n d w i t h
2. T u r n the b l o w e r s w i t c h o n . a jumper wire several times.
3. T u r n t h e A / C s w i t c h o n .
U N D E R - H O O D F U S E / R E L A Y B O X C O N N E C T O R (16P)
4. C h e c k t h e A / C C L U T C H in t h e D A T A L I S T w i t h t h e
HDS.
1 2 3
/ u
4
//
Does it indicate ON?
.7
/ 9 / 11 12
A C C (RED)
/ 16
Y E S - G o t o s t e p 5. JUMPER WIRE
N O — G o to t h e A / C p r e s s u r e s w i t c h circuit
5. C h e c k t h e A / C s y s t e m .
Does the A/C system operate? Is there clicking noise from the A/C compressor
clutch?
Y E S — T h e air c o n d i t i o n i n g s y s t e m circuit is OK.m
N O — G o to s t e p 6. (E18) a n d the A / C c l u t c h r e l a y . •
6. T u r n t h e ignition s w i t c h O F F . N O — U p d a t e the E C M if it d o e s not h a v e the latest

7. T u r n t h e ignition s w i t c h O N (II). g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e
8. A c t i v a t e the A / C C L U T C H in the I N S P E C T I O N E C M , r e p l a c e the original E C M ( s e e p a g e 11-389). •
M E N U with the H D S .
Is there a clicking noise from the A/C compressor

clutch?
Y E S — D o the A / C s y s t e m test ( s e e p a g e 21-77). •
11-455
Idle Control System
Alternator FR Signal Circuit Troubleshooting

1. S t a r t t h e e n g i n e , a n d let it idle. 8. T u r n the ignition s w i t c h O F F .
2. M o n i t o r the A L T E R N A T O R in t h e D A T A L I S T w i t h 9. J u m p the S C S line w i t h the H D S .

the H D S .
3. C h e c k if t h e i n d i c a t e d p e r c e n t a g e v a r i e s w h e n t h e
h e a d l i g h t s w i t c h is t u r n e d o n . 11. C o n n e c t alternator 4 P c o n n e c t o r t e r m i n a l N o . 4 to
Does the percentage vary?
ALTERNATOR 4P C O N N E C T O R
Y E S — T h e alternator s i g n a l c i r c u i t is OK.m
4. T u r n t h e h e a d l i g h t s w i t c h a n d ignition s w i t c h O F F . 1 2
ALTF (WHT/RED)
3 4
5. D i s c o n n e c t t h e alternator 4 P c o n n e c t o r . JUMPER WIRE
7. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r Wire side of f e m a l e t e r m i n a l s
ECM CONNECTORS
LG1 E C M connector terminal B13.
(BRN/YEL)
1 | 2 | 3 4 | 5 6 | 7 | 8 | 9
10
/ 13 14 15 16
/ / 18 20 21 E C M C O N N E C T O R B (24P)
23 24 25 26
/ / 28 30 31
ALTF (WHT/RED)
ALTF (WHT/RED) I — '•• '

B(24P) r
6 / \ 2 I 3 | 4 | 5 h /
8
/ 10 11
/ / 13
17 18 20 7
17 18 19 20 21
/

E C M connector terminal B13.
ALTF (WHT/RED)
I—
/ | 2 | 3 | 4 | 5
8
/ 10 11
/ / / 13
17 18 19
//
20 21
(B13) a n d t h e alternator. •
N O — U p d a t e the E C M if it d o e s not h a v e t h e latest

symptom/indication goes away with a known-good
Idle Control System
Electrical Power Steering (EPS) Signal Circuit Troubleshooting

1. S t a r t t h e e n g i n e , a n d let it idle. 11. C h e c k for continuity b e t w e e n E P S control unit 14P
2. A l i g n t h e s t e e r i n g w h e e l straight a h e a d .
E P S C O N T R O L U N I T 14P C O N N E C T O R
3. C h e c k the E P S S I G N A L in t h e D A T A L I S T w i t h t h e
HDS. 1 2 3
4 5 6 7
Does it indicate
LOW?
8
//
12 13 14
11
EPSLD (BLU/BLK)
4. T u r n t h e s t e e r i n g w h e e l q u i c k l y to the full lock

position.
5. C h e c k t h e E P S S I G N A L in the D A T A L I S T w i t h t h e
HDS. Is there continuity?
Does it change to HIGH? Y E S — S u b s t i t u t e a k n o w n - g o o d E P S control unit

(see p a g e 17-62), a n d r e c h e c k . •
Y E S — T h e E P S s i g n a l circuit i s O K . B
N O — R e p a i r o p e n in the w i r e b e t w e e n the E C M
N O — G o to s t e p 12. (E17) a n d t h e E P S control unit. •
9. D i s c o n n e c t t h e E P S control unit 14P c o n n e c t o r .
10. C o n n e c t E C M c o n n e c t o r t e r m i n a l E 1 6 to b o d y
1 | / | 3 | 4 | 5
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/
27 28 29 30
EPSLD (BLU/BLK)
/
JUMPER WIRE
11-458
13. D i s c o n n e c t the E P S c o n t r o l unit 14P c o n n e c t o r . 17. J u m p t h e S C S line w i t h t h e H D S .
14. T u r n t h e ignition s w i t c h O N (II). 18. D i s c o n n e c t E C M c o n n e c t o r E (31P).
15. M e a s u r e v o l t a g e b e t w e e n E C M c o n n e c t o r 19. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

terminals A9 and E16. terminal E 1 6 and body ground.
ECM CONNECTORS
LG1
(BRN/YEL)
1 2 3 4 | 5 6 | 7 8 | 9
1 / 3 | 4 [ 5 / I
10
/ 13 14 15 16
A / 18 20 21
/ 11 12 13 14 15 16 17 18 19 20 21
7 | 8 9
23 24 25 26
/ / 28 30 31
22
/ 24 25
/ 27 28 29 30
/
EPSLD (BLU/BLK)
EPSLD (BLU/BLK)
E(31P)
4 I 5
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/ W i r e s i d e of f e m a l e t e r m i n a l s
Y E S — S u b s t i t u t e a k n o w n - g o o d E P S control unit Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E C M
( s e e p a g e 17-62), a n d r e c h e c k . • (E16) a n d the E P S c o n t r o l u n i t . B
N O — G o to s t e p 16. N O — U p d a t e the E C M if it d o e s not h a v e the latest

symptom/indication goes a w a y with a known-good
11-459
Idle Control System
Brake Pedal Position Switch Signal Circuit Troubleshooting

t e r m i n a l E 2 2 a n d b r a k e p e d a l p o s i t i o n s w i t c h 4P
2. C h e c k t h e B R A K E S W I T C H in t h e D A T A L I S T w i t h c o n n e c t o r t e r m i n a l N o . 3.
the H D S .
Does it indicate OFF? 1 M 3 | 4 | 5 / \ 7 | 8 | 9
Y E S — G o to s t e p 3. / 11 12 13 14 15 16 17 18 19 20 21
N O — I n s p e c t the brake pedal position switch

22
/
BKSW
24 25
/ 2 7 28 29 30
/
(WHT/BLK)
(see page 22-144). •
BRAKE PEDAL POSITION
SWITCH 4P CONNECTOR
3. P r e s s t h e b r a k e p e d a l , a n d c h e c k t h e B R A K E
S W I T C H in t h e D A T A L I S T w i t h t h e H D S . BKSW ^
( W H T / B L K ) i-»
Does it change to ON ?
Y E S — T h e brake pedal position s w i t c h signal circuit
( B K S W line) is OK.M Is there continuity?
N O — G o to s t e p 4. Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the b r a k e
p e d a l p o s i t i o n s w i t c h a n d t h e N o . 47 S T O P (15 A )
4. T u r n t h e ignition s w i t c h O F F . f u s e . I n s p e c t the b r a k e p e d a l position s w i t c h
(see page 22-144). •
6. D i s c o n n e c t t h e b r a k e p e d a l p o s i t i o n s w i t c h 4 P (E22) a n d t h e b r a k e p e d a l p o s i t i o n s w i t c h . •
connector.
1 \/1 3 I
4 | 5 / \ I I« I »
7
/ 11 12 13 14 15 16 17 18 19 20 21
22
/
BKSW
24 25
/ 27 28 29 30
/
JWHT/BLK)
(E22) a n d t h e b r a k e p e d a l position s w i t c h . •
11-460
Idle Speed Inspection
NOTE: 5. S t a r t the e n g i n e . H o l d the e n g i n e s p e e d at
• B e f o r e c h e c k i n g t h e idle s p e e d , c h e c k t h e s e i t e m s : 3,000 r p m w i t h o u t l o a d (in neutral) until the
- T h e m a l f u n c t i o n indicator l a m p (MIL) h a s not b e e n radiator f a n c o m e s o n , t h e n let it idle.
reported o n .
- Ignition t i m i n g 6. C h e c k the idle s p e e d w i t h o u t load c o n d i t i o n s -
- Spark plugs h e a d l i g h t s , b l o w e r f a n , radiator f a n , a n d air
- A i r cleaner c o n d i t i o n e r off.
- PCV system
• A p p l y the parking b r a k e , a n d t h e m a k e s u r e t h e Idle s p e e d s h o u l d b e : 900±50rpm
h e a d l i g h t s a r e off.
7. L e t t h e e n g i n e idle for 1 m i n u t e w i t h h i g h electric
1. D i s c o n n e c t t h e e v a p o r a t i v e e m i s s i o n ( E V A P ) l o a d ( A / C s w i t c h O N , t e m p e r a t u r e s e t to m a x c o o l ,
canister purge valve connector. blower fan on high, rear w i n d o w defogger O N , and
headlights on high beam).
2. C o n n e c t the H D S to t h e data link c o n n e c t o r ( D L C )
(A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e of t h e front Idle s p e e d s h o u l d b e : 9 0 0 ± 5 0 rpm
console.
N O T E : If t h e idle s p e e d i s not w i t h i n s p e c i f i c a t i o n ,
d o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
If t h e idle is still out of s p e c i f i c a t i o n , g o to t h e
symptom troubleshooting.
8. R e c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e
connector.
it d o e s n ' t , g o to t h e D L C circuit t r o u b l e s h o o t i n g
( s e e p a g e 11-367).
11-461
Idle Control System
ECM Idle Learn Procedure
T h e idle l e a r n p r o c e d u r e m u s t b e d o n e s o t h e E C M c a n
l e a r n the e n g i n e idle c h a r a c t e r i s t i c s .
D o the idle l e a r n p r o c e d u r e w h e n e v e r y o u d o a n y of
these actions:
• Replace the E C M .
• Reset the E C M .
• U p d a t e the E C M .
• R e p l a c e o r c l e a n t h e throttle b o d y .
N O T E : E r a s i n g D T C s w i t h t h e H D S d o e s not r e q u i r e y o u
to d o the idle l e a r n p r o c e d u r e .
Procedure
1. M a k e s u r e all e l e c t r i c a l i t e m s ( A / C , a u d i o , r e a r
w i n d o w d e f o g g e r , lights, etc.) a r e off.
4. Start t h e e n g i n e . H o l d t h e e n g i n e s p e e d at
radiator f a n c o m e s o n , o r until t h e e n g i n e c o o l a n t
t e m p e r a t u r e r e a c h e s 194 °F (90 °C).
5. L e t t h e e n g i n e idle a b o u t 5 m i n u t e s w i t h t h e throttle
fully c l o s e d .
N O T E : If t h e radiator f a n c o m e s o n , d o not i n c l u d e
its r u n n i n g t i m e in t h e 5 m i n u t e s .
11-462
Fuel Supply System
FUELTANK
F U E L FEED LINE
F U E L T A N K UNIT
Includes:
F U E L RAIL FUEL PUMP
FUEL G A U G E SENDING UNIT
T e s t , p a g e 11-494
FUEL PRESSURE REGULATOR
FUEL FILTER
F U E L FILL C A P
FUEL LINE/
QUICK-CONNECT FITTING
Precautions, p a g e 11-480
R e m o v a l , p a g e 11-481
Installation, page 11-483
F U E L V A P O R LINE
FUEL LINE/
Q U I C K - C O N N E C T FITTING
P r e c a u t i o n s , p a g e 11-480
R e m o v a l , p a g e 11-481
PGM-FI MAIN R E L A Y 1 PGM-FI MAIN R E L A Y 2

(Fl M A I N ) (FUEL PUMP)
Updating, page 11-216
Substitution, p a g e 11-217
11-463
Fuel Supply System
DTC Troubleshooting
DTC P0461: Fuel Level Sensor (Fuel Gauge

Sending Unit) Circuit Range/Performance
Problem
NOTE:
any on-board snapshot, and review the general
• B e c a u s e it r e q u i r e s 162 m i l e s (260 km) of d r i v i n g
w i t h o u t refueling to c o m p l e t e t h i s d i a g n o s i s , D T C
P0461 c a n n o t b e d u p l i c a t e d d u r i n g t h i s
troubleshooting.
1. T e s t t h e fuel g a u g e s e n d i n g unit ( s e e p a g e 11-494).
Is the fuel gauge sending unit OK?
t e r m i n a l s at t h e fuel g a u g e s e n d i n g unit a n d t h e
gauge assembly. •
N O — R e p l a c e t h e fuel g a u g e s e n d i n g unit ( s e e p a g e
11 -488), t h e n g o to s t e p 2.
5 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S .
t e r m i n a l s at the fuel g a u g e s e n d i n g unit a n d t h e
g a u g e a s s e m b l y , t h e n g o to s t e p 1.
11-464
DTC P0462: Fuel Level Sensor (Fuel Gauge 11. T u r n t h e ignition s w i t c h O F F .
Sending Unit) Circuit Low Voltage
12. R e m o v e g a u g e a s s e m b l y ( s e e p a g e 22-89).
and any on-board snapshot, and review the general 13. D i s c o n n e c t g a u g e a s s e m b l y B 3 0 P c o n n e c t o r .
14. C h e c k for c o n t i n u i t y b e t w e e n fuel tank unit 5 P
1. T u r n t h e ignition s w i t c h O N (II). connector terminal No. 2 and body ground.
2. C l e a r t h e D T C w i t h the H D S , a n d w a i t 5 s e c o n d s . F U E L TANK UNIT 5P C O N N E C T O R
Is DTC P0462 Indicated? SIGNAL (YEL/BLK)
\ 4 | 5 / ©
at t h e g a u g e control m o d u l e a n d t h e fuel g a u g e
sending unit.• W i r e s i d e of f e m a l e t e r m i n a l s
5. R e m o v e t h e rear t r a y ( s e e p a g e 20-73).
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n g a u g e
6. R e m o v e t h e a c c e s s p a n e l f r o m t h e floor. a s s e m b l y ( s i g n a l line) a n d t h e fuel g a u g e s e n d i n g
unit, t h e n g o to s t e p 2 3 .
7. D i s c o n n e c t the fuel tank unit 5 P c o n n e c t o r .
15. R e c o n n e c t t h e g a u g e a s s e m b l y B 3 0 P c o n n e c t o r .
9. C l e a r t h e D T C w i t h t h e H D S , a n d w a i t 5 s e c o n d s .
10. C h e c k f o r T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
17. C o n n e c t t h e fuel tank unit 5 P c o n n e c t o r .
Y E S — R e p l a c e t h e fuel g a u g e s e n d i n g unit
( s e e p a g e 11-488), t h e n g o to s t e p 2 2 . 19. C l e a r t h e D T C w i t h the H D S .
(cont'd)
11-465
Fuel Supply System
2 0 . S e t t h e float (A) to t h e E p o s i t i o n . 2 8 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h the H D S .
t e r m i n a l s at t h e g a u g e a s s e m b l y a n d t h e fuel
g a u g e s e n d i n g unit, t h e n g o to s t e p 1.
2 9 . Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l .

g o o d E C M ( s e e p a g e 11-217).
2 1 . C h e c k t h e fuel g a u g e . Is DTC P0462 indicated?
Does the gauge move to the empty position? Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

Y E S — G o to s t e p 2 9 . g a u g e s e n d i n g unit, t h e n g o to s t e p 1. If the E C M
w a s u p d a t e d , substitute a k n o w n - g o o d E C M
N O — R e p l a c e the g a u g e a s s e m b l y (see page 22-89), ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e E C M w a s
t h e n g o to s t e p 2 2 . s u b s t i t u t e d , g o to s t e p 1.
2 2 . T u r n t h e ignition s w i t c h O F F . N O — I f the E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
2 3 . R e c o n n e c t all c o n n e c t o r s . original E C M ( s e e p a g e 11-389). If a n y other
24. Install t h e p a r t s in t h e r e v e r s e o r d e r of r e m o v a l . indicated D T C s troubleshooting. •
11-466
DTC P0463: Fuel Level Sensor (Fuel Gauge 9. R e m o v e the g a u g e a s s e m b l y ( s e e p a g e 22-89).
Sending Unit) Circuit High Voltage
10. D i s c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).
and a n y on-board s n a p s h o t , and r e v i e w the general 11. C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). c o n n e c t o r B (30P) t e r m i n a l N o . 2 a n d b o d y g r o u n d .
2. C l e a r t h e D T C w i t h the H D S , a n d w a i t 5 s e c o n d s .
/ 2 3 4 5
15 16 17 18 19 20 21
6 7
22 [XI23 24
8 9 10 11 12 13 14
25 26 27 28 29 30
Y E S - G o t o s t e p 4.
N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m i s O K at t h i s
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
at t h e g a u g e a s s e m b l y a n d the f u e l g a u g e s e n d i n g
unit.H
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e g a u g e
6. R e m o v e the a c c e s s p a n e l f r o m t h e floor. a s s e m b l y ( G N D line) a n d t h e fuel g a u g e s e n d i n g
7. D i s c o n n e c t the fuel tank unit 5 P c o n n e c t o r .
8. C o n n e c t fuel t a n k unit 5 P c o n n e c t o r t e r m i n a l N o . 1
F U E L T A N K UNIT 5P C O N N E C T O R
GND
(BLK)
JUMPER WIRE
W i r e s i d e of female t e r m i n a l s
(cont'd)
11-467
Fuel Supply System

12. C o n n e c t f u e l tank unit 5 P c o n n e c t o r t e r m i n a l N o . 2 14. R e m o v e t h e j u m p e r w i r e f r o m t h e fuel tank unit 5 P
to b o d y g r o u n d w i t h a j u m p e r w i r e . connector.
16. T e s t t h e f u e l g a u g e s e n d i n g unit ( s e e p a g e 11-494).
SIGNAL (YEL/BLK) Is the fuel gauge sending unit OK ?
1I2 ] / JUMPER WIRE Y E S — G o to s t e p 17.
N O — R e p l a c e the fuel g a u g e s e n d i n g unit ( s e e p a g e

11-488), t h e n g o to s t e p 2 3 .
W i r e s i d e of f e m a l e t e r m i n a l s 17. C o n n e c t t h e fuel tank unit 5 P c o n n e c t o r .
18. R e c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).
13. C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r B (30P) t e r m i n a l N o . TO a n d b o d y g r o u n d . 19. T u r n t h e ignition s w i t c h O N (II).
G A U G E A S S E M B L Y C O N N E C T O R B (30P) 20. C l e a r t h e D T C w i t h t h e H D S .
SIGNAL
(YEL/BLK)
/ 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22|X|23 24 25 26 27 28 29 30
IMO—Repair o p e n in t h e w i r e b e t w e e n t h e g a u g e
a s s e m b l y (signal line) a n d t h e fuel g a u g e s e n d i n g
11-468
2 1 . S e t t h e float (A) to t h e F p o s i t i o n . 2 9 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
g a u g e s e n d i n g unit, t h e n go to s t e p 1. If a n y other
indicated D T C s troubleshooting.
N O — T r o u b l e s h o o t i n g is c o m p l e t e . •
3 0 . Install t h e p a r t s in t h e r e v e r s e o r d e r of r e m o v a l .
g o o d E C M ( s e e p a g e 11-217).
2 2 . C h e c k the fuel g a u g e . Is DTC P0463 indicated?
Does the gauge move to the full position? Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

Y E S — G o to s t e p 30. g a u g e s e n d i n g unit. If t h e E C M w a s u p d a t e d ,
N O — R e p l a c e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89), t h e n r e c h e c k . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p
t h e n g o to s t e p 2 3 . 1.
2 3 . T u r n the ignition s w i t c h O F F . N O — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
24. R e c o n n e c t all c o n n e c t o r s . original E C M ( s e e p a g e 11-389). If a n y other
2 5 . Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l . indicated D T C s troubleshooting. •
2 7 . R e s e t the E C M w i t h the H D S .
11-469
Fuel Supply System
Fuel Pump Circuit Troubleshooting

If y o u s u s p e c t a p r o b l e m w i t h t h e fuel p u m p , c h e c k t h a t 4. M e a s u r e v o l t a g e b e t w e e n P G M - F I m a i n r e l a y 2
t h e fuel p u m p a c t u a l l y r u n s ; w h e n it is o n , y o u will h e a r ( F U E L P U M P ) 4P connector terminal No. 4 and
s o m e n o i s e if y o u listen to the fuel fill port w i t h t h e f u e l body ground.
fill c a p r e m o v e d . T h e fuel p u m p s h o u l d run for
2 s e c o n d s w h e n t h e ignition s w i t c h is first t u r n e d o n . If PGM-FI MAIN R E L A Y 2
t h e fuel p u m p d o e s not m a k e n o i s e , c h e c k a s f o l l o w s : (FUEL PUMP) 4P C O N N E C T O R
1. T u r n the ignition s w i t c h O F F . IGP1

(YEL/BLK)
2. R e m o v e P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) (A).
r e l a y 1 (Fl M A I N ) a n d P G M - F I m a i n r e l a y 2 ( F U E L
PUMP).
5. M e a s u r e v o l t a g e b e t w e e n P G M - F I m a i n r e l a y 2
( F U E L P U M P ) 4P connector terminal No. 1 and
body ground.
PGM-FI MAIN R E L A Y 2
(FUEL PUMP) 4P C O N N E C T O R
NO-
• R e p l a c e t h e N o . 2 F U E L P U M P S R S (15 A ) f u s e in
the u n d e r - d a s h f u s e / r e l a y b o x . H
• If n e e d e d , r e p l a c e t h e u n d e r - d a s h f u s e / r e l a y
box.H
11-470
6. T u r n t h e ignition s w i t c h O F F . 12. R e i n s t a l l P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) .
7. C o n n e c t P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) 4 P 13. C o n n e c t E C M c o n n e c t o r t e r m i n a l E 7 to b o d y
c o n n e c t o r t e r m i n a l N o . 3 to b o d y g r o u n d w i t h a ground with a jumper wire.
jumper wire.
PGM-FI MAIN R E L A Y 2 E C M C O N N E C T O R E (31P)

JUMPER WIRE
1 l / | 3 | 4 | 5 / I T 8|s I
/ 11 12 13 14 15 16 17 18 19 20 21
24 2 7 2 8 2 9 30
22
/ 25
/ /
9. J u m p t h e S C S line w i t h the H D S . E17 and body ground.
11. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d I I

E C M connector terminal E17, 1 / 3 4 | 5 / | 7 8. J 9
11 12 13 14 15 16 17 18 19 20 21
/22 24 2 7 28 2 9 3 0
/ 25
/ IMOFPR /
. (GRN/YEL)
1 | / | 3 | 4 | 5 /\ 7
1 8 | 9
/
22
11 12 13 14 15 16 17 18 19 20 21
2 7 2 8 2 9 30
/ 24 25
/ IMOFPR / W i r e s i d e of f e m a l e t e r m i n a l s
(GRN/YEL)
N O - R e p l a c e PGM-FI m a i n relay 2 ( F U E L P U M P ) .
N O — R e p a i r o p e n in the w i r e b e t w e e n P G M - F I m a i n
r e l a y 2 ( F U E L P U M P ) a n d the E C M ( E 1 7 ) . B
(cont'd)
11-471
Fuel Supply System
Fuel Pump Circuit Troubleshooting (cont'd)
16. T u r n t h e ignition s w i t c h O F F . 2 1 . T u r n t h e ignition s w i t c h O F F .
17. R e c o n n e c t E C M c o n n e c t o r E (31P), a n d d i s c o n n e c t 2 2 . R e m o v e the rear t r a y ( s e e p a g e 20-73).

the j u m p e r w i r e .
2 3 . R e m o v e t h e a c c e s s p a n e l f r o m t h e floor ( s e e p a g e
18. O p e n t h e S C S line w i t h t h e H D S . 11-487).
19. T u r n t h e ignition s w i t c h O F F . 24. T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e

v o l t a g e b e t w e e n fuel tank unit 5 P c o n n e c t o r
20. T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e terminal No. 5 and body ground within 2 s e c o n d s .
voltage between E C M connector terminal E17 and
body ground within 2 s e c o n d s .
FUEL PUMP
/
1 /' 3 4 I 5 / \ 7 8 | 9
11 12 13 14 15 16 17 18 19 20 21 VH7 (YEL/GRN)
22
/ 24 25
/ 2 7 28 29 30
IMOFPR /
JGRN/YEL)
Is there battery voltage? Y E S — G o to s t e p 2 9 .
Y E S — U p d a t e t h e E C M if it d o e s not h a v e t h e latest N O — G o to s t e p 2 5 .
g o o d E C M ( s e e p a g e 11-217), t h e n r e c h e c k . If t h e 2 5 . T u r n t h e ignition s w i t c h O F F .
E C M , r e p l a c e t h e original E C M ( s e e p a g e 11-389), 26. R e m o v e P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) .
N O — G o to s t e p 2 1 .
11-472
27. C o n n e c t PGM-FI main relay 2 ( F U E L P U M P ) 4P 3 0 . C h e c k for c o n t i n u i t y b e t w e e n fuel tank unit 5 P
c o n n e c t o r t e r m i n a l s No. 1 a n d N o . 2 w i t h a j u m p e r connector terminal No. 4 a n d body ground.
wire.
FUEL TANK UNIT CONNECTOR

FUEL
GND
(BLK)
1 2 /
PUMP
JUMPER
WIRE
V 5/
IG1
2 8 . T u r n t h e ignition s w i t c h O N (II), a n d m e a s u r e
v o l t a g e b e t w e e n f u e l tank unit 5 P c o n n e c t o r Y E S — R e p l a c e t h e fuel p u m p . B
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e fuel tank
unit 5 P c o n n e c t o r a n d G 6 0 1 . •
F U E L TANK UNIT 5P C O N N E C T O R
1 2 / FUEL PUMP
(YEL/GRN)
V 5/
Y E S - R e p l a c e PGM-FI main relay 2 ( F U E L

PUMP).B
r e l a y 2 ( F U E L P U M P ) a n d t h e fuel tank unit 5 P
connector. •
11-473
Fuel Supply System
Fuel Pressure Relieving
B e f o r e d i s c o n n e c t i n g fuel l i n e s or h o s e s , r e l i e v e 7. R e m o v e t h e fuel fill c a p to r e l i e v e t h e p r e s s u r e in

p r e s s u r e f r o m t h e s y s t e m b y d i s a b l i n g t h e fuel p u m p t h e fuel tank.
a n d t h e n d i s c o n n e c t i n g t h e fuel t u b e / q u i c k - c o n n e c t
fitting in t h e e n g i n e c o m p a r t m e n t 8. T u r n t h e ignition s w i t c h O N (II).
With the HDS 9. F r o m t h e I N S P E C T I O N M E N U of t h e H D S , s e l e c t

F u e l P u m p O F F , t h e n start t h e e n g i n e , a n d let it idle
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e until it s t a l l s .
NOTE:
2 . T u r n t h e ignition s w i t c h O F F . • Do not a l l o w t h e e n g i n e to idle a b o v e 1,000 r p m
or t h e E C M will c o n t i n u e to o p e r a t e the fuel
3. C o n n e c t t h e H D S to t h e d a t a link c o n n e c t o r ( D L C ) pump.
(A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e of t h e front • A D T C or a T e m p o r a r y D T C m a y be s e t d u r i n g
console. t h i s p r o c e d u r e . C h e c k for D T C s , a n d c l e a r t h e m
a s n e e d e d ( s e e p a g e 11-214).
12. R e m o v e t h e q u i c k - c o n n e c t fitting c o v e r (A).
it d o e s n ' t , g o to t h e D L C c i r c u i t t r o u b l e s h o o t i n g
( s e e p a g e 11-367).
11-474
13. C h e c k the fuel q u i c k - c o n n e c t fitting for dirt, a n d 16. A f t e r d i s c o n n e c t i n g t h e q u i c k - c o n n e c t fitting, c h e c k
c l e a n it if n e e d e d . it f o r dirt or d a m a g e ( s e e s t e p 4 o n p a g e 11-482).
14. P l a c e a rag or s h o p t o w e l o v e r t h e q u i c k - c o n n e c t 17. R e c o n n e c t the n e g a t i v e c a b l e to t h e battery.

fitting (A).
Without the HDS
2. R e m o v e P G M - F I m a i n r e l a y 2 ( F U E L P U M P ) (A).
15. D i s c o n n e c t the q u i c k - c o n n e c t fitting (A): Hold the

c o n n e c t o r (B) w i t h o n e h a n d , a n d s q u e e z e the
retainer t a b s (C) w i t h the other h a n d to r e l e a s e
t h e m f r o m the locking t a b s (D). Pull the c o n n e c t o r
off.
NOTE:
• B e c a r e f u l not to d a m a g e the line (E) or other
parts.
• Do not u s e t o o l s . 3 . S t a r t t h e e n g i n e , a n d let it idle until it s t a l l s .
• If the c o n n e c t o r d o e s not m o v e , k e e p the retainer
t a b s p r e s s e d d o w n , a n d alternately pull a n d p u s h N O T E : If a n y D T C s a r e s t o r e d , c l e a r a n d ignore
the c o n n e c t o r until it c o m e s off e a s i l y . them.
• D o not r e m o v e the retainer f r o m t h e line; o n c e
r e m o v e d , t h e retainer m u s t be r e p l a c e d w i t h a
new one.
(cont'd)
11-475
Fuel Supply System
Fuel Pressure Relieving (cont'd)
4. T u r n t h e ignition s w i t c h O F F . 10. D i s c o n n e c t the q u i c k - c o n n e c t fitting (A): Hold the

c o n n e c t o r (B) w i t h o n e h a n d , a n d s q u e e z e the
5. R e m o v e the fuel fill c a p . retainer t a b s (C) w i t h the o t h e r h a n d to r e l e a s e
t h e m f r o m the locking t a b s (D). Pull the c o n n e c t o r
6. D i s c o n n e c t the n e g a t i v e c a b l e f r o m t h e battery. off.
7. R e m o v e t h e q u i c k - c o n n e c t fitting c o v e r (A). NOTE:

• B e c a r e f u l not to d a m a g e t h e line (E) or other
parts.
• Do not u s e t o o l s .
• If the c o n n e c t o r d o e s not m o v e , k e e p t h e retainer
t a b s p r e s s e d d o w n , a n d alternately pull a n d p u s h
the c o n n e c t o r until it c o m e s off e a s i l y .
• Do not r e m o v e the retainer f r o m the line; o n c e
r e m o v e d , the retainer m u s t be r e p l a c e d w i t h a
new one.
11. After d i s c o n n e c t i n g t h e q u i c k - c o n n e c t fitting, c h e c k

it for dirt or d a m a g e ( s e e s t e p 4 o n p a g e 11-482).
12. R e c o n n e c t the n e g a t i v e c a b l e to the battery.
13. E n t e r the anti-theft c o d e for t h e a u d i o s y s t e m , t h e n

enter t h e a u d i o p r e s e t s . S e t t h e clock.
11-476
Fuel Pressure Test Fuel Tank Draining
Special Tools Required 1. R e m o v e t h e fuel tank unit ( s e e p a g e 11-487).

• F u e l pressure gauge 07406-004000B
• Fuel pressure gauge attachment set 0 7 A A J - S 6 M A 1 5 0 2. U s i n g a h a n d p u m p , a h o s e , a n d a c o n t a i n e r
s u i t a b l e for f u e l , d r a w t h e fuel f r o m t h e fuel tank.
3. Install t h e fuel tank unit ( s e e p a g e 11-487).
2. D i s c o n n e c t the q u i c k - c o n n e c t fitting. A t t a c h t h e f u e l
p r e s s u r e g a u g e s e t a n d the f u e l p r e s s u r e g a u g e .
• If the e n g i n e s t a r t s , g o to s t e p 5.
• If the e n g i n e d o e s not start, g o to s t e p 4.
4. C h e c k to s e e if the fuel p u m p is r u n n i n g : listen to

t h e fuel filler port w i t h t h e fuel fill c a p r e m o v e d .
T h e fuel p u m p s h o u l d run for 2 s e c o n d s w h e n t h e
ignition s w i t c h is first t u r n e d o n .
• If the p u m p r u n s , g o to s t e p 5.
• If the p u m p d o e s not r u n , d o t h e fuel p u m p circuit
t r o u b l e s h o o t i n g ( s e e p a g e 11-470).
5. R e a d the fuel p r e s s u r e g a u g e . T h e p r e s s u r e s h o u l d
2
be 3 8 0 - 4 3 0 kPa ( 3 . 9 - 4 . 4 k g f / c m , 5 5 - 6 3 p s i ) .
• If the p r e s s u r e is O K , the t e s t is c o m p l e t e .
• If the p r e s s u r e is out of s p e c i f i c a t i o n , r e p l a c e t h e
fuel p r e s s u r e regulator ( s e e p a g e 11-486) a n d t h e
fuel filter ( s e e p a g e 11-486), t h e n r e c h e c k t h e f u e l
pressure.
11-477
Fuel Supply System
Fuel Line Inspection
C h e c k the fuel s y s t e m l i n e s a n d h o s e s for d a m a g e , l e a k s , a n d d e t e r i o r a t i o n . R e p l a c e a n y d a m a g e d parts.
Make sure the connections are

s e c u r e and the quick-connect
fitting c o v e r s a r e f i r m l y l o c k e d in p l a c e .
11-478
C h e c k all c l a m p s , a n d r e t i g h t e n a n y if n e c e s s a r y .
M a k e s u r e that the i
c l a m p is in position
as shown.
c l a m p is in position
as shown.
11-479
Fuel Supply System
Fuel Line/Quick-Connect Fitting Precautions
T h e fuel t u b e / q u i c k - c o n n e c t fittings (A), ( B ) , ( C ) , (D), (E)
c o n n e c t t h e fuel rail (F) to fuel f e e d h o s e ( G ) , the f u e l
f e e d h o s e to t h e fuel line (H), t h e fuel line (I) to t h e f u e l
f e e d h o s e ( J ) , t h e fuel f e e d h o s e (K) to the fuel tank unit
(L), a n d fuel v a p o r line (M) to t h e E V A P c a n i s t e r (N).
W h e n removing or installing the fuel feed h o s e , the fuel
t a n k unit o r t h e f u e l tank, it is n e c e s s a r y to d i s c o n n e c t
o r c o n n e c t t h e q u i c k - c o n n e c t fittings.
P a y attention to t h e f o l l o w i n g :
• T h e fuel f e e d h o s e , fuel line a n d q u i c k - c o n n e c t fittings

a r e not h e a t - r e s i s t a n t ; b e c a r e f u l not to d a m a g e t h e m
during w e l d i n g or other heat-generating p r o c e d u r e s .
• T h e fuel f e e d h o s e , f u e l line a n d q u i c k - c o n n e c t fittings
a r e not a c i d - p r o o f ; d o not t o u c h t h e m w i t h a s h o p
t o w e l w h i c h w a s u s e d for w i p i n g battery e l e c t r o l y t e .
R e p l a c e t h e m if t h e y c a m e into c o n t a c t w i t h
electrolyte o r s o m e t h i n g s i m i l a r .
• W h e n c o n n e c t i n g o r d i s c o n n e c t i n g t h e fuel f e e d h o s e ,
fuel line a n d q u i c k - c o n n e c t fittings, b e c a r e f u l not to
b e n d or t w i s t t h e m e x c e s s i v e l y . R e p l a c e t h e m if
damaged.
A d i s c o n n e c t e d q u i c k - c o n n e c t fitting c a n b e
r e c o n n e c t e d , but t h e retainer o n t h e m a t i n g line c a n n o t
be r e u s e d o n c e it h a s b e e n r e m o v e d f r o m t h e pipe.
R e p l a c e t h e retainer w h e n :
• r e p l a c i n g t h e fuel rail.
• r e p l a c i n g t h e fuel line.
• r e p l a c i n g t h e fuel p u m p .
• r e p l a c i n g t h e fuel filter.
• replacing the E V A P canister.
• it h a s b e e n r e m o v e d f r o m t h e line.
• it is d a m a g e d .
Retainer Manufacturer Retainer Line

location Color diameter
A Tokai Blue green 0.3 i n .
(8.0 m m )
B Tokai Blue green 0.3 in.
(8.0 m m )
C Sanoh White 0.3 in.
(8.0 m m )
D Sanoh White 0.4 in.
(9.5 m m )
E Sanoh White 0.4 in.
(9.5 m m )
11-480
Fuel Line/Quick-Connect Fitting Removal
(cont'd)
11-481
Fuel Supply System
Fuel Line/Quick-Connect Fitting Removal (cont'd)
H o l d the c o n n e c t o r (A) w i t h o n e h a n d a n d s q u e e z e T o p r e v e n t d a m a g e a n d k e e p f o r e i g n m a t t e r out,
t h e retainer t a b s (B) w i t h t h e o t h e r h a n d to r e l e a s e c o v e r t h e d i s c o n n e c t e d c o n n e c t o r a n d line e n d w i t h
t h e m f r o m t h e l o c k i n g p a w l s ( C ) . Pull t h e c o n n e c t o r p l a s t i c b a g s (A).
off.
N O T E : T h e retainer c a n n o t be r e u s e d o n c e it h a s
NOTE: b e e n r e m o v e d f r o m the line.
• B e c a r e f u l not to d a m a g e t h e line (D) or o t h e r R e p l a c e t h e retainer w h e n :
p a r t s . D o not u s e t o o l s . • r e p l a c i n g the fuel rail.
• If the c o n n e c t o r d o e s not m o v e , k e e p t h e retainer • r e p l a c i n g the fuel f e e d line.
t a b s p r e s s e d d o w n , a n d alternately pull a n d p u s h • r e p l a c i n g the fuel p u m p .
t h e c o n n e c t o r until it c o m e s off e a s i l y . • r e p l a c i n g the fuel filter.
• D o not r e m o v e t h e retainer f r o m t h e line; o n c e • r e p l a c i n g the E V A P c a n i s t e r
r e m o v e d , the retainer m u s t b e r e p l a c e d w i t h a • it h a s b e e n r e m o v e d f r o m the line.
new one. • it is d a m a g e d .
C h e c k the c o n t a c t a r e a (A) of t h e line (B) for dirt a n d

damage.
• If it i s dirty, c l e a n it.
• If it is rusty or d a m a g e d , r e p l a c e the fuel p u m p ,
fuel filter, o r fuel f e e d line.
11-482
Fuel Line/Quick-Connect Fitting Installation
N O T E : B e f o r e y o u w o r k o n the fuel l i n e s a n d fittings, 3. B e f o r e c o n n e c t i n g a n e w fuel t u b e / q u i c k - c o n n e c t

r e a d t h e " F u e l L i n e / Q u i c k - C o n n e c t Fitting P r e c a u t i o n s " fitting a s s e m b l y (A), r e m o v e the o l d r e t a i n e r f r o m
( s e e p a g e 11-480). t h e m a t i n g line.
1. C h e c k t h e c o n t a c t a r e a (A) of t h e line (B) for dirt a n d

d a m a g e , a n d c l e a n if n e c e s s a r y .
Insert a n e w retainer (A) into the c o n n e c t o r (B) if t h e

retainer is d a m a g e d , or after:
• replacing the fuel rail.

• replacing the fuel f e e d line.
• replacing the fuel p u m p .
• replacing the fuel filter.
• replacing the E V A P canister
• r e m o v i n g the retainer f r o m t h e line.
(cont'd)
11-483
Fuel Supply System
Fuel Line/Quick-Connect Fitting Installation (cont'd)
C o n n e c t i o n t o n e w fuel f e e d line
4 . A l i g n the q u i c k - c o n n e c t fittings.with t h e line (A), Reconnection to existing retainer

a n d a l i g n t h e r e t a i n e r locking t a b s (B) w i t h t h e
connector g r o o v e s (C). T h e n p r e s s the quick-
c o n n e c t fittings o n t o t h e line until both r e t a i n e r t a b s
lock w i t h a c l i c k i n g s o u n d .
N O T E : If it i s h a r d to c o n n e c t , put a s m a l l a m o u n t of
n e w e n g i n e oil o n t h e line e n d .
Connection w i t h n e w retainer
11-484
Fuel Pulsation Damper
Replacement
5. W h e n y o u r e c o n n e c t the c o n n e c t o r (A) with t h e old
retainer, m a k e s u r e t h e c o n n e c t i o n is s e c u r e a n d
t h e t a b s (B) a r e f i r m l y locked into p l a c e ; c h e c k 1. R e m o v e t h e fuel rail ( s e e p a g e 11-382).
v i s u a l l y a n d a l s o b y pulling the c o n n e c t o r .
W h e n y o u r e p l a c e t h e fuel line with a n e w o n e , 2. R e m o v e t h e fuel p u l s a t i o n d a m p e r (A) f r o m t h e fuel
m a k e s u r e y o u r e m o v e the ring pull (C) u p w a r d s rail (B).
after y o u c o n f i r m t h e c o n n e c t i o n is s e c u r e .
N O T E : B e f o r e y o u r e m o v e t h e ring pull, m a k e s u r e
t h e fuel line c o n n e c t i o n is s e c u r e . If the c o n n e c t i o n
is not s e c u r e , the ring pull c o u l d b r e a k w h e n y o u try
to r e m o v e it.
3. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w w a s h e r (C),
C o n n e c t i o n t o n e w f u e l f e e d line
6. R e c o n n e c t t h e negative c a b l e to the battery, a n d

turn t h e ignition s w i t c h O N (II) (but d o not o p e r a t e
the starter motor). T h e fuel p u m p will run for a b o u t
2 s e c o n d s , a n d fuel p r e s s u r e w i l l rise. R e p e a t t w o
or t h r e e t i m e s , a n d c h e c k for l e a k a g e in t h e fuel
supply system.
11-485
Fuel Supply System
Fuel Pressure Regulator Fuel Filter Replacement
Replacement
T h e fuel filter s h o u l d be r e p l a c e d w h e n e v e r the fuel
p r e s s u r e d r o p s b e l o w the s p e c i f i e d v a l u e ( s e e p a g e
1. R e m o v e the fuel t a n k unit ( s e e p a g e 11-487). 11-477), after m a k i n g s u r e that t h e fuel p u m p a n d the
f u e l p r e s s u r e regulator a r e O K .
2 . R e m o v e t h e c l i p s (A).
2. R e m o v e t h e f u e l filter (A).
3. R e m o v e t h e h o l d e r (B).
4. R e m o v e the fuel p r e s s u r e r e g u l a t o r ( C ) .
5. Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w O - r i n g (D) a n d n e w c l i p s .
N O T E : C o a t the O-ring with c l e a n engine oil.
3. C h e c k t h e s e i t e m s before i n s t a l l i n g t h e fuel tank

unit:
• W h e n c o n n e c t i n g the w i r e h a r n e s s , m a k e s u r e
t h e c o n n e c t i o n is s e c u r e a n d t h e c o n n e c t o r s (B)
a r e f i r m l y l o c k e d into p l a c e .
• W h e n i n s t a l l i n g t h e fuel g a u g e s e n d i n g unit ( C ) ,
m a k e s u r e t h e c o n n e c t i o n is s e c u r e a n d the
not to b e n d o r t w i s t it e x c e s s i v e l y .
4. Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w O - r i n g s (D), n e w b r a c k e t ( E ) , n e w s p a c e r
(F), n e w g r o m m e t ( G ) , a n d n e w c l i p s (H). T h e n
installing the fuel tank unit ( s e e p a g e 11-487).
5. Install the fuel tank unit ( s e e p a g e 11-487).
11-486
Fuel Tank Unit Removal and Installation
Removal Installation
1. R e l i e v e the fuel p r e s s u r e ( s e e p a g e 11-474). 1. A t t a c h a n e w b a s e g a s k e t (A) a n d n e w plate (B) to

t h e fuel t a n k unit, t h e n install t h e fuel t a n k unit into
2. R e m o v e the fuel fill c a p . t h e fuel tank.
3. R e m o v e the rear t r a y ( s e e p a g e 20-73). NOTE:

• B e c a r e f u l not to d a m a g e t h e n e w b a s e g a s k e t .
4. R e m o v e t h e left trunk s i d e t r i m p a n e l ( s e e p a g e • B e c a r e f u l not to b e n d t h e f u e l g a u g e s e n d i n g
20-77). unit.
• D o not c o a t t h e b a s e g a s k e t w i t h oil.
5. R e m o v e the a c c e s s p a n e l (A) f r o m t h e floor.
9.8 N-m
(1.0 k g f m , 7 . 2 I b f f t )
UPPER
SIDE
6. D i s c o n n e c t t h e tank fuel unit 5 P c o n n e c t o r (B).
7. D i s c o n n e c t t h e q u i c k - c o n n e c t fitting (C) f r o m the

fuel tank unit.
8. R e m o v e t h e fuel t a n k unit (A).
(cont'd)
11-487
Fuel Supply System
Fuel Tank Unit Removal and Fuel Pump/Fuel Gauge Sending
Installation (cont'd) Unit Replacement
2 . C o n n e c t t h e q u i c k - c o n n e c t fitting (A) f r o m t h e fuel 1. R e m o v e t h e fuel tank unit ( s e e p a g e 11-487).

tank unit.
2. R e m o v e t h e fuel filter (A), t h e fuel g a u g e s e n d i n g
unit ( B ) , a n d t h e w i r e h a r n e s s (C).
A- \ - ^ / • / /
3. C o n n e c t t h e fuel t a n k unit 5 P c o n n e c t o r (B).
4. R e c o n n e c t the n e g a t i v e c a b l e to t h e battery, a n d
turn t h e ignition s w i t c h O N (II) (but d o not o p e r a t e
the starter m o t o r ) . T h e f u e l p u m p will r u n for a b o u t
2 s e c o n d s , a n d fuel p r e s s u r e w i l l rise. R e p e a t t h i s
t w o o r t h r e e t i m e s , t h e n c h e c k that t h e r e i s n o
l e a k a g e in t h e f u e l s u p p l y s y s t e m . Install t h e p a r t s in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w O - r i n g (D), n e w b r a c k e t ( E ) , n e w s p a c e r
5. Install the a c c e s s p a n e l ( C ) . (F), n e w g r o m m e t ( G ) , a n d n e w c l i p s (H), t h e n c h e c k
these items:
6. Install t h e left trunk s i d e t r i m p a n e l ( s e e p a g e 20-77).
• M a k e s u r e t h e c o n n e c t i o n is s e c u r e a n d t h e
7. R e m o v e t h e r e a r t r a y ( s e e p a g e 20-73). s u c t i o n filter (I) is f i r m l y c o n n e c t e d to t h e fuel
p u m p (J).
8. Install t h e fuel fill c a p . • W h e n connecting the wire harness, make sure
the c o n n e c t i o n is s e c u r e a n d t h e c o n n e c t o r s (K)
a r e f i r m l y l o c k e d into p l a c e .
• W h e n installing t h e fuel g a u g e s e n d i n g unit,
m a k e s u r e t h e c o n n e c t i o n i s s e c u r e a n d the
11-488
Fuel Tank Replacement
Removal 8. D i s c o n n e c t both A B S r e a r w h e e l s p e e d s e n s o r s 2 P
c o n n e c t o r s (A), a n d p u s h t h e c o n n e c t o r s out.
2. R e l i e v e the f u e l p r e s s u r e ( s e e p a g e 11-474).
4. R e m o v e t h e left trunk s i d e t r i m p a n e l ( s e e p a g e
20-77).
5. D r a i n t h e fuel tank ( s e e p a g e 11-477).
6. R e m o v e t h e b r a k e fluid f r o m t h e m a s t e r c y l i n d e r
reservoir with a syringe.
N O T E : Do not spill b r a k e fluid o n t h e v e h i c l e ; it m a y

d a m a g e t h e paint; if b r a k e fluid d o e s c o n t a c t the
paint, w a s h it off i m m e d i a t e l y w i t h w a t e r .
7. R e m o v e the a c c e s s p a n e l (A) f r o m t h e floor, a n d

d i s c o n n e c t t h e fuel t a n k unit 5 P c o n n e c t o r (B).
10. L o o s e n t h e rear w h e e l n u t s slightly, t h e n r a i s e the

v e h i c l e a n d m a k e s u r e it i s s e c u r e l y s u p p o r t e d .
(cont'd)
11-489
Fuel Supply System
12. R e m o v e t h e bolts f r o m both A B S r e a r w h e e l s p e e d 14. D i s c o n n e c t both p a r k i n g b r a k e c a b l e s (A), a n d
s e n s o r h a r n e s s b r a c k e t s (A). m o v e t h e m out of the w a y .
6x1.0 mm
9.8 N-m (1.0 k g f m , 7.2 Ibf-ft)
1 3 . R e m o v e both c a l i p e r s h i e l d s (A).
6x1.0 mm
9.8 N m (1.0 k g f - m , 7.2 Ibf-ft)
15. D i s c o n n e c t t h e b r a k e h o s e s f r o m both rear brake

lines u s i n g a 10 m m flare-nut w r e n c h .
11-490
16. R e m o v e t h e f l a n g e bolt (A) f r o m both r e a r d a m p e r s 19. R e m o v e t h e muffler (A).
(B).
10 x 1.25 m m
33 N-m
(3.4 k g f - m , 2 5 I b f f t )
2 0 . D i s c o n n e c t t h e F T P s e n s o r 3 P c o n n e c t o r (A), t h e
E V A P canister vent shut valve 2 P connector (B), and
t h e v a p o r line (C).
17. R e m o v e t h e c a n i s t e r c o v e r (A) a n d the r e a r

s u s p e n s i o n stiffener (B).
(1.0 k g f - m , 7.2 I b f f t )
18. R e m o v e t h e p r o p e l l e r shaft ( s e e p a g e 16-18). (1.0 k g f - m , 7.2 I b f f t )
2 1 . R e m o v e the E V A P c a n i s t e r (D).
(cont'd)
11-491
Fuel Supply System
2 2 . D i s c o n n e c t the q u i c k - c o n n e c t fitting (A) ( s e e p a g e 24. P l a c e t h e j a c k or s u p p o r t u n d e r t h e fuel tank (A),
11-481). t h e n r e m o v e the m o u n t i n g bolts (B) a n d the fuel
tank.
2 3 . P l a c e a j a c k or o t h e r s u p p o r t u n d e r t h e r e a r 8 x 1.25 m m
45 N-m
s u s p e n s i o n s u b f r a m e (A). R e m o v e t h e m o u n t i n g
(4.6 k g f - m , 3 3 Ibf-ft)
bolts (B) a n d the r e a r s u s p e n s i o n s u b f r a m e (A).
B
1 4 x 1.5 m m
103 N m
(10.5 k g f - m , 7 6 Ibf-ft)
1 2 x 1.5 m m
5 9 N m (6.0 k g f - m , 4 3 I b f - f t )
11-492
Installation
2. After installing t h e fuel tank, b l e e d t h e b r a k e

s y s t e m ( s e e p a g e 19-9), a n d a d j u s t t h e w h e e l
a l i g n m e n t ( s e e p a g e 18-7).
3. T u r n t h e ignition s w i t c h O N (II), but d o not o p e r a t e

t h e starter. After t h e fuel p u m p r u n s 2 s e c o n d s , the
fuel p r e s s u r e in the fuel line r i s e s . R e p e a t t h i s 2 or
3 t i m e s , t h e n c h e c k for fuel l e a k a g e .
Fuel Supply System
Fuel Gauge Sending Unit Test
N O T E : F o r t h e fuel g a u g e s y s t e m c i r c u i t d i a g r a m , refer 7. M e a s u r e v o l t a g e b e t w e e n fuel tank unit 5 P
to t h e G a u g e s C i r c u i t D i a g r a m ( s e e p a g e 2 2 - 6 3 ) . connector terminals No. 1 a n d No. 2 with the
ignition s w i t c h O N (II). T h e r e s h o u l d be battery
1. C h e c k t h e N o . 5 I N S T R U M E N T L I G H T B A C K U P voltage.
L I G H T (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x
before testing. • If t h e v o l t a g e i s O K , g o to s t e p 8.
• If t h e v o l t a g e i s not a s s p e c i f i e d , c h e c k for:
2. D o t h e D T C t r o u b l e s h o o t i n g ( s e e p a g e 22-6). - a s h o r t in t h e Y E L / B L K w i r e to g r o u n d .
- a n o p e n in t h e Y E L / B L K o r B L K w i r e .
• If n o p r o b l e m i s f o u n d , g o to s t e p 3.
• If D T C B 1 1 7 5 o r B 1 1 7 6 is i n d i c a t e d , g o to t h e
indicated D T C s troubleshooting.
(YEL/BLK)
4. R e m o v e t h e r e a r t r a y ( s e e p a g e 2 0 - 7 3 ) .
5. R e m o v e t h e a c c e s s p a n e l (A) f r o m t h e floor.
9. R e m o v e t h e fuel tank unit f r o m t h e fuel tank

( s e e p a g e 11-487).
6. D i s c o n n e c t t h e f u e l tank unit 5 P c o n n e c t o r (B).
11-494
10. M e a s u r e r e s i s t a n c e b e t w e e n fuel tank unit 5 P 11. R e c o n n e c t t h e fuel t a n k unit 5 P c o n n e c t o r .
c o n n e c t o r t e r m i n a l s No. 1 a n d No. 2 with t h e float
at E ( E M P T Y ) , L O W ( L O W F U E L I N D I C A T O R ) , 1/2 12. R e m o v e t h e N o . 2 F U E L P U M P (15 A ) f u s e f r o m the
(HALF F U L L ) , and F (FULL) positions. u n d e r - h o o d f u s e / r e l a y b o x for at least 10 s e c o n d s ,
If y o u d o not get t h e f o l l o w i n g r e a d i n g s , r e p l a c e t h e t h e n reinstall it.
fuel g a u g e s e n d i n g unit ( s e e p a g e 11-488).
Float F 1/2 LOW E
Position 3.2 in. 6.0 in. 8.4 in. 8.7 in. 14. C h e c k that t h e pointer of t h e fuel g a u g e i n d i c a t e s
(81.2 mm) (152 mm) (214.3 mm) (221.9 mm) " F " with t h e float at F .
Resistance 11 to 52 to 114.4 to 130 to
13 58 120.4 132 • If t h e pointer of t h e fuel g a u g e d o e s not indicate
" F " replace the gauge a s s e m b l y .
• If t h e g a u g e i s O K , t h e t e s t is c o m p l e t e .
NOTE:
• T h e pointer of the f u e l g a u g e returns to t h e
bottom of t h e g a u g e dial w h e n the ignition s w i t c h
is O F F , r e g a r d l e s s of t h e fuel l e v e l .
• R e m o v e t h e No. 2 F U E L P U M P (15 A ) f u s e f r o m
the u n d e r - h o o d f u s e / r e l a y box for at l e a s t
10 s e c o n d s after c o m p l e t i n g t r o u b l e s h o o t i n g ,
o t h e r w i s e it m a y t a k e up to 20 m i n u t e s for t h e
fuel g a u g e to indicate t h e c o r r e c t fuel l e v e l .
11-495
Fuel Supply System
Low Fuel Indicator Test
1. D o t h e fuel g a u g e s e n d i n g unit test ( s e e p a g e
11-494).
• If t h e s y s t e m i s O K , g o to s t e p 2.
• If t h e s y s t e m h a s a n y m a l f u n c t i o n , r e p a i r it.
2 . T u r n t h e ignition s w i t c h O F F . R e m o v e t h e N o . 2 5
B A C K U P (7.5 A ) f u s e f r o m t h e u n d e r - d a s h f u s e /
r e l a y b o x f o r at l e a s t 30 s e c o n d s , t h e n reinstall it.
3. T u r n t h e ignition s w i t c h O N (II) w i t h the float at the

E ( E M P T Y ) position.
• If t h e l o w fuel indicator is o n , g o to s t e p 4.
• If t h e l o w fuel indicator is not o n , refer to t h e l o w
fuel indicator C i r c u i t D i a g r a m ( s e e p a g e 22-73),
a n d c h e c k t h e circuit.
4. T u r n t h e ignition s w i t c h O F F . R e m o v e t h e N o . 2 5
B A C K U P (7.5 A ) f u s e f r o m the u n d e r - d a s h f u s e /
r e l a y b o x for at l e a s t 3 0 s e c o n d s , t h e n reinstall it.
5. Lift t h e float a b o v e t h e L O W p o s i t i o n .
• If t h e l o w fuel indicator g o e s off, t h e s y s t e m is O K .

• If t h e l o w fuel indicator is still o n , refer to t h e l o w
fuel indicator C i r c u i t D i a g r a m ( s e e p a g e 22-73),
a n d c h e c k t h e circuit.
11-496
Intake Air System
U p d a t i n g , p a g e 11-216
11-497
Intake Air System
Throttle Body Test

Carbon Accumulation Check Throttle Position Learning Check
1. C o n n e c t t h e H D S to t h e data link c o n n e c t o r ( D L C ) 1. C o n n e c t t h e H D S to t h e data link c o n n e c t o r ( D L C )

(A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e of t h e front (A) l o c a t e d b e h i n d t h e d r i v e r ' s s i d e of t h e front
console. console.
2. T u r n t h e ignition s w i t c h O N (II). 2. T u r n t h e ignition s w i t c h O N (II).
3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e E C M . If 3. M a k e s u r e t h e H D S c o m m u n i c a t e s with t h e E C M . If
it d o e s n ' t , g o to t h e D L C circuit t r o u b l e s h o o t i n g it d o e s n ' t , g o to t h e D L C circuit t r o u b l e s h o o t i n g
( s e e p a g e 11-367). ( s e e p a g e 11-367).
4. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 4. S e l e c t t h e I N S P E C T I O N M E N U w i t h the H D S .
radiator f a n c o m e s o n , t h e n let it idle. 5. D o the T P L E A R N I N G C H E C K in the E T C S T E S T . If
n e e d e d , c l e a n t h e throttle b o d y ( s e e p a g e 11-499).
5. C h e c k t h e R E L T P S E N S O R in t h e D A T A L I S T t h e
H D S . T h e r e a d i n g s h o u l d be b e l o w 2.46 d e g . If it is
not, c l e a n t h e throttle b o d y ( s e e p a g e 11-499).
11-498
Throttle Body Cleaning
^CAUTION
D o not insert y o u r f i n g e r s into t h e i n s t a l l e d throttle
1. C h e c k f o r d a m a g e t o the air c l e a n e r . If t h e air

c l e a n e r i s d a m a g e d , r e p l a c e it ( s e e p a g e 11-505).
2. R e m o v e t h e throttle b o d y ( s e e p a g e 11-500).
3. W i p e off t h e c a r b o n f r o m t h e throttle v a l v e a n d
i n s i d e t h e throttle b o d y w i t h a p a p e r t o w e l s o a k e d
in throttle plate a n d induction c l e a n e r .
NOTE:
• R e m o v e the throttle b o d y to c l e a n it.
• T o a v o i d r e m o v i n g the m o l y b d e n u m c o a t i n g , d o
not c l e a n t h e b e a r i n g a r e a of t h e throttle s h a f t ( A ) .
• D o not s p r a y t h e c l e a n e r directly o n t h e throttle
body.
• U s e H o n d a g e n u i n e throttle plate a n d i n d u c t i o n
cleaner.
4. Install the throttle b o d y ( s e e p a g e 11-500).
5. R e s e t t h e E C M with the H D S .
11-499
Intake Air System
Throttle Body Removal/Installation
D o not insert y o u r f i n g e r s into t h e i n s t a l l e d throttle b o d y w h e n y o u turn t h e ignition s w i t c h O N (II) or w h i l e t h e

ignition s w i t c h is O N (II). If y o u d o , y o u w i l l s e r i o u s l y injure y o u r f i n g e r s if t h e throttle v a l v e is a c t i v a t e d .
N O T E : If y o u a r e r e p l a c i n g t h e throttle b o d y , b e g i n at s t e p 1. If y o u a r e r e m o v i n g t h e throttle b o d y , b e g i n at s t e p 4.
1. C o n n e c t t h e H D S w h i l e t h e e n g i n e is s t o p p e d .
2. S e l e c t t h e I N S P E C T I O N M E N U w i t h t h e H D S .
3. D o t h e T P P O S I T I O N C H E C K in t h e E T C S T E S T .
5. R e m o v e t h e intake air d u c t (A).
6. D i s c o n n e c t t h e throttle b o d y c o n n e c t o r (B).
7. D i s c o n n e c t t h e w a t e r b y p a s s h o s e s ( C ) , a n d p l u g t h e m .
8. R e m o v e t h e throttle b o d y (D).
9. Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l with a n e w g a s k e t ( E ) , t h e n d o t h i s :
• D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
• Refill the radiator w i t h e n g i n e c o o l a n t ( s e e p a g e 10-9).
11-500
11-501
Intake Air System
Accelerator Pedal Replacement
1. R e m o v e the throttle c a b l e (A) f r o m t h e a c c e l e r a t o r
p e d a l (B).
2 . R e m o v e t h e nuts (C) a n d the a c c e l e r a t o r p e d a l .
11-502
Throttle Cable Removal/Installation
1. R e m o v e the throttle c a b l e c o v e r ( s e e p a g e 11-504). 5. Install t h e parts in the r e v e r s e o r d e r of r e m o v a l .
2 . F u l l y o p e n the throttle v a l v e , t h e n r e m o v e t h e 6. H o l d t h e c a b l e , r e m o v i n g all s l a c k f r o m it.

throttle c a b l e (A) f r o m t h e throttle link (B).
7. S e t t h e c a b l e o n the bracket (A). T u r n t h e a d j u s t i n g
nut (B) s o that its free p l a y is 0 m m .
T h e r e s h o u l d be
no clearance. B
GREASE n)
SILICONE G R E A S E
( P / N 08798-9002)
8. P o s i t i o n t h e a d j u s t i n g nut o n the other s i d e of the

3. R e m o v e the c a b l e h o u s i n g (C) f r o m the c a b l e b r a c k e t , t h e n tighten t h e locknut (C).
bracket (D).
9. C h e c k the throttle c a b l e free p l a y ( s e e p a g e 11-504).
4. R e m o v e the throttle c a b l e (A) f r o m t h e a c c e l e r a t o r
p e d a l (B). 10. W i t h t h e c a b l e p r o p e r l y a d j u s t e d , c h e c k t h e throttle
link to be s u r e it o p e n s fully w h e n y o u p u s h t h e
throttle link to be s u r e it returns w h e n e v e r y o u
r e l e a s e the a c c e l e r a t o r p e d a l .
r GREASE nl y-
SILICONE G R E A S E ( \vj
( P / N 08798-9002)
11-503
Intake Air System
Throttle Cable Adjustment Air Cleaner Removal/Installation
1. R e m o v e the throttle c a b l e c o v e r (A). 1. R e m o v e t h e air c l e a n e r e l e m e n t ( s e e p a g e 11-505).
2. R e m o v e the bolts (A).
2. C h e c k c a b l e free p l a y at the throttle linkage. C a b l e

f r e e p l a y (A) s h o u l d be 0.59—0.71 i n . ( 1 5 — 1 8 m m ) .
B A
3. R e m o v e the air c l e a n e r (B).
4. Install t h e parts in the r e v e r s e o r d e r of r e m o v a l .
3. If t h e f r e e p l a y is not w i t h i n s p e c (0.59—0.71 i n . ,
1 5 — 1 8 m m ) , l o o s e n the locknut (B), t u r n the
a d j u s t i n g nut (C) until t h e deflection is a s s p e c i f i e d ,
t h e n retighten t h e locknut.
4. W i t h t h e c a b l e p r o p e r l y a d j u s t e d , c h e c k t h e throttle
link to b e s u r e it o p e n s fully w h e n y o u p u s h t h e
throttle link to be s u r e it returns w h e n e v e r y o u
release the accelerator pedal.
11-504
Air Cleaner Element Inspection/Replacement
1. R e m o v e the air c l e a n e r h o u s i n g c o v e r (A).
2. R e m o v e the air c l e a n e r e l e m e n t (B) f r o m the air

cleaner housing (C).
3. C h e c k the air c l e a n e r e l e m e n t for d a m a g e or

c l o g g i n g . If it is d a m a g e d or c l o g g e d , r e p l a c e it.
N O T E : D o not u s e c o m p r e s s e d air to c l e a n the air

cleaner element.
4. C l e a n a n d r e m o v e a n y d e b r i s f r o m i n s i d e the air
cleaner housing.
6. R e s e t t h e m a i n t e n a n c e m i n d e r , if n e e d e d ( s e e p a g e
3-27).
11-505
T H R E E W A Y C A T A L Y T I CC O N V E R T E R (TWC)
Substitution, p a g e 11-217
11-506
DTC Troubleshooting
DTC P0420: Catalyst System Efficiency Below 7. M o n i t o r t h e O B D S T A T U S for D T C P 0 4 2 0 in t h e

Threshold D T C s M E N U with the H D S .
NOTE: Does the screen indicate FAILED?

a n y on-board s n a p s h o t , a n d r e v i e w the general Y E S — G o to s t e p 8.
• If s o m e of the D T C s listed b e l o w a r e s t o r e d at t h e N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent
s a m e t i m e a s D T C P 0 4 2 0 , t r o u b l e s h o o t t h e m first, f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . If t h e s c r e e n
t h e n r e c h e c k for D T C P 0 4 2 0 . i n d i c a t e s E X E C U T I N G , k e e p driving until a result
P 0 1 3 7 , P0138: S e c o n d a r y H 0 2 S ( S e n s o r 2) c o m e s o n . If t h e s c r e e n i n d i c a t e s O U T O F
P0141: S e c o n d a r y H 0 2 S ( S e n s o r 2) h e a t e r C O N D I T I O N , g o to s t e p 4 a n d r e c h e c k .
• P o o r quality fuel m a y c a u s e t h i s D T C .
9. R e p l a c e t h e t h r e e w a y c a t a l y t i c c o n v e r t e r ( T W C )
2. C l e a r the D T C w i t h the H D S . ( s e e p a g e 9-6).
3. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at 10. T u r n t h e ignition s w i t c h O N (II).

radiator f a n c o m e s o n , t h e n let it idle. 11. R e s e t t h e E C M w i t h t h e H D S .
4. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s : 12. D o t h e E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
• E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1) 13. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at
a b o v e 158 °F (70 °C) 3 , 0 0 0 r p m w i t h o u t l o a d (in neutral) until t h e
• T r a n s m i s s i o n in 5th g e a r radiator f a n c o m e s o n , t h e n let it idle.
• V e h i c l e s p e e d b e t w e e n 4 5 — 7 5 m p h (72 —
120 k m / h ) for 5 m i n u t e s or m o r e 14. T e s t - d r i v e for a b o u t 10 m i n u t e s , v a r y i n g t h e v e h i c l e
• V e h i c l e s p e e d 2 5 m p h (40 k m / h ) or m o r e for speed.
1 m i n u t e w i t h c r u i s e control s e t
15. C h e c k t h e C A T A M O N I T O R C O N D I T I O N in t h e
5. M o n i t o r the O B D S T A T U S for D T C P 0 4 2 0 in t h e D A T A L I S T with the H D S .
Is the temperature OK?
Does the screen indicate EXECUTING?
N O — G o to s t e p 13 a n d r e c h e c k .
NO—If the screen indicates O U T O F C O N D I T I O N ,
g o to s t e p 4 a n d r e c h e c k . If the s c r e e n i n d i c a t e s 16. T e s t - d r i v e u n d e r t h e s e c o n d i t i o n s :
P A S S E D , intermittent failure, the s y s t e m is O K at
t h i s t i m e . If the s c r e e n i n d i c a t e s F A I L E D , g o to s t e p • E n g i n e c o o l a n t t e m p e r a t u r e ( E C T S E N S O R 1)
8. a b o v e 158 °F ( 7 0 * 0
6. C o n t i n u e test d r i v i n g until a result c o m e s o n . • V e h i c l e s p e e d b e t w e e n 4 5 — 7 5 m p h (72 —
120 k m / h ) for 5 m i n u t e s or m o r e
• V e h i c l e s p e e d 2 5 m p h (40 km/h) or m o r e for
1 m i n u t e w i t h c r u i s e control s e t
(cont'd)
11-507
Does the screen indicate EXECUTING?
N O — G o to s t e p 16 a n d r e c h e c k .
18. C o n t i n u e t e s t d r i v i n g until a result c o m e s o n .
Y E S — C h e c k t h e fuel q u a l i t y , t h e n g o to s t e p 1.
N O — G o to s t e p 2 0 .
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e s e c o n d a r y
H 0 2 S ( s e n s o r 2) a n d t h e E C M . If t h e s c r e e n
i n d i c a t e s E X E C U T I N G , k e e p d r i v i n g until a r e s u l t
11-508
PCV System
11-509
PCV System
DTC Troubleshooting
DTC P2279: Intake Air System Leak 7. C h e c k for T e m p o r a r y D T C s or D T C s with the H D S .
NOTE: Is DTC P2279 indicated?

any on-board s n a p s h o t , a n d review the general Y E S — C h e c k for v a c u u m l e a k s at t h e P C V v a l v e , t h e
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). P C V h o s e , t h e p u r g e ( P C S ) line, t h e throttle b o d y ,
• If D T C P 0 4 4 3 i s s t o r e d at t h e s a m e t i m e a s D T C P 2 2 7 9 , t h e b r a k e b o o s t e r , or t h e brake b o o s t e r h o s e , t h e n
t r o u b l e s h o o t D T C P 0 4 4 3 first, t h e n r e c h e c k for D T C g o to s t e p 4.
P2279.
1. C h e c k for v a c u u m l e a k s at t h e s e p a r t s :
8. M o n i t o r t h e O B D S T A T U S for D T C P2279 in t h e
• PCV valve D T C s M E N U with the H D S .
• PCV hose
• P u r g e ( P C S ) line Does the screen indicate PASSED?
• Brake booster Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
• Brake booster h o s e g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Are the parts OK ? NO—If the s c r e e n indicates F A I L E D , g o t o step 1

a n d r e c h e c k . If t h e s c r e e n i n d i c a t e s N O T
Y E S — G o to s t e p 2 . C O M P L E T E D , k e e p idling until a result c o m e s o n .
N O — R e p a i r or replace the leaking part(s), then go
to s t e p 4.
radiator f a n c o m e s o n , t h e n let it idle 1 m i n u t e .
Y E S — C h e c k t h e c a m s h a f t t i m i n g ( s e e p a g e 6-15),
f a i l u r e , t h e s y s t e m is O K at t h i s t i m e . If t h e s c r e e n
i n d i c a t e s N O T C O M P L E T E D , g o to s t e p 2 a n d
recheck.
radiator f a n c o m e s o n , t h e n let it idle 1 m i n u t e .
11-510
PCV Valve Inspection PCV Valve Replacement
1. C h e c k t h e P C V v a l v e (A), h o s e s ( B ) , a n d 1. D i s c o n n e c t t h e P C V h o s e .
c o n n e c t i o n s for l e a k s or r e s t r i c t i o n s .
2 . R e m o v e the P C V v a l v e (A).
A B
B A
44 N m
(4.5 k g f - m , 3 3 Ibf-ft)
2 . A t idle, m a k e s u r e t h e r e i s a clicking s o u n d f r o m the 3 . Install t h e parts in t h e r e v e r s e o r d e r of r e m o v a l

P C V v a l v e w h e n the h o s e b e t w e e n the P C V v a l v e w i t h a n e w w a s h e r (B).
a n d intake m a n i f o l d is lightly p i n c h e d (A) w i t h y o u r
f i n g e r s or p l i e r s .
If t h e r e is n o c l i c k i n g s o u n d , c h e c k the h o s e for
c r a c k s or d a m a g e . If the h o s e i s O K , r e p l a c e t h e
PCV valve and recheck.
11-511
EVAP System
EVAPORATIVE EMISSION (EVAP)

CANISTER PURGE VALVE
EVAPORATIVE EMISSION (EVAP)

CANISTER VENT SHUT VALVE
FUEL TANK VAPOR CONTROL FLOAT

EVAPORATIVE EMISSION
(EVAP) CANISTER
Replacement,
p a g e 11-544
FUEL TANK PRESSURE

(FTP) S E N S O R
Replacement,
page 11-542
11-512
Updating, page 11-216
Substitution, page 11-217
11-513
EVAP System
DTC Troubleshooting
DTC P0443: EVAP Canister Purge Valve 7. S t a r t t h e e n g i n e , a n d let it idle.
Circuit Malfunction
Is there vacuum?
V a c u u m p u m p / g a u g e , 0—30 in.Hg, S n a p - o n Y A 4 0 0 0 A Y E S — G o to s t e p 8.
or equivalent, c o m m e r c i a l l y available
a n d any on-board s n a p s h o t , and review the general 8. T u r n t h e ignition s w i t c h O F F .
9. D i s c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e 2 P
1. T u r n the ignition s w i t c h O N (II). connector.
2. Clear the D T C with the H D S . 10. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e

v a l v e 2P connector terminal No. 2 and body ground.
3. S t a r t the e n g i n e . H o l d t h e e n g i n e s p e e d at
EVAP CANISTER P U R G E V A L V E 2P CONNECTOR

PCS
(RED/YEL)
at the E V A P c a n i s t e r p u r g e v a l v e a n d t h e E C M . • W i r e s i d e of f e m a l e t e r m i n a l s
5. T u r n t h e ignition s w i t c h O F F , a n d a l l o w t h e e n g i n e
to c o o l b e l o w 149 °F (65 °C). Is there continuity?
6. D i s c o n n e c t t h e v a c u u m h o s e (A) f r o m t h e E V A P Y E S — G o t o s t e p 11.
c a n i s t e r p u r g e v a l v e (B) in t h e e n g i n e c o m p a r t m e n t ,
and connect a v a c u u m p u m p / g a u g e , 0—30 in.Hg, to N O — G o to s t e p 2 4 .
the E V A P canister purge valve.
11-514
13. C h e c k for continuity b e t w e e n E V A P c a n i s t e r p u r g e 17. M e a s u r e v o l t a g e b e t w e e n E V A P c a n i s t e r p u r g e
valve 2 P connector terminal No. 2 a n d body ground. v a l v e 2 P c o n n e c t o r t e r m i n a l No. 1 a n d b o d y g r o u n d .
E V A P C A N I S T E R P U R G E V A L V E 2P C O N N E C T O R E V A P CANISTER PURGE V A L V E 2P CONNECTOR
1 2
PCS IG1
k (RED/YEL) (BLK/YEL)
Is there continuity? Is there battery voltage?
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n t h e E V A P Y E S — G o to s t e p 18.
c a n i s t e r p u r g e v a l v e a n d the E C M ( B 2 1 ) , t h e n g o to
step 25. N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E V A P
c a n i s t e r p u r g e v a l v e a n d t h e N o . 6 A C G (15 A ) f u s e
N O — G o to s t e p 3 1 . in t h e u n d e r - d a s h f u s e / r e l a y b o x , t h e n g o to s t e p
25.
18* T u r n t h e ignition s w i t c h O F F ,
15. D i s c o n n e c t the E V A P c a n i s t e r p u r g e v a l v e 2 P
connector. 19. J u m p the S C S line w i t h the H D S .
16. T u r n the ignition s w i t c h O N (II). 20. D i s c o n n e c t E C M c o n n e c t o r 6 (24P).
21. C o n n e c t E V A P canister purge valve 2P connector

E V A P C A N I S T E R P U R G E V A L V E 2P C O N N E C T O R
1 2
PCS (RED/YEL)
JUMPER WIRE
(cont'd)
11-515
EVAP System
2 2 . C h e c k for continuity b e t w e e n E C M c o n n e c t o r 2 6 . T u r n t h e ignition s w i t c h O N (II).
t e r m i n a l B21 a n d b o d y g r o u n d .
E C M CONNECTOR B(24P)
/ \ 2 I 3 | 4 | 5 2 9 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
8
/ 10 11
/ /// 13
17 18 19
///
20 21
I PCS (YEL/BLU)
t e r m i n a l s at t h e E V A P c a n i s t e r p u r g e v a l v e a n d the
E C M , t h e n g o to s t e p 1.
W i r e s i d e of f e m a l e t e r m i n a l s N O — G o to s t e p 3 0 .
Is there continuity? D T C s M E N U w i t h the H D S .
Y E S — G o to s t e p 2 3 . Does the screen indicate PASSED?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E V A P Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y o t h e r
c a n i s t e r p u r g e v a l v e a n d the E C M ( B 2 1 ) , t h e n g o to T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 2 9 ,
step 25. g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
23. At the purge valve side, m e a s u r e resistance N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r

between E V A P canister purge valve 2P connector c o n n e c t i o n s or l o o s e t e r m i n a l s at the E V A P c a n i s t e r
t e r m i n a l s N o . 1 a n d N o . 2. p u r g e v a l v e a n d t h e E C M , t h e n g o to s t e p 1. If t h e
s c r e e n i n d i c a t e s E X E C U T I N G or O U T O F
C O N D I T I O N , k e e p idling until a result c o m e s o n .
EVAP CANISTER P U R G E V A L V E 2P C O N N E C T O R
1 2
Is there about 33 0, at room temperature?
Y E S — G o to s t e p 3 1 .
24. R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e ( s e e p a g e
11-542).
11-516

g o o d E C M ( s e e p a g e 11-217).
3 3 . S t a r t t h e e n g i n e , a n d let it idle.
t e r m i n a l s at t h e E V A P c a n i s t e r p u r g e v a l v e a n d t h e
E C M . If the E C M w a s u p d a t e d , s u b s t i t u t e a k n o w n -
N O — G o to s t e p 3 5 .
3 5 . Monitor the O B D S T A T U S for D T C P 0 4 4 3 in t h e

g o to the i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E V A P c a n i s t e r
p u r g e v a l v e a n d t h e E C M . If t h e E C M w a s u p d a t e d ,
t h e n r e c h e c k . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p
1. If t h e s c r e e n i n d i c a t e s E X E C U T I N G or O U T O F
C O N D I T I O N , k e e p idling until a result c o m e s o n .
EVAP System
DTC P0451: FTP Sensor Circuit Range/ 11. C h e c k for T e m p o r a r y D T C s or D T C s with the H D S .
Performance Problem
Is DTCP0451 indicated?
NOTE:
• B e f o r e y o u t r o u b l e s h o o t r e c o r d all f r e e z e d a t a a n d Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
a n y on-board s n a p s h o t , a n d r e v i e w the general t e r m i n a l s at the F T P s e n s o r a n d t h e E C M , t h e n g o
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). to s t e p 1.
• If D T C P 2 4 2 2 is s t o r e d at t h e s a m e t i m e a s D T C P 0 4 5 1 ,
t r o u b l e s h o o t D T C P 2 4 2 2 first, t h e n r e c h e c k for D T C N O — G o to s t e p 12.
P0451.
12. M o n i t o r t h e O B D S T A T U S for D T C P0451 in t h e
1. T u r n t h e ignition s w i t c h O N (II). D T C s M E N U with t h e H D S .
2. C l e a r the D T C with the H D S . Does the screen indicate PASSED?
3. Start t h e e n g i n e , a n d let it idle. Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other

4. M o n i t o r t h e O B D S T A T U S for D T C P0451 in the g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Does the screen indicate FAILED? c o n n e c t i o n s or l o o s e t e r m i n a l s at the F T P s e n s o r
a n d the E C M , t h e n g o to s t e p 1. If t h e s c r e e n
Y E S — G o to s t e p 5. i n d i c a t e s N O T C O M P L E T E D , k e e p idling until a
f a i l u r e , t h e s y s t e m i s O K at t h i s t i m e . C h e c k f o r
p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e F T P
s e n s o r a n d t h e E C M . If t h e s c r e e n i n d i c a t e s N O T
6. R e p l a c e t h e F T P s e n s o r ( s e e p a g e 11-542).
11-518
DTC P0452: FTP Sensor Circuit Low Voltage 10. T u r n t h e ignition s w i t c h O F F .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a 11. D i s c o n n e c t t h e F T P s e n s o r 3 P c o n n e c t o r .

1. T u r n t h e ignition s w i t c h O N (II). 13. C h e c k t h e F T P S E N S O R in t h e D A T A L I S T w i t h t h e

HDS.
Is about - 7.3 kPa (-2.16 in.Hg, - 55 mmHg), or
3. T u r n t h e ignition s w i t c h O F F . 4.90 V indicated?
4. R e m o v e t h e fuel fill c a p . Y E S — G o to s t e p 14.
5. T u r n t h e ignition s w i t c h O N (II). N O — G o to s t e p 2 0 .
6. C h e c k t h e F T P S E N S O R in t h e D A T A L I S T w i t h t h e 14. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
HDS. terminal No. 1 and body ground.
Is about - 7.3 kPa (-2.16 ln.Hg f - 55 mmHg), or FTP S E N S O R 3P C O N N E C T O R

0.3 V or less indicated?
1 2 3
N O — G o to s t e p 7. VCC3
(YEL/BLU)
7. Install t h e fuel fill c a p .
8. S t a r t t h e e n g i n e , a n d let it idle w i t h o u t load (in

Is there about 5 V?
s e n s o r a n d the E C M . If t h e s c r e e n i n d i c a t e s N O T
(cont'd)
11-519
EVAP System
E 5 and body ground.
2 1 . R e p l a c e t h e F T P s e n s o r ( s e e p a g e 11-542).
VCC3
(YEL/BLU) 2 3 . T u r n t h e ignition s w i t c h O N (II).
1M»|4|B 7 | XI
| 8 | «
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/ 2 5 . D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462).
IsthereSV? t e r m i n a l s at t h e F T P s e n s o r a n d t h e E C M , t h e n g o
to s t e p 1.
(E5) a n d t h e F T P s e n s o r , t h e n g o to s t e p 2 2 . N O — G o to s t e p 2 7 .
N O — G o to s t e p 2 8 . 2 7 . M o n i t o r t h e O B D S T A T U S for D T C P 0 4 5 2 in t h e
18. D i s c o n n e c t E C M c o n n e c t o r E (31P). T e m p o r a r y D T C s o r D T C s w e r e i n d i c a t e d in s t e p 2 6 ,
19. C h e c k for c o n t i n u i t y b e t w e e n F T P s e n s o r 3 P
connector terminal No. 2 and body ground. N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e F T P s e n s o r
a n d t h e E C M , t h e n g o to s t e p 1. If t h e s c r e e n
FTP
(LTGRN)
(E14) a n d t h e F T P s e n s o r , t h e n g o to s t e p 2 2 .
N O — G o to s t e p 2 9 .
11-520

g o o d E C M ( s e e p a g e 11-217).

t e r m i n a l s at t h e F T P s e n s o r a n d t h e E C M . If the
( s e e p a g e 11-217), t h e n g o to s t e p 3 1 . If t h e E C M
N O — G o to s t e p 3 3 .
3 3 . M o n i t o r the O B D S T A T U S for D T C P 0 4 5 2 in the

go to the indicated D T C s troubleshooting. •
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e F T P s e n s o r
a n d t h e E C M . If the E C M w a s u p d a t e d , substitute a
s t e p 3 1 . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1. If
t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D , k e e p idling
11-521
EVAP System
DTC P0453: FTP Sensor Circuit High Voltage 12. C o n n e c t F T P s e n s o r 3 P c o n n e c t o r t e r m i n a l s N o . 2

a n d N o . 3 with a j u m p e r w i r e .
1 2 3
2. Clear the D T C with the H D S . FTP SG3
(LTGRN) (GRN)
JUMPER WIRE
4. R e m o v e t h e fuel fill c a p .
5. T u r n t h e ignition s w i t c h O N (II). W i r e s i d e of f e m a l e t e r m i n a l s
6. C h e c k t h e F T P S E N S O R in t h e D A T A L I S T w i t h t h e
Is about 7.3 kPa (2.16 in.Hg, 55 mmHg), or 4.7 V 14. C h e c k t h e F T P S E N S O R in t h e D A T A L I S T w i t h t h e

or more indicated? HDS.
Y E S — G o t o s t e p 10. Is about 7.3 kPa (2.16 in.Hg, 55 mmHg), or 4.7 V

or more indicated?
N O — G o to s t e p 2 5 .
neutral) until the radiator f a n c o m e s o n . 15. M e a s u r e v o l t a g e b e t w e e n F T P s e n s o r 3 P c o n n e c t o r
t e r m i n a l s No. 1 a n d N o . 3.
VCC3 SG3
N O — I f t h e s c r e e n i n d i c a t e s P A S S E D , intermittent (YEL/BLU) (GRN)
failure, t h e s y s t e m is O K at t h i s t i m e . C h e c k for
s e n s o r a n d E C M . If t h e s c r e e n i n d i c a t e s N O T
11. D i s c o n n e c t t h e F T P s e n s o r 3 P c o n n e c t o r . Is there about 5 V?
Y E S — G o to s t e p 2 1 .
11-522
16. T u r n the ignition s w i t c h O F F . 2 1 . T u r n t h e ignition s w i t c h O F F .
17. J u m p t h e S C S line w i t h the H D S . 22. Connect E C M connector terminals E 4 a n d E 1 4 with

a jumper wire.
19. C o n n e c t F T P s e n s o r 3 P c o n n e c t o r t e r m i n a l No. 3 to
SG3 (GRN)
r I
FTP SENSOR 3P CONNECTOR 1 \ / 3 4 | 5 X I 7 8 | 9
/ 11 12 13 14 15 16 17 18 19 20 21
1 2 3
22
/ 24 25
/ 27 28 29 30
FTP (LTGRN)
/
SG3 JUMPER WIRE
(GRN)
JUMPER WIRE W i r e s i d e of f e m a l e t e r m i n a l s
HDS.
terminal E 4 and body ground. Is about 7.3 kPa (2.16 in.Hg, 55 mmHg), or 4.7 V
or more indicated ?

Y E S — G o to s t e p 3 3 .
SG3 (GRN) i 1 N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E C M
1
Z 3 4 5 7T1
[8 9
(E14) a n d t h e F T P s e n s o r , t h e n g o to s t e p 2 7 .
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/
2 6 . R e p l a c e t h e F T P s e n s o r ( s e e p a g e 11-542).
Y E S — G o to s t e p 3 4 .
a n d t h e F T P s e n s o r , t h e n g o to s t e p 2 7 .
(cont'd)
11-523
EVAP System
2 8 . T u r n t h e ignition s w i t c h O N (II). 3 7 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S .
29. R e s e t the E C M with the H D S . Is DTC P0453 indicated?
3 0 . D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-462). Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e

t e r m i n a l s at t h e F T P s e n s o r a n d the E C M . If the
3 1 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h t h e H D S . E C M w a s updated, substitute a known-good E C M
Is DTC P0453 indicated? w a s s u b s t i t u t e d , g o to s t e p 1.
Y E S — - C h e c k for p o o r c o n n e c t i o n s or l o o s e N O — G o to s t e p 3 8 .
t e r m i n a l s at t h e F T P s e n s o r a n d t h e E C M , t h e n g o
to s t e p 1. 3 8 . M o n i t o r t h e O B D S T A T U S for D T C P 0 4 5 3 in the
D T C s M E N U w i t h the H D S ,
IMO—Go to s t e p 3 2 .
D T C s M E N U with the HDS. Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
Does the screen indicate PASSED? o r i g i n a l E C M ( s e e p a g e 11-389). If a n y other
T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 3 7 ,
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . If a n y other g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at the F T P s e n s o r
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r a n d t h e E C M . If t h e E C M w a s u p d a t e d , substitute a
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e F T P s e n s o r k n o w n - g o o d E C M ( s e e p a g e 11-217), t h e n g o to
a n d t h e E C M , t h e n g o to s t e p 1. If t h e s c r e e n s t e p 3 6 , If the E C M w a s s u b s t i t u t e d , g o to s t e p 1. If
i n d i c a t e s N O T C O M P L E T E D , k e e p idling until a t h e s c r e e n i n d i c a t e s N O T C O M P L E T E D , k e e p idling
result c o m e s o n . until a r e s u l t c o m e s o n .
g o o d E C M ( s e e p a g e 11-217).

11-524
DTC P0455: EVAP System Large Leak 2. C h e c k the fuel fill c a p s e a l (A) a n d t h e fuel fill p i p e
Detected m a t i n g s u r f a c e (B). V e r i f y that t h e fuel fill c a p tether
c o r d (C) is not c a u g h t u n d e r t h e c a p .
DTC P0456: EVAP System Very Small Leak
Detected B
1N0TICEI
T h e fuel s y s t e m Is d e s i g n e d to a l l o w s p e c i f i e d
deviate from the v a c u u m a n d p r e s s u r e tests a s
indicated in t h e s e p r o c e d u r e s . E x c e s s i v e p r e s s u r e /
v a c u u m w o u l d d a m a g e t h e E V A P c o m p o n e n t s or
c a u s e e v e n t u a l fuel tank f a i l u r e .

or equivalent, commercially available
NOTE: Is the fuel fill cap seal missing or damaged, is the

• B e f o r e y o u t r o u b l e s h o o t , r e c o r d all freeze d a t a a n d fuel fill pipe damaged, or is the tether cord caught
a n y on-board s n a p s h o t , a n d review the general under the cap?
• F r e s h fuel h a s a h i g h e r volatility that will c r e a t e Y E S — R e p l a c e t h e fuel fill c a p or t h e fuel fill p i p e ,
g r e a t e r p r e s s u r e / v a c u u m . T h e o p t i m u m c o n d i t i o n for t h e n g o to s t e p 2 2 .
t e s t i n g i s l e s s t h a n a full tank of f r e s h f u e l . If p o s s i b l e ,
to a s s i s t in leak d e t e c t i o n , a d d 1 g a l l o n of f r e s h fuel to N O — G o to s t e p 3.
t h e tank ( a s l o n g a s it will not fill t h e tank) j u s t before
starting t h e s e p r o c e d u r e s . 3. T u r n t h e ignition s w i t c h O N (II).
1. C h e c k t h e fuel fill c a p (the c a p m u s t s a y " T I G H T E N 4. C l e a r t h e D T C w i t h t h e H D S .

T O C L I C K " ) . It s h o u l d turn 1/4 turn after it's tight,
t h e n it c l i c k s . 5. D o t h e E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
Is the correct fuel fill cap installed and properly
tightened? Is the result OK?
YES-Gotostep2. Y E S — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s
N O — R e p l a c e or tighten t h e c a p , t h e n g o to s t e p 22. at t h e F T P s e n s o r , t h e E V A P c a n i s t e r p u r g e v a l v e , or
t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d the E C M . •
(cont'd)
11-525
EVAP System
6. T u r n the ignition s w i t c h O F F . 9. D i s c o n n e c t t h e v a c u u m h o s e (purge line) (A) f r o m

t h e E V A P c a n i s t e r p u r g e v a l v e (B) in t h e e n g i n e
7 . C h e c k for a p o o r c o n n e c t i o n o r d a m a g e at t h e f u e l c o m p a r t m e n t , a n d the v a c u u m p u m p / g a u g e ,
tank v a p o r r e c i r c u l a t i o n t u b e a n d fuel t a n k v a p o r 0 — 3 0 i n . H g , to t h e h o s e a s s h o w n .
control float ( s e e p a g e 11-545).
Is the tube OK?
NO—
• R e p l a c e t h e f u e l t a n k v a p o r c o n t r o l float
( s e e p a g e 11-545), t h e n g o to s t e p 2 2 .
A
• If n e c e s s a r y , r e p l a c e t h e fuel tank ( s e e p a g e
11-489), t h e n g o to s t e p 2 2 .
8. D i s c o n n e c t t h e f u e l t a n k v a p o r r e c i r c u l a t i o n t u b e
(A) f r o m t h e E V A P c a n i s t e r (B), a n d plug t h e E V A P
c a n i s t e r port (C).
11. S e l e c t E V A P C V S O N in t h e I N S P E C T I O N M E N U
with the H D S .
12. A p p l y v a c u u m to t h e h o s e until t h e F T P r e a d s
A
1.90 V ( - 0 . 5 9 i n . H g , - 1 5 . 1 m m H g ) .
N O T E : B e c a r e f u l not to e x c e e d the v a c u u m . If y o u
do, the F T P s e n s o r c a n be d a m a g e d .
13. M o n i t o r t h e F T P S E N S O R in t h e D A T A L I S T for
B
1 minute with the H D S .
Does the voltage increase more than 0.2 V

(O.Hn.Hg, 2.5 mmHg)?
YES-Gotostep14.
14. S e l e c t E V A P C V S O F F in t h e I N S P E C T I O N M E N U
with the H D S .
11-526
15. D i s c o n n e c t t h e f r e s h air h o s e s (A) f r o m t h e E V A P 18. C h e c k for a l o o s e or d a m a g e d E V A P c a n i s t e r p u r g e
c a n i s t e r v e n t s h u t v a l v e (B), a n d plug t h e E V A P line b e t w e e n the E V A P c a n i s t e r a n d the E V A P
c a n i s t e r v e n t s h u t v a l v e ports (C). canister purge valve.
Is the line OK?
Y E S — R e p l a c e the f o l l o w i n g p a r t s , t h e n g o to
step 21.
• F T P s e n s o r O - r i n g ( s e e p a g e 11-542)
• E V A P canister vent shut valve c a s e and O-ring
( s e e p a g e 11-543)
• E V A P c a n i s t e r ( s e e p a g e 11-544)
N O — R e c o n n e c t or repair the E V A P c a n i s t e r p u r g e
h o s e , t h e n g o to s t e p 21.
19. S e l e c t E V A P C V S O F F in t h e I N S P E C T I O N M E N U
w i t h the H D S .
2 0 . C h e c k t h e s e parts for l o o s e n e s s or d a m a g e :
• F u e l fill pipe
• F u e l v a p o r return pipe
16. A p p l y v a c u u m to the h o s e ( d i s c o n n e c t e d in s t e p 9)
until t h e F T P r e a d s 1.90 V (—0.59 i n . H g , Are the parts OK?
—15.1 mmHg).
Y E S — C h e c k the fuel p u m p b a s e g a s k e t ( s e e p a g e
N O T E : B e c a r e f u l not to e x c e e d t h e v a c u u m . If y o u 11-487), a n d c h e c k the fuel tank, t h e n g o to s t e p 21.
d o , t h e F T P s e n s o r c a n be d a m a g e d .
N O — R e p a i r or r e p l a c e the d a m a g e d p a r t s , t h e n g o
17. M o n i t o r t h e F T P S E N S O R in the D A T A L I S T for to s t e p 2 1 .
1 m i n u t e w i t h the H D S .
2 1 . R e c o n n e c t all h o s e s a n d c o n n e c t o r s .
Does the voltage Increase more than 0.2 V
(0.1 In.Hg, 2.5 mmHg)? 2 2 . T u r n the ignition s w i t c h O N (II).
Y E S — G o to s t e p 18. 2 3 . R e s e t the E C M w i t h the H D S .
N O — R e p l a c e the E V A P c a n i s t e r v e n t s h u t v a l v e 24. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).

2 5 . D o the E V A P F U N C T I O N T E S T in the I N S P E C T I O N
M E N U w i t h the H D S .
Is the result OK?
Y E S — T r o u b l e s h o o t i n g is c o m p l e t e . •
N O — C h e c k for poor c o n n e c t i o n s or l o o s e t e r m i n a l s
at the F T P s e n s o r , the E V A P c a n i s t e r p u r g e v a l v e , or
the E V A P canister vent shut valve and the E C M ,
11-527
EVAP System
DTC P0457: EVAP System Leak Detected/Fuel 5. D o t h e E V A P F U N C T I O N T E S T in the I N S P E C T I O N

Fill Cap Loose or Missing M E N U with the H D S .
N O T E : B e f o r e y o u t r o u b l e s h o o t , r e c o r d all f r e e z e d a t a Is the result OK?

a n d a n y on-board s n a p s h o t , a n d r e v i e w the general
t r o u b l e s h o o t i n g i n f o r m a t i o n ( s e e p a g e 11-213). Y E S — I n t e r m i t t e n t failure, the s y s t e m is O K at this
1. C h e c k the fuel fill c a p (the c a p m u s t s a y " T I G H T E N at t h e F T P s e n s o r or the E V A P c a n i s t e r v e n t s h u t
T O C L I C K " ) . It s h o u l d t u r n 1/4 t u r n after it's tight, v a l v e and the E C M . •
t h e n it c l i c k s .
Is the correct fuel fill cap installed and properly
tightened? 6. T u r n t h e ignition s w i t c h O F F .
Y E S — G o to s t e p 2. 7. R e m o v e t h e E V A P c a n i s t e r v e n t s h u t v a l v e f r o m the
E V A P c a n i s t e r ( s e e p a g e 11-543).
N O — R e p l a c e or tighten t h e c a p , t h e n g o to s t e p 19.
8. C o n n e c t t h e 2 P c o n n e c t o r to t h e E V A P c a n i s t e r v e n t
2 . C h e c k the fuel fill c a p s e a l (A) a n d t h e fuel fill p i p e shut valve.
m a t i n g s u r f a c e (B). V e r i f y that t h e fuel fill c a p t e t h e r
c o r d (C) i s not c a u g h t u n d e r t h e c a p . 9. T u r n t h e ignition s w i t c h O N (II).
B 10. S e l e c t E V A P C V S O N in the I N S P E C T I O N M E N U
with the H D S .
11. C h e c k t h e E V A P c a n i s t e r v e n t s h u t v a l v e (A)
operation.
Is the fuel fill cap seal missing or damaged, is the

fuel fill pipe damaged, or is the tether cord caught
under the cap?
Y E S — R e p l a c e t h e fuel fill c a p o r t h e fuel fill p i p e ,

Does the valve operate?
Y E S — C h e c k t h e routing of the E V A P c a n i s t e r v e n t
3. T u r n t h e ignition s w i t c h O N (II). t u b e , t h e n g o to s t e p 18.
4. C l e a r t h e D T C w i t h the H D S . N O — G o to s t e p 12.
11-528
13. R e p l a c e the E V A P c a n i s t e r v e n t s h u t v a l v e
( s e e p a g e 11-543).
17. D o t h e E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
Is the result OK?
at t h e F T P s e n s o r or the E V A P c a n i s t e r v e n t s h u t
v a l v e a n d the E C M , t h e n g o to s t e p 1.
18. R e i n s t a l l the E V A P c a n i s t e r v e n t s h u t v a l v e
( s e e p a g e 11-543).
22. Do t h e E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
M E N U w i t h the H D S .
Is the result OK?
at t h e F T P s e n s o r o r t h e E V A P c a n i s t e r v e n t s h u t
v a l v e a n d the E C M , t h e n go to s t e p 1.
11-529
EVAP System
DTC P0496: EVAP System High Purge Flow

Detected
3. D o the E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
M E N U with the HDS.
Is the result OK?
the E V A P c a n i s t e r v e n t s h u t v a l v e a n d t h e E C M . H
5. R e p l a c e the E V A P c a n i s t e r p u r g e v a l v e ( s e e p a g e
11-542).
8. D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
9. D o the E V A P F U N C T I O N T E S T in the I N S P E C T I O N
Is the result OK?
N O — C h e c k for poor c o n n e c t i o n s or l o o s e t e r m i n a l s
the E V A P canister vent shut valve and the E C M ,
11-530
DTC P0497: EVAP System Low Purge Flow 6. D i s c o n n e c t t h e v a c u u m h o s e (A) f r o m t h e E V A P
Detected c a n i s t e r p u r g e v a l v e (B) in t h e e n g i n e c o m p a r t m e n t ,
a n d c o n n e c t a T-fitting (C) f r o m the v a c u u m g a u g e
Special Tools Required a n d t h e v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to t h e
• V a c u u m / p r e s s u r e g a u g e , 0 — 4 in.Hg, 0 7 J A Z - 0 0 1 0 0 0 B E V A P canister purge valve a s s h o w n .
• V a c u u m p u m p / g a u g e , 0 — 3 0 in.Hg, S n a p - o n Y A 4 0 0 0 A
B
• Fuel pressure gauge attachment set 0 7 A A J - S 6 M A 1 5 0
A
1. C h e c k t h e fuel fill c a p installation (the c a p m u s t s a y

" T I G H T E N T O C L I C K " . T h e c a p s h o u l d tighten 1/4
t u r n after it i s tight.).
Is the fuel fill cap Installed and properly

tightened?
N O — P r o p e r l y install t h e fuel fill c a p , t h e n g o to

step 23.
3. C l e a r t h e D T C w i t h t h e H D S . 7. S e l e c t E V A P P C S O N in t h e I N S P E C T I O N M E N U
with the H D S .
4. D o t h e E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
M E N U with the H D S . 8. S l o w l y a p p l y a b o u t 2 k P a (0.6 i n . H g , 15 m m H g ) of
v a c u u m to t h e h o s e .
Is the result OK?
Does it hold vacuum?
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s Y E S — C h e c k for b l o c k a g e in the E V A P c a n i s t e r
at t h e F T P s e n s o r , t h e E V A P c a n i s t e r p u r g e v a l v e , o r p u r g e line b e t w e e n t h e intake m a n i f o l d a n d the
the E V A P canister vent shut valve a n d the E C M . • E V A P c a n i s t e r p u r g e v a l v e . If the v a c u u m h o s e is
O K , replace the E V A P canister purge v a l v e , then go
N O — G o to s t e p 5. to s t e p 2 2 .
5. C h e c k for a l o o s e o r d a m a g e d E V A P c a n i s t e r p u r g e N O — G o to s t e p 9.
line b e t w e e n t h e intake m a n i f o l d a n d t h e E V A P
canister purge valve. 9. R e c o n n e c t t h e v a c u u m h o s e to t h e E V A P c a n i s t e r
purge valve.
Is the line OK?
N O — R e c o n n e c t o r repair t h e E V A P c a n i s t e r p u r g e
line, t h e n g o to s t e p 2 3 .
(cont'd)
11-531
EVAP System
10. D i s c o n n e c t t h e v a c u u m h o s e f r o m t h e E V A P 14. C o n n e c t a T-fitting (A) f r o m the v a c u u m g a u g e a n d

c a n i s t e r p u r g e line ( E V A P c a n i s t e r s i d e ) , a n d the c o m m e r c i a l l y a v a i l a b l e v a c u u m p u m p / g a u g e ,
c o n n e c t a T-fitting (A) f r o m t h e v a c u u m g a u g e a n d 0 — 3 0 i n . H g , to the F T P s e n s o r (B) a s s h o w n .
t h e v a c u u m p u m p / g a u g e , 0 — 3 0 i n . H g , to the h o s e
as shown.
15. C h e c k a n d r e c o r d the F T P S E N S O R r e a d i n g in the

D A T A L I S T w i t h the H D S .
16. S l o w l y a p p l y a b o u t 1.3 kPa (0.4 in.Hg, 10 m m H g ) of

17. C h e c k t h e F T P S E N S O R in the D A T A L I S T w i t h the

11. S e l e c t E V A P P C S O N in t h e I N S P E C T I O N M E N U HDS.
w i t h the H D S .
Is the difference more than 1.1kPa (0.31 in.Hg,
12. S l o w l y a p p l y a b o u t 2 k P a (0.6 i n . H g , 15 m m H g ) of 8 mmHg) before and after applying vacuum?
v a c u u m to the h o s e .
Does it hold vacuum?
N O — R e p l a c e the F T P s e n s o r ( s e e p a g e 11-542),
Y E S — C h e c k for a restricted in t h e E V A P c a n i s t e r t h e n g o to s t e p 2 2 .
p u r g e line b e t w e e n t h e E V A P c a n i s t e r p u r g e v a l v e
a n d the E V A P c a n i s t e r , t h e n g o to s t e p 2 2 . 18. R e c o n n e c t t h e v a c u u m h o s e to the E V A P c a n i s t e r
p u r g e line ( E V A P c a n i s t e r s i d e ) , a n d reinstall the
N O — G o to s t e p 13. FTP sensor.
13. R e m o v e the F T P s e n s o r w i t h its c o n n e c t o r

c o n n e c t e d ( s e e p a g e 11-542).
11-532
19. D i s c o n n e c t the v a c u u m h o s e (A) f r o m t h e E V A P 26. D o the E V A P F U N C T I O N T E S T in t h e I N S P E C T I O N
c a n i s t e r p u r g e v a l v e (B), a n d c o n n e c t a T-fitting (C) M E N U with the H D S .
from the v a c u u m gauge and the v a c u u m p u m p /
g a u g e , 0 — 3 0 in.Hg, to t h e h o s e a s s h o w n . Is the result OK?
N O — C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s
at t h e F T P s e n s o r , t h e E V A P c a n i s t e r p u r g e v a l v e , or
t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d the E C M ,
07JAZ-001000B
2 0 . S e l e c t E V A P C V S O N in t h e I N S P E C T I O N M E N U
w i t h the H D S .
2 1 . S l o w l y a p p l y a b o u t 2 kPa (0.6 in.Hg, 15 m m H g ) of

Does the hose hold vacuum?
Y E S — C h e c k for b l o c k a g e at the E V A P c a n i s t e r port,

N O — R e p l a c e the E V A P c a n i s t e r v e n t s h u t v a l v e ,
2 2 . R e c o n n e c t all h o s e s .
11-533
EVAP System
DTC P0498: EVAP Canister Vent Shut Valve 8. A t t h e v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n

Circuit Low Voltage E V A P canister vent shut valve 2P connector
and any on-board s n a p s h o t , a n d review the general E V A P C A N I S T E R V E N T S H U T V A L V E 2P C O N N E C T O R
2. C l e a r the D T C w i t h the H D S , t h e n w a i t 5 s e c o n d s .
Y E S — G o to s t e p 6. T e r m i n a l s i d e of m a l e t e r m i n a l s
Is there about 25- 30 Q at room temperature?
w i t h the H D S . Y E S — G o to s t e p 9.
5. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . N O — G o to s t e p 12.
Is DTC P0498 indicated? 9. J u m p the S C S line w i t h t h e H D S .
Y E S — G o to s t e p 6. 10. D i s c o n n e c t E C M c o n n e c t o r E (31P).
N O — I n t e r m i t t e n t failure, t h e s y s t e m is O K at t h i s 11. C h e c k for continuity b e t w e e n E C M c o n n e c t o r

t i m e . C h e c k for p o o r c o n n e c t i o n s or l o o s e t e r m i n a l s terminal E19 and body ground.
at the E V A P c a n i s t e r v e n t s h u t v a l v e a n d t h e
ECM.B E C M C O N N E C T O R E (31P)
1 / ' 3 4 | 5
/ 8 9
7. D i s c o n n e c t the E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
connector. /22
/
12 13 14 15 16 17 18 19 20 21
24 25 / 27 28 2 9 30
/
V S V (LT G R N / W H T )
Y E S — R e p a i r s h o r t in t h e w i r e b e t w e e n the E V A P
canister vent shut valve and the E C M (E19), then go
to s t e p 13.
11-534
4fi
12. R e p l a c e t h e E V A P c a n i s t e r v e n t s h u t v a l v e 2 1 . R e c o n n e c t all c o n n e c t o r s .
( s e e p a g e 11-543).
13. R e c o n n e c t E C M c o n n e c t o r E (31P). s o f t w a r e ( s e e p a g e 11-216), o r s u b s t i t u t e a k n o w n -
g o o d E C M ( s e e p a g e 11-217).
14. R e c o n n e c t t h e E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
connector. 2 3 . S e l e c t E V A P C V S O N in t h e I N S P E C T I O N M E N U
with the H D S .
18. S e l e c t E V A P C V S O N in t h e I N S P E C T I O N M E N U t e r m i n a l s at t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d
with the H D S . t h e E C M . If t h e E C M w a s u p d a t e d , substitute a
19. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . s t e p 2 3 . If t h e E C M w a s s u b s t i t u t e d , g o to s t e p 1.
Is DTC P0498 indicated? N O — G o to s t e p 24.
Y E S - ^ C h e c k for poor c o n n e c t i o n s or l o o s e 2 5 . M o n i t o r t h e O B D S T A T U S f o r D T C P0498 in t h e

t e r m i n a l s at the E V A P c a n i s t e r v e n t s h u t v a l v e a n d D T C s M E N U with the H D S .
t h e E C M , t h e n g o to s t e p 1.
20. M o n i t o r t h e O B D S T A T U S for D T C P 0 4 9 8 in t h e c o m p l e t e . If t h e E C M w a s s u b s t i t u t e d , r e p l a c e t h e
D T C s M E N U w i t h the H D S . original E C M ( s e e p a g e 11-389). If a n y other
T e m p o r a r y D T C s or D T C s w e r e indicated in s t e p 2 4 ,
Does the screen indicate PASSED? g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
Y E S — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y other N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 19, c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E V A P c a n i s t e r
g o to t h e indicated D T C s t r o u b l e s h o o t i n g . • v e n t s h u t v a l v e a n d t h e E C M . If t h e E C M w a s
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r 11-217), t h e n g o to s t e p 2 3 . If t h e E C M w a s
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E V A P c a n i s t e r s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
v e n t s h u t v a l v e a n d the E C M , t h e n g o to s t e p 1. If N O T C O M P L E T E D , g o to s t e p 2 3 .
18.
11-535
EVAP System
DTC P0499: EVAP Canister Vent Shut Valve 8. M e a s u r e v o l t a g e b e t w e e n E V A P c a n i s t e r v e n t s h u t

Circuit High Voltage valve 2P connector terminal No. 2 and body ground.
EVAP CANISTERV E N T S H U T V A L V E 2P CONNECTOR
2. C l e a r t h e D T C w i t h t h e H D S , t h e n w a i t 5 s e c o n d s . IG1 ( W H T )
with the H D S .
4. C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . W i r e s i d e of f e m a l e t e r m i n a l s

t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E V A P
at t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d t h e canister vent shut valve a n d the A / F s e n s o r relay
ECM.B ( L A F ) , t h e n g o to s t e p 16.
6. D i s c o n n e c t t h e E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
connector.
11-536
10. A t t h e v a l v e s i d e , m e a s u r e r e s i s t a n c e b e t w e e n 14. C h e c k for continuity b e t w e e n E C M c o n n e c t o r
E V A P canister vent shut valve 2P connector terminal E19 and body ground.
E V A P CANISTER V E N T S H U T V A L V E 2P CONNECTOR
1 1/ 3 4 | 5 7 XI 8 9
/ 11 12 13 14 15 16 17 18 19 20 21
22
/ 24 25
/ 27 28 29 30
/
Is there about 25— 30 Q at room temperature?
Y E S — G o to s t e p 2 3 .
N O — G o to s t e p 15. c a n i s t e r v e n t s h u t v a l v e a n d t h e E C M (E-19), t h e n g o
to s t e p 16.
15. R e p l a c e the E V A P c a n i s t e r v e n t s h u t v a l v e
12. D i s c o n n e c t E C M c o n n e c t o r E (31P). ( s e e p a g e 11-543).
13. C o n n e c t E V A P c a n i s t e r v e n t s h u t v a l v e 2 P 16. R e c o n n e c t all c o n n e c t o r s .

c o n n e c t o r t e r m i n a l N o . 1 to b o d y g r o u n d w i t h a
jumper wire. 17. T u r n t h e ignition s w i t c h O N (II).

E V A P CANISTER V E N T S H U T V A L V E 2P C O N N E C T O R
1 2
with the HDS.
JUMPER WIRE
(cont'd)
11-537
EVAP System
2 1 . C h e c k for T e m p o r a r y D T C s or D T C s w i t h t h e H D S . 2 6 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e Y E S — C h e c k for p o o r c o n n e c t i o n s or l o o s e
t e r m i n a l s at t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d t e r m i n a l s at t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d
t h e E C M , t h e n g o to s t e p 1. t h e E C M . If the E C M w a s u p d a t e d , substitute a
N O — G o to s t e p 2 2 . s t e p 2 5 . If the E C M w a s s u b s t i t u t e d , g o to s t e p 1.
2 2 . M o n i t o r t h e O B D S T A T U S for D T C P 0 4 9 9 in t h e N O — G o to s t e p 2 7 .
Does the screen indicate PASSED? D T C s M E N U with the H D S .
Y E S — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y other Does the screen indicate PASSED?

g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . • Y E S — I f t h e E C M w a s u p d a t e d , t r o u b l e s h o o t i n g is
N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r original E C M ( s e e p a g e 11-389). If a n y other
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E V A P c a n i s t e r T e m p o r a r y D T C s or D T C s w e r e i n d i c a t e d in s t e p 2 6 ,
v e n t s h u t v a l v e a n d t h e E C M , t h e n g o to s t e p 1. If g o to t h e i n d i c a t e d D T C s t r o u b l e s h o o t i n g . •
20. N O — I f t h e s c r e e n i n d i c a t e s F A I L E D , c h e c k for p o o r
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e E V A P c a n i s t e r
2 3 . R e c o n n e c t all c o n n e c t o r s . v e n t s h u t v a l v e a n d t h e E C M . If t h e E C M w a s
updated, substitute a known-good E C M (see page
24. U p d a t e t h e E C M if it d o e s not h a v e t h e latest 11-217), t h e n g o to s t e p 2 5 . If t h e E C M w a s
s o f t w a r e ( s e e p a g e 11-216), or s u b s t i t u t e a k n o w n - s u b s t i t u t e d , g o to s t e p 1. If t h e s c r e e n i n d i c a t e s
g o o d E C M ( s e e p a g e 11-217). N O T C O M P L E T E D , g o to s t e p 2 5 .
with the H D S .
11-538
DTC P1454: FTP Sensor Range/Performance 10. C l e a r t h e D T C w i t h t h e H D S .
Problem
DTC P2422: EVAP Canister Vent Shut Valve
Stuck Closed Malfunction 12. R e m o v e t h e E V A P c a n i s t e r v e n t s h u t v a l v e f r o m t h e
E V A P c a n i s t e r ( s e e p a g e 11-543).
a n d a n y on-board s n a p s h o t , a n d review the general 13. C o n n e c t t h e 2 P c o n n e c t o r to t h e E V A P c a n i s t e r v e n t
t r o u b l e s h o o t i n g information ( s e e p a g e 11-213). shut valve.
1. T u r n the ignition s w i t c h O N (II). 14. T u r n t h e ignition s w i t c h O N (II).
2. C l e a r t h e D T C with the H D S . 15. S e l e c t E V A P C V S O N in t h e I N S P E C T I O N M E N U

t with the H D S .
16. C h e c k t h e E V A P c a n i s t e r v e n t s h u t v a l v e (A)
4. R e m o v e t h e fuel fill c a p , a n d w a i t 1 m i n u t e . operation.
HDS.
Is It between - 0.67 kPa and 0.67 kPa (- 0.2 and

0.2 in.Hg, - 5 and 5 mmHg), or 2.4-2.6 V?
8. S t a r t t h e e n g i n e . Hold t h e e n g i n e s p e e d at Does the valve operate?

radiator f a n c o m e s o n , t h e n let it idle. Y E S — C h e c k for a b l o c k a g e in t h e E V A P c a n i s t e r ,
c a n i s t e r filter, v e n t h o s e s , a n d d r a i n joint, t h e n
9. M o n i t o r the O B D S T A T U S for D T C P 1 4 5 4 in t h e install the E V A P c a n i s t e r v e n t s h u t v a l v e , a n d g o to
D T C s M E N U with the H D S . step 23.
Does the screen indicate FAILED? N O — R e p l a c e the E V A P canister vent shut valve
( s e e p a g e 11-543), t h e n g o to s t e p 2 3 .
s e n s o r or t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d t h e
E C M . A l s o c h e c k for a b l o c k a g e in the c a n i s t e r filter,
v e n t h o s e s , a n d d r a i n joint. If t h e s c r e e n i n d i c a t e s
N O T C O M P L E T E D , g o to s t e p 8 a n d r e c h e c k .
(cont'd)
11-539
EVAP System
17. D i s c o n n e c t the air t u b e (A) f r o m t h e F T P s e n s o r (B). 2 1 . T u r n t h e ignition s w i t c h O N (II).
2 2 . C h e c k t h e F T P S E N S O R in t h e D A T A L I S T w i t h t h e
HDS.
Is it between - 0.67 kPa and 0.67 kPa (- 0.2 and

0.2 in.Hg, - 5 and 5 mmHg), or 2.4-2.6 V?
Y E S — C h e c k for d e b r i s o r c l o g g i n g at the E V A P
c a n i s t e r a n d t h e F T P s e n s o r port, t h e n g o to s t e p 2 3 .
N O — R e p l a c e the F T P s e n s o r ( s e e p a g e 11-542),
18. C h e c k t h e F T P S E N S O R in the D A T A L I S T w i t h t h e
HDS. 2 5 . D o the E C M idle learn p r o c e d u r e ( s e e p a g e 11-462).
Is It between - 0.67 kPa and 0.67 kPa (- 0.2 and 26. Start the e n g i n e . Hold t h e e n g i n e s p e e d at
0.2 in.Hg, - 5 and 5 mmHg), or 2.4-2.6 V? 3,000 r p m w i t h o u t load (in neutral) until the
Y E S — C h e c k for a b l o c k a g e in t h e F T P s e n s o r air
t u b e , t h e n g o to s t e p 2 3 . 2 7 . C h e c k for T e m p o r a r y D T C s o r D T C s w i t h the H D S .
N O — G o to s t e p 19. Is DTC P1454 and/or P2422 indicated?
19. T u r n t h e ignition s w i t c h O F F . Y E S — C h e c k for poor c o n n e c t i o n s or l o o s e

t e r m i n a l s at t h e F T P s e n s o r o r t h e E V A P c a n i s t e r
20. R e m o v e t h e F T P s e n s o r (A) f r o m t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d the E C M , t h e n g o to s t e p 1.
w i t h its c o n n e c t o r c o n n e c t e d ( s e e p a g e 11-542).
N O — G o to s t e p 2 8 .
11-540
2 8 . Monitor t h e O B D S T A T U S for D T C P 1 4 5 4 in t h e
Y E S — T r o u b l e s h o o t i n g i s c o m p l e t e . If a n y o t h e r
c o n n e c t i o n s or l o o s e t e r m i n a l s at t h e F T P s e n s o r ,
or t h e E V A P c a n i s t e r v e n t s h u t v a l v e a n d t h e E C M ,
t h e n g o to s t e p 1. If the s c r e e n i n d i c a t e s N O T
EVAP System
FTP Sensor Replacement EVAP Canister Purge Valve
Replacement
1. R e m o v e the E V A P c a n i s t e r ( s e e p a g e 11-544).
2 . R e m o v e t h e r e t a i n i n g c l i p (A). 1. D i s c o n n e c t t h e E V A P c a n i s t e r p u r g e v a l v e 2 P
c o n n e c t o r (A) a n d h o s e s (B).
3. R e m o v e t h e F T P s e n s o r (B). 3. Install the parts in the r e v e r s e o r d e r of r e m o v a l .
4. Install the parts in t h e r e v e r s e o r d e r of r e m o v a l

with a n e w O-ring (C).
11-542
EVAP Canister Vent Shut Valve Replacement
1. R e m o v e the E V A P c a n i s t e r ( s e e p a g e 11 - 5 4 4 ) .
2 . Pry the lock t a b s (A) o u t w a r d , a n d r e m o v e the E V A P

c a n i s t e r v e n t s h u t v a l v e (B).
N O T E : B e c a r e f u l not to d a m a g e the lock t a b s .
B
>
3. Install the parts in t h e r e v e r s e o r d e r of r e m o v a l

w i t h a n e w O-ring (C).
N O T E : D o not c o a t the O-ring w i t h o i l , etc.
11-543
EVAP System
EVAP Canister Replacement
1. R e m o v e t h e E V A P c a n i s t e r c o v e r (A). 5. R e m o v e t h e c a n i s t e r filter (A).
2. R e m o v e the h o s e s (A), t h e F T P s e n s o r 3 P c o n n e c t o r
(B), a n d the E V A P c a n i s t e r v e n t s h u t v a l v e 2 P
c o n n e c t o r (C).
6. R e m o v e t h e E V A P c a n i s t e r bracket (A).
7. Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l .
3. R e m o v e t h e bolts (D).
4. R e m o v e the E V A P c a n i s t e r a s s e m b l y ( E ) .
11-544
Fuel Tank Vapor Control Float Replacement
1. R e m o v e t h e fuel tank ( s e e p a g e 11-489).
2 . R e m o v e t h e fuel tank v a p o r control float (A) f r o m

t h e fuel tank (B).
3. Install the p a r t s in t h e r e v e r s e o r d e r of r e m o v a l
w i t h a n e w p a c k i n g (C).
11-545
Transaxle
Clutch 12-1
Rear Differential 15-1
Driveline/Axle 16-1
I
Clutch
Special Tools 12-2

System Description 12-4
Clutch Hydraulic System Bleeding 12-6
Clutch Pedal, Clutch Pedal Position Switch,
and Clutch Interlock Switch Adjustment 12-7
Clutch Master Cylinder Replacement 12-8
Slave Cylinder Replacement 12-9
Clutch Replacement 12-10
Clutch
Special Tools

® 07LAB-PV00100 or 07924-PD20003 Ring G e a r Holder 1
® 07LAF-PT00110 Clutch Alignment Shaft 1
® 07746-0010200 A t t a c h m e n t , 3 2 x 37 m m 1
® 07749-0010000 Driver 1
® 07936-3710100 Remover Handle 1
12-2
/ CLUTCH MASTER CYLINDER

' R e p l a c e m e n t , p a g e 12-8 04-08 m o d e l s
RESERVOIR I CLUTCH INTERLOCK SWITCH
f T e s t , p a g e 4-9
A d j u s t m e n t , p a g e 12-7
SLAVE CYLINDER
CLUTCH MASTER
CYLINDER SEAL
R e p , 8 C e
L O C K PIN
CLUTCH PEDAL
POSITION SWITCH
T e s t , p a g e 4-72
Adjustment,
p a g e 12-7
CLUTCH DISC
R e m o v a l , p a g e 12-11
PILOT BEARING
Replacement,
p a g e 12-12
FLYWHEEL
PRESSURE PLATE
RELEASE BEARING R e m o v a l , p a g e 12-10
I n s p e c t i o n , p a g e 12-11 I n s t a l l a t i o n , p a g e 12-13
12-3
Clutch
System Description
Delay Orifice Mechanism ('04-08 models)
Function
T h e d e l a y orifice m e c h a n i s m i m p r o v e s c l u t c h o p e r a t i o n b y d e l a y i n g t h e s l a v e c y l i n d e r r e l e a s e s p e e d w h e n the c l u t c h
p e d a l is s u d d e n l y r e l e a s e d . T h e d e l a y orifice m e c h a n i s m is built into t h e s l a v e c y l i n d e r .
D E L A Y ORIFICE
MECHANISM
12-4
Operation
W h e n the c l u t c h p e d a l is p r e s s e d , the fluid p r e s s u r e f r o m the m a s t e r c y l i n d e r m o v e s the o n e - w a y v a l v e in the
direction s h o w n in t h e illustration. T h e fluid f l o w s t h r o u g h t w o p a s s a g e s : the orifice part a n d t h e filter part. It t h e n
f l o w s out to t h e s l a v e c y l i n d e r to r e l e a s e the p r e s s u r e plate a n d c l u t c h d i s c joint.
ORIFICE PART ONE-WAY VALVE
From M A S T E R CYLINDER
FILTER PART
W h e n the c l u t c h p e d a l i s r e l e a s e d , t h e fluid p r e s s u r e f r o m the s l a v e c y l i n d e r m o v e s t h e o n e - w a y v a l v e in the direction

s h o w n in t h e illustration. T h e o n e - w a y v a l v e b l o c k s the filter part p a s s a g e a n d d e l a y s t h e clutch r e l e a s e s p e e d b y
returning t h e fluid to t h e m a s t e r c y l i n d e r t h r o u g h o n l y the orifice part p a s s a g e .
To MASTER CYLINDER
FILTER PART
12-5
Clutch
Clutch Hydraulic System Bleeding
NOTE: 2 . A t t a c h o n e e n d of c l e a r t u b e to the b l e e d e r s c r e w
• Do not r e u s e t h e d r a i n e d fluid. A l w a y s u s e H o n d a (A), a n d t h e o t h e r e n d to t h e c o n t a i n e r of brake fluid.
D O T 3 Brake Fluid from a n unopened container. L o o s e n the b l e e d e r s c r e w to a l l o w a i r to e s c a p e
U s i n g a n o n - H o n d a b r a k e fluid c a n c a u s e c o r r o s i o n from the s y s t e m .
a n d s h o r t e n t h e life of t h e s y s t e m .
• Do not m i x different b r a n d s of brake f l u i d ; t h e y m a y '00-03 m o d e l s
not b e c o m p a t i b l e .
• M a k e s u r e dirt o r other f o r e i g n matter is not a l l o w e d A
9.8 N - m
to c o n t a m i n a t e t h e b r a k e fluid. (1.0 k g f m , 7.2 I b f f t )
• D o not s p i l l b r a k e fluid o n t h e v e h i c l e ; it m a y d a m a g e
t h e paint. If b r a k e fluid d o e s c o n t a c t t h e paint, w a s h it
off i m m e d i a t e l y w i t h w a t e r .
• If m a y b e n e c e s s a r y to limit t h e m o v e m e n t of t h e
r e l e a s e fork w i t h a block of w o o d to r e m o v e all t h e a i r
from the s y s t e m .
surfaces.
1. M a k e s u r e t h e brake fluid level in t h e r e s e r v o i r i s at

t h e M A X (upper) level line (A).
MAX
MIN t!_
3 . M a k e s u r e t h e r e i s a n a d e q u a t e s u p p l y of fluid in
the reservoir, then s l o w l y p u m p the clutch pedal
until no m o r e b u b b l e s a p p e a r at t h e c l e a r t u b e .
4. Tighten the bleeder s c r e w securely.
5 . Refill t h e b r a k e fluid in t h e r e s e r v o i r to t h e M A X
(upper) level line.
12-6
«0
Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch
Adjustment
NOTE: 5. T u r n in the c l u t c h p e d a l position s w i t c h a n
• C h e c k the c l u t c h p e d a l position s w i t c h ( s e e p a g e 4-72). additional 3/4 to 1 t u r n .
• C h e c k t h e c l u t c h interlock s w i t c h ( s e e p a g e 4-9).
• T h e c l u t c h is s e l f - a d j u s t i n g to c o m p e n s a t e for w e a r . 6. T i g h t e n t h e c l u t c h p e d a l p o s i t i o n s w i t c h locknut.
• If there is n o c l e a r a n c e b e t w e e n t h e m a s t e r c y l i n d e r
piston a n d p u s h r o d , t h e r e l e a s e b e a r i n g w i l l be held 7. L o o s e n t h e c l u t c h interlock s w i t c h locknut (H) a n d
a g a i n s t the d i a p h r a g m s p r i n g , w h i c h c a n result in the c l u t c h interlock s w i t c h (I).
clutch s l i p p a g e o r other c l u t c h p r o b l e m s .
8. P r e s s the c l u t c h p e d a l to t h e floor.
1. L o o s e n t h e c l u t c h p e d a l p o s i t i o n s w i t c h locknut (A),
a n d back off t h e c l u t c h p e d a l position s w i t c h (B) 9. R e l e a s e the c l u t c h p e d a l 1 5 — 2 0 m m ( 0 . 5 9 — 0 . 7 9 in.)
until it n o l o n g e r t o u c h e s t h e c l u t c h p e d a l (C). f r o m the fully p r e s s e d p o s i t i o n , a n d h o l d it t h e r e .
A d j u s t t h e position of the c l u t c h interlock s w i t c h s o
H
9.8 N - m (1.0 k g f - m , 7.2 Ibf-ft)
the e n g i n e w i l l start w i t h t h e c l u t c h p e d a l in t h i s
position.
10. T i g h t e n t h e c l u t c h interlock s w i t c h locknut.
11. C h e c k the c l u t c h o p e r a t i o n .
A
9.8 N m
(1.0 k g f m ,
7.2 lbfft)
2. L o o s e n t h e c l u t c h p u s h r o d locknut (D), a n d t u r n the

p u s h r o d (E) in or out to get t h e s p e c i f i e d height (F)
a n d stroke (G) at t h e c l u t c h p e d a l .
Clutch Pedal Stroke:

1 1 5 - 1 2 5 m m ( 4 . 5 3 - 4 . 9 2 in.)
Clutch Pedal Height:
189 m m (7.44 in.)
3. T i g h t e n t h e c l u t c h p u s h r o d locknut.
4. W i t h the c l u t c h p e d a l r e l e a s e d , t u r n in t h e c l u t c h
pedal position s w i t c h until it c o n t a c t s t h e c l u t c h
pedal.
12-7
Clutch
Clutch Master Cylinder Replacement
NOTE: 4. R e m o v e the c l u t c h m a s t e r c y l i n d e r (A).

surfaces.
• D o not spill brake fluid o n t h e v e h i c l e ; it m a y d a m a g e
the paint. If b r a k e fluid d o e s c o n t a c t t h e paint, w a s h it
1. R e m o v e the brake fluid f r o m the c l u t c h m a s t e r

c y l i n d e r r e s e r v o i r (A) w i t h a s y r i n g e .
5. Install t h e c l u t c h m a s t e r c y l i n d e r in t h e r e v e r s e
o r d e r of r e m o v a l .
6. B l e e d the c l u t c h h y d r a u l i c s y s t e m ( s e e p a g e 12-6).
2. D i s c o n n e c t t h e c l u t c h line (B) f r o m t h e c l u t c h
m a s t e r c y l i n d e r . P l u g o r w r a p the e n d of t h e c l u t c h 7. A d j u s t the c l u t c h p e d a l , c l u t c h p e d a l position
line w i t h a s h o p t o w e l to p r e v e n t brake fluid f r o m s w i t c h , a n d c l u t c h interlock s w i t c h ( s e e p a g e 12-7).
c o m i n g out.
8. C h e c k the c l u t c h o p e r a t i o n a n d c h e c k for l e a k s .
3. Pry out t h e lock pin (A), a n d pull the c l e v i s pin (B)
out of t h e y o k e . R e m o v e t h e m a s t e r c y l i n d e r 9. T e s t - d r i v e t h e v e h i c l e .
m o u n t i n g n u t s (C).
C
8 x 1.25 m m
1 3 N - m (1.3 k g f - m , 9.4 I b f f t )
12-8
Slave Cylinder Replacement
NOTE: 2. R e m o v e t h e t w o bolts ( E ) a n d s l a v e c y l i n d e r .
surfaces. 3. Pull b a c k t h e boot (A), a n d a p p l y M-77 a s s e m b l y
• D o not s p i l l b r a k e fluid o n t h e v e h i c l e ; it m a y d a m a g e paste (P/N 08798-9010) or equivalent rubber g r e a s e
t h e paint. If b r a k e fluid d o e s c o n t a c t t h e paint, w a s h it to t h e boot a n d s l a v e c y l i n d e r rod (B). R e i n s t a l l t h e
off i m m e d i a t e l y w i t h w a t e r . boot.
1. R e m o v e t h e b a n j o bolt (A) a n d w a s h e r s (B), t h e n

d i s c o n n e c t t h e c l u t c h h o s e (C) f r o m t h e s l a v e
c y l i n d e r (D). P l u g o r w r a p t h e e n d of t h e c l u t c h h o s e
w i t h a s h o p t o w e l to p r e v e n t b r a k e fluid f r o m
c o m i n g out.
'00-03 m o d e l s
(P/N 08798-9002)
GREASE nl
( P / N 08798-9010)
4. A p p l y s u p e r high t e m p u r e a g r e a s e
(P/N 0 8 7 9 8 - 9 0 0 2 ) to t h e tip of t h e s l a v e c y l i n d e r r o d .
5. Install t h e s l a v e c y l i n d e r in t h e r e v e r s e o r d e r of
r e m o v a l . U s e n e w b a n j o bolt w a s h e r s .
N O T E : M a k e s u r e t h e boot is installed o n t h e s l a v e
cylinder.
6. B l e e d t h e c l u t c h h y d r a u l i c s y s t e m ( s e e p a g e 12-6).
8x1.25 mm
2 2 N m ( 2 . 2 k g f - m , 1 6 Ibf-ft) 7. C h e c k t h e c l u t c h o p e r a t i o n a n d c h e c k for l e a k s .
'04-08 m o d e l s 8. T e s t - d r i v e t h e v e h i c l e .
B
Replace.
A
10x1.0 mm
2 9 N m (3.0 k g f - m , 2 2 Ibf-ft)
12-9
Clutch
Clutch Replacement
Special Tools Required 6. I n s p e c t t h e f i n g e r s of t h e d i a p h r a g m s p r i n g (A) for

• R i n g g e a r h o l d e r 0 7 L A B - P V 0 0 1 0 0 or w e a r at t h e r e l e a s e b e a r i n g c o n t a c t a r e a .
07924-PD20003
• Clutch alignment shaft 07LAF-PT00110 A
• A t t a c h m e n t 32 x 37 m m 07746-0010200
•Driver 07749-0010000
• R e m o v e r handle 07936-3710100
Pressure Plate R e m o v a l and Inspection
1. T r a n s m i s s i o n r e m o v a l ( s e e p a g e 13-6).
2. C h e c k t h e h e i g h t - v a r i a t i o n of t h e d i a p h r a g m s p r i n g
f i n g e r s u s i n g t h e dial i n d i c a t o r (A). If t h e v a r i a t i o n is
m o r e t h a n t h e s e r v i c e limit, r e p l a c e t h e p r e s s u r e
plate.
Standard (New): 0.4 m m (0.016 in.) m a x . 7. I n s p e c t t h e s u r f a c e of t h e p r e s s u r e (B) plate for

S e r v i c e Limit: 0.6 m m (0.024 in.) wear, cracks, and burning.
8. I n s p e c t f o r w a r p a g e u s i n g a straight e d g e (A) a n d
f e e l e r g a u g e (B). M e a s u r e a c r o s s t h e p r e s s u r e plate
(C). If t h e w a r p a g e is m o r e t h a n t h e s e r v i c e limit,
r e p l a c e t h e p r e s s u r e plate.
Standard (New): 0.03 m m (0.001 in.) m a x .

3. Install t h e ring g e a r h o l d e r (A), c l u t c h a l i g n m e n t

s h a f t ( B ) , a n d r e m o v e r h a n d l e (C).
0 7 L A B - P V 0 0 1 0 0 or 07924-PD20003
4. T o p r e v e n t w a r p i n g , r e m o v e t h e p r e s s u r e plate
m o u n t i n g bolts (D) in a c r i s s c r o s s pattern in s e v e r a l
s t e p s , t h e n r e m o v e t h e p r e s s u r e plate ( E ) .
5. R e m o v e t h e r e l e a s e b e a r i n g (F) f r o m t h e p r e s s u r e
plate.
12-10
Release Bearing Inspection 12. M e a s u r e the c l u t c h d i s c t h i c k n e s s . If t h e t h i c k n e s s
is l e s s t h a n the s e r v i c e limit, r e p l a c e the c l u t c h d i s c .
9. C h e c k t h e p l a y of t h e r e l e a s e b e a r i n g b y s p i n n i n g it
w i t h y o u r h a n d , if t h e r e is e x c e s s i v e p l a y or n o i s e , S t a n d a r d (New): 8 . 2 - 8 . 9 m m ( 0 . 3 2 - 0 . 3 5 in.)
r e p l a c e the r e l e a s e b e a r i n g . S e r v i c e Limit: 6.0 m m (0.24 in.)
N O T E : T h e r e l e a s e b e a r i n g is p a c k e d w i t h g r e a s e .
D o not w a s h it in s o l v e n t .
13. M e a s u r e t h e rivet depth f r o m the c l u t c h d i s c lining

s u r f a c e (A) to the rivets ( B ) , o n both s i d e s . If t h e
rivet depth i s l e s s t h a n t h e s e r v i c e limit, r e p l a c e the
clutch disc.
Clutch Disc Removal and Inspection S t a n d a r d (New): 1 . 2 - 1 . 7 m m ( 0 . 0 4 7 - 0 . 0 6 7 in.)

10. R e m o v e the c l u t c h d i s c (A), c l u t c h a l i g n m e n t shaft
(B), a n d r e m o v e r h a n d l e (C).
07936-3710100
07LAF-PT00110
71 IT
11. I n s p e c t the lining of the c l u t c h d i s c for s i g n s of

s l i p p i n g or oil. If the c l u t c h d i s c l o o k s burnt or is
s o a k e d w i t h , oil r e p l a c e it. If the c l u t c h d i s c is oil
s o a k e d , find a n d repair the s o u r c e of t h e oil leak.
(cont'd)
12-11
Clutch
Clutch Replacement (cont'd)
F l y w h e e l a n d Pilot B e a r i n g I n s p e c t i o n F l y w h e e l a n d Pilot B e a r i n g R e p l a c e m e n t
14. R e m o v e the ring g e a r h o l d e r . 19. Install the ring g e a r h o l d e r (A).
15. I n s p e c t t h e ring g e a r t e e t h for w e a r a n d d a m a g e .

A
0 7 L A B - P V 0 0 1 0 0 or
16. I n s p e c t t h e c l u t c h d i s c m a t i n g s u r f a c e o n t h e
f l y w h e e l for w e a r , c r a c k s , a n d b u r n i n g .
17. M e a s u r e the f l y w h e e l (A) r u n o u t u s i n g a dial

indicator (B) t h r o u g h at l e a s t t w o full t u r n s w i t h
p u s h i n g a g a i n s t t h e f l y w h e e l e a c h t i m e y o u t u r n it
to t a k e up the c r a n k s h a f t t h r u s t w a s h e r c l e a r a n c e . If
t h e r u n o u t is m o r e t h a n t h e s e r v i c e limit, r e p l a c e
t h e f l y w h e e l , a n d r e c h e c k t h e r u n o u t , g o to s t e p 19.
Standard (New): 0 . 0 5 m m (0.002 in.) m a x .

S e r v i c e Limit: 0 . 1 5 m m (0.006 in.)
20. R e m o v e the f l y w h e e l m o u n t i n g bolts (B) in a
B c r i s s c r o s s pattern in s e v e r a l s t e p s , t h e n r e m o v e the
f l y w h e e l a n d ring g e a r h o l d e r .
2 1 . R e m o v e the pilot b e a r i n g (A) f r o m the f l y w h e e l (B).
18. T u r n t h e i n n e r r a c e of t h e pilot b e a r i n g (A) w i t h

y o u r finger. T h e pilot b e a r i n g s h o u l d t u r n s m o o t h l y
a n d quietly. M a k e s u r e t h e pilot b e a r i n g outer r a c e
fits tightly in t h e f l y w h e e l . If t h e r a c e d o e s not t u r n
s m o o t h l y , quietly, o r fit tight in the f l y w h e e l ,
r e p l a c e the pilot b e a r i n g , g o to s t e p 19.
12-12
<3®
2 2 . Install t h e n e w pilot b e a r i n g into t h e f l y w h e e l u s i n g C l u t c h Disc a n d Pressure Plate Installation
the 32 x 37 m m a t t a c h m e n t (A) a n d d r i v e r (B) a s
s h o w n . A p p l y a light c o a t of e n g i n e oil to t h e 2 5 . A p p l y a t h i n , uniform c o a t of s u p e r high t e m p u r e a
bearing surface. g r e a s e (P/N 08798-9002) to t h e s p l i n e s (A) of the
c l u t c h d i s c ( B ) . T e m p o r a r y install the c l u t c h d i s c
o n t o t h e s p l i n e s of the t r a n s m i s s i o n m a i n s h a f t .
M a k e s u r e t h e clutch d i s c s l i d e s freely o n t h e
mainshaft, and remove extra overflow g r e a s e .
2 3 . A l i g n t h e hole in the f l y w h e e l w i t h t h e c r a n k s h a f t
d o w e l p i n , a n d install t h e f l y w h e e l . Install t h e
w a s h e r a n d m o u n t i n g bolts, finger-tight.
24. Install t h e ring g e a r h o l d e r (A), t h e n t o r q u e t h e

f l y w h e e l m o u n t i n g bolts in a c r i s s c r o s s pattern in
several steps.
12x1.0 mm
2 6 . Install t h e ring g e a r h o l d e r (C).
2 7 . Install t h e c l u t c h d i s c u s i n g t h e c l u t c h a l i g n m e n t
s h a f t (D) a n d r e m o v e r h a n d l e (E).
(cont'd)
12-13
Clutch
Clutch Replacement (cont'd)
2 8 . A p p l y s u p e r h ig h t e m p u r e a g r e a s e 3 0 . T o r q u e t h e m o u n t i n g bolts in a c r i s s c r o s s pattern in
(P/N 0 8 7 9 8 - 9 0 0 2 ) into t h e g r o o v e (A) of t h e r e l e a s e s e v e r a l s t e p s to p r e v e n t w a r p i n g t h e d i a p h r a g m
b e a r i n g (B), t h e n install t h e r e l e a s e b e a r i n g o n t h e spring.
p r e s s u r e plate ( 0 ) .
S p e c i f i e d T o r g u e : 2 5 N m (2.6 k g f - m , 19 Ibfft)
f \
2 9 . Install t h e p r e s s u r e plate a n d the m o u n t i n g bolts 3 1 . R e m o v e t h e ring g e a r h o l d e r , c l u t c h a l i g n m e n t

(D), finger-tight. M a k e s u r e t h e r e l e a s e b e a r i n g shaft, a n d r e m o v e r handle.
d o e s not c o m e off.
3 2 . M a k e s u r e t h e d i a p h r a g m s p r i n g f i n g e r s a r e all the
s a m e height.
3 3 . T r a n s m i s s i o n installation ( s e e p a g e 13-67).
12-14
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If manual transmission maintenance is required)
T h e S 2 0 0 0 S R S i n c l u d e s a d r i v e r ' s a i r b a g in t h e s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in t h e d a s h b o a r d a b o v e t h e
g l o v e b o x , a n d s e a t belt t e n s i o n e r s in the s e a t belt r e t r a c t o r s . I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e t h e S R S i s
i n c l u d e d in t h i s S e r v i c e M a n u a l . I t e m s m a r k e d w i t h a n a s t e r i s k ( * ) o n t h e c o n t e n t s p a g e i n c l u d e or a r e l o c a t e d n e a r
S R S c o m p o n e n t s . S e r v i c i n g , disassembling, or replacing these items requires special precautions and tools, and
s h o u l d be done by a n authorized Honda dealer.
• T o a v o i d r e n d e r i n g t h e S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury or d e a t h in t h e e v e n t of a s e v e r e frontal
c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d b e d o n e b y a n a u t h o r i z e d H o n d a d e a l e r .
• I m p r o p e r s e r v i c e p r o c e d u r e s , i n c l u d i n g i n c o r r e c t r e m o v a l a n d installation of t h e S R S , c o u l d l e a d to p e r s o n a l injury
c a u s e d b y unintentional activation of t h e a i r b a g s a n d s e a t belt t e n s i o n e r s .
• D o not b u m p or i m p a c t t h e S R S unit, or front i m p a c t s e n s o r s w h e n t h e ignition s w i t c h is O N (II), or for at l e a s t 3
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e box. D o not u s e e l e c t r i c a l
test e q u i p m e n t o n t h e s e c i r c u i t s .
Manual Transmission
Special Tools ......... 13-2 Countershaft Reassembly .......... 13-41

Transmission Fluid Inspection Secondary Shaft Disassembly ... 13-46
and Replacement ...» 13-3 Secondary Shaft Inspection 13-46
Back-up Light Switch Secondary Shaft Reassembly .... 13-47
Test and Replacement ............. 13-4 Shift Fork Clearance
Gearshift Mechanism Inspection 13-48
Replacement 13-5 Shift Fork Disassembly/
Transmission Removal 13-6 Reassembly , 13-50
Transmission Disassembly 13-14 Synchro Ring and
Mainshaft Assembly Clearance Gear Inspection 13-51
Inspection 13-25 Synchro Sleeve and Hub
Mainshaft Disassembly 13-29 Inspection and Reassembly .... 13-52
Mainshaft Inspection 13-30 Oil Pump Clearance
Mainshaft Reassembly 13-31 Inspection ............ 13-53
Shift Arm Rod Assembly Secondary Shaft Preload
Disassembly/Reassembly 13-36 Adjustment 13-54
Countershaft Assembly Mainshaft Thrust Clearance
Clearance Inspection 13-36 Adjustment 13-55
Countershaft Disassembly 13-39 Transmission Reassembly 13-56
Countershaft Inspection ............. 13-40 * Transmission Installation 13-67
Manual Transmission
Special Tools

**® 07GAJ-PG20110 Mainshaft Holder 1
**® 07GAJ-PG20130 Mainshaft B a s e 1
® 07JAB-001020A Holder Handle 1
® 07LAD-PW50601 A t t a c h m e n t , 40 x 50 m m I.D. 1
® 07PAB-001A300 Mainshaft Holder 1
® 07RAB-TB4010B C o m p a n i o n Flange Holder 1
*® 07736-A01000B Adjustable Bearing Puller, 20—40 m m 1
® 07746-0010300 A t t a c h m e n t , 42 x 47 m m 1
® 07746-0010500 Attachment, 62 x 68 m m 1
® 07746-0010600 Attachment, 72 x 75 m m 1
® 07746-0030100 Driver Handle 1
@ 07746-0030300 A t t a c h m e n t , 3 0 m m I.D. 1
® 07746-0030400 A t t a c h m e n t , 3 5 m m I.D. 1
® 07749-0010000 Driver 1
® 07946-MB00000 D r i v e r , 3 0 m m I.D. 1
® 07947-6890300 Attachment, 45 m m 1
® 07965-SA50500 A t t a c h m e n t , 3 5 m m I.D. 1
* Must be u s e d with c o m m e r c i a l l y available 3 / 8 " - 1 6 U N F slide h a m m e r .
* * Part of M a i n s h a f t I n s p e c t i o n T o o l S e t , 0 7 G A J - P G 2 0 1 0 A .
13-2
<S0
Transmission Fluid Inspection and Replacement
1. R a i s e the v e h i c l e o n a lift. 3 . If t h e fluid i s dirty, r e m o v e t h e d r a i n p l u g (A) a n d

d r a i n t h e fluid.
2 . R e m o v e the filler plug (A) a n d t h e s e a l i n g w a s h e r
C
(B), c h e c k the c o n d i t i o n of t h e fluid, a n d m a k e s u r e 44 N m
it i s at the proper level (C). (4.5 k g f - m
3 3 Ibf-ft)
( 4 . 0 k g f m , 2 9 l b f ft)
4 . Install t h e d r a i n plug w i t h a n e w s e a l i n g w a s h e r (B),

a n d refill t h e t r a n s m i s s i o n fluid to the p r o p e r l e v e l .
Fluid Capacity:
1.48 L (1.56 U S qt) a t f l u i d c h a n g e
1.62 L (1.71 U S qt) a t o v e r h a u l
A l w a y s u s e H o n d a m a n u a l t r a n s m i s s i o n fluid
( M T F ) . U s i n g e n g i n e oil c a n c a u s e stiff shifting
b e c a u s e it d o e s not c o n t a i n t h e p r o p e r a d d i t i v e s .
5 . Install the filler plug (C) w i t h a n e w s e a l i n g w a s h e r

(D).
13-3
Manual Transmission
Back-up Light Switch Test and Replacement
1. D i s c o n n e c t t h e b a c k - u p light s w i t c h 2 P c o n n e c t o r 6. P l a c e the floor j a c k u n d e r the t r a n s m i s s i o n , a n d
(A). r e m o v e the t h r e e t r a n s m i s s i o n r e a r m o u n t bolts (A),
a n d t h e n l o w e r t h e t r a n s m i s s i o n (B) 6 5 m m (2.56 in.).
2. C h e c k for t h e c o n t i n u i t y b e t w e e n the b a c k - u p light

s w i t c h 2 P c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 2.
T h e r e s h o u l d b e c o n t i n u i t y w h e n t h e shift l e v e r is
o n l y in r e v e r s e . If t h e r e is n o continuity, g o to s t e p 3
to r e p l a c e t h e b a c k - u p light s w i t c h . 7. R e p l a c e the b a c k - u p light s w i t c h (A) a n d t h e n e w
w a s h e r (B) b y t h e 3 / 8 " c r o w foot w r e n c h (19 m m )
3. R e m o v e t h e shift l e v e r k n o b , boot h o l d e r , shift boot, (C).
shift l e v e r , a n d shift l e v e r s p r i n g ( s e e p a g e 13-6).
4. R e m o v e the t h r e e w a y c a t a l y t i c c o n v e r t e r ( T W C )
( s e e s t e p 3 0 o n p a g e 13-11).
5. R e m o v e the p r o p e l l e r s h a f t ( s e e p a g e 16-18).
13-4
Gearshift Mechanism Replacement
(Multipurpose Grease)
SHIFT LEVER SPRING
6x1.0 mm SHIFT LEVER HOUSING

9.8 N - m
(1.0 k g f m ,
7.2 I b f f t )
Manual Transmission
Transmission Removal
N O T E : U s e f e n d e r c o v e r s to a v o i d d a m a g i n g p a i n t e d 5. R e m o v e the c e n t e r c o n s o l e ( s e e p a g e 20-80).
surfaces.
6. R e m o v e t h e boot h o l d e r (A) by r e l e a s i n g the lock
S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e t a b s (B) i n d i c a t e d b y t h e a r r o w h e a d s (C). Insert a
S R S c o m p o n e n t l o c a t i o n s for t h e a p p r o p r i a t e m o d e l : h o o k - s h a p e d tool (D) u n d e r n e a t h the boot h o l d e r ,
a n d lift s l i g h t l y w h i l e r e l e a s i n g t h e lock t a b s w i t h a
• '00-05 m o d e l s (see page 23-11) flat-tip s c r e w d r i v e r ( E ) .
• '06-08 m o d e l s ( s e e p a g e 2 3 - 1 2 )
2. D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m the battery,
then disconnect the positive cable.
3. R e m o v e t h e battery.
4. L o o s e n the l o c k n u t , t h e n r e m o v e t h e shift l e v e r
knob.
except C R model
7. Pull up a n d r e m o v e the boot h o l d e r a n d the shift

l e v e r boot (F).
8. R e m o v e t h e t h r e e bolts, t h e n r e m o v e the shift l e v e r

(A) a n d the shift l e v e r s p r i n g (B).
CR model
B
13-6
9. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t the air h o s e (A) a n d 11. ' 0 6 - 0 8 m o d e l s : D i s c o n n e c t t h e intake air
b r e a t h e r pipe (B), t h e n r e m o v e the air c l e a n e r t e m p e r a t u r e (IAT) s e n s o r c o n n e c t o r (A) a n d
h o u s i n g c o v e r (C) a n d air c l e a n e r e l e m e n t b r e a t h e r pipe (B), r e m o v e t h e m a n i f o l d a b s o l u t e
a s s e m b l y (D). p r e s s u r e ( M A P ) s e n s o r h a r n e s s (C) f r o m t h e holder,
t h e n r e m o v e the air c l e a n e r h o u s i n g c o v e r (D) a n d
air c l e a n e r e l e m e n t a s s e m b l y ( E ) .
10. ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t the air control v a l v e

v a c u u m control s o l e n o i d v a l v e c o n n e c t o r (A) a n d
v a c u u m h o s e s (B), t h e n r e m o v e the air c l e a n e r
h o u s i n g (C). 12. '06-08 m o d e l s : R e m o v e I A T s e n s o r h a r n e s s c l a m p s
(A), t h e n r e m o v e the air c l e a n e r h o u s i n g (B).
(cont'd)
13-7
Manual Transmission
Transmission Removal (cont'd)

13. T u r n t h e s t e e r i n g w h e e l to t h e s t r a i g h t - a h e a d 17. R e m o v e t h e f o u r e x h a u s t m a n i f o l d c o v e r m o u n t i n g
p o s i t i o n , t h e n r e m o v e t h e k e y f r o m t h e ignition bolts.
s w i t c h a n d lock t h e s t e e r i n g c o l u m n . M a k e
r e f e r e n c e m a r k s (A) a c r o s s t h e s t e e r i n g joint ( 6 ) .
18. R e m o v e t h e h e a t s h i e l d (A), t h e n r e m o v e t h e
exhaust manifold cover.
14. L o o s e n t h e u p p e r s t e e r i n g joint bolt ( C ) , a n d

r e m o v e the l o w e r s t e e r i n g joint bolt (D). D i s c o n n e c t
t h e s t e e r i n g joint f r o m t h e g e a r b o x .
15. R e m o v e the a l t e r n a t o r - c o m p r e s s o r belt a n d t h e

alternator ( s e e p a g e 4-45).
16. D i s c o n n e c t t h e 1P c o n n e c t o r (A), t h e n r e m o v e t h e
f o u r m o u n t i n g bolts a n d t h e A / C c o m p r e s s o r (B).
Hang the A / C c o m p r e s s o r from the body with a
p i e c e of w i r e .
13-8
19. '00-05 m o d e l s : R e m o v e the u p p e r starter m o t o r 2 1 . ' 0 0 - 0 5 m o d e l s : D i s c o n n e c t c a m s h a f t position ( C M P )
m o u n t i n g bolt (A) a n d u p p e r intake m a n i f o l d s e n s o r A (top d e a d c e n t e r ( T D C ) s e n s o r 1) a n d C M P
bracket m o u n t i n g bolt (B). D i s c o n n e c t t h e h o s e (C) s e n s o r B ( T D C s e n s o r 2) c o n n e c t o r s .
f r o m the s u c t i o n v a l v e .
2 2 . ' 0 6 - 0 8 m o d e l s : D i s c o n n e c t the c a m s h a f t position

(CMP) sensor connector.
20. '06-08 m o d e l s : R e m o v e the u p p e r starter m o t o r

m o u n t i n g bolt (A) a n d u p p e r intake m a n i f o l d
bracket m o u n t i n g bolt (B).
(cont'd)
13-9
Manual Transmission
2 3 . D i s c o n n e c t t h e 2 P c o n n e c t o r (A) f r o m t h e s t e e r i n g 28. R e m o v e the w i r e h a r n e s s (A), g r o u n d c a b l e (B), a n d

g e a r b o x (B). l o w e r intake m a n i f o l d bracket m o u n t i n g bolt, t h e n
r e m o v e t h e intake m a n i f o l d b r a c k e t (C).
29. Disconnect the primary heated o x y g e n s e n s o r

24. D i s c o n n e c t t h e t o r q u e s e n s o r 3 P c o n n e c t o r ( C ) , a n d ( p r i m a r y H 0 2 S ) ( s e n s o r 1) ('00-05 m o d e l s ) or t h e air
r e m o v e t h e w i r e h a r n e s s c l a m p (D). fuel ratio (A/F) s e n s o r ( s e n s o r 1) ('06-08 m o d e l s ) (A),
s e c o n d a r y heated oxygen s e n s o r (secondary
2 5 . R a i s e t h e v e h i c l e o n a lift. H 0 2 S ) ( s e n s o r 2) (B), a n d t h e b a c k - u p light s w i t c h
(C) c o n n e c t o r s , t h e n r e m o v e t h e w i r e h a r n e s s f r o m
26. R e m o v e t h e s p l a s h s h i e l d . the t r a n s m i s s i o n .
C A
2 7 . D r a i n t h e t r a n s m i s s i o n fluid. Install t h e d r a i n plug

w i t h a n e w w a s h e r ( s e e p a g e 13-3).
13-10
3 0 . R e m o v e t h e three w a y c a t a l y t i c c o n v e r t e r ( T W O 34. R e m o v e t h e r e l e a s e fork b o o t (A), t h e n c a r e f u l l y
(A) a n d g a s k e t s (B). r e m o v e t h e s l a v e c y l i n d e r ( B ) . D o not p r e s s the
c l u t c h p e d a l after the s l a v e c y l i n d e r h a s b e e n
removed.
'00-03 m o d e l s
3 1 . R e m o v e t h e e x h a u s t m a n i f o l d bracket (A) a n d t h e
e x h a u s t m a n i f o l d (B).
'04-08 m o d e l s
32. R e m o v e the p r o p e l l e r shaft ( s e e p a g e 16-18).
3 3 . R e m o v e the f o u r shift boot h o l d e r m o u n t i n g bolts.
(cont'd)
13-11
Manual Transmission
3 5 . Pull out t h e r e l e a s e fork (A) f r o m the r e l e a s e fork 3 7 . P l a c e a t r a n s m i s s i o n j a c k (A) u n d e r the front
h a n g e r . W e d g e a s h o p t o w e l (B) b e t w e e n t h e s u b f r a m e a n d t h e e n g i n e m o u n t i n g stiffener.
o p e n i n g in t h e c l u t c h h o u s i n g a n d t h e r e l e a s e fork
A
to h o l d t h e r e l e a s e fork in p l a c e .
38. R e m o v e t h e t w o c e n t e r m o u n t i n g bolts (B).
3 9 . L o o s e n t h e f o u r m o u n t i n g bolts 7 5 m m (3.0 in.) a s

shown.
40. L o w e r t h e front s u b f r a m e in until it t o u c h e s the f o u r

l o o s e n e d m o u n t i n g bolts.
41. S u p p o r t t h e t r a n s m i s s i o n w i t h a t r a n s m i s s i o n j a c k ,
and r e m o v e the three t r a n s m i s s i o n rear m o u n t
bolts.
13-12
00
42. L o w e r the t r a n s m i s s i o n . Disconnect the vehicle 46. R e m o v e t h e t r a n s m i s s i o n r e a r m o u n t f r o m t h e
s p e e d s e n s o r ( V S S ) ('00-05 m o d e l s ) or t h e output transmission.
shaft (countershaft) s p e e d s e n s o r ('06-08 m o d e l s )
c o n n e c t o r (A), t h e n r e m o v e t h e w i r e h a r n e s s (B)
f r o m the t r a n s m i s s i o n .
43. R e m o v e the three upper t r a n s m i s s i o n mounting

bolts.
44. Pull t h e t r a n s m i s s i o n a w a y f r o m the e n g i n e until it

c l e a r s the m a i n s h a f t .
4 5 . S l o w l y l o w e r t h e t r a n s m i s s i o n a b o u t 150 m m (6 in.).
C h e c k o n c e a g a i n t h a t all h o s e s a n d electrical
wiring are disconnected and free from the
t r a n s m i s s i o n , t h e n l o w e r it all the w a y .
13-13
Manual Transmission
Transmission Disassembly
Exploded View-Rear Cover
® CONICAL SPRING WASHER

Replace.
0 27 m m L O C K N U T
12 8 m m S P E C I A L B O L T
162 — 0 — 162 N-m (16.5 0 — 16.5 k g f m ,
31 N - m (3.2 k g f m , 2 3 Ibf-ft)
1 1 9 - + 0 ^ 1 1 9 Ibf-ft)
Replace. (13) S H I F T L E V E R H O U S I N G
® 27 m m S P R I N G W A S H E R 14 6 m m F L A N G E B O L T
12 N m (1.2 k g f m , 8.7 Ibf ft)
<D B A C K - U P R I N G
® 8 m m FLANGE BOLT
© O-RING
2 7 N m (2.8 k g f - m , 2 0 Ibf ft)
Replace.
<§> H A R N E S S B R A C K E T
® COMPANION FLANGE
® O-RING
6 4 0 x 6 0 x 9 m m OIL S E A L Replace.
Replace.
(D B A L L B E A R I N G 18 S H I F T R O D T U B E
Replace. m SECONDARY SHAFT ASSEMBLY
(DREAR COVER m BEARING OUTER RACE
® 8 m m D O W E L PIN @ 68 m m S H I M
® SHIFT A R M B 22 H A R N E S S C L A M P
13-14
Exploded View-Transmission Housing
® 29 m m L O C K N U T (Left-hand threads) ) DRAIN PLUG ) 12 m m D R A I N P L U G

172 — 0 — 172 N m 3 9 N - m (4.0 k g f - m , 2 9 Ibf-ft) 3 9 N m (4.0 k g f - m , 2 9 Ibf-ft)
(17.5 — 0 — 1 7 . 5 k g f m ,
) 1 4 x 2 0 m m D O W E L PIN ) S P R I N G L . 2 3 m m (0.91 in.) ( B L A C K )
127 — 0 — 127 Ibf-ft)
Replace. ) O-RING ) 8 mm FLANGE BOLT
Replace. 2 7 N - m (2.8 k g f - m , 2 0 Ibf-ft)
29 m m S P R I N G W A S H E R
»VEHICLE S P E E D S E N S O R (VSS) )TRANSMISSION HANGER A
30 x 64 x 20 m m N E E D L E B E A R I N G ('00-05 m o d e l s )
) TRANSMISSION HANGER
S E C O N D A R Y DRIVE G E A R OUTPUT SHAFT (COUNTERSHAFT)
S P E E D S E N S O R ('06-08 m o d e l s ) OIL G U I D E P L A T E M
OIL P U M P G E A R S H A F T
1 6 m m FLANGE BOLT 82 m m S H I M
OIL P U M P G E A R
1 2 N m (1.2 k g f m , 8.7 Ibf-ft) Selection.
6 m m FLANGE BOLT
) FILLER PLUG •SUCTION GUIDE
1 2 N m (1.2 k g f m , 8.7 Ibf-ft) 4 4 N m (4.5 k g f m , 3 3 Ibf-ft) CIRCLIP
OIL P U M P P L A T E WASHER
OIL P U M P S T R A I N E R
S P R I N G L . 19.1 m m ( 0 . 7 5 in.) Replace.
< S P R I N G L . 2 3 m m (0.91 i n . ) ( S I L V E R )
STEEL BALL DSET S C R E W
S
> S P R I N G L. 3 2 m m (1.26 in.)
OIL P U M P ROTOR I) S P R I N G L . 2 7 . 4 m m ( 1 . 0 8 in.)
® D WASHER
BEARING OUTER RACE STEEL BALL
Replace.
82 m m S H I M > 16x 2 6 x 7 m m OIL S E A L
Replace. ) BACK-UP LIGHT SWITCH
Selection.
f
> 12 m m W A S H E R D TRANSMISSION HOUSING
OIL GUIDE P L A T E S
Replace.
WASHER
Replace.
(cont'd)
13-15
Manual Transmission
Transmission Disassembly (cont'd)
Exploded View-Clutch Housing

®^ ®
COUNTERSHAFT ASSEMBLY ® 8 m m FLANGE BOLT 6 m m FLANGE BOLT

'00-03 m o d e l s : 34 N-m 12 N m ( 1 . 2 k g f - m , 8.7 I b f f t )
68 m m S N A P RING (3.5 k g f m , 2 5 I b f f t )
MAINSHAFT ASSEMBLY '04-08 m o d e l s : 27 N-m ) RELEASE BEARING GUIDE
(2.8 k g f - m , 2 0 Ibf-ft) 2 8 x 4 3 x 7 m m OIL SEAL
® 64 m m S P R I N G W A S H E R
Replace.
® 14 x 2 0 m m D O W E L PIN
OIL G U I D E PIPE
) 8 x 6 3 m m PIN
<$ S H I F T F O R K A S S E M B L Y
® REVERSE SHAFT HOLDER
) 10 m m F L A N G E B O L T
® SHIFT A R M ROD A S S E M B L Y
® REVERSE GEAR SHAFT 4 4 N-m (4.5 k g f - m , 3 3 Ibfft)
<3D8x40mmPIN
® THRUST WASHER ) CLUTCH HOUSING
® SELECT RETURN SPRING
® 20 x 2 5 x 26.5 m m N E E D L E B E A R I N G ) 1-2 S H I F T F O R K
® CLUTCH RELEASE HANGER
R E V E R S E IDLER G E A R ) REVERSE SHIFT FORK
I RELEASE HANGER SPRING
34 m m S E A L I N G B O L T ) 1-2 S H I F T L E V E R
6 9 N - m (7.0 k g f m , 51 Ibf-ft) 2i 8 m m S P E C I A L B O L T
2 7 N m (2.8 k g f m , 2 0 I b f f t ) ) MAGNET
® 8 m m WASHER
Replace. ® BREATHER PLATE
® 6 m m FLANGE BOLT
1 2 N m (1.2 k g f - m , 8.7 I b f f t )
13-16
Special Tools Required 3. R e m o v e the 8 m m f l a n g e bolts in a c r i s s c r o s s
• Holder h a n d l e 0 7 J A B - 0 0 1 0 2 0 A pattern in s e v e r a l s t e p s .
• Mainshaft holder 07PAB-001A300
• C o m p a n i o n flange holder 0 7 R A B - T B 4 0 1 0 B
• A d j u s t a b l e b e a r i n g puller, 2 0 — 4 0 m m 07736-A01000B
Rear Cover Removal
N O T E : P l a c e t h e c l u t c h h o u s i n g o n t w o p i e c e of w o o d
thick e n o u g h to k e e p t h e m a i n s h a f t f r o m hitting t h e
workbench.
1. R e m o v e t h e f o u r bolts, a n d r e m o v e t h e shift l e v e r
housing.
4. R e m o v e the rear c o v e r (A) a n d the 14 x 2 0 m m

d o w e l p i n s (B).
5. R e m o v e t h e shift rod t u b e a n d the O - r i n g s f r o m the

rear cover.
2. L o w e r t h e shift rod (A), t h e n r e m o v e t h e 8 m m

s p e c i a l bolt ( C ) , t h e c o n i c a l s p r i n g w a s h e r (D), a n d
shift a r m B.
(cont'd)
13-17
Manual Transmission
6. R a i s e the 27 m m locknut t a b f r o m t h e g r o o v e in t h e 8. R e m o v e the 27 m m locknut (A), the s p r i n g w a s h e r
s e c o n d a r y shaft. ( B ) , t h e b a c k - u p ring ( C ) , a n d the O-ring (D).
7. Install the h o l d e r h a n d l e (A) a n d c o m p a n i o n f l a n g e

h o l d e r (B) onto t h e c o m p a n i o n f l a n g e , a n d l o o s e n
the 27 m m locknut.
9. R e m o v e the c o m p a n i o n f l a n g e (A) u s i n g
c o m m e r c i a l l y a v a i l a b l e b e a r i n g puller (B) a s s h o w n .
13-18
e<H>
10. R e m o v e t h e oil s e a l f r o m the rear c o v e r . 13. R e m o v e t h e b e a r i n g outer r a c e (A) a n d t h e s h i m (B)
f r o m the rear cover (C).
14. R e m o v e t h e b e a r i n g outer r a c e (A) f r o m t h e r e a r

c o v e r (B) u s i n g the 2 0 — 4 0 m m a d j u s t a b l e b e a r i n g
puller (C) a n d c o m m e r c i a l l y a v a i l a b l e 3 / 8 " - 1 6 U N F
s l i d e h a m m e r (D).
12. R e m o v e the ball b e a r i n g (D) f r o m t h e r e a r c o v e r .
(cont'd)
13-19
Manual Transmission
Transmission Housing Removal 3. Install t h e m a i n s h a f t h o l d e r (A) onto t h e m a i n s h a f t
s p l i n e , a n d l o o s e n the 2 9 m m locknut (left-hand
1. R e m o v e t h e oil p u m p g e a r s h a f t a n d oil p u m p g e a r . threads).
2. R a i s e t h e 2 9 m m locknut t a b f r o m t h e g r o o v e in t h e 07PAB-001A300
countershaft.
4. R e m o v e the 2 9 m m locknut a n d s p r i n g w a s h e r .
13-20
0©
5. R e m o v e the n e e d l e b e a r i n g (A) u s i n g a 7. R e m o v e the 6 m m f l a n g e b o l t s , t h e n r e m o v e t h e oil
c o m m e r c i a l l y a v a i l a b l e b e a r i n g puller (B) a s s h o w n . p u m p plate (A), s p r i n g , steel b a l l , a n d oil p u m p
rotors (B).
8. R e m o v e the d r a i n p l u g (A), t h e filler plug (B), t h e

12 m m d r a i n p l u g ( C ) , w a s h e r s , t h e s e t s c r e w s (D),
s p r i n g s , s t e e l b a l l s , a n d the v e h i c l e s p e e d s e n s o r
( V S S ) ('00-05 m o d e l s ) or the output shaft
(countershaft) s p e e d s e n s o r ('06-08 m o d e l s ) (E).
(cont'd)
13-21
Manual Transmission
9. R e m o v e the s e t s c r e w s (A), s p r i n g s , s t e e l b a l l s , t h e 12. R e m o v e the b e a r i n g outer r a c e (A) u s i n g the

b a c k - u p light s w i t c h (B), a n d w a s h e r . 2 0 — 4 0 m m a d j u s t a b l e b e a r i n g puller (B) a n d
commercially available 3/8"-16 U N F slide h a m m e r
( C ) , t h e n r e m o v e 8 2 m m s h i m (D) a n d oil g u i d e
plate S .
10. R e m o v e t h e 8 m m f l a n g e bolts in a c r i s s c r o s s B
07736-A01000B
pattern in s e v e r a l s t e p s .
13. R e m o v e t h e 16 x 2 6 x 7 m m oil s e a l f r o m the

transmission housing.
11. R e m o v e the t r a n s m i s s i o n h o u s i n g a n d the 14 x

20 m m d o w e l p i n s (A).
13-22
<s0
14. R e m o v e t h e c i r c l i p (A), t h e n r e m o v e the s u c t i o n 16. R e m o v e t h e oil g u i d e p i p e (A) a n d the m a g n e t (B).
g u i d e (B) a n d t h e oil p u m p s t r a i n e r (C) f r o m t h e
.A
transmission housing.
17. R e m o v e t h e 8 m m f l a n g e bolt a n d w a s h e r , t h e n
r e m o v e t h e r e v e r s e s h a f t h o l d e r (A), the t h r u s t
w a s h e r ( B ) the r e v e r s e g e a r shaft (C), a n d t h e
r
n e e d l e b e a r i n g (D).
15. R e m o v e the 8 2 m m s h i m ( s ) (A) a n d oil g u i d e plate
M.
(cont'd)
13-23
Manual Transmission
18. R e m o v e t h e 10 m m f l a n g e bolt, t h e n r e m o v e t h e 2 1 . R e m o v e t h e 1-2 shift p i e c e .
8 x 6 3 m m pin (A) a n d t h e 1-2 shift l e v e r s (B).
2 2 . R e m o v e t h e 3 4 m m s e a l i n g bolt (A) f r o m t h e c l u t c h
housing.
19. R e m o v e the 5 x 2 5 m m s p r i n g pin (B) f r o m shift
a r m A w i t h a 5 m m pin d r i v e r , t h e n r e m o v e t h e shift
rod(C).
2 3 . E x p a n d the 6 8 m m s n a p ring (B) o n the

20. R e m o v e shift a r m A f r o m t h e interlock (D), t h e n c o u n t e r s h a f t ball b e a r i n g , a n d r e m o v e it f r o m the
r e m o v e the s e l e c t return s p r i n g (E) a n d t h e g r o o v e u s i n g a pair of s n a p ring p l i e r s .
8 x 40 m m pin (F).
2 4 . R e m o v e the m a i n s h a f t , c o u n t e r s h a f t , a n d t h e shift
f o r k s a s s e m b l y ( C ) , a n d r e m o v e the 6 4 m m s p r i n g
w a s h e r (D), the r e v e r s e idler g e a r ( E ) , a n d t h r u s t
w a s h e r (F).
13-24
Mainshaft Assembly Clearance
Inspection
25. R e m o v e t h e 6 m m f l a n g e bolts (A) a n d the r e l e a s e
b e a r i n g g u i d e (B).
NOTE:
• If r e p l a c e m e n t is r e q u i r e d , a l w a y s r e p l a c e t h e
s y n c h r o s l e e v e and s y n c h r o hub a s a set.
• Support the bearing inner race, a n d push d o w n on
the mainshaft.
1. M e a s u r e t h e c l e a r a n c e b e t w e e n 3rd g e a r (A) a n d
t h e ball b e a r i n g (B) w i t h a f e e l e r g a u g e .
• If t h e c l e a r a n c e is m o r e t h a n t h e s e r v i c e limit, g o
to s t e p 2.
• If the c l e a r a n c e is w i t h i n t h e s e r v i c e limit, g o to
s t e p 4.
Standard: 0 . 0 6 — 0 . 1 9 m m ( 0 . 0 0 2 — 0 . 0 0 7 in.)
S e r v i c e L i m i t : 0.3 m m (0.012 in.)
26. R e m o v e the 8 m m s p e c i a l bolts ( C ) , the c l u t c h

r e l e a s e h a n g e r (D), a n d the r e l e a s e h a n g e r s p r i n g
(E).
27. R e m o v e the 6 m m f l a n g e bolt (F) a n d t h e b r e a t h e r

plate ( G ) .
28. R e m o v e the oil s e a l f r o m the c l u t c h h o u s i n g .
(cont'd)
13-25
Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
2. M e a s u r e t h e length of the d i s t a n c e collar. '04-08 m o d e l s
• If t h e length is not w i t h i n the s t a n d a r d , r e p l a c e

the distance collar.
• If t h e length is w i t h i n the s t a n d a r d , g o to s t e p 3.
S t a n d a r d : 3 5 . 2 3 - 3 5 . 2 8 m m ( 1 . 3 8 7 - 1 . 3 8 9 in.)
4. M e a s u r e the c l e a r a n c e b e t w e e n 4th g e a r (A) a n d

the d i s t a n c e c o l l a r (B) w i t h a f e e l e r g a u g e .
• If the c l e a r a n c e is m o r e t h a n t h e s e r v i c e limit, g o
to s t e p 5.
• If the c l e a r a n c e i s w i t h i n t h e s e r v i c e limit, g o to
3. M e a s u r e the t h i c k n e s s of 3 r d g e a r . s t e p 7.
• If t h e t h i c k n e s s is l e s s t h a n t h e s e r v i c e limit, Standard: 0 . 0 6 — 0 . 1 9 m m ( 0 . 0 0 2 — 0 . 0 0 7 in.)

replace 3rd gear. S e r v i c e L i m i t : 0.3 m m (0.012 in.)
• If t h e t h i c k n e s s is w i t h i n the s e r v i c e limit, r e p l a c e
B
t h e 3rd/4th s y n c h r o h u b a n d 3rd/4th s y n c h r o
sleeve a s a set.
Standard: 3 5 . 0 9 - 3 5 . 1 7 m m ( 1 . 3 8 1 - 1 . 3 8 5 in.)
S e r v i c e L i m i t : 3 4 . 9 7 m m (1.377 in.)
t 1i
'00-03 m o d e l s
i i
(/ L
I f
f
13-26
5 . M e a s u r e t h e length © of t h e d i s t a n c e c o l l a r a s '04-08 m o d e l s
shown.
• If t h e length ® is not w i t h i n the s t a n d a r d , r e p l a c e

the distance collar.
• If t h e length ® is w i t h i n the s t a n d a r d , g o to
s t e p 6.
S t a n d a r d : 3 2 . 0 3 - 3 2 . 0 8 m m ( 1 . 2 6 1 - 1 . 2 6 3 in.)
7 . M e a s u r e t h e c l e a r a n c e b e t w e e n 5 t h g e a r (A) a n d
the d i s t a n c e c o l l a r (B) w i t h a dial indicator.
• If t h e c l e a r a n c e is m o r e t h a n the s e r v i c e limit, g o
to s t e p 8 .
• If t h e c l e a r a n c e is w i t h i n the s e r v i c e limit, g o to
step 1 0 .
6. M e a s u r e the t h i c k n e s s of 4th g e a r . Standard: 0 . 0 6 — 0 . 1 9 m m ( 0 . 0 0 2 — 0 . 0 0 7 in.)

* If t h e t h i c k n e s s is l e s s t h a n s e r v i c e limit, r e p l a c e
4th g e a r .
• If t h e t h i c k n e s s is w i t h i n the s e r v i c e limit, r e p l a c e
t h e 3rd/4th s y n c h r o h u b a n d 3rd/4th s y n c h r o
s l e e v e a s a set.
Standard: 3 1 . 8 9 - 3 1 . 9 7 m m ( 1 . 2 5 6 - 1 . 2 5 9 in.)
'00-03 m o d e l s
(cont'd)
13-27
Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
8 . M e a s u r e t h e l e n g t h ® of t h e d i s t a n c e c o l l a r a s 10. M e a s u r e t h e c l e a r a n c e b e t w e e n 6th g e a r (A) a n d

shown. t h e m a i n s h a f t (B) w i t h a dial indicator. If the
c l e a r a n c e is m o r e t h a n t h e s e r v i c e limit, g o to
• If the length ® is not w i t h i n t h e s t a n d a r d , r e p l a c e s t e p 11.
the d i s t a n c e c o l l a r .
• If the length ® i s w i t h i n t h e s t a n d a r d , g o to Standard: 0 . 0 6 - 0 . 1 9 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.)
s t e p 9. S e r v i c e L i m i t : 0.3 m m (0.012 in.)
S t a n d a r d : 3 2 . 0 3 - 3 2 . 0 8 m m ( 1 . 2 6 1 - 1 . 2 6 3 in.)
11. M e a s u r e t h e t h i c k n e s s of 6th g e a r .
9. M e a s u r e t h e t h i c k n e s s of 5th g e a r . • If t h e t h i c k n e s s i s l e s s t h a n t h e s e r v i c e limit,
r e p l a c e 6th g e a r .
• If the t h i c k n e s s is l e s s t h a n t h e s e r v i c e limit, • If the t h i c k n e s s is w i t h i n t h e s e r v i c e limit, r e p l a c e
r e p l a c e 5th g e a r . t h e 5th/6th s y n c h r o h u b a n d 5th/6th s y n c h r o
• If t h e t h i c k n e s s i s w i t h i n t h e s e r v i c e limit, r e p l a c e sleeve a s a set.
the 5th/6th s y n c h r o h u b a n d 5th/6th s y n c h r o
sleeve a s a set. Standard: 2 8 . 8 9 - 2 8 . 9 7 m m ( 1 . 1 3 7 - 1 . 1 4 1 in.)
S e r v i c e L i m i t : 2 8 . 7 7 m m (1.133 in.)
Standard: 3 1 . 8 9 - 3 1 . 9 7 m m ( 1 . 2 5 6 - 1 . 2 5 9 in.)
• S e r v i c e L i m i t : 3 1 . 7 7 m m (1.251 in.)
13-28
3®
Mainshaft Disassembly
1. S u p p o r t t h e ball b e a r i n g (A) w i t h a c o m m e r c i a l l y 8. R e m o v e the 42 x 47 x 3 0 . 5 m m n e e d l e b e a r i n g s , the

a v a i l a b l e b e a r i n g s e p a r a t o r , a n d r e m o v e the ball d i s t a n c e c o l l a r , 5th g e a r , t h e s y n c h r o r i n g , a n d the
bearing using a press a s s h o w n . synchro spring.
9. S u p p o r t 6th g e a r (A) w i t h a c o m m e r c i a l l y a v a i l a b l e
b e a r i n g s e p a r a t o r , a n d r e m o v e t h e 5th/6th s y n c h r o
h u b / s l e e v e (B), s y n c h r o ring, s y n c h r o spring, and
6th g e a r u s i n g a p r e s s a s s h o w n .
PRESS
2. R e m o v e 3 r d g e a r , the 3 5 x 40 x 3 5 m m n e e d l e
bearing, the distance collar.
A
3. ' 0 0 - 0 3 m o d e l s : R e m o v e t h e d o u b l e c o n e s y n c h r o ,
t h e s y n c h r o s p r i n g , a n d t h e 3rd/4th s y n c h r o s l e e v e .
4. ' 0 4 - 0 8 m o d e l s : R e m o v e t h e s y n c h r o r i n g , the 10. R e m o v e t h e 3 9 x 44 x 2 6 m m n e e d l e b e a r i n g .

s y n c h r o s p r i n g , a n d the 3rd/4th s y n c h r o s l e e v e .
11. S u p p o r t t h e ball b e a r i n g (A) w i t h a c o m m e r c i a l l y
5. S u p p o r t 4th g e a r (A) w i t h a c o m m e r c i a l l y a v a i l a b l e a v a i l a b l e b e a r i n g s e p a r a t o r , a n d r e m o v e the ball
b e a r i n g s e p a r a t o r , a n d r e m o v e the 3rd/4th s y n c h r o bearing using a press a s s h o w n .
h u b (B) a n d 4th g e a r .
PRESS
6. ' 0 0 - 0 3 m o d e l s : R e m o v e t h e s y n c h r o s p r i n g a n d t h e
double cone synchro.
7. ' 0 4 - 0 8 m o d e l s : R e m o v e the s y n c h r o s p r i n g a n d t h e
s y n c h r o ring.
13-29
Manual Transmission
Mainshaft Inspection
1. I n s p e c t t h e g e a r a n d b e a r i n g c o n t a c t a r e a s for w e a r 3. I n s p e c t for runout by s u p p o r t i n g both e n d s of
and damage. m a i n s h a f t . T h e n rotate t h e m a i n s h a f t t w o c o m p l e t e
t u r n s w h i l e m e a s u r i n g w i t h a dial g a u g e . If t h e
2 . M e a s u r e t h e m a i n s h a f t at points A , B, C , a n d D. If r u n o u t is m o r e t h a n the s e r v i c e limit, r e p l a c e the
a n y part of t h e m a i n s h a f t i s l e s s t h a n t h e s e r v i c e mainshaft.
limit, r e p l a c e it.
Standard: 0.02 m m (0.001 in.) m a x .
Standard: S e r v i c e L i m i t : 0.05 m m (0.002 in.)
A R e a r c o v e r s i d e ball b e a r i n g c o n t a c t a r e a :
2 7 . 9 8 7 - 2 8 . 0 0 0 m m ( 1 . 1 0 1 8 - 1 . 1 0 2 4 in.)
B 4th/5th gears contact area:
3 4 . 9 8 7 - 3 5 . 0 0 0 m m ( 1 . 3 7 7 4 - 1 . 3 7 8 0 in.)
C 6th gear contact area:
3 8 . 9 8 4 - 3 9 . 0 0 0 m m ( 1 . 5 3 4 8 - 1 . 5 3 5 4 in.)
D Clutch housing side ball bearing contact area:
2 8 . 0 0 2 - 2 8 . 0 1 5 m m ( 1 . 1 0 2 4 - 1 . 1 0 3 0 in.)
S e r v i c e Limit:
A: 27.94 mm (1.100 in.)
B: 34.94 mm (1.376 in.)
C: 38.94 mm (1.533 in.)
D: 27.95 mm (1.100 in.)
Clutch housing
side
Rear cover
side
13-30
Mainshaft Reassembly
Exploded View
'00-03 models
Thin edge of the outer ANGULAR BALL BEARING

race faces 3rd gear Check for wear and operation.
SYNCHRO RING Note the direction of
installation.
SYNCHRO 3RD GEAR

SPRING
5TH/6TH SYNCHRO
HUB 35 x 40 x 35 mm
NEEDLE BEARING
Check for wear
5TH/6TH and operation.
SYNCHRO
SLEEVE
Note the 28 x 35 x 36.2 mm
direction DISTANCE COLLAR
of installation.
DOUBLE CONE
SYNCHRO SPRING SYNCHRO
SYNCHRO SPRING
SYNCHRO RING
3RD/4TH SYNCHRO
SLEEVE
Note the direction
6TH GEAR of installation.
3RD/4TH SYNCHRO HUB

39 x 44 x 26 mm
NEEDLE BEARING
Check for wear
and operation. SYNCHRO SPRING
DOUBLE CONE SYNCHRO
4TH GEAR
MAINSHAFT
42 x 47 x 30.5 mm
NEEDLE BEARING
Check for wear
and operation.
35 x 42 x 68 mm
DISTANCE COLLAR
28x64x 18 mm 5TH GEAR

BALL BEARING
Note the direction
of installation.
42 x 47 x 30.5 mm
NEEDLE BEARING
64 mm SPRING WASHER Check for wear
Note the direction and operation.
of installation.
(cont'd)
13-31
Manual Transmission
Mainshaft Reassembly (cont'd)
Exploded View
'04-08 m o d e l s
SYNCHRO RING
T h n
SYNCHRO '
r a c e
edge of the outer ANGULAR BALL BEARING
SPRING faces 3rd gear Check for wear and operation.
Note the direction of
5TH/6TH installation.
SYNCHRO
HUB
5TH/6TH
SYNCHRO 3RD GEAR
SLEEVE
Note the
direction 35 x 40 x 35 mm
of installation NEEDLE BEARING
Check for wear
and operation.
SYNCHRO
SPRING 28 x 35 x 36.2 mm
DISTANCE COLLAR
SYNCHRO RING
SYNCHRO RING
SYNCHRO SPRING
6TH GEAR
3RD/4TH SYNCHRO
SLEEVE
Note the direction
of installation.
- 39 x 44 x 26 mm
NEEDLE BEARING
Check for wear 3RD/4TH SYNCHRO HUB
and operation.
SYNCHRO SPRING
SYNCHRO RING
4TH GEAR
MAINSHAFT
42 x 47 x 30.5 mm
NEEDLE BEARING
Check for wear
and operation.
35 x 42 x 68 mm
DISTANCE COLLAR
28 x 64 x 18 mm 5TH GEAR
BALL BEARING
Note the direction
of installation.
42 x 47 x 30.5 mm
NEEDLE BEARING
64 mm SPRING WASHER Check for wear
Note the direction and operation.
of installation.
13-32
Special Tools Required 4. P r e s s t h e 5th/6th s y n c h r o h u b u s i n g t h e d r i v e r
• Driver handle 07746-0030100 h a n d l e (A) a s s h o w n . After i n s t a l l i n g , c h e c k the
• A t t a c h m e n t , 30 m m L D . 0 7 7 4 6 - 0 0 3 0 3 0 0 o p e r a t i o n of the 5th/6th s y n c h r o h u b a n d 5th/6th
synchro sleeve.
N O T E : R e f e r to the E x p l o d e d V i e w , a s n e e d e d , d u r i n g
this procedure. PRESS
1. S u p p o r t 2 n d g e a r (A) o n s t e e l b l o c k s , t h e n install
t h e ball b e a r i n g (B) u s i n g the d r i v e r h a n d l e ( C ) ,
3 0 m m I.D. a t t a c h m e n t (D), a n d a p r e s s a s s h o w n .
07746-0030100
N O T E : T h e thin e d g e of the outer r a c e f a c e s 6th
gear.
PRESS
07746-0030100
Install t h e s y n c h r o s p r i n g , s y n c h r o r i n g , 42 x 47 x
3 0 . 5 m m n e e d l e b e a r i n g s , 5th g e a r , d i s t a n c e c o l l a r ,
a n d 4th g e a r .
2 . Install the 3 9 x 44 x 2 6 m m n e e d l e b e a r i n g , 6th g e a r ,

s y n c h r o ring, a n d s y n c h r o s p r i n g .
3. Install the 5th/6th s y n c h r o h u b (A) a n d t h e 5th/6th

s y n c h r o s l e e v e (B) b y a l i g n i n g t h e s t o p s (C).
(cont'd)
13-33
Manual Transmission
Mainshaft Reassembly (cont'd)
6. ' 0 0 - 0 3 m o d e l s : Install the d o u b l e c o n e s y n c h r o (A) 8. Install the 3rd/4th s y n c h r o h u b (A) a n d the 3rd/4th
a n d s y n c h r o ring (B). s y n c h r o s l e e v e (B) b y a l i g n i n g t h e s t o p s (C).
7. ' 0 4 - 0 8 m o d e l s : Install t h e s y n c h r o ring (A) a n d 9. P r e s s t h e 3rd/4th s y n c h r o h u b u s i n g t h e d r i v e r

s y n c h r o s p r i n g (B). h a n d l e (A) a s s h o w n . A f t e r i n s t a l l i n g , c h e c k the
o p e r a t i o n of t h e 3rd/4th s y n c h r o h u b a n d s l e e v e .
13-34
10. '00-03 m o d e l s : Install the s y n c h r o s p r i n g (A) a n d 12. Install t h e d i s t a n c e c o l l a r (A), t h e 3 5 x 40 x 3 5 m m
d o u b l e c o n e s y n c h r o (B). n e e d l e b e a r i n g ( B ) , a n d 3 r d g e a r (C).
11. '04-08 m o d e l s : Install the s y n c h r o s p r i n g (A) a n d

s y n c h r o ring (B).
13. Install the a n g u l a r ball b e a r i n g (A) w i t h the thin

e d g e of the o u t e r r a c e f a c i n g 3 r d g e a r (B). U s e t h e
d r i v e r h a n d l e (C) a n d a p r e s s .
PRESS
[^07746-0030100
A
13-35
Manual Transmission
Shift Arm Rod Assembly Countershaft Assembly Clearance
Disassembly/Reassembly Inspection
1. R e m o v e t h e s e l e c t return s p r i n g (B). N O T E : If r e p l a c e m e n t i s r e q u i r e d , a l w a y s r e p l a c e t h e
s y n c h r o s l e e v e a n d s y n c h r o hub a s a set.
PIN D R I V E R
1. M e a s u r e the c l e a r a n c e b e t w e e n 2 n d g e a r (A) a n d
the 3 r d g e a r (B) w i t h a dial indicator.
• If t h e c l e a r a n c e i s m o r e t h a n the s e r v i c e limit, g o
to s t e p 2.
• If the c l e a r a n c e i s w i t h i n the s e r v i c e limit, g o to
s t e p 3.
Standard: 0 . 0 4 — 0 . 1 7 m m ( 0 . 0 0 2 — 0 . 0 0 7 In.)
2. R e m o v e the 5 x 2 5 s p r i n g pin (C) f r o m shift a r m A

w i t h a 5 m m pin d r i v e r , t h e n r e m o v e t h e shift r o d
(D).
3. R e m o v e shift a r m A f r o m t h e interlock ( E ) .
4. C l e a n all t h e p a r t s in s o l v e n t , d r y t h e m , a n d a p p l y
M T F to a n y c o n t a c t s u r f a c e s .
5. Install shift a r m A to t h e interlock.
6. Install t h e shift rod a n d t h e n e w 5 x 2 5 s p r i n g pin.
7. Install t h e s e l e c t return s p r i n g .
13-36
2. M e a s u r e t h e t h i c k n e s s of 2 n d g e a r . 3. M e a s u r e the c l e a r a n c e b e t w e e n 1st g e a r (A) a n d
t h e d i s t a n c e c o l l a r (B) w i t h a dial indicator.
• If the t h i c k n e s s is l e s s t h a n t h e s e r v i c e limit,
replace 2nd gear. • If t h e c l e a r a n c e is m o r e t h a n t h e s e r v i c e limit, g o
• If the t h i c k n e s s is w i t h i n t h e s e r v i c e limit, r e p l a c e to s t e p 4 .
the 1st/2nd s y n c h r o h u b a n d 1st/2nd s y n c h r o • If t h e c l e a r a n c e is w i t h i n t h e s e r v i c e limit, g o to
sleeve a s a set. step 6.
Standard: 3 2 . 8 8 - 3 2 . 9 6 m m ( 1 . 2 9 4 - 1 . 2 9 8 in.) Standard:

S e r v i c e L i m i t : 3 2 . 7 6 m m (1.290 in.) '00-03 models: 0.04—0.22 m m
( 0 . 0 0 2 - 0 . 0 0 9 in.)
'00-03 m o d e l s '04-08 models: 0.04—0.17 m m
( 0 . 0 0 2 - 0 . 0 0 7 in.)
4 . M e a s u r e t h e length © of t h e d i s t a n c e c o l l a r a s
shown.
• If t h e length ® is not w i t h i n t h e s t a n d a r d , r e p l a c e
t h e d i s t a n c e collar.
• If the length © is w i t h i n t h e s t a n d a r d , g o to
step 5 .
S t a n d a r d : 2 8 . 0 3 - 2 8 . 0 8 m m ( 1 . 1 0 4 - 1 . 1 0 6 in.)
(cont'd)
13-37
Manual Transmission
Countershaft Assembly Clearance Inspection (cont'd)
5. M e a s u r e t h e t h i c k n e s s of 1st g e a r . 7. M e a s u r e t h e length ® of t h e d i s t a n c e collar a s

shown.
• If t h e t h i c k n e s s is l e s s t h a n t h e s e r v i c e limit,
r e p l a c e 1st g e a r . • If t h e length ® is not w i t h i n t h e s t a n d a r d , r e p l a c e
• If t h e t h i c k n e s s i s w i t h i n t h e s e r v i c e limit, r e p l a c e t h e d i s t a n c e collar.
t h e 1st/2nd s y n c h r o h u b a n d 1 s t / 2 n d s y n c h r o • If t h e length © is w i t h i n t h e s t a n d a r d , g o to
sleeve a s a set. step 8 .
Standard: S t a n d a r d : 2 5 . 5 3 - 2 5 . 5 8 m m ( 1 . 0 0 5 - 1 . 0 0 7 in.)
'00-03 m o d e l s : 31.18-31.26 mm
(1.228-1.231 in.)
'04-08 models: 27.88-27.96 mm
(1.098-1.101 in.)
Service Limit:
'00-03 m o d e l s : 3 1 . 0 6 m m (1.223 in.)
'04-08 models: 2 7 . 7 6 m m (1.093 in.)
8 . M e a s u r e t h e t h i c k n e s s of r e v e r s e g e a r .
• If t h e t h i c k n e s s is l e s s t h a n t h e s e r v i c e limit,
replace reverse gear.
• If the t h i c k n e s s i s w i t h i n t h e s e r v i c e limit, r e p l a c e
the reverse s y n c h r o hub a n d reverse s y n c h r o
sleeve a s a set.
6. M e a s u r e t h e c l e a r a n c e b e t w e e n r e v e r s e g e a r (A)
a n d t h e d i s t a n c e c o l l a r (B) w i t h a dial indicator. If Standard: 2 6 . 3 8 - 2 6 . 4 6 m m ( 1 . 0 3 9 - 1 . 0 4 2 in.)
t h e c l e a r a n c e i s m o r e t h a n t h e s e r v i c e limit, g o to S e r v i c e L i m i t : 2 6 . 2 6 m m (1.034 in.)
s t e p 7.
Standard: 0 . 0 4 — 0 . 2 2 m m ( 0 . 0 0 2 — 0 . 0 0 9 in.)
13-38
Countershaft Disassembly
1. R e m o v e t h e n e e d l e b e a r i n g . 3. R a i s e the 27 m m locknut t a b f r o m t h e g r o o v e in the

countershaft.
4. S e c u r e l y c l a m p 4th a n d 5th g e a r s in a b e n c h v i s e
w i t h w o o d b l o c k s (A).
5. R e m o v e t h e 27 m m locknut (B) a n d the s p r i n g

w a s h e r (C).
(cont'd)
13-39
Manual Transmission
Countershaft Disassembly (cont'd) Countershaft Inspection
6 . R e m o v e t h e ball b e a r i n g u s i n g a p r e s s a s s h o w n . 1. I n s p e c t t h e g e a r a n d b e a r i n g c o n t a c t a r e a s for w e a r
and damage.
PRESS
2 . M e a s u r e t h e c o u n t e r s h a f t at points A , B , C , a n d D. If
a n y part of the c o u n t e r s h a f t is l e s s t h a n the s e r v i c e
limit, r e p l a c e it.
Standard:
A Rear cover side needle bearing contact area:
3 0 . 0 2 0 - 3 0 . 0 2 9 m m ( 1 . 1 8 1 9 - 1 . 1 8 2 2 in.)
B Transmission housing side needle bearing
contact area:
3 4 . 0 0 2 - 3 4 . 0 1 8 m m ( 1 . 3 3 8 7 - 1 . 3 3 9 3 in)
C 2nd gear contact area:
4 3 . 9 8 4 - 4 4 . 0 0 0 m m ( 1 . 7 3 1 7 - 1 . 7 3 2 3 in.)
D Clutch housing side ball bearing contact area:
2 8 . 0 0 2 - 2 8 . 0 1 5 m m ( 1 . 1 0 2 4 - 1 . 1 0 3 0 in.)
7 . R e m o v e the r e m a i n i n g parts f r o m t h e c o u n t e r s h a f t . Service Limit:
A : 2 9 . 9 7 m m (1.180 in.)
B: 3 3 . 9 5 m m (1.337 in.)
C : 4 3 . 9 3 m m (1.730 in.)
D: 2 7 . 9 5 m m (1.100 in.)
s
d
ie
3 . I n s p e c t for runout by s u p p o r t i n g both e n d s of

c o u n t e r s h a f t . T h e n rotate the c o u n t e r s h a f t t w o
c o m p l e t e t u r n s w h i l e m e a s u r i n g w i t h a dial g a u g e .
If the r u n o u t is m o r e t h a n t h e s e r v i c e limit, r e p l a c e
the c o u n t e r s h a f t .
Standard: 0.02 m m (0.001 in.) m a x .

13-40
Countershaft Reassembly
Exploded View
'00-03 models
1ST/2ND SYNCHRO HUB 3 4 x 57 x 2 0 m m

NEEDLE BEARING
Check for w e a r a n d
operation.
SYNCHRO SPRING
DOUBLE CONE
SYNCHRO
COUNTERSHAFT
FRICTION DAMPER
1ST GEAR
51 x 57 x 2 3 m m
NEEDLE BEARING
C h e c k for w e a r a n d
operation.
DISTANCE COLLAR
3 8 x 43 x 2 6 m m
NEEDLE BEARING
44 x 50 x 28 m m
Check for w e a r a n d
NEEDLE BEARING
operation.
operation.
- REVERSE GEAR
2ND G E A R
S Y N C H R O RING
SYNCHRO SPRING FRICTION DAMPER
REVERSE SYNCHRO HUB
REVERSE SYNCHRO SLEEVE

Note t h e direction of installation. DOUBLE CONE
SYNCHRO
2 8 x 6 8 x 18 m m
BALLBEARING
C h e c k for w e a r
and operation.
Note t h e direction SYNCHRO SPRING
of installation.
27 m m
SPRING WASHER 1ST/2ND
Note t h e direction SYNCHRO SLEEVE
of installation. Note t h e direction
of installation.
27 m m L O C K N U T
N O T E : Left-hand t h r e a d s .
1 6 2 - + 0 — 162 N m
(16.5 - > 0 — 16.5 k g f m ,
119 — 0 — 119 Ibfft)
Replace.
(cont'd)
13-41
Manual Transmission
Countershaft Reassembly (cont'd)
'04-08 m o d e l s
3 4 x 57 x 2 0 m m
NEEDLE BEARING
1ST/2ND SYNCHRO HUB C h e c k for w e a r a n d
operation.
SYNCHRO SPRING
DOUBLE CONE COUNTERSHAFT

SYNCHRO
1ST GEAR
51 x 57 x 2 3 m m
NEEDLE BEARING
operation.
DISTANCE COLLAR
38 x 43 x 26 m m
NEEDLE BEARING
C h e c k for w e a r a n d 4 4 x 50 x 2 8 m m
operation. NEEDLE BEARING
- REVERSE GEAR operation.
2ND G E A R
S Y N C H R O RING
SYNCHRO SPRING FRICTION DAMPER
REVERSE SYNCHRO HUB
REVERSE SYNCHRO SLEEVE

N o t e t h e d i r e c t i o n of installation. DOUBLE CONE
SYNCHRO
2 8 x 6 8 x 18 m m
BALL BEARING
C h e c k for w e a r
and operation.
Note the direction SYNCHRO SPRING
of installation.
27 m m
SPRING WASHER 1ST/2ND
Note the direction SYNCHRO SLEEVE
of installation. Note t h e direction
of installation.
27 m m L O C K N U T
N O T E : Left-hand threads.
162 — 0 — 162 N m
(16.5 — 0 — 16.5 k g f m ,
1 1 9 — 0 - * 119 Ibfft)
Replace.
13-42
<3®
Special Tools Required 4. Install t h e s y n c h r o s p r i n g (A) a n d the d o u b l e c o n e
• Driver h a n d l e 0 7 7 4 6 - 0 0 3 0 1 0 0 s y n c h r o (B) a s s h o w n .
• A t t a c h m e n t , 30 m m I.D. 0 7 7 4 6 - 0 0 3 0 3 0 0
• A t t a c h m e n t , 3 5 m m I.D. 0 7 7 4 6 - 0 0 3 0 4 0 0
N O T E : R e f e r to t h e E x p l o d e d V i e w , a s n e e d e d , d u r i n g
this procedure.
1. Install t h e 44 x 50 x 28 m m n e e d l e b e a r i n g a n d 2 n d
gear.
2. Install t h e friction d a m p e r (A), the d o u b l e c o n e

s y n c h r o (B), a n d the s y n c h r o s p r i n g (C) a s s h o w n .
5. Install t h e friction d a m p e r ('00-03 m o d e l s ) o n 1st

g e a r , t h e n install 1st g e a r by a l i g n i n g t h e g r o o v e s
as shown.
3. Install the 1st/2nd s y n c h r o h u b (A) a n d the 1st/2nd

s y n c h r o s l e e v e (B) a s s h o w n .
(cont'd)
13-43
Manual Transmission
Countershaft Reassembly (cont'd)
6. Install t h e 51 x 57 x 2 3 m m n e e d l e b e a r i n g , d i s t a n c e 10. Install t h e ball b e a r i n g (A) u s i n g t h e d r i v e r h a n d l e

collar, and 38 x 43 x 26 m m needle bearing. ( B ) , 3 0 m m I.D. a t t a c h m e n t ( C ) , a n d a p r e s s a s
shown.
7. Install the r e v e r s e g e a r .
PRESS
07746-0030100
07746-0030300
8. Install t h e s y n c h r o ring a n d s y n c h r o s p r i n g .
11. S e c u r e l y c l a m p 4th a n d 5th g e a r s in a b e n c h v i s e
9. Install the r e v e r s e s y n c h r o h u b (A) a n d t h e r e v e r s e w i t h w o o d b l o c k s (A).
s y n c h r o s l e e v e (6).
C
Replace.
12. Install t h e s p r i n g w a s h e r (B) a n d t h e n e w 27 m m

locknut(C).
13. T i g h t e n t h e 27 m m locknut to t h e s p e c i f i e d v a l u e .
T o r q u e : 162 - * 0 - * 162 N-m

(16.5 — 0 — 16.5 k g f m ,
1 1 9 — 0 - 119 Ibf-ft)
13-44
14. S t a k e t h e locknut t a b into t h e g r o o v e . 16. Install t h e n e e d l e b e a r i n g .
Manual Transmission
Secondary Shaft Disassembly Secondary Shaft Inspection
1. R e m o v e t h e t a p e r e d roller b e a r i n g s u s i n g a 1. I n s p e c t t h e g e a r a n d b e a r i n g c o n t a c t a r e a s for w e a r
commercially available bearing separator and a and damage.
press as shown.
2 . M e a s u r e t h e c o u n t e r s h a f t at points A , B , a n d G . If
PRESS
a n y part of t h e s e c o n d a r y s h a f t is l e s s t h a n t h e
s e r v i c e limit, r e p l a c e it.
Standard:
A Ball bearing contact area:
3 1 . 0 0 2 - 3 1 . 0 1 3 m m ( 1 . 2 2 0 6 - 1 . 2 2 1 0 in.)
B P r o p e l l e r s h a f t s i d e t a p e r e d roller b e a r i n g
contact area:
4 1 . 0 0 2 - 4 1 . 0 1 8 m m ( 1 . 6 1 4 3 - 1 . 6 1 4 9 in.)
C T r a n s m i s s i o n h o u s i n g s i d e t a p e r e d roller
bearing contact area:
35.009-35.025 m m (1.3783-1.3790 in.)
S e r v i c e Limit:
A : 3 0 . 9 5 m m (1.219 in.)
B: 4 0 . 9 5 m m (1.612 in.)
C : 3 4 . 9 6 m m (1.376 in.)
housing side
13-46
Secondary Shaft Reassembly
I n s p e c t for runout b y s u p p o r t i n g both e n d s of Special Tools Required

s e c o n d a r y shaft. T h e n rotate the s e c o n d a r y shaft • A t t a c h m e n t , 40 x 50 m m I.D. 0 7 L A D - P W 5 0 6 0 1
t w o c o m p l e t e t u r n s w h i l e m e a s u r i n g w i t h a dial • A t t a c h m e n t , 45 m m 0 7 9 4 7 - 6 8 9 0 3 0 0
g a u g e . If t h e runout is m o r e t h a n t h e s e r v i c e limit,
r e p l a c e t h e s e c o n d a r y shaft. 1. Install t h e t a p e r e d roller b e a r i n g s (A) u s i n g t h e
40 x 50 m m I.D. a t t a c h m e n t (B) a n d a p r e s s a s
Standard: 0.02 m m (0.001 in.) m a x . shown.
PRESS
Rotate t w o c o m p l e t e
turns.
07947-6890300
13-47
Manual Transmission
Shift Fork Clearance Inspection
N O T E : If r e p l a c e m e n t is r e q u i r e d , a l w a y s r e p l a c e t h e 3. M e a s u r e the c l e a r a n c e b e t w e e n e a c h shift fork,
synchro s l e e v e and s y n c h r o hub a s a set. r e v e r s e shift p i e c e , a n d shift a r m A . If the c l e a r a n c e
e x c e e d s t h e s e r v i c e limit, g o to s t e p 4.
1. M e a s u r e t h e c l e a r a n c e b e t w e e n e a c h shift fork (A)
a n d its m a t c h i n g s y n c h r o s l e e v e (B). If t h e Standard: 0 . 2 — 0 . 6 m m ( 0 . 0 0 8 — 0 . 0 2 4 in.)
c l e a r a n c e e x c e e d s the s e r v i c e limit, g o to s t e p 2 . S e r v i c e L i m i t : 0.7 m m (0.028 in.)
Standard: 0 . 3 5 — 0 . 6 5 m m ( 0 . 0 1 4 — 0 . 0 2 6 in.)
4. M e a s u r e t h e w i d t h of shift a r m A .
2 . M e a s u r e t h e t h i c k n e s s of t h e shift fork f i n g e r s (A).
• If the w i d t h is l e s s t h a n t h e s e r v i c e limit, r e p l a c e
• If t h e t h i c k n e s s is l e s s t h a n t h e s t a n d a r d , r e p l a c e shift a r m A .
the shift fork. • If the w i d t h is w i t h i n the s e r v i c e limit, r e p l a c e the
• If t h e t h i c k n e s s is w i t h i n the s t a n d a r d , r e p l a c e t h e shift fork or t h e r e v e r s e shift p i e c e .
synchro sleeve and synchro hub a s a set.
• If o n e a r m of the shift fork s h o w s m o r e w e a r t h a n Standard: 1 6 . 8 - 1 7 . 0 m m ( 0 . 6 6 1 - 0 . 6 6 9 in.)
the o t h e r s , the fork m a y be b e n t a n d n e e d s to be S e r v i c e L i m i t : 16.7 m m (0.657 in.)
relaced.
Standard:
1-2 S h i f t F o r k : 7 . 4 - 7 . 6 m m ( 0 . 2 9 - 0 . 3 0 in.)
3 - 4 , 5 - 6 , R e v e r s e Shift Fork:
6 . 2 - 6 . 4 m m ( 0 . 2 4 - 0 . 2 5 in.)
13-48
<3&
5. M e a s u r e the c l e a r a n c e b e t w e e n the 1-2 shift l e v e r
R E V E R S E SHIFT PIECE
a n d e a c h shift fork a n d shift p i e c e . If t h e c l e a r a n c e
e x c e e d s the s e r v i c e limit, g o to s t e p 6.
Standard: 0 — 0 . 4 m m ( 0 — 0 . 0 1 6 in.)
6. M e a s u r e the w i d t h of t h e 1-2 shift l e v e r .
• If t h e w i d t h is l e s s t h a n the s e r v i c e limit, r e p l a c e
the 1-2 shift lever.
• If t h e w i d t h i s w i t h i n the s e r v i c e limit, r e p l a c e t h e
shift fork or shift p i e c e .
Standard: 1 7 . 0 - 1 7 . 2 m m ( 0 . 6 6 9 - 0 . 6 7 7 in.)
13-49
Manual Transmission
Shift Fork Disassembly/Reassembly
Prior to r e a s s e m b l i n g , c l e a n all t h e p a r t s in s o l v e n t , d r y t h e m , a n d a p p l y M T F to all c o n t a c t s u r f a c e s .
3-4 S H I F T F O R K 5-6 S H I F T F O R K
13-50
Synchro Ring and Gear Inspection
1. I n s p e c t the i n s i d e of e a c h s y n c h r o ring (A) for w e a r . 3. I n s p e c t the g e a r h u b t h r u s t s u r f a c e (A) for w e a r .

Inspect the teeth (B) o n e a c h s y n c h r o ring for w e a r
( r o u n d e d off).
4 . I n s p e c t the c o n e s u r f a c e (B) for w e a r a n d

roughness.
E x a m p l e of s y n c h r o ring t e e t h
5 . I n s p e c t t h e t e e t h o n all g e a r s (C) for u n e v e n w e a r ,

scoring, and cracks.
6. C o a t the c o n e s u r f a c e of e a c h g e a r w i t h M T F , a n d
GOOD WORN p l a c e the s y n c h r o ring o n it. R o t a t e t h e s y n c h r o ring,
m a k i n g s u r e t h a t it d o e s not s l i p .
2 . I n s p e c t the teeth (A) o n e a c h s y n c h r o s l e e v e a n d
m a t c h i n g teeth o n e a c h g e a r for w e a r ( r o u n d e d off). 7 . M e a s u r e t h e c l e a r a n c e b e t w e e n e a c h s y n c h r o ring
(A) a n d g e a r (B) all the w a y a r o u n d . Hold t h e
s y n c h r o ring a g a i n s t the g e a r e v e n l y w h i l e
m e a s u r i n g t h e c l e a r a n c e . If t h e c l e a r a n c e is l e s s
t h a n the s e r v i c e limit, r e p l a c e the s y n c h r o ring a n d
gear.
A
Synchro Ring-to-Gear Clearance
E x a m p l e of s y n c h r o s l e e v e t e e t h a n d g e a r t e e t h Standard:
'00-03 m o d e l s 5 t h , 6 t h g e a r :
Except '06-08 m o d e l s countershaft 2 n d gear teeth:
0 . 7 5 - 1 . 0 0 m m ( 0 . 0 3 0 - 0 . 0 3 9 in.)
'04-08 m o d e l s 3rd, 4th, 5th, a n d 6th gear:
0 . 8 5 - 1 . 1 0 m m ( 0 . 0 3 3 - 0 . 0 4 3 in.)
R e v e r s e gear: 0 . 8 5 — 1 . 1 0 m m ( 0 . 0 3 3 — 0 . 0 4 3 in.)
GOOD WORN
'06-08 m o d e l s countershaft 2 n d gear teeth:
GOOD WORN
(cont'd)
13-51
Manual Transmission
Synchro Ring and Gear Inspection Synchro Sleeve and Hub Inspection
(cont'd) and Reassembly
Double C o n e Synchro-to-Gear Clearance I n s p e c t g e a r t e e t h o n all s y n c h r o h u b s a n d s y n c h r o

Standard: s l e e v e s for w e a r ( r o u n d e d off c o r n e r s ) .
0: Outer S y n c h r o Ring to Synchro C o n e
'00-03 m o d e l s 1st a n d 2 n d gear: Install e a c h s y n c h r o h u b (A) in its m a t i n g s y n c h r o
0 . 7 0 - 1 . 0 9 m m ( 0 . 0 2 8 - 0 . 0 4 3 in.) s l e e v e ( B ) , a n d c h e c k for f r e e m o v e m e n t . M a k e
'00-03 m o d e l s 3rd a n d 4th gear: s u r e to m a t c h t h e t h r e e s e t s of longer teeth (C)
0 . 9 0 - 1 . 3 9 m m ( 0 . 0 3 5 - 0 . 0 5 5 in.) (120 d e g r e e s apart) o n the s y n c h r o s l e e v e w i t h the
'04-08 m o d e l s 1st a n d 2 n d gear: t h r e e s e t s of d e e p e r g r o o v e s (D) in the s y n c h r o h u b .
0 . 5 8 - 1 . 0 9 m m ( 0 . 0 2 3 - 0 . 0 4 3 in.)
©: Synchro Cone to Gear NOTE:
'00-03 m o d e l s 1st, 3rd, a n d 4th gear: • If r e p l a c e m e n t i s r e q u i r e d , a l w a y s r e p l a c e t h e
0 . 5 0 - 1 . 0 4 m m ( 0 . 0 2 0 - 0 . 0 4 1 in.) s y n c h r o s l e e v e a n d the s y n c h r o h u b a s a s e t .
'00-03 m o d e l s 2 n d gear: • D o not install the s y n c h r o s l e e v e w i t h its l o n g e r
0 . 6 5 - 1 . 7 8 m m ( 0 . 0 2 6 - 0 . 0 7 0 in.) t e e t h in the 1st/2nd s y n c h r o h u b s l o t s (E) b e c a u s e
'04-08 m o d e l s 1st a n d 2 n d gear: it w i l l d a m a g e the s p r i n g ring.
0 . 3 3 - 1 . 0 4 m m ( 0 . 0 1 3 - 0 . 0 4 1 in.)
®: Outer Synchro Ring to Gear
'00-03 m o d e l s 1st, 3rd, a n d 4th gears:
0 . 9 5 — 1 . 6 8 m m ( 0 . 0 3 7 - 0 . 0 6 6 in.)
'00-03 m o d e l s 2 n d gear:
0 . 7 0 - 1 . 8 2 m m ( 0 . 0 2 8 - 0 . 0 7 2 in.)
'04-08 m o d e l s 1st a n d 2 n d gear:
0 . 9 5 - 1 . 3 5 m m ( 0 . 0 3 7 - 0 . 0 5 3 in.)
Service Limit:
© : 0.3 m m (0.012 in.)
® : 0.3 m m (0.012 in.)
(3): 0.6 m m (0.024 in.)
13-52
Oil Pump Clearance Inspection
1. M e a s u r e the radial c l e a r a n c e b e t w e e n the i n n e r M e a s u r e t h e a x i a l c l e a r a n c e o n t h e p u m p rotor. If

rotor (A) a n d t h e o u t e r rotor (B) w i t h a f e e l e r g a u g e . the c l e a r a n c e e x c e e d s the s t a n d a r d , s e l e c t t h e
If t h e c l e a r a n c e e x c e e d s the s e r v i c e limit, r e p l a c e a p p r o p r i a t e rotor for t h e c o r r e c t c l e a r a n c e f r o m the
the oil p u m p outer a n d i n n e r rotors. chart a s s h o w n .
Standard: 0.14 m m (0.006 in.) m a x . Rotor-to-Transmission Housing Axial Clearance

S e r v i c e L i m i t : 0.20 m m (0.008 in.) S t a n d a r d : 0 . 0 3 — 0 . 0 7 m m ( 0 . 0 0 1 — 0 . 0 0 3 in.)
Outer a n d Inner Rotor S e t

Part Number Thickness
A 21168-PCY-0000 9.95—9.97 m m
( 0 . 3 9 2 - 0 . 3 9 3 in.)
B 21169-PCY-0000 9.93—9.95 m m
( 0 . 3 9 1 - 0 . 3 9 2 in.)
C 21170-PCY-0000 9.91—9.93 m m
( 0 . 3 9 0 - 0 . 3 9 1 in.)
2. M e a s u r e t h e radial c l e a r a n c e b e t w e e n the outer

rotor (B) a n d t h e t r a n s m i s s i o n h o u s i n g (C) w i t h a
f e e l e r g a u g e . If the c l e a r a n c e e x c e e d s t h e s e r v i c e
limit, r e p l a c e the oil p u m p outer a n d i n n e r rotors.
Standard: 0.1 — 0 . 2 m m ( 0 . 0 0 4 — 0 . 0 0 8 in.)

13-53
Manual Transmission
Secondary Shaft Preload Adjustment
1. Install oil g u i d e plate S , t h e 6 8 m m s h i m (A) a n d t h e If t h e p r e l o a d is not w i t h i n t h e s t a n d a r d , s e l e c t a

b e a r i n g o u t e r r a c e (B) o n t h e t r a n s m i s s i o n h o u s i n g 6 8 m m s h i m that will p r o v i d e c o r r e c t p r e l o a d .
( s e e s t e p 17 o n p a g e 13-59).
68 m m S h i m
Part N u m b e r Thickness
A 41381-PCY-0000 0.90 m m (0.0354 in.)
B 41382-PCY-0000 0.93 m m (0.0366 in.)
C 41383-PCY-0000 0.96 m m (0.0378 in.)
D 41384-PCY-0000 0.99 m m (0.0390 in.)
E 41385-PCY-0000 1.02 m m (0.0402 in.)
F 41386-PCY-0000 1.05 m m (0.0413 in.)
G 41387-PCY-0000 1.08 m m (0.0425 in.)
H 41388-PCY-0000 1.11 m m (0.0437 in.)
I 41389-PCY-0000 1.14 mm (0.0449 in.)
J 41390-PCY-0000 1.17 mm (0.0461 in.)
K 41391-PCY-0000 1.20 mm (0.0472 in.)
L 41392-PCY-0000 1.23 mm (0.0484 in.)
M 41393-PCY-0000 1.26 mm (0.0496 in.)
2. Install t h e r e a r c o v e r , t h e n t i g h t e n t h e 8 m m f l a n g e N 41394-PCY-0000 1.29 mm (0.0508 in.)
bolts in a c r i s s c r o s s pattern in s e v e r a l s t e p s . 0 41395-PCY-0000 1.32 mm (0.0520 in.)
P 41396-PCY-0000 1.35 mm (0.0531 in.)
Specified Torque: Q 41397-PCY-0000 1.38 mm (0.0543 in.)
8x1.25 mm R 41398-PCY-0000 1.41 mm (0.0555 in.)
2 7 N m (2.8 k g f - m , 2 0 Ibf-ft) S 41399-PCY-0000 1.44 mm (0.0567 in.)
T 41400-PCY-0000 1.47 m m (0.0579 in.)
3. Rotate t h e s e c o n d a r y s h a f t in both d i r e c t i o n s to
s e a t the t a p e r e d roller b e a r i n g .
4. M e a s u r e t h e t u r n i n g t o r q u e of t h e s e c o n d a r y s h a f t
b y rotating it in both d i r e c t i o n s w i t h a t o r q u e
wrench.
S t a n d a r d : 1.86—2.84 N-m
( 1 9 - 2 9 kgf-cm, 1 6 . 5 - 2 5 . 2 Ibfin)
13-54
Mainshaft Thrust Clearance Adjustment
Special Tools Required 4. A t t a c h t h e m a i n s h a f t h o l d e r (A) a n d m a i n s h a f t b a s e

• Mainshaft holder 0 7 G A J - P G 2 0 1 1 0 (B) to t h e m a i n s h a f t a s f o l l o w s :
• Mainshaft base 0 7 G A J - P G 2 0 1 3 0
• B a c k o u t t h e m a i n s h a f t h o l d e r bolt ( C ) , a n d l o o s e n
1. Install t h e m a i n s h a f t a s s e m b l y in t h e c l u t c h the t w o h e x bolts (D).
housing. • Fit t h e h o l d e r o v e r t h e m a i n s h a f t s o its lip is
t o w a r d s the t r a n s m i s s i o n .
2. Install oil g u i d e plate M a n d 8 2 m m s h i m ( s ) (A) into • A l i g n t h e m a i n s h a f t h o l d e r ' s lip a r o u n d t h e
the t r a n s m i s s i o n h o u s i n g . g r o o v e at t h e i n s i d e of t h e m a i n s h a f t s p l i n e s ,
t h e n tighten the h e x bolts.
07GAJ-PG20110
07GAJ-PG20130
3. Install t h e t r a n s m i s s i o n h o u s i n g o n t o t h e c l u t c h
h o u s i n g , t h e n tighten t h e 8 m m f l a n g e bolts in a 5. F u l l y s e a t the m a i n s h a f t b y t a p p i n g its e n d w i t h a
c r i s s c r o s s pattern in s e v e r a l s t e p s . plastic h a m m e r .
Specified Torque: 6. T h r e a d t h e m a i n s h a f t h o l d e r bolt in until it j u s t

8x1.25 mm c o n t a c t s t h e w i d e s u r f a c e of the m a i n s h a f t b a s e .
2 7 N-m (2.8 k g f - m , 2 0 I b f f t )
7. Z e r o a dial g a u g e (A) o n t h e e n d of t h e m a i n s h a f t .
07GAJ-PG20110
07GAJ-PG20130
(cont'd)
13-55
Manual Transmission
Mainshaft Thrust Clearance Transmission Reassembly

Adjustment (cont'd)
• Holder handle 0 7 J A B - 0 0 1 0 2 0 A
8. T u r n t h e m a i n s h a f t h o l d e r bolt (B) c l o c k w i s e ; s t o p • A t t a c h m e n t , 40 x 50 m m I.D. 0 7 L A D - P W 5 0 6 0 1
t u r n i n g w h e n t h e dial g a u g e h a s r e a c h e d its • Mainshaft holder 07PAB-001A300
m a x i m u m m o v e m e n t . T h e r e a d i n g o n t h e dial • C o m p a n i o n flange holder 0 7 R A B - T B 4 0 1 0 B
g a u g e is t h e a m o u n t of m a i n s h a f t e n d p l a y . • A t t a c h m e n t , 42 x 47 m m 0 7 7 4 6 - 0 0 1 0 3 0 0
• Attachment, 62 x 68 m m 07746-0010500
N O T E : D o not turn the m a i n s h a f t h o l d e r bolt m o r e • Attachment, 72 x 75 m m 07746-0010600
t h a n 6 0 d e g r e e s after t h e n e e d l e of t h e dial g a u g e • Driver handle 07746-0030100
stops moving. Applying more pressure with the • D r i v e r 07749-0010000
m a i n s h a f t h o l d e r bolt m a y d a m a g e t h e • D r i v e r , 30 m m I.D. 07946-MBOOOOO
transmission. • A t t a c h m e n t , 3 5 m m I.D. 0 7 9 6 5 - S A 5 0 5 0 0
9. If t h e r e a d i n g is w i t h i n t h e s t a n d a r d , t h e c l e a r a n c e Transmission Housing Installation

is c o r r e c t . If t h e r e a d i n g i s not within t h e s t a n d a r d ,
select the appropriate s h i m needed f r o m the table, N O T E : Prior to r e a s s e m b l i n g , c l e a n all t h e parts in
and recheck the s h i m thickness. s o l v e n t , d r y t h e m , a n d a p p l y M T F to a n y c o n t a c t
surfaces.
S t a n d a r d : 0 . 1 4 - 0 . 2 1 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.)
1. Install t h e oil s e a l (A) u s i n g t h e 4 2 x 4 7 mm
82 m m S h i m a t t a c h m e n t (B) a n d d r i v e r (C).
Parts Number Thickness
A 23931-PR8-F000 0.60 m m (0.0236 in.)
B 23932-PR8-F000 0.63 m m (0.0248 in.)
C 23933-PR8-F000 0.66 m m (0.0260 in.)
D 23934-PR8-F000 0.69 m m (0.0271 in.)
E 23935-PR8-F000 0.72 mm (0.0283 in.)
F 23936-PR8-F000 0.75 mm (0.0295 in.)
G 23937-PR8-F000 0.78 mm (0.0307 in.)
H 23938-PR8-F000 0.81 mm (0.0319 in.)
I 23939-PR8-F000 0.84 mm (0.0331 in.)
J 23940-PR8-F000 0.87 mm (0.0343 in.)
K 23941-PR8-F000 0.90 mm (0.0354 in.)
L 23942-PR8-F000 0.93 mm (0.0366 in.)
M 23943-PR8-F000 0.96 mm (0.0378 in.) 2. Install the r e l e a s e b e a r i n g g u i d e (A) w i t h t h r e e bolts
N 23944-PR8-F000 0.99 mm (0.0390 in.) (B), t h e c l u t c h r e l e a s e h a n g e r ( C ) , t h e r e l e a s e
O 23945-PR8-F000 1.02 mm (0.0402 in.) h a n g e r s p r i n g (D) w i t h t w o bolts ( E ) , a n d the
P 23946-PR8-F000 1.05 mm (0.0413 in.) b r e a t h e r plate (F) w i t h a bolt ( G ) .
Q 23947-PR8-F000 1.08 mm (0.0425 in.)
R 23948-PR8-F000 1.11 mm (0.0437 in.)
S 23949-PR8-F000 1.14 mm (0.0449 in.)
T 23950-PR8-F000 1.17 mm (0.0461 in.)
U 23951-PR8-F000 1.20 mm (0.0472 in.)
A B
6x1.0 mm
12 N-m
(1.2 kgfm, 8.7 Ibf-ft)
13-56
3. Install t h e t h r u s t w a s h e r (A) a n d t h e 64 m m s p r i n g 6. Install t h e 1-2 shift p i e c e .
w a s h e r (B).
7. Install t h e s e l e c t return s p r i n g (A) a n d t h e 8 x 40 pin

(B) onto t h e c l u t c h h o u s i n g , t h e n install t h e
interlock (C).
4. Install t h e r e v e r s e idler g e a r ( C ) , m a i n s h a f t ,
c o u n t e r s h a f t , a n d the shift f o r k s a s s e m b l y (D) w i t h 8. Install shift a r m A b y a l i g n i n g t h e interlock f i n g e r
t h e s n a p ring p l i e r s , a n d s e t t h e 68 m m s n a p ring a n d t h e shift fork g r o o v e s .
(E) into t h e g r o o v e of t h e c o u n t e r s h a f t b e a r i n g .
N O T E : C h e c k that the s n a p ring i s s e c u r e l y s e a t e d

in t h e g r o o v e of t h e c o u n t e r s h a f t b e a r i n g .
Dimension 0 as installed: 0 — 6 . 9 3 m m ( 0 — 0 . 2 7 3 in.)
5. A p p l y liquid g a s k e t , P/N 0 8 7 1 8 - 0 0 0 1 , e v e n l y to t h e
m a t i n g s u r f a c e of the t h r e a d s of the 34 m m s e a l i n g
bolt (F) a n d t h e t r a n s m i s s i o n h o u s i n g . Install t h e
c o m p o n e n t w i t h i n 5 m i n u t e s of a p p l y i n g t h e liquid
gasket.
NOTE:
• If y o u a p p l y liquid g a s k e t P/N 0 8 7 1 8 - 0 0 1 2 , t h e
c o m p o n e n t m u s t be i n s t a l l e d within 4 m i n u t e s .
• If t o o m u c h t i m e h a s p a s s e d after a p p l y i n g t h e
liquid g a s k e t , r e m o v e the o l d g a s k e t a n d r e s i d u e ,
t h e n r e a p p l y n e w liquid g a s k e t .
(cont'd)
13-57
Manual Transmission
Transmission Reassembly (cont'd)
9. Install t h e shift rod (A) into t h e interlock a s s e m b l y 12. Install t h e n e e d l e b e a r i n g (A), t h e r e v e r s e g e a r shaft
(B) w i t h t h e r e c e s s e d h o l e (C) t o w a r d t h e t o p of t h e (B), the thrust w a s h e r (C), a n d the reverse shaft
c l u t c h h o u s i n g (D), t h e n install t h e 5 x 2 5 s p r i n g pin h o l d e r (D), t h e n install t h e w a s h e r a n d 8 m m f l a n g e
(E). bolt.
/ 3 4 N m (3.5 kgf m , 2 5 Ibfft)

A '04-08 m o d e l s :
2 7 N m (2.8 k g f m , 2 0 Ibf ft)
10. Install t h e outer s i d e 1-2 shift l e v e r (A) first, t h e n

install t h e i n n e r s i d e 1-2 shift l e v e r (B). 13. Install t h e oil g u i d e pipe (A) a n d t h e m a g n e t ( B ) .
10 x 1.25 m m
4 4 N - m (4.5 k g f m , 3 3 Ibf-ft)
14. Install oil g u i d e plate M a n d t h e 8 2 m m s h i m ( s ) (A).
11. Install t h e 8 x 6 3 pin ( C ) , t h e n tighten t h e 10 m m

f l a n g e bolt (D).
13-58
15. Install t h e oil p u m p s t r a i n e r (A), t h e s u c t i o n g u i d e 17. Install oil g u i d e plate S a n d t h e 68 m m s h i m (A),
( B ) , a n d t h e circlip (C). t h e n install t h e b e a r i n g o u t e r r a c e (B) u s i n g the
6 2 x 6 8 m m a t t a c h m e n t (G) a n d d r i v e r (D) a s s h o w n .
07746-0010500
18. G l e a n a n y dirt or oil f r o m t h e t r a n s m i s s i o n h o u s i n g

m a t i n g s u r f a c e . A p p l y liquid g a s k e t , P/N
08718-0001 e v e n l y to t h e m a t i n g s u r f a c e of t h e
t r a n s m i s s i o n h o u s i n g a n d the clutch h o u s i n g .
Install t h e c o m p o n e n t w i t h i n 5 m i n u t e s of a p p l y i n g
t h e liquid g a s k e t .
NOTE:
c o m p o n e n t m u s t be installed within 4 minutes.
• If too m u c h t i m e h a s p a s s e d after a p p l y i n g t h e
liquid g a s k e t , r e m o v e t h e old liquid g a s k e t a n d
r e s i d u e , t h e n r e a p p l y n e w liquid g a s k e t .
• A l l o w it to c u r e at l e a s t 20 m i n u t e s after
a s s e m b l y b e f o r e filling t h e t r a n s m i s s i o n w i t h
MTF.
Liquid gasket
(cont'd)
13-59
Manual Transmission
19. Install t h e 14 x 2 0 d o w e l p i n s ( B ) , t h e t r a n s m i s s i o n 2 1 . A p p l y liquid g a s k e t , P/N 0 8 7 1 8 - 0 0 0 1 , e v e n l y to t h e
housing (C), 8 m m flange bolts, the t r a n s m i s s i o n m a t i n g s u r f a c e of t h e t h r e a d s of t h e s e t s c r e w s ( A ) ,
h a n g e r (D), a n d t r a n s m i s s i o n h a n g e r A . t h e n install t h e s e t s c r e w s , t h e s t e e l b a l l s , a n d
s p r i n g s . Install t h e c o m p o n e n t w i t h i n 5 m i n u t e s of
a p p l y i n g t h e liquid g a s k e t .
NOTE:
liquid g a s k e t , r e m o v e t h e o l d liquid g a s k e t a n d
A
1 2 x 1.0 m m
C 2 2 N m (2.2 k g f m , 1 6 I b f f t )
2 5 N-m L: 2 7 . 4 m m
(2.5 k g f m , ( 1 . 0 8 in.)
18 Ibfft) (Gold)
2 0 . T i g h t e n t h e 8 m m f l a n g e bolts in a c r i s s c r o s s
pattern in s e v e r a l s t e p s a s s h o w n .
Specified Torque:
8x1.25 mm
27 N m (2.8 k g f - m , 2 0 I b f f t )
A L: 2 3 m m (0.91 i n . )
12x1.0 m m (Silver)
A
(2.2 k g f m , ™»in.) 1 2 x 1.0 m m
16 Ibfft) «*old) 22 N m
(2.2 k g f m , 1 6 I b f f t )
2 2 . Install t h e n e w w a s h e r (B) a n d t h e b a c k - u p light

switch (C).
13-60
2 3 . Install t h e n e w w a s h e r s (A), t h e d r a i n plug (B), t h e 2 6 . Install t h e s e c o n d a r y d r i v e g e a r (A) o n t h e
12 m m d r a i n plug ( C ) , a n d t h e v e h i c l e s p e e d s e n s o r c o u n t e r s h a f t u s i n g t h e 3 0 m m I.D. d r i v e r (B) a s
( V S S ) ('00-05 m o d e l s ) or t h e output s h a f t shown.
(countershaft) s p e e d s e n s o r ('06-08 m o d e l s ) (D)
w i t h a n e w O - r i n g ( E ) . Install the filler p l u g (F)
finger-tight.
v A i.u IIIIII
12 N m (1.2 k g f m , 8.7 Ibf.ft)
24. A p p l y liquid g a s k e t , P/N 0 8 7 1 8 - 0 0 0 1 , e v e n l y t o t h e 2 7 . Install t h e n e e d l e b e a r i n g (A) o n t h e c o u n t e r s h a f t

m a t i n g s u r f a c e of t h e t h r e a d s of t h e s e t s c r e w s ( G ) , u s i n g t h e 3 5 m m I.D. a t t a c h m e n t (B) a s s h o w n .
t h e n install t h e s e t s c r e w s , t h e s t e e l b a l l s , a n d
s p r i n g s . Install t h e c o m p o n e n t w i t h i n 5 m i n u t e s of
a p p l y i n g t h e liquid g a s k e t .
NOTE:
c o m p o n e n t m u s t b e installed w i t h i n 4 m i n u t e s .
A
2 5 . Install t h e oil p u m p i n n e r a n d outer rotors (A), t h e
s t e e l ball (B), t h e s p r i n g ( C ) , a n d t h e oil p u m p plate
(D).
(cont'd)
13-61
Manual Transmission
28. Install the s p r i n g w a s h e r (A) a n d t h e n e w 29 m m 30. S t a k e t h e 2 9 m m locknut t a b into t h e g r o o v e .
locknut (B) finger-tight (left-hand t h r e a d s ) .
3 1 . Install the oil p u m p g e a r a n d oil p u m p g e a r shaft.
2 9 . Install the m a i n s h a f t h o l d e r (A) o n t h e m a i n s h a f t ,

t h e n tighten t h e 2 9 m m locknut (left-hand t h r e a d s )
to t h e s p e c i f i e d v a l u e .
Torque:
1 7 2 — 0 — 172 N m
( 1 7 . 5 — 0 — 17.5 k g f m ,
127— 0 —127 Ibf-ft)
07PAB-001A300
13-62
Rear Cover Installation 3. Install t h e s e c o n d a r y s h a f t a s s e m b l y into t h e rear
cover.
N O T E : Prior to r e a s s e m b l i n g , c l e a n all t h e parts in
s o l v e n t , d r y t h e m , a n d a p p l y M T F to a n y c o n t a c t
surfaces.
1. Install t h e b e a r i n g outer r a c e (A) u s i n g t h e

7 2 x 7 5 m m a t t a c h m e n t (B) a n d d r i v e r (C) a s s h o w n .
2. Install the s h i m a n d the b e a r i n g outer r a c e into t h e

rear c o v e r u s i n g the 62 x 6 8 m m a t t a c h m e n t (A)
a n d driver (B) a s s h o w n .
(cont'd)
13-63
Manual Transmission
5. Install the n e w oil s e a l (A) u s i n g t h e 40 x 50 m m I.D. 7. Install the n e w O-ring (A), t h e b a c k - u p ring (B), t h e
a t t a c h m e n t (B), 42 x 47 m m a t t a c h m e n t (C), a n d s p r i n g w a s h e r ( C ) , a n d t h e n e w 27 m m locknut (D).
d r i v e r (D).
D
Replace.
07749-0010000
07746-0010300
07LAD-PW50601
A
Replace
6. Install the c o m p a n i o n f l a n g e (A) u s i n g t h e d r i v e r

h a n d l e (B) a s s h o w n .
07746-0030100
8. Install t h e h o l d e r h a n d l e (A) a n d c o m p a n i o n f l a n g e
h o l d e r (B) o n the c o m p a n i o n f l a n g e , t h e n tighten
t h e 27 m m locknut t h e to t h e s p e c i f i e d v a l u e .
Torque:
1 6 2 — 0 — 162 N-m
(16.5— 0 — 16.5 k g f m ,
1 1 9 — 0 — 119 Ibf-ft)
07RAB-TB4010B
07JAB-001020A
13-64
<3®
9. S t a k e t h e 27 m m locknut t a b into t h e g r o o v e . 11. C l e a n a n y dirt or oil f r o m t h e r e a r c o v e r m a t i n g
s u r f a c e . A p p l y liquid g a s k e t , P/N 0 8 7 1 8 - 0 0 0 1 ,
e v e n l y to the m a t i n g s u r f a c e of t h e rear c o v e r a n d
t r a n s m i s s i o n h o u s i n g . Install t h e c o m p o n e n t w i t h i n
5 m i n u t e s of a p p l y i n g t h e liquid g a s k e t .
NOTE:
c o m p o n e n t m u s t be i n s t a l l e d w i t h i n 4 m i n u t e s .
10. Install t h e shift rod t u b e a n d n e w O - r i n g s .
Replace.
Liquid gasket
12. Install the 14 x 20 d o w e l p i n s (A), rear c o v e r

a s s e m b l y (B), h a r n e s s bracket ( C ) , h a r n e s s c l a m p
Replace. (D), a n d 8 m m f l a n g e bolts.
(cont'd)
13-65
Manual Transmission
13. T i g h t e n t h e 8 m m f l a n g e bolts in a c r i s s c r o s s 15. Install t h e shift l e v e r h o u s i n g a n d t h e d o w l p i n s .

6x1.0 mm
9.8 N-m
Specified Torque: (1.0 k g f - m , 7 . 2 I b f f t )
8 x 1.25 m m
2 7 N m (2.8 k g f - m , 2 0 I b f f t )
14. L o w e r t h e shift rod (A), t h e n install t h e shift a r m B ,

the n e w conical spring w a s h e r (C), a n d 8 m m
s p e c i a l bolt.
8 x 1.0 m m
31 N - m
(3.2 k g f - m ,
2 3 Ibf ft)
13-66
Transmission Installation
N O T E : U s e f e n d e r c o v e r s to a v o i d d a m a g i n g painted 3. A p p l y s u p e r high t e m p u r e a g r e a s e (P/N 0 8 7 9 8 -
surfaces. 9002) to t h e r e l e a s e fork (A), t h e r e l e a s e h a n g e r (B),
a n d t h e r e l e a s e b e a r i n g g u i d e (C). Install the
S R S c o m p o n e n t s a r e located in t h i s a r e a . R e v i e w the r e l e a s e fork into t h e o p e n i n g in t h e c l u t c h h o u s i n g .
S R S c o m p o n e n t l o c a t i o n s for t h e a p p r o p r i a t e m o d e l :
• '00-05 m o d e l s ( s e e p a g e 23-11)
• '06-08 m o d e l s ( s e e p a g e 23-12)
A l s o review the precaution and procedures (see page

23-13) before d o i n g r e p a i r s o r s e r v i c e .
1. Install t h e t r a n s m i s s i o n r e a r m o u n t (A).
(P/N 08798-9002)
4. Pull t h e r e l e a s e fork (A) out until it s t o p s , t h e n

w e d g e a s h o p t o w e l (B) b e t w e e n the r e l e a s e fork
a n d c l u t c h h o u s i n g to hold t h e r e l e a s e fork in p l a c e .
5. P l a c e t h e t r a n s m i s s i o n o n a t r a n s m i s s i o n j a c k , a n d
r a i s e it to t h e e n g i n e l e v e l .
(cont'd)
13-67
Manual Transmission
Transmission Installation (cont'd)
6. Install t h e t h r e e u p p e r t r a n s m i s s i o n m o u n t i n g bolts. 9 . P l a c e a floor j a c k u n d e r t h e front s u b f r a m e a n d t h e

e n g i n e m o u n t i n g stiffener, a n d r a i s e it to t h e f r a m e .
1 2 x 1.25 m m
6 4 N-m (6.5 k g f m , 47 I b f f t ) 1 4 x 1.5 m m
116 N-m (11.8 k g f m , 85.3 Ibfft)
Replace.
7. Install t h e w i r e h a r n e s s (A) t o t h e t r a n s m i s s i o n ,
12x1.25 m m
then connect the vehicle s p e e d sensor ( V S S )
5 9 N - m (6.0 k g f m , 4 3 I b f f t )
('00-05 m o d e l s ) o r t h e output s h a f t (countershaft) Replace.
s p e e d s e n s o r ('06-08 m o d e l s ) c o n n e c t o r ( B ) .
10. T i g h t e n t h e f o u r m o u n t i n g b o l t s , a n d install t h e t w o
c e n t e r m o u n t i n g bolts.
11. Install t h e five l o w e r t r a n s m i s s i o n m o u n t i n g bolts.
10x1.25 mm
4 4 N-m (4.5 k g f m , 3 3 Ibfft)
8. R a i s e t h e t r a n s m i s s i o n , t h e n install t h e t h r e e
transmission rear mount bolts.
1 2 x 1.25 m m
6 4 N - m (6.5 k g f - m , 4 7 I b f f t )
12. R e m o v e t h e s h o p t o w e l , a n d install t h e r e l e a s e fork

onto the release hanger.
10 x 1.25 m m
38 N m (3.9 k g f m , 28 Ibfft)
13-68
<3®
13. A p p l y s u p e r high t e m p u r e a g r e a s e ( P / N 0 8 7 9 8 - 14. Install t h e f o u r shift b o o t h o l d e r m o u n t i n g bolts.
9 0 0 2 ) to t h e e n d of t h e s l a v e c y l i n d e r p u s h r o d (A).
Install t h e s l a v e c y l i n d e r (B) w i t h t w o bolts, a n d the
r e l e a s e fork boot ( C ) .
'00-03 m o d e l s
6x1.0 mm
9 . 8 N m (1.0 k g f m , 7 . 2 I b f f t )
15. Install t h e p r o p e l l e r s h a f t ( s e e p a g e 16-19).
16. Install t h e g a s k e t (A), e x h a u s t m a n i f o l d (B), a n d t h e

e x h a u s t m a n i f o l d bracket ( C ) .
GBEASEKI
(P/N 08798-9002)
'04-08 m o d e l s
8 x 1.25 m m
10x1.25 m m 31 N m
44 N m (3.2 k g f m , 2 3 I b f f t )
(4.5 k g f m , Replace.
33 Ibfft)
(P/N 08798-9002)
(cont'd)
13-69
Manual Transmission
17. Install t h e n e w g a s k e t s (A) w i t h n e w n u t s , a n d t h r e e 19. Install g r o u n d c a b l e (A) t h e intake m a n i f o l d b r a c k e t

w a y c a t a l y t i c c o n v e r t e r ( T W C ) (B) w i t h n e w bolts ( B ) , a n d l o w e r m o u n t i n g bolt, t h e n install t h e w i r e
and new springs. h a r n e s s (C) o n t h e intake m a n i f o l d bracket.
1 0 x 1.25 m m 10 x 1.25 m m
3 3 N m (3.4 k g f m , 2 5 Ibf ft) 44 N m
A Replace. kgf-m,
Replace ft)
8x1.25 mm
2 2 N m (2.2 k g f - m , 16 Ibf-ft)
Replace.
2 0 . Refill t h e t r a n s m i s s i o n w i t h t h e r e c o m m e n d e d fluid
18. Install t h e w i r e h a r n e s s (A) onto t h e t r a n s m i s s i o n , ( s e e s t e p 4 o n p a g e 13-3).
then connect the primary heated oxygen s e n s o r
( p r i m a r y H 0 2 S ) ( s e n s o r 1) ('00-05 m o d e l s ) , t h e air 2 1 . Install t h e s p l a s h s h i e l d .
fuel ratio ( A / F ) s e n s o r ( s e n s o r 1) ('06-08 m o d e l s ) (B),
secondary heated oxygen sensor (secondary
H 0 2 S ) ( s e n s o r 2) ( C ) , a n d t h e b a c k - u p light s w i t c h
(D) c o n n e c t o r s .
8x1.25 mm
24 N m
(2.4 k g f m ,
17 Ibf ft)
13-70
2 2 . L o w e r the v e h i c l e o n the lift. 2 5 . ' 0 0 - 0 5 m o d e l s : C o n n e c t the c a m s h a f t position
( C M P ) s e n s o r A (top d e a d c e n t e r ( T D C ) s e n s o r 1)
23. C o n n e c t the t o r q u e s e n s o r 3 P c o n n e c t o r (A), a n d a n d C M P s e n s o r B ( T D C s e n s o r 2) c o n n e c t o r s .
install the w i r e h a r n e s s c l a m p (B).
26. ' 0 6 - 0 8 m o d e l s : C o n n e c t the c a m s h a f t position

(CMP) s e n s o r connector.
24. R e c o n n e c t the 2 P c o n n e c t o r (C) to t h e s t e e r i n g

g e a r b o x (D).
(cont'd)
13-71
Manual Transmission
2 7 . ' 0 0 - 0 5 m o d e l s : Install t h e u p p e r intake m a n i f o l d 2 9 . Install t h e h e a t s h i e l d w i t h bolts.

b r a c k e t m o u n t i n g bolt (A) a n d u p p e r starter m o t o r
m o u n t i n g bolt (B). C o n n e c t t h e h o s e (C) to t h e
suction valve.
10x1.25 m m
44 N m
5 kgf-m,
3 3 Ibf m )
6x1.0 mm
9.8 N - m (1.0 k g f - m , 7 . 2 I b f f t )
10x1.25 m m
4 4 N m ( 4 . 5 k g f m , 3 3 Ibf ft)
3 0 . Install t h e e x h a u s t m a n i f o l d c o v e r w i t h bolts.
2 8 . ' 0 6 - 0 8 m o d e l s : Install t h e u p p e r intake m a n i f o l d
b r a c k e t m o u n t i n g bolt (A) a n d u p p e r s t a r t e r m o t o r
m o u n t i n g bolt ( B ) .
8 x 1.25 m m
1 0 x 1.25 m m 2 2 N m (2.2 k g f - m , 1 6 I b f f t )
44 N m
(4.5 k g f - m ,
1 0 x 1.25 m m 3 3 lbf-m)
44 N m
(4.5 k g f - m ,
33 Ibfft)
13-72
3 1 . Install t h e A / C c o m p r e s s o r w i t h bolts, t h e n c o n n e c t 34. R e m o v e t h e s t e e r i n g w h e e l ( s e e p a g e 17-6).
t h e 1P c o n n e c t o r .
3 5 . C e n t e r t h e c a b l e r e e l , a n d reinstall t h e s t e e r i n g
w h e e l ( s e e p a g e 17-8).
3 6 . ' 0 0 - 0 5 m o d e l s : Install t h e a i r c l e a n e r h o u s i n g (A)

w i t h bolts, t h e n c o n n e c t t h e a i r c o n t r o l s o l e n o i d
v a l v e c o n n e c t o r (B) a n d v a c u u m h o s e s ( C ) .
44 N-m
(4.5 kgf-m,
33 Ibfft)
3 2 . Install t h e a l t e r n a t o r a n d t h e a l t e r n a t o r - c o m p r e s s o r
belt ( s e e p a g e 4-45).
3 3 . C o n n e c t t h e s t e e r i n g joint (A) by a l i g n i n g t h e
r e f e r e n c e m a r k s (B) y o u m a d e , a n d t i g h t e n t h e
bolts (C) to t h e s p e c i f i e d t o r q u e . 3 7 . ' 0 0 - 0 5 m o d e l s : Install t h e a i r c l e a n e r e l e m e n t
a s s e m b l y (A) a n d t h e air c l e a n e r h o u s i n g c o v e r ( B ) ,
U.S.A. models: V I N JHMAP114 * YT000001 t h e n c o n n e c t t h e a i r h o s e (C) a n d t h e b r e a t h e r p i p e
through V I N J H M A P 1 1 4 * YT008411 (D).
T o r q u e : 2 2 N - m (2.2 k g f m , 16 Ibfft)
Canada models: V I N JHMAP114 * YT800001

through VIN JHMAP114 * YT800750
T o r q u e : 2 2 N m (2.2 k g f m , 1 6 Ibfft)
Other models:
T o r q u e : 2 9 N m (3.0 k g f m , 2 2 Ibfft)
(cont'd)
13-73
Manual Transmission
3 8 . '06-08 m o d e l s : Install t h e air c l e a n e r h o u s i n g (A) 40. A p p l y m u l t i p u r p o s e g r e a s e a s s h o w n . Install t h e

w i t h bolts, t h e n install t h e intake air t e m p e r a t u r e shift l e v e r s p r i n g (A) a n d t h e shift l e v e r (B).
(IAT) s e n s o r h a r n e s s c l a m p s (B).
..B
6 x 1.0 m m
12 N m
M 6 x 1.0 m m
(1.2 k g f m , 8.7 Ibf-ft)

^ U * ^ A — — 9 . 8 N m
W I / (1-0 k g f - m ,
• K^f / 7.2 Ibf-ft)
3 9 . '06-08 m o d e l s : Install t h e a i r c l e a n e r e l e m e n t
a s s e m b l y (A) a n d t h e a i r c l e a n e r h o u s i n g c o v e r ( B ) , 41. Install t h e shift l e v e r boot (A) a n d t h e boot h o l d e r
t h e n c o n n e c t t h e I A T s e n s o r c o n n e c t o r (C) a n d (B).
b r e a t h e r pipe (D), install t h e m a n i f o l d a b s o l u t e
p r e s s u r e ( M A P ) s e n s o r h a r n e s s (E) to t h e h o l d e r .
42. Install t h e c e n t e r c o n s o l e ( s e e p a g e 20-80).

E
13-74
43. Install the shift l e v e r k n o b , a n d tighten t h e locknut.
except C R model
C R model
44. Install the battery. C l e a n t h e battery p o s t s a n d

c a b l e t e r m i n a l s . C o n n e c t the positive c a b l e to the
battery, t h e n c o n n e c t the negative c a b l e , a n d a p p l y
g r e a s e to p r e v e n t c o r r o s i o n .
45. C h e c k the front w h e e l a l i g n m e n t ( s e e p a g e 18-7).
46. C h e c k t h e shift l e v e r a n d c l u t c h o p e r a t i o n .
47. ' 0 0 - 0 5 m o d e l s : D o the E C M idle l e a r n p r o c e d u r e

( s e e p a g e 11-140).
48. T e s t - d r i v e t h e v e h i c l e .

13-75
Rear Differential
Rear Differential
Special Tools 15-2
Precautions for Torsen Type
Limited-slip Differential (LSD) 15-4
Torsen Type Limited-slip
Differential (LSD) Operation Check 15-4
Differential Fluid Inspection and Replacement 15-7
Differential Removal 15-8
Differential Case Assembly
Removal and Installation 15-11
Oil Seal Replacement 15-13
Backlash Inspection 15-14
Differential Disassembly 15-15
Differential Reassembly 15-20
Differential Installation 15-27
Differential Breather Box Replacement 15-30
Differential Mount Replacement 15-31
Rear Differential
Special Tools
® 07JAD-PL90100 Oil S e a l D r i v e r 1
® 07JAB-001020A Holder Handle 1
07LAD-PW50601 A t t a c h m e n t , 40 x 5 0 m m I.D. 1
® 07MAD-PR90100 A t t a c h m e n t , 45 x 5 5 m m I.D. 1
® 07NAD-PX40100 A t t a c h m e n t , 78 x 8 0 m m 1
® 07RAB-TB4010B C o m p a n i o n Flange Holder 1
® 07725-0030000 U n i v e r s a l Holder 1
® 07746-0030100 D r i v e r , 40 m m I.D. 1
® 07746-0030300 A t t a c h m e n t , 30 m m I.D. 1
® 07749-0010000 Driver 1
© © ® ©
© ® © © ®
15-2
15-3
Rear Differential
Precautions for Torsen Type Torsen Type Limited-slip
Limited-slip Differential (LSD) Differential (LSD) Operational Check
• T h e T o r s e n differentials a r e m e c h a n i c a l limited-slip T h e T o r s e n t y p e limited-slip differential ( L S D )

differential w h i c h d e l i v e r s t h e a v a i l a b l e p o w e r to t h e d i s t r i b u t e s o p t i m u m p o w e r b e t w e e n t h e t w o driving
w h e e l s a n d driveshafts with the m o s t grip or d r i v e s h a f t s a c c o r d i n g to the d i f f e r e n c e in t o r q u e
r e s i s t a n c e a s t h e e n g i n e t o r q u e output i n c r e a s e s . d e m a n d e d b y t h e d r i v i n g w h e e l s . U n d e r no
• D o not d o r e p a i r p r o c e d u r e s that r e q u i r e t h e e n g i n e c i r c u m s t a n c e s s h o u l d t h e e n g i n e b e started w i t h either
running with one rear w h e e l raised; s u c h a s an on-car w h e e l r a i s e d off t h e g r o u n d , s u c h a s u s i n g a n o n - c a r
wheel balancer. w h e e l b a l a n c e r o r w h e n t r a n s p o r t i n g the v e h i c l e in t h e
• D o not t o w t h e v e h i c l e w i t h t h e r e a r w h e e l s o n t h e e v e n t of a n a c c i d e n t .
ground.
• N e v e r d i s m a n t l e a n y part of t h e differential o t h e r 1. R a i s e t h e v e h i c l e o n a lift.
t h a n right a n d left t a p e r e d roller b e a r i n g s .
• T o o p t i m i z e t h e T o r s e n differential, e q u i p y o u r 2 . Rotate either r e a r w h e e l b y h a n d , a n d c h e c k that
v e h i c l e w i t h rear tires of t h e s a m e b r a n d , t h e s a m e t h e other w h e e l rotates in t h e o p p o s i t e d i r e c t i o n .
size, a n d with even w e a r . C h e c k both w h e e l s .
3 . If t h e o p p o s i t e r e a r w h e e l d o e s not rotate, or if y o u
c a n not s p i n t h e r e a r w h e e l s at a l l , a n d t h e b r a k e s
a r e not b i n d i n g , t h e limited-slip differential is faulty
a n d s h o u l d be r e p l a c e d .
15-4
System Description
T h e v e h i c l e u s e s the T o r s e n t y p e limited-slip differential ( L S D ) w h i c h is r u b b e r - m o u n t e d to t h e s u b f r a m e .
Construction
• T h e T o r s e n t y p e L S D a s s e m b l y c o n s i s t s of t h e t w o s i d e g e a r s , eight p l a n e t a r y g e a r s , t h r e e s i d e w a s h e r s , t w o c e n t e r
w a s h e r s , a gear c a s e cover and a gear case.
• T h e planetary g e a r c o n s i s t s of the s h o r t a n d long p l a n e t a r y g e a r s , a n d the long p l a n e t a r y g e a r m e s h e s horizontally
w i t h t h e s i d e g e a r . T h e t w o p l a n e t a r y g e a r s m e s h w i t h t h e s i d e g e a r s at both e n d s .
• T h e planetary g e a r s a r e h o u s e d in t h e p o c k e t s of the g e a r c a s e .
• T h e left a n d right o u t p u t s h a f t s a r e e n g a g e d w i t h the s i d e g e a r s .
• T h e T o r s e n t y p e L S D a s s e m b l y is a n o n - s e r v i c e a b l e part e x c e p t t h e t a p e r e d roller b e a r i n g s . If the T o r s e n t y p e ( L S D )
a s s e m b l y is faulty, it m u s t be r e p l a c e d a s a n a s s e m b l y .
GEAR CASE
(cont'd)
15-5
Rear Differential
S y s t e m D e s c r i p t i o n (cont'd)
Operation
• Straight-road driving
T h e differential c a r r i e r a n d g e a r s rotate t o g e t h e r a s a unit w h e n both w h e e l s rotate at t h e s a m e s p e e d . T u r n i n g effort
f r o m t h e ring g e a r is d i r e c t l y t r a n s m i t t e d to both w h e e l s .
• W h e n rounding a curve
W h e n t h e v e h i c l e r o u n d s a c u r v e , t h e differential a l l o w s t h e o u t e r w h e e l to rotate a little f a s t e r t h a n t h e i n n e r w h e e l .
W h e n t h i s t a k e s p l a c e , t h e s h o r t a n d l o n g p i n i o n g e a r s rotate, a n d w a l k a r o u n d the s i d e g e a r s in t h e d i r e c t i o n s
s h o w n . If, for e x a m p l e , t h e right s h a f t is rotated in a c o u n t e r c l o c k w i s e direction w i t h the differential c a r r i e r h e l d
s t a t i o n a r y , t h e f o r c e i s t r a n s m i t t e d t h r o u g h t h e right s i d e g e a r , s h o r t p i n i o n g e a r s a n d long p i n i o n g e a r s to t h e left
s i d e g e a r , c a u s i n g t h e left s h a f t to rotate in a c l o c k w i s e d i r e c t i o n . T h i s a l l o w s t h e outer w h e e l to turn m o r e t i m e s
than the inner w h e e l w h e n the vehicle g o e s around a turn.
• W h e n limiting differential a c t i o n
T h e limited-slip differential a c t s to limit the differential a c t i o n w h e n either w h e e l s l i p s o n ice o r s n o w o r o n t u r n s .
T h i s is d o n e b y u s i n g t h e friction c r e a t e d b e t w e e n p i n i o n g e a r s a n d the g e a r c a s e :
(1) T h e p i n i o n s a r e f o r c e d a g a i n s t t h e g e a r c a s e b y the f o r c e a s t h e y a r e rotated a n d r e p e l l e d o u t w a r d .
(2) T h e e n d s of the p i n i o n g e a r s a r e h e l d f i r m l y a g a i n s t the g e a r c a s e d u e to the t h r u s t f o r c e f r o m the
helical gears.
WASHER
W i t h t h e pinion g e a r s l o c k e d , t h e t o r q u e a p p l i e d to t h e s l i p p i n g w h e e l is r e d u c e d a n d t h e t o r q u e a p p l i e d to t h e
other w h e e l is i n c r e a s e d .
15-6
Differential Fluid Inspection and Replacement
1. R a i s e t h e v e h i c l e o n a lift. 5 . C l e a n t h e d r a i n p l u g , t h e n r e i n s t a l l it w i t h a n e w
s e a l i n g w a s h e r (B), a n d refill t h e differential w i t h
2 . R e m o v e t h e filler p l u g (A) a n d t h e s e a l i n g w a s h e r t h e r e c o m m e n d e d fluid to t h e p r o p e r l e v e l .
(B), t h e n c h e c k t h e c o n d i t i o n of the f l u i d , a n d m a k e
s u r e t h e fluid is at t h e p r o p e r level (C). Fluid capacity
0.74 L (0.78 U S q t ) , a t f l u i d c h a n g e
0.77 L (0.81 U S q t ) , a t o v e r h a u l
B
R e c o m m e n d e d fluid
Replace.
H y p o i d g e a r oil
A P I C l a s s i f i c a t i o n : G L 5 or G L 6
Viscosity: S A E 90
6 . R e i n s t a l l t h e filler p l u g (C) w i t h a n e w s e a l i n g
w a s h e r (D).
3 . T h e fluid level m u s t b e up to t h e fill h o l e . If it is

b e l o w t h e h o l e , a d d t h e r e c o m m e n d e d fluid until it
r u n s out.
• If the fluid is dirty, g o to s t e p 4 .

• If the fluid is not dirty, reinstall the filler p l u g w i t h
a new sealing washer.
4 . R e m o v e t h e d r a i n p l u g (A), a n d d r a i n t h e fluid.
4 6 N m (4.7 k g f m , 3 4 Ibf-ft)
15-7
Rear Differential
Differential Removal
1. R a i s e t h e v e h i c l e o n a lift. 5. R e m o v e t h e w h e e l s p e e d s e n s o r h a r n e s s f r o m the
upper arm.
3. Lift u p t h e l o c k i n g t a b (A) o n t h e s p i n d l e nut ( B ) ,

t h e n r e m o v e t h e nut.
4. R e m o v e t h e cotter pin f r o m t h e l o w e r a r m ball joint

c a s t l e nut, t h e n r e m o v e t h e c a s t l e nut. T h e n
s e p a r a t e t h e ball joint f r o m t h e l o w e r a r m u s i n g t h e
ball joint t h r e a d protector a n d t h e ball joint
r e m o v e r ( s e e s t e p 12 o n p a g e 18-34).
NOTE:
• T o a v o i d d a m a g i n g t h e ball joint, install t h e ball
joint t h r e a d protector o n t o t h e t h r e a d s of t h e ball
joint.
• B e c a r e f u l not to d a m a g e t h e ball joint boot w h e n
installing t h e r e m o v e r .
7. R e m o v e t h e s i x i n b o a r d joint m o u n t i n g bolts (D)

and nuts (E), then r e m o v e the inboard joint f r o m
t h e r e a r differential.
8. D r a i n t h e differential fluid ( s e e p a g e 15-7).
9. R e m o v e t h e p r o p e l l e r s h a f t ( s e e p a g e 16-18).
15-8
1 2 . P l a c e a t r a n s m i s s i o n j a c k u n d e r the rear
differential.
(cont'd)
15-9
Rear Differential
Differential Removal (cont'd)
13. ' 0 0 - 0 5 m o d e l s : R e m o v e t h e f o u r differential m o u n t 15. L o w e r t h e r e a r differential o n the t r a n s m i s s i o n j a c k ,
bracket B mounting nuts.
16. R e m o v e right a n d left differential m o u n t b r a c k e t A

14. R e m o v e the four differential m o u n t b r a c k e t A f r o m the differential; '00-05 m o d e l s ( s e e p a g e
m o u n t i n g bolts. 15-31), ' 0 6 - 0 8 m o d e l s ( s e e p a g e 15-32).
15-10
Differential Case Assembly Removal and Installation
1. R e m o v e t h e output s h a f t s (A) f r o m t h e differential C l e a n t h e dirt a n d oil f r o m t h e m a t i n g s u r f a c e s .
u s i n g t h e pry b a r s (B). A p p l y liquid g a s k e t , P/N 0 8 7 1 8 - 0 0 0 1 e v e n l y to t h e
m a t i n g s u r f a c e of t h e differential c a s e a n d the
differential c a r r i e r . I n s t a l l t h e c o m p o n e n t w i t h i n
5 m i n u t e s of a p p l y i n g t h e liquid g a s k e t .
NOTE:
• If y o u a p p l y liquid g a s k e t P/N 0 8 7 1 8 - 0 0 1 2 , the
liquid g a s k e t , r e m o v e t h e o l d liquid g a s k e t a n d
• A l l o w it to c u r e at l e a s t 30 m i n u t e s after
a s s e m b l y b e f o r e filling t h e differential w i t h t h e
recommended fluid.
R e m o v e t h e t e n m o u n t i n g bolts in a c r i s s c r o s s
pattern in s e v e r a l s t e p s , t h e n r e m o v e t h e
differential c a s e .
Liquid gasket
4. Install t h e differential c a s e .
(cont'd)
15-11
Rear Differential
Differential Case Assembly Removal and Installation (cont'd)
5 . T i g h t e n t h e t e n m o u n t i n g bolts in a c r i s s c r o s s
2 4 N - m ( 2 . 4 k g f - m , 1 7 Ibf-ft)
6. Install the n e w c l i p s (A) o n t h e output s h a f t s , t h e n

install t h e output s h a f t s ( B ) .
A
Replace.
15-12
<S0
Oil Seal Replacement
Special Tools Required 3. Install the oil s e a l u s i n g t h e oil s e a l d r i v e r (A) a s

Oil s e a l d r i v e r 0 7 J A D - P L 9 0 1 0 0 shown.
1. R e m o v e t h e output shaft (A) f r o m the differential

u s i n g t h e pry b a r s (B). 07JAD-PL90100
4. R e p e a t s t e p s 1 t h r o u g h 3 for the other s i d e .
5. Install t h e n e w c l i p s (A) o n t h e output s h a f t s , t h e n

install t h e output s h a f t s (B).
2. R e m o v e the oil s e a l .
N O T E : B e c a r e f u l not to d a m a g e the differential

c a s e w h i l e prying out t h e s e a l .
15-13
Rear Differential
Backlash Inspection
Special Tools Required 6. M e a s u r e t h e b a c k l a s h of t h e ring g e a r (A).

Universal holder 07725-0030000
• S e t t h e dial g a u g e tip at a right a n g l e to t h e ring
1. R e m o v e t h e output s h a f t s a n d differential c a s e gear teeth.
( s e e p a g e 15-11). • M e a s u r e f o u r p o i n t s o n the ring g e a r 9 0 d e g r e e s
apart.
2. S e c u r e l y c l a m p the differential c a r r i e r a s s e m b l y in • B a c k l a s h will be w i t h i n the s t a n d a r d if at o n e
a bench vise with w o o d blocks. point t h e ring g e a r b a c k l a s h is w i t h i n t h e
s t a n d a r d , m i n i m u m m e a s u r e m e n t of 0.05 m m
3. T h o r o u g h l y c l e a n t h e ring g e a r teeth (A) a n d d r i v e (0.0020 in.) o r a b o v e a n d the difference b e t w e e n
pinion g e a r teeth ( B ) , a n d paint t h e ring g e a r teeth the m a x i m u m and m i n i m u m m e a s u r e m e n t s do
w i t h P r u s s i a n B l u e lightly a n d e v e n l y . not e x c e e d 0.07 m m (0.0028 in.).
• Both a d j u s t m e n t s c r e w s m u s t b e a d j u s t e d .
F o r e x a m p l e , if y o u turn o n e a d j u s t m e n t s c r e w
o n e n o t c h c l o c k w i s e , y o u m u s t t u r n t h e other
a d j u s t m e n t s c r e w o n e notch c o u n t e r c l o c k w i s e .
Backlash:
S t a n d a r d : 0 . 0 9 - 0 . 1 1 m m ( 0 . 0 0 3 5 - 0 . 0 0 4 3 in.)
M i n i m u m : 0.05 m m (0.0020 in.)
D i f f e r e n c e r a n g e : 0.07 m m (0.0028 in.)
G o o d contact pattern
07725-0030000
B
45 N m B
(4.6 k g f m , 45 N m
(4.6 k g f m ,
33 Ibfft)
33 Ibfft)
4. Rotate t h e c o m p a n i o n f l a n g e (C) t h r e e full t u r n s

f o r w a r d a n d t h e n b a c k w a r d to p r o d u c e a c o n t a c t
pattern o n t h e ring g e a r .
5. L o o s e n t h e b e a r i n g c a p m o u n t i n g bolts (D).
7. T i g h t e n t h e b e a r i n g c a p m o u n t i n g bolts (B).
15-14
<3®
Differential Disassembly
Exploded View
A: 24 N m (2.4 k g f m , 17 Ibf-ft)
B: 45 N m (4.6 k g f - m , 3 3 Ibf-ft)
C: 2 2 N-m (2.2 k g f m , 16 Ibf ft)
D: 76 N-m (7.7 k g f m , 5 6 Ibf-ft)
E: 11 N m (1.1 k g f m , 8 Ibf-ft)
0 L1 O2 7C -K2N8U4T N m ®
®
DRIVE PINION G E A R
ADJUSTMENT SCREW
)SEALING WASHER
Replace.
( 1 3 . 0 - 2 9 . 0 kgf-m, ® BEARING OUTER RACE DIFFERENTIAL CASE
9 4 - 2 1 0 Ibf-ft) ® TAPERED ROLLER BEARING SEALING WASHER
Replace. ® RING GEAR Replace.
® DRIVE PINION W A S H E R ® TORSEN LSD ASSEMBLY ) DRAIN P L U G
® COMPANION FLANGE ® TAPERED ROLLER BEARING 4 6 N - m (4.7 k g f - m , 3 4 Ibf-ft)
® OIL S E A L ® BEARING OUTER RACE OIL S E A L
Replace. ® ADJUSTMENT SCREW Replace.
® SPACER ® BEARING CAP »CLIP
® TAPERED ROLLER BEARING ® LOCK PLATE Replace.
® BEARING OUTER RACE @ OUTPUT SHAFT »OUTPUT SHAFT
® DIFFERENTIAL CARRIER ® CLIP ) LOCK PLATE
BEARING OUTER RACE Replace. »BEARING C A P
PINION S P A C E R (§) O I L S E A L ) BREATHER PLATE
Replace. Replace.
TAPERED ROLLER BEARING ® FILLER P L U G
© THRUST WASHER 4 6 N - m (4.7 k g f - m , 3 4 Ibf-ft)
(cont'd)
15-15
Rear Differential
Differential Disassembly (cont'd)
Special Tools Required 3. R e m o v e t h e output s h a f t s .

• Holder handle 0 7 J A B - 0 0 1 0 2 0 A
• C o m p a n i o n f l a n g e holder 0 7 R A B - T B 4 0 1 0 B
1. C a r e f u l l y c l a m p t h e r e a r differential in a b e n c h v i s e .
4. R e m o v e t h e ten m o u n t i n g bolts in a c r i s s c r o s s
pattern in s e v e r a l s t e p s , t h e n r e m o v e the
differential c a s e .
2 . P r y out the output s h a f t s (A) w i t h t h e pry b a r s (B).
15-16
5. Make marks on the bearing cap, adjustment s c r e w , 7 . R e m o v e t h e a d j u s t m e n t s c r e w s (A), b e a r i n g o u t e r
a n d differential c a r r i e r . r a c e s (B), a n d T o r s e n L S D a s s e m b l y ( C ) .
(cont'd)
15-17
Rear Differential
Differential Disassembly (cont'd)
9. R e m o v e t h e c o m p a n i o n f l a n g e u s i n g a 1 1 . R e m o v e t h e oil s e a l (A), s p a c e r (B), t a p e r e d roller

c o m m e r c i a l l y a v a i l a b l e b e a r i n g puller a s s h o w n . b e a r i n g ( C ) a n d b e a r i n g outer r a c e (D) f r o m t h e
f
differential c a r r i e r .
1 2 . R e m o v e t h e b e a r i n g outer r a c e f r o m the differential

carrier.
1 0 . R e m o v e the p i n i o n s p a c e r (A) a n d t h e d r i v e p i n i o n
g e a r (B) b y t a p p i n g o n t h e d r i v e p i n i o n w i t h a
plastic h a m m e r . S u p p o r t t h e differential c a r r i e r
with a w o o d block under the driver pinion gear.
15-18
13. R e m o v e t h e t a p e r e d roller b e a r i n g (A) a n d t h r u s t 16. R e m o v e t h e t e n m o u n t i n g bolts in a c r i s s c r o s s
w a s h e r (B) f r o m t h e d r i v e p i n i o n (G) u s i n g a pattern in s e v e r a l s t e p s , t h e n r e m o v e t h e ring g e a r .
commercially available bearing separator and a
press as s h o w n .
17. R e m o v e the b r e a t h e r plate (A), filler plug (B), drain

plug (C), and sealing w a s h e r s .
14. R e m o v e t h e t a p e r e d roller b e a r i n g s f r o m t h e
Torsen L S D a s s e m b l y using a commercially
a v a i l a b l e b e a r i n g puller a s s h o w n .
18. R e m o v e the oil s e a l s .
15. M a k e m a r k s o n t h e T o r s e n L S D a s s e m b l y a n d ring
gear.
15-19
Rear Differential
Differential Reassembly
Special Tools Required 3. Install t h e t a p e r e d roller b e a r i n g u s i n g t h e
• Oil s e a l driver 0 7 J A D - P L 9 0 1 0 0 40 x 50 m m I.D. a t t a c h m e n t (A) a n d a p r e s s a s
• Holder handle 0 7 J A B - 0 0 1 0 2 0 A shown.
• A t t a c h m e n t , 40 x 50 m m I.D. 0 7 L A D - P W 5 0 6 0 1
• A t t a c h m e n t , 45 x 5 5 m m I.D. 0 7 M A D - P R 9 0 1 0 0
• A t t a c h m e n t , 78 x 8 0 m m 0 7 N A D - P X 4 0 1 0 0
• C o m p a n i o n flange holder 0 7 R A B - T B 4 0 1 0 B
• Universal holder 07725-0030000
• D r i v e r , 40 m m I.D. 0 7 7 4 6 - 0 0 3 0 1 0 0
• A t t a c h m e n t , 3 0 m m I.D. 0 7 7 4 6 - 0 0 3 0 3 0 0
•Driver 07749-0010000
1. A p p l y H o n d a l o c k 1 (P/N 0 8 7 1 3 - 0 0 0 1 ) to t h e s u r f a c e
of t h e ring g e a r a n d t e n m o u n t i n g bolts.
Hondalock 1
4. Install t h e s t a n d a r d t h r u s t w a s h e r 3.47 m m
(0.1366 in.) (A) onto t h e d r i v e p i n i o n g e a r (B). T h e n
install t h e t a p e r e d roller b e a r i n g (C) u s i n g t h e o l d
p i n i o n s p a c e r (D), 40 m m I.D. d r i v e r ( E ) , a n d 30 m m
I.D. a t t a c h m e n t (F) a s s h o w n .
PRESS
2. Install t h e ring g e a r , t h e n tighten t h e t e n m o u n t i n g

bolts in a c r i s s c r o s s pattern in s e v e r a l s t e p s .
15-20
5. Install t h e b e a r i n g outer r a c e s (A) into the 6. A p p l y t h e r e c o m m e n d e d fluid to t h e t a p e r e d roller
differential c a r r i e r u s i n g t h e 4 5 x 5 5 m m I.D. b e a r i n g (A), t h e n install the d r i v e pinion g e a r (B)
a t t a c h m e n t ( B ) , 40 m m I.D, d r i v e r ( C ) , 7 8 x 8 0 m m a n d n e w p i n i o n s p a c e r (C) into t h e differential
a t t a c h m e n t (D), a n d d r i v e r (E) a s s h o w n . c a r r i e r (D).
7. A p p l y t h e r e c o m m e n d e d fluid t o t h e t a p e r e d roller
b e a r i n g , t h e n install t h e t a p e r e d roller b e a r i n g a n d
s p a c e r (A) u s i n g t h e 40 m m I.D. d r i v e r (B) a n d
3 0 m m I.D. a t t a c h m e n t (C) w h i l e h o l d i n g t h e d r i v e
pinion g e a r (D).
(cont'd)
15-21
Rear Differential
Differential Reassembly (cont'd)
8. Install t h e n e w oil s e a l u s i n g t h e c o m p a n i o n f l a n g e 10. Install t h e h o l d e r h a n d l e (A) a n d c o m p a n i o n f l a n g e

a n d 40 m m I.D. d r i v e r (A) a s s h o w n . h o l d e r (B) to t h e c o m p a n i o n f l a n g e , t h e n tighten the
locknut to 2 0 N-m (2.0 kgf-m, 14 Ibf-ft).
11. Rotate t h e d r i v e p i n i o n s e v e r a l t i m e s to e n s u r e
p r o p e r t a p e r e d roller b e a r i n g c o n t a c t . M e a s u r e t h e
d r i v e p i n i o n t u r n i n g t o r q u e before tightening t h e
9. A p p l y m o l y b d e n u m g r e a s e to t h e s u r f a c e e n d of locknut to t h e s p e c i f i e d t o r q u e .
t h e c o m p a n i o n f l a n g e , t h e n install t h e c o m p a n i o n
f l a n g e (A), d r i v e p i n i o n w a s h e r ( B ) , a n d n e w locknut
(C).
15-22
12. T i g h t e n the locknut to 127 N-m (13.0 kgf-m, 14. Install t h e T o r s e n L S D a s s e m b l y (A), b e a r i n g o u t e r
9 4 lbf-ft), t h e n r e m o v e t h e h o l d e r h a n d l e (A) a n d r a c e s ( B ) , a n d a d j u s t m e n t s c r e w s (C) onto t h e
c o m p a n i o n f l a n g e h o l d e r (B). differential c a r r i e r .
NOTE:
• R e i n s t a l l t h e a d j u s t m e n t s c r e w s in their original
p o s i t i o n o n t h e differential c a r r i e r .
• A l i g n t h e t h r e a d s of t h e a d j u s t m e n t s c r e w s a n d
differential c a r r i e r h o u s i n g .
13. Rotate t h e d r i v e p i n i o n s e v e r a l t i m e s to a s s u r e
p r o p e r t a p e r e d roller b e a r i n g c o n t a c t . M e a s u r e t h e
d r i v e pinion t u r n i n g t o r q u e .
• If the d r i v e pinion t u r n i n g t o r q u e e x c e e d s the

standard, replace the pinion spacer.
• If the d r i v e p i n i o n t u r n i n g t o r q u e is l e s s t h a n the
s t a n d a r d , a d j u s t b y t i g h t e n i n g the locknut a little
at a t i m e , but k e e p t h e t o r q u e w i t h i n
1 2 7 - 2 8 4 N m ( 1 3 . 0 - 2 9 . 0 k g f m , 9 4 - 2 1 0 Ibfft).
If t h i s is not p o s s i b l e , r e p l a c e t h e p i n i o n s p a c e r .
15. Install t h e b e a r i n g c a p s (A) w h i l e a l i g n i n g both t h e
Turning Torque: m a r k s (B) o n t h e t h r e a d s of t h e a d j u s t m e n t s c r e w s
0 . 8 8 - 1 . 3 7 N-m ( 9 . 0 - 1 4 . 0 k g f - c m , a n d b e a r i n g c a p s , t h e n install the m o u n t i n g bolts
7 . 8 - 1 2 . 1 I b f i n ) + T p (from s t e p 11) finger-tight.
T p : A c t u a l m e a s u r e m e n t of d r i v e pinion t u r n i n g
torque
(cont'd)
15-23
Rear Differential
16. M e a s u r e t h e b a c k l a s h of t h e ring g e a r ( s e e p a g e 2 0 . C h e c k t h e tooth c o n t a c t pattern a n d a d j u s t it if

15-14). needed.
17. T i g h t e n the b e a r i n g c a p m o u n t i n g bolts. • T o e C o n t a c t : U s e a t h i n n e r t h r u s t w a s h e r to

m o v e t h e d r i v e p i n i o n g e a r a w a y f r o m t h e ring
4 5 N m (4.6 k g f - m , 3 3 Ibf ft) gear.
• Heel C o n t a c t : U s e a t h i c k e r t h r u s t w a s h e r to
m o v e t h e d r i v e p i n i o n g e a r t o w a r d f r o m the ring
gear.
• F l a n k C o n t a c t : T o m o v e t h e ring g e a r a w a y f r o m
t h e d r i v e pinion g e a r , tighten t h e a d j u s t m e n t
s c r e w on the drive pinion gear side a n d loosen
t h e a d j u s t m e n t s c r e w o n t h e ring g e a r s i d e .
R e c h e c k b a c k l a s h after a d j u s t i n g t h e a d j u s t m e n t
s c r e w s . If out of s p e c i f i c a t i o n , a d j u s t a s d e s c r i b e d
under T o e Contact.
• F a c e C o n t a c t : T o m o v e t h e ring g e a r t o w a r d the
d r i v e p i n i o n g e a r , tighten t h e a d j u s t m e n t s c r e w
o n t h e ring g e a r s i d e , a n d l o o s e n t h e a d j u s t m e n t
s c r e w on the drive pinion gear side. Recheck
b a c k l a s h after a d j u s t i n g t h e a d j u s t m e n t s c r e w s . If
out of s p e c i f i c a t i o n , a d j u s t a s d e s c r i b e d u n d e r
Heel C o n t a c t .
Correct Tooth Contact

18. T h o r o u g h l y c l e a n t h e ring g e a r t e e t h (A) a n d d r i v e
p i n i o n g e a r t e e t h , a n d paint t h e rin g g e a r t e e t h (B)
w i t h P r u s s i a n B l u e lightly a n d e v e n l y .
Toe Contact
19. Rotate t h e c o m p a n i o n f l a n g e (C) t h r e e full t u r n s

f o r w a r d a n d t h e n b a c k w a r d to p r o d u c e a c o n t a c t
pattern o n the ring g e a r . D u r i n g t h i s o p e r a t i o n ,
r e s i s t a n c e s h o u l d be a p p l i e d to t h e ring g e a r .
15-24
2 1 . Rotate t h e T o r s e n L S D a s s e m b l y s e v e r a l t i m e s to
Heel Contact
e n s u r e p r o p e r t a p e r e d roller b e a r i n g c o n t a c t .
M e a s u r e the T o r s e n L S D a s s e m b l y preload using
the push/pull gauge.
• If the T o r s e n L S D a s s e m b l y p r e l o a d e x c e e d s t h e
Flank Contact standard, adjust by loosening the adjustment
s c r e w s a n o t c h at a t i m e .
• If t h e T o r s e n L S D a s s e m b l y p r e l o a d is l e s s t h a n
t h e s t a n d a r d , a d j u s t by t i g h t e n i n g t h e a d j u s t m e n t
s c r e w s a n o t c h at a t i m e .
Standard: 1 4 - 3 0 N
( 1 . 4 - 3 . 1 kgf, 3 . 1 - 6 . 8 Ibf)
Face Contact
Thrust Washer
Part Number Thickness
A 41361-PCZ-003 3.08 m m (0.1213 in.)
B 41362-PCZ-003 3.11 m m (0.1224 in.)
C 41363-PCZ-003 3.14 m m (0.1236 in.)
D 41364-PCZ-003 3.17 m m (0.1248 in.)
E 41365-PCZ-003 3.20 m m (0.1260 in.)
F 41366-PCZ-003 3.23 m m (0.1272 in.)
G 41367-PCZ-003 3.26 m m (0.1283 in.) 2 2 . Install t h e lock p l a t e s (A).
H 41368-PCZ-003 3.29 m m (0.1295 in.)
2 2 N m (2.2 k g f m , 1 6 I b f f t )
1 41369-PCZ-003 3.32 m m (0.1307 in.)
J 41370-PCZ-003 3.35 m m (0.1319 in.)
K 41371-PCZ-003 3.38 m m (0.1331 in.)
L 41372-PCZ-003 3.41 m m (0.1343 in.)
M 41373-PCZ-003 3.44 m m (0.1354 in.)
1ST 41374-PCZ-003 3.47 m m (0.1366 in.)
0 41375-PCZ-003 3.095 m m (0.1219 in.)
P 41376-PCZ-003 3.125 m m (0.1230 in.)
Q 41377-PCZ-003 3.155 m m (0.1242 in.)
R 41378-PCZ-003 3.185 m m (0.1254 in.)
S 41379-PCZ-003 3.215 mm (0.1266 in.)
T 41380-PCZ-003 3.245 mm (0.1278 in.)
AA 41381-PCZ-003 3.275 mm (0.1289 in.)
AO 41382-PCZ-003 3.305 mm (0.1301 in.)
AP 41383-PCZ-003 3.335 m m (0.1313 in.)
AO 41384-PCZ-003 3.365 m m (0.1325 in.)
AR 41385-PCZ-003 3.395 m m (0.1337 in.)
AS 41386-PCZ-003 3 . 4 2 5 m m (0.1348 in.)
AT 41387-PCZ-003 3.455 m m (0.1360 in.)
: Standard
(cont'd)
15-25
Rear Differential
2 3 . Install t h e n e w oil s e a l u s i n g t h e oil s e a l d r i v e r (A) 2 5 . C l e a n t h e dirt a n d oil f r o m t h e m a t i n g s u r f a c e s .

as shown. A p p l y liquid g a s k e t , P/N 08718-0001 e v e n l y to t h e
m a t i n g s u r f a c e of t h e differential c a s e a n d t h e
differential c a r r i e r . Install t h e c o m p o n e n t w i t h i n
5 m i n u t e s of a p p l y i n g the liquid g a s k e t .
NOTE:
c o m p o n e n t m u s t be i n s t a l l e d w i t h i n 4 m i n u t e s .
• If too m u c h t i m e h a s p a s s e d after a p p l y i n g the
• A l l o w it to c u r e at l e a s t 3 0 m i n u t e s after
a s s e m b l y before filling t h e differential w i t h t h e
r e c o m m e n d e d fluid.
24. Install t h e b r e a t h e r plate (A), d r a i n p l u g (B), a n d

n e w s e a l i n g w a s h e r s ( C ) . Install t h e filler p l u g (D)
finger-tight.
Liquid gasket
2 6 . Install t h e differential c a s e .
15-26
Differential Installation
2 7 . T i g h t e n t h e t e n m o u n t i n g bolts in a c r i s s c r o s s 1. Install right a n d left differential m o u n t bracket A t o

pattern in s e v e r a l s t e p s . the rear differential; ' 0 0 - 0 5 m o d e l s ( s e e p a g e 15-31),
'06-08 m o d e l s ( s e e p a g e 15-32).
2 4 N m (2.4 k g f m , 17 Ibfft)
2 . P l a c e t h e r e a r differential o n t h e t r a n s m i s s i o n j a c k ,
a n d r a i s e it to t h e m o u n t i n g l e v e l .
28. Install t h e n e w c l i p s (A) o n t h e output s h a f t s , t h e n

install t h e output s h a f t s (B).
3. '00-05 m o d e l s : Install f o u r differential m o u n t

bracket B m o u n t i n g n u t s .
'06-08 m o d e l s : Install t h e differential b r e a t h e r b o x
(see p a g e 15-30). T h e n install f o u r differential
m o u n t b r a c k e t B m o u n t i n g nuts.
1 2 x 1.25 m m
7 4 N m (7.5 k g f m , 5 4 I b f f t )
A
Replace.
(cont'd)
15-27
Rear Differential
Differential Installation (cont'd)
4 . Install t h e right a n d left differential m o u n t b r a c k e t A 5 . Install the e v a p o r a t i v e e m i s s i o n ( E V A P ) c a n i s t e r

m o u n t i n g bolts. cover.
'00-05 m o d e l s
1 0 x 1.25 m m
4 5 N - m (4.6 k g f m , 33 Ibf-ft)
6 x 1.0 m m
9.8 N m
(1.0 k g f m , 7.2 Ibf-ft)
'06-08 m o d e l s
6 x 1.0 m m
9.8 N m (1.0 k g f m , 7.2 Ibf ft)
15-28
6. Install t h e rear s u s p e n s i o n stiffener. 8. Install t h e ball j o i n t s onto t h e l o w e r a r m s (A), t h e n
install t h e n e w c a s t l e nuts (B) a n d n e w cotter p i n s .
N O T E : M a k e s u r e t h e ball joint b o o t s a r e not

d a m a g e or c r a c k e d .
B
10 x 1.25 m m 69-78 N m
4 5 N m (4.6 k g f m , 6x1.0 mm
(7.0-8.0 kgfm,
33 Ibfft) 9.8 N m (1.0 k g f m , 7.2 I b f f t )
5 1 - 5 8 Ibfft)
Replace.
Replace.
7. Install t h e i n b o a r d j o i n t s (A) onto t h e rear
differential b y a l i g n i n g t h e r e f e r e n c e m a r k s (B) y o u 9. Install t h e w h e e l s p e e d s e n s o r h a r n e s s onto t h e
made. upper a r m .
SPECIAL NUT
Replace.
9 . 8 N - m (1.0 k g f m , 7 . 2 I b f f t )
10. Install t h e p r o p e l l e r s h a f t to t h e t r a n s m i s s i o n a n d
t h e rear differential b y a l i g n i n g t h e r e f e r e n c e m a r k s
SPECIAL BOLT y o u m a d e ( s e e p a g e 16-19).
10 x 1.25 m m
6 9 N - m (7.0 k g f m , 51 I b f f t )
Replace.
(cont'd)
15-29
Rear Differential
Differential Installation (cont'd) Differential Breather Box
Replacement
11. Refill t h e differential fluid ( s e e p a g e 15-7).
12. A p p l y a s m a l l a m o u n t of e n g i n e oil to t h e s e a t i n g '06-08 models

s u r f a c e of t h e n e w s p i n d l e nut (A).
1. R e m o v e t h e t w o differential m o u n t b r a c k e t B
m o u n t i n g n u t s (A).
(25.0 k g f m , 181 Ibf-ft)

Replace.
12 x 1.25 m m
13. Install a n e w s p i n d l e nut, t h e n tighten t h e nut. After 7 4 N - m (7.5 k g f - m , 5 4 Ibf-ft)
t i g h t e n i n g , u s e a drift to s t a k e t h e s p i n d l e nut
s h o u l d e r (B) a g a i n s t t h e d r i v e s h a f t . 2. R e m o v e t h e c l i p s ( B ) , t h e n r e m o v e t h e differential
b r e a t h e r b o x f r o m t h e differential b r e a t h e r b o x
14. C l e a n t h e m a t i n g s u r f a c e s of the b r a k e d i s c a n d t h e bracket (C). T h e n r e m o v e the b r e a t h e r b o x s t a y .
r e a r w h e e l , t h e n install t h e r e a r w h e e l s .
3. D i s c o n n e c t t h e b r e a t h e r b o x t u b e (D) f r o m t h e
15. T u r n t h e r e a r w h e e l b y h a n d , a n d m a k e s u r e t h e r e differential b r e a t h e r b o x (E) s i d e .
is no i n t e r f e r e n c e b e t w e e n t h e d r i v e s h a f t a n d
surrounding parts. 4. R e m o v e t h e differential b r e a t h e r b o x t u b e f r o m t h e
r e a r differential.
16. C h e c k t h e r e a r w h e e l a l i g n m e n t , a n d a d j u s t it if
n e c e s s a r y ( s e e p a g e 18-7). 5. Install the differential b r e a t h e r b o x t u b e to t h e r e a r
differential.
6. Install t h e differential b r e a t h e r b o x bracket.
7. C o n n e c t t h e differential b r e a t h e r b o x t u b e . M a k e
s u r e t h e w h i t e m a r k s o n the t u b e c o m e u p s i d e .
8. Install the differential b r e a t h e r b o x .
9. Install the t w o differential m o u n t bracket B

mounting nuts.
15-30
Differential Mount Replacement
N O T E : If i n s t a l l i n g t h e r e a r differential a n d m o u n t a s s e m b l i e s , tighten t h e differential m o u n t b r a c k e t B m o u n t i n g n u t s

first, t h e n t i g h t e n t h e differential m o u n t b r a c k e t A m o u n t i n g bolts.
'00-05 m o d e l s
15-31
Rear Differential
Differential Mount Replacement (cont'd)
N O T E : If i n s t a l l i n g t h e r e a r differential a n d m o u n t a s s e m b l i e s , tighten t h e differential m o u n t b r a c k e t B m o u n t i n g n u t s

first, t h e n t i g h t e n t h e differential m o u n t b r a c k e t A m o u n t i n g bolts.
'06-08 m o d e l s
DIFFERENTIAL DIFFERENTIAL MOUNT

BREATHER BOX BRACKET A
12x1.25 mm
6 4 N m (6.5 k g f m , 4 7 Ibf ft)
15-32
Driveline/Axle
Driveline/Axle
Special Tools 16-2
Driveshaft Inspection 16-4
Driveshaft Removal 16-4
Driveshaft Disassembly 16-6
Driveshaft Reassembly 16-9
Driveshaft Installation 16-16
Propeller Shaft Inspection 16-17
Propeller Shaft Removal 16-18
Propeller Shaft Installation 16-19
Driveline/Axle
Special Tools
© 07XAC-001020A T h r e a d e d A d a p t e r , 24 x 1.5 m m 1
16-2
<3®
PROPELLER SHAFT
R e m o v a l , p a g e 16-18
16-3
Driveline/Axle
Driveshaft Inspection Driveshaft Removal
1. C h e c k t h e i n b o a r d boot (A) a n d o u t b o a r d boot (B) 1. R a i s e t h e v e h i c l e o n a lift.
o n t h e d r i v e s h a f t (C) for c r a c k s , d a m a g e , l e a k i n g
g r e a s e , a n d l o o s e boot b a n d s (D). If a n y d a m a g e is 2. R e m o v e the rear w h e e l s .
f o u n d , r e p l a c e t h e boot a n d boot b a n d s .
3. Lift up t h e locking t a b (A) o n t h e s p i n d l e nut ( B ) ,
t h e n r e m o v e t h e nut.
2. C h e c k t h e d r i v e s h a f t for c r a c k s a n d d a m a g e . If a n y
d a m a g e is f o u n d , r e p l a c e t h e d r i v e s h a f t .
4. R e m o v e the cotter pin f r o m the l o w e r a r m ball joint
3. C h e c k t h e i n b o a r d joint (E) a n d t h e o u t b o a r d joint c a s t l e nut, t h e n r e m o v e t h e c a s t l e nut, t h e n
(F) for c r a c k s a n d d a m a g e . If a n y d a m a g e is f o u n d , s e p a r a t e t h e ball joint f r o m the l o w e r a r m u s i n g t h e
r e p l a c e t h e i n b o a r d joint or t h e o u t b o a r d joint a s a n ball joint t h r e a d protector a n d t h e ball joint
assembly. r e m o v e r ( s e e s t e p 12 o n p a g e 18-34).
4. Hold t h e i n b o a r d joint a n d turn t h e r e a r w h e e l b y NOTE:

h a n d , t h e n m a k e s u r e t h e joint is not e x c e s s i v e l y • T o a v o i d d a m a g i n g the ball joint, install ball joint
l o o s e . If n e c e s s a r y , r e p l a c e t h e i n b o a r d joint o r t h e t h r e a d protector onto the t h r e a d s of t h e ball joint.
o u t b o a r d joint a s a n a s s e m b l y . • B e c a r e f u l not to d a m a g e the ball joint boot w h e n
installing t h e r e m o v e r ( s e e p a g e 18-13).
16-4
3®
5 . R e m o v e t h e w h e e l s p e e d s e n s o r h a r n e s s (A) f r o m 9 . Pull t h e k n u c k l e o u t w a r d , a n d s e p a r a t e t h e
the upper a r m . d r i v e s h a f t o u t b o a r d joint f r o m the r e a r h u b u s i n g a
plastic h a m m e r .
6 . M a k e r e f e r e n c e m a r k s (A) a c r o s s t h e i n b o a r d joint
(B) a n d t h e rear differential ( C ) . 1 0 . R e m o v e the d r i v e s h a f t .
7 . R e m o v e the s i x i n b o a r d joint m o u n t i n g bolts (D)

a n d n u t s ( E ) , t h e n r e m o v e the i n b o a r d joint f r o m
t h e r e a r differential.
8 . Pull t h e knuckle o u t w a r d , a n d r e m o v e the i n b o a r d

joint f r o m the rear differential.
16-5
Driveline/Axle
Driveshaft Disassembly
Special Tools Required 2. M a k e m a r k s (A) o n e a c h roller (B) a n d i n b o a r d joint
• T h r e a d e d a d a p t e r , 24 x 1.5 m m 0 7 X A C - 0 0 1 0 2 0 A (C) to identify t h e l o c a t i o n s of rollers a n d g r o o v e s
• S l i d e h a m m e r , 5/8"-18 U N F , c o m m e r c i a l l y available in t h e i n b o a r d joint. T h e n r e m o v e t h e i n b o a r d joint
• Bearing remover, U N F , commercially available o n a s h o p t o w e l (D). B e c a r e f u l not to d r o p t h e
rollers w h e n separating t h e m from the inboard
Inboard Joint Side joint.
1. R e m o v e the boot b a n d s . B e c a r e f u l not to d a m a g e

t h e boot.
• If the boot b a n d i s a d o u b l e loop t y p e (A), lift up

t h e b a n d e n d (B), a n d p u s h it into t h e clip (C).
• If the boot b a n d is a l o w profile t y p e (D), p i n c h
t h e boot b a n d u s i n g c o m m e r c i a l l y a v a i l a b l e boot
band pliers (E).
Double loop t y p e
3. M a k e m a r k s (A) o n t h e rollers (B) a n d s p i d e r (C) to

identify t h e l o c a t i o n s of rollers o n t h e s p i d e r , t h e n
r e m o v e the rollers.
N O T E : Do not e n g r a v e or s c r i b e m a r k s o n the
rolling s u r f a c e .
L o w profile t y p e
4. R e m o v e the c i r c l i p (D).
5. M a k e m a r k s (E) o n the s p i d e r a n d d r i v e s h a f t to
identify the p o s i t i o n of t h e s p i d e r o n t h e shaft.
6. R e m o v e the s p i d e r u s i n g c o m m e r c i a l l y a v a i l a b l e
b e a r i n g r e m o v e r (F).
16-6
7. W r a p t h e s p l i n e s o n the d r i v e s h a f t w i t h v i n y l t a p e Outboard Joint Side
(A) to p r e v e n t d a m a g e to the boot.
1. Lift up t h e t h r e e t a b s (A) w i t h a s c r e w d r i v e r , t h e n
r e m o v e t h e boot b a n d s (B). B e c a r e f u l not to
d a m a g e t h e boot.
8 . R e m o v e t h e i n b o a r d boot. B e c a r e f u l not to d a m a g e
t h e boot.
9 . R e m o v e the vinyl tape.

2 . S l i d e t h e o u t b o a r d boot partially to t h e i n b o a r d
joint s i d e . B e c a r e f u l not to d a m a g e t h e boot.
(cont'd)
16-7
Driveline/Axle
Driveshaft Disassembly (cont'd)
3. W i p e off t h e g r e a s e to e x p o s e t h e d r i v e s h a f t a n d 8. R e m o v e t h e s t o p ring (A) f r o m t h e d r i v e s h a f t (B).
t h e o u t b o a r d joint i n n e r r a c e .
4. M a k e a m a r k (A) o n t h e d r i v e s h a f t (B) at t h e s a m e
l e v e l a s t h e o u t b o a r d joint rim (C).
9. W r a p t h e s p l i n e s o n t h e d r i v e s h a f t with v i n y l t a p e
(A) to p r e v e n t d a m a g i n g t h e boot.
5. S e c u r e l y c l a m p t h e d r i v e s h a f t in a b e n c h v i s e w i t h
a shop towel.
6. R e m o v e t h e o u t b o a r d joint (A) u s i n g t h e
2 4 x 1.5 m m t h r e a d e d a d a p t e r (B) a n d a
c o m m e r c i a l l y available 5/8"-18 U N F slide h a m m e r
(C).
10. R e m o v e t h e o u t b o a r d boot. B e c a r e f u l not to

d a m a g e t h e boot.
11. R e m o v e t h e v i n y l t a p e .
7. R e m o v e t h e d r i v e s h a f t f r o m t h e b e n c h v i s e .
16-8
0©
Driveshaft Reassembly
Exploded View
(cont'd)
16-9
Driveline/Axle
Driveshaft Reassembly (cont'd)
Special Tools Required 5. Fit t h e r o l l e r s (A) o n t o the s p i d e r (B) a s s h o w n , a n d

• B o o t b a n d t o o l , KD-3191 or e q u i v a l e n t , c o m m e r c i a l l y note t h e s e i t e m s :
available
• B o o t b a n d p l i e r s , K e n t - M o o r e J - 3 5 9 1 0 or e q u i v a l e n t , • R e i n s t a l l t h e r o l l e r s in their original p o s i t i o n s o n
commercially available the s p i d e r b y a l i g n i n g t h e m a r k s (C) y o u m a d e .
• Hold t h e d r i v e s h a f t pointed up to p r e v e n t the
N O T E : R e f e r to t h e E x p l o d e d V i e w , a s n e e d e d , d u r i n g rollers f r o m falling off.
this procedure.
Inboard Joint Side
1. W r a p t h e s p l i n e s w i t h v i n y l t a p e (A) to p r e v e n t
d a m a g e to t h e i n b o a r d boot.
6. P a c k t h e i n b o a r d joint with t h e joint g r e a s e

i n c l u d e d in t h e n e w i n b o a r d boot s e t .
G r e a s e quantity
I n b o a r d j o i n t : 1 5 0 — 1 6 0 g (5.3—5.6 oz)
2. Install t h e i n b o a r d boot onto t h e d r i v e s h a f t , t h e n

r e m o v e t h e v i n y l t a p e . B e c a r e f u l not to d a m a g e t h e
i n b o a r d boot.
3. Install t h e s p i d e r (A) onto t h e d r i v e s h a f t (B) b y

a l i g n i n g t h e m a r k s (C) y o u m a d e o n t h e s p i d e r , a n d
t h e e n d of t h e d r i v e s h a f t .
4. Install the n e w c i r c l i p (D) into t h e d r i v e s h a f t g r o o v e .

A l w a y s rotate the c i r c l i p in its g r o o v e to m a k e s u r e
it is fully s e a t e d .
16-10
7 . Fit t h e i n b o a r d joint onto t h e d r i v e s h a f t a n d note 1 0 . A d j u s t t h e length of t h e d r i v e s h a f t s to the
these items: d i m e n s i o n s s h o w n , t h e n a d j u s t t h e b o o t s to
h a l f w a y b e t w e e n full c o m p r e s s i o n a n d full
• R e i n s t a l l the i n b o a r d joint o n t o the d r i v e s h a f t b y e x t e n s i o n . D o i n g t h i s p r e v e n t s a v a c u u m or too
a l i g n i n g t h e m a r k s (A) y o u m a d e o n the i n b o a r d m u c h a i r in t h e boot, p r e v e n t i n g it f r o m
joint a n d t h e r o l l e r s . c o m p r e s s i n g or e x t e n d i n g p r o p e r l y .
• Hold t h e d r i v e s h a f t s o the i n b o a r d joint is
pointing up to p r e v e n t it f r o m falling off. W i t h o u t b o a r d joint:
Right driveshaft: 5 7 9 . 0 - 5 8 4 . 0 m m ( 2 2 . 8 - 2 3 . 0 in.)
Left d r i v e s h a f t : 6 2 4 . 0 — 6 2 9 . 0 m m (24.6—24.8 in.)
8 . A d j u s t the i n b o a r d joint until t h e rollers a r e in the

m i d d l e of t h e joint.
9. Fit t h e boot (A) e n d s onto the d r i v e s h a f t (B) a n d t h e

i n b o a r d joint (C).
(cont'd)
16-11
Driveline/Axle
11. Fit t h e boot e n d s onto t h e d r i v e s h a f t a n d t h e 14. T h r e a d t h e free e n d of t h e b a n d t h r o u g h t h e n o s e

i n b o a r d joint, t h e n install t h e n e w d o u b l e l o o p b a n d s e c t i o n of t h e c o m m e r c i a l l y a v a i l a b l e boot b a n d
(A) onto t h e boot (B). tool KD-3191 or e q u i v a l e n t (A), a n d into t h e slot o n
t h e w i n d i n g m a n d r e l (B).
N O T E : P a s s t h e e n d of t h e n e w d o u b l e l o o p b a n d
t h r o u g h t h e clip (C) t w i c e in t h e d i r e c t i o n of t h e
f o r w a r d rotation of t h e d r i v e s h a f t .
15. U s i n g a w r e n c h o n t h e w i n d i n g m a n d r e l of t h e boot
b a n d t o o l , to tighten the b a n d until t h e m a r k e d s p o t
(C) o n the b a n d m e e t s t h e e d g e of t h e c l i p .
12. Pull up t h e s l a c k in t h e b a n d b y h a n d . 16. Lift up the boot b a n d tool to b e n d t h e f r e e e n d of

t h e b a n d 9 0 d e g r e e s to t h e c l i p . C e n t e r - p u n c h t h e
13. M a r k a p o s i t i o n (A) o n t h e b a n d 1 0 — 1 4 m m c l i p , t h e n fold o v e r t h e r e m a i n i n g tail onto t h e c l i p .
(0.4—0.6 in.) f r o m t h e c l i p (B).
16-12
e®
17. U n w i n d t h e boot b a n d t o o l , a n d c u t off t h e e x c e s s Outboard Joint Side
free e n d of t h e b a n d to l e a v e a 5—TO m m
(0.2—0.4 in.) tail protruding f r o m t h e clip. 1. W r a p t h e s p l i n e s w i t h v i n y l t a p e (A) to p r e v e n t
d a m a g i n g t h e o u t b o a r d boot.
18. B e n d t h e b a n d e n d (A) by t a p p i n g it d o w n w i t h a
hammer. 2. Install t h e n e w e a r c l a m p b a n d s (B) a n d t h e
o u t b o a r d boot. B e c a r e f u l not to d a m a g e the
NOTE: o u t b o a r d boot.
• M a k e s u r e t h e b a n d a n d clip d o not interfere w i t h
a n y t h i n g , a n d t h e b a n d d o e s not m o v e . 3. R e m o v e t h e v i n y l t a p e .
• R e m o v e a n y g r e a s e remaining on the
surrounding surfaces. 4. Install t h e n e w s t o p ring (A) into t h e d r i v e s h a f t
g r o o v e (B).
19. R e p e a t s t e p s 11 t h r o u g h 18 for t h e b a n d o n t h e
other e n d of t h e boot.
(cont'd)
16-13
Driveline/Axle
5. P a c k a b o u t 3 5 g (1.2 oz) g r e a s e i n c l u d e d in t h e n e w 7. C h e c k t h e a l i g n m e n t of the paint m a r k (A) y o u

o u t b o a r d b o o t s e t into t h e d r i v e s h a f t h o l e in t h e m a d e w i t h t h e o u t b o a r d joint r i m (B).
o u t b o a r d joint. I n s e r t t h e d r i v e s h a f t (A) into t h e
o u t b o a r d j o i n t (B) until t h e s t o p ring (C) i s c l o s e d to
t h e joint.
8. P a c k t h e o u t b o a r d joint w i t h t h e r e m a i n i n g joint
g r e a s e i n c l u d e d in t h e n e w o u t b o a r d boot s e t .
Total grease quantity

6. T o c o m p l e t e l y s e a t t h e o u t b o a r d joint, pick u p t h e O u t b o a r d joint: 1 1 9 - 1 2 9 g ( 4 . 2 - 4 . 6 oz)
d r i v e s h a f t a n d j o i n t , a n d t a p o r hit t h e m f r o m a
h e i g h t of a b o u t 10 c m (4 in.) o n t o a h a r d s u r f a c e .
N O T E : D o not u s e a h a m m e r a s e x c e s s i v e f o r c e
m a y d a m a g e t h e d r i v e s h a f t . B e c a r e f u l not to
d a m a g e t h e t h r e a d e d s e c t i o n (A) of t h e o u t b o a r d
joint.
16-14
Fit t h e boot e n d s (A) o n t o t h e d r i v e s h a f t (B) a n d 11 C l o s e t h e e a r portion (A) of t h e b a n d w i t h
o u t b o a r d joint (C). c o m m e r c i a l l y a v a i l a b l e boot b a n d plters K e n t -
M o o r e J - 3 5 9 1 0 o r e q u i v a l e n t (B).
10. A d j u s t t h e length of t h e d r i v e s h a f t s to t h e
d i m e n s i o n s s h o w n , t h e n a d j u s t the b o o t s to 12. C h e c k t h e c l e a r a n c e b e t w e e n the c l o s e d e a r portion
h a l f w a y b e t w e e n full c o m p r e s s i o n a n d full of t h e b a n d . If t h e c l e a r a n c e i s not w i t h i n t h e
e x t e n s i o n . D o i n g t h i s p r e v e n t s a v a c u u m or t o o s t a n d a r d , c l o s e t h e e a r portion of t h e b a n d tighter.
m u c h air in t h e boot, p r e v e n t i n g it f r o m
c o m p r e s s i n g or e x t e n d i n g properly.
6.0 m m
(0.24 in.) M A X .
W i t h o u t b o a r d joint:
R i g h t d r i v e s h a f t : 5 7 9 . 0 - 5 8 4 . 0 m m ( 2 2 . 8 - 2 3 . 0 in.)
Left d r i v e s h a f t : 6 2 4 . 0 - 6 2 9 . 0 m m ( 2 4 . 6 - 2 4 . 8 in.)
on
3.0 m m (0.12 in.) M A X .
13. R e p e a t s t e p s 11 a n d 12 for t h e b a n d o n t h e other

e n d of t h e boot.
16-15
Driveline/Axle
Driveshaft Installation
N O T E : B e f o r e starting i n s t a l l a t i o n , m a k e s u r e t h e 3 . Install the k n u c k l e (A) onto t h e l o w e r a r m (B). B e

m a t i n g s u r f a c e s of t h e joint a n d t h e s p l i n e d s e c t i o n a r e c a r e f u l not to d a m a g e t h e ball joint boot (C). W i p e
not d u s t y or dirty. off t h e g r e a s e before tightening the nut at t h e ball
joint. T o r q u e t h e n e w c a s t l e nut (D) to t h e l o w e r
1. Pull t h e knuckle o u t w a r d , a n d install t h e o u t b o a r d t o r q u e s p e c i f i c a t i o n , t h e n tighten it o n l y far e n o u g h
joint into t h e r e a r h u b . t o a l i g n t h e slot w i t h t h e pin h o l e .
NOTE:
• M a k e s u r e t h e ball joint boot is not d a m a g e d or
cracked.
• D o not a l i g n t h e nut b y l o o s e n i n g it.
2 . Install t h e i n b o a r d joint (A) into t h e r e a r differential

(B) b y a l i g n i n g t h e r e f e r e n c e m a r k s (C) y o u m a d e ,
t h e n install t h e n e w s i x i n b o a r d joint m o u n t i n g
bolts (D) a n d n e w n u t s ( E ) .
4 . Install the n e w cotter pin (E) into the pin h o l e , a n d

b e n d it.
5 . Install t h e w h e e l s p e e d s e n s o r h a r n e s s (A) a n d
f l a n g e bolts (B) o n t h e u p p e r a r m .
B
6 x 1.0 m m
9 . 8 N m (1.0 k g f m , 7.2 Ibf ft)
16-16
Propeller Shaft Inspection
6. A p p l y a s m a l l a m o u n t of e n g i n e oil to t h e s e a t i n g Universal Joint
s u r f a c e of the n e w s p i n d l e nut (A).
1. S h i f t t h e t r a n s m i s s i o n to n e u t r a l .
2. R a i s e the v e h i c l e o n a lift.
3. C h e c k t h e u n i v e r s a l joint b o o t s for d a m a g e a n d
d e t e r i o r a t i o n . If t h e b o o t s a r e d a m a g e d or
d e t e r i o r a t e d , r e p l a c e t h e p r o p e l l e r shaft.
4. C h e c k the u n i v e r s a l j o i n t s for e x c e s s i v e p l a y or
rattle. If the u n i v e r s a l j o i n t s h a v e e x c e s s i v e p l a y or
rattle, r e p l a c e the p r o p e l l e r shaft.
(25.0 k g f - m , 181 Ibf ft) Propeller Shaft Runout

Replace.
5. Install a dial indicator (A) w i t h its n e e d l e o n t h e
7. Install the n e w s p i n d l e nut, t h e n tighten the nut. c e n t e r of t h e p r o p e l l e r s h a f t (B).
After tightening, u s e a drift to s t a k e the s p i n d l e nut
B
s h o u l d e r (B) a g a i n s t t h e d r i v e s h a f t .
8. C l e a n the m a t i n g s u r f a c e s of the brake d i s c a n d t h e

r e a r w h e e l , t h e n install t h e rear w h e e l .
9. T u r n the rear w h e e l by h a n d , a n d m a k e s u r e t h e r e
is no interference b e t w e e n the d r i v e s h a f t a n d
s u r r o u n d i n g parts.
10. L o w e r the v e h i c l e o n t h e lift.
11. C h e c k the rear w h e e l a l i g n m e n t , a n d a d j u s t it if

n e c e s s a r y ( s e e p a g e 18-7).
12. T e s t - d r i v e the v e h i c l e .
6. T u r n t h e propeller s h a f t s l o w l y , a n d c h e c k the
runout. If the runout e x c e e d s the s e r v i c e limit,
r e p l a c e the p r o p e l l e r shaft.
Runout
16-17
Driveline/Axle
Propeller Shaft Removal
1. R a i s e the v e h i c l e o n a lift. 5 . M a k e r e f e r e n c e m a r k s (A) a c r o s s the p r o p e l l e r s h a f t

(B) a n d the r e a r differential c o m p a n i o n f l a n g e (C).
2 . R e m o v e the p r o p e l l e r s h a f t protector.
3 . M a k e r e f e r e n c e m a r k s (A) a c r o s s t h e p r o p e l l e r s h a f t
(B) a n d the t r a n s m i s s i o n c o m p a n i o n f l a n g e (C).
6 . S e p a r a t e t h e p r o p e l l e r s h a f t f r o m the rear
differential, t h e n r e m o v e t h e p r o p e l l e r shaft.
4 . S e p a r a t e the p r o p e l l e r shaft f r o m t h e t r a n s m i s s i o n .
16-18
Propeller Shaft Installation
1. Install t h e propeller shaft (A) onto t h e r e a r 3. Install t h e p r o p e l l e r s h a f t protector (A).

differential (B) b y a l i g n i n g t h e r e f e r e n c e m a r k s (C)
you made.
N O T E : W h e n t h e p r o p e l l e r s h a f t i s r e p l a c e d , align
t h e w h i t e m a r k s (D) o n t h e n e w p r o p e l l e r shaft w i t h
t h e w h i t e m a r k o n t h e differential.
SPECIAL BOLTS
'00-03 m o d e l s :
8x1.25 mm
32 N m (3.3 k g f m , 2 4 Ibfft)
'04-08 m o d e l s :
10x1.25 mm
49 N m (5.0 k g f m , 3 6 Ibfft)
Replace.
8 x 1.25 m m
2 2 N m (2.2 k g f m , 1 6 I b f f t )
4 . Test-drive the vehicle.
Install t h e p r o p e l l e r shaft (A) onto t h e t r a n s m i s s i o n

(B) by a l i g n i n g t h e r e f e r e n c e m a r k s (C) y o u m a d e .
N O T E : W h e n t h e propeller s h a f t i s r e p l a c e d , align
t h e w h i t e m a r k s (D) o n the n e w p r o p e l l e r shaft w i t h
the white mark on the transmission.
SPECIAL BOLTS
'00-03 m o d e l s :
8 x 1.25 m m
32 N m (3.3 k g f m , 2 4 Ibfft)
'04-08 m o d e l s :
10x1.25 mm
49 N m (5.0 k g f m , 36 Ibfft)
Replace.
A
16-19
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If steering maintenance is required)

g l o v e b o x , a n d s e a t belt t e n s i o n e r s in t h e s e a t belt retractors. I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e the S R S is
s h o u l d be d o n e by a n a u t h o r i z e d H o n d a d e a l e r .
• T o a v o i d r e n d e r i n g t h e S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury or d e a t h in the e v e n t of a s e v e r e frontal

c a u s e d by unintentional activation of t h e a i r b a g s a n d s e a t belt t e n s i o n e r s .
• D o not b u m p or i m p a c t the S R S unit, o r front i m p a c t s e n s o r s w h e n t h e ignition s w i t c h is O N (II), or for at l e a s t 3
m i n u t e s after the ignition s w i t c h is t u r n e d O F F ; o t h e r w i s e , the s y s t e m m a y fail in a c o l l i s i o n , or a i r b a g s m a y d e p l o y .
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e the g l o v e box. D o not u s e electrical
test equipment on t h e s e circuits.
Steering
Steering
Special Tools . 17-2
Steering Wheel Rotational Play Check 17-4
Power Assist Check 17-4
Steering Linkage and Gearbox Inspection 17-5
* Steering Wheel Removal 17-6
Steering Wheel Disassembly/Reassembly 17-7
* Steering Wheel Installation 17-8
* Steering Column Removal and Installation .. 17-9
Steering Shaft Removal and Installation 17-10
Steering Column/Steering Shaft Inspection 17-12
Steering Lock Replacement 17-13
Rack Guide Adjustment 17-14
EPS (Electrical Power Steering)

Components 17-16
Steering
Special Tools

© 07MAA-SL0020A L o c k n u t W r e n c h , 43 m m
® 07MAC-SL0A202 Ball J o i n t R e m o v e r , 2 8 m m 1
® 07746-0010100 A t t a c h m e n t , 32 x 3 5 m m 1
® 07749-0010000 Driver 1
® 07974-6790000 Oil S e a l Driver 1
© ©
17-2
STEERING GEARBOX
Rack G u i d e A d j u s t m e n t , p a g e 17-14
ELECTRICAL POWER STEERING (EPS)
p a g e 17-16
17-
Steering
Steering Wheel Rotational Play Power Assist Check
Check
N O T E : T h i s t e s t s h o u l d b e d o n e w i t h original e q u i p m e n t
t i r e s a n d w h e e l s at t h e c o r r e c t tire p r e s s u r e .
1. T u r n t h e front w h e e l s to t h e s t r a i g h t a h e a d p o s i t i o n .
1. S t a r t t h e e n g i n e a n d let it idle.
2. M e a s u r e h o w far y o u c a n t u r n t h e s t e e r i n g w h e e l
left a n d right w i t h o u t m o v i n g t h e front w h e e l s . 2. A t t a c h a c o m m e r c i a l l y a v a i l a b l e s p r i n g s c a l e to t h e
s t e e r i n g w h e e l . W i t h t h e e n g i n e idling a n d t h e
• If t h e p l a y is w i t h i n t h e limit, t h e g e a r b o x a n d v e h i c l e o n a c l e a n , dry floor, pull t h e s c a l e a s
linkage are O K . s h o w n a n d r e a d it a s s o o n a s t h e tires b e g i n to t u r n .
• If t h e p l a y e x c e e d s t h e limit, a d j u s t t h e r a c k g u i d e
( s e e p a g e 17-14). If t h e p l a y i s still e x c e s s i v e after
rack g u i d e a d j u s t m e n t , i n s p e c t t h e s t e e r i n g
linkage a n d g e a r b o x ( s e e p a g e 17-5).
R o t a t i o n a l p l a y : 0 — 1 0 m m ( 0 — 0 . 3 9 in.)
3. If t h e s c a l e r e a d s n o m o r e t h a n 3 4 N (3.5 kgf, 7.7 Ibf),

the p o w e r a s s i s t is O K . If it r e a d s m o r e , c h e c k t h e s e
items:
• S t e e r i n g l i n k a g e ( s e e p a g e 17-5).
• R a c k g u i d e a d j u s t m e n t ( s e e p a g e 17-14).
• E P S s y s t e m ( s e e p a g e 17-17).
17-4
Steering Linkage and Gearbox Inspection
Inspect for d a m a g e a n d deterioration.
17-5
Steering
Steering Wheel Removal
S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e 6. Install a c o m m e r c i a l l y a v a i l a b l e s t e e r i n g w h e e l
S R S c o m p o n e n t location: ' 0 0 - 0 5 m o d e l s ( s e e p a g e puller (A) o n t h e s t e e r i n g w h e e l (B). F r e e t h e
2 3 - 1 1 ) , '06-08 m o d e l s ( s e e p a g e 2 3 - 1 2 ) , a n d p r e c a u t i o n , steering w h e e l from the steering c o l u m n shaft by
a n d p r o c e d u r e s ( s e e p a g e 23-13) b e f o r e d o i n g r e p a i r s t u r n i n g t h e p r e s s u r e bolt (C) of t h e puller.
or service.
Note t h e s e items w h e n r e m o v i n g the steering
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e f o r t h e wheel:
a u d i o , t h e n write d o w n t h e a u d i o p r e s e t s .
• D o not t a p o n t h e s t e e r i n g w h e e l or t h e s t e e r i n g
2. M a k e s u r e t h e ignition s w i t c h is O F F , t h e n c o l u m n shaft w h e n r e m o v i n g the steering w h e e l
d i s c o n n e c t t h e n e g a t i v e battery c a b l e f r o m t h e • If y o u t h r e a d t h e puller bolts (D) into t h e w h e e l
battery. h u b m o r e t h a n five t h r e a d s , t h e bolts will hit t h e
c a b l e reel a n d d a m a g e it. T o p r e v e n t t h i s , install
3. A l i g n t h e front w h e e l s s t r a i g h t a h e a d , t h e n r e m o v e a pair of j a m n u t s five t h r e a d s up o n e a c h puller
the driver's airbag from the steering w h e e l bolt.
( s e e p a g e 23-164).
4. D i s c o n n e c t t h e c r u i s e control s w i t c h c o n n e c t o r (A)
a n d h o r n s w i t c h c o n n e c t o r (B).
7. R e m o v e the s t e e r i n g w h e e l puller, t h e n r e m o v e t h e
5. L o o s e n t h e s t e e r i n g w h e e l bolt (A). s t e e r i n g w h e e l bolt a n d s t e e r i n g w h e e l f r o m t h e
steering column.
17-6
Steering Wheel Disassembly/Reassembly
STEERING WHEEL
CRUISE CONTROL SET/DECEL,

RESUME/ACCEL SWITCH
17-7
Steering
Steering Wheel Installation
1. B e f o r e installing the s t e e r i n g w h e e l , m a k e s u r e t h e 3. Install the s t e e r i n g w h e e l bolt a n d tighten it to the

front w h e e l s a r e pointing straight a h e a d , t h e n specified torque.
c e n t e r t h e c a b l e reel (A). D o this by first rotating t h e
39 N m (4.0 k g f - m , 29 Ibf-ft)
c a b l e reel c l o c k w i s e until it s t o p s . T h e n rotate it
c o u n t e r c l o c k w i s e a b o u t t w o a n d half t u r n s . T h e
a r r o w m a r k (B) o n the c a b l e reel label point s h o u l d
point s t r a i g h t u p .
4. C o n n e c t the h o r n s w i t c h c o n n e c t o r a n d c r u i s e
control s w i t c h c o n n e c t o r .
5. Install the d r i v e r ' s a i r b a g , a n d c o n f i r m that the

s y s t e m is o p e r a t i n g p r o p e r l y ( s e e p a g e 23-165).
2. P o s i t i o n t h e t w o t a b s (A) of the t u r n s i g n a l
c a n c e l i n g s l e e v e (B) a s s h o w n . Install t h e s t e e r i n g 6. R e c o n n e c t the n e g a t i v e battery c a b l e to the battery.
w h e e l o n to t h e s t e e r i n g c o l u m n s h a f t , m a k i n g s u r e
the s t e e r i n g w h e e l h u b (C) e n g a g e s t h e p i n s (D) of 7. C h e c k the h o r n , c r u i s e control s e t / r e s u m e s w i t c h ,
the c a b l e reel a n d t a b s of t h e t u r n s i g n a l c a n c e l i n g a n d t u r n s i g n a l c a n c e l i n g for p r o p e r o p e r a t i o n .
s l e e v e . D o not t a p o n the s t e e r i n g w h e e l or s t e e r i n g
c o l u m n s h a f t w h e n installing the s t e e r i n g w h e e l . 8. E n t e r the anti-theft c o d e for the a u d i o , t h e n enter
the audio presets.
9. F o r ' 0 1 - 0 8 m o d e l s ; r e s e t t h e c l o c k .
10. F o r ' 0 0 - 0 5 m o d e l s ; d o the E C M idle l e a r n p r o c e d u r e

( s e e p a g e 11-140).
17-8
Steering Column Removal and Installation
S R S c o m p o n e n t s a r e located in this a r e a . R e v i e w the S R S c o m p o n e n t location: '00-05 m o d e l s ( s e e p a g e 2 3 - 1 1 ) ,
'06-08 m o d e l s ( s e e p a g e 23-12), a n d p r e c a u t i o n , a n d p r o c e d u r e s ( s e e p a g e 23-13) before d o i n g r e p a i r s or s e r v i c e .
Removal
1. M a k e s u r e y o u h a v e the anti-theft c o d e for the a u d i o , t h e n w r i t e d o w n t h e a u d i o p r e s e t , a n d d i s c o n n e c t t h e

n e g a t i v e battery c a b l e f r o m the battery.
2. R e m o v e the d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 23-164), s t e e r i n g w h e e l , a n d the c a b l e reel ( s e e p a g e 23-173).
3. R e m o v e the c o l u m n c o v e r s (A).
4. R e m o v e the c o m b i n a t i o n s w i t c h a s s e m b l y (B) f r o m the s t e e r i n g c o l u m n shaft by d i s c o n n e c t i n g the c o n n e c t o r s

a n d r e m o v i n g the s c r e w s .
5. D i s c o n n e c t the ignition s w i t c h c o n n e c t o r s f r o m the u n d e r - d a s h f u s e / r e l a y box.
6. R e m o v e the s t e e r i n g joint bolt (C).
7. R e m o v e the s t e e r i n g c o l u m n (D) b y r e m o v i n g the a t t a c h i n g nuts (E) a n d bolts (F).
(cont'd)
17-9
Steering
Steering Column Removal and Steering Shaft Removal and
Installation (cont'd) Installation
Installation Removal
1. Install the s t e e r i n g c o l u m n , a n d m a k e s u r e t h e 1. R e m o v e t h e s t e e r i n g c o l u m n ( s e e p a g e 17-9).

w i r e s a r e not c a u g h t or p i n c h e d b y a n y p a r t s .
2 . M a r k (A) the s t e e r i n g joint (B) a n d p i n i o n shaft (C)
2. Insert t h e l o w e r e n d of t h e s t e e r i n g joint (A) onto to identify t h e position of the joint o n the pinion
t h e s t e e r i n g s h a f t (B) (line u p t h e bolt h o l e (C) w i t h shaft.
t h e flat portion (D) o n t h e s h a f t ) .
E D
3. Pull o n t h e s t e e r i n g joint to m a k e s u r e that t h e

s t e e r i n g joint is fully s e a t e d , but d o not pull 3 . R e m o v e the s t e e r i n g joint bolts (D).
e x c e s s i v e l y o n t h e joint. T h e n install t h e s t e e r i n g
joint bolt (E) a n d t i g h t e n it to t h e s p e c i f i e d t o r q u e . 4. D i s c o n n e c t t h e s t e e r i n g joint f r o m the pinion s h a f t
b y pulling t h e s t e e r i n g shaft (E).
'00 m o d e l :
U.S.A. models VIN JHMAP114-YT000001 thru 5. R e m o v e the s t e e r i n g joint f r o m the s t e e r i n g shaft.
VIN J H M A P 114-YT008411
C a n a d a m o d e l s VIN J H M A P 114-YT800001 thru 6. R e m o v e the s t e e r i n g s h a f t .
VIN J H M A P 114-YT800750
Torque: 2 2 N m (2.2 k g f m , 16 I b f f t )
Other models:
Torque: 2 9 N m (3.0 k g f m , 2 2 I b f f t )
4. F i n i s h t h e i n s t a l l a t i o n , a n d note t h e s e i t e m s :
• M a k e s u r e t h e w i r e h a r n e s s is routed a n d
fastened properly.
• Make s u r e the connectors are properly connected.
• R e i n s t a l l t h e s t e e r i n g w h e e l ( s e e p a g e 17-8).
• R e c o n n e c t t h e n e g a t i v e battery c a b l e to the
battery.
- E n t e r t h e anti-theft c o d e for t h e a u d i o , t h e n
enter the audio presets.
- For '01-08 m o d e l s ; set the clock.
- F o r ' 0 0 0 5 m o d e l s ; d o t h e E C M idle l e a r n
:
• Verify cruise control, horn, a n d turn signal switch
operation.
• C h e c k w h e e l a l i g n m e n t ( s e e p a g e 18-7).
17-10
Installation 5. S l i p t h e u p p e r e n d (A) of t h e s t e e r i n g joint onto t h e
s t e e r i n g shaft-(B) (from the e n g i n e c o m p a r t m e n t ) ;
1. A p p l y m u l t i p u r p o s e g r e a s e to t h e i n s i d e s u r f a c e of B e s u r e t h e s t e e r i n g joint a n d s t e e r i n g s h a f t a r e
t h e p i n i o n d u s t s e a l (A). a l i g n e d w i t h the s e r r a t i o n s ; the joint s h o u l d s l i p o n
f r e e l y . If not, r e p o s i t i o n t h e s e r r a t i o n of the s t e e r i n g
joint.
2. Insert t h e s t e e r i n g s h a f t (B) into t h e e n g i n e

c o m p a r t m e n t c a r e f u l l y to a v o i d d a m a g i n g t h e
p i n i o n d u s t s e a l . M a k e s u r e t h e s h a f t c o m e s out of
the frame hole.
6. L i n e u p t h e bolt h o l e (C) w i t h t h e flat portion (D) of
3. Install t h e s t e e r i n g c o l u m n w i t h t h e c o l u m n t h e s t e e r i n g s h a f t , a n d l o o s e l y install t h e u p p e r
m o u n t i n g nuts a n d c o l u m n h o l d e r ( s e e p a g e 17-9). joint bolt ( E ) . Pull t h e s t e e r i n g joint to m a k e s u r e
that t h e joint is fully s e a t e d .
4 . S l i p t h e joint (A) of t h e c o l u m n s h a f t onto t h e
s t e e r i n g s h a f t ( B ) , t h e n l o o s e l y install t h e joint bolt 7. S l i p o n t h e l o w e r e n d (F) of t h e s t e e r i n g joint by
(C) (line u p the bolt hole (D) w i t h t h e flat portion (E) a l i g n i n g the m a r k s (G) o n t h e pinion s h a f t (H) a n d
of t h e shaft). Pull t h e s t e e r i n g s h a f t t o w a r d t h e joint. L i n e up t h e bolt hole (I) w i t h g r o o v e a r o u n d
column. (J) t h e p i n i o n s h a f t , a n d install t h e l o w e r joint bolt
(K) a n d tighten it b y h a n d . Don't t o r q u e t h e bolt yet.
Pull t h e s t e e r i n g joint to m a k e s u r e that t h e joint is
fully s e a t e d .
8. Pull t h e s t e e r i n g s h a f t t o w a r d t h e pinion shaft. T h e n

tighten t h e u p p e r joint bolt, the l o w e r joint bolt
(both in t h e e n g i n e c o m p a r t m e n t ) , a n d t h e joint bolt
o n c o l u m n s h a f t ( u n d e r t h e d a s h b o a r d ) to t h e
specified torque.
'00 model:
U . S . A . m o d e l s V I N J H M A P 114-YT000001 t h r u
V I N J H M A P 114-YT008411
C a n a d a m o d e l s V I N J H M A P 114-YT800001
thru
V I N J H M A P 114-YT800750
T o r q u e : 2 2 N m (2.2 k g f m , 16 Ibf-ft)
Other models:
T o r q u e : 2 9 N-m (3.0 k g f m , 2 2 Ibf-ft)
17-11
Steering
Steering Column/Steering Shaft Inspection
• C h e c k t h e s t e e r i n g c o l u m n ball b e a r i n g (A) a n d t h e s t e e r i n g joint b e a r i n g s (B) for p l a y a n d p r o p e r m o v e m e n t . If a n y
b e a r i n g is n o i s y or h a s e x c e s s i v e p l a y , r e p l a c e t h e s t e e r i n g c o l u m n a s a n a s s e m b l y .
• C h e c k t h e retaining c o l l a r (C) for d a m a g e . If it is d a m a g e d , r e p l a c e the s t e e r i n g c o l u m n a s a n a s s e m b l y .
• C h e c k t h e a b s o r b i n g p l a t e s (D) for distortion o r b r e a k a g e . If t h e r e is distortion or b r e a k a g e , r e p l a c e t h e s t e e r i n g
column as an assembly.
• C h e c k t h e s l i d i n g c a p s u l e s (E) for distortion o r b r e a k a g e . If t h e r e is distortion or b r e a k a g e , r e p l a c e t h e s t e e r i n g
column as an assembly.
• C h e c k t h e s t e e r i n g s h a f t (F) for b e n d i n g a n d d a m a g e .
• C h e c k t h e joint d u s t s e a l ( G ) for deterioration a n d d a m a g e .
17-12
Steering Lock Replacement
1. R e m o v e t h e s t e e r i n g c o l u m n ( s e e p a g e 17-9).
2. C e n t e r p u n c h e a c h of the t w o s h e a r bolts, a n d drill

their h e a d s off w i t h a 5 m m (3/16 in.) drill bit. B e
c a r e f u l not to d a m a g e t h e s w i t c h b o d y w h e n
r e m o v i n g t h e s h e a r bolts.
3. R e m o v e t h e s h e a r bolts f r o m t h e s w i t c h b o d y .
4. Install t h e s w i t c h b o d y w i t h o u t the key i n s e r t e d .
5. L o o s e l y tighten the n e w s h e a r bolts.
6. Insert t h e ignition k e y , a n d m a k e s u r e t h e s t e e r i n g
w h e e l lock w o r k s p r o p e r l y a n d that the ignition k e y
t u r n s freely.
7. T i g h t e n t h e s h e a r bolts (A) until t h e h e x h e a d s (B)

t w i s t off.
8. Install t h e s t e e r i n g c o l u m n ( s e e p a g e 17-10).
9. R e g i s t e r t h e i m m o b i l i z e r c o n t r o l u n i t - r e c e i v e r w i t h
the H D S , a n d m a k e s u r e t h e i m m o b i l i z e r s y s t e m
w o r k s properly.
17-13
Steering
Rack Guide Adjustment
Special Tools Required 7. T i g h t e n t h e locknut to 2 5 N-m (2.5 kgf-m, 18 Ibfft)
w h i l e h o l d i n g t h e rack g u i d e s c r e w .
Locknut w r e n c h , 43 m m 0 7 M A A - S L 0 0 2 0 A
8. Install the l o w e r radiator h o s e bracket.
1. S e t t h e w h e e l s in t h e s t r a i g h t a h e a d p o s i t i o n .
9. Install the s p l a s h s h i e l d .
2. R e m o v e t h e s p l a s h s h i e l d .
10. C h e c k for tight or l o o s e s t e e r i n g f r o m lock to lock.
3. R e m o v e t h e l o w e r radiator h o s e b r a c k e t (A).
11. D o t h e s e i n s p e c t i o n s :
• S t e e r i n g w h e e l rotational p l a y ( s e e p a g e 17-4).
• P o w e r a s s i s t w i t h v e h i c l e p a r k e d ( s e e p a g e 17-4).
5. T i g h t e n t h e r a c k g u i d e s c r e w to 2 5 N-m (2.5 kgf-m,

18 lbf-ft), t h e n l o o s e n it.
6. R e t i g h t e n t h e r a c k g u i d e s c r e w to 3.9 N-m
(0.4 kgf-m, 2.9 Ibfft) t h e n b a c k it off to t h e s p e c i f i e d
angle.
0
S p e c i f i e d r e t u r n a n g l e : 10 ° t o 2 0
17-14
Steering
Steering - 17-1
EPS (Electrical Power Steering) Components
General Troubleshooting Information 17-17
DTC Troubleshooting Index 17-22
DTC Troubleshooting 17-30
Symptom Troubleshooting 17-45
Memorizing the Torque Sensor Neutral Position 17-48
Steering Gearbox Removal and Installation 17-49
Steering Gearbox Overhaul 17-56
Torque Sensor Replacement 17-57
Rack Guide Removal/Installation 17-57
Rack End Removal and Installation 17-58
Gearbox Bracket Removal/Installation 17-61
Tie-rod Ball Joint Boot Replacement 17-61
EPS Control Unit Removal/Installation 17-62
Gearbox Mount Cushion Replacement 17-62
EPS Components
STEERING G E A R B O X (MOTOR)
R e m o v a l a n d Installation, p a g e 17-49
O v e r h a u l , p a g e 17-56
R a c k G u i d e R e m o v a l / I n s t a l l a t i o n , p a g e 17-57
R a c k E n d R e m o v a l a n d I n s t a l l a t i o n , p a g e 17-58
G e a r b o x B r a c k e t R e m o v a l / I n s t a l l a t i o n , p a g e 17-61
T i e - r o d B a l l J o i n t B o o t R e p l a c e m e n t , p a g e 17-61
G e a r b o x M o u n t C u s h i o n R e p l a c e m e n t , p a g e 17-62
17-16
EPS Indicator T h e E P S c o n t r o l unit d o e s t h e f o l l o w i n g f u n c t i o n s w h e n

a p r o b l e m is d e t e c t e d by s e l f - d i a g n o s i s :
U n d e r n o r m a l c o n d i t i o n s , t h e E P S indicator c o m e s on
w h e n t h e ignition s w i t c h is t u r n e d to O N (II) p o s i t i o n , 1. T u r n s o n t h e E P S indicator.
t h e n if g o e s off after t h e e n g i n e is s t a r t e d . T h i s i n d i c a t e s 2. M e m o r i z e s t h e D T C .
that the b u l b a n d its circuit a r e o p e r a t i n g c o r r e c t l y . 3; S t o p s p o w e r a s s i s t a n d m a n u a l s t e e r i n g o p e r a t i o n
If t h e r e is a failure in t h e s y s t e m after t h e e n g i n e is resumes.
s t a r t e d , t h e E P S indicator w i l l s t a y o n , a n d t h e p o w e r
a s s i s t i s t u r n e d off or r e s t r i c t e d . NOTE:
W h e n t h e E P S indicator c o m e s o n , t h e c o n t r o l unit • W h e n D T C 2 3 (a p r o b l e m w i t h t h e c i r c u i t for
m e m o r i z e s t h e D T C . In t h i s c a s e , t h e c o ntrol unit will engine s p e e d signal) is stored, the p o w e r assist
not a c t i v a t e t h e E P S s y s t e m after t h e e n g i n e s t a r t s will return to n o r m a l w h e n t h e c o n t r o l unit
a g a i n , but it k e e p s t h e E P S indicator o n . detects the engine s p e e d signal a n d the vehicle
W h e n D T C 1 1 , 1 2 , or 13 a r e s t o r e d in t h e c o n t r o l unit, s p e e d i s 6.2 m p h (10 k m / h ) o r a b o v e .
the E P S i n d i c a t o r will s t a y o n until the D T C is e r a s e d . • F o r D T C s 2 1 , 2 2 , a n d 2 3 t h e E P S i n d i c a t o r will g o
E v e n t h o u g h t h e s y s t e m i s o p e r a t i n g n o r m a l l y , the E P S off a u t o m a t i c a l l y , a n d t h e s y s t e m r e t u r n s to
indicator w i l l c o m e o n u n d e r t h e s e c o n d i t i o n s : normal.
• W h e n t h e v e h i c l e is b a r e l y m o v i n g , 1 m p h (1 km/h) or Restriction on Power Assist Operation

s t o p p e d , a n d the e n g i n e s p e e d is 2,000 r p m o r m o r e
for a b o u t 3 m i n u t e s . R e p e a t e d e x t r e m e s t e e r i n g f o r c e , s u c h a s t u r n i n g the
• W h e n t h e e n g i n e s p e e d is 5 0 0 r p m o r l e s s , a n d the steering w h e e l continuously back-and-forth with the
v e h i c l e is t r a v e l i n g at a s p e e d of 6.2 m p h (10 km/h) or v e h i c l e s t o p p e d , c a u s e s a n i n c r e a s e of p o w e r
m o r e for a b o u t 3 m i n u t e s . c o n s u m p t i o n in t h e E P S m o t o r . T h e i n c r e a s e of electric
c u r r e n t c a u s e s t h e m o t o r to h e a t up. B e c a u s e t h i s heat
T o d e t e r m i n e t h e a c t u a l c a u s e of t h e p r o b l e m , q u e s t i o n a d v e r s e l y a f f e c t s t h e s y s t e m , t h e control unit m o n i t o r s
the c u s t o m e r a b o u t t h e c o n d i t i o n s d u r i n g w h i c h the t h e e l e c t r i c c u r r e n t of the m o t o r .
p r o b l e m o c c u r r e d , taking t h e a b o v e c o n d i t i o n s into
consideration. W h e n the c o n t r o l unit d e t e c t s h e a t b u i l d - u p in the m o t o r ,
it r e d u c e s t h e e l e c t r i c c u r r e n t to t h e m o t o r g r a d u a l l y to
Diagnostic Trouble Code (DTC) protect t h e s y s t e m , a n d it r e s t r i c t s t h e p o w e r a s s i s t
o p e r a t i o n . T h e E P S i n d i c a t o r d o e s not c o m e o n d u r i n g
• If t h e C P U c a n n o t be a c t i v a t e d , o r if it f a i l s , t h e E P S this function.
indicator c o m e s o n , but t h e D T C is not m e m o r i z e d .
• T h e m e m o r y c a n h o l d a l a r g e n u m b e r of D T C s . W h e n s t e e r i n g t o r q u e is not a p p l i e d to t h e s t e e r i n g
H o w e v e r , w h e n the s a m e D T C is d e t e c t e d m o r e t h a n w h e e l , o r w h e n t h e ignition is t u r n e d to L O C K (0), the
o n c e , t h e m o s t r e c e n t D T C is written o v e r t h e prior control unit w i l l restore t h e p o w e r a s s i s t g r a d u a l l y until
D T C ; t h e r e f o r e o n l y o n e o c c u r r e n c e is m e m o r i z e d . it's fully r e s t o r e d (after a b o u t 8 m i n u t e s ) .
• T h e l o w e s t D T C is i n d i c a t e d first. T h e D T C s a r e
i n d i c a t e d in a s c e n d i n g o r d e r , not in t h e o r d e r that EPS Control Unit Noise
they occurred.
• T h e D T C s a r e m e m o r i z e d in the E E P R O M A relay s o u n d or "click" c a n be heard f r o m the E P S
(non-volatile m e m o r y ) , t h e r e f o r e t h e m e m o r i z e d control unit a b o u t 30 s e c o n d s after t h e ignition s w i t c h is
D T C s c a n n o t be e r a s e d b y d i s c o n n e c t i n g t h e battery. t u r n e d to L O C K (0). T h i s s o u n d is n o r m a l .
D o t h e s p e c i f i e d p r o c e d u r e s to c l e a r D T C s .
Self-diagnosis
S e l f - d i a g n o s i s c a n be c l a s s i f i e d into t w o c a t e g o r i e s :
• Initial d i a g n o s i s : D o n e right after t h e e n g i n e s t a r t s

a n d until t h e E P S indicator g o e s off.
• R e g u l a r d i a g n o s i s : D o n e right after t h e initial
d i a g n o s i s until the ignition s w i t c h i s t u r n e d to
L O C K (0).
(cont'd)
17-17
EPS Components
Torque Sensor Neutral Position How to Retrieve DTCs Using the HDS (Honda
Diagnostic System)
T h e E P S c o n t r o l unit s t o r e s t h e t o r q u e s e n s o r neutral
p o s i t i o n in t h e E E P R O M . M e m o r i z e t h e t o r q u e s e n s o r 1. W i t h t h e ignition s w i t c h to L O C K (0), c o n n e c t t h e
neutral p o s i t i o n w h e n e v e r t h e g e a r b o x i s r e m o v e d a n d H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d
i n s t a l l e d , o r w h e n t h e t o r q u e s e n s o r or E P S c o n t r o l unit u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d .
is r e p l a c e d .
N O T E : T h e t o r q u e s e n s o r neutral position is not

effected w h e n e r a s i n g t h e D T C s .
How to Troubleshoot DTCs
T h e troubleshooting flowchart procedures a s s u m e that

t h e c a u s e of t h e p r o b l e m is still p r e s e n t a n d t h e E P S
indicator is still o n . F o l l o w i n g t h e f l o w c h a r t w h e n t h e
E P S i n d i c a t o r d o e s not c o m e o n c a n result in a n
incorrect diagnosis.
T h e c o n n e c t o r illustrations s h o w the f e m a l e t e r m i n a l
c o n n e c t o r s w i t h a s i n g l e outline a n d t h e m a l e t e r m i n a l
c o n n e c t o r s w i t h a d o u b l e outline. 2. T u r n the ignition s w i t c h to O N (II).
1. Q u e s t i o n t h e c u s t o m e r a b o u t t h e c o n d i t i o n s w h e n 3. F o r ' 0 6 - 0 8 m o d e l s ; m a k e s u r e t h e H D S
t h e p r o b l e m o c c u r r e d , a n d try to r e p r o d u c e t h e c o m m u n i c a t e s w i t h t h e v e h i c l e a n d t h e E P S control
s a m e c o n d i t i o n s for t r o u b l e s h o o t i n g . F i n d out unit. If it d o e s n ' t , t r o u b l e s h o o t the D L C circuit
w h e n t h e E P S indicator c a m e o n , s u c h a s w h i l e ( s e e p a g e 11-367).
t u r n i n g after t u r n i n g , w h e n t h e v e h i c l e w a s at a
c e r t a i n s p e e d , o n start u p , etc. 4. F o l l o w t h e p r o m p t s o n t h e H D S to d i s p l a y t h e
D T C ( s ) o n t h e s c r e e n . After d e t e r m i n i n g t h e D T C ,
2. W h e n t h e E P S indicator d o e s not c o m e o n d u r i n g refer to t h e D T C T r o u b l e s h o o t i n g .
t h e t e s t d r i v e , but t r o u b l e s h o o t i n g is d o n e b a s e d o n
t h e D T C , c h e c k for l o o s e c o n n e c t o r s , p o o r t e r m i n a l N O T E : S e e t h e H D S Help m e n u for s p e c i f i c
c o n t a c t , e t c . , b e f o r e y o u start t r o u b l e s h o o t i n g . instructions.
3. After t r o u b l e s h o o t i n g , c l e a r t h e D T C a n d t e s t - d r i v e
t h e v e h i c l e . B e s u r e t h e E P S indicator d o e s not
come on.
17-18
How to Retrieve DTCs (Service Check Signal 7. T h e blinking f r e q u e n c y i n d i c a t e s t h e D T C . D T C s a r e
Circuit Method (Flash codes)) i n d i c a t e d b y a s e r i e s of l o n g a n d s h o r t b l i n k s . A d d
t h e long a n d s h o r t blinks t o g e t h e r to d e t e r m i n e the
1. W i t h the ignition s w i t c h to L O C K (0), c o n n e c t the D T C . A f t e r d e t e r m i n i n g t h e D T C , refer to t h e D T C
H D S to t h e data link c o n n e c t o r ( D L C ) (A) located troubleshooting.
u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d .
T h e s y s t e m w i l l not i n d i c a t e t h e D T C u n l e s s t h e s e
c o n d i t i o n s a r e met:
• S e t t h e front w h e e l s in the straight a h e a d driving

position.
• T h e ignition s w i t c h is t u r n e d to O N (II).
• T h e e n g i n e is s t o p p e d .
• T h e S C S circuit is s h o r t e d to b o d y g r o u n d before
t h e ignition s w i t c h is t u r n e d to O N (II).
E x a m p l e of D T C 12
Short blinks
(two times)
L o n g blink
ON
3. F o r ' 0 6 - 0 8 m o d e l s ; m a k e s u r e the H D S OFF-

c o m m u n i c a t e s w i t h the v e h i c l e a n d the E P S control
unit. If it d o e s n ' t , t r o u b l e s h o o t t h e D L C circuit E x a m p l e of D T C 23
( s e e p a g e 11-367). Short blinks
L o n g blinks
(three times)
(two times)
ON
5. S h o r t t h e S C S circuit to b o d y g r o u n d u s i n g the H D S .
6. T u r n the ignition s w i t c h to O N (II). OFF-
9. D i s c o n n e c t the H D S f r o m the D L C .
(cont'd)
17-19
EPS Components
General Troubleshooting Informal (cont'd)
H o w to Clear D T C s Using the H D S (Honda H o w to Clear D T C s Using the Service Check

Diagnostic System) Signal Circuit M e t h o d
1. W i t h t h e ignition s w i t c h to L O C K (0), c o n n e c t the N O T E : U s e this procedure w h e n the H D S software d o e s
H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d not m a t c h t h e y e a r / m o d e l v e h i c l e y o u a r e w o r k i n g o n .
u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d .
1. W i t h t h e ignition s w i t c h to L O C K (0), c o n n e c t t h e
H D S to the data link c o n n e c t o r ( D L C ) (A) located
u n d e r t h e d r i v e r ' s s i d e of the d a s h b o a r d .
3. F o r ' 0 6 - 0 8 m o d e l s ; m a k e s u r e t h e H D S
c o m m u n i c a t e s w i t h t h e v e h i c l e a n d t h e E P S control 2 . W i t h the v e h i c l e o n the g r o u n d , s e t t h e front w h e e l s
unit. If it d o e s n ' t , t r o u b l e s h o o t t h e D L C circuit in t h e straight a h e a d driving p o s i t i o n .
(see p a g e 11-367).
3. S h o r t t h e S C S circuit to b o d y g r o u n d u s i n g the H D S .
4. C l e a r t h e D T C ( s ) b y f o l l o w i n g t h e s c r e e n p r o m p t s
on the HDS. 4. T u r n the s t e e r i n g w h e e l 4 5 d e g r e e s to the left f r o m
t h e straight a h e a d d r i v i n g p o s i t i o n , a n d hold the
N O T E : S e e t h e H D S H e l p m e n u for s p e c i f i c s t e e r i n g w h e e l in that position.
instructions.
5. T u r n t h e ignition s w i t c h to O N (II). T h e E P S
i n d i c a t o r c o m e s o n , t h e n it g o e s off after 4 s e c o n d s .
6. W i t h i n 4 s e c o n d s after the E P S indicator g o e s off,

return t h e s t e e r i n g w h e e l to t h e straight a h e a d
d r i v i n g position a n d r e l e a s e the s t e e r i n g w h e e l .
T h e E P S indicator c o m e s o n a g a i n 4 s e c o n d s after
releasing the steering w h e e l .
7. W i t h i n 4 s e c o n d s after t h e E P S i n d i c a t o r c o m e s o n ,
t u r n t h e s t e e r i n g w h e e l 4 5 d e g r e e s to t h e left a g a i n
a n d h o l d it in that p o s i t i o n .
T h e E P S indicator g o e s off after 4 s e c o n d s .
17-20
8. W i t h i n 4 s e c o n d s after the E P S indicator g o e s off,
return t h e s t e e r i n g w h e e l to t h e s t r a i g h t a h e a d
driving position again and release the steering
w h e e l . T h e E P S indicator b l i n k s t w i c e 4 s e c o n d s
after r e l e a s i n g t h e s t e e r i n g w h e e l , indicating that
the D T C w a s e r a s e d .
N O T E : If t h e E P S indicator d o e s not blink t w i c e , a n

e r r o r w a s m a d e in t h e p r o c e d u r e a n d t h e D T C w a s
not e r a s e d . T u r n t h e ignition s w i t c h to L O C K (0),
a n d r e p e a t t h e o p e r a t i o n f r o m s t e p 3.
9. T u r n t h e ignition s w i t c h to L O C K (0) w i t h i n 5
s e c o n d s after t h e E P S indicator blinks t w i c e .
N O T E : If t h e ignition s w i t c h is not t u r n e d to L O C K
(0) w i t h i n 5 s e c o n d s after t h e E P S indicator b l i n k s ,
t h e s y s t e m will g o to t h e m e m o r i z i n g m o d e of t h e
t o r q u e s e n s o r neutral p o s i t i o n . T o a v o i d t h i s , t u r n
t h e s t e e r i n g w h e e l 4 5 d e g r e e s to left f r o m t h e
straight a h e a d d r i v i n g position a n d turn t h e ignition
s w i t c h to L O C K (0). T h i s w i l l return t h e s y s t e m to
t h e alert m o d e .
10. D i s c o n n e c t t h e H D S f r o m t h e D L C .
11. R e c h e c k for t h e D T C to be s u r e it h a s b e e n e r a s e d .
EPS INDICATOR
EPS Components
DTC Detection Item Note
1 Power Relay Stuck O N ( s e e p a g e 17-30)
2 Fail-safe Relay Stuck O N ( s e e p a g e 17-30)
3 Lower F E T Stuck O N (see page 17-30)
4 Upper F E T Stuck O N (see page 17-31)
5 O p e n in t h e M o t o r C i r c u i t (see page 17-32)
11 Torque Sensor (see page 17-34)
12 Torque Sensor PVF (see page 17-35)
13 Torque Sensor (see page 17-34)
14 Torque S e n s o r (Resistance) (see page 17-36)
21 V o l t a g e for IG1 (see page 17-37)
22 Vehicle S p e e d Signal (see page 17-38)
23 Engine S p e e d S i g n a l Circuit (see page 17-38)
30 Submicrocomputer (see page 17-41)
31 Motor Current S e n s o r (see page 17-41)
32 Motor Current S e n s o r ( s e e p a g e 17-41)
33 Motor Current S e n s o r ( s e e p a g e 17-41)
34 E P S C o n t r o l U n i t Internal C i r c u i t ( s e e p a g e 17-42)
35 E P S C o n t r o l Unit Internal C i r c u i t ( s e e p a g e 17-42)
36 Incorrect M o t o r V o l t a g e ( s e e p a g e 17-42)
37 No Motor Voltage ( s e e p a g e 17-43)
50 to 6 2 Central Processing Unit (CPU) ( s e e p a g e 17-45)
17-22
Symptom Diagnostic procedure

H D S d o e s not c o m m u n i c a t e w i t h t h e E P S T r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367)
control unit or t h e v e h i c l e ('06-08 m o d e l s )
E P S indicator d o e s not c o m e o n S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 17-45)
E P S indicator d o e s not g o off, a n d n o D T C s S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 17-45)
are stored
E P S indicator d o e s not c o m e o n , a n d n o 1. C h e c k t h e R E D w i r e b e t w e e n t h e E P S c o n t r o l unit a n d the m o t o r
D T C s a r e s t o r e d , but t h e r e is n o p o w e r for a s h o r t to b o d y g r o u n d . R e p a i r a s n e e d e d .
assist 2. If t h e R E D w i r e i s O K , r e p l a c e t h e s t e e r i n g g e a r b o x ( s e e p a g e
17-49) (short in t h e m o t o r ) .
17-23
EPS Components
System Description
EPS Control Unit Inputs and Outputs for Connector A (2P)
Terminal W i r e color Terminal sign Description Signal

number (Terminal n a m e ) Terminals Conditions Voltage
1 GRN MOTOR- D r i v e s t h e actuator m o t o r
(Motor m i n u s )
2 RED MOTOR+ D r i v e s the actuator motor
(Motor plus)
EPS Control Unit Inputs and Outputs for Connector B (14P)
f1 1 r 3^1
4 .2 6 7
8 / V '11
V12 13

1 YEL IG1 P o w e r s o u r c e for activating 1—GND Ignition s w i t c h O N (II) Battery voltage
(Ignition 1) the s y s t e m Ignition s w i t c h L O C K OV
(0)
2 WHT/BLK VSP Detects v e h i c l e s p e e d signal 2-GND Depending on vehicle A b o u t 5—0 V
(Vehicle s p e e d pulse) f r o m the s p e e d o m e t e r speed
3 PNK VS1 Detects torque s e n s o r
(Voltage s e n s o r 1) signal
4 BLK GND2 G r o u n d for the E P S control
( G r o u n d 2) unit
5 BLU NEP Detects t a c h o m e t e r s i g n a l 5-GND With e n g i n e running Pulses
( E n g i n e pulse)
6 BLK GND1 G r o u n d for the E P S control
( G r o u n d 1) unit
7 BLU/RED PVF D r i v e s t h e torque s e n s o r
(Voltage fade)
8 BRN SCS Detects s e r v i c e c h e c k
( S e r v i c e c h e c k signal) c o n n e c t o r signal
11 WHT/GRN VS2 Detects t o r q u e s e n s o r
(Voltaqe s e n s o r 2) signal
12 YEL/BLU WLP D r i v e s t h e E P S indicator 12-GND W i t h e n g i n e running Battery voltage
(Warning) light
13 BLU/BLK EPSLD P r o v i d e s idle s p e e d - u p 13-GND Start the e n g i n e a n d Battery voltage
(Electrical P / S load signal to the E C M turn the steering w h e e l for 1 s e c o n d
detect) to full lock
14 LT BLU DIAG-H C o m m u n i c a t e s with H D S
(Diaqonosis-H)
17-24
EPS Control Unit Inputs and Outputs for Connector C (2P)

1 BLK PG G r o u n d for the actuator
(Power ground) motor
2 WHT/RED +B P o w e r s o u r e e f or the • 2-GND A t all t i m e s Battery voltage
(Plus battery) actuator motor
17-25
EPS Components
Circuit Diagram
'00-03 m o d e l s
©
AUXL
IA
IRY
-+-) BAT
TERY UND
E RH
-OODF
U SER
/EL
A Y BOX
No. 33 (70A1A) WHT

R
/ED
UNDERD
-A S
H
F
U SER
/EL
A Y BOX
• YEL •
IG1 H
O T in ON (II)
and ST
A RT (III)
YEL
GA
UGEAS
SEMBL
Y
-A
EPS N
ID
CIAT
O R
YELB
/LU
BLU T
ACH
O ME
TER
ECM S
PEE
D OME
TER {t] WHT
B
/LK
BLU • -BLU
J EPSL
D
\ * © BLUB
/L
K •BL
U B
/L
K
• PNK •
- BL
U R
/ED -
•WHT
G
/RN-
GAUGEAS
SEMBL
YCON
NEC
TORA (14P)
(O: connector)
T
O RQUES
ENS
O R 3P C
O N
NEC
TOR ECM C
O N
NEC
TORA (32P)
1
7?
7 8 9
4 6 6
/ / 14
GAUGEAS
SEMBL
YCON
NEC
TORB (12P)
(A: connector)
BUTT
Hi Yki
2
^^Ly\ 9
}$\
GAUGEAS
SEMBL
YCON
NEC
TORC (20P)
(•: connector)
T e r m i n a l s i d e of f e m a l e t e r m i n a l s W i r e s i d e of f e m a l e t e r m i n a l s
17-26
-WHT/RED
EPS CONTROL UNIT
P OWE
R RELAY I 0~O—
r ^ i
-{2]
+B
- WHT/RED
I
IG1 ^
YEL ^—<7>- - 5 V R
EGULATOR -| I I • . . • 1
-^Sr^RED
FAIL-SAFE RELAY M-
• GRN
MOTOR I
O"0-
BLK
•YEL/BLU
WLP
(G4)
VSP
• WHT/BLK
It
NEP +B
7
BLU -
SCS
) BRN
W
HT
/G
RN
EPSLD
- BLU/BLK -
W
i A
G H
- • I I JTT" 1
DO
CAT
A
N
NE
CLO
TIR
NK(DLC) ,rrw<
Mr
»
G10r1
A,)
»(G401)
VS1
PNK -
PVF
• BLU/RED •
VS2 > K
WHT/GRN 0-
- • - : 1
(•: connector)
2V (G402) (G201) (G351)
EPS CONTROL UNIT CONNECTOR A (2P)
-0-:5V (A: connector)
(53
MOTOR 2P CONNECTOR
dflD
EPS CONTROL UNIT CONNECTOR C (2P)
03
EPS CONTROL UNIT

UTICONNECTOR B (14P) DATA LINK CONNECTOR (DLC)
(O: connector)
I*
T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s
17
EPS Components
'04-08 m o d e l s
AUXILIARY
e BATTERY UNDER-HOOD FUSE/RELAY BOX
No. 33 (70A1A) WHT/RED
UNDER-DASH
FUSE/RELAY BOX
IGNITION SWITCH
C2 WHT /15T\ BLK/YEL B7 No. 5 (7.5 A) YEL •

IG1r 4HOT
o oin4 ON
- i (II)
and START (III)
X
YEL
GAUGE ASSEMBLY
EPS INDICATOR
~@ YEL/BLU
• BLU TACHOMETER
ECM SPEEDOMETER WHT/BLK
@ — BLU -BLU
-EPSLD
BLU/BLK • BLU/BLK
• PNK •
•BLU/RED -
WHT/GRN-
ECM CONNECTOR A (32P) GAUGE ASSEMBLY CONNECTOR A (22P)

('04-05 models) (O: connector)
TORQUE SENSOR 3P CONNECTOR
[D[0Lin[C[BiB^naiIDiBn]l!Sll5il
GAUGE ASSEMBLY CONNECTOR B (30P)

(3I2IT W i r e s i d e of f e m a l e t e r m i n a l s (©: connector)
('06-08 models) M 21 s UI B I e I T L!><!J e I a hohi |12|13|14J
17-28
* ('06-08 models)
- WHT/RED
EPS CONTROL UNIT
P
OW
ER RELAY r*-, +B
tzj = WHT/RED •
I. 5 V REGULATOR -j
IG1
•YEL •
.f 1 *1 *
( I CURRENT 1 A M+ D c n
' SENSOR H E | 1 RED
MOTOR I
FAIL-SAFE RELAY^ G R N - < ^ @ ^ ) J
•o-o-
BLK
WLP
V
' YEL/BLU
• WHT/BLK
" I
NEP C
CAN
AN
1
1-L
- HT •
W E
C
M
• BLU •
WHT/CAN1
- H •V
S
A
GRN
• RAMI
. _ oen —is. I modulator-
| - RED - P - 1 ^ n t r o ,
u n i t
EPSLD
- BLU/BLK •
•o 6 6 6 6 6
14C
DO
(D*
AN9E
TA
N16C
L1O
T 4R
I*K6*(DLC4
N )
• PNK S1<S)_
PVF
• BLU/RED •
VS2 >K
1
S
WHT/GRN -Qv BLK BLK BLK
A- -A-
MOTOR 2P CONNECTOR
- • - : 1 2V
EPS CONTROL UNIT CONNECTOR C (2P)
(G402) (G201) (G351)
EPS CONTROL UNIT CONNECTOR A (2P)
(•: connector)
-0-:5V (A: connector)
ED (HQ 2J 1
T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s
EPS CONTROL UNIT CONNECTOR B (14P) DATA LINK CONNECTOR (DLC) DATA LINK CONNECTOR (DLC)
(O: connector) ('04-05 models) ('06-08 models)
ilM/l4|5|6|7H
V14M3M27
T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of f e m a l e t e r m i n a l s
17
EPS Components
DTC Troubleshooting
DTC 1: Power Relay Stuck ON DTC 3: Lower FET Stuck ON
DTC 2: Fail-safe Relay Stuck ON 1. D i s c o n n e c t E P S c o n t r o l unit c o n n e c t o r A (2P) a n d

the motor 2P connector.
2. C h e c k for continuity b e t w e e n E P S control unit
2. C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20). c o n n e c t o r A (2P) t e r m i n a l N o . 2 a n d m o t o r 2 P
c o n n e c t o r t e r m i n a l N o . 1.
4. W a i t at l e a s t 10 s e c o n d s .
E P S C O N T R O L UNIT
MOTOR 2P C O N N E C T O R C O N N E C T O R A (2P)
Does the EPS indicator come on and is DTC 1 or
DTC 2 indicated?
MOTOR-T-
Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s . MOTOR+
IRED)
If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S c o n t r o l (RED)
unit a n d r e c h e c k . •
N O — T h e s y s t e m is O K at t h i s t i m e . •
N O — R e p a i r o p e n in the w i r e b e t w e e n E P S control
unit a n d t h e motor. •
3. C h e c k for continuity b e t w e e n t h e E P S control unit

c o n n e c t o r A (2P) t e r m i n a l N o . 1 a n d m o t o r 2 P
M O T O R 2P C O N N E C T O R C O N N E C T O R A (2P)
MOTOR-
(GRN)
MOTOR-
(GRN)
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e E P S
control unit a n d t h e motor. •
17-30
4 . C h e c k f o r continuity b e t w e e n E P S c o n t r o l unit DTC 4: Upper FET Stuck ON
c o n n e c t o r A (2P) t e r m i n a l s N o . 2 a n d N o . 1.
1. D i s c o n n e c t E P S c o n t r o l unit c o n n e c t o r C (2P).
E P S CONTROL UNIT 2. C h e c k for c o n t i n u i t y b e t w e e n E P S c o n t r o l unit

C O N N E C T O R A (2P) c o n n e c t o r C (2P) t e r m i n a l N o . 1 a n d b o d y g r o u n d .
MOTOR+ r MOTOR- E P S C O N T R O L U N I T C O N N E C T O R C (2P)

(RED) (GRN)
P G (BLK)
Y E S — R e p a i r short between the R E D and G R N
w i r e s f o r t h e E P S m o t o r circuit. •
N O — R e p l a c e t h e s t e e r i n g g e a r b o x ( S h o r t c i r c u i t to
body ground inside the gearbox). • Y E S — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s .
If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S c o n t r o l
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E P S
c o n t r o l unit a n d t h e b o d y g r o u n d ( G 3 5 1 ) . •
17-31
EPS Components
DTC 5: Open in the Motor Circuit 8. M e a s u r e t h e v o l t a g e b e t w e e n E P S control unit

c o n n e c t o r C (2P) t e r m i n a l No. 2 a n d b o d y g r o u n d .
2. C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20).
E P S C O N T R O L U N I T C O N N E C T O R C (2P)
4. T u r n t h e s t e e r i n g w h e e l to right or left, a n d w a i t
10 s e c o n d s or m o r e . (WHT/RED) f ~ ' /
Does the EPS indicator come on?
T e r m i n a l s i d e of f e m a l e terminals
N O — C h e c k for l o o s e t e r m i n a l s or p o o r c o n n e c t i o n s .
If the c o n n e c t i o n s a r e g o o d , t h e s y s t e m is O K at
this time. • Is there battery voltage?
5. S t o p the e n g i n e , a n d c h e c k for D T C s w i t h the H D S . Y E S — G o t o s t e p 9.
Is DTC 5 indicated? N O — R e p a i r o p e n in the w i r e b e t w e e n t h e N o . 3 3

(70 A) f u s e in t h e a u x i l i a r y u n d e r - h o o d f u s e / r e l a y
Y E S — G o to s t e p 6. b o x a n d t h e E P S control u n i t . B
N O — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e 9. C h e c k for continuity b e t w e e n E P S control unit

code i n d i c a t e d . ! c o n n e c t o r C (2P) t e r m i n a l N o . 1 a n d b o d y g r o u n d .
6. C h e c k the No; 3 3 (70 A ) f u s e in the a u x i l i a r y u n d e r - E P S C O N T R O L U N I T C O N N E C T O R C (2P)

h o o d f u s e / r e l a y b o x , a n d reinstall the f u s e if it is O K .
Is the fuse OK?
N O — R e p l a c e the f u s e a n d r e c h e c k . •
7. M a k e s u r e t h e ignition s w i t c h is in L O C K (0), t h e n
d i s c o n n e c t E P S control unit c o n n e c t o r C (2P).
N O — R e p a i r o p e n in the w i r e b e t w e e n the E P S
control unit a n d b o d y g r o u n d ( G 3 5 1 ) . B
10. D i s c o n n e c t E P S control unit c o n n e c t o r A (2P) a n d

the motor 2 P c o n n e c t o r .
17-32
11. C h e c k f o r continuity b e t w e e n E P S co n tro l unit 13. C h e c k f o r c o n t i n u i t y b e t w e e n E P S contr o l unit
c o n n e c t o r A (2P) t e r m i n a l N o . 2 a n d m o t o r 2 P c o n n e c t o r A (2P) t e r m i n a l N o . 1 a n d b o d y g r o u n d .
EPS CONTROL UNIT

CONNECTOR A (2P)
EPS CONTROL UNIT
MOTOR 2 P CONNECTOR CONNECTOR A (2P)
c \ r V 2 1J MOTOR-
(GRN)
2 1
J MOTOR+ t 2 1
v (RED)
MOTOR+
(RED)
Y E S — G o to s t e p 12. b e t w e e n t h e E P S control unit a n d t h e m o t o r . •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n E P S control N O — G o to s t e p 14.
unit a n d t h e motor. •
14. C h e c k f o r continuity b e t w e e n E P S c o n t r o l unit
12. C h e c k f o r continuity b e t w e e n t h e E P S co ntrol unit c o n n e c t o r A (2P) t e r m i n a l N o . 2 a n d b o d y g r o u n d .
c o n n e c t o r A (2P) t e r m i n a l N o . 1 a n d m o t o r 2 P
connector terminal No. 2.
EPS CONTROL UNIT
CONNECTOR A (2P)
MOTOR 2 P CONNECTOR
EPS CONTROL UNIT
CONNECTOR A (2P)
fLT T1l lJ MOTOR-

MOTOR+
(RED)
(33
E D (GRN)
MOTOR-
(GRN)
Is there continuity? Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e
b e t w e e n t h e E P S control unit a n d t h e m o t o r . •
N O — C h e c k f o r l o o s e E P S control unit c o n n e c t o r s . If
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e E P S n e c e s s a r y , substitute a k n o w n - g o o d E P S control
c o n t r o l unit a n d t h e m o t o r . • unit a n d r e c h e c k . •
17-33
EPS Components
DTC 11,13: Torque Sensor 8. C h e c k for continuity b e t w e e n t h e a p p r o p r i a t e
t o r q u e s e n s o r 3 P c o n n e c t o r t e r m i n a l arid b o d y
1. T u r n t h e ignition s w i t c h to O N (II). ground (see table).
2. C l e a r the D T C w i t h t h e H D S ( s e e p a g e 17-20). Terminal name Torque sensor terminal No.

VS1 1
3. Start t h e e n g i n e . PVF 2
VS2 3
T O R Q U E S E N S O R 3P
CONNECTOR
VS2
(WHT/GRN) V S 1 (PNK)
N O — C h e c k for l o o s e t e r m i n a l s o r p o o r c o n n e c t i o n s .
If t h e c o n n e c t i o n s a r e g o o d , t h e s y s t e m i s O K at
3 2
this time. • PVF
(BLU/RED)
4. S t o p t h e e n g i n e , a n d c h e c k for D T C s w i t h t h e H D S .
Is DTC 11 or 13 indicated?
Y E S — G o to s t e p 5. T e r m i n a l side of female terminals
N O — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g for the Is there continuity?

code indicated. •
Y E S — R e p a i r s h o r t to b o d y g r o u n d in the
5. M a k e s u r e t h e ignition s w i t c h is in L O C K (0), t h e n a p p r o p r i a t e s e n s o r circuit b e t w e e n the t o r q u e
d i s c o n n e c t E P S control unit c o n n e c t o r B (14P). s e n s o r a n d the E P S control u n i t . B
6. C h e c k for continuity b e t w e e n E P S c o n t r o l unit N O — G o to s t e p 9.

c o n n e c t o r B (14P) t e r m i n a l N o . 3 a n d b o d y g r o u n d .
9. O n t h e s e n s o r s i d e , c h e c k for continuity between
the torque s e n s o r 3P connector terminal No. 2 a n d
EPS CONTROL UNIT
body ground.
C O N N E C T O R B (14P)
TORQUE SENSOR 3P
CONNECTOR
V S 1 (PNK)
11
V34I13 V
T e r m i n a l side of f e m a l e t e r m i n a l s
Terminal side of male terminals
Y E S — R e p l a c e the t o r q u e s e n s o r . •
N O — T h e E P S s y s t e m is O K at t h i s t i m e . C h e c k for
7. D i s c o n n e c t t h e t o r q u e s e n s o r 3 P c o n n e c t o r . l o o s e E P S control unit c o n n e c t o r s . If n e c e s s a r y ,
s u b s t i t u t e a k n o w n - g o o d E P S c ontr o l unit a n d
recheck.1
17-34
10. C h e c k f o r continuity b e t w e e n the a p p r o p r i a t e E P S DTC 12: Torque Sensor PVF
control unit c o n n e c t o r B (14P) a n d t o r q u e s e n s o r 3 P
connector terminals (see table). 1. T u r n t h e ignition s w i t c h to O N (II).
Terminal Torque E P S control 2. C l e a r the D T C w i t h the H D S ( s e e p a g e 17-20).

name sensor unit
terminal No. terminal No. 3. S t a r t the e n g i n e .
VS1 1 3
PVF 2 7 4. W a i t at l e a s t 10 s e c o n d s .
VS2 3 11
E P S C O N T R O L UNIT TORQUE SENSOR3P
C O N N E C T O R B (14P) CONNECTOR
V S 1 (PNK)
f3 2 N O — C h e c k for l o o s e t e r m i n a l s or p o o r c o n n e c t i o n s .
7 (3 5 4
1 1 ,/ If t h e c o n n e c t i o n s a r e g o o d , t h e s y s t e m is O K at
/ 8
,1/1 O VS2 this t i m e . B
1Qh (WHT/GRN)
PVF (BLU/RED)

Is DTC 12 indicated?
Is there continuity? Y E S — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s .

If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S control
Y E S — G o t o s t e p 11. unit a n d r e c h e c k . •
N O — R e p a i r o p e n in t h e a p p r o p r i a t e t o r q u e s e n s o r N O — D o the appropriate troubleshooting for the

circuit b e t w e e n t h e E P S control unit a n d t h e t o r q u e code indicated. •
sensor. •
11. D i s c o n n e c t t h e t o r q u e s e n s o r c o n n e c t o r .
12. O n t h e s e n s o r s i d e , c h e c k for r e s i s t a n c e b e t w e e n
torque s e n s o r 3P connector terminals No. 1 and
N o . 2 , a n d b e t w e e n t e r m i n a l s N o . 2 a n d N o . 3.
T
O
C
OR
Q
N
NU
E
E
CT
OSENSOR 3P
R
— @ —
Is the resistance between 12— 14 0, (at 68 °F,

20 °C)?
Y E S — T h e E P S s y s t e m is O K at t h i s t i m e . C h e c k for
l o o s e E P S control unit c o n n e c t o r s . If n e c e s s a r y ,
substitute a k n o w n - g o o d E P S control unit a n d
recheck. •
N O — R e p l a c e the torque s e n s o r . •
17-35
EPS Components
DTC 14: Torque Sensor (Resistance) 8. C h e c k for continuity b e t w e e n t o r q u e s e n s o r 3 P
2 . C l e a r the D T C w i t h t h e H D S ( s e e p a g e 17-20). CONNECTOR
VS2
(WHT/GRN)
4. T u r n the s t e e r i n g w h e e l fully to t h e left, a n d h o l d it
in t h a t p o s i t i o n for 10 s e c o n d s or m o r e .

PVF
(BLU/RED)
If t h e c o n n e c t i o n s a r e g o o d , t h e s y s t e m i s O K at
this t i m e . B Is there continuity?
5. S t o p t h e e n g i n e , a n d c h e c k for D T C s w i t h t h e H D S . Y E S — R e p a i r short between the W H T / G R N and

B L U / R E D w i r e s in t h e t o r q u e s e n s o r circuit b e t w e e n
Is DTC 14 indicated? the t o r q u e s e n s o r a n d the E P S control u n i t . B
N O — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g for the 9. C h e c k for continuity b e t w e e n t o r q u e s e n s o r 3 P

code indicated. B c o n n e c t o r t e r m i n a l s N o . 1 a n d N o . 3.
6. M a k e s u r e t h e ignition s w i t c h i s in L O C K (0), t h e n T O R Q U E S E N S O R 3P
CONNECTOR
disconnect the torque s e n s o r 3P connector and E P S
c o n t r o l unit c o n n e c t o r B (14P).
7. C h e c k f o r c o n t i n u i t y b e t w e e n t o r q u e s e n s o r 3 P
CONNECTOR
VS2 V S 1 (PNK)
(WHT/GRN)
PVF | @ "
(BLU/RED)
3 21 V S 1 (PNK) Is there continuity?
Y E S — R e p a i r s h o r t b e t w e e n the W H T / G R N a n d P N K
w i r e s in the t o r q u e s e n s o r circuit b e t w e e n t h e
t o r q u e s e n s o r a n d t h e E P S control u n i t . B
Is there continuity? N O — G o to s t e p 10.
Y E S — R e p a i r short between the B L U / R E D and PNK

w i r e s in t h e t o r q u e s e n s o r circuit b e t w e e n t h e
torque s e n s o r a n d the E P S control unit.B
17-36
10. O n the s e n s o r s i d e , c h e c k for r e s i s t a n c e b e t w e e n DTC 21: Voltage for IG1
t h e t o r q u e s e n s o r 3 P c o n n e c t o r t e r m i n a l s No. 1 a n d
No. 2 , a n d b e t w e e n t e r m i n a l s No. 2 a n d N o . 3. 1. C h e c k t h e No. 5 (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e /
T
O R
Q U
ES EN
SOR 3P
r e l a y b o x , a n d reinstall t h e f u s e if it is O K .
CONNE
CTO
R
N O T E : All indicators except the charging s y s t e m

i n d i c a t o r will not c o m e o n w h e n t h e No. 5 (7.5 A )
f u s e is b l o w n .
Is the fuse OK?

N O — R e p l a c e the fuse and recheck. •
Is the resistance between 12— 14 Q (at 68 °F, 2. D i s c o n n e c t E P S control unit c o n n e c t o r B (14P).

20 °C)?
3. T u r n t h e ignition s w i t c h t o O N (II).
4. M e a s u r e the v o l t a g e b e t w e e n E P S control unit
N O — R e p l a c e the torque sensor. • c o n n e c t o r B (14P) t e r m i n a l N o . 1 a n d b o d y g r o u n d .
11. C h e c k for continuity b e t w e e n t h e a p p r o p r i a t e E P S

E P S CONTROL UNIT
control unit c o n n e c t o r B (14P) a n d t o r q u e s e n s o r 3 P
connector terminals (see table).
IG1IYEL)
Terminal Torque E P S control
name sensor unit
323ZE
terminal No. terminal No.
VS1
PVF
1
2
3
7
114113 V
VS2 3 11
EPS CONTROL UNIT TORQUESENSOR3P T e r m i n a l s i d e of f e m a l e t e r m i n a l s

CONNECTOR B (14P) CONNECTOR
VS1 (PNK)
f3 Is there battery voltage?

7 6 5 4
11 / / 8
Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s .
V]4|13|12>/ VS2
If n e c e s s a r y , substitute a k n o w n - g o o d E P S control
(WHT/GRN)
PVF (BLU/RED)
N O — C h e c k for a n o p e n in the w i r e b e t w e e n t h e
u n d e r - d a s h f u s e / r e l a y b o x a n d t h e E P S control unit,
a n d repair it if n e c e s s a r y . If t h e w i r e is O K , c h e c k
Is there continuity? for a n o p e n circuit i n s i d e the u n d e r - d a s h f u s e / r e l a y
box. •
Y E S — T h e E P S s y s t e m is O K at this t i m e . C h e c k for
l o o s e E P S control unit c o n n e c t o r s . If n e c e s s a r y ,
substitute a k n o w n - g o o d E P S control unit a n d
recheck. •
N O — R e p a i r o p e n in the a p p r o p r i a t e t o r q u e s e n s o r
circuit b e t w e e n the E P S control unit a n d t h e t o r q u e
sensor. •
17-37
EPS Components
DTC 22: Vehicle Speed Signal DTC 23: Engine Speed Signal Circuit
NOTE: N O T E : If the M I L indicator is o n , t r o u b l e s h o o t the

• If the M I L indicator is O N , t r o u b l e s h o o t t h e P G M - F I P G M - F I p r o b l e m first.
s y s t e m first.
• W h e n t h e e n g i n e is r u n n i n g at 2,000 r p m or a b o v e 1. S t a r t the e n g i n e , a n d c h e c k the t a c h o m e t e r .
a n d the v e h i c l e s p e e d is 1 m p h (1 k m / h ) or b e l o w for
3 m i n u t e s , t h e E P S indicator c o m e s o n . Is the tachometer working correctly?
1. T e s t - d r i v e t h e v e h i c l e . Y E S — G o to s t e p 2.
Is the vehicle speedometer working correctly? N O — G o to s t e p 5.
Y E S — G o to s t e p 2. 2. C o n n e c t a c o m m e r c i a l l y a v a i l a b l e s p r i n g s c a l e to
the s t e e r i n g w h e e l .
N O — D o the s p e e d o m e t e r s y s t e m
t r o u b l e s h o o t i n g : '00-05 m o d e l s ( s e e p a g e 22-94), 3. Pull o n the s c a l e to m e a s u r e w h e n t h e front w h e e l s
' 0 6 - 0 8 m o d e l s ( s e e p a g e 22-95). • start to m o v e . If the s y s t e m is in g o o d c o n d i t i o n ,
t h e s c a l e s h o u l d r e a d no m o r e t h a n 3 4 N (3.5 kgf,
2. T u r n the ignition s w i t c h to L O C K (0). 7.7 Ibf).
3. B l o c k the front w h e e l s a n d r e l e a s e the parking

brake.
4. R a i s e the v e h i c l e , a n d s u p p o r t it w i t h s a f e t y s t a n d s
in the p r o p e r l o c a t i o n s ( s e e p a g e 1-18).
5. D i s c o n n e c t E P S control unit c o n n e c t o r B (14P).
6. B l o c k the right rear w h e e l , a n d s l o w l y rotate the left

rear w h e e l and m e a s u r e the voltage between E P S
control unit c o n n e c t o r B (14P) t e r m i n a l N o . 2 a n d
body ground.
EPS CONTROL UNIT Is the measurement within the specification?

CONNECTOR B (14P)
Y E S — T h e s y s t e m is O K at t h i s t i m e . B
VSP
(WHT/BLK)
f3 N O — G o to s t e p 4.
7 i3 5 4
,1/1 1 3 1 4. T e s t - d r i v e the v e h i c l e w i t h the v e h i c l e a b o v e

6.2 m p h (10 k m / h ) .
Terminal side of female terminals Does EPS provide power assist?
Does the voltage pulse 0 V and 5V?
N O — D o the t r o u b l e s h o o t i n g for D T C 2 2 . •
Y E S — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s .
If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S control 5. T u r n the ignition s w i t c h to L O C K (0).
N O — R e p a i r o p e n or s h o r t to b o d y g r o u n d in the
w i r e b e t w e e n the E P S control unit a n d b o d y g r o u n d , 7. S t a r t the e n g i n e .
or faulty s p e e d o m e t e r . •
17-38
8. M e a s u r e the v o l t a g e b e t w e e n E P S control unit 10. D i s c o n n e c t E C M c o n n e c t o r A (32P) ('00-05 m o d e l s )
c o n n e c t o r B (14P) t e r m i n a l N o . 5 a n d b o d y g r o u n d . or E C M c o n n e c t o r E (31P) ('06-08 m o d e l s ) .
E P S CONTROL UNIT 11. C h e c k for c o n t i n u i t y b e t w e e n E C M c o n n e c t o r A

CONNECTOR B (14P) (32P) t e r m i n a l A 1 9 ('00-05 m o d e l s ) o r E C M
c o n n e c t o r E (31P) t e r m i n a l E 2 5 ('06-08 m o d e l s ) a n d
E P S control unit c o n n e c t o r B (14P) c o n n e c t o r
t e r m i n a l N o . 5.
NEP (BLU)
11 '00-05 m o d e l s
Ui[13 v
E P S CONTROL UNIT
E C M CONNECTOR A (32P)
CONNECTOR B (14P)
NEP(BLU) NEP (BLU)

/ / / 6 / / 9 10 9\
p
Is there about 3to6V? 1 2
12 13 / 15 16 17 18 1S 2C 21 / / 16 5 4
Y E S — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s . 25 26 27 28
/ '30 31 M 11/ / 8
If n e c e s s a r y , substitute a k n o w n - g o o d E P S control 113 V
unit a n d r e c h e c k . • Wire side of f e m a l e terminals
female terminals
9. T u r n the ignition s w i t c h to L O C K (0). '06-08 m o d e l s
E C M CONNECTOR E (31P) E P S CONTROL UNIT

CONNECTOR B (14P)
NEP (BLU)
1 M 3 | 4 | 5 I8T9
/ 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 27 28 29 30 11I/V18
/
NEP (BLU) / VJ4|13 v
Wire side of female terminals female terminals
YES-Gotostep12.
N O — R e p a i r t h e o p e n in the w i r e b e t w e e n t h e E P S
control unit a n d the E C M . H
(cont'd)
17-39
EPS Components
12. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r C (20P)
('00-03 m o d e l s ) or B (30P) ('04-08 m o d e l s ) .
13. C h e c k for c o n t i n u i t y b e t w e e n E P S control unit

c o n n e c t o r B (14P) t e r m i n a l N o . 5 a n d b o d y g r o u n d .
Y E S — R e p a i r t h e s h o r t in the w i r e b e t w e e n t h e E P S
control unit a n d the E C M . H
N O — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s . If
n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S control
17-40
DTC 30: Submicrocomputer DTC 31,32,33: Motor Current Sensor
1. T u r n t h e ignition s w i t c h to O N (II). 1. T u r n t h e ignition s w i t c h to O N (II).
2. C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20). 2. C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20).
3. S t a r t t h e e n g i n e . 3. S t a r t t h e e n g i n e .
4. W a i t at l e a s t 10 s e c o n d s . 4. W a i t at l e a s t 10 s e c o n d s .
Does the EPS indicator come on? Does the EPS indicator come on?
Y E S — G o to s t e p 5. Y E S — G o to s t e p 5.
N O — C h e c k for l o o s e t e r m i n a l s or p o o r c o n n e c t i o n s . N O — C h e c k for l o o s e t e r m i n a l s o r p o o r c o n n e c t i o n s .
If t h e c o n n e c t i o n s a r e g o o d , the s y s t e m is O K at If t h e c o n n e c t i o n s a r e g o o d , the s y s t e m i s O K at
this t i m e . B this time. •
5. C h e c k for D T C s w i t h t h e H D S . 5. C h e c k for D T C s w i t h t h e H D S .
Is DTC 30 indicated? Is DTC 31,32, or 33 indicated?
Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s . Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s .

If n e c e s s a r y , substitute a k n o w n - g o o d E P S control If n e c e s s a r y , substitute a k n o w n - g o o d E P S control
unit a n d r e c h e c k . • unit a n d r e c h e c k . •
N O — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e N O — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e

code indicated.• code indicated. •
17-41
EPS Components
DTC 34,35: EPS Control Unit Internal Circuit DTC 36: Incorrect Motor Voltage
2 . C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20). 2. C l e a r t h e D T C w i t h t h e H D S ( s e e p a g e 17-20).
3. Start the engine. 3. S t a r t t h e e n g i n e .
4. W a i t at l e a s t 10 s e c o n d s . 4. T u r n t h e s t e e r i n g w h e e l to right or left, a n d w a i t
10 s e c o n d s or m o r e .
If t h e c o n n e c t i o n s a r e g o o d , t h e s y s t e m is O K at N O — C h e c k for l o o s e t e r m i n a l s or p o o r c o n n e c t i o n s .
this t i m e . B If t h e c o n n e c t i o n s a r e g o o d , t h e s y s t e m is O K at
this time. •
5. S t o p t h e e n g i n e , a n d c h e c k for D T C s w i t h the H D S .
Y E S — C h e c k for l o o s e E P S c o n t r o l unit c o n n e c t o r s .
If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d E P S control Y E S — G o to s t e p 6.
N O — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e
N O — D o the a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e code indicated. •
code indicated. •
6. C h e c k t h e N o . 3 3 (70 A ) f u s e in t h e a u x i l i a r y u n d e r -
h o o d f u s e / r e l a y b o x , a n d reinstall the f u s e if it is O K .
Is the fuse OK?
N O — R e p l a c e the f u s e a n d recheck. •
7. D i s c o n n e c t E P S control unit c o n n e c t o r C (2P).
17-42
8. M e a s u r e t h e v o l t a g e b e t w e e n E P S control unit DTC 37: No Motor Voltage
c o n n e c t o r C (2P) t e r m i n a l N o . 2 a n d b o d y g r o u n d .
1. C h e c k t h e No. 3 3 (70 A ) f u s e in t h e a u x i l i a r y u n d e r -
E P S C O N T R O L U N I T C O N N E C T O R C (2P) h o o d f u s e / r e l a y b o x , a n d reinstall t h e f u s e if it is O K .
Is the fuse OK?
N O — R e p l a c e the f u s e a n d r e c h e c k . •
2. C h e c k for continuity b e t w e e n E P S c o n t r o l unit

c o n n e c t o r C (2P) t e r m i n a l N o . 1 a n d b o d y g r o u n d .
T e r m i n a l s i d e of f e m a l e t e r m i n a l s E P S C O N T R O L U N I T C O N N E C T O R C (2P)

N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e No. 3 3
(70 A ) f u s e in t h e a u x i l i a r y u n d e r - h o o d f u s e / r e l a y
b o x a n d t h e E P S control unit. • T e r m i n a l s i d e of f e m a l e t e r m i n a l s
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the E P S
control unit a n d b o d y g r o u n d ( G 3 5 1 ) . B
3. D i s c o n n e c t E P S c o n t r o l unit c o n n e c t o r A (2P) a n d
t h e motor 2 P c o n n e c t o r .
(cont'd)
17-43
EPS Components
4. C h e c k for continuity b e t w e e n E P S control unit 6. C h e c k for continuity b e t w e e n E P S control unit

c o n n e c t o r A (2P) t e r m i n a l No. 2 a n d m o t o r 2 P c o n n e c t o r A (2P) t e r m i n a l No. 1 a n d b o d y g r o u n d .
C O N N E C T O R A (2P)
EPS CONTROL UNIT
M O T O R 2P C O N N E C T O R C O N N E C T O R A (2P)
r \
2 1 MOTOR-
J (GRN)
MOTOR+
(RED)
G
MOTOR+
(RED)
Y E S — R e p a i r s h o r t to b o d y g r o u n d in the G R N w i r e
Y E S — G o to s t e p 5. b e t w e e n t h e E P S control unit a n d the motor. •
N O — R e p a i r o p e n in the R E D w i r e b e t w e e n t h e E P S N O — G o to s t e p 7.
control unit a n d t h e m o t o r . •
5. C h e c k for continuity b e t w e e n E P S control unit c o n n e c t o r A (2P) t e r m i n a l N o . 2 a n d b o d y g r o u n d .
c o n n e c t o r A <2P) t e r m i n a l N o . 1 a n d m o t o r 2 P
EPS C O N T R O L UNIT
C O N N E C T O R A (2P)
M O T O R 2P C O N N E C T O R C O N N E C T O R A (2P) MOTOR+ r~r
(RED) | 1 2
MOTOR-
G (GRN)
MOTOR-
(GRN)
Is there continuity? Y E S — R e p a i r s h o r t to b o d y g r o u n d in the R E D w i r e

b e t w e e n t h e E P S control unit a n d t h e motor. •
N O — C h e c k for l o o s e E P S control unit c o n n e c t o r s . If
N O — R e p a i r o p e n in t h e G R N w i r e b e t w e e n t h e E P S n e c e s s a r y , substitute a k n o w n - g o o d E P S control
control unit a n d t h e m o t o r . • unit a n d r e c h e c k . •
17-44
S y m p t o m Troubleshooting
DTC 50 to 62: Central Processing Unit (CPU) EPS indicator does not come on/EPS
indicator does not go off, and no DTCs are
1. T u r n the ignition s w i t c h to O N (II). stored
2. C l e a r t h e D T C w i t h the H D S ( s e e p a g e 17-20). 1. T u r n t h e ignition s w i t c h to O N (II), start t h e e n g i n e ,

a n d w a t c h the E P S indicator.
4. W a i t at least 10 s e c o n d s .
Y E S — I f the E P S indicator c o m e s o n a n d g o e s off, it's
Does the EPS indicator come on? O K . If t h e E P S indicator s t a y s o n or blinks, g o to
s t e p 13.
N O — C h e c k for l o o s e t e r m i n a l s or poor c o n n e c t i o n s .
If t h e c o n n e c t i o n s a r e g o o d , the s y s t e m is O K at 2. T u r n t h e ignition s w i t c h to L O C K (0), t h e n O N (II)
this time. • a g a i n , a n d w a t c h the brake s y s t e m indicator.
5. C h e c k for D T C s w i t h the H D S . Does the brake system indicator come on?
Is DTC 50 to 62 indicated? Y E S — G o to s t e p 3.
Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s . N O — R e p a i r o p e n in the indicator p o w e r s o u r c e

If n e c e s s a r y , substitute a k n o w n - g o o d E P S control circuit: •
• B l o w n N o . 5 (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e /
N O — D o the appropriate t r o u b l e s h o o t i n g for the relay box.
code indicated. • • O p e n in t h e w i r e b e t w e e n t h e No. 5 (7.5 A ) f u s e
and gauge assembly.
• O p e n circuit i n s i d e the u n d e r - d a s h f u s e / r e l a y box.
4. C h e c k the E P S indicator bulb in the g a u g e

assembly.
Is the bulb OK?
N O — R e p l a c e the E P S indicator b u l b . H
(cont'd)
17-45
EPS Components
Symptom Troubleshooting (cont'd)
6. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r A (14P) 11. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d E P S
t e r m i n a l N o . 14 ('00-03 m o d e l s ) or t h e g a u g e c o n t r o l unit c o n n e c t o r B (14P) t e r m i n a l s No. 4 a n d
a s s e m b l y c o n n e c t o r B (30P) t e r m i n a l N o . 21 No. 6 i n d i v i d u a l l y .
('04-08 m o d e l s ) to b o d y g r o u n d w i t h a j u m p e r w i r e .
'00-03 models E P S C O N T R O L UNIT

GAUGE ASSEMBLY CONNECTOR A (14P)
1 // 4 5 6
7 8 9 10M11 14
//
JUMPER WIRE WLP (YEL/BLU) GND1 (BLK) G N D 2 (BLK)
'04-08 models
V34|13l12y
/ 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22IXI23 24 25 26 27 28 29 30
JUMPER WIRE WLP (YEL/BLU)
Does the EPS indicator come on ? Y E S — G o to s t e p 12.
Y E S — G o to s t e p 7. N O — R e p a i r o p e n in t h e w i r e s b e t w e e n t h e E P S
control unit a n d ^ o d y g r o u n d (G201 a n d G 4 0 2 ) , B
N O — R e p l a c e t h e bulb circuit b o a r d in t h e g a u g e
assembly. • 12. M e a s u r e t h e v o l t a g e b e t w e e n E P S c o n t r o l unit
c o n n e c t o r B (14P) t e r m i n a l No. 1 a n d b o d y g r o u n d .
8. D i s c o n n e c t E P S control unit c o n n e c t o r B (14P). C O N N E C T O R B (14P)
cm
IG1 ( Y E L )
10. C o n n e c t E P S control unit c o n n e c t o r B (14P)

T
t e r m i n a l N o . 12 a n d b o d y g r o u n d w i t h a j u m p e r
11M/18
wire.
114113 V
EPS CONTROL UNIT
CONNECTOR B (14P)
in. T e r m i n a l s i d e of f e m a l e t e r m i n a l s
f 3 2 \\
7 (3 5 4 WLP
11/ '/
VJ4|13|1#
(YEL/BLU) Is there battery voltage?
JUMPER
WIRE Y E S — C h e c k for l o o s e E P S control unit c o n n e c t o r s .
Does the EPS indicator come on? (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e E P S control u n i t . B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e
a s s e m b l y a n d t h e E P S control u n i t . B
17-46
13. T u r n the ignition s w i t c h to L O C K (0). 19. M e a s u r e t h e v o l t a g e b e t w e e n data link c o n n e c t o r
(DLC) terminal No. 9 and body ground.
15. D i s c o n n e c t the c o n n e c t o r s f r o m the t h e s e units.
• E C M c o n n e c t o r A (32P) ('00-05 m o d e l s ) or E C M
c o n n e c t o r E (31P) ('06-08 m o d e l s ) 1_ZZ_1 5
6I7
• A B S m o d u l a t o r - c o n t r o l unit ('00-05 m o d e l s ) or
V S A m o d u l a t o r - c o n t r o l unit ('06-08 m o d e l s ) S C S (BRN)
• S R S unit

EPS CONTROL UNIT
Is there about 6 V?
YES-Gotostep20.
71615, S C S (BRN)
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e d a t a link
c o n n e c t o r ( D L C ) a n d the E P S control u n i t . B
VJ4113 V
2 1 . C o n n e c t all d i s c o n n e c t e d c o n n e c t o r s .
2 2 . D i s c o n n e c t E P S control unit c o n n e c t o r B (14P).

2 3 . T u r n the ignition s w i t c h to O N (II), a n d start t h e
Y E S — R e p a i r s h o r t to b o d y g r o u n d in the S C S engine.
circuit. •
Does the EPS indicator go off?
IMO—Go to s t e p 17.
17. C o n n e c t E P S control unit c o n n e c t o r B (14P).
N O — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e
18. T u r n the ignition s w i t c h to O N (II). b e t w e e n t h e E P S indicator a n d the E P S c o n t r o l
unit.B
24. I n s p e c t the bulb circuit b o a r d in the g a u g e

a s s e m b l y , p o w e r a n d g r o u n d to the E P S unit, a n d
t e r m i n a l fit ' 0 0 - 0 3 m o d e l s ; ( s e e p a g e 22-63),
'04-05 m o d e l s ; ( s e e p a g e 2 2 - 6 8 ) , '06-08 m o d e l s ;
( s e e p a g e 22-73).
Is it normal?

If n e c e s s a r y , substitute a k n o w n - g o o d E P S c o n t r o l
unit a n d r e c h e c k . B
N O — R e p l a c e t h e bulb circuit b o a r d in t h e g a u g e
assembly. B
17-47
EPS Components
Memorizing the Torque Sensor Neutral Position
T h e t o r q u e s e n s o r neutral p o s i t i o n m u s t b e m e m o r i z e d 10. W i t h i n 4 s e c o n d s after the E P S indicator c o m e s o n ,
w h e n e v e r t h e g e a r b o x is r e m o v e d o r i n s t a l l e d , or w h e n turn t h e s t e e r i n g w h e e l 4 5 d e g r e e s to the left a g a i n
t h e t o r q u e s e n s o r or E P S control unit is r e p l a c e d , a n d a n d hold it in that p o s i t i o n .
after d o i n g w h e e l a l i g n m e n t . N o t e that the t o r q u e T h e E P S indicator g o e s off after 4 s e c o n d s .
s e n s o r neutral position i s not affected w h e n e r a s i n g t h e
DTC. 11. W i t h i n 4 s e c o n d s after t h e E P S indicator g o e s off,
return t h e s t e e r i n g w h e e l to t h e straight a h e a d
1. W i t h t h e ignition s w i t c h in L O C K (0), c o n n e c t t h e driving position a n d release the steering w h e e l . Do
H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d not m o v e t h e s t e e r i n g w h e e l before turning the
u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d . ignition s w i t c h to L O C K (0).
N O T E : If t h e s t e e r i n g w h e e l is m o v e d , t h e torque
s e n s o r neutral p o s i t i o n c a n n o t b e written to
memory.
12. T h e E P S indicator blinks t w i c e 4 s e c o n d s after

r e l e a s i n g t h e s t e e r i n g w h e e l , t h e n it blinks t h r e e
t i m e s 5 s e c o n d s after. T h e n , t h e indicator g o e s off.
T h e t o r q u e s e n s o r neutral p o s i t i o n is m e m o r i z e d .
N O T E : If t h e E P S indicator s t a y s o n , t h e r e w a s a n
e r r o r in w r i t i n g t h e t o r q u e s e n s o r neutral position
to m e m o r y . R e p e a t t h e p r o c e d u r e starting f r o m
s t e p 3.
2. W i t h t h e v e h i c l e o n t h e g r o u n d , s e t the front w h e e l s 13. T u r n t h e ignition s w i t c h to L O C K (0).

in t h e s t r a i g h t a h e a d d r i v i n g p o s i t i o n .
14. D i s c o n n e c t t h e H D S f r o m the D L C .
3. T u r n t h e ignition s w i t c h to O N (II). EPS INDICATOR
4. F o r ' 0 6 - 0 8 m o d e l s ; m a k e s u r e t h e H D S
c o m m u n i c a t e s w i t h t h e v e h i c l e a n d the E P S c o n t r o l
unit. If it d o e s n ' t , t r o u b l e s h o o t t h e D L C circuit
( s e e p a g e 11-367).
6. S h o r t t h e S C S circuit to b o d y g r o u n d u s i n g t h e H D S .
7. T u r n t h e s t e e r i n g w h e e l 4 5 d e g r e e s to t h e left f r o m
t h e straight a h e a d d r i v i n g p o s i t i o n , a n d h o l d t h e
s t e e r i n g w h e e l in that p o s i t i o n .
8. T u r n t h e ignition s w i t c h to O N (II). T h e E P S
i n d i c a t o r c o m e s o n , t h e n it g o e s off after 4 s e c o n d s .
9. W i t h i n 4 s e c o n d s after t h e E P S i n d i c a t o r g o e s off,
return t h e s t e e r i n g w h e e l to t h e s t r a i g h t a h e a d
d r i v i n g position a n d r e l e a s e t h e s t e e r i n g w h e e l .
T h e E P S indicator c o m e s o n a g a i n 4 s e c o n d s after
releasing the steering w h e e l .
17-48
Steering Gearbox Removal and Installation
Special Tools Required 9. U n d e r the d a s h b o a r d ; l o o s e n the joint bolt (A) o n

t h e c o l u m n , a n d pull t h e s t e e r i n g shaft (B) fully to
Ball j o i n t r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2 the c o l u m n side.
Removal
Note t h e s e i t e m s d u r i n g r e m o v a l :
• U s i n g s o l v e n t a n d a b r u s h , w a s h a n y oil a n d dirt off
t h e g e a r b o x . B l o w dry w i t h c o m p r e s s e d air.
• B e s u r e to r e m o v e the s t e e r i n g w h e e l before
d i s c o n n e c t i n g t h e s t e e r i n g joint. D a m a g e to t h e c a b l e
reel c a n o c c u r .
1. M a k e s u r e y o u h a v e the anti-theft c o d e for the
a u d i o , t h e n w r i t e d o w n the a u d i o p r e s e t .
D i s c o n n e c t the n e g a t i v e battery c a b l e f r o m the
battery.
in t h e p r o p e r l o c a t i o n s ( s e e p a g e 1-18).
3. R e m o v e t h e front w h e e l s .
4. R e m o v e t h e d r i v e r ' s a i r b a g ( s e e p a g e 23-164). 10. In the e n g i n e c o m p a r t m e n t ; d i s c o n n e c t the s t e e r i n g

joint (A) a n d pinion s h a f t (B) by m o v i n g t h e s t e e r i n g
5. R e m o v e the s t e e r i n g w h e e l ( s e e p a g e 17-6). joint t o w a r d t h e s t e e r i n g s h a f t (C).
6. F o r '00-07 m o d e l s ; p l a c e a m a r k (A) o n t h e s t e e r i n g
joint (B) a n d the pinion shaft (C) to identify the
position of the joint o n t h e pinion shaft.
7. R e m o v e the l o w e r joint bolt (D) f r o m the s t e e r i n g

joint.
8. L o o s e n the u p p e r joint bolt (E) o n t h e s t e e r i n g joint,

a n d pull the s t e e r i n g joint fully to the s t e e r i n g s h a f t
(F) s i d e .
(cont'd)
17-49
EPS Components
Steering Gearbox Removal and Installation (cont'd)
11. R e m o v e a n d d i s c a r d the cotter pin (A) f r o m the 14. R e m o v e the stabilizer b a r h o l d e r b r a c k e t s (A) f r o m
12 m m nut ( B ) , t h e n r e m o v e the nut. the f r a m e , a n d l o w e r the stabilizer bar (B).
1 2 x 1.25 mm
12x1.25 mm
15. D i s c o n n e c t the g r o u n d c a b l e (A) a n d m o t o r 2 P

07MAC-SL0A202 c o n n e c t o r (B). L o o s e n the h a r n e s s b a n d (C), a n d
r e l e a s e the w i r e h a r n e s s (D) f r o m the g e a r b o x .
12. S e p a r a t e t h e tie-rod ball joint a n d k n u c k l e u s i n g the After d i s c o n n e c t i n g the c o n n e c t o r , put a p i e c e of
ball joint r e m o v e r ( s e e p a g e 18-13). t a p e o v e r the s t e e r i n g g e a r b o x c o n n e c t o r to protect
it f r o m d u s t , dirt, a n d foreign m a t e r i a l s .
13. R e m o v e the s e v e n c l i p s (A) a n d t h e t w o f l a n g e
bolts ( B ) , t h e n r e m o v e t h e s p l a s h s h i e l d (C).
6 x 1.0 mm
B
6 x 1.0 mm
17-50
16. D i s c o n n e c t the t o r q u e s e n s o r 3 P c o n n e c t o r (A). 18. C R m o d e l : R e m o v e the g e a r b o x m o u n t i n g bolts,
After d i s c o n n e c t i n g the c o n n e c t o r , put a p i e c e of s t e e r i n g g e a r b o x front stiffener (A), a n d s t e e r i n g
t a p e o v e r the s t e e r i n g g e a r b o x c o n n e c t o r to protect g e a r b o x r e a r stiffener (B).
it f r o m d u s t , dirt, a n d foreign m a t e r i a l s .
Front side:
10 x 1.25 mm
Rear side:
17. E x c e p t C R m o d e l : R e m o v e the g e a r b o x m o u n t i n g
bolts. 10 x 1.25 mm
6x1.0 mm
Right side: 10x1.25 mm
10x1.25 mm
19. Pull t h e s t e e r i n g g e a r b o x t o w a r d the front. M o v e

t h e s t e e r i n g g e a r b o x to the p a s s e n g e r ' s s i d e a n d
r e m o v e it.
Left s i d e :
(cont'd)
17-51
EPS Components
Steering Gearbox Removal and Installation (cont'd)
Installation 4 . C R m o d e J : Install the g e a r b o x m o u n t i n g b o l t s ,

s t e e r i n g g e a r b o x front stiffener ( A ) , a n d s t e e r i n g
1. B e f o r e installing t h e g e a r b o x , c e n t e r t h e s t e e r i n g g e a r b o x rear stiffener ( B ) .
rack w i t h i n its s t r o k e .
Front side:
2 . P a s s t h e d r i v e r ' s s i d e of t h e s t e e r i n g g e a r b o x
10 x 1.25 m m
t h r o u g h t h e right w h e e l h o u s i n g . P l a c e t h e s t e e r i n g 43 N m
g e a r b o x o n t h e front s u b f r a m e , a n d m o v e it into t h e (4.4 k g f m , 3 2 Ibf ft)
original p o s i t i o n .
Rear side:
10x1.25 mm
43 N-m
(4.4 k g f - m , 3 2 Ibf-ft)
3. E x c e p t C R m o d e l : Install t h e g e a r b o x m o u n t i n g 10 x 1.25 m m 6 x 1.0 m m
43 N-m
bolts. 9.8 N - m
(4.4 k g f m , 3 2 Ibf-ft) (1.0 k g f m ,
7.2 I b f ft)
Right side:
10 x 1.25 mm
43 Nm
(4.4 kgfm, 32 Ibf-ft)
Left s i d e :
10 x 1.25 mm
43 Nm
(4.4 kgfm, 32 Ibf ft)
17-52
5. C o n n e c t t h e torque s e n s o r 3 P c o n n e c t o r (A). 7. R a i s e t h e stabilizer b a r (A) to t h e original p o s i t i o n ,
a n d install t h e stabilizer b a r h o l d e r b r a c k e t s (B).
C o n n e c t t h e motor 2 P c o n n e c t o r (A) a n d g r o u n d
c a b l e (B). S e c u r e t h e w i r e h a r n e s s (C) w i t h t h e
h a r n e s s b a n d (D).
61 Ibf ft)
8. Install t h e s p l a s h s h i e l d (A) w i t h t h e s e v e n c l i p s (B)

a n d t w o f l a n g e bolts (C).
6 x 1.0 m m
9.8 N m
(1.0 k g f m , 7.2 Ibf-ft)
C
6x1.0 mm
9.8 N - m
(1.0 k g f m , 7.2 Ibf-ft)
(cont'd)
17-53
EPS Components
Steering Gearbox Removal and Ins ion (cont'd)
9. W i p e off a n y g r e a s e c o n t a m i n a t i o n f r o m t h e 12. F r o m t h e u n d e r t h e d a s h b o a r d , p u s h t h e s t e e r i n g
t a p e r e d s e c t i o n a n d t h r e a d s of t h e ball joint. T h e n s h a f t (A) fully to e n g i n e c o m p a r t m e n t s i d e , but d o
r e c o n n e c t t h e tie-rod e n d s (A) to t h e s t e e r i n g not p u s h e x c e s s i v e l y o n t h e s t e e r i n g shaft. T h e n
k n u c k l e s ( B ) , a n d tighten t h e 12 m m nut (C) to t h e tighten t h e joint bolt (B) to t h e s p e c i f i e d t o r q u e .
specified torque.
'00 m o d e l
U.S.A. m o d e l s V I N J H M A P 114-YT000001 thru
V I N J H M A P 114-YT008411
C a n a d a m o d e l s V I N J H M A P 114-Y T8 00 00 1
thru
VIN J H M A P 114-YT800750
T o r q u e : 2 2 N m (2.2 k g f m , 16 Ibfft)
Other models:
T o r q u e : 2 9 N m (3.0 k g f - m , 2 2 Ibfft)
10. Install t h e n e w cotter p i n s (D), a n d b e n d t h e m a s

shown.
11. F r o m t h e e n g i n e c o m p a r t m e n t , s l i p t h e l o w e r
e n d (A) of t h e s t e e r i n g joint (B) b y a l i g n i n g t h e
m a r k s (C) o n t h e p i n i o n s h a f t (D) a n d joint.
17-54
13. L i n e up t h e bolt hole (A) w i t h t h e g r o o v e a r o u n d (B) 18. After i n s t a l l a t i o n , d o t h e s e c h e c k s .
the pinion s h a f t , a n d install t h e l o w e r joint bolt (C)
a n d t h e u p p e r joint bolt (D) to t h e s p e c i f i e d t o r q u e . • M a k e s u r e t h e s t e e r i n g g e a r b o x w i r e s a r e not
c a u g h t o r p i n c h e d by a n y p a r t s .
'00 m o d e l • Make sure the steering gearbox connectors are
U . S . A m o d e l s V I N J H M A P 114-YT000001 t h r u properly connected.
V I N J H M A P 114-YT008411 • T u r n t h e ignition s w i t c h to O N (II), a n d c h e c k that
C a n a d a m o d e l s VIN J H M A P 114-YT800001 t h e E P S i n d i c a t o r g o e s off.
thru • D o the t o r q u e s e n s o r m e m o r i z a t i o n .
VIN J H M A P 114-YT800750 • If the s t e e r i n g g e a r b o x is r e p l a c e d , t h e E P S
T o r q u e : 2 2 N-m (2.2 k g f m , 16 I b f ft) control unit m u s t m e m o r i z e t h e t o r q u e s e n s o r
neutral p o s i t i o n ( s e e p a g e 17-48).
Other models: • F o r ' 0 0 - 0 5 m o d e l s ; d o t h e E C M idle l e a r n
T o r q u e : 2 9 N m (3.0 k g f m , 2 2 Ibf ft) p r o c e d u r e ( s e e p a g e 11-140).
• Test-drive the vehicle:
- C h e c k that t h e E P S indicator light d o e s not
come on.
- Check the steering w h e e l spoke angle. Recheck
a n d a d j u s t t h e front w h e e l a l i g n m e n t , if
necessary.
D • E n t e r t h e anti-theft c o d e for the a u d i o , t h e n e n t e r
the a u d i o p r e s e t s .
• For '01-08 m o d e l s ; set the clock.
14. Install t h e s t e e r i n g w h e e l ( s e e p a g e 17-8).
15. Install t h e d r i v e r ' s a i r b a g ( s e e p a g e 23-165).
16. R e c o n n e c t t h e n e g a t iv e battery c a b l e to t h e battery.
17. Install t h e front w h e e l s , a n d a d j u s t t h e front w h e e l

a l i g n m e n t ( s e e p a g e 18-7).
17-55
EPS Components
Steering Gearbox Overhaul
Exploded View
MOUNTING BUSHING
Inspect for d a m a g e a n d GEARBOX BRACKET
deterioration.
8x1.25 mm
25 N m
(2.5 k g f m ,
18 I b f f t ) LOCKNUT
RUBBERSTOP
Inspect for d a m a g e a n d
deterioration. O-RING
Replace. .8x1.25 mm
20 N m
RACK GUIDE SCREW (2.0 k g f - m ,
14 Ibfft)
RACK GUIDE
SPRING
PINION D U S T C O V E R
Inspect for d a m a g e a n d
deterioration.
STEERING GEARBOX A S S E M B L Y (MOTOR)
If t h e g e a r b o x i s f a u l t y , r e p l a c e O-RING
it a s a n a s s e m b l y . Replace.
TORQUE SENSOR ASSEMBLY

If t h e t o r q u e s e n s o r i s f a u l t y ,
r e p l a c e it a s a n a s s e m b l y .
Inspect for d a m a g e a n d TIE-ROD CLIP

deterioration.
17-56
Torque Sensor Replacement Rack Guide Removal/Installation
Note t h e s e i t e m s d u r i n g r e p l a c e m e n t : N O T E : D u r i n g r e m o v a l / i n s t a l l a t i o n , d o not a l l o w d u s t ,
• D o not a l l o w d u s t , dirt, or o t h e r f o r e i g n m a t e r i a l s to dirt, or other f o r e i g n m a t e r i a l s to e n t e r the g e a r b o x .
enter the gearbox.
• D o not try to d i s a s s e m b l e t h e t o r q u e s e n s o r a s s e m b l y . 1. L o o s e n t h e locknut (A), t h e n r e m o v e the rack g u i d e
If t h e t o r q u e s e n s o r is faulty, r e p l a c e it a s a n s c r e w (B), t h e s p r i n g (C), a n d t h e rack g u i d e (D).
assembly.
• If t h e t o r q u e s e n s o r is r e p l a c e d , t h e E P S control unit
m u s t m e m o r i z e t h e t o r q u e s e n s o r neutral position
( s e e p a g e 17-48).
1. C e n t e r the s t e e r i n g rack w i t h i n its s t r o k e .
2. R e m o v e t h e t o r q u e s e n s o r a s s e m b l y (A).
2. A p p l y m u l t i p u r p o s e g r e a s e to t h e s l i d i n g s u r f a c e of
t h e rack g u i d e , a n d install it onto t h e g e a r b o x
housing.
3. C o a t t h e n e w O - r i n g (E) w i t h m u l t i p u r p o s e g r e a s e ,
a n d c a r e f u l l y fit it o n t h e rack g u i d e s c r e w g r o o v e .
4. Install t h e s p r i n g , t h e rack g u i d e s c r e w , a n d the

locknut.
5. A d j u s t t h e rack g u i d e s c r e w ( s e e p a g e 17-14).
After a d j u s t i n g , c h e c k that t h e rack m o v e s
3. C o a t the n e w O - r i n g (B) w i t h m u l t i p u r p o s e g r e a s e , s m o o t h l y by s l i d i n g t h e rack right a n d left.
a n d c a r e f u l l y fit it o n t h e t o r q u e s e n s o r h o u s i n g .
4. A p p l y m u l t i p u r p o s e g r e a s e to the n e e d l e b e a r i n g
(C) in the g e a r b o x h o u s i n g .
5. Install the t o r q u e s e n s o r a s s e m b l y o n t h e g e a r b o x
h o u s i n g by e n g a g i n g t h e g e a r .
T h e a l p h a b e t s t a m p i n g (for e x a m p l e " A B " ) (D) o n
t h e pinion shaft a l i g n s w i t h the rack g u i d e s c r e w (E)
w h e n the rack is in t h e straight a h e a d driving
position.
W h e n installing t h e t o r q u e s e n s o r a s s e m b l y , m a k e
s u r e t h e " a l p h a b e t " s t a m p i n g ( " A B " ) is w i t h i n t h e
range s h o w n .
6. T i g h t e n the 8 m m f l a n g e bolts (F) to t h e s p e c i f i e d

torque.
17-57
EPS Components
Rack End Removal and Installation
Special Tools Required 2. U n b e n d t h e lock w a s h e r .
• Attachment, 32 x 35 m m 07746-0010100
• D r i v e r 07749-0010000
NOTE:
• D o not a l l o w d u s t , dirt, or other f o r e i g n m a t e r i a l s to
e n t e r the g e a r b o x .
• D o not d i s a s s e m b l e t h e s t e e r i n g g e a r b o x a s s e m b l y
(motor). If t h e m o t o r is faulty, r e p l a c e it a s a n
assembly.
Removal
1. R e m o v e the boot b a n d s (A) a n d d i s c a r d t h e m .

R e m o v e t h e tie-rod c l i p s (B), a n d pull t h e b o o t s
a w a y f r o m t h e e n d s of t h e s t e e r i n g g e a r b o x .
3. Hold t h e flat s u r f a c e s e c t i o n s (A) o n t h e p a s s e n g e r ' s
N O T E : After r e m o v i n g t h e boot, c h e c k for w a t e r , s i d e s t e e r i n g rack s h a f t with o n e w r e n c h , a n d
dirt, or other f o r e i g n matter o n t h e ball s c r e w u n s c r e w both rack e n d s (B) w i t h a n o t h e r w r e n c h .
s u r f a c e (C) a n d interior of the boot. If c o n t a m i n a t e d , B e c a r e f u l not to d a m a g e the shaft s u r f a c e w i t h t h e
c l e a n the ball s c r e w , g e a r b o x h o u s i n g , a n d boot w r e n c h . R e m o v e t h e lock w a s h e r s (C) a n d d i s c a r d
completely. them.
Replace.
17-58
4 . C h e c k the r u b b e r s t o p (A) for d a m a g e or Installation
deterioration. If t h e r u b b e r s t o p is d a m a g e d or
deteriorated, r e p l a c e it. 1. Install the n e w lock w a s h e r (A) o n t h e rack s h a f t .
G r a s p the left rack e n d , a n d pull the rack shaft all A l i g n the lock w a s h e r t a b s (B) w i t h t h e s l o t s (C) in
t h e w a y to the left. C a r e f u l l y r e m o v e the r u b b e r t h e rack shaft. Install t h e rack e n d (D) w h i l e holding
s t o p by prying it out of the g e a r b o x h o u s i n g (B) t h e lock w a s h e r in p l a c e . R e p e a t t h i s s t e p for t h e
w i t h a flat tip s c r e w d r i v e r (C) o n the cut-out portion other s i d e of t h e rack shaft.
(D) s o a s not to d a m a g e the h o u s i n g .
5 . If the rubber s t o p w a s r e m o v e d , position a n e w

r u b b e r s t o p (A) in the g e a r b o x h o u s i n g , t h e n d r i v e 2 . Hold the flat s u r f a c e s e c t i o n s (E) o n the s t e e r i n g
it in u s i n g the a t t a c h m e n t a n d t h e d r i v e r a s s h o w n . rack shaft w i t h o n e w r e n c h , a n d tighten both rack
M a k e s u r e that the a t t a c h m e n t a n d the d r i v e r e n d s w i t h a n o t h e r w r e n c h . B e c a r e f u l not to
p r e s s e s a g a i n s t the metal portion (B) of the r u b b e r d a m a g e the s h a f t s u r f a c e w i t h t h e w r e n c h .
stop.
3 . B e n d the lock w a s h e r (A) b a c k a g a i n s t t h e flat s p o t s
o n the rack e n d j o i n t h o u s i n g .
Replace.
(cont'd)
17-59
EPS Components
Rack End Removal and Installation :'d)
4. A p p l y m u l t i p u r p o s e g r e a s e to the c i r c u m f e r e n c e 8. Install the n e w boot b a n d (A) by a l i g n i n g the t a b s
(A) of the rack e n d joint h o u s i n g . (B) w i t h h o l e s (C) of the b a n d .
(P/N: 08733-B070E)
5. A p p l y a light c o a t of s i l i c o n e g r e a s e to t h e boot 9. C l o s e t h e e a r portion (A) of the b a n d w i t h a

g r o o v e s (B) o n t h e rack e n d s . c o m m e r c i a l l y a v a i l a b l e Oetiker 1098 p i n c e r s or
e q u i v a l e n t (B).
6. C e n t e r t h e s t e e r i n g rack w i t h i n its s t r o k e . Install the
b o o t s (A) in t h e rack e n d w i t h t h e tie-rod c l i p s (B).
C l e a n off a n y g r e a s e or c o n t a m i n a t i o n f r o m the
g r o o v e a r o u n d (C) o n the h o u s i n g .
10. S l i d e the rack right a n d left to be c e r t a i n that the

boots a r e not d e f o r m e d or t w i s t e d .
7. After installing the b o o t s , w i p e the g r e a s e off the
t h r e a d s e c t i o n (D) of the rack e n d .
17-60
Gearbox Bracket Removal/ Tie-rod Ball Joint Boot Replacement
Installation
Oil s e a l d r i v e r 0 7 9 7 4 - 6 7 9 0 0 0 0
1. R e m o v e t h e bracket c l a m p bolt (A) f r o m t h e
g e a r b o x bracket (B), t h e n pry o p e n t h e bracket to 1. R e m o v e t h e boot f r o m t h e tie-rod e n d , a n d w i p e the
r e m o v e it f r o m t h e g e a r b o x . o l d g r e a s e off t h e ball pin.
2 . P a c k the l o w e r a r e a of t h e ball pin (A) w i t h f r e s h

multipurpose grease.
2. Install t h e g e a r b o x b r a c k e t o n t h e g e a r b o x w i t h the
bracket c l a m p bolt t o w a r d the rear.
3. A d j u s t the d i s t a n c e b e t w e e n t h e bracket m o u n t i n g
bolt hole (A) a n d t h e g e a r b o x m o u n t i n g bolt hole 3. P a c k the interior of t h e n e w boot (B) a n d lip (C) with
(B) to t h e d i m e n s i o n s h o w n . M a k e s u r e t h e bracket fresh multipurpose grease.
m o u n t i n g bolt h o l e s a r e parallel w i t h g e a r b o x
m o u n t i n g bolt h o l e s . Note t h e s e i t e m s w h e n installing n e w g r e a s e :
• K e e p g r e a s e off t h e boot installation s e c t i o n (D)
a n d t h e t a p e r e d s e c t i o n (E) of the ball pin.
• Do not a l l o w d u s t , dirt, or other f o r e i g n m a t e r i a l s
3 9 0 ± 1 m m ( 1 5 . 3 5 ± 0 . 0 4 in.) to enter the boot.
4. Install t h e n e w boot (A) u s i n g t h e oil s e a l driver.

T h e boot m u s t not h a v e a g a p at t h e boot
installation s e c t i o n s (B). After installing t h e boot,
c h e c k t h e ball pin t a p e r e d s e c t i o n for g r e a s e
c o n t a m i n a t i o n , a n d w i p e it off if n e c e s s a r y .
4. Install t h e bracket c l a m p bolt, a n d tighten it to

2 5 N-m (2.5 kgf-m, 18 Ibf-ft).
17-61
EPS Components
EPS Control Unit Removal/ Gearbox Mount Cushion
Installation Replacement
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e 1. R e m o v e t h e s t e e r i n g g e a r b o x ( s e e p a g e 17-49).

a u d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e s for t h e
a u d i o p r e s e t buttons. D i s c o n n e c t t h e n e g a t i v e 2. Position a 3 4 m m s o c k e t w r e n c h (A) o n t h e f l a n g e
battery c a b l e f r o m t h e battery. part of t h e g e a r b o x h o u s i n g w i t h a w a s h e r (B), a
10 x 105 m m f l a n g e bolt (C) a n d a 10 m m nut (D) a s
2. R e m o v e the E P S control unit. shown.
3. D i s c o n n e c t t h e E P S c o n t r o l unit c o n n e c t o r s . 3. Hold the nut w i t h a w r e n c h , a n d tighten the f l a n g e

bolt w i t h a n o t h e r w r e n c h . R e m o v e t h e g e a r b o x
4. Install t h e E P S control unit in the r e v e r s e o r d e r of mount c u s h i o n (E).
removal.
4. A p p l y a m i l d s o a p a n d w a t e r s o l u t i o n to t h e n e w
N O T E : If t h e E P S control unit is r e p l a c e d , the E P S g e a r b o x m o u n t c u s h i o n s u r f a c e (A), t h e n p l a c e it o n
control unit m u s t m e m o r i z e t h e t o r q u e s e n s o r t h e g e a r b o x m o u n t i n g c u s h i o n hole.
neutral p o s i t i o n ( s e e p a g e 17-48).
5. R e c o n n e c t t h e n e g a t i v e battery c a b l e to t h e battery,
and do these items:
• F o r ' 0 0 - 0 5 m o d e l s ; d o t h e E C M idle l e a r n
• E n t e r t h e anti-theft c o d e for t h e a u d i o , t h e n e n t e r
the audio presets.
• F o r ' 0 1 - 0 8 m o d e l s ; set the clock.
TOT
5. P o s i t i o n a 3 4 m m s o c k e t w r e n c h o n the f l a n g e part
of t h e g e a r b o x h o u s i n g w i t h a w a s h e r , a f l a n g e bolt,
a n d a nut a s s h o w n .
6. Install the g e a r b o x m o u n t c u s h i o n b y tightening t h e

nut until t h e m o u n t c u s h i o n e d g e s (B) c o n t a c t t h e
gearbox flange surface.
7. Install the s t e e r i n g g e a r b o x ( s e e p a g e 17-52).
17-62
Suspension
Front and Rear Suspension

Special Tools , 18-2
Tire Sealant Removal 18-5
Wheel Alignment . 18-7
Wheel Bearing End Play Inspection 18-11
Wheel Runout Inspection 18-12
Wheel Bolt Replacement 18-12
Ball Joint Removal 18-13
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement 18-14
BallJoint Boot Replacement 18-20
Stabilizer Link Removal/Installation 18-21
Stabilizer Bar Replacement 18-22
Lower Arm Removal/Installation 18-23
Upper Arm Replacement 18-25
Damper/Spring Removal and Installation 18-26
Damper/Spring Disassembly,
Inspection, and Reassembly 18-29
Rear Suspension
Knuckle/Hub/Wheel Bearing Replacement 18-32
Ball Joint Boot Replacement 18-38
Stabilizer Link Removal/Installation 18-39
Stabilizer Bar Replacement 18-40
Lower Arm Removal/Installation 18-40
Upper Arm Removal/Installation 18-42
Control Arm Replacement 18-43
Damper/Spring Removal and Installation 18-44
Damper/Spring Disassembly,
Inspection, and Reassembly 18-46
TPMS (Tire Pressure Monitoring System)

('08 Model) 18-49
Special Tools

© 07AAF-SDAA100 Ball J o i n t T h r e a d Protector, 12 m m 1
® 07GAD-SD40101 Attachment, 78 x 90 m m 1
® 07GAF-SD40100 H u b D i s / A s s e m b l y T o o l , 42 m m 1
® 07GAF-SD40200 Inner B e a r i n g Driver A t t a c h m e n t , 42 m m 1
® 07GAG-SD40700 Ball J o i n t B o o t C l i p G u i d e , 42 x 44 m m 1
0 7 J A F - S H 2 0 3 3 0 or Bushing Base 1
07933-HR3000A
w i t h o u t a d j u s t i n g bolt
® 07MAC-SL0A202 Ball J o i n t R e m o v e r , 2 8 m m 1
® 071AF-S3VA000 Ball J o i n t T h r e a d Protector, 14 m m 1
® 07746-0010400 A t t a c h m e n t , 52 x 5 5 m m 1
@ 07746-0010500 A t t a c h m e n t , 62 x 68 m m 1
® 07746-0010600 Attachment, 72 x 75 m m 1
® 07749-0010000 D r i v e r , 15 x 135L 1
® 07965-SD90100 Support B a s e , 73 x 78/82.6 m m 1
® ® @
18-2
Front S u s p e n s i o n
DAMPER/SPRING
R e m o v a l , p a g e 18-26
Disassembly, Inspection, and
R e a s s e m b l y , p a g e 18-29
UPPER ARM
BALL JOINT
B o o t R e p l a c e m e n t , p a g e 18-20
STABILIZER LINK
Removal/Installation, page 18-21
STABILIZER BAR
KNUCKLE/
HUB/WHEEL BEARING
BALL JOINT
WHEEL BOLT
LOWER ARM R e p l a c e m e n t , p a g e 18-12
R e m o v a l / I n s t a l l a t i o n , p a g e 18-23
18-
Rear Suspension
STABILIZER BAR
DAMPER/SPRING
R e m o v a l , p a g e 18-44
Disassembly, Inspection, and
R e a s s e m b l y , p a g e 18-46
UPPER ARM
BALL JOINT
WHEEL BOLT
LOWER ARM
KNUCKLE/
HUB/WHEEL BEARING
CONTROLARM BALL JOINT
R e p l a c e m e n t , p a g e 18-43 B o o t R e p l a c e m e n t , p a g e 18-38
BALL JOINT
STABILIZER LINK
Boot R e p l a c e m e n t , p a g e 18-38
18-4
Tire Sealant Removal
NOTE: U s e a c o m m e r c i a l l y a v a i l a b l e s q u e e z e bottle,
• T h i s p r o c e d u r e is o n l y to be u s e d w i t h the t e m p o r a r y s i p h o n g u n (A), a c o m m e r c i a l l y a v a i l a b l e air, o r
tire repair s e a l a n t . h a n d v a c u u m tool w i t h a p r o p e r t u b e to r e m o v e t h e
• T h e tire inflator a n d t e m p o r a r y repair s e a l a n t a r e tire s e a l a n t . Insert t h e t u b e into t h e tire t h r o u g h t h e
u s e d o n v e h i c l e s w i t h o u t a s p a r e tire. v a l v e s t e m h o l e , a n d stick it d o w n until the e n d of
• T h e t e m p o r a r y r e p a i r s e a l a n t u s e d to repair t h e tire t h e t u b e is i m m e r s e d into the s e a l a n t (B).
m u s t be r e m o v e d before the tire is p e r m a n e n t l y
repaired.
• T h e t e m p o r a r y r e p a i r s e a l a n t ( o n c e u s e d or p a s t the
expiration date) is c o n s i d e r e d h a z a r d o u s w a s t e , a n d
m u s t be d i s p o s e d of in a n e n v i r o n m e n t a l l y s a f e
m a n n e r ( s u c h a s u s e d e n g i n e oil a n d c o o l a n t ) . C h e c k
w i t h y o u r local r e g u l a t i o n s for p r o p e r d i s p o s a l .
• T h e expiration d a t e of the t e m p o r a r y repair s e a l a n t is
printed o n the label of the c o n t a i n e r .
1. R a i s e t h e v e h i c l e , a n d s u p p o r t it w i t h s a f e t y s t a n d s
2. R e m o v e the a p p r o p r i a t e w h e e l a n d deflate t h e tire.
3. P l a c e t h e w h e e l a n d tire a s s e m b l y u p right w i t h t h e
tire v a l v e hole at the 6 o ' c l o c k p o s i t i o n .
4. R e m o v e t h e v a l v e s t e m nut (A) a n d w a s h e r (B),

t h e n p u s h the tire p r e s s u r e s e n s o r (C) into the 6. R e m o v e the tire s e a l a n t . T o c o m p l e t e l y e m p t y the
w h e e l , d o w n into the tire. tire of s e a l a n t , c a r e f u l l y rock t h e w h e e l b a c k a n d
forth.
NOTE:
• B e c a r e f u l not to spill the tire s e a l a n t f r o m the N O T E : If u s i n g the bottle w i t h t h e t u b e , s e t the
v a l v e s t e m h o l e (D). bottle in a l o w e r position t h a n t h e tire a n d s q u e e z e
• C h e c k the nut a n d the w a s h e r . If t h e y h a v e t h e bottle to s i p h o n the tire s e a l a n t into the bottle.
d e t e r i o r a t e d or d a m a g e d , r e p l a c e with n e w o n e s
during r e a s s e m b l y . 7. C o m p l e t e l y s e a l a n d d i s p o s e of t h e bottle
c o n t a i n i n g t h e tire s e a l a n t in t h e p r o p e r m a n n e r for
h a z a r d o u s w a s t e . C h e c k w i t h y o u r local r e g u l a t i o n s .
(cont'd)
18-5
Tire Sealant Removal (cont'd)
8. R e m o v e t h e tire f r o m t h e w h e e l , a n d r e m o v e t h e 11. C l e a n the m a t i n g s u r f a c e s of the brake d i s c a n d t h e

tire p r e s s u r e s e n s o r (A) a n d the g r o m m e t (B) (if i n s i d e of w h e e l , t h e n install the w h e e l .
r e m o v e d ) f r o m i n s i d e t h e tire.
12. T e s t - d r i v e t h e v e h i c l e at 28 m p h (45 km/h) or m o r e
for at l e a s t 1 m i n u t e .
13. M a k e s u r e t h e T P M S indicator or t h e l o w tire

p r e s s u r e indicator d o e s not c o m e o n ( s e e p a g e
18-51).
N O T E : U s i n g t h e tire s e a l a n t o n c e m a y c a u s e to b e
T P M S faulty. In t h i s c a s e r e p l a c e t h e tire p r e s s u r e
s e n s o r ( s e e p a g e 18-81).
14. R e d u c e t h e p r e s s u r e in o n e tire l e s s t h a n 150 kPa

2
(1.5 k g f / c m , 2 2 p s i ) .
15. M a k e s u r e t h e l o w tire p r e s s u r e indicator t u r n s o n

9. C o m p l e t e l y r i n s e t h e tire p r e s s u r e s e n s o r w i t h c o l d ( s e e p a g e 18-51). If t h e l o w tire p r e s s u r e indicator
w a t e r to r e m o v e t h e tire s e a l a n t . d o e s not c o m e o n , r e p l a c e t h e tire p r e s s u r e s e n s o r
( s e e p a g e 18-81).
N O T E : D o not u s e a n y s o a p o r c l e a n e r . U s e c o l d
w a t e r o n l y . M a k e s u r e t h e tire s e a l a n t d o e s not 16. Inflate t h e tire ( s e e p a g e 18-7).
stick to t h e s e n s o r . If t h e s e a l a n t h a s d r i e d onto t h e
tire p r e s s u r e s e n s o r , t h e n t h e s e n s o r m u s t b e
r e p l a c e d ( s e e p a g e 18-82).
10. If y o u a r e r e p a i r i n g t h e tire for r e u s e , c o m p l e t e l y

w i p e out t h e i n s i d e of t h e tire, fix t h e flat, a n d
reinstall t h e tire p r e s s u r e s e n s o r ( s e e p a g e 18-82) a
n e w tire v a l v e .
NOTE:
• W i p e t h e fluid s e a l a n t c o m p l e t e l y s o that t h e
b e a d e d e d g e of t h e tire a n d t h e m a t i n g portion of
the w h e e l rim a n d t h e b e a d a r e c l e a r e d .
• T h e d a m a g e d portion s u c h a s p u n c t u r e s m a y be
filled w i t h the fluid s e a l a n t , d e p e n d i n g o n t h e
extent of t h e d a m a g e .
18-6
Wheel Alignment
T h e s u s p e n s i o n c a n be a d j u s t e d for c a s t e r , c a m b e r , a n d 7. C h e c k t h e ride height of e a c h s u s p e n s i o n . M a k e
toe. H o w e v e r , e a c h of t h e s e a d j u s t m e n t s a r e related to s u r e t h e v e h i c l e is e m p t y , is p a r k e d o n a level
e a c h other. F o r e x a m p l e , w h e n y o u a d j u s t c a m b e r , the s u r f a c e , a n d h a s p r o p e r l y inflated t i r e s (the
toe will c h a n g e . T h e r e f o r e , y o u m u s t a d j u s t t h e t r e a d w e a r indicator m u s t not b e s h o w i n g ) . If t h e
front/rear a l i g n m e n t w h e n e v e r y o u a d j u s t c a s t e r , height is o u t of s p e c i f i c a t i o n , a d j u s t t h e load a s
c a m b e r , o r toe. necessary.
Pre-Alignment Checks Height:

Front: 1 9 2 - 2 0 2 m m ( 7 . 5 6 - 7 . 9 5 in.)
F o r p r o p e r i n s p e c t i o n a n d a d j u s t m e n t of the w h e e l Rear: 2 0 6 — 2 1 6 m m ( 8 . 1 1 — 8 . 5 0 in.)
alignment, do the following:
Front:
1. R e l e a s e t h e parking brake to a v o i d a n i n c o r r e c t
FRONT
measurement.
t
2. M a k e s u r e t h e s u s p e n s i o n is not m o d i f i e d .
3. C h e c k t h e tire size a n d tire p r e s s u r e .
T i r e s i z e ('00-03 m o d e l s ) :
Front: 205/55R16 89W
Rear: 225/50R16 92W
T i r e s i z e ('04-07 m o d e l s ) :
Front: 215/45R17 87W
Rear: 245/40R17 91W
T i r e s i z e ('08 m o d e l ) : T h e h e i g h t f r o m t h e g r o u n d to t h e c e n t e r of t h e h e a d
of t h e l o w e r a r m ' s f r o n t a d j u s t i n g bolt.
Front: 215/45R17 87W
Rear (except C R model): 245/40R17 9 1 W
Rear (CR model): 255/40R17 94W Rear:
T i r e p r e s s u r e (at cold):
2
F r o n t / R e a r : 2 2 0 k P a (2.2 k g f / c m , 3 2 p s i )
4. C h e c k t h e runout of the w h e e l s a n d t i r e s ( s e e p a g e
18-12).
5 . C h e c k t h e s u s p e n s i o n ball j o i n t s (Hold a tire w i t h

y o u r h a n d s , a n d m o v e it up a n d d o w n a n d right a n d
left to c h e c k for w o b b l i n g . )
T h e h e i g h t f r o m t h e g r o u n d t o t h e c e n t e r of t h e h e a d
of t h e l o w e r a r m ' s r e a r a d j u s t i n g bolt.
6. B o u n c e the v e h i c l e up a n d d o w n s e v e r a l t i m e s to
settle t h e s u s p e n s i o n .
(cont'd)
18-7
W h e e l A l i g n m e n t (cont'd)
Caster Inspection/Adjustment Front Camber Inspection/Adjustment
U s e c o m m e r c i a l l y available computerized four w h e e l U s e c o m m e r c i a l l y a v a i l a b l e c o m p u t e r i z e d four w h e e l

a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t
(caster, c a m b e r , toe, a n d turning angle). Follow the (caster, c a m b e r , toe, a n d turning angle). Follow the
equipment manufacturer's instructions. equipment manufacturer's instructions.
1. C h e c k t h e c a s t e r a n g l e . If a d j u s t m e n t is r e q u i r e d , 1. C h e c k t h e c a m b e r a n g l e . If a d j u s t m e n t is r e q u i r e d ,
g o to s t e p 2. g o to s t e p 2.
C a s t e r angle: 6°00'± 1 5 ' Front c a m b e r angle: —0 ° 3 0 ' ± 1 0 '

M a x i m u m d i f f e r e n c e b e t w e e n t h e r i g h t a n d left M a x i m u m difference b e t w e e n t h e right a n d left
side: 0 ° 1 5 ' side:0°10'
2. H o l d t h e s e l f - l o c k i n g c a m nut (A) o n t h e r e a r of t h e 2. Hold t h e a d j u s t i n g bolt (A) o n t h e front of t h e l o w e r

l o w e r a r m , a n d l o o s e n t h e f l a n g e bolt (B). a r m , a n d l o o s e n t h e s e l f - l o c k i n g nut (B).
3 . R e p l a c e t h e s e l f - l o c k i n g c a m nut w i t h a n e w o n e , 3 . R e p l a c e t h e self-locking nut w i t h a n e w o n e , a n d

a n d lightly tighten it. lightly tighten it.
N O T E : A l w a y s u s e a n e w s e l f - l o c k i n g c a m nut N O T E : A l w a y s u s e a n e w s e l f - l o c k i n g nut w h e n e v e r
w h e n e v e r it h a s b e e n l o o s e n e d . it h a s b e e n l o o s e n e d .
4 . T u r n t h e a d j u s t i n g c a m c o l l a r (C) until t h e c a s t e r i s 4 . T u r n t h e a d j u s t i n g bolt until t h e c a m b e r is c o r r e c t .

correct.
5. After a d j u s t i n g , tighten t h e s e l f - l o c k i n g nut w h i l e
5. A f t e r a d j u s t i n g , t i g h t e n t h e f l a n g e bolt w h i l e h o l d i n g t h e a d j u s t i n g bolt.
h o l d i n g t h e s e l f - l o c k i n g c a m nut.
6. B o u n c e t h e v e h i c l e s e v e r a l t i m e s , a n d r e c h e c k t h e
6. B o u n c e t h e v e h i c l e s e v e r a l t i m e s , a n d r e c h e c k t h e c a m b e r reading.
caster reading.
18-8
Rear Camber Inspection/Adjustment Front Toe Inspection/Adjustment
Use c o m m e r c i a l l y a v a i l a b l e c o m p u t e r i z e d f o u r w h e e l Use c o m m e r c i a l l y a v a i l a b l e c o m p u t e r i z e d f o u r w h e e l
a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t
( c a s t e r , c a m b e r , t o e , a n d turning a n g l e ) . F o l l o w the (caster, c a m b e r , toe, and turning angle). F o l l o w the
equipment manufacturer's instructions. equipment manufacturer's instructions.
1. C h e c k the c a m b e r a n g l e . If a d j u s t m e n t is r e q u i r e d , 1. C e n t e r the s t e e r i n g w h e e l s p o k e s a n d install a

g o to s t e p 2. steering w h e e l holder tool.
Rear camber angle: — 1 °30 ' ± 1 0 • 2. C h e c k t h e toe w i t h t h e w h e e l s pointed straight

a h e a d . If a d j u s t m e n t is r e q u i r e d , g o to s t e p 3.
2. Hold the a d j u s t i n g bolt (A) o n the control a r m , a n d
l o o s e n the s e l f - l o c k i n g nut (B). Front toe-in: 0 ± 2 m m ( 0 ± 0 . 0 8 in.)
3. Hold the tie-rod e n d (A), a n d l o o s e n the tie-rod

locknut (B).
3. R e p l a c e the s e l f - l o c k i n g nut w i t h a n e w o n e , a n d
lightly tighten it. (4.5 k g f m , 3 3 I b f f t )
N O T E : A l w a y s u s e a n e w self-locking nut w h e n e v e r 4. T u r n the tie-rod until the toe is c o r r e c t .

it h a s b e e n l o o s e n e d .
5. After a d j u s t i n g , tighten t h e locknut w h i l e h o l d i n g
4. T u r n the a d j u s t i n g bolt until the c a m b e r is c o r r e c t . the tie-rod e n d . R e p o s i t i o n the r a c k - e n d boot if it is
t w i s t e d or d i s l o c a t e d .
5. After a d j u s t i n g , tighten the s e l f - l o c k i n g nut w h i l e
holding the a d j u s t i n g bolt.
(cont'd)
18-9
Wheel Alignment (cont'd)
Rear Toe Inspection/Adjustment 4 . R e p l a c e t h e s e l f - l o c k i n g nuts w i t h n e w o n e , a n d

lightly t i g h t e n t h e m .
U s e c o m m e r c i a l l y available computerized four w h e e l
a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t N O T E : A l w a y s u s e n e w self-locking nuts w h e n e v e r
(caster, c a m b e r , toe, a n d turning angle). Follow the they have been loosened.
equipment manufacturer's instructions.
5 . T u r n both a d j u s t i n g bolts in o p p o s i t e d i r e c t i o n s
1. R e l e a s e t h e p a r k i n g b r a k e to p r e v e n t a n i n c o r r e c t until t h e t o e is c o r r e c t .
measurement.
N O T E : A d j u s t the r e a r toe b y a d j u s t i n g t h e c ontrol
2 . C h e c k t h e t o e . If a d j u s t m e n t is r e q u i r e d , g o to a r m a n d t h e l o w e r a r m b y the s a m e a m o u n t in
step 3 . o p p o s i t e d i r e c t i o n s to e a c h other (for e x a m p l e ,
w h e n y o u m o v e t h e control a r m out, m o v e t h e
Rear toe-in: lower arm in, and vice versa).
'00-03 m o d e l s : 6 . 0 ± 2 m m ( 0 . 2 4 ± 0 . 0 8 in.)
'04-08 m o d e l s : 6 . After a d j u s t i n g , tighten both s e l f - l o c k i n g n u t s w h i l e
Except C R model: 3 . 6 ± 2 m m ( 0 . 1 4 ± 0 . 0 8 in.) h o l d i n g t h e r e s p e c t i v e a d j u s t i n g bolts.
CR model: 5 . 5 ± 2 m m ( 0 . 2 2 ± 0 . 0 8 in.)
3 . Hold t h e a d j u s t i n g bolt of t h e c o n t r o l a r m (A), a n d

l o o s e n t h e s e l f - l o c k i n g nut (B). H o l d t h e a d j u s t i n g
bolt of t h e l o w e r a r m ( C ) , a n d l o o s e n t h e self-
locking nut (D).
7 4 N m (7.5 k g f m , 5 4 Ibf-ft)
Replace.
18-10
Wheel Bearing End Play Inspection
Turning Angle Inspection 1. R a i s e t h e v e h i c l e , a n d s u p p o r t it w i t h s a f e t y s t a n d s
U s e c o m m e r c i a l l y a v a i l a b l e c o m p u t e r i z e d four w h e e l
a l i g n m e n t e q u i p m e n t to m e a s u r e w h e e l a l i g n m e n t 2. R e m o v e the w h e e l s .
(caster, c a m b e r , toe, a n d turning angle). Follow the
equipment manufacturer's instructions. 3. Install s u i t a b l e flat w a s h e r s (A) a n d t h e w h e e l n u t s .
T i g h t e n t h e nuts to t h e s p e c i f i e d t o r q u e to hold t h e
1. T u r n the front w h e e l s right a n d left w h i l e a p p l y i n g b r a k e d i s c s e c u r e l y a g a i n s t the h u b .
t h e b r a k e , a n d m e a s u r e the t u r n i n g a n g l e s of both
wheels. Front:
Turning angle:
Inward: 3 4 ° 00 ' ± 2 °
O u t w a r d (reference): 2 9 ° 0 0 '
108 N-m
(11.0 k g f m , 7 9 . 6 I b f f t )
Rear:
2. If t h e turning a n g l e s a r e out of s p e c i f i c a t i o n or t h e
i n w a r d turning a n g l e s differ b e t w e e n the right a n d
left, c h e c k t h e t o e , a n d a d j u s t a c c o r d i n g l y .
3. If t h e toe a d j u s t m e n t is c o r r e c t but t h e turning

a n g l e s a r e out of s p e c i f i c a t i o n , c h e c k for bent o r
damaged suspension components.
4. A t t a c h t h e dial g a u g e . P l a c e the dial g a u g e a g a i n s t

the hub flange.
5. M e a s u r e t h e b e a r i n g e n d play m o v i n g the brake

d i s c i n w a r d or o u t w a r d .
Standard:
F r o n t / R e a r : 0 — 0 . 0 5 m m (0—0.002 in.)
6. If the b e a r i n g e n d p l a y m e a s u r e m e n t is m o r e t h a n
the standard, replace the wheel bearing.
18-11
Wheel Runout Inspection Wheel Bolt Replacement
1. R a i s e t h e v e h i c l e , a n d s u p p o r t it w i t h s a f e t y s t a n d s INOTICE1
in t h e p r o p e r l o c a t i o n s ( s e e p a g e 1-18). • D o not u s e a h a m m e r or air or e l e c t r i c i m p a c t
t o o l s to r e m o v e a n d install t h e w h e e l bolts.
2. C h e c k for bent or d e f o r m e d w h e e l s . • B e c a r e f u l not to d a m a g e t h e t h r e a d s of t h e
w h e e l bolts.
3. S e t up the dial g a u g e a s s h o w n , a n d m e a s u r e a x i a l
runout b y t u r n i n g t h e w h e e l . 1. R e m o v e t h e front h u b o r rear h u b : front ( s e e p a g e
18-14), r e a r ( s e e p a g e 18-32).
Front and rear w h e e l axial runout:
Standard: 0 — 0 . 7 m m ( 0 — 0 . 0 3 in.) 2. S e p a r a t e t h e w h e e l bolt (A) f r o m t h e h u b (B) u s i n g
S e r v i c e limit: 2.0 m m (0.08 in.) a hydraulic press. S u p p o r t the hub with hydraulic
p r e s s a t t a c h m e n t s (C) or e q u i v a l e n t t o o l s .
NOTE:
• B e f o r e installing t h e n e w w h e e l bolt, c l e a n t h e
m a t i n g s u r f a c e s o n t h e bolt a n d t h e h u b .
• T h e illustration s h o w s a rear ftub.
Press
4. R e s e t t h e dial g a u g e to t h e p o s i t i o n s h o w n , a n d
\
m e a s u r e t h e radial runout.
Front a n d rear w h e e l radial runout:

Standard: 0 — 0 . 7 m m ( 0 — 0 . 0 3 in.)
/
S e r v i c e limit: 1.5 m m (0.06 in.)
3. I n s e r t the n e w w h e e l bolt into t h e h u b w h i l e
a l i g n i n g t h e s p l i n e d s u r f a c e s o n the h u b hole with
t h e w h e e l bolt.
NOTE:
• D e g r e a s e all a r o u n d t h e w h e e l bolt.
• M a k e s u r e t h e w h e e l bolt is i n s t a l l e d v e r t i c a l l y in
relation to t h e h u b d i s c s u r f a c e .
4. Install t h e w h e e l bolt u s i n g a h y d r a u l i c p r e s s until

t h e w h e e l bolt s h o u l d e r is fully s e a t e d .
5. Install t h e front h u b or rear h u b : front ( s e e p a g e

18-14), rear ( s e e p a g e 18-32).
5. If t h e w h e e l r u n o u t i s out of s p e c i f i c a t i o n , c h e c k t h e N O T E : If y o u c a n n o t tighten t h e w h e e l nut to t h e

w h e e l b e a r i n g e n d p l a y ( s e e p a g e 18-11), a n d m a k e s p e c i f i e d t o r q u e v a l u e w h e n installing t h e w h e e l ,
s u r e the mating s u r f a c e s on the brake disc a n d the r e p l a c e t h e front h u b or r e a r h u b a s a n a s s e m b l y .
i n s i d e of the w h e e l a r e c l e a n .
6. If t h e b e a r i n g e n d p l a y i s w i t h i n t h e s p e c i f i c a t i o n
but t h e w h e e l r u n o u t i s m o r e t h a n t h e s e r v i c e limit,
r e p l a c e the w h e e l .
18-12
Ball Joint Removal
Special Tools Required 3. L o o s e n the p r e s s u r e bolt (A), a n d install t h e ball
Ball joint r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2 joint r e m o v e r a s s h o w n . Insert t h e j a w s c a r e f u l l y ,
m a k i n g s u r e not to d a m a g e t h e ball joint boot.
1NOTICE1 A d j u s t t h e j a w s p a c i n g by t u r n i n g t h e a d j u s t i n g bolt
A l w a y s u s e a ball joint r e m o v e r to d i s c o n n e c t a ball (B).
joint. D o not strike the h o u s i n g o r a n y o t h e r part of
t h e ball joint c o n n e c t i o n to d i s c o n n e c t it. N O T E : F a s t e n t h e s a f e t y c h a i n (C) s e c u r e l y to a
s u s p e n s i o n a r m or t h e s u b f r a m e (D). D o not f a s t e n
1. Install a h e x nut (A) onto t h e t h r e a d s of the ball joint it to a b r a k e line or w i r e h a r n e s s .
(B). M a k e s u r e the nut is f l u s h w i t h t h e ball joint pin
e n d to p r e v e n t d a m a g e to the t h r e a d e d e n d of the
ball joint p i n .
4. After a d j u s t i n g t h e a d j u s t i n g bolt, m a k e s u r e t h e
h e a d of t h e a d j u s t i n g bolt i s in t h e position s h o w n
to a l l o w t h e j a w (E) to pivot.
5. W i t h a w r e n c h , tighten t h e p r e s s u r e bolt until t h e

ball joint pin p o p s l o o s e f r o m t h e ball joint
c o n n e c t i n g h o l e . If n e c e s s a r y , a p p l y penetrating
t y p e lubricant to l o o s e n t h e ball joint pin.
N O T E : D o not u s e p n e u m a t i c o r e l e c t r i c t o o l s o n
t h e p r e s s u r e bolt.
6. R e m o v e the ball joint r e m o v e r , t h e n r e m o v e t h e

nut f r o m t h e e n d of t h e ball joint p i n , a n d pull t h e
ball joint out of t h e ball joint c o n n e c t i n g hole.
I n s p e c t the ball joint boot, a n d r e p l a c e it if
damaged.
07MAC-SL0A202
18-13
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement
Exploded View
HUBCAP
Check for deformation a n d d a m a g e .
KNUCKLE
C h e c k for deformation a n d d a m a g e .
WHEEL BEARING
Replace.
SNAP RING
SPLASH GUARD
C h e c k for deformation
SPINDLE NUT and damage.
2 4 x 1.5 m m
329 N-m
(33.5 k g f m , 2 4 2 Ibf-ft) SCREW
Replace. 5 x 0.8 m m
6 N-m
(0.6 k g f m , 4 Ibf-ft)
A p p l y a s m a l l a m o u n t of e n g i n e oil
to t h e s e a t i n g s u r f a c e o f t h e n u t .
LOWER ARM
BALL JOINT
1 2 x 1.25 m m
64 N-m
(6.5 k g f - m , 4 7 Ibf-ft)
BALL JOINT BOOT
C h e c k for deterioration a n d d a m a g e
FLAT SCREW
6 x 1.0 m m
9.8 N - m
(1.0 k g f m , 7.2 Ibf-ft)
FRONT HUB
Check for deformation,
damage, and cracks.
BRAKE DISC
C h e c k for w e a r , d a m a g e , a n d rust.
18-14
Special Tools Required 5. R e m o v e t h e f l a n g e bolts (A) a n d w h e e l s p e e d
• A t t a c h m e n t , 7 8 x 90 m m 0 7 G A D - S D 4 0 1 0 1 s e n s o r (B) f r o m t h e k n u c k l e (G). D o not d i s c o n n e c t
• Inner b e a r i n g d r i v e r a t t a c h m e n t , 42 m m the w h e e l s p e e d s e n s o r connector.
07GAF-SD40200
• Ball joint r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2
• Ball joint t h r e a d protector, 14 m m 0 7 1 A F - S 3 V A O O 0
•Attachment, 72 x 75 m m 07746-0010600
• Driver, 15 x 1 3 5 L 0 7 7 4 9 - 0 0 1 0 0 0 0
• S u p p o r t b a s e , 7 3 x 78/82.6 m m 0 7 9 6 5 - S D 9 0 1 0 0
1. R a i s e t h e front of the v e h i c l e , a n d s u p p o r t it with

s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e
1-18).
2. R e m o v e t h e w h e e l nuts (A) a n d t h e front w h e e l .
6. R e m o v e t h e brake d i s c ( s e e p a g e 19-16).
7. C h e c k t h e front hub for d a m a g e a n d c r a c k s .
8. R e m o v e t h e cotter pin (A) f r o m the tie-rod e n d ball

joint, t h e n r e m o v e t h e nut (B).
N O T E : D u r i n g installation, install the n e w cotter pin

3. R e m o v e t h e brake h o s e bracket m o u n t i n g bolts (A). after t i g h t e n i n g the nut, a n d b e n d its e n d a s s h o w n .
B
12 x 1.25 mm
'00-03 and '06-08 models:
108 N-m (11.0 kgf m, 79.6 Ibf ft)
'04-05 models:
113 Nm (11.5 kgf-m, 83.2 Ibf-ft)
9. D i s c o n n e c t t h e tie-rod e n d ball joint f r o m t h e

4. R e m o v e t h e brake c a l i p e r bracket m o u n t i n g bolts k n u c k l e u s i n g the ball joint r e m o v e r ( s e e p a g e
(B), t h e n r e m o v e the c a l i p e r a s s e m b l y (C) f r o m t h e 18-13).
k n u c k l e . T o prevent d a m a g e to the c a l i p e r
a s s e m b l y or brake h o s e , u s e a s h o r t p i e c e of w i r e
to h a n g t h e c a l i p e r a s s e m b l y f r o m the
u n d e r c a r r i a g e . Do not t w i s t the brake h o s e
excessively.
(cont'd)
18-15
Front Suspension
Knuckle/Hub/Wheel Bearing Replacement (cont'd)
1.0. R e m o v e t h e cotter p i n (A) f r o m t h e l o w e r a r m ball 12. R e m o v e t h e lock pin (A) f r o m t h e u p p e r a r m ball
joint, t h e n r e m o v e t h e c a s t l e nut ( B ) . joint, t h e n r e m o v e t h e c a s t l e nut ( B ) .
N O T E : D u r i n g i n s t a l l a t i o n , install t h e n e w cotter p i n N O T E : D u r i n g installation, install t h e lock pin a s

after t i g h t e n i n g t h e c a s t l e nut, a n d b e n d its e n d a s s h o w n after t i g h t e n i n g t h e c a s t l e nut.
shown.
07MAC-SL0A202
071AF-S3VA000
1 2 x 1.25 m m
07MAC-SL0A202 '00-03 models:
1 4 x 1.5 m m
'00-03 m o d e l s : 49-59 N m
59-69 N m ( 5 . 0 - 6 . 0 k g f - m , 3 6 - 4 3 Ibf-ft)
(6.0-7.0 kgfm,
4 3 - 5 1 Ibf-ft) '04-08 m o d e l s :
56-66 N m
'04-08 m o d e l s : ( 5 . 7 - 6 . 7 k g f m , 4 1 - 4 8 Ibf-ft)
6 9 - 7 8 N-m
(7.0-8.0 kgfm, 13. D i s c o n n e c t t h e u p p e r a r m ball joint f r o m t h e
5 1 - 5 8 Ibf-ft)
k n u c k l e u s i n g t h e ball joint r e m o v e r ( s e e p a g e
11. D i s c o n n e c t t h e l o w e r a r m ball joint f r o m t h e l o w e r 18-13).
a r m u s i n g t h e ball joint t h r e a d protector a n d t h e
ball joint r e m o v e r ( s e e p a g e 18-13). 14. R e m o v e t h e k n u c k l e .
15. R e m o v e t h e h u b c a p (A).
C
Replace.
16. R a i s e t h e s t a k e (B) of t h e s p i n d l e nut ( C ) , a n d

r e m o v e t h e nut a n d p u l s a r (D).
18-16
17. S e p a r a t e the h u b (A) f r o m t h e k n u c k l e (B) u s i n g a 19. P r e s s t h e w h e e l b e a r i n g (A) out of t h e k n u c k l e (B)
h y d r a u l i c p r e s s . B e c a r e f u l not to d e f o r m t h e s p l a s h u s i n g t h e d r i v e r , the a t t a c h m e n t , a n d a p r e s s .
g u a r d . Hold onto the h u b to k e e p it f r o m falling
Press
w h e n p r e s s e d clear. 07749-0010000
07746-0010600
20. P r e s s t h e w h e e l b e a r i n g i n n e r r a c e (A) out of t h e

18. R e m o v e t h e s p l a s h g u a r d (A) a n d t h e s n a p ring (B) h u b (B) u s i n g a c o m m e r c i a l l y a v a i l a b l e b e a r i n g
f r o m t h e k n u c k l e (C). s e p a r a t o r (C) a n d a p r e s s .
Press
(cont'd)
18-17
Front Suspension
2 1 . W a s h t h e k n u c k l e a n d h u b t h o r o u g h l y in a high 25. W a s h t h e s p i n d l e t h o r o u g h l y in a high f l a s h point
f l a s h point s o l v e n t b e f o r e r e a s s e m b l y . solvent before r e a s s e m b l y .
2 2 . P r e s s a n e w w h e e l b e a r i n g (A) into t h e knuckle (B) 26. Install the h u b (A) onto t h e knuckle (B) u s i n g t h e
u s i n g t h e old b e a r i n g ( C ) , a s t e e l plate (D), t h e inner bearing driver attachment, support b a s e , and
attachment, the support b a s e , a n d a press. Place a h y d r a u l i c p r e s s . B e c a r e f u l not to distort t h e
the w h e e l bearing on the knuckle with the pack s e a l s p l a s h g u a r d (C).
s i d e f a c i n g (E) (metal c o l o r ) t o w a r d t h e i n s i d e . B e
c a r e f u l not to d a m a g e t h e s l e e v e of t h e p a c k s e a l . 07GAF-SD40200
Press
07965-SD90100
27. Install the p u l s e r (A).
07GAD-SD40101
-07965-SD90100
2 4 x 1.5 m m
329 N m
2 3 . Install the s n a p ring (A) s e c u r e l y in t h e knuckle (B). (33.5 k g f - m ,
2 4 2 Ibf-ft)
Replace.
28. A p p l y a s m a l l a m o u n t of e n g i n e oil to the s e a t i n g

D
5 x 0.8 m m
s u r f a c e of t h e n e w s p i n d l e nut (B). Install the nut,
6 N m (0.6 k g f - m , 4 Ibf-ft) a n d tighten it to the s p e c i f i e d t o r q u e v a l u e . S t a k e
(C) t h e nut s h o u l d e r a g a i n s t t h e s p i n d l e w i t h a drift.
24. Install t h e s p l a s h g u a r d ( C ) , a n d tighten t h e s c r e w s
(D) to t h e s p e c i f i e d t o r q u e v a l u e . 29. Install t h e h u b c a p (D).
18-18
30. Install the k n u c k l e in the r e v e r s e o r d e r of r e m o v a l ,
p a y i n g particular attention to t h e f o l l o w i n g i t e m s :
• First install all of t h e c o m p o n e n t s , a n d lightly

tighten the bolts a n d n u t s , t h e n r a i s e t h e
s u s p e n s i o n to l o a d it w i t h t h e v e h i c l e ' s w e i g h t
before fully tightening to the s p e c i f i e d t o r q u e .
• B e careful not to d a m a g e t h e ball joint boot w h e n
connecting the knuckle.
• B e f o r e c o n n e c t i n g the ball joint to t h e k n u c k l e ,
degrease the threaded section and tapered
portion of t h e ball joint p i n , t h e ball joint
c o n n e c t i n g h o l e , the t h r e a d e d s e c t i o n a n d m a t i n g
s u r f a c e s of t h e c a s t l e nut.
• T o r q u e t h e c a s t l e nut to t h e l o w e r t o r q u e
s p e c i f i c a t i o n , t h e n tighten it o n l y far e n o u g h to
align the slot w i t h t h e ball joint pin hole. Do not
align the c a s t l e nut by l o o s e n i n g i t
• B e f o r e installing t h e brake d i s c , c l e a n t h e m a t i n g
s u r f a c e s of t h e front h u b a n d t h e i n s i d e of t h e
brake d i s c .
• B e f o r e installing the w h e e l , c l e a n the m a t i n g
s u r f a c e s of t h e b r a k e d i s c a n d t h e i n s i d e of t h e
wheel.
• C h e c k t h e w h e e l a l i g n m e n t , a n d a d j u s t it if
Front Suspension
Ball Joint Boot Replacement

Special Tools Required 5. A d j u s t t h e ball joint boot clip g u i d e w i t h t h e
a d j u s t i n g bolt (A) until its b a s e is j u s t a b o v e t h e
Ball joint boot clip g u i d e , 4 2 x 44 m m 0 7 G A G - S D 4 0 7 0 0 g r o o v e a r o u n d the bottom of the boot. T h e n s l i d e
t h e clip (B) o v e r t h e ball joint boot clip g u i d e into
1. R e m o v e t h e boot clip a n d t h e boot. the p o s i t i o n o n the boot.
2. P a c k t h e interior a n d lip of t h e n e w boot (A) w i t h
f r e s h g r e a s e . D o not c o n t a m i n a t e t h e l o w e r c o l l a r
of t h e boot (B) w i t h g r e a s e .
6. After installing a boot, w i p e a n y g r e a s e off t h e

e x p o s e d portion of t h e ball joint p i n .
3. W i p e t h e g r e a s e off t h e t a p e r e d s e c t i o n of t h e ball
joint pin ( C ) , a n d p a c k t h e b a s e (D) w i t h f r e s h
grease.
4. Install t h e boot onto t h e ball joint p i n , t h e n s q u e e z e

it g e n t l y to f o r c e out a n y air. Do not let dirt o r o t h e r
f o r e i g n m a t e r i a l s get into t h e boot.
18-20
Stabilizer Link Removal/Installation
1. R a i s e the front of t h e v e h i c l e , a n d s u p p o r t it w i t h 6. Install t h e n e w s e l f - l o c k i n g nut a n d t h e n e w f l a n g e

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e nut, a n d lightly tighten t h e m .
1-18).
7. P l a c e a j a c k u n d e r t h e l o w e r a r m , a n d r a i s e t h e
2 . R e m o v e the front w h e e l . s u s p e n s i o n to l o a d t h e stabilizer bar.
3. R e m o v e t h e s p l a s h s h i e l d ( s e e s t e p 3 o n p a g e 8. T i g h t e n t h e s e l f - l o c k i n g nut (A) a n d t h e f l a n g e nut

18-22). (B) to t h e s p e c i f i e d t o r q u e v a l u e s w h i l e h o l d i n g t h e
r e s p e c t i v e joint pin (C) w i t h a h e x w r e n c h (D).
4. R e m o v e t h e s e l f - l o c k i n g nut (A) a n d t h e f l a n g e nut
(B) w h i l e holding t h e r e s p e c t i v e joint pin (C) w i t h a
h e x w r e n c h (D), a n d d i s c o n n e c t the stabilizer link
(E) f r o m t h e stabilizer b a r (F) a n d the l o w e r a r m (G).
9. Install t h e s p l a s h s h i e l d ( s e e s t e p 3 o n p a g e 18-22).
5. Install the stabilizer link to t h e stabilizer b a r a n d 10. C l e a n t h e m a t i n g s u r f a c e s of the brake d i s c a n d t h e

l o w e r a r m w i t h t h e joint p i n s s e t at the c e n t e r (A) of i n s i d e of the w h e e l , t h e n install t h e front w h e e l , a n d
their r a n g e of m o v e m e n t . test-drive t h e v e h i c l e .
N O T E : T h e left stabilizer link h a s a y e l l o w paint 11. After 5 m i n u t e s of d r i v i n g , tighten t h e s e l f - l o c k i n g

m a r k o n t h e rod (B), w h i l e the right stabilizer link nut a g a i n to t h e s p e c i f i e d t o r q u e v a l u e .
h a s a w h i t e paint m a r k .
18-21
Front Suspension
Stabilizer Bar Replacement
1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it w i t h 5. R e m o v e the bolts (A) a n d b u s h i n g h o l d e r s (B), t h e n
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e r e m o v e t h e b u s h i n g s (C) a n d t h e stabilizer bar (D).
1-18).
2. R e m o v e the front w h e e l s .
3. R e m o v e the s e v e n c l i p s (A) a n d t w o f l a n g e bolts ( B ) ,

t h e n r e m o v e the s p l a s h s h i e l d (C).
6. R e p l a c e t h e stabilizer hold bracket (E) if n e c e s s a r y .
7. Install the stabilizer bar in the r e v e r s e o r d e r of

r e m o v a l , a n d note t h e s e i t e m s :
6 x 1.0 m m
9.8 N m (1.0 k g f m , 7.2 I b f f t )
• R e f e r to stabilizer link r e m o v a l / i n s t a l l a t i o n to
c o n n e c t the stabilizer b a r to the links ( s e e p a g e
4. R e m o v e t h e s e l f - l o c k i n g nut (A) w h i l e h o l d i n g t h e 18-21).
joint pin (B) w i t h a h e x w r e n c h ( C ) , a n d d i s c o n n e c t • B e f o r e installing the w h e e l , c l e a n the m a t i n g
both stabilizer links (D) f r o m the stabilizer bar ( E ) . s u r f a c e s of the brake d i s c a n d i n s i d e of the w h e e l .
N O T E : D u r i n g installation, install t h e n e w self- n e c e s s a r y ( s e e p a g e 18-7).
locking nut.
18-22
Lower Arm Removal/Installation
Special Tools Required 5. R e m o v e t h e cotter pin (A) f r o m t h e l o w e r a r m ball

• Ball joint t h r e a d protector, 14 m m 0 7 1 A F - S 3 V A 0 0 0 joint, t h e n r e m o v e t h e c a s t l e nut (B).
N O T E : D u r i n g i n s t a l l a t i o n , install the n e w cotter pin
1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it with after t i g h t e n i n g the c a s t l e nut, a n d b e n d its e n d a s
s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e shown.
1-18).
2. R e m o v e t h e front w h e e l .
3. R e m o v e t h e f l a n g e nut (A) w h i l e h o l d i n g t h e joint

pin (B) w i t h a h e x w r e n c h ( C ) , a n d d i s c o n n e c t the
stabilizer link (D) f r o m t h e l o w e r a r m ( E ) .
N O T E : D u r i n g installation, install the n e w f l a n g e

nut.
6. D i s c o n n e c t t h e l o w e r a r m ball joint f r o m t h e l o w e r
ball joint r e m o v e r ( s e e p a g e 18-13).
4. R e m o v e t h e f l a n g e bolt (A), a n d d i s c o n n e c t the

d a m p e r (B) f r o m t h e l o w e r a r m (C).
N O T E : D u r i n g installation, install t h e n e w f l a n g e
bolt.
Replace.
(cont'd)
18-23
Front Suspension
Lower Arm Removal/Installation (cont'd)
7. R e m o v e t h e s e l f - l o c k i n g nut (A) a n d f l a n g e bolt ( B ) , Install t h e l o w e r a r m in t h e r e v e r s e o r d e r of
t h e n r e m o v e t h e a d j u s t i n g c a m plate ( C ) , a d j u s t i n g r e m o v a l , a n d note t h e s e items:
bolt (D), a d j u s t i n g c a m c o l l a r ( E ) , s e l f - l o c k i n g c a m
nut ( F ) , a n d t h e l o w e r a r m ( G ) . • F i r s t install all of t h e c o m p o n e n t s , a n d lightly
t i g h t e n t h e bolts a n d nuts, t h e n r a i s e t h e
N O T E : D u r i n g i n s t a l l a t i o n , install t h e n e w s e l f - s u s p e n s i o n to l o a d it with t h e v e h i c l e ' s w e i g h t
locking nut a n d t h e n e w s e l f - l o c k i n g c a m nut. b e f o r e fully tightening to t h e s p e c i f i e d t o r q u e .
1 2 x 1.25 m m
7 8 N m (8.0 k g f m , 5 8 Ibf-ft) • B e f o r e c o n n e c t i n g t h e ball joint to the k n u c k l e ,
Replace. degrease the threaded section a n d tapered
portion of t h e ball joint pin, t h e ball joint
connecting hole, the threaded section and mating
• T o r q u e t h e c a s t l e nut to the l o w e r t o r q u e
a l i g n t h e slot w i t h t h e ball joint p i n hole. D o not
a l i g n t h e c a s t l e nut by l o o s e n i n g it.
• B e f o r e installing t h e w h e e l , c l e a n the m a t i n g
wheel.
F
Replace. n e c e s s a r y ( s e e p a g e 18-7).
12x1.25 m m
78 N-m
(8.0 k g f - m , 5 8 Ibf-ft)
Replace.
18-24
Upper Arm Replacement
Special Tools Required 6. R e m o v e t h e f l a n g e bolts (A), a n d r e m o v e t h e u p p e r
Ball joint r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2 arm.
1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it with N O T E : D u r i n g installation, install t h e n e w f l a n g e

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e bolts.
1-18).
3. R e m o v e t h e f l a n g e bolts (A) a n d t h e w h e e l s p e e d
s e n s o r h a r n e s s (B) f r o m t h e u p p e r a r m (C).
1 2 x 1.25 m m
103 N m (10.5 k g f m , 75.9 Ibfft)
Replace.
7. Install t h e u p p e r a r m in t h e r e v e r s e o r d e r of
A
6x1.0 mm • First install all of t h e c o m p o n e n t s , a n d lightly
9.8 N m (1.0 k g f m , 7 . 2 Ibf ft) tighten t h e bolts a n d n u t s , t h e n r a i s e the
s u s p e n s i o n to load it w i t h t h e v e h i c l e ' s w e i g h t
4. R e m o v e the lock pin (A) f r o m t h e u p p e r a r m ball before fully tightening to t h e s p e c i f i e d t o r q u e .
joint, t h e n r e m o v e t h e c a s t l e nut (B). • B e c a r e f u l not to d a m a g e t h e ball joint boot w h e n
N O T E : During installation, install t h e lock pin a s • B e f o r e c o n n e c t i n g t h e ball joint to t h e k n u c k l e ,
s h o w n after tightening t h e c a s t l e nut. d e g r e a s e the t h r e a d e d s e c t i o n a n d t a p e r e d
portion of the ball joint p i n , t h e ball joint
07MAC-SL0A202
connecting hole, the threaded section a n d mating
s u r f a c e s of t h e c a s t l e n u t
s p e c i f i c a t i o n , t h e n tighten it o n l y f a r e n o u g h to
a l i g n t h e slot with t h e ball joint pin hole. D o not
a l i g n t h e c a s t l e nut b y l o o s e n i n g it.
B • B e f o r e installing t h e w h e e l , c l e a n t h e m a t i n g
12x1.25 m m s u r f a c e s of t h e b r a k e d i s c a n d t h e i n s i d e of t h e
'00-03 m o d e l s :
wheel.
49-59 N m
(5.0-6.0 kgfm, • C h e c k t h e w h e e l a l i g n m e n t , a n d a d j u s t it if
3 6 - 4 3 Ibfft) n e c e s s a r y ( s e e p a g e 18-7).
'04-08 m o d e l s :
56-66 N m
(5.7-6.7 kgfm,
4 1 - 4 8 Ibfft)
5. D i s c o n n e c t t h e u p p e r a r m ball joint f r o m t h e
knuckle u s i n g t h e ball joint r e m o v e r ( s e e p a g e
18-13).
18-25
Front Suspension
Damper/Spring Removal and Installation

Special Tools Required 6. R e m o v e t h e f l a n g e nuts (A) f r o m t h e top of t h e
• B a l l joint t h r e a d protector, 14 m m 0 7 1 A F - S 3 V A O 0 0 damper.
• B a l l joint r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2
Removal
1. R a i s e t h e front of the v e h i c l e , a n d s u p p o r t it w i t h
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e
1-18).
3. R e m o v e the f l a n g e bolt (A) a n d b r a k e h o s e

m o u n t i n g bracket (B) f r o m t h e d a m p e r .
7. R e m o v e t h e f l a n g e bolt (A) at t h e b o t t o m of t h e
damper.
A
Replace.
4. R e m o v e t h e cotter pin (A) f r o m t h e l o w e r a r m ball

joint, t h e n r e m o v e t h e c a s t l e nut (B).
07MAC-SL0A202
071AF-S3VA000
A
Replace.
18-26
8 . L o w e r the l o w e r a r m , a n d r e m o v e t h e d a m p e r Installation
a s s e m b l y (A).
1. L o w e r t h e l o w e r a r m , a n d p o s i t i o n t h e d a m p e r
N O T E : B e c a r e f u l not to d a m a g e t h e b o d y . a s s e m b l y (A) in t h e b o d y .
N O T E : B e c a r e f u l not to d a m a g e t h e b o d y .
2 . L o o s e l y install t h e n e w flange nuts (A) onto t h e top

of t h e d a m p e r s t u d s .
A
10x1.25 mm
4 9 N - m (5.0 k g f - m , 3 6 I b f f t )
Replace.
(cont'd)
18-27
Front Suspension
Damper/Spring Removal and Installation (cont'd)
P o s i t i o n t h e b o t t o m of t h e d a m p e r o n t h e l o w e r 8. T i g h t e n t h e f l a n g e bolt c o n n e c t i n g t h e d a m p e r
a r m (A), a n d connect the lower a r m a n d the lower b o t t o m to t h e l o w e r a r m to t h e s p e c i f i e d t o r q u e
ball joint ( B ) . value.
9. T i g h t e n t h e f l a n g e nuts o n t h e t o p of t h e d a m p e r to
the specified torque value.
10. Install t h e b r a k e h o s e m o u n t i n g b r a c k e t (A) a n d t h e

f l a n g e bolt (B) to t h e d a m p e r , a n d tighten t h e bolt
to t h e s p e c i f i e d t o r q u e v a l u e .
8x1.25 mm
22 N m
(2.2 k g f m , 1 6 I b f f t )
12x1.25 m m
64 N-m
(6.5 k g f m , 4 7 I b f f t )
Replace.
4. Install t h e n e w f l a n g e bolt ( C ) , a n d lightly t i g h t e n .
5. R a i s e t h e s u s p e n s i o n until t h e v e h i c l e j u s t lifts off

the safety s t a n d .
6. Install t h e c a s t l e nut (A) onto t h e l o w e r a r m ball

joint p i n , a n d tighten it t o t h e l o w e r t o r q u e
s p e c i f i c a t i o n , t h e n t i g h t e n it o n l y f a r e n o u g h t o
a l i g n t h e s l o t w i t h t h e ball joint p i n h o l e . D o not 1 1 . C l e a n t h e m a t i n g s u r f a c e s of t h e brake d i s c a n d t h e
a l i g n t h e c a s t l e nut b y l o o s e n i n g it. i n s i d e of t h e w h e e l , t h e n install t h e front w h e e l .
12. C h e c k t h e w h e e l a l i g n m e n t , a n d a d j u s t it if
A
1 4 x 1.5 m m
'00-03 m o d e l s :
59-69 N m
(6.0—7.0 kgf m ,
4 3 - 5 1 Ibfft)
'04-08 m o d e l s :
6 9 - 7 8 N-m
(7.0—8.0 k g f m ,
51—58 Ibfft)
7. Install a n e w cotter p i n (B) after t i g h t e n i n g t h e

c a s t l e nut, a n d b e n d its e n d a s s h o w n .
18-28
Damper/Spring Disassembly, Inspection, and Reassembly
Exploded View
SELF-LOCKING NUT
10 x 1.25 m m
2 9 N m (3.0 k g f m , 2 2 I b f f t )
Replace.
DAMPER MOUNTING COLLAR
RUBBER BUSHING
Check for deterioration a n d damage UPPER SPRING MOUNTING CUSHION
Check for deterioration and damage.
DAMPER MOUNTING BASE DUST COVER PLATE
=^ / D U S T COVER SLEEVE
RUBBER BUSHING "^y^ Check for bending and damage.
DUST COVER END

Check for d e f o r m a t i o n and damage.
BUMP STOP PLATE
DAMPER SPRING BUMP STOP

Check for damage. Check for weakness, damage,
or oil c o n t a m i n a t i o n .
LOWER SPRING MOUNTING CUSHION

DAMPER UNIT
Check for oil leaks, gas leaks,
a n d s m o o t h operation.
(cont'd)
18-29
Front Suspension
Damper/Spring Disassembly, Inspection, and Reassembly (cont'd)
N O T E : W h e n c o m p r e s s i n g the d a m p e r s p r i n g , u s e a Inspection
c o m m e r c i a l l y a v a i l a b l e strut s p r i n g c o m p r e s s o r
( B r a n i c k M S T - 5 8 0 A or m o d e l 7 2 0 0 , or e q u i v a l e n t ) 1. R e a s s e m b l e all of the p a r t s , e x c e p t the d a m p e r
a c c o r d i n g to t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s . spring.
Disassembly 2. C o m p r e s s the d a m p e r a s s e m b l y b y h a n d , a n d
c h e c k for s m o o t h o p e r a t i o n t h r o u g h a full s t r o k e ,
1. C o m p r e s s the d a m p e r s p r i n g , t h e n r e m o v e the self- both c o m p r e s s i o n a n d e x t e n s i o n . T h e d a m p e r
locking nut (A) w h i l e h o l d i n g the d a m p e r shaft (B) should extend smoothly and constantly w h e n
w i t h a h e x w r e n c h . D o not c o m p r e s s the s p r i n g c o m p r e s s i o n is r e l e a s e d . If it d o e s not, the g a s is
m o r e t h a n n e c e s s a r y to r e m o v e the nut. l e a k i n g , a n d the d a m p e r s h o u l d be r e p l a c e d .
3. C h e c k for oil l e a k s , a b n o r m a l n o i s e s , or binding

during these tests.
R e l e a s e the p r e s s u r e f r o m the strut s p r i n g

c o m p r e s s o r , t h e n d i s a s s e m b l e the d a m p e r a s
s h o w n in t h e E x p l o d e d V i e w .
18-30
Reassembly 5 . Install a n e w s e l f - l o c k i n g nut (A) o n the d a m p e r
shaft.
1. A s s e m b l e all of the d a m p e r c o m p o n e n t s e x c e p t the
s e l f - l o c k i n g nut onto the d a m p e r unit. A l i g n the
s p r i n g b o t t o m e n d (A), the s t e p p e d part of the
l o w e r s p r i n g m o u n t i n g c u s h i o n , a n d t h e s t e p o n the
l o w e r s p r i n g s e a t (B).
(3.0 k g f - m , 2 2 Ibf-ft)
Replace.
6 . Hold the d a m p e r s h a f t w i t h a h e x w r e n c h ( B ) , a n d
tighten the s e l f - l o c k i n g nut to t h e s p e c i f i e d t o r q u e .
2 . Install the d a m p e r a s s e m b l y o n a c o m m e r c i a l l y
a v a i l a b l e strut s p r i n g c o m p r e s s o r (C).
3 . Position the s t u d bolt (A) in t h e d a m p e r mounting

base a s s h o w n .
Viewing from top
Left Right
4 . C o m p r e s s the d a m p e r s p r i n g w i t h the s p r i n g
compressor.
18-31
Rear Suspension
Knuckle/Hub/Wheel Bearing Replacement
Exploded View
KNUCKLE
C h e c k for d e f o r m a t i o n a n d d a m a g e .
A p p l y a s m a l l a m o u n t of e n g i n e oil
t o t h e s e a t i n g s u r f a c e of t h e nut.
18-32
1
Special Tools Required R e m o v e t h e f l a n g e bolt (A) a n d w h e e l s p e e d s e n s o r
• Ball joint t h r e a d protector, 12 m m 0 7 A A F - S D A A 1 0 0 (B) f r o m t h e k n u c k l e . D o not d i s c o n n e c t t h e w h e e l
• H u b d i s / a s s e m b l y tool, 42 m m 0 7 G A F - S D 4 0 1 0 0 speed sensor connector.
A
•Attachment, 52 x 55 m m 07746-0010400 6x1.0 mm D
•Attachment, 62 x 68 m m 07746-0010500 9 . 8 N m (1.0 k g f - m , 7 . 2 I b f f t )

• D r i v e r , 15 x 1 3 5 L 0 7 7 4 9 - 0 0 1 0 0 0 0
• S u p p o r t b a s e , 7 3 x 78/82.6 m m 0 7 9 6 5 - S D 9 0 1 0 0
1. R a i s e t h e rear of t h e v e h i c l e , a n d s u p p o r t it w i t h
1-18).
2. R e m o v e t h e w h e e l nuts (A) a n d rear w h e e l .
A
108 N-m
(11.0 k g f m ,
79.6 Ibfft)
5. R a i s e t h e s t a k e (A) of t h e s p i n d l e nut (B), a n d

r e m o v e t h e nut.
2 4 x 1.5 m m
245 N-m
(25.0 k g f m , 181 I b f f t )
Replace.
R e m o v e t h e brake c a l i p e r bracket m o u n t i n g bolts
(A), t h e n r e m o v e t h e c a l i p e r a s s e m b l y (B) f r o m t h e
k n u c k l e . T o p r e v e n t d a m a g e to t h e c a l i p e r
a s s e m b l y or brake h o s e , u s e a s h o r t p i e c e of w i r e
to h a n g t h e c a l i p e r a s s e m b l y f r o m t h e
u n d e r c a r r i a g e . D o not t w i s t t h e b r a k e h o s e
excessively.
A
10x1.25 m m
55 N-m
(5.6 k g f m , 41 I b f f t )
(cont'd)
18-33
Rear Suspension
6. R e m o v e t h e b r a k e d i s c ( s e e p a g e 19-25). 11. R e m o v e the control a r m .
7. C h e c k t h e r e a r h u b for d a m a g e a n d c r a c k s . 12. R e m o v e the cotter pin (A) f r o m t h e l o w e r a r m ball

8. R e m o v e t h e s e l f - l o c k i n g nut (A), a d j u s t i n g c a m
plate (B), a n d a d j u s t i n g bolt ( C ) , t h e n d i s c o n n e c t t h e N O T E : D u r i n g installation, install t h e n e w cotter pin
c o n t r o l a r m (D) f r o m t h e f r a m e . after tightening t h e c a s t l e nut, a n d b e n d its e n d a s
shown.
N O T E : D u r i n g i n s t a l l a t i o n , install t h e n e w s e l f -
locking nut.
12 x 1.25 m m
5 4 N - m (5.5 k g f m , 4 0 Ibf-ft)
Replace.
9. R e m o v e t h e lock pin (A) f r o m t h e c on tro l a r m ball

N O T E : D u r i n g i n s t a l l a t i o n , install t h e lock pin a s 13. D i s c o n n e c t t h e l o w e r a r m ball joint f r o m t h e l o w e r

s h o w n after t i g h t e n i n g t h e c a s t l e nut. a r m u s i n g the ball joint t h r e a d protector a n d t h e
07MAC-SL0A202
10. D i s c o n n e c t t h e c o n t r o l a r m ball joint f r o m the

18-13).
N O T E : T u r n t h e c o n t ro l a r m (C) o u t w a r d to install
t h e ball joint r e m o v e r .
18-34
I
14. R e m o v e t h e lock pin (A) f r o m the u p p e r a r m ball 17. S e p a r a t e t h e h u b (A) f r o m the k n u c k l e (B) u s i n g t h e
joint, t h e n r e m o v e t h e c a s t l e nut (B). h u b d i s / a s s e m b l y tool a n d a h y d r a u l i c p r e s s . B e
c a r e f u l not to d e f o r m t h e s p l a s h g u a r d . Hold o n t o
N O T E : D u r i n g i n s t a l l a t i o n , install t h e lock pin a s t h e h u b to k e e p it f r o m falling w h e n p r e s s e d c l e a r .
s h o w n after t i g h t e n i n g t h e c a s t l e nut.
18. R e m o v e t h e s c r e w s (A), t h e s p l a s h g u a r d (B), a n d

t h e s n a p ring (C) f r o m t h e k n u c k l e (D).
15. D i s c o n n e c t t h e u p p e r a r m ball joint f r o m the

18-13).
16. R e m o v e t h e d r i v e s h a f t o u t b o a r d joint (A) f r o m t h e

k n u c k l e (B) by t a p p i n g the d r i v e s h a f t e n d (C) w i t h a
soft f a c e h a m m e r w h i l e pulling t h e knuckle
outward.
N O T E : Do not pull t h e d r i v e s h a f t o u t w a r d . T h e
d r i v e s h a f t i n b o a r d joint m a y c o m e apart.
B
D
(cont'd)
18-35
Rear Suspension
19. P r e s s t h e w h e e l b e a r i n g (A) out of t h e k n u c k l e (B) 2 1 . W a s h t h e k n u c k l e a n d h u b t h o r o u g h l y in a high

using the driver, the attachment, and a press. f l a s h point s o l v e n t before r e a s s e m b l y .
Press
2 2 . P r e s s a n e w w h e e l b e a r i n g (A) into the knuckle (B)
07749-0010000 u s i n g t h e o l d b e a r i n g ( C ) , a s t e e l plate (D), t h e
07746-0010400 s u p p o r t b a s e , a n d a p r e s s . P l a c e the w h e e l b e a r i n g
o n the k n u c k l e w i t h the p a c k s e a l s i d e f a c i n g (E)
(metal c o l o r ) t o w a r d the i n s i d e . B e c a r e f u l not to
d a m a g e the s l e e v e of t h e pack s e a l .
Press
METALCOLOR
S E A L SIDE
20. P r e s s t h e w h e e l b e a r i n g i n n e r r a c e (A) out of t h e

h u b (B) u s i n g t h e h u b d i s / a s s e m b l y t o o l , a
commercially available bearing separator (C), and a
press.
07965-SD90100
07GAF-SD40100
Press
2 3 . Install the s n a p ring (A) s e c u r e l y in t h e knuckle (B).
D A
5 x 0.8 m m
6 N-m
(0.6 k g f - m , 4 Ibf ft)
24. Install t h e s p l a s h g u a r d ( C ) , a n d tighten t h e s c r e w s

(D) to t h e s p e c i f i e d t o r q u e v a l u e .
18-36
1
2 5 . Install the h u b (A) o n t o the k n u c k l e (B) u s i n g the 26. Install t h e k n u c k l e in the r e v e r s e o r d e r of r e m o v a l ,
driver, t h e a t t a c h m e n t , t h e s u p p o r t b a s e , a n d a a n d note t h e s e i t e m s :
h y d r a u l i c p r e s s . B e c a r e f u l not to distort the s p l a s h
g u a r d (C). • First install all of t h e c o m p o n e n t s , a n d lightly
tighten the bolts a n d n u t s , t h e n r a i s e t h e
Press
07749-0010000 before fully t i g h t e n i n g to t h e s p e c i f i e d t o r q u e .
07746-0010500 • B e c a r e f u l not to d a m a g e t h e ball joint boot w h e n
• U s e t h e n e w s p i n d l e nut d u r i n g r e a s s e m b l y .
• B e f o r e installing t h e s p i n d l e nut, a p p l y a s m a l l
a m o u n t of e n g i n e oil to t h e s e a t i n g s u r f a c e of t h e
nut. After t i g h t e n i n g , u s e a drift to s t a k e t h e
s p i n d l e nut s h o u l d e r a g a i n s t t h e d r i v e s h a f t .
• B e f o r e c o n n e c t i n g t h e ball joint to t h e k n u c k l e ,
degrease the threaded section and tapered
portion of t h e ball joint p i n , t h e ball joint
a l i g n the s l o t w i t h t h e ball joint pin h o l e . D o not
07965-SD90100 align the c a s t l e nut by l o o s e n i n g it.
• B e f o r e installing t h e b r a k e d i s c , c l e a n t h e m a t i n g
s u r f a c e s of t h e r e a r h u b a n d t h e i n s i d e of t h e
brake disc.
• B e f o r e installing t h e w h e e l , c l e a n t h e m a t i n g
wheel.
18-37
Rear Suspension
Ball Joint Boot Replacement
Special Tools Required 6. F o r t h e c o n t r o l a r m ball joint, s e t the boot o n t h e
• Ball j o i n t boot clip g u i d e , 42 x 44 m m 0 7 G A G - S D 4 0 7 0 0 j o i n t p i n , a n d p r e s s it w i t h the b u s h i n g b a s e until
• B u s h i n g b a s e 0 7 J A F - S H 2 0 3 3 0 or 0 7 9 3 3 - H B 3 0 0 0 A t h e r e is no g a p at t h e bottom of the boot (A).
w i t h o u t a d j u s t i n g bolt
1. R e m o v e the boot c l i p ( e x c e p t for t h e c o n t r o l a r m

ball joint) a n d t h e boot.
2. P a c k t h e interior a n d lip of t h e n e w b o o t (A) w i t h

f r e s h g r e a s e . D o not c o n t a m i n a t e t h e l o w e r c o l l a r
of t h e boot (B) w i t h g r e a s e .
3. W i p e t h e g r e a s e off t h e t a p e r e d s e c t i o n of t h e ball
j o i n t pin ( C ) , a n d p a c k the b a s e (D) w i t h f r e s h
grease.
4. Install t h e boot o n t o t h e ball joint p i n , t h e n s q u e e z e

it g e n t l y to f o r c e out a n y air. D o not let dirt o r o t h e r
f o r e i g n m a t e r i a l s get into t h e boot.
5. F o r t h e u p p e r a n d l o w e r a r m ball j o i n t , a d j u s t t h e
ball joint boot c l i p g u i d e w i t h t h e a d j u s t i n g bolt (A)
until its b a s e is j u s t a b o v e t h e g r o o v e a r o u n d t h e
b o t t o m of the boot. T h e n s l i d e the c l i p (B) o v e r t h e
boot clip g u i d e into t h e p o s i t i o n o n t h e boot.
18-38
Stabilizer Link Removal/Installation
1. R a i s e t h e rear of t h e v e h i c l e , a n d s u p p o r t it w i t h 5. Install t h e n e w s e l f - l o c k i n g nut a n d the n e w f l a n g e

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e nut, a n d lightly tighten t h e m .
1-18).
6. P l a c e a j a c k u n d e r t h e l o w e r a r m , a n d r a i s e t h e
2. R e m o v e t h e rear w h e e l . s u s p e n s i o n to load the stabilizer bar.
3. R e m o v e t h e s e l f - l o c k i n g nut (A) a n d the f l a n g e nut 7. T i g h t e n t h e s e l f - l o c k i n g nut (A) a n d the f l a n g e nut

(B) w h i l e holding the r e s p e c t i v e joint pin (C) w i t h a (B) to the s p e c i f i e d t o r q u e v a l u e s w h i l e h o l d i n g the
h e x w r e n c h (D), a n d d i s c o n n e c t the stabilizer link r e s p e c t i v e j o i n t pin (G) w i t h a h e x w r e n c h (D).
(E) f r o m t h e stabilizer bar (F) a n d the l o w e r a r m (G),
10x1.25 mm
4. Install t h e stabilizer link to the stabilizer bar a n d 2 9 N m (3.0 k g f m , 2 2 Ibf ft)
Replace.
l o w e r a r m w i t h t h e joint p i n s s e t at the c e n t e r (A) of
their r a n g e of m o v e m e n t . 8. C l e a n the m a t i n g s u r f a c e s of the brake d i s c a n d the
i n s i d e of t h e w h e e l , t h e n install the rear w h e e l , a n d
test-drive the v e h i c l e .
9. After 5 m i n u t e s of d r i v i n g , tighten the s e l f - l o c k i n g

nut a g a i n to the s p e c i f i e d t o r q u e v a l u e .
18-39
Rear Suspension
Stabilizer Bar Replacement Lower Arm Removal/Installation
1. R a i s e t h e r e a r of t h e v e h i c l e , a n d s u p p o r t it w i t h Special Tools Required

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e • Ball joint t h r e a d protector, 12 m m 0 7 A A F - S D A A 1 0 0
1-18). • Ball joint r e m o v e r , 2 8 m m 0 7 M A C - S L 0 A 2 0 2
2. R e m o v e t h e r e a r w h e e l s . 1. R a i s e t h e rear of t h e v e h i c l e , a n d s u p p o r t it w i t h
3. R e m o v e t h e s e l f - l o c k i n g nut (A) w h i l e h o l d i n g t h e 1-18).
j o i n t pin (B) w i t h a h e x w r e n c h ( C ) , a n d d i s c o n n e c t
both stabilizer links (D) f r o m t h e stabilizer b a r ( E ) . 2. R e m o v e t h e r e a r w h e e l .
N O T E : D u r i n g installation, install t h e n e w s e l f - 3. R e m o v e t h e f l a n g e nut (A) w h i l e h o l d i n g t h e joint

locking nut. pin (B) w i t h a h e x w r e n c h ( C ) , a n d d i s c o n n e c t t h e
stabilizer link (D) f r o m t h e l o w e r a r m ( E ) .
A
c 10x1.25 mm
43 N-m (4.4 kgfm, 32 Ibf-ft)
Replace. N O T E : D u r i n g installation, install t h e n e w f l a n g e
nut.
4. R e m o v e t h e bolts (A) a n d b u s h i n g h o l d e r s (B), t h e n

r e m o v e t h e b u s h i n g s (C) a n d t h e stabilizer b a r (D).
10 x 1.25 m m
2 9 N - m (3.0 k g f m , 2 2 Ibf-ft)
Replace.
5. Install t h e s t a b i l i z e r b a r in t h e r e v e r s e o r d e r of
• R e f e r to stabilizer link r e m o v a l / i n s t a l l a t i o n to
c o n n e c t t h e stabilizer b a r to t h e links ( s e e p a g e
18-39).
s u r f a c e s of t h e brake d i s c a n d i n s i d e of t h e w h e e l .
18-40
4. R e m o v e the f l a n g e bolt (A), a n d d i s c o n n e c t the 7. R e m o v e t h e f l a n g e bolt ( A ) , s e l f - l o c k i n g nut ( B ) ,
d a m p e r (B) f r o m the l o w e r a r m ( C ) . a d j u s t i n g c a m plate ( C ) , a d j u s t i n g bolt (D), a n d t h e
lower a r m (E).
N O T E : D u r i n g installation, install t h e n e w f l a n g e
bolt. N O T E : D u r i n g i n s t a l l a t i o n , install t h e n e w f l a n g e
bolt, t h e n e w a d j u s t i n g bolt, a n d t h e n e w s e l f -
locking nut.
A
1 2 x 1.25 m m
123 N-m (12.5 k g f m , 9 0 . 4 Ibfft)
Replace.
12 x 1.25 m m
64 N-m
(6.5 k g f - m
Replace.
D
Replace. 1 2 x 1.25 m m
74 N-m
5. R e m o v e t h e cotter pin (A) f r o m t h e l o w e r a r m ball
(7.5 k g f m , 5 4 I b f f t )
joint, t h e n r e m o v e t h e c a s t l e nut (B). Replace.
N O T E : During installation, install the n e w cotter pin Install t h e l o w e r a r m in t h e r e v e r s e o r d e r of

after tightening t h e c a s t l e nut, a n d b e n d its e n d a s r e m o v a l , a n d note t h e s e i t e m s :
shown.
tighten t h e bolts a n d n u t s , t h e n r a i s e t h e
07MAC-SL0A202
s u s p e n s i o n to load it w i t h t h e v e h i c l e ' s w e i g h t
b e f o r e fully tightening to t h e s p e c i f i e d t o r q u e .
07 A A F - S D A A 1 0 0 • B e f o r e c o n n e c t i n g t h e ball joint to t h e k n u c k l e ,
degrease the threaded section a n d tapered
connecting hole, the threaded section a n d mating
12x1.25 m m • T o r q u e t h e c a s t l e nut to t h e l o w e r t o r q u e
69-78 N m
(7.0-8.0 kgfm,
5 1 - 5 8 Ibfft) a l i g n t h e slot w i t h t h e ball joint pin h o l e . D o not
align the c a s t l e nut b y l o o s e n i n g it.
A
Replace. s u r f a c e s of t h e b r a k e d i s c a n d t h e i n s i d e of t h e
wheel.
18-41
Rear Suspension
Upper Arm Removal/Installation
Special Tools Required 6. R e m o v e t h e f l a n g e bolts (A), a n d r e m o v e t h e u p p e r

Ball joint r e m o v e r , 2 8 m m 0 7 M A C - S L 0 A 2 0 2 arm.
1. R a i s e t h e r e a r of t h e v e h i c l e , a n d s u p p o r t it w i t h N O T E : D u r i n g installation, install t h e n e w f l a n g e
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e bolts.
1-18).
2. R e m o v e the rear w h e e l .
3. R e m o v e t h e f l a n g e bolts (A) a n d t h e w h e e l s p e e d
s e n s o r h a r n e s s (B) f r o m t h e u p p e r a r m ( C ) .
A
12 x 1.25 m m
1 3 2 N m ( 1 3 . 5 k g f m , 9 7 . 6 Ibf-ft)
Replace.
7. Install t h e u p p e r a r m in t h e r e v e r s e o r d e r of

tighten t h e bolts a n d n u t s , t h e n r a i s e t h e
9.8 N m (1.0 k g f m , 7 . 2 Ibf-ft)
b e f o r e fully tightening to t h e s p e c i f i e d t o r q u e .
4. R e m o v e t h e lock pin (A) f r o m t h e u p p e r a r m ball • B e c a r e f u l not to d a m a g e t h e ball joint boot w h e n
joint, t h e n r e m o v e t h e c a s t l e nut (B). connecting the knuckle.
N O T E : D u r i n g i n s t a l l a t i o n , install t h e lock p i n a s degrease the threaded section and tapered
s h o w n after t i g h t e n i n g t h e c a s t l e nut. portion of t h e ball joint pin, t h e ball joint
a l i g n t h e s l o t w i t h t h e ball joint pin h o l e . D o not
align t h e c a s t l e nut b y l o o s e n i n g it.
s u r f a c e s of t h e brake d i s c a n d t h e i n s i d e of t h e
wheel.
'04-08 m o d e l s :
5 6 - 6 6 N-m
( 5 . 7 - 6 . 7 k g f m , 4 1 - 4 8 Ibf-ft)
5. D i s c o n n e c t t h e u p p e r a r m ball joint f r o m t h e
18-13).
18-42
Control Arm Replacement
Special Tools Required 4. R e m o v e t h e lock pin (A) f r o m t h e c o n t r o l a r m ball

Ball joint r e m o v e r , 28 m m 0 7 M A C - S L 0 A 2 0 2 joint, t h e n r e m o v e t h e c a s t l e nut (B).
1. R a i s e the rear of t h e v e h i c l e , a n d s u p p o r t it with N O T E : D u r i n g i n s t a l l a t i o n , install t h e lock pin a s

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e page s h o w n after t i g h t e n i n g t h e c a s t l e nut.
1-18).
2. R e m o v e t h e rear w h e e l .
3. R e m o v e t h e self-locking nut (A), a d j u s t i n g c a m

plate (B), a n d a d j u s t i n g bolt ( C ) , t h e n d i s c o n n e c t the
control a r m (D) f r o m the f r a m e .
N O T E : D u r i n g installation, install the n e w self-

locking nut.
07MAC-SL0A202
5. D i s c o n n e c t t h e c o n t r o l a r m ball joint f r o m the

18-13).
N O T E : T u r n the c o n t r o l a r m (C) o u t w a r d to install

12 x 1.25 m m t h e ball joint r e m o v e r .
5 4 N-m (5.5 k g f - m , 4 0 I b f f t )
Replace.
6. R e m o v e t h e control a r m .
7. Install the control a r m in t h e r e v e r s e o r d e r of


tighten t h e bolts a n d n u t s , t h e n r a i s e the
s u s p e n s i o n to l o a d it w i t h the v e h i c l e ' s w e i g h t
before fully t i g h t e n i n g to t h e s p e c i f i e d torque.
• B e c a r e f u l not to d a m a g e the ball joint boot w h e n
c o n n e c t i n g the k n u c k l e .
d e g r e a s e the t h r e a d e d s e c t i o n a n d t a p e r e d
s u r f a c e s of the c a s t l e nut.
align the slot w i t h t h e ball joint pin hole. Do not
align the c a s t l e nut by l o o s e n i n g it.
s u r f a c e s of the b r a k e d i s c a n d the i n s i d e of the
wheel.
• C h e c k the w h e e l a l i g n m e n t , a n d a d j u s t it if
18-43
Rear Suspension
Damper/Spring Removal and Installation
Removal 6. L o w e r the lower a r m , a n d r e m o v e the d a m p e r

a s s e m b l y (A).
1. R e m o v e t h e s p a r e tire (if e q u i p p e d ) f r o m t h e trunk.
5 . R e m o v e t h e f l a n g e bolt (A) at t h e b o t t o m of t h e
damper.
18-44
Installation 3. P o s i t i o n t h e b o t t o m of the d a m p e r o n t h e l o w e r
a r m (A).
1. L o w e r t h e l o w e r a r m , a n d position the d a m p e r
a s s e m b l y (A) in t h e b o d y .
4. Install t h e n e w f l a n g e bolt ( B ) , a n d lightly t i g h t e n .
5. R a i s e the s u s p e n s i o n until t h e v e h i c l e j u s t lifts off

the safety stand.
6. T i g h t e n t h e f l a n g e bolt c o n n e c t i n g t h e d a m p e r
b o t t o m to the l o w e r a r m to t h e s p e c i f i e d t o r q u e
2 . L o o s e l y install the n e w f l a n g e n u t s (A) onto t h e top value.
of t h e d a m p e r s t u d s .
7. T i g h t e n t h e f l a n g e nuts o n t h e t o p of t h e d a m p e r to
the specified torque value.
8. C l e a n the m a t i n g s u r f a c e s of t h e b r a k e d i s c a n d t h e
i n s i d e of t h e w h e e l , t h e n install t h e rear w h e e l .
9. C h e c k t h e w h e e l a l i g n m e n t , a n d a d j u s t it if
10. Put t h e s p a r e tire (if e q u i p p e d ) b a c k in t h e trunk.
18-45
Rear Suspension
Damper/Spring Disassembly, Inspection, and Reassembly
Exploded View
SELF-LOCKING NUT
10x1.25 mm
2 9 N m (3.0 k g f m , 2 2 I b f f t )
Replace.
DAMPER MOUNTING COLLAR
RUBBER BUSHING
C h e c k for deterioration a n d d a m a g e . UPPER SPRING MOUNTING CUSHION
C h e c k for deterioration a n d d a m a g e .
O-RING
DUST COVER PLATE
DUST COVER SLEEVE

C h e c k for b e n d i n g a n d d a m a g e .
RUBBER BUSHING
C h e c k for deterioration a n d d a m a g e ,
DUST COVER END
C h e c k for deformation a n d d a m a g e .
BUMP STOP PLATE
BUMP STOP
DAMPER SPRING C h e c k for w e a k n e s s , d a m a g e ,
C h e c k for d a m a g e . o r oil c o n t a m i n a t i o n .
LOWER SPRING MOUNTING CUSHION

C h e c k for deterioration a n d d a m a g e . DAMPER UNIT
C h e c k f o r oil l e a k s , g a s l e a k s ,
and smooth operation.
18-46
N O T E : W h e n c o m p r e s s i n g the d a m p e r s p r i n g , u s e a Inspection
c o m m e r c i a l l y a v a i l a b l e strut s p r i n g c o m p r e s s o r
(Branick M S T - 5 8 0 A or M o d e l 7 2 0 0 , or e q u i v a l e n t ) 1. R e a s s e m b l e all of the p a r t s , e x c e p t t h e d a m p e r
a c c o r d i n g to the m a n u f a c t u r e r ' s i n s t r u c t i o n s . spring.
Disassembly 2. C o m p r e s s t h e d a m p e r a s s e m b l y b y h a n d , a n d
c h e c k for s m o o t h o p e r a t i o n t h r o u g h a full s t r o k e ,
1. C o m p r e s s the d a m p e r s p r i n g , t h e n r e m o v e the self- both c o m p r e s s i o n a n d e x t e n s i o n . T h e d a m p e r
locking nut (A) w h i l e holding the d a m p e r s h a f t (B) should extend smoothly and constantly w h e n
w i t h a h e x w r e n c h . D o not c o m p r e s s t h e s p r i n g c o m p r e s s i o n is r e l e a s e d . If it d o e s not, the g a s is
m o r e t h a n n e c e s s a r y to r e m o v e the nut. l e a k i n g , a n d t h e d a m p e r s h o u l d be r e p l a c e d .
3. C h e c k for oil l e a k s , a b n o r m a l n o i s e s , or b i n d i n g
during these tests.
2. R e l e a s e the p r e s s u r e f r o m the strut s p r i n g

c o m p r e s s o r , t h e n d i s a s s e m b l e the d a m p e r a s
s h o w n in the E x p l o d e d V i e w .
(cont'd)
18-47
Rear Suspension
Damper/Spring Disassembly, Inspection, and Reassembly (cont'd)
Reassembly 5 . Install a n e w self-locking nut (A) o n the d a m p e r

shaft.
1. A s s e m b l e all of the d a m p e r c o m p o n e n t s e x c e p t t h e
s e l f - l o c k i n g nut onto t h e d a m p e r unit. A l i g n t h e
s p r i n g b o t t o m e n d (A), t h e s t e p p e d part of the
lower spring mounting c u s h i o n , and the step on the
l o w e r s p r i n g s e a t (B).
A
10x1.25 mm
2 9 N - m (3.0 k g f m , 2 2 I b f f t )
Replace.
6 . H o l d the d a m p e r s h a f t w i t h a h e x w r e n c h (B), a n d
t i g h t e n t h e s e l f - l o c k i n g nut to t h e s p e c i f i e d t o r q u e .
2 . Install the d a m p e r a s s e m b l y o n a c o m m e r c i a l l y
a v a i l a b l e strut s p r i n g c o m p r e s s o r (C).
3 . P o s i t i o n t h e s t u d bolt (A) in the d a m p e r mounting

base as shown.
Viewing from top
Left Right
4 . C o m p r e s s the d a m p e r s p r i n g w i t h the s p r i n g
compressor.
18-48
Suspension
Front and Rear S u s p e n s i o n 18-2
Front S u s p e n s i o n 18-14
Rear S u s p e n s i o n 18-32
T P M S (Tire Pressure Monitoring S y s t e m ) ('08 model)

Memorizing the Tire Pressure Sensor ID . 18-54
Tire Pressure Sensor Location 18-55
TPMS Control Unit Replacement 18-80
Tire Pressure Sensor Replacement 18-81
TPMS
TIRE P R E S S U R E S E N S O R
18-50
1
System Indicator Locations If t h e s y s t e m i s O K , t h e T P M S i n d i c a t o r a n d t h e l o w tire

p r e s s u r e indicator s h o u l d c o m e o n w h e n y o u t u r n the
T h e s y s t e m h a s two indicators. ignition s w i t c h to O N (II), a n d t h e n g o off 2 s e c o n d s
later. If t h e y don't, t h e r e is a p r o b l e m w i t h t h e s y s t e m .
• T h e l o w tire p r e s s u r e indicator (A)
• T h e T P M S indicator (B) If t h e s y s t e m d e t e c t s l o w p r e s s u r e in a n y of t h e four
t i r e s , t h e l o w tire p r e s s u r e indicator c o m e s o n , a n d t h e
c o n t r o l unit w i l l s e t o n e o r m o r e of t h e s e c o d e s :
D T C 1 1 , 1 3 , 1 5 , 1 7 . W h e n t h e tire p r e s s u r e r e t u r n s to
n o r m a l , t h e control unit t u r n s off the i n d i c a t o r s a n d
s t o r e s the D T C ( s ) . H o w e v e r , if t h e c o n t r o l unit d e t e c t s a
p r o b l e m in t h e s y s t e m d u r i n g a n indication of l o w tire
p r e s s u r e , it t u r n s off t h e l o w tire p r e s s u r e indicator,
s t o r e s the D T C ( s ) , a n d t u r n s o n t h e T P M S indicator(s).
N O T E : T i r e p r e s s u r e s i n c r e a s e slightly a s t h e
t e m p e r a t u r e in the t i r e s r i s e s d u r i n g d r i v i n g at h i g h w a y
s p e e d s . Pressures c a n also increase or d e c r e a s e
s l i g h t l y w i t h c h a n g e s in o u t s i d e air t e m p e r a t u r e .
A A t e m p e r a t u r e c h a n g e of a b o u t 18 °F (10 *€) c h a n g e s
2
tire p r e s s u r e b y a b o u t 10 kPa (0.1 k g f / c m , 1 . 5 p s i ) . If t h e
How TPMS Works t e m p e r a t u r e d r o p s , tire p r e s s u r e c o u l d d e c r e a s e j u s t
e n o u g h to turn o n t h e l o w tire p r e s s u r e indicator, but
T h e T P M S (tire p r e s s u r e m o n i t o r i n g s y s t e m ) h a s a l o w later, the tire t e m p e r a t u r e c o u l d i n c r e a s e e n o u g h to
tire p r e s s u r e indicator a n d a T P M S indicator. W h e n t h e t u r n t h e indicator off. T o r e s o l v e a c o m p l a i n t of s u c h
T P M S control unit d e t e c t s l o w p r e s s u r e in a tire, or a intermittent i n d i c a t i o n s , c o n f i r m a n d c l e a r t h e s t o r e d
p r o b l e m in the s y s t e m , it t u r n s o n t h e a p p r o p r i a t e D T C ( s ) a n d c h e c k t h e tire p r e s s u r e s . T h e n e x p l a i n to t h e
indicator. c u s t o m e r h o w t e m p e r a t u r e c h a n g e s c a n affect the
s y s t e m , e s p e c i a l l y w h e n tire p r e s s u r e s a r e n e a r the l o w
• If l o w tire p r e s s u r e i s detected in o n e or m o r e t i r e s , e n d of the T P M S n o r m a l r a n g e - 1 6 8 to 2 2 0 kPa (1.7 to
2
t h e l o w tire p r e s s u r e indicator c o m e s o n . 2.2 k g f / c m , 2 4 to 3 2 p s i ) .
• If a p r o b l e m in t h e s y s t e m is d e t e c t e d , the T P M S
indicator c o m e s o n . If a p r o b l e m is d e t e c t e d in the s y s t e m , the T P M S
• If l o w tire p r e s s u r e a n d a p r o b l e m in the s y s t e m a r e indicator c o m e s o n a n d s t a y s o n until t h e s y s t e m
d e t e c t e d , o n l y the T P M S i n d i c a t o r c o m e s o n . r e t u r n s to n o r m a l w i t h m o s t D T C s . If D T C 8 1 , 8 3 , or 8 5 is
s e t , the T P M S indicator g o e s off o n l y w h e n the ignition
s w i t c h is t u r n e d to L O C K (0).
E x c e p t C R m o d e l : W h e n a flat tire is r e p l a c e d w i t h t h e
s p a r e tire, the T P M S indicator c o m e s o n ( D T C 3 2 , 3 4 ,
3 6 , or 38) b e c a u s e t h e s y s t e m is n o l o n g e r r e c e i v i n g the
s i g n a l f r o m the t i r e ' s transmitter.
T h i s is not a p r o b l e m w i t h the s p a r e tire.
C R m o d e l : W h e n a tire s e a l a n t is c h a r g e d into the flat

tire, t h e r e is a p o s s i b i l i t y that the T P M S indicator or the
l o w tire p r e s s u r e indicator m a y c o m e o n a n d c a u s e a
D T C to be s t o r e d .
T h e r e f o r e , it is n e c e s s a r y to c l e a n the tire p r e s s u r e
s e n s o r after r e m o v i n g the tire s e a l a n t a n d repair t h e flat
tire ( s e e p a g e 18-5).
(cont'd)
18-51
TPMS
Problems That Are Not System Faults How to Troubleshoot DTCs
• Tire Sealant D T C t r o u b l e s h o o t i n g p r o c e d u r e s a s s u m e t h e c a u s e of
F l u i d s e a l a n t u s e d to r e p a i r a p u n c t u r e d tire c a n t h e p r o b l e m is still p r e s e n t a n d the T P M S indicator is
d a m a g e t h e tire p r e s s u r e s e n s o r m o u n t e d o n e a c h still o n . ( N O T E : T h e T P M S indicator c o m e s o n for D T C s
w h e e l . It c a n p r e v e n t t h e s y s t e m f r o m detecting t h e 1 1 , 1 3 , 1 5 , a n d 17 o n l y if t h e l o w tire p r e s s u r e indication
c o r r e c t tire p r e s s u r e , w h i c h s e t s a D T C 1 1 , 1 3 , 1 5 , or is f a l s e , c a u s e d by a p r o b l e m in t h e s y s t e m . ) Do not u s e
17 e v e n t h o u g h the s y s t e m is n o r m a l . a t r o u b l e s h o o t i n g p r o c e d u r e u n l e s s the s y s t e m h a s s e t
• Cold Weather t h e D T C listed for it.
W h e n t h e w e a t h e r is e x t r e m e l y c o l d - a b o u t —40 °F
(—40 °C) or c o l d e r - the output of t h e lithium battery 1. A s k t h e c u s t o m e r to d e s c r i b e t h e c o n d i t i o n s w h e n
in e a c h tire p r e s s u r e s e n s o r m a y d r o p far e n o u g h that t h e indicator c a m e o n , a n d try to r e p r o d u c e t h e
t h e c o n t r o l unit s e t s a D T C for l o w battery v o l t a g e (31, s a m e c o n d i t i o n s for t r o u b l e s h o o t i n g . F i n d out if the
3 3 , 3 5 , or 37) e v e n t h o u g h t h e s y s t e m is n o r m a l . c u s t o m e r c h e c k e d a n d / o r a d j u s t e d tire p r e s s u r e s
• Non-TPMS Wheels s i n c e t h e indicator c a m e o n .
Vehicles equipped with T P M S m u s t u s e w h e e l s m a d e
for t h e s y s t e m . E v e r y T P M S w h e e l h a s a n e x c l u s i v e 2. If a n indicator d o e s not c o m e o n d u r i n g the test-
m a r k ; d o not u s e a n y other t y p e of w h e e l . d r i v e , c h e c k for l o o s e t e r m i n a l s , poor c o n t a c t d u e
to d a m a g e d t e r m i n a l s , etc. before y o u start
How a Diagnostic Trouble Code (DTC) is Set troubleshooting.
• W h e n the s y s t e m detects a problem, the T P M S 3. After t r o u b l e s h o o t i n g , repair a n d c l e a r t h e D T C s ,

control unit s e t s a c o d e , but s h i f t s to f a i l - s a f e m o d e , a n d test-drive t h e v e h i c l e . M a k e s u r e no indicators
a n d will not alert the d r i v e r to l o w tire p r e s s u r e s . come on.
• If t h e T P M S control unit l o s e s p o w e r , or f a i l s , the
T P M S indicator will c o m e o n , but n o D T C a r e s e t . 4. C h e c k for D T C s f r o m g a u g e a s s e m b l y that is
• T h e m e m o r y c a n hold all t h e D T C s that c o u l d c o n n e c t e d v i a F - C A N . If t h e r e a r e D T C s that a r e
p o s s i b l y b e s e t . H o w e v e r , w h e n t h e s a m e D T C is r e l a t e d to F - C A N , t h e m o s t likely c a u s e w a s that t h e
detected m o r e than o n c e , the m o s t recent one ignition s w i t c h w a s t u r n e d to O N (II) w i t h the T P M S
o v e r w r i t e s t h e p r e v i o u s o n e , s o o n l y t h e latest D T C of control unit c o n n e c t o r d i s c o n n e c t e d . C l e a r t h e
e a c h t y p e is s t o r e d . D T C s . C h e c k for g a u g e a s s e m b l y a n d T P M S c o d e s ,
• D T C s a r e i n d i c a t e d in a s c e n d i n g o r d e r , not in the a n d t r o u b l e s h o o t t h o s e first.
order they occurred.
• S e t D T C s a r e s t o r e d in t h e E E P R O M (nonvolatile
m e m o r y ) , t h e y c a n n o t be c l e a r e d b y d i s c o n n e c t i n g
t h e battery. T o c l e a r a D T C , c o n n e c t t h e H D S ( H o n d a
D i a g n o s t i c S y s t e m ) to t h e d a t a link c o n n e c t o r ( D L C ) ,
and follow the s c r e e n prompts.
18-52
How to Retrieve DTCs How to Clear DTCs
1. W i t h the ignition s w i t c h at L O C K (0), c o n n e c t the 1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e

H D S ( H o n d a D i a g n o s t i c S y s t e m ) to t h e data link H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d
c o n n e c t o r ( D L C ) (A) located u n d e r the d r i v e r ' s s i d e u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d .
of t h e d a s h b o a r d .
2 . T u r n t h e ignition s w i t c h to O N (II).
3. M a k e s u r e t h e H D S c o m m u n i c a t e s with t h e v e h i c l e a n d t h e T P M S control unit. If it d o e s n ' t ,
a n d the T P M S control unit. If it d o e s n ' t , t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
t r o u b l e s h o o t the D L C circuit ( s e e p a g e 11-367).
4. C l e a r t h e D T C ( s ) by f o l l o w i n g t h e s c r e e n p r o m p t s
4. F o l l o w t h e p r o m p t s o n the H D S to d i s p l a y t h e on the H D S .
D T C ( s ) o n t h e s c r e e n . After d e t e r m i n i n g t h e D T C ,
refer to t h e D T C t r o u b l e s h o o t i n g . N O T E : S e e t h e H D S Help m e n u for s p e c i f i c
instructions.
N O T E : S e e t h e H D S Help m e n u for s p e c i f i c
instructions. 5. T u r n the ignition s w i t c h to L O C K (0).
18-53
TPMS
Memorizing the Tire Pressure Sensor ID
Special Tools Required F o l l o w H D S s c r e e n p r o m p t s to turn o n t h e T P M S

T P M S s e n s o r initializer tool A K S 0 6 2 0 0 0 6 s e n s o r initializer tool (A). V e r i f y t h e p o w e r s w i t c h
Available through the Honda Tool a n d E q u i p m e n t (B) is in the " L o w " p o s i t i o n .
Program; call 888-424-6857
A l l four tire p r e s s u r e s e n s o r I D s m u s t be m e m o r i z e d to
t h e T P M S c o n t r o l unit w h e n e v e r y o u d o a n y of t h e s e
actions:
• R e p l a c e t h e T P M S control unit.
• R e p l a c e t h e tire p r e s s u r e s e n s o r .
• S u b s t i t u t e a k n o w n - g o o d w h e e l w i t h tire p r e s s u r e
sensor.
NOTE:
• T o e n s u r e t h e control unit m e m o r i z e s t h e c o r r e c t ID, A
t h e v e h i c l e w i t h t h e n e w s e n s o r m u s t be at l e a s t 10 ft AKS0620006
(3 m ) a w a y f r o m o t h e r v e h i c l e s that h a v e tire
pressure sensors. Hold the T P M S s e n s o r initializer tool n e a r o n e
• W h e n d o i n g a tire rotation, m e m o r i z i n g t h e s e n s o r s w h e e l , m e m o r i z e t h e p r e s s u r e s e n s o r ID by
in not n e e d e d . f o l l o w i n g the s c r e e n p r o m p t s o n t h e H D S .
1. W i t h t h e ignition s w i t c h at L O C K (0) w a i t 5 m i n u t e s NOTE:

or m o r e for t h e T P M S s e n s o r s to g o to s l e e p m o d e . • If y o u turn t h e ignition s w i t c h to L O C K (0) before
C o n n e c t t h e H D S to t h e data link c o n n e c t o r ( D L C ) m e m o r i z i n g all four s e n s o r I D s , t h e m e m o r i z i n g
(A) l o c a t e d u n d e r the d r i v e r ' s s i d e of the d a s h b o a r d . ID is c a n c e l e d .
• S e e the H D S Help m e n u for s p e c i f i c i n s t r u c t i o n s .
AKS0620006
7. R e p e a t s t e p 6 for e a c h w h e e l until all f o u r s e n s o r

2. T u r n t h e ignition s w i t c h to O N (II). IDs a r e m e m o r i z e d . W h e n all four IDs a r e
m e m o r i z e d , t h e l o w tire p r e s s u r e indicator blinks.
a n d t h e T P M S control unit. If it d o e s n ' t ,
t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
4. S e l e c t S e n s o r ID L e a r n i n g f r o m the m o d e m e n u o n
the H D S .
18-54
Tire Pressure Sensor Location
8. T u r n the ignition s w i t c h to L O C K (0). Special Tools Required
T P M S s e n s o r initializer tool A K S 0 6 2 0 0 0 6
9. D i s c o n n e c t the H D S f r o m the D L C . A v a i l a b l e t h r o u g h the H o n d a T o o l a n d E q u i p m e n t
P r o g r a m ; call 8 8 8 - 4 2 4 - 6 8 5 7
10. T e s t - d r i v e the v e h i c l e at 2 8 m p h (45 k m / h ) or m o r e
for at l e a s t 1 m i n u t e . N O T E : T h i s p r o c e d u r e l o c a t e s w h e r e t h e tire p r e s s u r e
s e n s o r s n u m b e r 1 , 2 , 3 , 4 are mounted, w h e n activated
11. M a k e s u r e the l o w tire p r e s s u r e indicator d o e s not b y the T P M S s e n s o r initializer tool.
blink.
• M e m o r i z i n g tire p r e s s u r e s e n s o r IDs ( i n c l u d i n g
12. T u r n the ignition s w i t c h to L O C K (0). r e p l a c i n g the T P M S control unit, or t h e tire p r e s s u r e
sensors).
13. R e d u c e the p r e s s u r e in o n e tire until it is l e s s t h a n • W h e e l rotation.
the a p p r o p r i a t e s p e c i f i c a t i o n .
1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t the
14. T u r n the ignition s w i t c h to O N (II). H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d
u n d e r the d r i v e r ' s s i d e of the d a s h b o a r d .
16. M a k e s u r e the l o w tire p r e s s u r e indicator t u r n s o n ,

t h e n inflate the tire ( s e e p a g e 18-7).
17. R e p e a t s t e p 12 to 16 for all the other t i r e s .
18. C l e a r a n y D T C s w i t h the H D S .
3. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h the v e h i c l e
a n d t h e T P M S control unit. If it d o e s n ' t ,
4. S e l e c t F u n c t i o n T e s t f r o m the m o d e m e n u , t h e n
s e l e c t S e n s o r Position C h e c k o n the H D S .
(cont'd)
18-55
TPMS
Tire Pressure Sensor Location (cont'd)
5. F o l l o w H D S s c r e e n p r o m p t s to turn o n t h e T P M S 6. F o l l o w the p r o m p t s o n t h e H D S to activate the tire

s e n s o r initializer tool (A). V e r i f y the p o w e r s w i t c h p r e s s u r e s e n s o r s u s i n g the T P M S s e n s o r initializer
(B) i s in t h e " L o w " p o s i t i o n . t o o l . S t a r t w i t h the left-front (LF) w h e e l .
NOTE:
• S e e t h e H D S Help m e n u for s p e c i f i c i n s t r u c t i o n s .
• Initialize the w h e e l in the s e q u e n c e s h o w n .
AKS0620006
AKS0620006
INITIALIZATION SEQUENCE:
® Right -front (RF) ) Right -rear (RR)
L D
L D
© Left -front (LF) © Left -rear (LR)
7. C h e c k the H D S s c r e e n , a n d note the a c t i v e s e n s o r

r e c e p t i o n o r d e r of the tire p r e s s u r e s e n s o r 1 , 2 , 3 , 4.
N O T E : If the s e n s o r d o e s not r e s p o n d to the T P M S

initializer, rotate the tire 1/4 turn a n d retry. If the
s e n s o r still d o e s not r e s p o n d after o n e full rotation
of the tire, s w a p t h e tire to a k n o w n - g o o d location
a n d retry. If the s e n s o r still d o e s not r e s p o n d after
o n e full rotation of the tire, r e p l a c e the tire p r e s s u r e
sensor.
8. N o t e the s e n s o r location for r e f e r e n c e .
18-56
DTC Detection Item Troubleshooting

11 Tire 1 L o w Air Pressure ( s e e p a g e 18-65)
13 Tire 2 L o w Air Pressure ( s e e p a g e 18-65)
15 Tire 3 L o w Air Pressure (see page 18-65)
17 Tire 4 L o w Air Pressure (see page 18-65)
21 Tire 1 Pressure Sensor A b n o r m a l l y High T e m p e r a t u r e (see page 18-67)
31 Tire 1 Pressure Sensor L o w Battery V o l t a g e (see page 18-68)
32 Tire 1 Pressure Sensor Transmission Failure (see page 18-69)
33 Tire 2 Pressure Sensor L o w Battery V o l t a g e (see page 18-68)
34 Tire 2 Pressure S e n s o r Transmission Failure (see page 18-69)
35 T i r e 3 P r e s s u r e S e n s o r L o w Battery V o l t a g e (see page 18-68)
36 Tire 3 Pressure S e n s o r Transmission Failure (see page 18-69)
37 T i r e 4 P r e s s u r e S e n s o r L o w Battery V o l t a g e (see page 18-68)
38 Tire 4 Pressure Sensor Transmission Failure (see page 18-69)
41 Abnormal Signal Reception Error (see page 18-70)
51 Tire 1 Pressure S e n s o r Registration Error (see page 18-71)
53 Tire 2 Pressure S e n s o r Registration Error (see page 18-71)
55 Tire 3 P r e s s u r e S e n s o r Registration Error ( s e e p a g e 18-71)
57 Tire 4 Pressure S e n s o r Registration Error ( s e e p a g e 18-71)
81 T P M S C o n t r o l Unit F a i l u r e ( s e e p a g e 18-72)
83 N o V S P Signal (see page 18-72)
85 F-CAN Communication Failure (see page 18-73)
91 Tire 1 Pressure Sensor Internal Error (see page 18-75)
18-57
TPMS

H D S d o e s not c o m m u n i c a t e w i t h t h e T r o u b l e s h o o t i n g t h e D L C circuit ( s e e p a g e
T P M S control unit o r t h e v e h i c l e 11-367)
L o w tire p r e s s u r e i n d i c a t o r d o e s not c o m e S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 18-76)
on, and no D T C s are stored
L o w tire p r e s s u r e i n d i c a t o r d o e s not g o off, S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 18-77)
and no D T C s are stored
T P M S indicator d o e s not c o m e o n , a n d n o S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 18-78)
D T C s are stored
T P M S indicator d o e s not g o off, a n d n o S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 18-78)
D T C s are stored
18-58
System Description
TPMS Control Unit Inputs and Outputs for 20P Connector
1 l / l / l 4 ! / ! / [ 7 8 |7[
Terminal Wire color Terminal sign Description Signal

number (Terminal name) Terminal Conditions Voltage
1 WHT CAN2 H (CAN2 S e n d s the Ignition s w i t c h O N (II) Pulses
communication communication
s i g n a l high) signal
4 BLK G R D (Ground) G r o u n d for t h e 4-GND A t all t i m e s L e s s than
T P M S control unit 0.1 V
7 GRY K - L I N E (Data link Communications
connector) w i t h the H D S
8 YEL IG1 (Ignition P o w e r s o u r c e for 8-GND Ignition s w i t c h O N (II) Battery
s w i t c h 1) activating t h e voltage
system Ignition s w i t c h L O C K Less than
(0) 0.1 V
10 RED +B (Battery P o w e r s o u r c e for 10-GND A t all t i m e s Battery
positive) t h e T P M S control voltage
unit
11 RED CAN2 L (CAN2 S e n d s the Ignition s w i t c h O N (II) Pulses
communication communication
s i g n a l low) signal
(cont'd)
18-59
TPMS
System Structure
O n c e t h e v e h i c l e s p e e d e x c e e d s 28 m p h (45 k m / h ) , t h e T P M S c o n t r o l unit m o n i t o r s all f o u r t i r e s a n d the s y s t e m . If it

d e t e c t s l o w p r e s s u r e in a tire, it alerts t h e d r i v e r b y t u r n i n g o n t h e l o w tire p r e s s u r e indicator. If it d e t e c t s a p r o b l e m in
the s y s t e m , it t u r n s o n t h e T P M S indicator.
Control unit
M o u n t e d u n d e r the d r i v e r ' s s i d e of the d a s h , t h e T P M S c o n t r o l unit r e c e i v e s p r e s s u r e s e n s o r ID s i g n a l s e v e r y t i m e the
v e h i c l e s p e e d s e x c e e d s 2 8 m p h (45 k m / h ) . It a l s o r e c e i v e s s i g n a l s f r o m t h e t r a n s m i t t e r s for tire p r e s s u r e a n d the
s e n s o r c o n d i t i o n , a n d it c o n t i n u o u s l y m o n i t o r s a n d c o n t r o l s t h e s y s t e m .
Indicators
T w o i n d i c a t o r s a r e in t h e g a u g e a s s e m b l y : T h e l o w tire p r e s s u r e indicator c o m e s o n w h e n a n y tire p r e s s u r e is l o w , a n d
t h e T P M S indicator that c o m e s o n o n l y if t h e r e ' s a p r o b l e m w i t h t h e s y s t e m .
T h e l o w tire p r e s s u r e indicator alerts the d r i v e r that a tire(s) p r e s s u r e is l o w , but d o e s not s p e c i f y the tire(s) location.
Vehicle
Gauge Assembly
Indicators (bulb)
Tire Pressure S e n s o r
Tire Pressure S e n s o r (sensor-transmitter
(sensor-transmitter with acceleration sensor)
with acceleration sensor)
Wheel
Wheel Control Unit
(TPMS type)
(TPMS type) (with radio
frequency antenna)
(sensor-transmitter
(sensor-transmitter
Wheel Wheel
(TPMS type) (TPMS type)
18-60
Tire pressure sensor
E a c h s e n s o r is a n integrated unit m a d e up of t h e tire v a l v e s t e m , a p r e s s u r e s e n s o r , a n d a t r a n s m i t t e r . T h e unit is
a t t a c h e d to the i n s i d e of the w h e e l , a r o u n d the v a l v e s t e m . T h e s e n s o r t r a n s m i t s t h e internal tire i n f o r m a t i o n to t h e
control unit o n c e e v e r y 60 s e c o n d s w h e n the v e h i c l e s p e e d e x c e e d s 28 m p h (45 k m / h ) . W h e n t h e T P M S control unit
2
r e c e i v e s a tire p r e s s u r e s i g n a l that is l e s s t h a n 175 kPa (1.8 k g f / c m , 2 5 p s i ) , t h e T P M S control unit t h e n t u r n s o n t h e
2
l o w tire p r e s s u r e indicator. W h e n that t i r e ' s p r e s s u r e is i n c r e a s e d to m o r e t h a n 2 0 0 kPa (2.0 k g f / c m , 2 9 p s i ) , a n d t h e
v e h i c l e is d r i v e n a b o v e 28 m p h (45 km/h) t h e t r a n s m i t t e r s e n d s t h e tire p r e s s u r e s i g n a l to t h e c o n t r o l unit, a n d t h e n t h e
c o n t r o l unit t u r n s t h e indicator off.
D o not m i x t h e tire p r e s s u r e s e n s o r with a n o t h e r T P M S t y p e .
S e n s o r active;
• W h e n t h e w h e e l rotates o v e r 2 8 m p h (45 k m / h ) , t h e s e n s o r d e t e c t s the m o m e n t u m , s w i t c h e s t h e s e n s o r to t h e
n o r m a l function m o d e .
• T h e L F (low f r e q u e n c y ) s i g n a l of t h e T P M S initializer tool m a k e s t h e s e n s o r a c t i v e e v e n t h o u g h t h e v e h i c l e is s t o p p e d .
T h e tire p r e s s u r e s e n s o r g o e s into s l e e p m o d e w h e n the a c c e l e r a t i o n s e n s o r d e t e c t s t h e w h e e l is s t a t i o n a r y for
5 m i n u t e s or m o r e c o n t i n u o u s l y .
Wheels
T P M S will not w o r k u n l e s s T P M S t y p e w h e e l s a r e installed o n t h e v e h i c l e . T h e original e q u i p m e n t w h e e l s h a v e a
" T P M S " m a r k (A) o n t h e m a n d c o u n t e r w e i g h t s (B) a r e m o u n t e d to c o u n t e r b a l a n c e t h e w e i g h t of t h e tire p r e s s u r e
s e n s o r (C).
(cont'd)
18-61
TPMS
System Communication
• W h e n t h e v e h i c l e is t r a v e l i n g m o r e t h a n 2 8 m p h (45 k m / h ) , a n R F (radio f r e q u e n c y ) b a n d w a v e s i g n a l is c o n t i n u o u s l y
t r a n s m i t t e d f r o m e a c h tire p r e s s u r e s e n s o r to the c o n t r o l unit.
• W h e n t h e w h e e l s rotate, a n d t h e tire p r e s s u r e s e n s o r s m o m e n t u m i s d e t e c t e d , s w i t c h i n g t h e m f r o m s l e e p m o d e to
n o r m a l f u n c t i o n m o d e . After t h e v e h i c l e is s t a t i o n a r y for 5 m i n u t e s , t h e s e n s o r s s w i t c h f r o m n o r m a l f u n c t i o n m o d e
b a c k to s l e e p m o d e to e x t e n d their battery life.
• E a c h tire p r e s s u r e s e n s o r h a s its o w n ID to p r e v e n t j a m m i n g b y s i m i l a r s y s t e m s o n other v e h i c l e s . After m e m o r i z i n g
all t h e s e n s o r I D s , the c o n t r o l unit r e c e i v e s o n l y t h o s e s p e c i f i c s i g n a l s .
• A n ID c a n n o t be m e m o r i z e d a u t o m a t i c a l l y . T h e control unit k n o w s w h i c h ID b e l o n g s to e a c h tire p r e s s u r e s e n s o r .
T h i s r e c u r r i n g ID c o n f i r m a t i o n p r e v e n t s a n y c o n f u s i o n in t h e s y s t e m a s a r e s u l t of n o r m a l tire rotation.
N O T E : B e c a r e f u l not to b e n d t h e b r a c k e t s o n t h e T P M S c o n t r o l unit: M i s a l i g n m e n t of t h e control unit c o u l d interfere

with sending and receiving signals.
Control Unit Tire Pressure Sensor

(with Radio Frequency Antenna) (Sensor-transmitter with acceleration sensor)
18-62
1
^ T P M S
Circuit Diagram
MAIN UNDER-HOOD UNDER-DASH

FUSE/RELAY BOX FUSE/RELAY BOX
No. 21
(7.5 A)
—OXD—
IGNITION SWITCH No. 5

{7.5 A)
BLK/YEL —<TVO—
GAUGE ASSEMBLY
"
POWER CIRCUIT
LOW TIRE PRESSURE
INDICATOR
@-
1TPMS INDICATOR TPMS CONTROL UNIT
@-±
INDICATOR -WHT
DRIVER CAN2 H CAN
CIRCUIT 11 CONTROLLER
CAN2L
1 CPU
1*
OUTPUT SHAFT
{COUNTERSHAFT)
SPEED SENSOR
BLU/WHT
4^ IG1
A18 +B
-BLU/WHT *• - BLU/WHT
NC
A20 VOLTAGE
- YEL/BLU
VCC2 REGULATOR
A23
- GRN/YEL
SG2
E11
-RED
CANH
E24
CANL
DATA LINK
CONNECTOR (DLC)
KLINE
4
1 -•-:12V
-0-:5V
(cont'd)
18-63
TPMS
MAIN UNDER-HOOD F U S E / R E L A Y BOX UNDER-DASH FUSE/RELAY BOX

C O N N E C T O R D (16P) C O N N E C T O R B (7P)
1 i,
1 2 3 n 4 / 1 2 3
7
/ 9 12
/ 14 16 4 5 6 7
G A U G E A S S E M B L Y C O N N E C T O R A (22P) G A U G E A S S E M B L Y C O N N E C T O R B (30P)
/
X
1 2 3 4 5 7 8 9 10 2 3 4 5 6 7 8 9 10 11 12 13 14
11 12 13 14 15 16
X 17 18 19 20 21 22 15 16 17 18 19 20 21 22 V 23 24 25 26 27 28 29 30
T P M S C O N T R O L UNIT 20P C O N N E C T O R OUTPUT SHAFT (COUNTERSHAFT)

n n
// 4 / / 7 8 /10
E C M C O N N E C T O R A (31P) E C M C O N N E C T O R E (31P)
1 2 3 4 5 6 7 u 8 9 1 /' 3 4 5 7 8 9 u
/ /
n// //
10 13 14 15 16 18 20 21 11 12 13 14 15 16 17 18 19 20 21
23 2 4 n 25 26 28 30 31 2 2 23 2 4
n 25
/ n 27 28 29 30
/
4 5 6 7
/1l2l/|l4|/fl6J
18-64
DTC Troubleshooting
DTC 11,13,15,17: Tire Low Air Pressure 7. N o t e t h e tire p r e s s u r e s e n s o r ( s ) n u m b e r b y t h e

indicated D T C .
N O T E : If l o w tire p r e s s u r e is d e t e c t e d , t h e control unit
s e t s o n e or m o r e of t h e s e D T C s , a n d t u r n s o n the l o w DTC Tire pressure sensor
tire p r e s s u r e indicator. If the l o w tire p r e s s u r e indicator 11 No. 1
c o m e s o n d u e to t r u e l o w tire p r e s s u r e , a n d t h e 13 No. 2
c u s t o m e r c o r r e c t s it b e f o r e bringing the v e h i c l e i n , the 15 No. 3
D T C s will h a v e b e e n s t o r e d , but the indicator will be off. 17 No. 4
1. T u r n the ignition s w i t c h to L O C K (0). 8. D e t e r m i n e t h e affected tire location b y t h e tire

p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
2. C h e c k the p r e s s u r e of all four t i r e s .
9. C h e c k the T I R E 1, T I R E 2 , T I R E 3 , or T I R E 4 A I R
Is there 175 kPa (1.8 kgf/crrf, 25 psi) or less? P R E S S U R E in t h e T P M S D A T A L I S T w i t h t h e H D S ,
a n d c o m p a r e it w i t h t h e a c t u a l m e a s u r e d tire
Y E S — G o to s t e p 3. pressure.
N O — G o to s t e p 5. Is the indicated tire pressure on the HDS within

40 kPa (0.4 kgf/crrf, 6 psi) of the actual tire
3. C h e c k for a n d r e p a i r the c a u s e of air l o s s , a n d t h e n pressure?
inflate the tire ( s e e p a g e 18-7).
YES-GotosteplO.
for at least 1 m i n u t e . N O — R e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
( s e e p a g e 18-81 ) . •
Does the low tire pressure indicator go off?
Y E S — T h e s y s t e m is O K at this t i m e . C l e a r the D T C
w i t h the H D S . •
(cont'd)
18-65
TPMS
11. T e s t - d r i v e t h e v e h i c l e at 2 8 m p h (45 k m / h ) or m o r e
Is DTC 11, 13,15, or 17 indicated?
N O — I f a n y other D T C s a r e i n d i c a t e d , t r o u b l e s h o o t
t h e a p p r o p r i a t e D T C . If n o D T C s a r e i n d i c a t e d , t h e
s y s t e m is O K at t h i s t i m e . •
15. S u b s t i t u t e a k n o w n - g o o d T P M S w h e e l .
16. M e m o r i z e t h e tire p r e s s u r e s e n s o r ID w i t h t h e H D S
( s e e p a g e 18-54).
17. T e s t - d r i v e t h e v e h i c l e at 2 8 m p h (45 k m / h ) o r m o r e
Is DTC 11, 13, 15, or 17 indicated?
Y E S — R e p l a c e t h e T P M S c o n t r o l unit ( s e e p a g e
18-80).B
N O — R e p l a c e t h e o r i g i n a l tire p r e s s u r e s e n s o r
(see page 1 8 - 8 D . B
18-66
1
DTC 21,22,23,24: Tire Pressure Sensor 6. D e t e r m i n e t h e affected tire l o c a t i o n b y t h e tire
Abnormally High Temperature p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
1. T u r n the ignition s w i t c h to L O C K (0). 7. C h e c k t h e T I R E 1, T I R E 2 , T I R E 3 , or T I R E 4 A I R

T E M P E R A T U R E in t h e T P M S D A T A L I S T w i t h t h e
2. Make s u r e the tires have cooled d o w n . HDS.
N O T E : A n a b n o r m a l rise in t h e internal t e m p e r a t u r e Is 176 °F (80 °C) or more indicated?

of t h e t i r e s c a n be c a u s e d b y
• E x c e s s i v e braking Y E S — R e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
• F a i l u r e to r e l e a s e the parking b r a k e (rear t i r e s (see page 1 8 - 8 D . B
only)
• L e a v i n g t h e v e h i c l e r u n n i n g w h i l e p a r k e d (rear N O — G o to s t e p 8.
tires o n l y )
• I m p r o p e r a s s e m b l y of a w h e e l a n d tire 8. C l e a r t h e D T C w i t h t h e H D S .
3. T e s t - d r i v e t h e v e h i c l e at 2 8 m p h (45 k m / h ) o r m o r e 9. T e s t - d r i v e t h e v e h i c l e at 28 m p h (45 k m / h ) o r m o r e
for at l e a s t 1 m i n u t e . for at l e a s t 1 m i n u t e .
Does the TPMS indicator go off? 10. C h e c k for D T C s w i t h t h e H D S .
Y E S — T h e s y s t e m is O K at t h i s t i m e . C l e a r t h e D T C Is DTC 21,22,23, or 24 indicated?

with the H D S . B
Y E S — C h e c k for l o o s e t e r m i n a l s a n d p o o r
N O — G o to s t e p 4. c o n n e c t i o n s at t h e T P M S c o n t r o l unit. If n e c e s s a r y ,
s u b s t i t u t e a k n o w n - g o o d T P M S control unit
4. C h e c k for D T C s w i t h t h e H D S . ( s e e p a g e 18-80), a n d r e c h e c k . •
5. Note t h e tire p r e s s u r e s e n s o r ( s ) n u m b e r b y t h e NO—If a n y other D T C s are indicated, troubleshoot

indicated D T C . t h e a p p r o p r i a t e D T C . If n o D T C a r e i n d i c a t e d , t h e
s y s t e m is O K at t h i s t i m e . •
DTC Tire pressure sensor
21 No. 1
22 No. 2
23 No. 3
24 No. 4
18-67
TPMS
DTC 31,33,35,37: Tire Pressure Sensor Low 4. D e t e r m i n e t h e affected tire location by t h e tire
Battery Voltage p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
N O T E : T h i s problem occurs w h e n the temperature Did each tire pressure sensor respond to the
a r o u n d the s e n s o r i s — 4 0 °F (—40 °C) or l e s s . N o t e that TPMS initializer tool?
t h e d i a g n o s i s m u s t b e m a d e in a p l a c e w h e r e a m b i e n t
t e m p e r a t u r e is — 4 0 °F (—40 °C) or m o r e . Y E S — G o t o s t e p 5.
1. T e s t - d r i v e t h e v e h i c l e at 28 m p h (45 k m / h ) or m o r e N O — C h e c k that the tire p r e s s u r e s e n s o r is p r o p e r l y

for at l e a s t 1 m i n u t e . m o u n t e d . If n e c e s s a r y , r e p l a c e the a p p r o p r i a t e tire
pressure sensor (see page 1 8 - 8 D . B
Does the TPMS indicator go off?
5. C h e c k t h e T I R E 1, T I R E 2 , T I R E 3, or T I R E 4
Y E S — T h e s y s t e m is O K at t h i s t i m e . C l e a r t h e D T C P R E S S U R E S E N S O R T R A N S M I T T E R B A T T E R Y in
w i t h the H D S . • the T P M S D A T A L I S T with the H D S .
N O — G o to s t e p 2. Is LOW indicated?
2. C h e c k for D T C s w i t h t h e H D S . Y E S — R e p l a c e the a p p r o p r i a t e tire p r e s s u r e s e n s o r

(see page 1 8 - 8 1 ) . •
3. Note the tire p r e s s u r e s e n s o r ( s ) n u m b e r b y t h e
indicated D T C . N O — C h e c k for l o o s e t e r m i n a l s a n d poor
c o n n e c t i o n s at the T P M S control unit. If n e c e s s a r y ,
DTC Tire pressure sensor substitute a k n o w n - g o o d T P M S control unit
31 No. 1 ( s e e p a g e 18-80), a n d r e c h e c k . •
33 No. 2
35 No. 3
37 No. 4
18-68
DTC 32,34,36,38: Tire Pressure Sensor 8. T u r n t h e ignition s w i t c h to O N (II).
Transmission Failure
9. D e t e r m i n e the affected tire location b y t h e tire
N O T E : I n s p e c t for a n aftermarket e l e c t r i c a l d e v i c e p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
interfering w i t h the R F s i g n a l f r o m t h e s e n s o r s w h e n
d r i v i n g the v e h i c l e . Did each tire sensor respond to the TPMS
initializer tool?
N O — C h e c k for a n a f t e r m a r k e t e l e c t r i c a l d e v i c e
3. Note the tire p r e s s u r e s e n s o r ( s ) n u m b e r by t h e interfering with t h e R F s i g n a l s f r o m the s e n s o r s . If
indicated D T C . t h e r e a r e n o electrical d e v i c e s c a u s i n g i n t e r f e r e n c e ,
r e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
DTC Tire pressure sensor (see page 1 8 - 8 D . B
32 No. 1
34 No. 2 10. T u r n t h e ignition s w i t c h to L O C K (0), a n d w a i t
36 No. 3 5 m i n u t e s or m o r e .
38 No. 4
12. Identify t h e affected tire s e n s o r n u m b e r f r o m the
5. M a k e s u r e all four w h e e l s a r e T P M S w h e e l s w i t h D T C list o n s t e p 3.
t h e p r o p e r l y m o u n t e d tire p r e s s u r e s e n s o r s .
13. L o c a t e t h e effected tire p r e s s u r e s e n s o r c h e c k i n g
Are TPMS type wheels with a tire pressure sensor the T I R E 1, T I R E 2 , T I R E 3 , or T I R E 4 A I R P R E S S U R E
mounted on the vehicle? in t h e T P M S D A T A L I S T w i t h the H D S .
Y E S — G o t o s t e p 8. Is the default pressure of 145 psi displayed?
N O — G o to s t e p 6. Y E S — G o t o s t e p 14.
6. S u b s t i t u t e a k n o w n - g o o d T P M S w h e e l . N O — R e p e a t s t e p s 10 t h r o u g h 13 until the default

p r e s s u r e (145 psi) is d i s p l a y e d . If the default
7. M e m o r i z e the tire p r e s s u r e s e n s o r ID w i t h the H D S p r e s s u r e i s n e v e r d i s p l a y e d , r e p l a c e the T P M S
( s e e p a g e 18-54). control unit ( s e e p a g e 18-80). •
Did the TPMS control unit memorize the tire 14. D r i v e t h e v e h i c l e o v e r 2 8 m p h (45 k m / h ) , a n d
pressure sensors? m o n i t o r t h e effected tire p r e s s u r e s e n s o r with the
HDS.
Y E S — R e p l a c e the original tire p r e s s u r e s e n s o r
( s e e p a g e 18-81 ) . • Did the effected tire pressure sensor change from
the default pressure (145 psi) to the correct tire
N O — G o to s t e p 8. pressure?
Y E S — T h e s y s t e m is O K at t h i s t i m e . C l e a r the D T C
with the H D S . B
N O — R e p l a c e the a p p r o p r i a t e tire p r e s s u r e s e n s o r
(see page 1 8 - 8 D . B
18-69
TPMS
DTC 41: Abnormal Signal Reception Error 5. M e m o r i z e the tire p r e s s u r e s e n s o r ID w i t h the H D S

( s e e p a g e 18-54).
N O T E : I n s p e c t for a n a f t e r m a r k e t e l e c t r i c a l d e v i c e
interfering w i t h t h e R F s i g n a l f r o m the s e n s o r s w h e n Did each tire pressure sensor location respond to
d r i v i n g the v e h i c l e . the TPMS initializer tool?
1. T u r n the ignition s w i t c h to L O C K (0). Y E S — T h e s y s t e m is O K at t h i s t i m e , c l e a r the D T C

with the H D S . •
2. M a k e s u r e all f o u r w h e e l s a r e T P M S w h e e l s w i t h
tire p r e s s u r e s e n s o r s . N O — R e p l a c e the T P M S c o n t r o l unit ( s e e p a g e
18-80). •
Are TPMS type wheels with tire pressure sensors
mounted on the vehicle?
3. S u b s t i t u t e k n o w n - g o o d T P M S w h e e l s .
4. M e m o r i z e t h e tire p r e s s u r e s e n s o r ID w i t h the H D S
( s e e p a g e 18-54).
Did each tire pressure sensor location respond to

the TPMS initializer tool?
Y E S — R e p l a c e the original T P M S w h e e l s . B
N O — R e p l a c e the T P M S c o n t r o l unit ( s e e p a g e
18-80). •
18-70
DTC 51,53,55,57: Tire Pressure Sensor
Registration Error
3. Note t h e tire p r e s s u r e s e n s o r ( s ) n u m b e r b y the

indicated D T C .
DTC Tire pressure sensor

51 No. 1
53 No. 2
55 No. 3
57 No. 4
5. M a k e s u r e all f o u r w h e e l s a r e T P M S w h e e l s w i t h
t h e p r o p e r l y m o u n t e d tire p r e s s u r e s e n s o r s . If
n e c e s s a r y substitute known-good T P M S w h e e l s .
8. M e m o r i z e t h e tire p r e s s u r e s e n s o r ID w i t h t h e H D S
( s e e p a g e 18-54).
9. T e s t - d r i v e t h e v e h i c l e . Drive the v e h i c l e at 28 m p h
(45 k m / h ) for 1 m i n u t e or m o r e .
Is DTC 51, 53, 55, or 57 Indicated?
s u b s t i t u t e a k n o w n - g o o d T P M S c o n t r o l unit
( s e e p a g e 18-80), a n d r e c h e c k . •
N O — R e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
(see page 1 8 - 8 D . B
TPMS
D T C 8 1 : TPMS Control Unit Failure D T C 8 3 : NoVSP Signal

N O T E : L o w battery v o l t a g e c a n c a u s e t h i s D T C . M a k e N O T E : If D T C 8 5 is s t o r e d at t h e s a m e t i m e a s D T C 8 3 ,
s u r e t h e battery is fully c h a r g e d a n d in g o o d c o n d i t i o n t r o u b l e s h o o t D T C 8 5 first, t h e n r e c h e c k for D T C 8 3 .
( s e e p a g e 22-47).
3. T e s t - d r i v e t h e v e h i c l e at 7 m p h (10 k m / h ) or m o r e .
3. T u r n t h e ignition s w i t c h to L O C K (0), t h e n t u r n t h e
ignition s w i t c h to O N (II) a g a i n . 4. C h e c k the s p e e d o m e t e r .
4. C h e c k for D T C s w i t h t h e H D S . Does the speedometer register speed?
Is DTC 81 indicated? Y E S — G o to s t e p 9.
Y E S — R e p l a c e t h e T P M S control unit ( s e e p a g e N O — G o to s t e p 5.
18-80). •
6. C h e c k a n d t r o u b l e s h o o t t h e fuel a n d e m i s s i o n s
s y s t e m D T C ( s e e p a g e 11-213). If n e c e s s a r y , d o t h e
v e h i c l e s p e e d s i g n a l circuit t r o u b l e s h o o t i n g
( s e e p a g e 22-95).
7. T e s t - d r i v e the v e h i c l e at 7 m p h (10 k m / h ) or m o r e .
8. C h e c k t h e s p e e d o m e t e r .
Does the speedometer register speed?
Y E S — T h e s y s t e m is O K at this t i m e . •
NO—Substitute a known-good gauge assembly

( s e e p a g e 22-89), a n d r e c h e c k . If n o c o d e s a r e s h o w n ,
r e p l a c e t h e original g a u g e a s s e m b l y . !
9. C h e c k t h e V E H I C L E S P E E D in the T P M S D A T A L I S T
w i t h the H D S .
Is the vehicle speed indicated?
Y E S — T h e s y s t e m is O K at this t i m e . •
N O — S u b s t i t u t e a k n o w n - g o o d T P M S control unit
18-72
DTC 85: F-CAN Communication Failure 10. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d
T P M S c o n t r o l unit 2 0 P c o n n e c t o r t e r m i n a l s N o . 1
N O T E : C h e c k for g a u g e D T C s w i t h t h e H D S ( s e e p a g e a n d N o . 11 i n d i v i d u a l l y .
22-6). If g a u g e D T C s a r e s t o r e d , t r o u b l e s h o o t t h o s e
D T C s first.
T P M S C O N T R O L UNIT 20P C O N N E C T O R
CAN2H
2. C l e a r the D T C w i t h t h e H D S . (WHT)
3. T u r n the ignition s w i t c h to L O C K (0), t h e n t u r n t h e

ignition s w i t c h to O N (II) a g a i n .
4. W a i t a b o u t 5 s e c o n d s .
5. C h e c k for D T C s w i t h t h e H D S . W i r e s i d e of f e m a l e t e r m i n a l s
N O — T h e s y s t e m i s O K at t h i s t i m e . C h e c k for l o o s e b e t w e e n t h e T P M S control unit a n d the g a u g e
t e r m i n a l s b e t w e e n t h e T P M S control unit a n d t h e assembly. •
gauge assembly. •
11. C h e c k for c o n t i n u i t y b e t w e e n T P M S control unit
Does the speedometer work? 2 0 P c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 11.
N O — C h e c k for l o o s e t e r m i n a l s a n d p o o r
c o n n e c t i o n s at t h e g a u g e a s s e m b l y . If n e c e s s a r y , CAN2H
substitute a k n o w n - g o o d g a u g e a s s e m b l y (WHT)
( s e e p a g e 22-89), a n d r e c h e c k . • 1 M X U IXIXljIslXho
7. T u r n the ignition s w i t c h to L O C K (0). C A N 2 L (RED)
8. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r A (22P).
9. D i s c o n n e c t the T P M S control unit 2 0 P c o n n e c t o r . W i r e s i d e of f e m a l e t e r m i n a l s
Y E S — R e p a i r s h o r t in t h e w i r e s b e t w e e n t h e T P M S
control unit a n d t h e g a u g e a s s e m b l y . •
(cont'd)
18-73
TPMS
12. C h e c k f o r c o n t i n u i t y b e t w e e n t h e T P M S control unit 13. S u b s t i t u t e a k n o w n - g o o d T P M S control unit

20P connector terminals and gauge assembly ( s e e p a g e 18-80).
c o n n e c t o r A (22P) t e r m i n a l s ( s e e table).
Terminal name T P M S control Gauge assembly
unit t e r m i n a l terminal 15. M e m o r i z e t h e tire p r e s s u r e s e n s o r ID w i t h t h e H D S
CAN2L N o . 11 N o . 21 ( s e e p a g e 18-54).
CAN2H No. 1 No. 22
G A U G E A S S E M B L Y C O N N E C T O R A (22P)
1 2 3 4 5 7 8 9 10
18. T u r n t h e ignition s w i t c h to L O C K (0), t h e n turn the
11 12 13 14 15 1 6 1 7 18 19 20 21 22
X C A N 2 L (RED)
ignition s w i t c h to O N (II) a g a i n .
C A N 2 H (WHT) 19. W a i t a b o u t 5 s e c o n d s .
Y E S — R e p l a c e the g a u g e a s s e m b l y ( s e e p a g e
22-89). •
Is there continuity? N O — R e p l a c e the original T P M S control unit

(see page 18-80).B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e T P M S
c o n t r o l unit a n d t h e g a u g e a s s e m b l y . •
18-74
DTC 91,93,95,97: Tire Pressure Sensor 7. C h e c k for D T C s w i t h t h e H D S .
Internal Error
Is DTC 91, 93, 95, or 97 indicated?
Y E S — R e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
2. C h e c k for D T C s w i t h t h e H D S . ( s e e p a g e 18-81) a n d r e c h e c k . If D T C s a r e still
p r e s e n t , s u b s t i t u t e a k n o w n - g o o d T P M S control
3. Note t h e tire p r e s s u r e s e n s o r ( s ) n u m b e r b y t h e unit ( s e e p a g e 18-80), a n d r e c h e c k . •
indicated DTC.
NO—If a n y other D T C s are indicated, troubleshoot
DTC Tire pressure sensor the a p p r o p r i a t e D T C . If no D T C s a r e i n d i c a t e d , t h e
91 No. 1 s y s t e m is O K at t h i s t i m e . •
93 No. 2
95 No. 3
97 No. 4
4. D e t e r m i n e the affected tire location by t h e tire

p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
Did the sensors respond to the TPMS initializer

tool?
N O — C h e c k that t h e tire p r e s s u r e s e n s o r is p r o p e r l y
m o u n t e d . If n e c e s s a r y , r e p l a c e t h e a p p r o p r i a t e tire
pressure sensor (see page 18-8D.B
6. T e s t - d r i v e the v e h i c l e at 2 8 m p h (45 k m / h ) o r m o r e
for at least 1 m i n u t e .
18-75
TPMS
S y m p t o m Troubleshooting
Low tire pressure indicator does not come 7. D e t e r m i n e t h e effected tire location b y t h e tire
on, and no DTCs are stored p r e s s u r e s e n s o r n u m b e r ( s e e p a g e 18-55).
1. T u r n t h e ignition s w i t c h to O N (II). Did the sensors respond to the TPMS initializer

tool?
2. C h e c k t h e l o w tire p r e s s u r e i n d i c a t o r f o r s e v e r a l
s e c o n d s w h e n t h e ignition s w i t c h i s t u r n e d to Y E S — G o to s t e p 8.
O N (II).
N O — C h e c k that t h e tire p r e s s u r e s e n s o r i s p r o p e r l y
Did the indicator come on and then go off? m o u n t e d . If n e c e s s a r y , r e p l a c e t h e a p p r o p r i a t e tire
pressure sensor (see page 1 8 - 8 D . B
8. C h e c k t h e T I R E 1, T I R E 2 , T I R E 3 , o r T I R E 4 A I R
N O — G o to s t e p 3. P R E S S U R E in t h e T P M S D A T A L I S T w i t h t h e H D S ,
a n d c o m p a r e w i t h t h e a c t u a l m e a s u r e d tire
3. T u r n t h e ignition s w i t c h to L O C K (0). pressure.
4. C h e c k t h e l o w tire p r e s s u r e i n d i c a t o r b u l b in t h e Is the indicated tire pressure on the HDS within

gauge a s s e m b l y (see page 22-59). 40 kPa (0.4 kgf/crrf, 6 psi) of the actual tire
pressure?
Is the bulb OK?
Y E S — D o the t r o u b l e s h o o t i n g for t h e g a u g e
a s s e m b l y ( s e e p a g e 22-60). If n e c e s s a r y , s u b s t i t u t e N O — R e p l a c e t h e a p p r o p r i a t e tire p r e s s u r e s e n s o r
a known-good g a u g e a s s e m b l y (see page 22-89), (see page 1 8 - 8 D . B
and recheck. •
N O — R e p l a c e t h e l o w tire p r e s s u r e i n d i c a t o r b u l b
( s e e p a g e 22-59). •
5. T e s t - d r i v e t h e v e h i c l e at 2 8 m p h (45 k m / h ) o r m o r e
6. S t o p t h e v e h i c l e , a n d l o w e r t h e p r e s s u r e in e a c h
tire until t h e l o w tire p r e s s u r e i n d i c a t o r c o m e s o n .
Reinflate t h e tire b e f o r e c o n t i n u i n g to t h e next tire.
N O T E : If 5 m i n u t e s h a s p a s s e d s i n c e f i n i s h i n g t h e
last t e s t - d r i v e , r e a c t i v a t e t h e a p p r o p r i a t e tire
p r e s s u r e s e n s o r s u s i n g t h e T P M S s e n s o r initializer
tool ( s e e p a g e 18-55).
Does the indicator come on when the pressure

drops below 175 kPa (1.8 kgf/crrf, 25 psi) or less?
Y E S — T h e s y s t e m i s O K at t h i s t i m e . •
18-76
10. D i s c o n n e c t the T P M S control unit 2 0 P c o n n e c t o r . Low tire pressure indicator does not go off,
and no DTCs are stored
11. M e a s u r e v o l t a g e b e t w e e n T P M S control unit 2 0 P
c o n n e c t o r t e r m i n a l s No. 4 a n d N o . 8. 1. T u r n the ignition s w i t c h to L O C K (0).
2. D i s c o n n e c t the T P M S control unit 2 0 P c o n n e c t o r .

3. T u r n the ignition s w i t c h to O N (H).
G N D ( B L Ki
—w- IG1 ( Y E L ) 4. C h e c k the l o w tire p r e s s u r e indicator for s e v e r a l
n s e c o n d s w h e n t h e ignition s w i t c h is t u r n e d to
4 72 7
5/110 O N (II).
1 1 7 7 7 7 7 7 7 7 7
Did the indicator come on and then go off?
W i r e s i d e of f e m a l e t e r m i n a l s c o n n e c t i o n s at t h e T P M S control unit. If n e c e s s a r y ,
s u b s t i t u t e a k n o w n - g o o d T P M S c o n t r o l unit
1$ there battery voltage?
N O — D o the t r o u b l e s h o o t i n g for t h e g a u g e
Y E S — R e p a i r s h o r t to p o w e r in t h e w i r e b e t w e e n a s s e m b l y ( s e e p a g e 22-60). If n e c e s s a r y , substitute
t h e T P M S control unit a n d the N o . 5 (7.5 A ) f u s e in a k n o w n - g o o d g a u g e a s s e m b l y ( s e e p a g e 22-89),
the under-dash fuse/relay box.H and recheck. •
N O — C h e c k for l o o s e t e r m i n a l s a n d poor
substitute a k n o w n - g o o d T P M S control unit
18-77
TPMS
TPMS indicator does not come on, and no TPMS indicator does not go off, and no DTCs
DTCs are stored are stored
1. T u r n t h e ignition s w i t c h to L O C K (0). 1. T u r n the ignition s w i t c h to O N (II).
2. D i s c o n n e c t t h e T P M S control unit 2 0 P c o n n e c t o r . 2. C h e c k the T P M S i n d i c a t o r for s e v e r a l s e c o n d s

w h e n the ignition s w i t c h is t u r n e d to O N (II).
Did the indicator come on and then go off?
4. C h e c k the T P M S indicator for s e v e r a l s e c o n d s
w h e n t h e ignition s w i t c h is t u r n e d to O N (II). Y E S — T h e s y s t e m is O K at this t i m e . •
Did the indicator come on? N O — G o to s t e p 3.
Y E S — C h e c k for l o o s e t e r m i n a l s a n d p o o r 3. T u r n the ignition s w i t c h to L O C K (0).

s u b s t i t u t e a k n o w n - g o o d T P M S control unit 4. C h e c k the N o . 21 (7.5 A ) f u s e in t h e u n d e r - d a s h
( s e e p a g e 18-80), a n d r e c h e c k . • f u s e / r e l a y box.
N O — G o to s t e p 5. Is the fuse blown?
5. T u r n t h e ignition s w i t c h to L O C K (0). Y E S — R e p l a c e the No. 21 (7.5 A ) f u s e , a n d

recheck. •
6. C h e c k the T P M S indicator bulb in t h e g a u g e
a s s e m b l y ( s e e p a g e 22-59). N O — R e i n s t a l l the f u s e , t h e n g o to s t e p 5.
Is the bulb OK? 5. C h e c k the No. 5 (7.5 A ) f u s e in the u n d e r - d a s h

fuse/relay box.
Y E S — D o t h e t r o u b l e s h o o t i n g for the g a u g e
a s s e m b l y ( s e e p a g e 22-60). If n e c e s s a r y , s u b s t i t u t e Is the fuse blown?
a known-good gauge a s s e m b l y (see page 22-89),
and recheck. • Y E S — R e p l a c e the No. 5 (7.5 A ) f u s e , a n d r e c h e c k . •
N O — R e p l a c e the T P M S indicator bulb ( s e e p a g e N O — R e i n s t a l l the f u s e , t h e n g o to s t e p 6.

22-59). •
6. D i s c o n n e c t the T P M S control unit 2 0 P c o n n e c t o r .
18-78
7. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d T P M S 10. T u r n t h e ignition s w i t c h to L O C K (0).
control unit 2 0 P c o n n e c t o r t e r m i n a l No. 10.
11. R e c o n n e c t t h e T P M S c o n t r o l unit 2 0 P c o n n e c t o r .
13. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d T P M S
c o n t r o l unit 2 0 P c o n n e c t o r t e r m i n a l N o . 4.
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e T P M S
control unit a n d t h e No. 21 (7.5 A ) f u s e in the u n d e r -
dash fuse/relay b o x . B Is there 0.1 V or more?
8. T u r n the ignition s w i t c h to O N (II). Y E S — R e p a i r o p e n or high r e s i s t a n c e in the w i r e

b e t w e e n t h e T P M S control unit a n d b o d y g r o u n d
9. M e a s u r e v o l t a g e b e t w e e n b o d y g r o u n d a n d T P M S (G40D.B
control unit 2 0 P c o n n e c t o r t e r m i n a l No. 8.
N O — D o the t r o u b l e s h o o t i n g for t h e g a u g e
a s s e m b l y ( s e e p a g e 22-60). If t h e g a u g e a s s e m b l y
is O K , c h e c k for l o o s e t e r m i n a l s a n d p o o r
c o n n e c t i o n s at t h e T P M S control unit. If n e c e s s a r y ,
s u b s t i t u t e a k n o w n - g o o d T P M S control unit
IG1 ( Y E L )
n n ( s e e p a g e 18-80), a n d r e c h e c k . •
1
// // 4 7 8 / 10
N O — R e p a i r o p e n in the w i r e b e t w e e n the T P M S
control unit a n d the No. 5 (7.5 A ) f u s e in t h e u n d e r -
dash fuse/relay box.H
18-79
TPMS
TPMS Control Unit Replacement
N O T E : M a k e s u r e t h e T P M S c o n t r o l unit m o u n t i n g 5. R e m o v e t h e T P M S control unit (A) f r o m t h e bracket

bracket i s not bent or t w i s t e d a s t h i s m a y affect its (B).
c o m m u n i c a t i o n w i t h t h e tire p r e s s u r e s e n s o r s .
N O T E : W h i l e s e p a r a t i n g t h e T P M S control unit
1. T u r n t h e ignition s w i t c h to L O C K (0). f r o m t h e bracket, r e l e a s e t h e hook (C) o n t h e T P M S
c o n t r o l unit u s i n g a flat-tipped s c r e w d r i v e r (D), a n d
2. R e m o v e t h e d r i v e r ' s d a s h b o a r d l o w e r c o v e r p u s h it u p to r e m o v e t h e bracket.
( s e e p a g e 20-85).
3. D i s c o n n e c t t h e T P M S c o n t r o l unit c o n n e c t o r (A).
N O T E : T h e T P M S c o n t r o l unit is l o c a t e d a b o v e t h e
hood release handle.
6. Install t h e T P M S control unit in the r e v e r s e o r d e r of

removal.
N O T E : M a k e s u r e the T P M S control unit i s p r o p e r l y

i n s t a l l e d . Y o u w i l l h e a r a click w h e n t h e T P M S
control unit is s e c u r e l y m o u n t e d o n t h e bracket.
A B
6 x 1.0 m m 7. C o n n e c t t h e H D S , a n d m e m o r i z e t h e tire p r e s s u r e
9 . 8 N - m (1.0 k g f m , 7.2 Ibf ft) s e n s o r I D s u s i n g t h e T P M S initializer tool ( s e e p a g e
18-54).
4. R e m o v e t h e f l a n g e bolt ( B ) , a n d r e m o v e t h e T P M S
control unit (C) w i t h t h e b r a c k e t (D).
18-80
Tire Pressure Sensor Replacement
Removal 5. P o s i t i o n t h e w h e e l s o the t i r e m a c h i n e (A) a n d tire

iron (B) a r e next to the v a l v e s t e m (C) a n d w i l l m o v e
N O T E : F o r C R m o d e l , If tire s e a l a n t h a s b e e n u s e d for a w a y f r o m it w h e n the m a c h i n e s t a r t s . T h e n
repair t h e flat tire, d o t h e tire s e a l a n t r e m o v a l ( s e e p a g e r e m o v e t h e tire f r o m t h e w h e e l .
18-5) first. In t h i s c a s e , t h e tire r e m o v a l p r o c e d u r e is
n o r m a l l y , but be c a r e f u l not to d a m a g e the tire p r e s s u r e
s e n s o r is d r o p p e d into t h e i n s i d e of the tire, a n d not to
spill the r e m a i n i n g tire s e a l a n t .
in the p r o p e r l o c a t i o n s ( s e e p a g e 1-18).
2. R e m o v e the w h e e l w i t h the faulty s e n s o r .
3. R e m o v e t h e tire v a l v e s t e m c a p a n d the v a l v e s t e m
c o r e , a n d let the tire deflate.
4. R e m o v e a n y b a l a n c e w e i g h t s , a n d t h e n b r e a k t h e
bead loose from the w h e e l with a c o m m e r c i a l l y
a v a i l a b l e tire c h a n g e r (A).
6. R e m o v e t h e v a l v e s t e m nut (A) a n d w a s h e r ( B ) ,
IIMOTICEl t h e n r e m o v e t h e tire p r e s s u r e s e n s o r w i t h v a l v e
Note t h e s e i t e m s to a v o i d d a m a g i n g t h e tire s t e m (C) f r o m t h e w h e e l .
pressure sensor:
• D o the o u t s i d e of the w h e e l first. N O T E : C h e c k the nut a n d the w a s h e r , if t h e y h a v e
• Position the w h e e l a s s h o w n s o the v a l v e deterioration or d a m a g e , r e p l a c e w i t h n e w o n e s
s t e m (B) is 90 d e g r e e s f r o m t h e b e a d during reassembly.
b r e a k e r (C) a s s h o w n .
• Do not position t h e b e a d b r e a k e r of t h e tire
c h a n g e r too c l o s e to t h e r i m .
(cont'd)
18-81
TPMS
Tire Pressure Sensor Replacement ( t'd)
7 . R e m o v e a n d d i s c a r d the v a l v e s t e m g r o m m e t (A) Installation

f r o m t h e tire p r e s s u r e s e n s o r (B>.
N O T E : U s e o n l y w h e e l s that h a v e a " T P M S " s t a m p (A)
NOTE: on them.
• T h e v a l v e s t e m g r o m m e t m i g h t s t a y in t h e w h e e l ;
m a k e s u r e y o u r e m o v e it.
• Always use a new valve stem grommet
w h e n e v e r the tire p r e s s u r e s e n s o r h a s b e e n
r e m o v e d from the w h e e l . W h e n only removing a
tire f r o m the w h e e l , r e p l a c e the v a l v e s t e m
g r o m m e t if it is p o s s i b l e .
1. B e f o r e installing t h e tire p r e s s u r e s e n s o r , c l e a n the

m a t i n g s u r f a c e s o n the s e n s o r a n d the w h e e l .
2. Install the tire p r e s s u r e s e n s o r (A) a n d the w a s h e r

(B) to t h e w h e e l ( C ) , a n d tighten the v a l v e s t e m nut
(D) f i n g e r tight. M a k e s u r e the p r e s s u r e s e n s o r is
r e s t i n g o n the w h e e l .
8 . C R m o d e l : T h o r o u g h l y c l e a n the tire a n d t h e i n s i d e
of the w h e e l w i t h c o l d w a t e r if the tire s e a l a n t w a s
used.
(0.4 k g f - m , 3 Ibf-ft)
3. T i g h t e n t h e v a l v e s t e m nut to the s p e c i f i e d t o r q u e
w h i l e h o l d i n g the tire p r e s s u r e s e n s o r .
NOTE:
• Do not u s e air or e l e c t r i c i m p a c t t o o l s to tighten a
valve stem nut
• Do not t w i s t t h e tire p r e s s u r e s e n s o r w i t h the
w h e e l , a s t h i s w i l l d a m a g e or d e f o r m the v a l v e
stem grommet.
18-82
4. L u b e t h e tire b e a d s p a r i n g l y , a n d p o s i t i o n t h e
w h e e l s o the tire m a c h i n e (A) a n d tire iron (B) a r e
next to the v a l v e s t e m (C) a n d will m o v e a w a y f r o m
it w h e n the m a c h i n e s t a r t s . T h e n install t h e tire
onto t h e w h e e l .
5. W i t h a d r y air s o u r c e , inflate the tire to 3 0 0 kPa

2
(3.1 k g f / c m , 4 4 psi) to s e a t the tire b e a d to the r i m ,
t h e n a d j u s t t h e tire p r e s s u r e ( s e e p a g e 18-7), t h e n
install the v a l v e s t e m c a p .
N O T E : M a k e s u r e t h e tire b e a d is s e a t e d o n both
s i d e s of the rim uniformly.
6. C h e c k a n d a d j u s t t h e w h e e l b a l a n c e , t h e n install the
w h e e l s o n the v e h i c l e .
7. R e m o v e t h e j a c k s t a n d s , a n d l o w e r t h e v e h i c l e .
T o r q u e t h e w h e e l nuts to s p e c i f i c a t i o n s .
8. C o n n e c t the H D S , a n d m e m o r i z e t h e tire p r e s s u r e
s e n s o r IDs u s i n g t h e T P M S s e n s o r initializer tool
( s e e p a g e 18-54).
Brakes
Conventional Brake Components

Special Tools 19-2
Brake System Inspection and Test 19-4
Brake Pedal and Brake Pedal Position Switch
Adjustment 19-6
Parking Brake Inspection and Adjustment 19-7
Brake System Bleeding 19-9
Brake System Indicator Circuit Diagram 19-11
Parking Brake Switch Test 19-12
Brake Fluid Level Switch Test 19-12
Front Brake Pad Inspection and Replacement 19-13
Front Brake Disc Inspection 19-15
Front Brake Disc Replacement 19-16
Front Brake Caliper Overhaul 19-17
Master Cylinder/Brake Booster Replacement 19-18
Master Cylinder Inspection 19-19
Master Cylinder Pushrod Clearance
Adjustment 19-19
Brake Booster Test 19-21
Rear Brake Pad Inspection and Replacement 19-22
Rear Brake Disc Inspection 19-24
Rear Brake Disc Replacement 19-25
Rear Brake Caliper Removal/Installation 19-26
Rear Brake Caliper Overhaul 19-27
Brake Hose and Line Inspection 19-28
Brake Hose Replacement 19-29
Parking Brake Cable Replacement 19-30
ABS (Anti-lock Brake System)

Components ('00-05 Models) 19-31
VSA (Vehicle Stability Assist)
System Components ('06-08 Models) 19-67
Special Tools

© 07JAG-SD40100 Pushrod Adjustment Gauge 1
19-2
MASTER CYLINDER
B r a k e S y s t e m B l e e d i n g , p a g e 19-9
Pushrod Clearance Adjustment,
p a g e 19-19
BRAKE BOOSTER
T e s t , p a g e 19-21
BRAKE S Y S T E M INDICATOR
Circuit Diagram,
p a g e 19-11
Parking Brake S w i t c h
T e s t , p a g e 19-12
Brake Fluid Level Switch Test,
p a g e 19-12
PARKING BRAKE
Inspection and Adjustment,
p a g e 19-7
Cable Replacement,
p a g e 19-30
REAR BRAKE
Pad Inspection and Replacement,
p a g e 19-22
Disc Inspection,
p a g e 19-24
Caliper Removal/Installation,
p a g e 19-26
Disc Replacement,
FRONT BRAKE p a g e 19-25
Pad Inspection and Caliper Overhaul,
R e p l a c e m e n t , p a g e 19-13 p a g e 19-27
Disc Inspection,
p a g e 19-15
Disc Replacement, BRAKE H O S E and LINE
p a g e 19-16 I n s p e c t i o n , p a g e 19-28
Caliper Overhaul, B r a k e H o s e R e p l a c e m e n t , p a g e 19-29
p a g e 19-17
BRAKE PEDAL
Brake Pedal a n d Brake Pedal Position
S w i t c h A d j u s t m e n t , p a g e 19-6
19-3
Brake System Inspection and Test
I n s p e c t t h e b r a k e s y s t e m c o m p o n e n t s listed. R e p a i r or r e p l a c e a n y p a r t s t h a t a r e leaking or d a m a g e d .
Component Inspections:
Component Procedure A l s o c h e c k for
Master Cylinder L o o k for d a m a g e or s i g n s of fluid l e a k a g e at: B u l g i n g s e a l at r e s e r v o i r c a p . T h i s is a
• R e s e r v o i r or m a s t e r c y l i n d e r b o d y . s i g n of fluid c o n t a m i n a t i o n .
• L i n e s , g r o m m e t s , a n d their j o i n t s .
• Between master cylinder and booster.
Brake Hoses L o o k for d a m a g e or s i g n s of fluid l e a k a g e at: B u l g i n g , t w i s t e d , or bent l i n e s .
• L i n e j o i n t s a n d b a n j o bolt c o n n e c t i o n s .
• H o s e s a n d l i n e s , a l s o i n s p e c t for t w i s t i n g or
damage.
Caliper L o o k for d a m a g e or s i g n s of fluid l e a k a g e at: S e i z e d or sticking c a l i p e r p i n s .
• Piston s e a l .
• B a n j o bolt c o n n e c t i o n s .
• Bleed screw.
A B S or V S A L o o k for d a m a g e or s i g n s of fluid l e a k a g e at:
Modulator-control • Line joints.
Unit • M o d u l a t o r - c o n t r o l unit.
Brake System Test
Brake pedal sinks/fades w h e n braking
1. S e t t h e p a r k i n g b r a k e , a n d start t h e e n g i n e , t h e n turn off t h e A / C . A l l o w t h e e n g i n e to w a r m up to n o r m a l o p e r a t i n g

t e m p e r a t u r e (radiator f a n c o m e s o n t w i c e ) .
2. A t t a c h a 50 m m (2 in.) p i e c e of m a s k i n g t a p e a l o n g t h e b o t t o m of t h e s t e e r i n g w h e e l , a n d d r a w a horizontal
r e f e r e n c e m a r k a c r o s s it.
3. W i t h t h e t r a n s m i s s i o n in t h e N e u t r a l p o s i t i o n , p r e s s a n d h o l d t h e b r a k e p e d a l lightly, t h e n r e l e a s e t h e parking
brake.
4. W h i l e still h o l d i n g t h e b r a k e p e d a l , h o o k t h e e n d of t h e t a p e m e a s u r e b e h i n d the brake p e d a l , t h e n pull t h e t a p e up

to t h e s t e e r i n g w h e e l . Note t h e m e a s u r e m e n t b e t w e e n the brake p e d a l a n d t h e r e f e r e n c e m a r k o n t h e s t e e r i n g
wheel.
5. A p p l y s t e a d y p r e s s u r e to t h e b r a k e p e d a l for 3 m i n u t e s .
6. W a t c h t h e t a p e m e a s u r e .
• If t h e m e a s u r e m e n t i n c r e a s e s 10 m m (3/8 in.) or l e s s , t h e m a s t e r c y l i n d e r is O K .
• If t h e m e a s u r e m e n t i n c r e a s e s m o r e t h a n 10 m m (3/8 in.), r e p l a c e t h e m a s t e r c y l i n d e r .
19-4
Symptom Troubleshooting
Rapid brake pad wear, vehicle vibration 5 . L o o s e n t h e h y d r a u l i c l i n e s at t h e m a s t e r c y l i n d e r ,

(after a long drive), or high, hard brake pedal t h e n s p i n t h e w h e e l s to c h e c k for b r a k e d r a g .
N O T E : M a k e s u r e that t h e c a l i p e r p i n s a r e i n s t a l l e d Is there brake drag at any of the wheels?

correctly.
T h e u p p e r c a l i p e r pin A a n d l o w e r c a l i p e r pin B a r e Y E S — G o t o s t e p 6.
different. If the p i n s a r e i n s t a l l e d in the w r o n g l o c a t i o n ,
it w i l l c a u s e v i b r a t i o n , u n e v e n or rapid brake p a d w e a r , N O — C h e c k t h e m a s t e r c y l i n d e r r e s e r v o i r for
a n d p o s s i b l y u n e v e n tire w e a r . F o r p r o p e r c a l i p e r pin c o n t a m i n a t i o n in t h e b r a k e f l u i d . If y o u find
location ( s e e p a g e 19-17). c o n t a m i n a t i o n , f l u s h t h e entire brake s y s t e m of all
c o n t a m i n a t e d fluid. If t h e b r a k e fluid is O K , r e p l a c e
1. D r i v e t h e v e h i c l e until t h e b r a k e s d r a g or until the t h e m a s t e r c y l i n d e r ( s e e p a g e 19-18). •
p e d a l is high a n d h a r d . T h i s c a n take 20 or m o r e
b r a k e pedal a p p l i c a t i o n s d u r i n g a n e x t e n d e d test- 6. L o o s e n t h e b l e e d s c r e w s at e a c h c a l i p e r , t h e n s p i n
drive. t h e w h e e l s to c h e c k for b r a k e d r a g .
2. W i t h t h e e n g i n e r u n n i n g , r a i s e the v e h i c l e o n a lift, Is there brake drag at any of the wheels?

a n d s p i n all four w h e e l s b y h a n d .
Y E S — C h e c k t h e m a s t e r c y l i n d e r r e s e r v o i r for
Is there brake drag at any of the wheels? c o n t a m i n a t i o n in t h e b r a k e fluid. If y o u find
c o n t a m i n a t i o n , f l u s h t h e entire brake s y s t e m of all
Y E S — G o to s t e p 3. c o n t a m i n a t e d fluid. If t h e b r a k e fluid i s O K ,
d i s a s s e m b l e a n d r e p a i r the c a l i p e r o n the w h e e l ( s )
N O — L o o k for other c a u s e s of p a d w e a r , high p e d a l , w i t h brake d r a g . B
or v e h i c l e vibration. •
N O — L o o k for a n d r e p l a c e a n y d a m a g e d b r a k e l i n e s .
3. T u r n the ignition s w i t c h to L O C K (0), p r e s s t h e If all b r a k e l i n e s a r e O K , r e p l a c e the A B S or V S A
b r a k e pedal s e v e r a l t i m e s to d e p l e t e t h e v a c u u m in m o d u l a t o r - c o n t r o l unit: A B S ( s e e p a g e 19-63), V S A
t h e brake b o o s t e r , a n d t h e n s p i n the w h e e l s a g a i n ( s e e p a g e 19-127). •
to c h e c k for brake d r a g .
Is there brake drag at any of the wheels?
N O — R e p l a c e t h e brake b o o s t e r ( s e e p a g e 1 9 - 1 8 ) . B
4 . W i t h o u t r e m o v i n g t h e brake l i n e s , unbolt a n d
s e p a r a t e t h e m a s t e r c y l i n d e r f r o m the b o o s t e r , t h e n
s p i n t h e w h e e l s to c h e c k for brake d r a g .
Is there brake drag at any of the wheels?
N O — C h e c k t h e brake p e d a l position s w i t c h
a d j u s t m e n t a n d p e d a l free play ( s e e p a g e 19-6). •
19-5
Brake Pedal and Brake Pedal Position Switch Adjustment
Pedal Height 3. L o o s e n t h e p u s h r o d locknut (A), a n d s c r e w the

p u s h r o d (B) in or out w i t h p l i e r s , until t h e s t a n d a r d
1. T u r n the brake p e d a l p o s i t i o n s w i t c h (A) p e d a l height f r o m t h e floor is r e a c h e d . After
c o u n t e r c l o c k w i s e , a n d pull it b a c k until it is n o a d j u s t m e n t , tighten t h e locknut firmly. D o not
l o n g e r t o u c h i n g t h e brake p e d a l . a d j u s t t h e p e d a l height w i t h t h e p u s h r o d p u s h e d in.
Lower the pedal
Raise
the pedal
A
15 N m
(1.5 k g f - m , 11 Ibf.ft)
Brake Pedal Position S w i t c h Clearance
4. S c r e w in the b r a k e p e d a l position s w i t c h until its

p l u n g e r is fully p u s h e d in ( t h r e a d e d e n d (A)
t o u c h i n g t h e p a d (B) o n t h e p e d a l a r m ) . T h e n back
off the s w i t c h 1/4 turn to m a k e 0.3 m m (0.01 in.) of
c l e a r a n c e b e t w e e n t h e t h r e a d e d e n d a n d the p a d .
T i g h t e n t h e locknut f i r m l y .
N O T E : T h e b r a k e s will d r a g if t h e r e is no c l e a r a n c e .
C o n n e c t t h e brake p e d a l position s w i t c h c o n n e c t o r .
M a k e s u r e that t h e brake lights g o off w h e n t h e
p e d a l is r e l e a s e d .
Pull b a c k t h e c a r p e t a n d find t h e c u t o u t (B) in t h e

i n s u l a t i o n . Lift up t h e i n s u l a t i o n c u t o u t a n d
m e a s u r e t h e p e d a l height (C) at t h e c e n t e r of t h e
p e d a l p a d (D) to t h e floor.
Standard pedal height (with carpet m o v e d aside):

179 m m (7 1 / 1 6 in.)
01 in.)
5. C h e c k t h e brake p e d a l free play.
19-6
®
Parking Brake Inspection and
Adjustment
Pedal Free Play
1. W i t h the ignition s w i t c h to L O C K (0), i n s p e c t the Inspection

f r e e play (A) o n t h e brake p e d a l p a d (B) b y p u s h i n g
t h e b r a k e pedal by h a n d . If the brake p e d a l free play 1. Pull t h e p a r k i n g b r a k e l e v e r (A) w i t h 196 N (20 kgf,
is out of s p e c i f i c a t i o n , a d j u s t the brake p e d a l 44 Ibf) of f o r c e to fully a p p l y t h e parking b r a k e . T h e
position s w i t c h (C). If t h e brake p e d a l f r e e play is p a r k i n g b r a k e l e v e r s h o u l d be l o c k e d w i t h i n t h e
insufficient, it m a y result in brake d r a g . s p e c i f i e d c l i c k s (B).
F r e e p l a y : 1 — 5 m m ( 1 / 1 6 — 3 / 1 6 in.) Lever locked clicks: 9 t o 13
Pulled up with 196 N (20 kgf, 44 Ibf)
2. A d j u s t t h e parking b r a k e if t h e l e v e r c l i c k s a r e not
within the specification.
(cont'd)
19-7
Parking Brake Inspection and Adjustment (cont'd)
Adjustment 6. M a k e s u r e t h e parking brake l e v e r (A) o n the rear

b r a k e c a l i p e r c o n t a c t s t h e s t o p pin (B).
1. R e m o v e t h e c o n s o l e p a n e l ( s e e p a g e 2 0 - 8 0 ) .
N O T E - T h e p a r k i n g brake l e v e r w i l l o n l y c o n t a c t t h e
2 . R e l e a s e t h e parking b r a k e l e v e r fully. s t o p pin w h e n t h e parking brake a d j u s t i n g nut is
loosened.
3. L o o s e n t h e p a r k i n g b r a k e a d j u s t i n g nut (A).
7. C l e a n t h e m a t i n g s u r f a c e s of t h e brake d i s c a n d t h e
i n s i d e of t h e w h e e l , t h e n install the rear w h e e l s .
8. Pull t h e parking b r a k e l e v e r 1 click.

4. R a i s e t h e r e a r of t h e v e h i c l e , a n d s u p p o r t it w i t h
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e 9. T i g h t e n t h e parking brake a d j u s t i n g nut until the
1-18). p a r k i n g b r a k e s d r a g slightly w h e n t h e rear w h e e l s
are turned.
10. R e l e a s e t h e parking brake l e v e r fully, a n d c h e c k
t h a t t h e parking b r a k e s d o not d r a g w h e n t h e r e a r
w h e e l s a r e t u r n e d . R e a d j u s t if n e c e s s a r y .
11. M a k e s u r e t h e p a r k i n g b r a k e s a r e fully a p p l i e d
w h e n t h e parking b r a k e l e v e r is p u l l e d all the w a y
(9 to 13 c l i c k s ) .
12. Install t h e c o n s o l e p a n e l ( s e e p a g e 20-80).
19-8
©
Brake System Bleeding
NOTE: 3 . H a v e s o m e o n e s l o w l y p u m p t h e b r a k e pedal
• D o not r e u s e t h e d r a i n e d fluid. several times, then apply steady pressure.
• U s e only clean Honda D O T 3 Brake Fluid from a n
u n o p e n e d c o n t a i n e r . U s i n g a n o n - H o n d a b r a k e fluid 4 . S t a r t i n g at t h e left-front, l o o s e n t h e b r a k e b l e e d
c a n c a u s e c o r r o s i o n a n d s h o r t e n t h e life of t h e s c r e w to a l l o w air to e s c a p e f r o m t h e s y s t e m . T h e n
system. tighten t h e b l e e d s c r e w s e c u r e l y .
• D o not m i x different b r a n d s of brake fluid; t h e y m a y
not be c o m p a t i b l e . 5 . R e p e a t t h e p r o c e d u r e for e a c h c a l i p e r until n o air
• M a k e s u r e no dirt o r other f o r e i g n matter is a l l o w e d b u b b l e s a r e in t h e fluid. B l e e d t h e c a l i p e r s in t h e
to c o n t a m i n a t e t h e brake fluid. sequence shown.
t h e paint; if brake fluid d o e s c o n t a c t t h e paint, w a s h it BLEEDING SEQUENCE:
• T h e r e s e r v o i r c o n n e c t e d to the m a s t e r c y l i n d e r m u s t
be at the M A X (upper) level m a r k at t h e start of t h e © Front Right ) Rear Right
b l e e d i n g p r o c e d u r e a n d c h e c k e d after b l e e d i n g e a c h
b r a k e c a l i p e r . A d d fluid a s r e q u i r e d .
1. M a k e s u r e t h e b r a k e fluid level in t h e r e s e r v o i r is at
t h e M A X (upper) level line (A).
© F r o n t Left ® Rear Left
6 . Refill t h e m a s t e r c y l i n d e r r e s e r v o i r to t h e M A X
(upper) level line.
Pressure Bleeding
Install t h e a p p r o p r i a t e p o w e r p r o b e p r e s s u r e b l e e d e r
a d a p t e r onto t h e m a s t e r c y l i n d e r .
U s e t h e b l e e d i n g s e q u e n c e a b o v e , a n d f o l l o w the
b l e e d i n g i n s t r u c t i o n s that c o m e w i t h y o u r p r e s s u r e
A t t a c h a p i e c e of c l e a r plastic h o s e o v e r t h e first bleeder.
b l e e d s c r e w , a n d s u b m e r g e t h e other e n d in a
c o n t a i n e r of n e w b r a k e fluid.
(cont'd)
19-9
Brake System Bleeding (cont'd)
Bleed s c r e w locations
Front
9 I M - m (0.9 k g f m , 7 Ibf-ft)
Rear
9 N - m (0.9 k g f - m , 7 Ibf-ft)
19-10
®
Brake System Indicator Circuit Diagram
UNDER-HOOD F U S E / IGNITION S W I T C H
IG1 H O T in O N (II)
RELAY BOX
and S T A R T (III)
B A T T E R Y (100 A) IG1 MAIN (40 A)
1BLK" — C T \ J > ^ CTX_£>
®—
-BLK/YEL •
INSTRUMENT UNDER-DASH F U S E /
L I G H T (7.5 A) RELAY BOX
C O N V E R T I B L E T O P C O N T R O L UNIT .
DAYTIME RUNNING LIGHTS < j
C O N T R O L UNIT ^
GRN/WHT GRN/RED
BRAKE FLUID
PARKING BRAKE SWITCH LEVEL SWITCH
C L O S E D : Lever up C L O S E D : Float d o w n
O P E N : Lever d o w n O P E N : Float up
_L
G301
*1:'00-03 models
* 2 : '04-08 m o d e l s
19-11
Parking Brake Switch Test Brake Fluid Level Switch Test
1. R e m o v e the c e n t e r c o n s o l e ( s e e p a g e 20-80). C h e c k for c o n t i n u i t y b e t w e e n the t e r m i n a l s (A) w i t h t h e
float in t h e d o w n position a n d t h e u p p o s i t i o n .
2. D i s c o n n e c t t h e p a r k i n g brake s w i t c h c o n n e c t o r (A)
f r o m t h e parking b r a k e s w i t c h (B). • R e m o v e t h e b r a k e fluid c o m p l e t e l y f r o m t h e r e s e r v o i r .
A
3. C h e c k for c o n t i n u i t y b e t w e e n the s w i t c h t e r m i n a l
(C) a n d b o d y g r o u n d .
• W i t h t h e p a r k i n g b r a k e l e v e r u p , t h e r e s h o u l d be
continuity.
• With the parking brake lever d o w n , there s h o u l d
be no continuity.
N O T E : If t h e p a r k i n g b r a k e s w i t c h i s O K , but t h e
b r a k e s y s t e m i n d i c a t o r d o e s not w o r k , d o t h e input
t e s t for t h e d a y t i m e r u n n i n g lights c o n t r o l unit
(see page 22-127).
4. C o n n e c t t h e p a r k i n g b r a k e s w i t c h c o n n e c t o r .
5. R e i n s t a l l t h e c e n t e r c o n s o l e ( s e e p a g e 20-80).
19-12
Front Brake Pad Inspection and Replacement
Replacement
ACAUTION
F r e q u e n t i n h a l a t i o n of brake p a d d u s t , r e g a r d l e s s of 1. R e m o v e s o m e brake fluid f r o m t h e m a s t e r c y l i n d e r .
m a t e r i a l c o m p o s i t i o n , c o u l d b e h a z a r d o u s to y o u r
health. 2 . R a i s e t h e front of the v e h i c l e , a n d s u p p o r t it w i t h
• A v o i d breathing dust particles. s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e
• N e v e r u s e a n air h o s e o r b r u s h to c l e a n b r a k e 1-18).
assemblies. Use an OSHA-approved vacuum
cleaner. 3 . R e m o v e t h e front w h e e l s .
4. R e m o v e t h e f l a n g e bolt (A) w h i l e h o l d i n g t h e
Inspection c a l i p e r pin (B) w i t h a w r e n c h a n d b e i n g c a r e f u l not
to d a m a g e t h e pin boot, a n d p i v o t t h e c a l i p e r (C) u p
1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it w i t h out of t h e w a y . C h e c k t h e b r a k e h o s e a n d pin b o o t s
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e for d a m a g e a n d d e t e r i o r a t i o n .
1-18).
2. R e m o v e t h e front w h e e l s .
3. R e m o v e t h e b r a k e p a d s .
4. U s i n g v e r n i e r c a l i p e r s , m e a s u r e the t h i c k n e s s of
e a c h b r a k e p a d lining. T h e m e a s u r e m e n t d o e s not
i n c l u d e t h e b r a k e p a d b a c k i n g plate (A) t h i c k n e s s .
Brake pad thickness: A

8x1.0 mm
Standard: 9 . 5 — 1 0 . 5 m m (0.37—0.41 in.)
5. R e m o v e t h e brake p a d s (A) a n d the p a d s h i m s (B).
5. If t h e b r a k e p a d t h i c k n e s s is l e s s t h a n t h e s e r v i c e
limit, r e p l a c e the front b r a k e p a d s a s a s e t .
6. C l e a n t h e m a t i n g s u r f a c e s of the b r a k e d i s c a n d t h e
i n s i d e of the w h e e l , t h e n install the front w h e e l s .
(cont'd)
19-13
Front Brake Pad Inspection and Replacement (cont'd)
6. R e m o v e t h e p a d r e t a i n e r s (A). 12. P u s h in t h e p i s t o n (A) s o t h e c a l i p e r will fit o v e r t h e
c brake p a d s . C h e c k the b r a k e fluid l e v e l . T h e brake
fluid m a y o v e r f l o w if t h e r e s e r v o i r is too full. M a k e
s u r e t h e p i s t o n boot is in position to p r e v e n t
d a m a g i n g it w h e n pivoting t h e c a l i p e r d o w n .
N O T E : B e c a r e f u l w h e n p r e s s i n g in the c a l i p e r
p i s t o n ; brake fluid m i g h t o v e r f l o w f r o m t h e m a s t e r
cylinder's reservoir.
C
8 x 1.0 m m
3 2 N m (3.3 k g f m , 2 4 I b f f t )
7. C l e a n t h e c a l i p e r t h o r o u g h l y ; r e m o v e a n y r u s t a n d
c h e c k for g r o o v e s a n d c r a c k s . V e r i f y that t h e c a l i p e r
p i n s (C) m o v e in a n d out s m o o t h l y . C l e a n a n d lube
if n e e d e d .
8. I n s p e c t t h e b r a k e d i s c , a n d c h e c k for d a m a g e a n d
c r a c k s ( s e e p a g e 19-15).
9. Install t h e p a d r e t a i n e r s . W i p e e x c e s s a s s e m b l y
p a s t e off t h e r e t a i n e r s . K e e p t h e a s s e m b l y p a s t e off
of t h e b r a k e d i s c a n d b r a k e p a d s .
10. A p p l y a thin c o a t of M-77 a s s e m b l y p a s t e (P/N

0 8 7 9 8 - 9 0 1 0 ) to t h e p a d s i d e of t h e s h i m s (A), t h e
b a c k of the b r a k e p a d s ( B ) , a n d t h e o t h e r a r e a s
i n d i c a t e d b y t h e a r r o w s . W i p e e x c e s s p a s t e off t h e
p a d s h i m s a n d brake p a d s . C o n t a m i n a t e d brake
d i s c s o r b r a k e p a d s r e d u c e s t o p p i n g ability. K e e p
a s s e m b l y p a s t e off of t h e b r a k e d i s c s a n d b r a k e 13. Pivot t h e c a l i p e r (B) d o w n into p o s i t i o n . Install t h e
pads. f l a n g e bolt ( C ) , a n d tighten it to t h e s p e c i f i e d t o r q u e
w h i l e h o l d i n g t h e c a l i p e r pin (D) w i t h a w r e n c h a n d
b e i n g c a r e f u l not to d a m a g e t h e pin boot.
14. C l e a n t h e m a t i n g s u r f a c e s of the brake d i s c a n d the

i n s i d e of t h e w h e e l , t h e n install the front w h e e l s .
15. A d d b r a k e fluid a s n e e d e d .
16. P r e s s t h e brake p e d a l s e v e r a l t i m e s to m a k e s u r e
the brakes work.
N O T E : E n g a g e m e n t m a y require a g r e a t e r p e d a l
s t r o k e i m m e d i a t e l y after t h e b r a k e p a d s h a v e b e e n
r e p l a c e d a s a s e t . S e v e r a l a p p l i c a t i o n s of the brake
p e d a l will r e s t o r e t h e n o r m a l p e d a l s t r o k e .
17. After installation, c h e c k for l e a k s at h o s e a n d line

11. Install t h e b r a k e p a d s a n d p a d s h i m s c o r r e c t l y . j o i n t s or c o n n e c t i o n s , a n d retighten if n e c e s s a r y .
Install t h e b r a k e p a d s w i t h t h e w e a r i n d i c a t o r (C) o n T e s t - d r i v e t h e v e h i c l e , t h e n c h e c k for l e a k s
t h e l o w e r i n s i d e , if y o u a r e r e u s i n g t h e b r a k e p a d s , ( s e e p a g e 19-28).
a l w a y s reinstall t h e b r a k e p a d s in t h e i r o r i g i n a l
p o s i t i o n s to p r e v e n t a m o m e n t a r y l o s s of b r a k i n g
efficiency.
19-14
®
Front Brake Disc Inspection
Runout Thickness and Parallelism
1. R a i s e the front of t h e v e h i c l e , a n d s u p p o r t it w i t h 1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it w i t h

s a f e t y s t a n d s in t h e proper l o c a t i o n s ( s e e p a g e s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e
1-18). 1-18).
2. R e m o v e the front w h e e l s . 2. R e m o v e t h e front w h e e l s .
3. R e m o v e the b r a k e p a d s ( s e e p a g e 19-13). 3. R e m o v e t h e b r a k e p a d s ( s e e p a g e 19-13).
4. I n s p e c t the brake d i s c s u r f a c e for d a m a g e a n d 4. U s i n g a m i c r o m e t e r , m e a s u r e the b r a k e d i s c

c r a c k s . C l e a n the brake d i s c t h o r o u g h l y , a n d t h i c k n e s s at eight p o i n t s , a b o u t 4 5 ° a p a r t a n d
r e m o v e all rust. 10 m m (3/8 in.) in f r o m t h e o u t e r e d g e of t h e b r a k e
d i s c . R e p l a c e t h e b r a k e d i s c if t h e s m a l l e s t
5. Install s u i t a b l e flat w a s h e r s (A) a n d w h e e l n u t s , a n d m e a s u r e m e n t is l e s s t h a n t h e m a x . r e f i n i s h i n g l i m i t
t i g h t e n the w h e e l nuts to s p e c i f i e d t o r q u e to hold
t h e b r a k e d i s c s e c u r e l y a g a i n s t the h u b . Brake disc thickness:
S t a n d a r d : 2 4 . 9 — 2 5 . 1 m m (0.98—0.99 in.)
M a x . r e f i n i s h i n g limit: 2 3 . 0 m m (0.91 in.)
B r a k e d i s c p a r a l l e l i s m : 0.015 m m (0.0006 in.) m a x .
N O T E : T h i s is t h e m a x i m u m a l l o w a b l e d i f f e r e n c e
between the t h i c k n e s s m e a s u r e m e n t s .
10 m m ( 3 / 8 in.)
1 0 8 N m (11.0 k g f m , 7 9 . 6 I b f f t )
6. S e t u p the dial g a u g e a g a i n s t t h e b r a k e d i s c a s
s h o w n , a n d m e a s u r e runout at 10 m m (3/8 in.) f r o m
t h e o u t e r e d g e of t h e brake d i s c .
B r a k e disc runout:
5. If t h e b r a k e d i s c is b e y o n d t h e s e r v i c e limit for
7. If t h e b r a k e d i s c i s b e y o n d the s e r v i c e limit, refinish p a r a l l e l i s m , refinish t h e brake d i s c w i t h a
the brake disc with a commercially available on-car c o m m e r c i a l l y a v a i l a b l e o n - c a r b r a k e lathe.
b r a k e lathe.
N O T E : If t h e brake d i s c is b e y o n d t h e s e r v i c e limit
M a x . r e f i n i s h i n g limit: 23.0 m m (0.91 in.) for r e f i n i s h i n g , r e p l a c e it ( s e e p a g e 19-16).
NOTE:
• If t h e brake d i s c is b e y o n d t h e s e r v i c e limit for
r e f i n i s h i n g , r e p l a c e it ( s e e p a g e 19-16).
• A n e w d i s c s h o u l d b e r e f i n i s h e d if its r u n o u t is
g r e a t e r t h a n 0.04 m m (0.0016 in.).
19-15
Front Brake Disc Replacement
N O T E : K e e p a n y g r e a s e off the b r a k e d i s c a n d b r a k e 5. R e m o v e t h e brake d i s c flat s c r e w s (A).

pads.
1. R a i s e t h e front of t h e v e h i c l e , a n d s u p p o r t it w i t h
1-18).
2 . R e m o v e t h e front w h e e l .
3 . R e m o v e t h e b r a k e h o s e bracket m o u n t i n g bolt (A).
B
12x1.25 mm
'00-03 a n d '06-08 m o d e l s :
1 0 8 N-m (11.0 k g f - m , 7 9 . 6 Ibf ft)
'04-05 models:
1 1 3 N - m (11.5 k g f m , 8 3 . 2 Ibf-ft)
6. R e m o v e t h e b r a k e d i s c (B) f r o m t h e front h u b .
N O T E : If t h e b r a k e d i s c is s t u c k to t h e front h u b ,
t h r e a d t w o 8 x 1.25 m m bolts (C) into t h e brake d i s c
to p u s h it a w a y f r o m t h e front h u b . T u r n e a c h bolt
9 0 d e g r e e s at a t i m e to p r e v e n t t h e brake d i s c f r o m
binding.
7. Install t h e b r a k e d i s c in t h e r e v e r s e o r d e r of
removal.
N O T E : B e f o r e installing t h e brake d i s c , c l e a n t h e
m a t i n g s u r f a c e of t h e front h u b a n d t h e i n s i d e of
the brake disc.
4. R e m o v e t h e b r a k e c a l i p e r bracket m o u n t i n g bolts 8. C l e a n t h e m a t i n g s u r f a c e s of the brake d i s c a n d the

(B), t h e n r e m o v e t h e c a l i p e r a s s e m b l y (C) f r o m t h e i n s i d e of t h e w h e e l , t h e n install the front w h e e l .
a s s e m b l y or b r a k e h o s e , u s e a s h o r t p i e c e of w i r e
to h a n g t h e c a l i p e r a s s e m b l y f r o m t h e
u n d e r c a r r i a g e . D o not t w i s t t h e brake h o s e
excessively.
19-16
®
Front Brake Caliper Overhaul
ACAUTION
F r e q u e n t inhalation of brake p a d d u s t , r e g a r d l e s s of m a t e r i a l c o m p o s i t i o n , c o u l d b e h a z a r d o u s to y o u r h e a l t h .
• A v o i d breathing dust particles.
• N e v e r u s e a n air h o s e or b r u s h to c l e a n brake a s s e m b l i e s . U s e a n O S H A - a p p r o v e d v a c u u m c l e a n e r .
R e m o v e , d i s a s s e m b l e , i n s p e c t , r e a s s e m b l e , a n d install t h e c a l i p e r , a n d note t h e s e i t e m s :
N O T E : M a k e s u r e that t h e c a l i p e r p i n s a r e installed c o r r e c t l y . U p p e r c a l i p e r pin A a n d l o w e r c a l i p e r pin B a r e different.

If t h e s e c a l i p e r p i n s a r e i n s t a l l e d in t h e w r o n g l o c a t i o n , it will c a u s e v i b r a t i o n , u n e v e n o r r a p i d p a d w e a r , a n d p o s s i b l y
u n e v e n tire w e a r .
• D o not spill b r a k e fluid o n t h e v e h i c l e ; it m a y d a m a g e t h e paint; if b r a k e fluid g e t s o n t h e paint, w a s h it off

immediately with water.
• T o p r e v e n t dripping brake fluid, c o v e r d i s c o n n e c t e d h o s e j o i n t s with r a g s or s h o p t o w e l s .
• C l e a n all parts in b r a k e fluid a n d air d r y ; b l o w out all p a s s a g e s w i t h c o m p r e s s e d air.
• B e f o r e r e a s s e m b l i n g , c h e c k that all p a r t s a r e free of d u s t a n d other f o r e i g n p a r t i c l e s .
• R e p l a c e parts w i t h n e w o n e s a s s p e c i f i e d in t h e illustration.
• M a k e s u r e n o dirt o r other f o r e i g n matter is a l l o w e d to c o n t a m i n a t e t h e b r a k e fluid.
• M a k e s u r e n o g r e a s e o r oil g e t s o n t h e brake d i s c s o r p a d s .
• W h e n r e u s i n g b r a k e p a d s , a l w a y s reinstall t h e m in their original p o s i t i o n s to p r e v e n t l o s s of braking e f f i c i e n c y .
• D o not r e u s e d r a i n e d brake fluid. U s e o n l y c l e a n H o n d a D O T 3 B r a k e F l u i d f r o m a n u n o p e n e d c o n t a i n e r . U s i n g a
n o n - H o n d a brake fluid c a n c a u s e c o r r o s i o n a n d s h o r t e n t h e life of t h e s y s t e m .
• D o not m i x different b r a n d s of brake fluid a s t h e y m a y not b e c o m p a t i b l e .
• C o a t t h e p i s t o n , piston s e a l g r o o v e , a n d c a l i p e r b o r e w i t h c l e a n b r a k e fluid.
• R e p l a c e all r u b b e r p a r t s with n e w o n e s w h e n e v e r d i s a s s e m b l e d .
• After installing t h e c a l i p e r , c h e c k t h e b r a k e h o s e a n d line for l e a k s , i n t e r f e r e n c e , a n d t w i s t i n g .
GREASEXI H o n d a s i l i c o n e g r e a s e ( P / N 08C30-B0234M)
:
8x1.25 mm
CALIPER BOLT
3 2 N-m (3.3 k g f m , 2 4 Ibfft)
BRAKE HOSE
PAD R E T A I N E R S
W E A R INDICATOR CALIPER BRACKET

Install inner pad with 12x1.25 mm
its wear indicator downward. FLANGE BOLT
'00-03 a n d '06-08 m o d e l s :
BRAKE PADS 108 N m (11.0 k g f m , 79.6 Ibfft)
'04-05 m o d e l s :
113 N m (11.5 k g f m , 83.2 Ibfft)
19-17
Master Cylinder/Brake Booster Replacement
N O T E : D o not spill brake fluid o n t h e v e h i c l e ; it m a y d a m a g e t h e paint. If brake fluid d o e s c o n t a c t the paint, w a s h it off
1. D i s c o n n e c t t h e b r a k e fluid level s w i t c h c o n n e c t o r .
2. R e m o v e t h e brake fluid f r o m t h e m a s t e r c y l i n d e r r e s e r v o i r w i t h a s y r i n g e .
3. D i s c o n n e c t t h e brake l i n e s f r o m t h e m a s t e r c y l i n d e r . T o p r e v e n t s p i l l s , c o v e r t h e line joints w i t h r a g s or s h o p

towels.
4. R e m o v e t h e m a s t e r c y l i n d e r m o u n t i n g n u t s a n d w a s h e r s .
5. R e m o v e t h e m a s t e r c y l i n d e r f r o m the brake b o o s t e r .
6. D i s c o n n e c t t h e brake b o o s t e r v a c u u m h o s e f r o m t h e brake b o o s t e r .
7. R e m o v e t h e lock pin a n d y o k e p i n .
8. R e m o v e t h e four brake b o o s t e r m o u n t i n g n u t s .
9. Pull t h e b r a k e b o o s t e r f o r w a r d , a n d r e m o v e t h e brake b o o s t e r f r o m t h e e n g i n e c o m p a r t m e n t . B e c a r e f u l not to

b e n d or d a m a g e t h e brake l i n e s w h e n r e m o v i n g it.
10. Install t h e brake b o o s t e r a n d m a s t e r c y l i n d e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• R e p l a c e all r u b b e r parts a n d t h e g a s k e t w i t h n e w o n e s w h e n e v e r r e m o v e d .
• C o a t t h e lip of t h e n e w r o d s e a l w i t h r e c o m m e n d e d s e a l g r e a s e .
• Install t h e rod s e a l onto t h e b r a k e b o o s t e r w i t h its g r o o v e d s i d e t o w a r d t h e m a s t e r c y l i n d e r .
• ' 0 0 - 0 5 m o d e l s , a d j u s t t h e p u s h r o d length before installing t h e b o o s t e r ( s e e p a g e 19-19).
• Fill t h e m a s t e r c y l i n d e r r e s e r v o i r , a n d b l e e d t h e brake s y s t e m ( s e e p a g e 19-9).
• After installation, c h e c k t h e brake p e d a l height a n d b r a k e p e d a l f r e e p l a y ( s e e p a g e 19-6) a n d a d j u s t if n e c e s s a r y .
• B l e e d t h e brake s y s t e m ( s e e p a g e 19-9).
• S p i n t h e w h e e l s to c h e c k for brake d r a g .
8 x 1.25 mm
13 Nm
(1.3 kgfm, 9.4 Ibf-ft)
15 N m(1.5 kgf m, 11 Ibf-ft)

VSA:
12 x 1.0 mm
22 N m (2.2 kgf-m, 16 Ibf-ft)
19-18
®
Master Cylinder Inspection Master Cylinder Pushrod Clearance
Adjustment
1. I n s p e c t a n d note t h e s e i t e m s :
• B e f o r e r e a s s e m b l i n g , c h e c k that all parts a r e f r e e Special Tools Required

of dirt a n d other f o r e i g n p a r t i c l e s . Pushrod adjustment gauge 07JAG-SD40100
• D o not try to d i s a s s e m b l e t h e m a s t e r c y l i n d e r
a s s e m b l y . Replace the master cylinder a s s e m b l y N O T E : M a s t e r c y l i n d e r p u s h rod-to-piston c l e a r a n c e
w i t h a n e w part if n e c e s s a r y . m u s t be c h e c k e d a n d a d j u s t m e n t s m a d e , if n e c e s s a r y ,
• D o not a l l o w dirt or f o r e i g n matter to b e f o r e installing t h e m a s t e r c y l i n d e r .
c o n t a m i n a t e t h e brake fluid.
1. S e t the p u s h r o d a d j u s t m e n t g a u g e (A) o n the
m a s t e r c y l i n d e r b o d y (B), p u s h in the c e n t e r s h a f t
(C) until t h e top of it c o n t a c t s t h e e n d of the
s e c o n d a r y p i s t o n (D) b y t u r n i n g the a d j u s t i n g nut
(E).
MASTER CYLINDER
C h e c k for leaks, rust, a n d d a m a g e .
2. W i t h o u t d i s t u r b i n g the c e n t e r s h a f t ' s p o s i t i o n ,
install t h e p u s h r o d a d j u s t m e n t g a u g e (A) onto t h e
booster.
( 0 - 7 6 0 m m H g , 0 - 3 0 in.Hg) 07JAG-SD40100
3. Install t h e m a s t e r c y l i n d e r n u t s (B), a n d tighten to

the s p e c i f i e d t o r q u e .
4. C o n n e c t t h e b o o s t e r in-line w i t h a v a c u u m g a u g e
(C) 0 - 1 0 1 kPa ( 0 - 7 6 0 m m H g , 0 - 3 0 in.Hg) to t h e
booster's engine v a c u u m supply, and maintain an
e n g i n e s p e e d that will d e l i v e r 6 6 kPa (500 m m H g ,
20 in.Hg) v a c u u m .
(cont'd)
19-19
Master Cylinder Pushrod Clearance Adjustment (cont'd)
W i t h a f e e l e r g a u g e (A), m e a s u r e the c l e a r a n c e 9. C h e c k the p u s h r o d length (A) a s s h o w n if the
b e t w e e n t h e g a u g e b o d y a n d t h e a d j u s t i n g nut (B) b o o s t e r is r e m o v e d . If the length is incorrect,
as shown. l o o s e n the p u s h r o d locknut (B), a n d turn the y o k e
If the c l e a r a n c e b e t w e e n the g a u g e b o d y a n d t h e (C) in or out to a d j u s t .
a d j u s t i n g nut is 0.4 m m (0.02 in.), the p u s h r o d - t o -
A
piston c l e a r a n c e is 0 m m . H o w e v e r , if t h e c l e a r a n c e 1 1 6 m m (4.6 in.)
b e t w e e n t h e g a u g e b o d y a n d the a d j u s t i n g nut is
0 m m , the p u s h r o d - t o - p i s t o n c l e a r a n c e is 0.4 m m
(0.02 in.) o r m o r e . T h e r e f o r e , it m u s t be a d j u s t e d
and rechecked.
Clearance: 0 — 0 . 4 m m ( 0 — 0 . 0 2 in.)
07JAG-SD40100
B
15 N-m
(1.5 k g f m , 11 I b f f t )
10. Install the m a s t e r c y l i n d e r ( s e e p a g e 19-18).
If the c l e a r a n c e is i n c o r r e c t , l o o s e n the s t a r locknut

(A), a n d t u r n t h e a d j u s t e r (B) in or out to a d j u s t .
• A d j u s t the c l e a r a n c e w h i l e the s p e c i f i e d v a c u u m
is a p p l i e d to the b o o s t e r .
• Hold the y o k e (C) w h i l e a d j u s t i n g .
A
0 — 0 . 4 m m ( 0 — 0 . 0 2 in.) 21 N-m
(2.1 k g f m , 1 5 I b f f t )
07JAG-SD40100
7. T i g h t e n t h e s t a r locknut s e c u r e l y .
8. R e m o v e the p u s h r o d a d j u s t m e n t g a u g e (D).
19-20
©
Brake Booster Test
Functional Test 3. D i s c o n n e c t t h e brake b o o s t e r v a c u u m h o s e (A) at

the b o o s t e r . T h e c h e c k v a l v e (B) is built into t h e
1. W i t h the ignition s w i t c h at L O C K (0), p r e s s t h e hose.
brake pedal s e v e r a l t i m e s to deplete the v a c u u m
r e s e r v o i r , t h e n p r e s s the b r a k e p e d a l h a r d , a n d hold
it for 15 s e c o n d s . If the brake p e d a l s i n k s , either t h e
m a s t e r c y l i n d e r is b y p a s s i n g internally, or t h e
brake s y s t e m is l e a k i n g . I n s p e c t the brake h o s e s
a n d lines ( s e e p a g e 19-28).
2. S t a r t the e n g i n e w i t h the brake pedal p r e s s e d . If the

brake p e d a l s i n k s slightly, the v a c u u m b o o s t e r is
o p e r a t i n g n o r m a l l y . If t h e brake p e d a l height d o e s
not v a r y , d o the brake s y s t e m t e s t ( s e e p a g e 19-4).
Leak Test
1. P r e s s the brake p e d a l w i t h the e n g i n e r u n n i n g , t h e n

s t o p the e n g i n e . T h e brake p e d a l height s h o u l d not 4. S t a r t the e n g i n e , a n d let it idle. T h e r e s h o u l d be
v a r y w h i l e p r e s s e d for 3 0 s e c o n d s . If the p e d a l v a c u u m a v a i l a b l e . If no v a c u u m is a v a i l a b l e , t h e
height r i s e s , g o to s t e p 6. If it d o e s not r i s e , g o to c h e c k v a l v e is not w o r k i n g properly. R e p l a c e t h e
s t e p 2. brake booster v a c u u m h o s e a n d check v a l v e , and
retest. If v a c u u m is f o u n d , g o to s t e p 5.
2. Start the e n g i n e , a n d let it idle for 30 s e c o n d s . T u r n
t h e ignition s w i t c h to L O C K (0), a n d w a i t 5. W i t h t h e ignition s w i t c h at L O C K (0), r e c o n n e c t the
30 s e c o n d s . P r e s s the brake p e d a l s e v e r a l t i m e s v a c u u m h o s e to the brake b o o s t e r .
u s i n g n o r m a l p r e s s u r e . W h e n the p e d a l is first
p r e s s e d , it s h o u l d be l o w . O n c o n s e c u t i v e 6. S t a r t the e n g i n e , a n d t h e n p i n c h the brake b o o s t e r
a p p l i c a t i o n s , the p e d a l height s h o u l d g r a d u a l l y r i s e . v a c u u m h o s e between the check valve and the
D o e s t h e p e d a l rise o n e a c h c o n s e c u t i v e booster.
a p p l i c a t i o n ? If it r i s e s t h e b o o s t e r is O K . If it d o e s
not g o to s t e p 3. 7. T u r n the ignition s w i t c h to L O C K (0), a n d w a i t
30 s e c o n d s . Press the brake pedal several t i m e s
u s i n g n o r m a l p r e s s u r e . W h e n the p e d a l is first
p r e s s e d , it s h o u l d be l o w . O n c o n s e c u t i v e
a p p l i c a t i o n s , t h e p e d a l height s h o u l d g r a d u a l l y r i s e .
• If the p e d a l position d o e s not v a r y i n s p e c t t h e

s e a l b e t w e e n t h e m a s t e r c y l i n d e r a n d b o o s t e r . If
the s e a l is O K , r e p l a c e t h e brake b o o s t e r .
• If the p e d a l position v a r i e s , r e p l a c e the b r a k e
booster v a c u u m hose/check valve a s s e m b l y .
19-21
Rear Brake Pad Inspection and Replacement

Replacement
ACAUTION
F r e q u e n t i n h a l a t i o n of b r a k e p a d d u s t , r e g a r d l e s s of 1. R e m o v e s o m e brake fluid f r o m t h e m a s t e r c y l i n d e r .
m a t e r i a l c o m p o s i t i o n , c o u l d be h a z a r d o u s to y o u r
health. 2. R a i s e t h e r e a r of t h e v e h i c l e , a n d s u p p o r t it w i t h
• A v o i d breathing dust particles. s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e
• N e v e r u s e a n air h o s e or b r u s h to c l e a n b r a k e 1-18).
assemblies. U s e an OSHA-approved v a c u u m
cleaner. 3. R e m o v e the rear w h e e l s .
4. R e m o v e the f l a n g e bolts (A) w h i l e h o l d i n g t h e

Inspection c a l i p e r pin (B) w i t h a w r e n c h a n d b e i n g c a r e f u l not
to d a m a g e the pin boot, a n d r e m o v e the c a l i p e r (C)
1. R a i s e t h e r e a r of the v e h i c l e , a n d s u p p o r t it w i t h f r o m the bracket. C h e c k t h e brake h o s e a n d pin
s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e b o o t s for d a m a g e a n d deterioration.
1-18).
A
3. R e l e a s e t h e p a r k i n g b r a k e . 8 x 1.25 mm
4. R e m o v e t h e b r a k e p a d s .
5. U s i n g v e r n i e r c a l i p e r s , m e a s u r e the t h i c k n e s s of
e a c h b r a k e p a d lining. T h e m e a s u r e m e n t d o e s not
i n c l u d e t h e p a d b a c k i n g plate (A) t h i c k n e s s .
Brake pad thickness:

Standard: 8.9—9.1 m m ( 0 . 3 5 — 0 . 3 6 in.)
5. R e m o v e the p a d s h i m s (A) a n d b r a k e p a d s (B).
If t h e b r a k e p a d t h i c k n e s s is l e s s t h a n t h e s e r v i c e
limit, r e p l a c e t h e r e a r b r a k e p a d s a s a s e t .
C l e a n t h e m a t i n g s u r f a c e s of t h e b r a k e d i s c a n d the
i n s i d e of t h e w h e e l , t h e n install the rear w h e e l s .
19-22
®
6. R e m o v e t h e p a d r e t a i n e r s (A). 12. Rotate t h e c a l i p e r p i s t o n (A) c l o c k w i s e into the
c y l i n d e r , t h e n align t h e cutout (B) in t h e piston w i t h
c
t h e t a b (C) o n t h e i n n e r p a d by t u r n i n g t h e piston
back. L u b r i c a t e t h e boot w i t h r u b b e r p a s t e to a v o i d
t w i s t i n g t h e piston boot. If the p i s t o n boot is t w i s t e d ,
b a c k it out s o it is p o s i t i o n e d p r o p e r l y .
N O T E : B e c a r e f u l w h e n m o v i n g in t h e p i s t o n b a c k
in t h e c a l i p e r ; brake fluid m i g h t o v e r f l o w f r o m t h e
master cylinder's reservoir.
E
8x1.25 mm
23 Nm
(2.3 kgfm, 17 Ibf-ft)
7. C l e a n t h e c a l i p e r t h o r o u g h l y ; r e m o v e a n y rust, a n d
c h e c k for g r o o v e s a n d c r a c k s . V e r i f y that the c a l i p e r
p i n s (C) m o v e in a n d out s m o o t h l y . C l e a n a n d lube
if n e e d e d .
8. I n s p e c t the brake d i s c , a n d c h e c k for d a m a g e a n d

c r a c k s ( s e e p a g e 19-24).
9. Install the p a d r e t a i n e r s . W i p e e x c e s s a s s e m b l y
p a s t e off the r e t a i n e r s . K e e p t h e a s s e m b l y p a s t e off
of t h e brake d i s c a n d brake p a d s .
10. A p p l y a thin c o a t of M-77 a s s e m b l y p a s t e (P/N

08798-9010) to the p a d s i d e of the s h i m s (A), the
b a c k of the brake p a d s (B), a n d the o t h e r a r e a s
i n d i c a t e d by the a r r o w s . W i p e e x c e s s a s s e m b l y
p a s t e off the p a d s h i m s a n d brake p a d s . 13. Install t h e brake c a l i p e r (D).
C o n t a m i n a t e d brake d i s c s or p a d s r e d u c e s t o p p i n g
ability. K e e p a s s e m b l y p a s t e off of t h e brake d i s c s 14. Install t h e f l a n g e bolts ( E ) , a n d tighten it to the
a n d brake p a d s . s p e c i f i e d torque w h i l e holding t h e c a l i p e r pin (F)
w i t h a w r e n c h a n d b e i n g careful not to d a m a g e the
pin boot.
15. C l e a n t h e m a t i n g s u r f a c e s of the brake d i s c a n d the

i n s i d e of t h e w h e e l , t h e n install t h e r e a r w h e e l s .
16. A d d b r a k e fluid a s n e e d e d .
17. P r e s s t h e brake p e d a l s e v e r a l t i m e s to m a k e s u r e
the b r a k e s w o r k .
N O T E : E n g a g e m e n t m a y require a g r e a t e r pedal
stroke i m m e d i a t e l y after t h e brake p a d s h a v e b e e n
r e p l a c e d a s a s e t . S e v e r a l a p p l i c a t i o n s of the brake
11. Install the brake p a d s a n d p a d s h i m s o n the c a l i p e r p e d a l w i l l restore t h e n o r m a l p e d a l s t r o k e .
bracket. Install the inner p a d w i t h its w e a r indicator
(C) f a c i n g u p w a r d . If y o u a r e r e u s i n g t h e brake p a d s , 18. After installation, c h e c k for leaks at h o s e a n d line
a l w a y s reinstall the brake p a d s in t h e i r original j o i n t s or c o n n e c t i o n s , a n d retighten if n e c e s s a r y .
p o s i t i o n s to prevent a m o m e n t a r y l o s s of braking T e s t - d r i v e the v e h i c l e , t h e n c h e c k for l e a k s
efficiency. ( s e e p a g e 19-28).
19-23
Rear Brake Disc Inspection
Runout Thickness and Parallelism
1. R a i s e t h e rear of t h e v e h i c l e , a n d s u p p o r t it w i t h 1. R a i s e t h e rear of the v e h i c l e , a n d s u p p o r t it w i t h

s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e s a f e t y s t a n d s in the p r o p e r l o c a t i o n s ( s e e p a g e
1-18). 1-18).
2. R e m o v e t h e r e a r w h e e l s . 2. R e m o v e the r e a r w h e e l s .
3. R e m o v e the b r a k e p a d s ( s e e p a g e 19-22). 3. R e m o v e the brake p a d s ( s e e p a g e 19-22).
4. I n s p e c t the b r a k e d i s c s u r f a c e for d a m a g e a n d 4. U s i n g a m i c r o m e t e r (A), m e a s u r e t h e brake d i s c

cracks. C l e a n the brake disc thoroughly, and t h i c k n e s s at eight p o i n t s , a p p r o x i m a t e l y 45 ° a p a r t
r e m o v e all rust. a n d 10 m m (3/8 in.) in f r o m t h e outer e d g e of t h e
brake d i s c . R e p l a c e t h e brake d i s c if t h e s m a l l e s t
5. Install s u i t a b l e flat w a s h e r s (A) a n d w h e e l n u t s , a n d m e a s u r e m e n t is l e s s t h a n the m a x . r e f i n i s h i n g limit.
tighten the w h e e l n u t s to t h e s p e c i f i e d t o r q u e to
h o l d t h e brake d i s c s e c u r e l y a g a i n s t t h e h u b . Brake disc thickness:
S t a n d a r d : 1 1 . 9 - 1 2 . 1 m m ( 0 . 4 6 9 - 0 . 4 7 6 in.)
M a x . r e f i n i s h i n g limit: 10.0 m m (0.39 in.)
B r a k e d i s c p a r a l l e l i s m : 0.015 m m (0.0006 in.) m a x .
N O T E : T h i s is t h e m a x i m u m a l l o w a b l e difference
b e t w e e n the t h i c k n e s s m e a s u r e m e n t s .
1 0 m m ( 3 / 8 in.)
1 0 8 N m (11.0 k g f - m , 7 9 . 6 I b f f t )
6 . S e t u p the dial g a u g e a g a i n s t t h e b r a k e d i s c a s
s h o w n , a n d m e a s u r e t h e r u n o u t at 10 m m (3/8 in.)
f r o m the outer e d g e of t h e b r a k e d i s c .
Brake disc runout: 5. If the brake d i s c is b e y o n d the s e r v i c e limit for

S e r v i c e limit: 0.04 m m (0.0016 in.) p a r a l l e l i s m , refinish t h e brake d i s c w i t h a
c o m m e r c i a l l y a v a i l a b l e o n - c a r brake lathe.
7 . If t h e b r a k e d i s c i s b e y o n d t h e s e r v i c e limit, r e f i n i s h
the brake disc with a c o m m e r c i a l l y available on-car N O T E : If the b r a k e d i s c is b e y o n d t h e s e r v i c e limit
b r a k e lathe. for r e f i n i s h i n g , r e p l a c e it ( s e e p a g e 19-25).
M a x . r e f i n i s h i n g limit: 10.0 m m (0.39 in.)
NOTE:
• If t h e brake d i s c is b e y o n d t h e s e r v i c e limit f o r
r e f i n i s h i n g , r e p l a c e it ( s e e p a g e 19-25).
• A n e w brake d i s c s h o u l d b e r e f i n i s h e d if its
r u n o u t is g r e a t e r t h a n 0.04 m m (0.0016 in.).
19-24
Rear Brake Disc Replacement
N O T E : K e e p a n y g r e a s e off the b r a k e d i s c a n d b r a k e 5. R e m o v e the b r a k e d i s c flat s c r e w s (A).

pads.
1. R a i s e the rear of t h e v e h i c l e , a n d s u p p o r t it w i t h
1-18).
2. R e m o v e the r e a r w h e e l .
3. R e m o v e the b r a k e c a l i p e r b r a c k e t m o u n t i n g bolts
( A ) , t h e n r e m o v e t h e c a l i p e r a s s e m b l y (B) f r o m t h e
a s s e m b l y or b r a k e h o s e , u s e a s h o r t p i e c e of w i r e
to h a n g the c a l i p e r a s s e m b l y f r o m t h e
C
u n d e r c a r r i a g e . D o not t w i s t t h e b r a k e h o s e 8x1.25 mm
excessively. A ^
6x1.0 mm
9 . 8 N m (1.0 k g f m , 7.2 Ibf-ft)
10 x 1.25 m m
55 N-m
(5.6 k g f m , 41 Ibf ft) 6. R e m o v e t h e brake d i s c (B) f r o m t h e r e a r h u b .
NOTE:
• If t h e b r a k e d i s c i s s t u c k to t h e r e a r h u b , t h r e a d
t w o 8 x 1.25 m m bolts (C) into t h e b r a k e d i s c to
p u s h it a w a y f r o m t h e r e a r h u b . T u r n e a c h bolt
9 0 d e g r e e s at a t i m e to p r e v e n t t h e b r a k e d i s c
from binding.
• After installation, c h e c k t h e p a r k i n g b r a k e , a n d
a d j u s t it if n e c e s s a r y ( s e e p a g e 19-7).
7. Install t h e brake d i s c in t h e r e v e r s e o r d e r of
removal.
N O T E : B e f o r e installing t h e b r a k e d i s c , c l e a n the
4. R e l e a s e the p a r k i n g brake. m a t i n g s u r f a c e of t h e r e a r h u b a n d t h e i n s i d e of t h e
brake disc.
8. C l e a n t h e m a t i n g s u r f a c e s of t h e b r a k e d i s c a n d t h e
i n s i d e of t h e w h e e l , t h e n install t h e rear w h e e l .
19-25
Rear Brake Caliper Removal/Installation
6. R e m o v e t h e c a b l e clip (A) f r o m t h e parking brake
ACAUTION c a b l e (B).
F r e q u e n t inhalation of brake p a d d u s t , r e g a r d l e s s of
m a t e r i a l c o m p o s i t i o n , c o u l d b e h a z a r d o u s to y o u r
health.
• A v o i d breathing dust particles.
• N e v e r u s e a n air h o s e or b r u s h to c l e a n b r a k e
assemblies. Usean OSHA-approved vacuum
cleaner.
• T h o r o u g h l y c l e a n t h e o u t s i d e of t h e c a l i p e r to
p r e v e n t d u s t a n d dirt f r o m e n t e r i n g i n s i d e .
1. R a i s e t h e r e a r of t h e v e h i c l e , a n d s u p p o r t it w i t h
s a f e t y s t a n d s in t h e p r o p e r l o c a t i o n s ( s e e p a g e D i s c o n n e c t t h e p a r k i n g brake c a b l e e n d f r o m t h e
1-18). parking brake a r m (C).
2. R e m o v e t h e rear w h e e l . R e m o v e t h e b a n j o bolt (A), a n d d i s c o n n e c t t h e

b r a k e h o s e (B). R e m o v e t h e t w o s e a l i n g w a s h e r s
3. R e l e a s e t h e parking brake. ( C ) , a n d r e p l a c e t h e m . D o not spill brake fluid o n
t h e v e h i c l e ; it m a y d a m a g e t h e paint; if brake fluid
4. R e m o v e t h e c a l i p e r s h i e l d (A). g e t s o n t h e paint, w a s h it off i m m e d i a t e l y w i t h
6x1.0 mm water.
9.8 N-m /
(1.0 k g f m D
7.2 Ibf-fi 8 x 1.25 mm
23 N-m
(2.3 kgf m, 17 Ibf-ft)
A
10 x1.0 mm C
34 N-m Replace.
(3.5 kgf-m, 25 Ibf-ft)
R e m o v e t h e f l a n g e bolt (D) w h i l e holding t h e

5. R e m o v e t h e brake h o s e m o u n t i n g b r a c k e t (A) f r o m c a l i p e r pin (E) w i t h a w r e n c h a n d being c a r e f u l not
the r e a r c a l i p e r b o d y . to d a m a g e t h e pin boot, a n d r e m o v e t h e c a l i p e r (F)
f r o m t h e bracket.
6x1.0 mm
9.8 N-m
(1.0 kgf m, 7.2 Ibf-ft)
10. Install the rear brake c a l i p e r in t h e r e v e r s e o r d e r of
• W h e n installing t h e c a l i p e r , align t h e cutout in t h e

p i s t o n w i t h t h e t a b o n t h e inner p a d ( s e e p a g e
19-22).
• C h e c k t h e b r a k e h o s e a n d c a l i p e r fitting for l e a k s ,
a n d tighten t h e b a n j o bolt if n e c e s s a r y .
• C h e c k t h e b r a k e h o s e s for interference a n d
twisting.
• C o n t a m i n a t e d brake d i s c s or p a d s r e d u c e
s t o p p i n g ability. K e e p p a s t e off of the d i s c s a n d
pads.
19-26
Rear Brake Caliper Overhaul
ACAUTION
F r e q u e n t inhalation of brake p a d d u s t , r e g a r d l e s s of m a t e r i a l c o m p o s i t i o n , c o u l d b e h a z a r d o u s to y o u r h e a l t h .
• Avoid breathing dust particles.
• N e v e r u s e a n air h o s e or b r u s h to c l e a n brake a s s e m b l i e s . U s e a n O S H A - a p p r o v e d v a c u u m c l e a n e r .
R e m o v e , d i s a s s e m b l e , i n s p e c t , r e a s s e m b l e , a n d install t h e c a l i p e r , a n d note t h e s e i t e m s :
• D o not spill b r a k e fluid o n t h e v e h i c l e ; it m a y d a m a g e t h e paint; if b r a k e fluid g e t s o n t h e paint, w a s h it off

• T o p r e v e n t d r i p p i n g brake fluid, c o v e r d i s c o n n e c t e d h o s e j o i n t s w i t h r a g s o r s h o p t o w e l s .
• C l e a n all parts in b r a k e fluid a n d air dry; b l o w out all p a s s a g e s w i t h c o m p r e s s e d air.
• B e f o r e r e a s s e m b l i n g , c h e c k that all parts are f r e e of dirt a n d o t h e r f o r e i g n p a r t i c l e s .
• R e p l a c e parts w i t h n e w o n e s a s s p e c i f i e d in t h e illustration.
• M a k e s u r e no dirt or other f o r e i g n matter is a l l o w e d to c o n t a m i n a t e t h e b r a k e fluid.
• M a k e s u r e no g r e a s e or oil g e t s o n t h e brake d i s c s or p a d s .
• W h e n r e u s i n g p a d s , a l w a y s reinstall t h e m in their original p o s i t i o n s to p r e v e n t l o s s of braking efficiency.
• D o not r e u s e d r a i n e d brake fluid. U s e o n l y c l e a n H o n d a D O T 3 B r a k e F l u i d f r o m a n u n o p e n e d c o n t a i n e r . U s i n g a
n o n - H o n d a b r a k e fluid c a n c a u s e c o r r o s i o n a n d s h o r t e n t h e life of t h e s y s t e m .
• D o not m i x different b r a n d s of brake fluid a s t h e y m a y not b e c o m p a t i b l e .
• C o a t t h e p i s t o n , piston s e a l g r o o v e , a n d c a l i p e r b o r e w i t h c l e a n b r a k e fluid.
• R e p l a c e all r u b b e r parts w i t h n e w o n e s w h e n e v e r d i s a s s e m b l e d .
• After installing the c a l i p e r , c h e c k the b r a k e h o s e a n d line for l e a k s , i n t e r f e r e n c e , a n d t w i s t i n g .
19-27
Brake Hose and Line Inspection
1. I n s p e c t t h e b r a k e h o s e s for d a m a g e , d e t e r i o r a t i o n , l e a k s , i n t e r f e r e n c e , a n d t w i s t i n g .
2. C h e c k t h e brake l i n e s for d a m a g e , r u s t i n g , a n d l e a k a g e . A l s o c h e c k for bent b r a k e l i n e s .
3. C h e c k f o r l e a k s at h o s e a n d line j o i n t s o r c o n n e c t i o n s , a n d retighten if n e c e s s a r y .
4. C h e c k t h e m a s t e r c y l i n d e r a n d A B S o r V S A m o d u l a t o r - c o n t r o l unit for d a m a g e a n d l e a k a g e .
N O T E : R e p l a c e t h e b r a k e h o s e c l i p w h e n e v e r t h e b r a k e h o s e is s e r v i c e d .
Connection Component Connected to Specified Torque Value Note

Point
A Front brake caliper Brake hose 3 4 N-m (3.5 kgf-m, 2 5 Ibf-ft) B a n j o bolt
Bleed screw 9 N m (0.9 kgf-m, 7 Ibf-ft)
B Rear brake caliper Brake hose 3 4 N-m (3.5 kgf-m, 2 5 Ibf-ft) B a n j o bolt
Bleed screw 9 N-m (0.9 k g f m , 7 Ibf-ft)
C Brake hose Brake line 15 N-m (1.5 kgf-m, 11 Ibf-ft) F l a r e nut
D Master cylinder (ABS) Brake line 15 N-m (1.5 kgf-m, 11 Ibf-ft) F l a r e nut
Master cylinder (VSA) 2 2 N m (2.2 k g f m , 16 Ibf-ft)
E A B S modulator-control B r a k e line 15 N-m (1.5 k g f m , 11 Ibf-ft) F l a r e nut
unit
V S A modulator-control B r a k e line (12 m m nut) 2 2 N*m (2.2 kgf-m, 16 Ibf-ft) F l a r e nut
unit B r a k e line (10 m m nut) 15 N-m (1.5 k g f m , 11 Ibf-ft) F l a r e nut
F Proportioning control B r a k e line 15 N-m (1.5 k g f m , 11 Ibf-ft) F l a r e nut
valve (ABS)
4 - w a y joint ( V S A )
19-28
®
Brake Hose Replacement
NOTE: 6. Install the b r a k e h o s e (A) o n t h e knuckle a n d
• B e f o r e r e a s s e m b l i n g , c h e c k that all parts a r e f r e e of d a m p e r bracket w i t h t w o 6 m m f l a n g e bolts (B) a n d
d u s t a n d other f o r e i g n p a r t i c l e s . t h e 8 m m f l a n g e bolt (C) first, t h e n c o n n e c t t h e
• R e p l a c e parts w i t h n e w o n e s w h e n e v e r s p e c i f i e d to b r a k e h o s e to t h e c a l i p e r w i t h t h e b a n j o bolt (D) a n d
do s o . n e w s e a l i n g w a s h e r s (E).
the paint; if brake fluid g e t s o n t h e paint, w a s h it off
i m m e d i a t e l y with w a t e r .
• T o p r e v e n t t h e brake fluid f r o m f l o w i n g , plug a n d
c o v e r t h e h o s e e n d s a n d j o i n t s w i t h a s h o p t o w e l or
equivalent material.
1. R e m o v e the w h e e l .
2. D i s c o n n e c t t h e b r a k e h o s e (A) f r o m the b r a k e line

(B) u s i n g a 10 m m flare-nut w r e n c h (C).
7. Install t h e b r a k e h o s e (A) o n t o t h e u p p e r b r a k e h o s e
bracket (B) o n t h e b o d y w i t h a n e w brake h o s e clip
(C).
8. C o n n e c t t h e brake line (D) to t h e brake h o s e .
9. After installing the b r a k e h o s e , b l e e d t h e b r a k e

s y s t e m ( s e e p a g e 19-9).
10. D o t h e f o l l o w i n g c h e c k s :
• C h e c k t h e brake h o s e a n d line joint for l e a k s , a n d

tighten if n e c e s s a r y ( s e e p a g e 19-28).
4. R e m o v e t h e b a n j o bolt (C), a n d d i s c o n n e c t t h e • C h e c k t h e brake h o s e s for i n t e r f e r e n c e a n d
brake h o s e f r o m t h e c a l i p e r . twisting.
5. R e m o v e t h e brake h o s e f r o m the k n u c k l e a n d 11. C l e a n t h e m a t i n g s u r f a c e s of the brake d i s c a n d the

d a m p e r bracket. i n s i d e of t h e w h e e l , t h e n install t h e w h e e l .
19-29
Parking Brake Cable Replacement

Exploded View
Sliding surface
19 -30
Brakes
Conventional Brake C o m p o n e n t s 19-1
A B S (Anti-lock Brake S y s t e m ) C o m p o n e n t s
('00-05 Models)
DTC Troubleshooting Index . 19-37
System Description , 19-39
Circuit Diagram . 19-46
ABS Modulator-Control Unit
Wheel Speed Sensor Inspection 19-65
Wheel Speed Sensor Replacement 19-65
V S A (Vehicle Stability Assist)

S y s t e m C o m p o n e n t s ('06-08 Models) 19-67
ABS Components
19-32
ABS

ABS Indicator Diagnostic Trouble Code (DTC)
• If t h e s y s t e m is O K , t h e A B S indicator g o e s off • T h e m e m o r y c a n h o l d a n y n u m b e r of D T C s . H o w e v e r ,
2 s e c o n d s after t u r n i n g the ignition s w i t c h to O N (II) w h e n t h e s a m e D T C is d e t e c t e d m o r e t h a n o n c e , t h e
w i t h o u t starting t h e e n g i n e , a n d t h e n c o m e s o n a g a i n m o r e r e c e n t D T C is w r i t t e n o v e r the e a r l i e r o n e .
a n d g o e s off 2 s e c o n d s later after starting t h e e n g i n e . T h e r e f o r e , w h e n t h e s a m e p r o b l e m is d e t e c t e d
T h i s o c c u r s b e c a u s e the A B S m o d u l a t o r - c o n t r o l unit r e p e a t e d l y , it is m e m o r i z e d a s a s i n g l e D T C .
is t u r n e d o n by t h e I G 2 p o w e r s o u r c e . • T h e D T C s a r e i n d i c a t e d in n u m e r i c a l o r d e r .
• T h e A B S indicator c o m e s o n w h e n t h e A B S • T h e D T C s a r e m e m o r i z e d in t h e E E P R O M . T h e r e f o r e ,
m o d u l a t o r - c o n t r o l unit d e t e c t s a p r o b l e m in t h e t h e m e m o r i z e d D T C s a r e not e r a s e d w h e n t h e battery
s y s t e m . H o w e v e r , e v e n t h o u g h t h e s y s t e m is is d i s c o n n e c t e d , t h e ignition s w i t c h is t u r n e d to
o p e r a t i n g p r o p e r l y , the indicator w i l l c o m e o n u n d e r L O C K (0), or the s y s t e m r e t u r n s to n o r m a l . D o the
these conditions: s p e c i f i e d p r o c e d u r e s to c l e a r t h e D T C s .
- O n l y t h e drive w h e e l s rotate
- O n e drive w h e e l is s t u c k Self-diagnosis
- T h e v e h i c l e g o e s into a s p i n
- T h e A B S c o n t i n u e s to o p e r a t e for a long t i m e • S e l f - d i a g n o s i s c a n b e c l a s s i f i e d into t w o c a t e g o r i e s :
- T h e v e h i c l e is s u b j e c t e d to a n e l e c t r i c a l s i g n a l - Initial d i a g n o s i s :
disturbance D o n e right after t h e ignition s w i t c h is t u r n e d to
O N (II) a n d until t h e A B S indicator g o e s off
T o d e t e r m i n e t h e a c t u a l c a u s e of t h e p r o b l e m , q u e s t i o n - Regular diagnosis:
t h e c u s t o m e r , taking t h e s e c o n d i t i o n s into D o n e right after t h e initial d i a g n o s i s until the
consideration. ignition s w i t c h is t u r n e d to L O C K (0)
• W h e n a p r o b l e m is d e t e c t e d b y s e l f - d i a g n o s i s , t h e
• W h e n a p r o b l e m is d e t e c t e d a n d t h e A B S indicator s y s t e m d o e s the f o l l o w i n g :
c o m e s o n , t h e r e a r e c a s e s w h e n t h e indicator s t a y s - T u r n s the A B S indicator o n
o n until the ignition s w i t c h is t u r n e d to L O C K (0), a n d - M e m o r i z e s the D T C
c a s e s w h e n t h e indicator g o e s off a u t o m a t i c a l l y w h e n - S t o p s A B S operation
t h e s y s t e m r e t u r n s to n o r m a l .
- D T C 61 or 6 2 : T h e A B S indicator g o e s off Kickback
a u t o m a t i c a l l y w h e n the s y s t e m r e t u r n s to n o r m a l .
- D T C 1 1 , 1 3 , 1 5 , 1 7 , 3 1 , 3 2 , 3 3 , 34, 35, 36, 37, 38, 54, T h e p u m p motor operates w h e n the A B S modulator-
7 1 , or 81: T h e A B S indicator s t a y s o n until the c o n t r o l unit is f u n c t i o n i n g , a n d the fluid in the r e s e r v o i r
ignition s w i t c h is t u r n e d to L O C K (0) w h e t h e r or not is f o r c e d out to the m a s t e r c y l i n d e r , c a u s i n g kickback at
t h e s y s t e m r e t u r n s to n o r m a l . the brake pedal.
- D T C 1 2 , 1 4 , 1 6 , 1 8 , 2 1 , 2 2 , 2 3 , 2 4 , 4 1 , 4 2 , 4 3 , 44, 5 1 ,
5 2 , or 53: T h e A B S indicator g o e s off w h e n t h e Pump Motor
v e h i c l e is d r i v e n a g a i n a n d t h e s y s t e m is O K after
t h e ignition s w i t c h is t u r n e d f r o m L O C K (0) to • T h e p u m p motor o p e r a t e s w h e n t h e A B S m o d u l a t o r -
O N (II). c o n t r o l unit is f u n c t i o n i n g .
• T h e A B S m o d u l a t o r - c o n t r o l unit c h e c k s the p u m p
m o t o r operation w h e n the v e h i c l e is started t h e first
t i m e after the ignition s w i t c h is t u r n e d to O N (II). Y o u
m a y h e a r the m o t o r o p e r a t e at t h i s t i m e , but it is
normal.
(cont'd)
19-33
ABS Components
How to Troubleshoot DTCs How to Retrieve DTCs
T h e t r o u b l e s h o o t i n g p r o c e d u r e s a s s u m e that the c a u s e Honda Diagnostic S y s t e m (HDS) Method

of the p r o b l e m is still p r e s e n t a n d t h e A B S indicator i s
still o n . F o l l o w i n g t h e f l o w c h a r t w h e n the A B S indicator 1. W i t h the ignition s w i t c h at L O C K (0), c o n n e c t the
d o e s not c o m e o n c a n result in i n c o r r e c t d i a g n o s i s . H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A).
T h e c o n n e c t o r illustrations s h o w the f e m a l e t e r m i n a l F o r '00-01 m o d e l s , t h e D L C is located u n d e r the
c o n n e c t o r s w i t h a s i n g l e outline a n d the m a l e t e r m i n a l p a s s e n g e r ' s s i d e of the d a s h b o a r d .
c o n n e c t o r s w i t h a d o u b l e outline. F o r '02-05 m o d e l s , t h e D L C is located b e h i n d the
d r i v e r ' s s i d e of the front c o n s o l e .
1. Q u e s t i o n the c u s t o m e r a b o u t t h e c o n d i t i o n s w h e n
the p r o b l e m o c c u r r e d , a n d try to r e p r o d u c e the N O T E : T h e illustration s h o w s '02-05 m o d e l s .
s a m e c o n d i t i o n s for t r o u b l e s h o o t i n g . F i n d out
w h e n the A B S i n d i c a t o r c a m e o n , s u c h a s d u r i n g
c o n t r o l , after c o n t r o l , w h e n t h e v e h i c l e w a s
t r a v e l i n g at a c e r t a i n s p e e d , etc. If n e c e s s a r y , h a v e
the c u s t o m e r d e m o n s t r a t e t h e c o n c e r n .
2. W h e n t h e A B S indicator d o e s not c o m e o n d u r i n g
the t e s t - d r i v e , but t r o u b l e s h o o t i n g is d o n e b a s e d o n
the D T C , c h e c k for l o o s e c o n n e c t o r s , p o o r c o n t a c t
of the t e r m i n a l s , e t c . , before y o u start
troubleshooting.
3. After t r o u b l e s h o o t i n g , or r e p a i r s a r e d o n e , c l e a r t h e
D T C s , a n d t e s t - d r i v e t h e v e h i c l e u n d e r the s a m e
conditions a s originally set with the D T C s . Make
s u r e the A B S indicator d o e s not c o m e o n . 2. T u r n the ignition s w i t c h to O N (II), a n d f o l l o w the
p r o m p t s o n t h e H D S to d i s p l a y the D T C ( s ) o n the
Intermittent Failures s c r e e n . After d e t e r m i n i n g the D T C , refer to t h e
appropriate D T C Troubleshooting.
T h e term "intermittent failure" m e a n s a s y s t e m m a y
h a v e h a d a f a i l u r e , but it c h e c k s O K n o w . If t h e N O T E : S e e the H D S H e l p m e n u for s p e c i f i c
indicator(s) of the s y s t e m d o e s not c o m e o n , c h e c k for instructions.
l o o s e c o n n e c t i o n s a n d g r o u n d s , p o o r c o n t a c t of the
t e r m i n a l s related to t h e circuit that y o u a r e
troubleshooting.
19-34
"ABS
Service Check Signal ( S C S ) Circuit Method 4. T h e blinking f r e q u e n c y i n d i c a t e s t h e D T C . D T C s a r e

i n d i c a t e d by a s e r i e s of long a n d s h o r t blinks. O n e
1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e long blink e q u a l s t e n s h o r t b l i n k s . A d d t h e long a n d
H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A). s h o r t blinks t o g e t h e r to d e t e r m i n e t h e D T C . After
F o r '00-01 m o d e l s , t h e D L C is l o c a t e d u n d e r t h e d e t e r m i n i n g t h e D T C , refer to t h e a p p r o p r i a t e D T C
p a s s e n g e r ' s s i d e of t h e d a s h b o a r d . Troubleshooting.
F o r '02-05 m o d e l s , t h e D L C is l o c a t e d b e h i n d t h e
d r i v e r ' s s i d e of t h e front c o n s o l e . NOTE:
• If t h e D T C is not m e m o r i z e d , t h e A B S indicator
N O T E : T h e illustration s h o w s ' 0 2 - 0 5 m o d e l s . will g o off for 3.6 s e c o n d s , a n d t h e n c o m e b a c k
on.
• If t h e A B S i n d i c a t o r s t a y s o n , t r o u b l e s h o o t for
" A B S indicator d o e s not g o off, a n d no D T C s a r e
s t o r e d " ( s e e p a g e 19-61).
T h e s y s t e m will not indicate t h e D T C u n l e s s t h e s e

conditions are met:
• T h e b r a k e p e d a l is not p r e s s e d .
• T h e ignition s w i t c h is t u r n e d to O N (II).
t h e ignition s w i t c h is t u r n e d to O N (II).
E x a m p l e of D T C 15
Short blinks
L o n g blink , (five t i m e s )
2. S h o r t the S C S circuit to b o d y g r o u n d u s i n g t h e H D S
w i t h o u t t h e brake p e d a l p r e s s e d . ON
N O T E : If t h e brake p e d a l is p r e s s e d w h e n t u r n i n g OFF
t h e ignition s w i t c h to O N (II), the s y s t e m shifts to
the D T C clearing mode.
E x a m p l e of D T C 2 2
Short blinks
L o n g blinks (two times) (two times)
ON | 1 i 1 n r
OFF
6. D i s c o n n e c t t h e H D S f r o m t h e D L C .
(cont'd)
19-35
ABS Components
How to Clear DTCs Service C h e c k Signal ( S C S ) Circuit Method
HDS Method 1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e

H D S to the data link c o n n e c t o r ( D L C ) (A).
1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e F o r '00-01 m o d e l s , t h e D L C is l o c a t e d u n d e r the
H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A). p a s s e n g e r ' s s i d e of t h e d a s h b o a r d .
F o r '00-01 m o d e l s , t h e D L C is l o c a t e d u n d e r the F o r '02-05 m o d e l s , t h e D L C is l o c a t e d b e h i n d the
p a s s e n g e r ' s s i d e of t h e d a s h b o a r d . d r i v e r ' s s i d e of t h e front c o n s o l e .
F o r ' 0 2 - 0 5 m o d e l s , t h e D L C is l o c a t e d b e h i n d t h e
d r i v e r ' s s i d e of t h e front c o n s o l e . N O T E : T h e illustration s h o w s ' 0 2 - 0 5 m o d e l s .
N O T E : T h e illustration s h o w s ' 0 2 - 0 5 m o d e l s .
2. S h o r t t h e S C S circuit to b o d y g r o u n d u s i n g t h e H D S .
3. P r e s s t h e brake p e d a l .
4. T u r n t h e ignition s w i t c h to O N (II) w h i l e c o n t i n u i n g
to p r e s s t h e b r a k e p e d a l .
2. T u r n the ignition s w i t c h to O N (II), a n d c l e a r t h e 5. After t h e A B S indicator g o e s off, r e l e a s e the brake

D T C ( s ) b y f o l l o w i n g the s c r e e n p r o m p t s o n t h e H D S . pedal.
N O T E : S e e t h e H D S Help m e n u for s p e c i f i c 6. After t h e A B S indicator c o m e s o n , p r e s s t h e brake

instructions. pedal again.
7. After t h e A B S indicator g o e s off, r e l e a s e the brake

pedal.
Y o u cannot clear the D T C u n l e s s t h e s e conditions

a r e met:
• T h e v e h i c l e s p e e d is 6 m p h (10 k m / h ) or l e s s .
the ignition s w i t c h is t u r n e d to O N (II).
• T h e brake p e d a l is p r e s s e d b e f o r e t h e ignition
s w i t c h is t u r n e d to O N (II).
8. After a f e w s e c o n d s , t h e A B S indicator blinks t w i c e

a n d t h e D T C is c l e a r e d . If t h e indicator d o e s not
blink t w i c e , r e p e a t s t e p s 1 thru 7. If t h e A B S
i n d i c a t o r s t a y s o n after it blinks t w i c e , c h e c k the
D T C , b e c a u s e a p r o b l e m w a s d e t e c t e d d u r i n g initial
d i a g n o s i s before shifting to D T C c l e a r i n g m o d e .
10. D i s c o n n e c t the H D S f r o m t h e D L C .
19-36
DTC Detection Item Note

11 Right-front W h e e l S p e e d S e n s o r ( O p e n / S h o r t to B o d y G r o u n d / S h o r t to ( s e e p a g e 19-50)
Power)
12 Right-front W h e e l S p e e d S e n s o r (Electrical N o i s e / I n t e r m i t t e n t ( s e e p a g e 19-51)
Interruption)
13 Left-front W h e e l S p e e d S e n s o r ( O p e n / S h o r t to B o d y G r o u n d / S h o r t to ( s e e p a g e 19-50)
Power)
14 Left-front W h e e l S p e e d S e n s o r (Electrical N o i s e / I n t e r m i t t e n t ( s e e p a g e 19-51)
Interruption)
15 Right-rear W h e e l S p e e d S e n s o r ( O p e n / S h o r t to B o d y G r o u n d / S h o r t to ( s e e p a g e 19-50)
Power)
16 Right-rear W h e e l S p e e d S e n s o r (Electrical Noise/Intermittent ( s e e p a g e 19-51)
Interruption)
17 Left-rear W h e e l S p e e d S e n s o r ( O p e n / S h o r t to B o d y G r o u n d / S h o r t to ( s e e p a g e 19-50)
Power)
18 Left-rear W h e e l S p e e d S e n s o r (Electrical Noise/Intermittent ( s e e p a g e 19-51)
Interruption)
21 Right-front P u l s e r (see page 19-53)
22 Left-front P u l s e r (see page 19-53)
23 Right-rear P u l s e r (see page 19-53)
24 Left-rear P u l s e r (see page 19-53)
31 ABS Solenoid (see page 19-53)
34 ABS Solenoid ( s e e p a g e 19-53)
35 ABS Solenoid ( s e e p a g e 19-53)
36 A B S Solenoid (see page 19-53)
41 Right-front W h e e l L o c k (see page 19-54)
42 Left-front W h e e l Lock (see page 19-54)
43 Right-rear W h e e l L o c k (see page 19-54)
44 Left-rear W h e e l L o c k (see page 19-54)
51 Motor L o c k (see page 19-54)
52 Motor S t u c k O F F (see page 19-55)
53 Motor S t u c k O N (see page 19-56)
54 A B S Fail-safe Relay (see page 19-57)
61 L o w F S R + B Voltage (see page 19-57)
62 High F S R + B V o l t a g e ( s e e p a g e 19-57)
71 Different D i a m e t e r T i r e ( s e e p a g e 19-58)
81 C e n t r a l P r o c e s s i n g Unit ( C P U ) D i a g n o s i s , a n d R O M / R A M D i a g n o s i s ( s e e p a g e 19-58)
19-37
ABS Components
A B S indicator d o e s not c o m e o n ('00-03 m o d e l s ) S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-59)
A B S indicator d o e s not c o m e o n ('04-05 m o d e l s ) S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-60)
A B S indicator d o e s not g o off, a n d n o D T C s a r e S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-61)
stored
19-38
System Description
ABS Modulator-control Unit Inputs and Outputs for 25P Connector
Terminal Wire Terminal sign Description Measurement (Disconnect t h e A B S modulator-control

number color (Terminal unit 2 5 P c o n n e c t o r )
name) Terminals Conditions Result
2 BLU FRS (-) D e t e c t s right-front 2-18 Wheel Spin wheel A C : 0.053 V or
(Front-right wheel speed sensor at 1 t u r n / s e c o n d above
wheel signal Reference
negative) Oscilloscope
3 BLU/ FLS (+) D e t e c t s left-front 3~12 0.15 V p - p o r
ORN (Front-left wheel speed sensor above
wheel signal
positive)
4 WHT/ STOP D e t e c t s brake p e d a l 4-GND Brake pedal Pressed Battery
BLK position s w i t c h voltage
signal Released B e l o w 0.3 V
5 YEL/ RLS (+) D e t e c t s left-rear 5-14 Wheel Spin wheel A C : 0.053 V or
RED (Rear-left wheel speed sensor at 1 t u r n / s e c o n d above
positive) Oscilloscope
6 BLU/ RRS (-) D e t e c t s right-rear 6-15 0.15 V p - p or
YEL (Rear-right wheel speed sensor above
wheel signal
negative)
7 BLU/ WALP D r i v e s A B S indicator 7-GND A B S indicator ON About 6 V
RED (Warning (Ignition s w i t c h to OFF B e l o w 0.3 V * 1
lamp) O N (II))
8 WHT/ FSR+B P o w e r s o u r c e for the 8-GND A t all t i m e s Battery
GRN ( A B S fail- A B S fail-safe r e l a y voltage
safe relay
battery)
9 WHT/ MR+B P o w e r s o u r c e for the 9-GND A t all t i m e s Battery
BLU (Motor r e l a y m o t o r relay voltage
battery)
10 LT DIAG-H Communicates with
BLU (Data link the H D S
connector)
* 1: W h e n m e a s u r e d w i t h t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r t e r m i n a l N o . 7 c o n n e c t e d to b o d y g r o u n d
with a jumper wire.
(cont'd)
19-39
ABS Components
A B S Modulator-control Unit Inputs and Outputs for 25P Connector (cont'd)
Terminal Wire Terminal sign Description M e a s u r e m e n t (Disconnect the A B S modulator-control

number color (Terminal unit 2 5 P connector)
name) Terminals Conditions Result
12 BRN/ FLS(-) D e t e c t s left-front 12-3 Wheel Spin wheel A C : 0.053 V or
WHT (Front-left wheel speed sensor at 1 t u r n / s e c o n d above
0.15 V p - p or
above
13 BRN SCS Detects service check
(Service connector signal
check ( D T C indication or
signal) D T C clearing)
14 GRY/ RLS(-) D e t e c t s left-rear 14-5 Wheel Spin wheel A C : 0.053 V or
RED (Rear-left wheel speed sensor at 1 t u r n / s e c o n d above
15 GRN/ RRS (+) D e t e c t s right-rear 15-6 0.15 V p - p or
WHT (Rear-right wheel speed sensor above
wheel signal
positive)
16 YEL/ IG2 P o w e r s o u r c e for 16-GND Battery
BLK (Ignition 2) a c t i v a t i n g the s y s t e m voltage
18 GRN/ FRS (+) D e t e c t s right-front 18-2 Wheel Spin wheel A C : 0.053 V or
BLK (Front-right wheel speed sensor at 1 t u r n / s e c o n d above
positive) Oscilloscope
0.15 V p - p or
above
24 BLK GND1 Ground 24-GND A t all t i m e s continuity
( G r o u n d 1)
25 BLK GND2 Ground 25-GND A t all t i m e s continuity
( G r o u n d 2)
19-40
Features
W h e n the brake p e d a l is p r e s s e d w h i l e d r i v i n g , the w h e e l s c a n lock b e f o r e t h e v e h i c l e c o m e s to a s t o p . In s u c h a n

e v e n t , the m a n e u v e r a b i l i t y of the v e h i c l e i s r e d u c e d if t h e front w h e e l s a r e l o c k e d , a n d t h e stability of t h e v e h i c l e i s
r e d u c e d if the rear w h e e l s a r e l o c k e d , c r e a t i n g a n e x t r e m e l y u n s t a b l e c o n d i t i o n . T h e A B S p r e c i s e l y c o n t r o l s the s l i p
rate of t h e w h e e l s to e n s u r e m a x i m u m grip f o r c e f r o m t h e t i r e s , a n d it t h e r e b y e n s u r e s t h e m a n e u v e r a b i l i t y a n d
stability of the v e h i c l e .
T h e A B S c a l c u l a t e s the s l i p rate of the w h e e l s b a s e d o n t h e v e h i c l e s p e e d a n d the w h e e l s p e e d , t h e n it c o n t r o l s the
b r a k e fluid p r e s s u r e to r e a c h the t a r g e t s l i p rate.
G r i p f o r c e of t i r e a n d r o a d s u r f a c e
T A R G E T SLIP RATE
COEFFICIENT OF
FRICTION
SLIP RATE
(cont'd)
19-41
ABS Components
COMPONENTS MAIN FUNCTION
Wheel speed sensor T h e w h e e l s p e e d s e n s o r o u t p u t s the s p e e d s i g n a l to the A B S control unit
a c c o r d i n g to t h e p u l s e r ' s rotation s p e e d .
A B S modulator- A B S c o n t r o l unit T h e A B S c o n t r o l unit p r o c e s s e s the s i g n a l f r o m t h e w h e e l s p e e d s e n s o r ,
c o n t r o l unit t h e n o u t p u t s t h e A B S control s i g n a l to t h e m o d u l a t o r unit.
M o d u l a t o r unit T h e m o d u l a t o r unit r e c e i v e s t h e control s i g n a l , t h e n c o n t r o l s b r a k e fluid
p r e s s u r e for e a c h w h e e l .
P u m p m o t o r r e l a y (inside of t h e A B S T h e p u m p m o t o r r e l a y d r i v e s t h e p u m p motor.
control unit)
A B S f a i l - s a f e r e l a y (inside of t h e T h e A B S f a i l - s a f e r e l a y c u t s t h e p o w e r to t h e s o l e n o i d v a l v e w h e n t h e
A B S control unit) p r o b l e m is d e t e c t e d .
19-42
ABS Control Unit
Main Control
T h e A B S control unit d e t e c t s t h e w h e e l s p e e d b a s e d o n the w h e e l s p e e d s e n s o r s i g n a l it r e c e i v e d , t h e n it c a l c u l a t e s the
v e h i c l e s p e e d b a s e d o n the d e t e c t e d w h e e l s p e e d . T h e control unit d e t e c t s the v e h i c l e s p e e d d u r i n g d e c e l e r a t i o n
b a s e d o n the rate of d e c e l e r a t i o n .
T h e A B S control unit c a l c u l a t e s t h e s l i p rate of e a c h w h e e l , a n d t r a n s m i t s the c o n t r o l s i g n a l to t h e m o d u l a t o r unit

s o l e n o i d v a l v e w h e n the s l i p rate is h i g h .
T h e p r e s s u r e reduction control h a s t h r e e m o d e s : P r e s s u r e r e d u c i n g , p r e s s u r e r e t a i n i n g , a n d p r e s s u r e intensifying.
ABS CONTROL UNIT

1
DETECT REFERENCE
VEHICLE SPEED SLIP RATE
RIGHT-REAR DETECT . . . DETECT ABS DRIVE RIGHT-REAR

WHEEL SPEED WHEEL SPEED | SLIP RATE SOLENOID SOLENOID
SENSOR J J J >4 CONTROL
LEFT-REAR
WHEEL SPEED
SENSOR
DETECT
WHEEL SPEED
. . • . SELECT LOW I N
^ ) — • ] SPEED WHEEL I V
DRIVE
SOLENOID 1 _ LEFT-REAR
SOLENOID
RIGHT-FRONT
RIGHT-FRONT DETECT DETECT ABS DRIVE RIGHT-FRONT
WHEEL SPEED WHEEL SPEED SLIP RATE SOLENOID SOLENOID
SENSOR CONTROL
LEFT-FRONT
LEFT-FRONT DETECT DETECT ABS DRIVE LEFT-FRONT
WHEEL SPEED WHEEL SPEED SLIP RATE SOLENOID SOLENOID
SENSOR CONTROL
Self-diagnosis Function
1. T h e A B S control unit is e q u i p p e d w i t h a m a i n C P U a n d a s u b C P U . E a c h C P U c h e c k s the o t h e r for p r o b l e m s .
2 . T h e C P U s c h e c k the circuit of the s y s t e m .
3 . T h e A B S control unit t u r n s o n the A B S indicator w h e n the unit d e t e c t s a p r o b l e m , a n d the unit s t o p s the s y s t e m .
4 . T h e s e l f - d i a g n o s i s c a n be c l a s s i f i e d into t h e s e t w o c a t e g o r i e s :
• Initial d i a g n o s i s
• Regular diagnosis
On-board Diagnosis Function

T h e A B S c a n be d i a g n o s e d w i t h t h e H D S .
T h e A L B C h e c k e r c a n n o t be u s e d w i t h t h i s s y s t e m . F o r air b l e e d i n g a n d c h e c k i n g w h e e l s p e e d s e n s o r s i g n a l s , u s e the
HDS.
S e e the H D S Help m e n u for s p e c i f i c o p e r a t i n g i n s t r u c t i o n s .
(cont'd)
19-43
ABS Components
Modulator Unit
T h e A B S m o d u l a t o r c o n s i s t s of the inlet s o l e n o i d v a l v e , outlet s o l e n o i d v a l v e , r e s e r v o i r , p u m p , p u m p m o t o r , a n d the

d a m p i n g c h a m b e r . T h e m o d u l a t o r r e d u c e s the c a l i p e r fluid p r e s s u r e directly. It is a circulating-type m o d u l a t o r
b e c a u s e the b r a k e fluid c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i c control h a s
t h r e e m o d e s : P r e s s u r e i n t e n s i f y i n g , p r e s s u r e r e t a i n i n g , a n d p r e s s u r e r e d u c i n g . T h e h y d r a u l i c circuit is a n i n d e p e n d e n t
four c h a n n e l t y p e , o n e c h a n n e l for e a c h w h e e l .
Pressure intensifying mode: Inlet v a l v e o p e n , outlet v a l v e c l o s e d :

M a s t e r c y l i n d e r fluid is p u m p e d out to t h e c a l i p e r .
P r e s s u r e retaining m o d e : Inlet v a l v e c l o s e d , outlet v a l v e c l o s e d :

C a l i p e r fluid is r e t a i n e d b y t h e inlet v a l v e a n d outlet v a l v e .
Pressure reducing mode: Inlet v a l v e c l o s e d , outlet v a l v e o p e n :

C a l i p e r fluid f l o w s t h r o u g h the outlet v a l v e to the r e s e r v o i r .
Motor operation m o d e : W h e n starting t h e p r e s s u r e r e d u c i n g m o d e , t h e p u m p m o t o r is O N .

W h e n s t o p p i n g A B S o p e r a t i o n , the p u m p m o t o r is O F F .
T h e r e s e r v o i r fluid is p u m p e d out b y t h e p u m p , t h r o u g h the d a m p i n g c h a m b e r , to the
master cylinder.
19-44
ABS
Wheel Speed Sensors
T h e w h e e l s p e e d s e n s o r s a r e the m a g n e t i c c o n t a c t l e s s t y p e . A s the g e a r p u l s e r teeth rotate p a s t t h e w h e e l s p e e d

s e n s o r ' s m a g n e t i c c o i l , A C c u r r e n t is g e n e r a t e d . T h e A C f r e q u e n c y c h a n g e s in a c c o r d a n c e w i t h t h e w h e e l s p e e d . T h e
A B S m o d u l a t o r - c o n t r o l unit detects t h e w h e e l s p e e d s e n s o r s i g n a l f r e q u e n c y a n d t h e r e b y d e t e c t s t h e w h e e l s p e e d .
GEAR PULSER at HIGH S P E E D
WHEEL SPEED SENSOR

LU at L O W S P E E D
Wheel S p e e d and Modulator Control
SPEED VEHICLE SPEED
REFERENCE VEHICLE SPEED
WHEEL SPEED
PRESSURE
OUTLET
VALVE oN-4-
INLET
VALVE ON--
MOTOR
W h e n the w h e e l s p e e d d r o p s s h a r p l y b e l o w t h e v e h i c l e s p e e d , t h e inlet v a l v e c l o s e s a n d if n e c e s s a r y , the outlet v a l v e

o p e n s m o m e n t a r i l y to r e d u c e the c a l i p e r fluid p r e s s u r e . T h e p u m p m o t o r s t a r t s at t h i s t i m e . A s t h e w h e e l s p e e d is
r e s t o r e d , the outlet v a l v e c l o s e s , a n d t h e inlet v a l v e o p e n s m o m e n t a r i l y to i n c r e a s e the c a l i p e r fluid p r e s s u r e .
19-45
ABS Components
Circuit Diagram
'00-03 M o d e l s
BAIIfcHl
MAIN UNDER-HOOD
FUSE/RELAY BOX BRAKE PEDAL POSITION SWITCH
No. 47 STOP Closed: Brake pedal pressed
2
(10 A) *' (15 A ) *
0~YD-
UNDER-DASH FUSE/RELAY BOX GAUGE ASSEMBLY
' No. 41 BATTERY (100 A)

YEL
No.42IG1 MAIN (40 A)
ABS INDICATOR
D8
BLU/RED •
No. 48 ABS F/S(20A)

G501
OVO
No. 50 ABS MOTOR (30 A)
0\0 WHEEL SPEED SENSOR
• GRN/BLK
— BLU —
- YEL/RED •
- GRY/RED •
• GRN/WHT •
DATA LINK I
CONNECTOR (DLC) WHT/GRN - BLU/YEL •
• LT BLU •
1
. BRN mm
"2.
G401 G101
WHEEL SPEED
BRAKE SWITCH SENSOR 2P
4P CONNECTOR CONNECTOR
MAIN UNDER-HOOD FUSE/RELAY BOX GAUGE ASSEMBLY CONNECTOR D (16P)
CONNECTOR A (18P)
Fl I 2 II 3 In I 4 I 5 lei
/
fl3 z)
// //
8
9 10 11 12|13 14 15 16
4
FRONT
MAIN UNDER-HOOD FUSE/RELAY BOX GAUGE ASSEMBLY CONNECTOR B (12P)
CONNECTOR B (7P)
DATA LINK CONNECTOR (DLC)
M
4l5l6j7
V2
6 7, l l l
8 9
3 4 5
,10 11 12 REAR
ntBi
Wire side of female Wire side of female terminals
terminals Terminal side of female terminals Terminal side of
male terminals
1
<m m 1 1
19-46
ABS MODULATOR-CONTROL UNIT 25P CONNECTOR
12 13 14 15 16
\AAAAA
8 9
24 25

1
ABS Components

'04-05 M o d e l s
© MAIN UNDER-HOOD
FUSE/RELAY BOX BRAKE PEDAL POSITION SWITCH
Closed: Brake pedal pressed
No. 47 STOP (15 A)
UNDER-DASH FUSE/RELAY BOX GAUGE ASSEMBLY
' No. 41 BATTERY (100 A)
No.42IG1 MAIN (40 A) C2 /IGT^-BLK/YEL

1
0\0 -WHT/BLK
IG2CUT YEL
RELAY I
BLK/RED "fcT" I I
fSWITCH
WITCH >
*^
B L U
/ W H T 1
TflQQr
I -I L T B L
" — > INTER LOCK
SWITCH
No. 48 ABS F/S (20 A)

• WHT/GRN «
No. 50 ABS MOTOR (30 A)
• WHT/BLU •
o\o WHEEL SPEED SENSOR
• GRN/BLK
— BLU —
SI
» YEL/RED •
- GRY/RED •
+B
• GRN/WHT •
DATA LINK Y
CONNECTOR (DLC) WHT/GRN « BLU/YEL «
5 BRN——---—-—
WHEEL SPEED
DATA LINK CONNECTOR (DLC) SENSOR 2P
CONNECTOR
JKi!K.UJSSS"A22S
CONNECTOR A (18P)
H
F U S E
' R E L A Y B O X
GAUGE ASSEMBLY CONNECTOR A (22P) wuisi FRONT
N ?I I I r p J * \<<Y\ 111 Z 13141 B l^><^JV| T I e I a hoiTerminal side of female terminals

©
GAUGE ASSEMBLY CONNECTOR B (30P) REAR
CONNECTOR B (7P) BRAKE SWITCH
4P CONNECTOR
/ 2 3 4 5 6 7
"><' 8 9 10
/ 12 13
/ fl 2! 1
4|5l6l7
Wire side of female

15 16 17 18 19 20 21

24
/ 26 27 28 29 30
3 4
terminals Wire side of female terminals Terminal side of

male terminals
19-48
ABS MODULATOR-CONTROL UNIT
ABS CONTROL UNIT MODULATOR UNfT
BR
A
LI
GK
TE
H
J J
TSv
"
-1
ToVCC
ABS FAIL-SAFE RELAY
|*1 REGULATOR j"^. LEFT-FRONT SOLENOID
r!—-KmiTsr
- P U M
^ MOTOR RELAY RIGHT-FRONT SOLENOID
I—NBbs
•
LEFT-REAR SOLENOID
L c r i n e w Owl*
vcc !—kffl£kr
H IS vcc
I RIGHT-REAR SOLENOID
!—kmy-
J—knkd-
- i it ^" PUMP MOTOR
SL
A B S MODULATOR-CONTROL UNIT 25P CONNECTOR
3
2 3 4 5 6 7 8 9
10 12 13 14 15 16
Z4 25
18
/////
ABS Components
DTC Troubleshooting
DTC 11,13,15,17: Wheel Speed Sensor 5. C h e c k f o r continuity b e t w e e n t h e a p p r o p r i a t e

(Open/Short to Body Ground/Short to Power) w h e e l s p e e d s e n s o r (-h) circuit t e r m i n a l of t h e A B S
m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r a n d b o d y
1. D i s c o n n e c t the A B S m o d u l a t o r - c o n t r o l u n i t 2 5 P g r o u n d ( s e e table).
connector.
DTC Appropriate Terminal
2. S t a r t t h e e n g i n e . 11 (Right-front) N o . 18: F R S ( + )
13 (Left-front) N o . 3: F L S ( + )
3. M e a s u r e t h e v o l t a g e b e t w e e n t h e a p p r o p r i a t e 15 (Right-rear) No. 15: R R S ( + )
w h e e l s p e e d s e n s o r ( + ) c i r c u i t t e r m i n a l of t h e A B S 17 (Left-rear) N o . 5: R L S ( + )
ground (see table).
A B S MODULATOR-CONTROL UNIT 25P C O N N E C T O R
FLS (+) (BLU/ORN) R L S (+) (YEL/RED)
11 (Right-front) N o . 18: F R S ( + )
2 3 4 5 6 7 8
13 (Left-front) N o . 3: F L S ( + ) 9
10 12 13 14 15 16
15 (Right-rear) N o . 15: R R S ( + )
17 (Left-rear) No.5:RLS(+)
"FRSH-)
18
/ / / / R/R S2 4( +?)5
(GRN/BLK) (GRN/WHT)
A B S MODULATOR-CONTROL UNIT 25P C O N N E C T O R
FLS (+) (BLU/ORN) RLS (+) (YEL/RED)
6. D i s c o n n e c t t h e w i r e h a r n e s s 2 P c o n n e c t o r f r o m t h e
a p p r o p r i a t e w h e e l s p e e d s e n s o r , t h e n c h e c k for
Is there 0.1 V or more? c o n t i n u i t y b e t w e e n t h e ( + ) a n d (—) t e r m i n a l s of t h e
wire harness connector and body ground
Y E S — R e p a i r s h o r t t o p o w e r in t h e ( + ) c i r c u i t w i r e individually.
b e t w e e n t h e A B S m o d u l a t o r - c o n t r o l unit a n d t h e
appropriate w h e e l s p e e d sensor. • Is there continuity?
N O — G o to s t e p 4. Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e ( + ) or (—)
circuit w i r e b e t w e e n t h e A B S m o d u l a t o r - c o n t r o l
4. T u r n t h e ignition s w i t c h to L O C K (0). unit a n d t h e w h e e l s p e e d s e n s o r . •
N O — R e p l a c e the w h e e l s p e e d sensor. •
19-50
7. C h e c k t h e r e s i s t a n c e b e t w e e n t h e a p p r o p r i a t e DTC 12,14,16,18: Wheel Speed Sensor
w h e e l s p e e d s e n s o r ( + ) a n d (—) circuit t e r m i n a l s of (Electrical Noise/Intermittent Interruption)
t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r ( s e e
table). N O T E : If t h e A B S i n d i c a t o r c o m e s o n b e c a u s e of
e l e c t r i c a l n o i s e , t h e i n d i c a t o r g o e s off w h e n y o u t e s t -
DTC Appropriate Terminal d r i v e the v e h i c l e at 19 m p h (30 k m / h ) .
(+) Side (-)Side
11 (Right-front) No.18:FRS(+) No. 2: FRS H 1. V i s u a l l y c h e c k for a p p r o p r i a t e w h e e l s p e e d s e n s o r
13 (Left-front) No.3:FLS(+) No. 12: F L S ( - ) a n d p u l s e r installation ( s e e t a b l e ) . M e a s u r e p u l s e r -
15 (Right-rear) No.15:RRS(+) No. 6: R R S ( - ) t o - s e n s o r c l e a r a n c e . I n s p e c t t h e p u l s e r s for c h i p p e d
17 (Left-rear) No.5:RLS(+) No. 14: RLS ( - ) or d a m a g e d t e e t h ( s e e p a g e 19-65).
DTC Appropriate Wheel S p e e d

A B S M O D U L A T O R - C O N T R O L UNIT 25P C O N N E C T O R
Sensor
FLS (+) (BLU/ORN) RLS (+) (YEL/RED)
12 Right-front
14 Left-front
16 Right-rear
18 Left-rear
Are the wheel speed sensor and pulser installed

correctly?
FLS ( - ) (BRN/WHT) RLS (-) (GRY/RED) Y E S — G o to s t e p 2 .

N O — R e i n s t a l l or replace the appropriate w h e e l
s p e e d sensor or pulser. •
Is the resistance between 450-2,000 Q ?
2 . D i s c o n n e c t t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P
Y E S — C h e c k for l o o s e t e r m i n a l s in the A B S connector.
m o d u l a t o r - c o n t r o l unit 3 1 P c o n n e c t o r . If n e c e s s a r y ,
substitute a known-good A B S modulator-control
unit, a n d r e c h e c k . •
Disconnect the wire h a r n e s s 2P connector from the

appropriate w h e e l s p e e d s e n s o r , and check the
r e s i s t a n c e b e t w e e n the ( + ) a n d (—) t e r m i n a l s of
the w h e e l s p e e d s e n s o r .
Is the resistance between 450-2,000 Q ?
Y E S — R e p a i r o p e n in t h e ( + ) or (—) c i r c u i t w i r e , o r
s h o r t b e t w e e n the ( + ) c i r c u i t w i r e a n d t h e (—)
circuit w i r e b e t w e e n t h e A B S m o d u l a t o r - c o n t r o l
unit a n d t h e w h e e l s p e e d s e n s o r . •
N O — R e p l a c e the w h e e l s p e e d s e n s o r . •
(cont'd)
19-51
ABS Components
M e a s u r e the r e s i s t a n c e b e t w e e n the a p p r o p r i a t e 4. C h e c k for continuity b e t w e e n the a p p r o p r i a t e

w h e e l s p e e d s e n s o r ( + ) a n d (—) circuit t e r m i n a l s of w h e e l s p e e d s e n s o r ( + ) circuit t e r m i n a l a n d o t h e r
t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r ( s e e w h e e l s p e e d s e n s o r (+•) circuit t e r m i n a l s of the
table). A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r ( s e e
table).
(+) Side ( - ) Side DTC Appropriate Other Terminals
12 (Right-front) No. 18: FRS {+) No.2:FRS(-) Terminal
14 (Left-front) No.3:FLS{+) No. 12: F L S ( - ) 12 No. 18: No. 3 No. 15 No. 5
16 (Right-rear) No. 15: RRS(+) No. 6: RRS H FRS (+)
18 (Left-rear) No. 5: RLS (+) No. 14: R L S ( - ) 14 No. 3: No. 18 No. 15 No. 5
FLS (+)
16 No. 15: No. 18 No. 3 No. 5
RRS (+)
FLS (+) (BLU/ORN) R L S (+) (YEL/RED)
18 No. 5: No. 18 No. 3 No. 15
R L S (+)
FLS (+) (BLU/ORN)
\ R L S (+) (YEL/RED)
2 3 4 5
/ 6 7 8 9
FLS ( - ) (BRN/WHT) RLS (-) (GRY/RED)
10 12 13 14 15 16
/ / ?7 /
18 2 4 25
Is there less than 450 Q ? RRS (+) f (GRN/WHT)
FRS (+) (GRN/BLK)

Y E S — R e p a i r s h o r t in the w i r e s b e t w e e n the
a p p r o p r i a t e w h e e l s p e e d s e n s o r a n d t h e other
wheel speed sensor. •
N O — C l e a r t h e D T C , a n d test-drive the v e h i c l e . If
t h e A B S indicator c o m e s o n a n d the s a m e D T C is
indicated, replace the A B S modulator-control
unit.B
5. D i s c o n n e c t t h e h a r n e s s 2 P c o n n e c t o r f r o m the
a p p r o p r i a t e w h e e l s p e e d s e n s o r , a n d c h e c k the
r e s i s t a n c e b e t w e e n t h e (•+•) s i d e a n d t h e (—) s i d e of
the w h e e l s p e e d s e n s o r .
Is there less than 450 0, ?
Y E S — R e p l a c e the w h e e l s p e e d s e n s o r . •
N O — R e p a i r s h o r t in w i r e b e t w e e n the a p p r o p r i a t e
w h e e l s p e e d s e n s o r ( + ) a n d (—) circuits. •
19-52
D T C 2 1 , 2 2 , 2 3 , 2 4 : Pulser DTC 31,32,33,34,35,36,37,38: ABS
1. C l e a r t h e D T C ( s e e p a g e 19-36). Solenoid
2. T e s t - d r i v e the v e h i c l e at 19 m p h (30 km/h) o r m o r e . 1. C l e a r t h e D T C ( s e e p a g e 19-36).
Does the ABS indicator come on, and are DTCs 21, 2. T u r n t h e ignition s w i t c h to O N (II).
22,23,24 indicated?
3. V e r i f y t h e D T C .
Y E S — G o to s t e p 3. Does the ABS indicator come on, and are DTCs 31,
32, 33, 34, 35, 36,37, 38 indicated?
Y E S — C h e c k p o w e r a n d g r o u n d to t h e A B S
3. C h e c k t h e a p p r o p r i a t e p u l s e r g e a r s for c h i p p e d o r m o d u l a t o r - c o n t r o l unit. If O K , c h e c k for l o o s e
d a m a g e d teeth ( s e e table). A l s o c h e c k t h e a i r g a p t e r m i n a l s in t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P
(see p a g e 19-65). c o n n e c t o r . If n e c e s s a r y , s u b s t i t u t e a k n o w n - g o o d
ABS m o d u l a t o r - c o n t r o l unit, a n d r e c h e c k . •
DTC Appropriate Pulser
21 Right-front N O — T h e s y s t e m is O K at t h i s t i m e . •
22 Left-front
23 Right-rear
24 Left-rear
Are the pulser gears OK?
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e A B S
substitute a k n o w n - g o o d A B S m o d u l a t o r - c o n t r o l
N O — R e p l a c e t h e d r i v e s h a f t or h u b unit w i t h t h e
chipped pulser g e a r . B
19-53
ABS Components
DTC 41,42,43,44: Wheel Lock DTC 51: Motor Lock
1. Lift up t h e v e h i c l e s o all four w h e e l s a r e off the 1. C h e c k the A B S M O T O R (30 A ) f u s e in t h e m a i n

ground, and release the parking brake. u n d e r - h o o d f u s e / r e l a y b o x , a n d reinstall the f u s e if
it is O K .
2 . C h e c k for b r a k e d r a g w i t h the b r a k e s hot.
Is the fuse OK?
Do the brakes drag?
Y E S — R e p a i r the brake drag. •
N O — R e p l a c e the f u s e , a n d r e c h e c k . •
2. D i s c o n n e c t the A B S m o d u l a t o r - c o n t r o l unit 2 5 P
3. C h e c k the installation of the a p p r o p r i a t e w h e e l connector.
s p e e d s e n s o r (see table).
3. M e a s u r e the v o l t a g e b e t w e e n A B S m o d u l a t o r -
DTC Appropriate Wheel c o n t r o l unit 2 5 P c o n n e c t o r t e r m i n a l N o . 9 a n d b o d y
41 Right-front ground.
42 Left-front
43 Right-rear
44 Left-rear
Is it correct? MR + B (WHT/BLU)
Y E S — T h e p r o b a b l e c a u s e w a s the v e h i c l e s p u n
2 3 4 5 6 7 8 9
d u r i n g c o r n e r i n g . If t h e c o d e r e c u r s d u r i n g n o r m a l
10 12 13 14 15 16
driving, replace the A B S modulator-control unit.H
18
///// 24 28
N O — R e i n s t a l l the w h e e l s p e e d s e n s o r c o r r e c t l y . •
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e A B S
M O T O R (30 A ) f u s e a n d the A B S m o d u l a t o r - c o n t r o l
unit.B
19-54
4. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d DTC 52: Motor Stuck OFF
A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r
t e r m i n a l s No. 24 a n d No. 2 5 i n d i v i d u a l l y . 1. C h e c k t h e A B S M O T O R (30 A ) f u s e in t h e m a i n
u n d e r - h o o d f u s e / r e l a y box, a n d reinstall t h e f u s e if
it is O K .
Is the fuse OK ?
2 3 4 5 6 7 8 9
10 12 13 14 15 16 Y E S — G o to s t e p 2.
18
///// 24
N O — R e p l a c e the fuse, and recheck. •
2. D i s c o n n e c t t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P
connector.
W i r e s i d e of f e m a l e t e r m i n a l s 3. M e a s u r e the v o l t a g e b e t w e e n A B S m o d u l a t o r -
c o n t r o l unit 2 5 P c o n n e c t o r t e r m i n a l N o . 9 a n d b o d y
ground.
N O — R e p a i r o p e n or high r e s i s t a n c e in t h e w i r e MR + B (WHT/BLU)
b e t w e e n the A B S m o d u l a t o r - c o n t r o l unit 2 5 P
connector and body ground G 3 0 3 . H
2 3 4 5 6 7 8 9
5. R e c o n n e c t t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P
connector.
10
/
18
12 13 14 15 16
24
6. C l e a r t h e D T C ( s e e p a g e 19-36).
Does the ABS indicator come on, and is DTC 51 Is there battery voltage?
indicated?
Y E S — C h e c k for l o o s e t e r m i n a l s at t h e A B S
m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r . If N O — R e p a i r o p e n in the w i r e b e t w e e n t h e A B S
connections are good, replace the A B S modulator- M O T O R (30 A ) f u s e a n d the A B S m o d u l a t o r - c o n t r o l
control u n i t . B unit.B
N O — T h e s y s t e m is O K at this t i m e . •
(cont'd)
19-55
ABS Components
4. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d DTC 53: Motor Stuck ON

A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r
terminals No. 24 a n d No. 25 individually. 1. C l e a r t h e D T C ( s e e p a g e 19-36).
Does the ABS indicator come on, and is DTC 5 3

2 3 4 5 6 7 8
indicated?
9
10 1 2 1 3 1 4 1 5 16
18
///// 24 ?R Y E S — R e p l a c e the A B S modulator-control unit.H
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e A B S
unit, a n d r e t e s t . B
N O — R e p a i r o p e n in t h e w i r e ( s ) b e t w e e n t h e A B S
ground G 3 0 3 . B
19-56
DTC 54: ABS Fail-safe Relay DTC 61: Low FSR + B Voltage
1. C l e a r t h e D T C ( s e e p a g e 19-36). DTC 62: High FSR + B Voltage
2. T e s t - d r i v e t h e v e h i c l e . 1. C l e a r t h e D T C ( s e e p a g e 19-36).
Does the ABS indicator come on, and is DTC 54 2. T e s t - d r i v e t h e v e h i c l e at 6 m p h (10 k m / h ) o r m o r e .

indicated?
Does the ABS indicator come on?
Y E S — R e p l a c e the A B S modulator-control u n i t . B
N O — I n t e r m i t t e n t failure; the v e h i c l e is O K at t h i s
time.B N O — T h e s y s t e m is O K at t h i s t i m e , B
3. V e r i f y t h e D T C .
Y E S — C h e c k the battery a n d c h a r g i n g s y s t e m . B
N O — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e
DTC indicated.fl
19-57
ABS Components
DTC 71: Different Diameter Tire DTC 81: Central Processing Unit (CPU)
Diagnosis, and ROM/RAM Diagnosis
2. T e s t - d r i v e the v e h i c l e .
Does the ABS indicator come on, and is DTC 71
indicated? Does the ABS indicator come on, and is DTC 81
indicated?
Y E S — M a k e s u r e all f o u r t i r e s a r e t h e s p e c i f i e d s i z e
a n d a r e inflated to t h e p r o p e r s p e c i f i c a t i o n . • Y E S — R e p l a c e the A B S m o d u l a t o r - c o n t r o l unit.B
N O — I n t e r m i t t e n t f a i l u r e ; t h e v e h i c l e i s O K at t h i s N O — I n t e r m i t t e n t failure; t h e v e h i c l e i s O K at t h i s
time.B time.B
19-58
A B S indicator does not come on 8. R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).

('00-03 models)
9. D i s c o n n e c t the g a u g e a s s e m b l y c o n n e c t o r D (16P).
1. T u r n the ignition s w i t c h to O N (II), a n d w a t c h t h e
A B S indicator. 10. C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r D (16P) t e r m i n a l N o . 8 a n d b o d y g r o u n d .
N O — G o to s t e p 2. WALP (BLU/RED)
2. T u r n the ignition s w i t c h to L O C K (0), t h e n t u r n it to

O N (II) a g a i n .
/9 /10 /11 // 8
12 13 14 15 16
Does the brake system indicator come on?
Y E S — G o to s t e p 3. W i r e s i d e of f e m a l e terminals
N O — R e p a i r o p e n in t h e indicator p o w e r s o u r c e
circuit: • Is there continuity?
• B l o w n I N S T R U M E N T L I G H T (7.5 A ) f u s e in the Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e

u n d e r - d a s h f u s e / r e l a y box. b e t w e e n t h e g a u g e a s s e m b l y a n d the A B S
• O p e n in the w i r e b e t w e e n t h e I N S T R U M E N T modulator-control unit.B
L I G H T (7.5 A ) f u s e a n d g a u g e a s s e m b l y .
• O p e n circuit i n s i d e t h e f u s e box. N O — G o to s t e p 11.
3. T u r n the ignition s w i t c h to L O C K (0). 11. R e c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r D (16P).
4. D i s c o n n e c t the A B S m o d u l a t o r - c o n t r o l unit 2 5 P 12. T u r n the ignition s w i t c h to O N (II), t h e n m e a s u r e

connector. the v o l t a g e b e t w e e n g a u g e a s s e m b l y c o n n e c t o r B
(12P) t e r m i n a l N o . 9 a n d b o d y g r o u n d .
Y E S — C h e c k for l o o s e t e r m i n a l s in the A B S V 2 3 4 5
6 10 11 12
i KI
8
G N D (BLK)
6. C h e c k the A B S indicator bulb in the g a u g e W i r e side of f e m a l e terminals

assembly.
Is the bulb OK? Is there 0.1 V or less?
Y E S — G o to s t e p 7. Y E S — C h e c k for l o o s e t e r m i n a l s in the g a u g e
a s s e m b l y c o n n e c t o r s . If t h e c o n n e c t o r is O K ,
N O — R e p l a c e t h e A B S indicator b u l b . B replace the gauge a s s e m b l y . B
7. T u r n the ignition s w i t c h to L O C K (0). N O — R e p a i r o p e n in the w i r e b e t w e e n t h e g a u g e

a s s e m b l y and body ground ( G 5 0 D . B
19-59
ABS Components
ABS indicator does not come on 8. R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).

('04-05 models)
1. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h t h e
A B S indicator. 10. C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y
/ 2 3 4 5 6 7 8 9 10 /
12 13 /
2. T u r n the ignition s w i t c h to L O C K (0), t h e n t u r n it to 15 16 17 18 19 20 21 /
WALP (BLU/RED)
24 26 27 28 29 30
Y E S — G o to s t e p 3. W i r e s i d e of f e m a l e terminals
N O — R e p a i r o p e n in the i n d i c a t o r p o w e r s o u r c e
circuits Is there continuity ?
• B l o w n I N S T R U M E N T L I G H T (7.5 A ) f u s e in the Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e

under-dash fuse/relay box. b e t w e e n the g a u g e a s s e m b l y a n d the A B S
• O p e n in the w i r e b e t w e e n t h e I N S T R U M E N T modulator-control unit.B
L I G H T (7.5 A ) f u s e a n d g a u g e a s s e m b l y .
• O p e n circuit i n s i d e t h e f u s e b o x . N O — G o to s t e p 11.
3. T u r n the ignition s w i t c h to L O C K (0). 11. R e c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).
4. D i s c o n n e c t t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P 12. T u r n the ignition s w i t c h to O N (II), t h e n m e a s u r e

connector. the voltage between gauge a s s e m b l y connector A
(22P) t e r m i n a l No. 18 a n d b o d y g r o u n d .
Y E S — C h e c k for l o o s e t e r m i n a l s in the A B S
m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r . If n e c e s s a r y , 1 2 3 4 5 7 8 9 10
12 13 14 15 18 19 20
unit, a n d r e c h e c k . • / is|Xl 17
//
G N D (BLK)
6. C h e c k the A B S indicator b u l b in t h e g a u g e W i r e side of f e m a l e terminals

assembly.
Is the bulb OK? Is there 0.1 V or less?
Y E S — G o to s t e p 7. Y E S — C h e c k for l o o s e t e r m i n a l s in the g a u g e
a s s e m b l y c o n n e c t o r s . If the c o n n e c t o r is O K ,
N O — R e p l a c e the A B S indicator b u l b . a r e p l a c e the g a u g e a s s e m b l y . •
7. T u r n the ignition s w i t c h to L O C K (0). N O — R e p a i r o p e n in the w i r e b e t w e e n the g a u g e

a s s e m b l y and body ground ( G 5 0 D . B
19-60
ABS indicator does not go off, and no DTCs 6. M e a s u r e the v o l t a g e b e t w e e n A B S m o d u l a t o r -
are stored control unit 2 5 P c o n n e c t o r t e r m i n a l N o . 16 a n d
body ground.
1. C h e c k t h e A B S F / S (20 A) f u s e in the m a i n u n d e r -
h o o d f u s e / r e l a y b o x , a n d reinstall the f u s e if it is O K . A B S M O D U L A T O R - C O N T R O L UNIT 25P C O N N E C T O R
Is the fuse OK?
2 3 4 5 6 7 8 9
10
/ 12 13 14 15 16
18
//// / 24 ?R
N O — R e p l a c e the f u s e , a n d r e c h e c k . If the f u s e is IG2 ( Y E L / B L K )
b l o w n , c h e c k for a s h o r t to b o d y g r o u n d in this f u s e
circuit. If the circuit is O K , r e p l a c e the A B S
modulator-control u n i t . B
2. C h e c k t h e R / C M I R R O R (7.5 A ) f u s e in the
u n d e r - d a s h f u s e / r e l a y b o x , a n d reinstall the f u s e if
it is O K .
Is the fuse OK?
N O — R e p a i r o p e n in t h e w i r e b e t w e e n f u s e # 1 9
N O — R e p l a c e the f u s e , a n d r e c h e c k . If t h e f u s e is (7.5 A ) a n d the A B S m o d u l a t o r - c o n t r o l unit, fl
b l o w n , c h e c k for a s h o r t to b o d y g r o u n d in this f u s e
circuit. B 7. T u r n t h e ignition s w i t c h to L O C K (0).
3. D i s c o n n e c t the A B S m o d u l a t o r - c o n t r o l unit 2 5 P 8. C h e c k for continuity b e t w e e n A B S m o d u l a t o r -

connector. control unit 2 5 P c o n n e c t o r t e r m i n a l N o . 2 4 a n d
body ground.
4. M e a s u r e the v o l t a g e b e t w e e n A B S m o d u l a t o r -
control unit 2 5 P c o n n e c t o r t e r m i n a l N o . 8 a n d b o d y
ground. A B S M O D U L A T O R - C O N T R O L UNIT 25P C O N N E C T O R
A B S M O D U L A T O R - C O N T R O L U N I T 25P C O N N E C T O R
2 3 4 5 6 7 8 9
10 12 13 14 15 16
FSR + B
(WHT/GRN)
18
///// 24 ?5
GND1 (BLK)
2 3 4 5 6 7 8 9
10 12 13 14 15 16
18
///// 24 25
Wire s i d e of f e m a l e terminals
Y E S — G o to s t e p 5. N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e A B S
m o d u l a t o r - c o n t r o l unit a n d b o d y g r o u n d ( G 3 0 3 ) .
N O — R e p a i r o p e n in the w i r e b e t w e e n the A B S F / S
(20 A ) f u s e a n d t h e A B S m o d u l a t o r - c o n t r o l u n i t . B
5. T u r n t h e ignition s w i t c h to O N (II). (cont'd)
19-61
ABS Components

9. C o n n e c t A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r 11. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P)
terminal No. 7 and body ground with a j u m p e r wire, terminal No. 20 and body ground with a j u m p e r
t h e n turn the ignition s w i t c h to O N (II). wire.
A B S M O D U L A T O R - C O N T R O L UNIT 25P C O N N E C T O R G A U G E A S S E M B L Y C O N N E C T O R B (30P)
WALP (BLU/RED)
/ 2 3 4 5 6 7 8 9 10
/ 12 13 /
2 3 4 5 6 7 8 9
JUMPER
WIRE
15 16 17 18 19 20 21
WALP
/
(BLU/RED)
24 26 27 28 29 30
10
/18 12 13 14 15 16 24 25
///// JUMPER WIRE
Does the ABS indicator go off? Does the ABS indicator go off?
Y E S — C h e c k for l o o s e t e r m i n a l s in the A B S Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e
m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r . If n e c e s s a r y , a s s e m b l y a n d the A B S modulator-control unit.H
substitute a known-good A B S modulator-control
unit, a n d r e c h e c k . • N O — C h e c k for l o o s e t e r m i n a l s in the g a u g e
IMO—Go to s t e p 10 ('00-03 m o d e l s ) or s t e p 11 replace the g a u g e a s s e m b l y . •
('04-05 m o d e l s ) .
10. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r D (16P)
terminal No. 8 and body ground with a j u m p e r wire.
WALP (BLU/RED)
JUMPER
WIRE
8
9 10 11 12 13 14 15 16
Does the ABS indicator go off?
Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e
a s s e m b l y a n d the A B S modulator-control unit.H
N O — C h e c k for l o o s e t e r m i n a l s in t h e g a u g e
replace the gauge a s s e m b l y . •
19-62
ABS Modulator-Control Unit Removal and Installation
NOTE:
• D o not spill brake fluid o n t h e v e h i c l e ; it m a y d a m a g e t h e paint; if b r a k e fluid g e t s o n t h e paint, w a s h it off
• T a k e c a r e not to d a m a g e or d e f o r m the brake l i n e s d u r i n g r e m o v a l a n d i n s t a l l a t i o n .
• T o p r e v e n t t h e brake fluid f r o m f l o w i n g , p l u g a n d c o v e r t h e h o s e e n d s a n d j o i n t s w i t h a s h o p t o w e l or e q u i v a l e n t
material.
Removal ('00-03 Models)
2. Pull up the lock (A) of the A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r (B), t h e n d i s c o n n e c t the c o n n e c t o r .
3. D i s c o n n e c t the s i x brake l i n e s f r o m the A B S m o d u l a t o r - c o n t r o l unit (C).
4. R e m o v e t h e t w o 6 m m n u t s .
5. R e m o v e the A B S m o d u l a t o r - c o n t r o l unit.
Installation ('00-03 Models)
1. Install t h e A B S m o d u l a t o r - c o n t r o l unit, t h e n tighten the t w o 6 m m n u t s .
2. A l i g n the c o n n e c t i n g s u r f a c e of t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r .
3. P u s h in t h e lock of t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r until y o u h e a r it click into p l a c e , t h e n c o n n e c t t h e

connector.
4. B l e e d t h e b r a k e s y s t e m , starting w i t h the front w h e e l s ( s e e p a g e 19-9).
5. Start t h e e n g i n e , a n d c h e c k that t h e A B S i n d i c a t o r g o e s off.
6. T e s t - d r i v e t h e v e h i c l e , a n d c h e c k that t h e A B S indicator d o e s not c o m e o n .
19-63
ABS Components
ABS Modulator-Control Unit Removal and Installation (cont'd)
Removal ('04-05 Models)
2. Pull up t h e lock (A) of t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r (B), t h e n d i s c o n n e c t t h e c o n n e c t o r .
9 . 8 N - m (1.0 k g f m , 7.2 I b f f t )
3. D i s c o n n e c t t h e s i x b r a k e l i n e s f r o m t h e A B S m o d u l a t o r - c o n t r o l unit (C).
4. R e m o v e t h e t h r e e 6 m m bolts.
5. R e m o v e t h e A B S m o d u l a t o r - c o n t r o l unit.
Installation ('04-05 Models)
1. Install t h e A B S m o d u l a t o r - c o n t r o l unit, t h e n tighten t h e t h r e e 6 m m bolts.
2 . A l i g n t h e c o n n e c t i n g s u r f a c e of t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r .
3. P u s h in t h e lock of t h e A B S m o d u l a t o r - c o n t r o l unit 2 5 P c o n n e c t o r until y o u h e a r it click into p l a c e , t h e n c o n n e c t t h e

connector.
4. B l e e d t h e b r a k e s y s t e m , starting w i t h t h e front w h e e l s ( s e e p a g e 19-9).
5. S t a r t t h e e n g i n e , a n d c h e c k that t h e A B S i n d i c a t o r g o e s off.
6. T e s t - d r i v e t h e v e h i c l e , a n d c h e c k that t h e A B S indicator d o e s not c o m e o n .
19-64
ABS
Wheel Speed Sensor Inspection Wheel Speed Sensor Replacement

1. I n s p e c t the front a n d rear p u l s e r s for c h i p p e d or N O T E : Install the s e n s o r s c a r e f u l l y to a v o i d twisting t h e
d a m a g e d teeth. wires.
2. M e a s u r e the air g a p b e t w e e n the w h e e l s p e e d Front

s e n s o r a n d p u l s e r all the w a y a r o u n d w h i l e rotating
the p u l s e r . R e m o v e the rear b r a k e d i s c to m e a s u r e 6 mm BOLT
the g a p o n t h e r e a r w h e e l s p e e d s e n s o r . If t h e g a p
e x c e e d s 1.0 m m (0.04 in.), c h e c k for a bent
suspension arm.
Standard:
F r o n t / R e a r : 0.4—1.0 m m ( 0 . 0 2 — 0 . 0 4 in.)
Front/Rear
0.4—1.0 m m
( 0 . 0 2 - 0 . 0 4 in.)
9.8 N - m (1.0 k g f m , 7 . 2 Ibf ft)
Rear
WHEEL SPEED SENSOR
19-65
Brakes
Conventional Brake C o m p o n e n t s 19-1
A B S (Anti-lock Brake S y s t e m )
C o m p o n e n t s ('00-05 Models) 19-31
V S A (Vehicle Stability Assist) S y s t e m C o m p o n e n t s

('06-08 Models)
DTC Troubleshooting - 19-89
Steering Angle Sensor Replacement 19-124
Sensor Cluster Replacement 19-125
VSA Sensor Neutral Position Memorization 19-125
VSA OFF Switch Test 19-126
VSA Modulator-Control Unit
Wheel Speed Sensor Inspection 19-129
Wheel Speed Sensor Replacement 19-129
VSA System Components
V S A OFF SWITCH
T e s t , page 19-126
STEERING ANGLE SENSOR

RIGHT-REAR W H E E L SPEED S E N S O R
SENSOR CLUSTER
MAIN UNDER-HOOD F U S E / R E L A Y B O X R e p l a c e m e n t , p a g e 19-125
LEFT-REAR WHEEL SPEED S E N S O R

RIGHT-FRONT W H E E L SPEED S E N S O R
R e p l a c e m e n t , p a g e 19-129 UNDER-DASH FUSE/RELAY BOX
V S A MODULATOR-CONTROL UNIT
R e m o v a l and Installation,
p a g e 19-127
LEFT-FRONT WHEEL SPEED S E N S O R

19-68
VSA
System Indicator A B S / V S A Indicator
T h i s s y s t e m h a s four i n d i c a t o r s : • If t h e s y s t e m is O K , t h e A B S a n d V S A i n d i c a t o r s g o
off 2 s e c o n d s after t u r n i n g t h e ignition s w i t c h to
• A B S indicator (A) O N (II).
• B r a k e s y s t e m indicator (B) • T h e A B S and V S A indicators c o m e on w h e n the
• V S A i n d i c a t o r (C) control unit d e t e c t s a p r o b l e m in t h e s y s t e m .
• V S A activation indicator (D) H o w e v e r , e v e n t h o u g h t h e s y s t e m is o p e r a t i n g
p r o p e r l y , t h e indicator m a y c o m e o n u n d e r t h e s e
conditions:
- O n l y t h e d r i v e w h e e l s rotate.
- O n e d r i v e w h e e l is s t u c k .
- T h e v e h i c l e g o e s into a s p i n .
- T h e A B S o r V S A c o n t i n u e s to o p e r a t e for a l o n g
time.
- T h e v e h i c l e is s u b j e c t e d to a n electrical s i g n a l
disturbance.
T o d e t e r m i n e t h e a c t u a l c a u s e of t h e p r o b l e m , q u e s t i o n
t h e c u s t o m e r , taking t h e s e c o n d i t i o n s into
consideration.
• W h e n a p r o b l e m is d e t e c t e d , t h e r e a r e c a s e s w h e n
t h e indicator s t a y s o n until t h e ignition s w i t c h is
t u r n e d to L O C K (0), a n d c a s e s w h e n t h e indicator
g o e s off a u t o m a t i c a l l y w h e n t h e s y s t e m r e t u r n s to
W h e n t h e s y s t e m d e t e c t s a p r o b l e m , it will turn the normal.
a p p r o p r i a t e indicator o n . D e p e n d i n g o n t h e f a i l u r e , the - D T C 61 or 62:
V S A m o d u l a t o r - c o n t r o l unit d e t e r m i n e s w h i c h T h e A B S a n d V S A i n d i c a t o r s g o off a u t o m a t i c a l l y
indicators a r e t u r n e d o n . w h e n t h e s y s t e m r e t u r n s to n o r m a l .
W h e n t h e s y s t e m is O K , e a c h indicator c o m e s o n for - DTC 31,32, 33,34, 35,36, 37,38, 54,81,121,122,
a b o u t 2 s e c o n d s after t u r n i n g t h e ignition s w i t c h to 123 or 124:
O N (II), t h e n g o e s off. T h e A B S a n d V S A i n d i c a t o r s s t a y o n until t h e
ignition s w i t c h is t u r n e d to L O C K (0) w h e t h e r or not
A B S Indicator t h e s y s t e m r e t u r n s to n o r m a l .
- D T C 1 1 , 1 2 , 1 3 , 1 4 , 1 5 , 1 6 , 1 7 , 1 8 , 2 1 , 2 2 , 2 3 , 2 4 , 51
T h e A B S indicator c o m e s o n w h e n t h e A B S function is or 52:
lost. T h e b r a k e s still w o r k like a c o n v e n t i o n a l s y s t e m . T h e A B S a n d V S A i n d i c a t o r s s t a y on until t h e
s y s t e m r e t u r n s to n o r m a l after the e n g i n e is
B r a k e S y s t e m Indicator r e s t a r t e d , a n d the v e h i c l e is d r i v e n .
- D T C 2 5 , 2 6 , 2 7 , 6 4 , 6 5 , 6 6 , 6 8 , 8 3 , 8 6 , 9 1 , 1 0 4 or 105:
T h e b r a k e s y s t e m indicator c o m e s o n w h e n t h e E B D T h e V S A indicator s t a y s o n until t h e ignition s w i t c h
function is lost, t h e parking brake is a p p l i e d , a n d / o r t h e is t u r n e d to L O C K (0) w h e t h e r or not t h e s y s t e m
brake fluid level is low. returns to n o r m a l .
- D T C 84:
V S A Indicator T h e V S A activation indicator g o off a u t o m a t i c a l l y
w h e n t h e s y s t e m r e t u r n s to n o r m a l .
T h e V S A indicator c o m e s o n , w h e n V S A f u n c t i o n is lost.
V S A A c t i v a t i o n Indicator
T h e V S A activation indicator b l i n k s , w h e n t h e V S A
function is a c t i v a t i n g . T h e V S A a c t i v a t i o n indicator
c o m e s o n , w h e n the V S A is t u r n e d O F F by u s i n g the
V S A O F F s w i t c h , or t h e V S A f u n c t i o n is lost.
(cont'd)
19-69
Diagnostic Trouble Code (DTC) How to Troubleshoot DTCs
• T h e m e m o r y c a n h o l d a n y n u m b e r of D T C s . H o w e v e r , T h e t r o u b l e s h o o t i n g p r o c e d u r e s a s s u m e that t h e c a u s e
w h e n t h e s a m e D T C is d e t e c t e d m o r e t h a n o n c e , t h e of t h e p r o b l e m is still p r e s e n t a n d t h e A B S a n d / o r V S A
m o r e r e c e n t D T C i s written o v e r t h e e a r l i e r o n e . indicator is still o n . F o l l o w i n g t h e t r o u b l e s h o o t i n g
T h e r e f o r e , w h e n t h e s a m e p r o b l e m is d e t e c t e d p r o c e d u r e w h e n t h e A B S a n d / o r V S A indicator d o e s not
r e p e a t e d l y , it is m e m o r i z e d a s a s i n g l e D T C . c o m e o n (no p r o b l e m is p r e s e n t ) c a n result in i n c o r r e c t
• T h e D T C s a r e i n d i c a t e d in a s c e n d i n g n u m b e r o r d e r , diagnosis.
not in t h e o r d e r t h e y o c c u r . T h e c o n n e c t o r illustrations s h o w the f e m a l e t e r m i n a l
• T h e D T C s a r e m e m o r i z e d in t h e E E P R O M . T h e r e f o r e , c o n n e c t o r s w i t h a s i n g l e outline a n d t h e m a l e t e r m i n a l
t h e m e m o r i z e d D T C s c a n n o t b e e r a s e d by c o n n e c t o r s w i t h a d o u b l e outline.
d i s c o n n e c t i n g t h e battery. D o t h e s p e c i f i e d
p r o c e d u r e s to c l e a r t h e D T C s . 1. Q u e s t i o n t h e c u s t o m e r a b o u t t h e c o n d i t i o n s w h e n
t h e p r o b l e m o c c u r r e d , a n d try to r e p r o d u c e the
Self-diagnosis s a m e c o n d i t i o n s for t r o u b l e s h o o t i n g . F i n d out
w h e n the A B S a n d / o r V S A indicator c a m e o n , s u c h
• S e l f - d i a g n o s i s c a n b e c l a s s i f i e d into t w o c a t e g o r i e s : a s d u r i n g a c t i v a t i o n , after a c t i v a t i o n , w h e n t h e
- Initial d i a g n o s i s : D o n e right after t h e ignition s w i t c h v e h i c l e w a s t r a v e l i n g at a c e r t a i n s p e e d , etc. If
is t u r n e d to O N (II) a n d until t h e A B S a n d V S A n e c e s s a r y , h a v e t h e c u s t o m e r d e m o n s t r a t e the
i n d i c a t o r s g o off. concern.
- R e g u l a r d i a g n o s i s : D o n e right after t h e initial
d i a g n o s i s until t h e ignition s w i t c h is t u r n e d to 2. W h e n t h e A B S or V S A indicator d o e s not c o m e o n
L O C K (0). d u r i n g t h e t e s t - d r i v e , but t r o u b l e s h o o t i n g is d o n e
• W h e n the s y s t e m detects a problem, the V S A b a s e d o n t h e D T C , c h e c k for l o o s e c o n n e c t o r s , p o o r
m o d u l a t o r - c o n t r o l unit s h i f t s to f a i l - s a f e m o d e . c o n t a c t of t h e t e r m i n a l s , etc. before y o u start
troubleshooting.
Kickback
3. After t r o u b l e s h o o t i n g , or r e p a i r s a r e d o n e , c l e a r the
T h e p u m p motor operates w h e n the V S A modulator- D T C s , a n d t e s t - d r i v e t h e v e h i c l e u n d e r the s a m e
control unit is f u n c t i o n i n g , a n d t h e fluid in t h e r e s e r v o i r conditions a s originally set with the D T C s . Make
is f o r c e d out to t h e m a s t e r c y l i n d e r , c a u s i n g kickback at s u r e the A B S a n d V S A i n d i c a t o r s d o not c o m e o n .
the b r a k e p e d a l .
4. C h e c k for D T C s f r o m other s y s t e m s w h i c h
Pump Motor c o n n e c t e d v i a F - C A N , if t h e r e a r e D T C s that a r e
related to F - C A N , t h e m o s t likely c a u s e w a s that t h e
• T h e p u m p motor operates w h e n the V S A modulator- ignition s w i t c h w a s t u r n e d to O N (II) w i t h the V S A
control unit is f u n c t i o n i n g . m o d u l a t o r - c o n t r o l unit c o n n e c t o r d i s c o n n e c t e d .
• T h e V S A m o d u l a t o r - c o n t r o l unit c h e c k s t h e p u m p C l e a r t h e D T C s . C h e c k for fuel a n d e m i s s i o n s c o d e s ,
m o t o r o p e r a t i o n o n e t i m e after c o m p l e t i n g initial a n d t r o u b l e s h o o t t h o s e first.
diagnosis during regular d i a g n o s i s w h e n the v e h i c l e
is d r i v e n o v e r 12 m p h (20 k m / h ) . Y o u m a y h e a r t h e Intermittent Failures
m o t o r o p e r a t e at t h i s t i m e , but it is n o r m a l .
T h e t e r m "intermittent f a i l u r e " m e a n s a s y s t e m m a y
Brake Fluid Replacement/Air Bleeding h a v e h a d a f a i l u r e , but it c h e c k s O K n o w . If t h e
indicator(s) of t h e s y s t e m d o e s not c o m e o n , c h e c k for
B r a k e fluid r e p l a c e m e n t a n d air b l e e d i n g p r o c e d u r e s l o o s e c o n n e c t o r s a n d g r o u n d s , p o o r c o n t a c t of t h e
a r e identical to the p r o c e d u r e s u s e d o n v e h i c l e s w i t h o u t t e r m i n a l s related to the circuit that y o u a r e
t h e V S A s y s t e m ( s e e p a g e 19-9). troubleshooting.
19-70
How to Use the HDS (Honda Diagnostic How to Retrieve DTCs
System)
1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e
1. If t h e s y s t e m i n d i c a t o r s s t a y o n , c o n n e c t t h e H D S to H D S to t h e data link c o n n e c t o r ( D L C ) u n d e r t h e
t h e d a t a link c o n n e c t o r ( D L C ) (A) l o c a t e d u n d e r t h e d r i v e r ' s s i d e of t h e d a s h b o a r d .
d r i v e r ' s s i d e of t h e d a s h b o a r d .
3. M a k e s u r e t h e H D S c o m m u n i c a t e s with the v e h i c l e
a n d t h e V S A m o d u l a t o r - c o n t r o l unit. If it d o e s n ' t ,
4. F o l l o w t h e p r o m p t s o n t h e H D S to d i s p l a y the
D T C ( s ) o n t h e s c r e e n . After d e t e r m i n i n g the D T C ,
refer to t h e D T C t r o u b l e s h o o t i n g .
How to Clear DTCs
1. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t t h e
H D S to t h e d a t a link c o n n e c t o r ( D L C ) u n d e r t h e
a n d t h e V S A m o d u l a t o r - c o n t r o l unit. If it d o e s n ' t , 3. M a k e s u r e t h e H D S c o m m u n i c a t e s with the v e h i c l e
t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367). a n d t h e V S A m o d u l a t o r - c o n t r o l unit. If it d o e s n ' t ,
4. C h e c k t h e d i a g n o s t i c trouble c o d e ( D T C ) a n d note it.
T h e n refer to t h e indicated D T C s t r o u b l e s h o o t i n g , 4. C l e a r t h e D T C ( s ) by f o l l o w i n g t h e s c r e e n p r o m p t s
a n d d o the a p p r o p r i a t e t r o u b l e s h o o t i n g p r o c e d u r e . on the H D S .
NOTE: 5. T u r n t h e ignition s w i t c h to L O C K (0).

• T h e H D S c a n r e a d the D T C , t h e c u r r e n t d a t a , a n d
other s y s t e m data.
• F o r s p e c i f i c o p e r a t i o n s , refer to t h e Help m e n u
that c a m e w i t h t h e H D S .
19-71
DTC Detection Item ABS Brake VSA VSA Note

Indicator System Indicator Activation
Indicator Indicator
11 Right-front W h e e l S p e e d S e n s o r ON ON or OFF* ON ON (see p a g e 19-89)
( S h o r t to P o w e r / S h o r t to B o d y G r o u n d
/Open)
12 Right-front W h e e l S p e e d S e n s o r ON ON or OFF* ON ON (see p a g e 19-92)
(Electrical Noise/Intermittent
Interruption)
13 Left-front W h e e l S p e e d S e n s o r ( S h o r t ON ON or OFF* ON ON (see p a g e 19-89)
to P o w e r / S h o r t to B o d y G r o u n d / O p e n )
14 Left-front W h e e l S p e e d S e n s o r ON ON or OFF* ON ON (see p a g e 19-92)
( E l e c t r i c a l Noise/Intermittent
Interruption)
15 Right-rear W h e e l S p e e d S e n s o r (Short ON ON or OFF* ON ON (see p a g e 19-89)
16 Right-rear W h e e l S p e e d S e n s o r ON ON or OFF* ON ON (see p a g e 19-92)
( E l e c t r i c a l Noise/Intermittent
Interruption)
17 Left-rear W h e e l S p e e d S e n s o r ( S h o r t ON ON or OFF* ON ON (see p a g e 19-89)
18 Left-rear W h e e l S p e e d S e n s o r ON ON or OFF* ON ON (see p a g e 19-92)
(Electrical Noise/Intermittent
Interruption)
21 Right-front P u l s e r ON ON or OFF* ON ON (see page 19-94)
22 Left-front P u l s e r ON ON or OFF* ON ON (see page 19-94)
23 Right-rear Pulser ON ON or OFF* ON ON (see page 19-94)
24 Left-rear Pulser ON ON or OFF* ON ON (see page 19-94)
25 Y a w Rate S e n s o r OFF OFF ON ON (see page 19-94)
26 Lateral Acceleration S e n s o r OFF OFF ON ON (see page 19-94)
27 Steering Angle Sensor OFF OFF ON ON (see page 19-96)
31 A B S Solenoid ON ON ON ON (see p a g e 19-98)
* : B r a k e s y s t e m i n d i c a t o r t u r n s O N w h e n t w o o r m o r e w h e e l s fail.
19-72
VSA
DTC Detection Item ABS Brake VSA VSA Note

Indicator System Indicator Activation
Indicator Indicator
51 Motor L o c k ON OFF ON ON (see page 19-98)
52 Motor S t u c k O N / O F F ON OFF ON ON (see page 19-98)
54 Fail-safe Relay ON ON ON ON (see page 19-99)
61 L o w + B - F S R Voltage ON O N or O F F ON ON (see page 19-100)
62 High + B - F S R V o l t a g e ON ON ON ON (see page 19-100)
64 S e n s o r Power Voltage OFF OFF ON ON ( s e e p a g e 19-100)
65 Brake Fluid Level OFF OFF ON ON ( s e e p a g e 19-101)
66 V S A P r e s s u r e S e n s o r (Inside of V S A OFF OFF ON ON ( s e e p a g e 19-102)
Modulator-control Unit)
68 B r a k e P e d a l Position S w i t c h OFF OFF ON ON ( s e e p a g e 19-102)
81 Central Processing Unit (CPU) O N or O F F O N or O F F ON ON ( s e e p a g e 19-103)
83 E C M Communication OFF OFF ON ON ( s e e p a g e 19-104)
84 V S A S e n s o r Neutral P o s i t i o n OFF OFF OFF ON ( s e e p a g e 19-104)
86 F-CAN Communication OFF OFF ON ON ( s e e p a g e 19-105)
91 V S A Operation OFF OFF ON ON ( s e e p a g e 19-108)
104 Sensor Cluster OFF OFF ON ON (see page 19-94)
105 H y d r a u l i c Unit T e m p e r a t u r e S e n s o r OFF OFF ON ON (see page 19-111)
121 V S A Solenoid ON ON ON ON (see page 19-111)
122 V S A Solenoid ON ON ON ON (see page 19-111)
123 V S A Solenoid ON ON ON ON ( s e e p a g e 19-111)
124 V S A Solenoid ON ON ON ON ( s e e p a g e 19-111)
* : B r a k e s y s t e m indicator t u r n s O N w h e n t w o or m o r e w h e e l s fail.
19-73
W h e n the v e h i c l e h a s o n e of t h e s e s y m p t o m s , c h e c k for a d i a g n o s t i c t r o u b l e c o d e ( D T C ) w i t h t h e H D S . If t h e r e is no
D T C , d o the d i a g n o s t i c p r o c e d u r e for t h e s y m p t o m , in t h e s e q u e n c e l i s t e d , until y o u f i n d t h e c a u s e .

H D S d o e s not c o m m u n i c a t e w i t h t h e V S A T r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367)
m o d u l a t o r - c o n t r o l unit or t h e v e h i c l e
A B S indicator d o e s not c o m e o n S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-112)
A B S indicator d o e s not g o off, a n d no D T C s a r e S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-113)
stored
B r a k e s y s t e m i n d i c a t o r d o e s not c o m e o n S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-115)
B r a k e s y s t e m indicator d o e s not g o off, a n d no S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-117)
DTCs are stored
V S A indicator d o e s not c o m e o n S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-119)
V S A indicator d o e s not g o off, a n d no D T C s a r e S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-120)
stored
V S A activation i n d i c a t o r d o e s not c o m e o n at start- S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-122)
up (bulb c h e c k )
V S A activation indicator d o e s not g o off, a n d n o S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 19-122)
D T C s are stored
19-74
System Description
V S A Modulator-control Unit Inputs and Outputs for 47P Connector
1 2/ 4 7 6/ / 9 / 11 / 13 / 15 16
17 / ' / / / / / / 75 / - F l / 29/31
32 47
33 34 35 36 37 / /// 42 43 44 45 46
Terminal W i r e color Terminal Description M e a s u r e m e n t (Disconnect t h e V S A modulator-

number sign c o n t r o l unit 4 7 P c o n n e c t o r )
Terminal Conditions Result
1 WHT/BLU +B-P P o w e r s o u r c e for the 1-GND A t all t i m e s Battery
pump motor voltage
2 GRY K-LINE C o m m u n i c a t e s with
HDS
4 BLK/YEL IG1 P o w e r s o u r c e for 4-GND Ignition s w i t c h O N (II) Battery
activating the s y s t e m voltage
6 GRN/WHT CLST-IG P o w e r s o u r c e for t h e
sensor cluster
9 GRN/RED BFLS D e t e c t s brake fluid 9—GND Ignition s w i t c h High Battery
level s w i t c h O N (II) a n d voltage
b r a k e fluid Low 1.0 V or l e s s
level
11 RED CAN1-H F-CAN
communication
circuit
13 PNK WL-EBD D r i v e s brake s y s t e m 13-GND Ignition s w i t c h O N (II) Battery
indicator voltage
15 WHT CAN1-L F-CAN
communication
circuit
16 BLK GND-V G r o u n d for the V S A 16-GND A t all t i m e s Continuity
modulator-control
unit
17 PNK/BLK VSA D r i v e s V S A indicator 17-GND Ignition s w i t c h O N (II) Battery
voltage
25 RED CAN2-L CAN2
communication
circuit
27 WHT VSA OFF Detects V S A O F F
SW switch signal
29 WHT CAN2-H CAN2
communication
circuit
(cont'd)
19-75
VSA Modulator-control Unit Inputs and Outputs for 47P Connector (confd)
1 2/ 4/ 6 / / 9 / 11 / 13 / 15 16
17 / / / / / ~ 7 ~ 7 25 / 27~7 29 / 31
32 47
33 34 35 36 37 / /// 42 43 44 45 46
Terminal Wire color Terminal Description M e a s u r e m e n t (Disconnect the V S A modulator-

number sign c o n t r o l unit 4 7 P c o n n e c t o r )
Terminal Conditions Result
31 LTGRN CLST-GND G r o u n d for t h e
sensor cluster
32 WHT/RED +B-V P o w e r s o u r c e for t h e 32-GND A t all t i m e s Battery
fail-safe relay voltage
33 BLU FRS (-) D e t e c t s right-front
34 GRN/BLK FRS (+) wheel speed sensor
signal
35 GRN ACT Drives V S A 35-GND Ignition s w i t c h O N (II) Battery
a c t i v a t i o n indicator voltage
36 YEL/RED RLS (+) D e t e c t s left-rear
37 GRY/RED R L S <-) wheel speed sensor
signal
42 BLU/YEL RRS (-) D e t e c t s right-rear
43 GRN/WHT RRS (+) wheel speed sensor
signal
44 BLU/RED ABS D r i v e s A B S indicator 44-GND Ignition s w i t c h O N (II) Battery
voltage
45 BLU/ORN FLS (+) D e t e c t s left-front
46 BRN/WHT FLS (-) wheel speed sensor
signal
47 BLK GND-P G r o u n d for t h e p u m p 47-GND A t all t i m e s Continuity
motor
19-76
A B S Features
W h e n the brake p e d a l is p r e s s e d w h i l e d r i v i n g , t h e w h e e l s c a n lock b e f o r e t h e v e h i c l e c o m e s to a s t o p . In s u c h a n
e v e n t , the m a n e u v e r a b i l i t y of the v e h i c l e is r e d u c e d if the front w h e e l s a r e l o c k e d , a n d the stability of the v e h i c l e i s
r e d u c e d if t h e rear w h e e l s a r e l o c k e d , c r e a t i n g a n e x t r e m e l y u n s t a b l e c o n d i t i o n . T h e A B S p r e c i s e l y c o n t r o l s the s l i p
rate of the w h e e l s to e n s u r e m a x i m u m grip f o r c e f r o m t h e t i r e s , a n d it t h e r e b y e n s u r e s m a n e u v e r a b i l i t y a n d stability
of the v e h i c l e .
T h e A B S c a l c u l a t e s the s l i p rate of the w h e e l s b a s e d o n the v e h i c l e s p e e d a n d the w h e e l s p e e d , a n d t h e n it c o n t r o l s the
brake fluid p r e s s u r e to r e a c h the target s l i p rate.
G r i p f o r c e of t i r e a n d r o a d s u r f a c e
SLIP RATE
T C S Features
T h e T C S p r o v i d e s l o w - s p e e d traction. W h e n a d r i v e w h e e l l o s e s traction o n a s l i p p e r y r o a d s u r f a c e a n d s t a r t s to s p i n ,
t h e V S A m o d u l a t o r - c o n t r o l unit a p p l i e s b r a k e p r e s s u r e to s l o w the s p i n n i n g w h e e l . A t that t i m e , the V S A m o d u l a t o r -
control unit s e n d s a traction control s i g n a l to the E C M to r e d u c e e n g i n e p o w e r .
NORMAL ROAD SURFACE SLIPPERY ROAD SURFACE
(cont'd)
19-77
V S A System Features
Oversteer control
A p p l i e s t h e b r a k e to t h e front a n d r e a r o u t s i d e w h e e l s
T h e brake m a k e s t h e y a w rate opposite

to t h e turning direction
Understeer control
• A p p l i e s t h e b r a k e to t h e r e a r i n s i d e w h e e l
• Controls the engine torque w h e n accelerating
T h e brake increases the y a w rate t o w a r d

the turning direction
T h e throttle control effect;

• reduces vehicle speed
• increases cornering force
19-78
Electronic Brake Distribution (EBD)
E l e c t r o n i c brake distribution ( E B D ) h a s b e e n a d d e d to t h e V S A s y s t e m . E B D e l i m i n a t e s t h e n e e d for a n e x t e r n a l ,

m e c h a n i c a l proportioning v a l v e a n d i m p r o v e s o v e r a l l braking p e r f o r m a n c e .
W h e n t h e v e h i c l e is h e a v i l y l o a d e d , m o s t of the i n c r e a s e in w e i g h t i s b o r n by t h e r e a r w h e e l s , i n c r e a s i n g b r a k i n g
c a p a b i l i t y . P r o p o r t i o n i n g v a l v e s m a i n t a i n a f i x e d distribution of b r a k e p r e s s u r e b e t w e e n t h e front a n d t h e r e a r w h e e l s ,
m a k i n g it v e r y difficult to fully utilize i n c r e a s e d r e a r w h e e l b r a k i n g c a p a b i l i t y . E B D v a r i e s brake p r e s s u r e distribution
a c c o r d i n g to l o a d , u s i n g input f r o m t h e w h e e l s p e e d s e n s o r s , w h i c h i m p r o v e s o v e r a l l b r a k i n g p e r f o r m a n c e .
Best distribution under h e a v y load Under heavy load
Rear wheel
brake pressure
Front w h e e l brake pressure
Normal Braking
U n d e r n o r m a l braking c o n d i t i o n s , b r a k e p r e s s u r e is e v e n l y d i s t r i b u t e d b e t w e e n t h e f r o n t a n d rear b r a k e s , a n d E B D is
not u s e d .
Firm Braking
U n d e r h a r d braking c o n d i t i o n s , the V S A m o d u l a t o r - c o n t r o l unit m o n i t o r s w h e e l s p e e d in o r d e r to a l l o w a m a x i m u m
a m o u n t of brake distribution i n d i v i d u a l l y to the r e a r w h e e l s . O n c e t h e V S A m o d u l a t o r - c o n t r o l unit d e t e c t s that o n e o r
both r e a r w h e e l s a r e n e a r i n g their m a x i m u m braking potential, t h e inlet v a l v e c l o s e s for o n e or both r e a r w h e e l s ,
m a i n t a i n i n g the c u r r e n t p r e s s u r e . If the traction is i m p r o v e d , a n d t h e w h e e l ( s ) is no l o n g e r n e a r i n g its limits, t h e V S A
m o d u l a t o r - c o n t r o l unit will o p e n t h e inlet s o l e n o i d a l l o w i n g a d d i t i o n a l p r e s s u r e to b e distributed to t h e r e a r w h e e l . T h e
r e a r w h e e l s a r e c o n t r o l l e d i n d e p e n d e n t l y of e a c h o t h e r d u r i n g E B D f u n c t i o n .
If d u r i n g E B D f u n c t i o n the V S A m o d u l a t o r - c o n t r o l unit d e t e r m i n e s t h a t t h e w h e e l s a r e b e g i n n i n g to s l i p m o r e t h a n a
p r e d e t e r m i n e d a m o u n t , the control unit a b a n d o n s E B D control a n d s h i f t s to s e l e c t l o w 3 - c h a n n e l A B S c o n t r o l .
(cont'd)
19-79
Brake Assist Features
B r a k e a s s i s t h e l p s e n s u r e that a n y d r i v e r c a n a c h i e v e t h e full b r a k i n g potential of t h e v e h i c l e b y i n c r e a s i n g brake

s y s t e m p r e s s u r e in a p a n i c s i t u a t i o n , b r i n g i n g t h e v e h i c l e into a full A B S s t o p .
If d u r i n g a p a n i c s t o p t h e V S A m o d u l a t o r - c o n t r o l unit d e t e r m i n e s that t h e b r a k e s y s t e m p r e s s u r e i n c r e a s e s a b o v e a
t h r e s h o l d in l e s s t h a n a c e r t a i n a m o u n t of t i m e , t h e V S A m o d u l a t o r - c o n t r o l unit e n g a g e s brake a s s i s t .
B e c a u s e t h e b r a k e s y s t e m p r e s s u r e c r o s s e d t h e p r e s s u r e t h r e s h o l d before t h e t i m e t h r e s h o l d h a d e x p i r e d , the V S A
m o d u l a t o r - c o n t r o l unit g o e s into b r a k e a s s i s t m o d e .
Brake Pedal
Effort Reduced
Panic Stop with Brake Assist
Pressure
Brake Assist
Begins Panic Stop without Brake Assist
Pressure -i
Threshold
Normal Stop
Time
Threshold Time
19-80
Modulator Unit
T h e m o d u l a t o r unit c o n s i s t s of t h e inlet s o l e n o i d v a l v e , outlet s o l e n o i d v a l v e , V S A n o r m a l l y o p e n (NO) s o l e n o i d v a l v e ,

V S A n o r m a l l y c l o s e d (NC) s o l e n o i d v a l v e , r e s e r v o i r , p u m p , p u m p m o t o r , a n d t h e d a m p i n g c h a m b e r .
T h e m o d u l a t o r c o n t r o l s the c a l i p e r fluid p r e s s u r e directly. It is a c i r c u l a t i n g - t y p e m o d u l a t o r b e c a u s e the brake fluid
c i r c u l a t e s t h r o u g h the c a l i p e r , t h e r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r .
T h e h y d r a u l i c control h a s t h r e e m o d e s : p r e s s u r e i n t e n s i f y i n g , p r e s s u r e retaining, a n d p r e s s u r e r e d u c i n g .
T h e h y d r a u l i c circuit is a n i n d e p e n d e n t four c h a n n e l t y p e , o n e c h a n n e l for e a c h w h e e l .
ABS Control
P r e s s u r e Intensifying M o d e
V S A N O v a l v e o p e n , V S A N C v a l v e c l o s e d , inlet v a l v e o p e n , outlet v a l v e c l o s e d .
M a s t e r c y l i n d e r fluid is p u m p e d out to the c a l i p e r .
Pump Motor
W h e n starting the p r e s s u r e r e d u c i n g m o d e , the p u m p m o t o r is O N . W h e n s t o p p i n g A B S o p e r a t i o n , the p u m p m o t o r is
OFF.
T h e r e s e r v o i r fluid is p u m p e d out b y the p u m p , t h r o u g h t h e d a m p i n g c h a m b e r , to the m a s t e r c y l i n d e r .
MASTER CYLINDER
M
O
I
D
UL
AT
OR UNIT
r z d > M
•I °™< JM 3
COB pi
(cont'd)
19-81
Pressure Retaining Mode

V S A N O v a l v e o p e n , V S A N C v a l v e c l o s e d , inlet v a l v e c l o s e d , outlet v a l v e c l o s e d .
C a l i p e r fluid is retained b y t h e inlet v a l v e a n d outlet v a l v e .
MASTER CYLINDER
RL FR FL RR
Pressure Reducing Mode

V S A N O v a l v e o p e n , V S A N C v a l v e c l o s e d , inlet v a l v e c l o s e d , outlet v a l v e o p e n .
C a l i p e r fluid f l o w s t h r o u g h t h e outlet v a l v e to t h e r e s e r v o i r .
MASTER CYLINDER
RL FR FL RR
19-82
VSA
T C S Control
Pressure Intensifying M o d e
V S A N O v a l v e c l o s e d , V S A N C v a l v e o p e n , inlet v a l v e o p e n , outlet v a l v e c l o s e d , p u m p m o t o r O N .
T h e r e s e r v o i r a n d m a s t e r c y l i n d e r fluid is p u m p e d out by the p u m p , t h r o u g h t h e d a m p i n g c h a m b e r , to the r e a r c a l i p e r .
MASTER CYLINDER
RL FR FL RR

V S A N O v a l v e c l o s e d , V S A N C v a l v e o p e n , inlet v a l v e c l o s e d , outlet v a l v e c l o s e d , p u m p m o t o r O N .
R e a r c a l i p e r fluid is retained by t h e inlet v a l v e a n d outlet v a l v e .
MASTER CYLINDER
RL FR FL RR
(cont'd)

V S A N O v a l v e o p e n , V S A N C v a l v e c l o s e d , inlet v a l v e c l o s e d , r e a r outlet v a l v e o p e n , p u m p m o t o r O N .
C a l i p e r fluid f l o w s t h r o u g h the outlet v a l v e to t h e r e s e r v o i r .
MASTER CYLINDER
RL FR FL RR
V S A Control
Pressure Intensifying M o d e
V S A N O v a l v e c l o s e d , V S A N C v a l v e o p e n , inlet v a l v e o p e n , outlet v a l v e c l o s e d , p u m p m o t o r O N .
T h e r e s e r v o i r a n d m a s t e r c y l i n d e r fluid i s p u m p e d out b y t h e p u m p , t h r o u g h the d a m p i n g c h a m b e r , to the front a n d
rear calipers.
MASTER CYLINDER
RL FR FL RR
19-84
V S A N O v a l v e c l o s e d , V S A N C v a l v e o p e n , inlet v a l v e c l o s e d , outlet v a l v e c l o s e d , p u m p m o t o r O N .
F r o n t a n d rear c a l i p e r fluid is retained b y the inlet v a l v e a n d outlet v a l v e .
MASTER CYLINDER
RL FR FL RR

V S A N O v a l v e o p e n , V S A N C v a l v e c l o s e d , inlet v a l v e c l o s e d , outlet v a l v e o p e n , p u m p m o t o r O N .
C a l i p e r fluid f l o w s t h r o u g h the outlet v a l v e to the r e s e r v o i r .
MASTER CYLINDER
RL FR FL RR
Circuit Diagram
GAUGE ASSEMBLY
VSA INDICATOR
• PNK/BLK
ABS INDICATOR
> BLU/RED
—
{gO) I EBD CIRCUIT ~ —
- GRN/RED
• GRN/WHT
PARKING
B R A K E FLUID
BRAKE SWITCH
L E V E L SWITCH
Closed: Apply
Closed: L o w fluid
MAIN UNDER-HOOD parking brake
F U S E / R E L A Y BOX
BLK
IGNITION SWITCH
UNDER-DASH
F U S E / R E L A Y BOX
No. 5 (7.5 A)
11
G501 G301
WHT -K> C j - BLK/YEL
No. 6 (15 A)
• BLK/YEL • BLK/YEL •
- WHT/RED •
• WHT/BLU •
B R A K E PEDAL POSITION SWITCH STEERING ANGLE
Closed: Brake pedal pressed SENSOR
WHT/GRN WHT/BLK - > BLK/YEL
- RED -
• WHT «
E22
Ell
• WHT/BLK « 1
— RED —
E24
—WHT —
+B
- WHT/GRN - J
DATA LINK
C O N N E C T O R (DLC)
19-86
V S A MODULATOR-CONTROL UNIT
CONTROL UNIT
ACT
17 DTC
' PNK/BLK •
EEPROM
_44
> BLU/RED •
• GRN/RED-
3^
V S A OFF SWITCH
-BLK
• GRN/WHT «
. RED/BLK ^ I RI E^L A
YY " CLST-IG
29 MODULATOR UNIT
— WHT —
- R E D — > GGAAUUGGEE CAN2-H CAN
ASSEMBLY CONTROLLER
25
> RED < PRESSURE
SENSOR
• LTGRN CLST-GND
I
G501
5V
• BLK/YEL
IG1 REGULATOR Tfc-
32
• WHT/RED -
+B-V
FAIL-SAFE
t
RELAY
1
- WHT/BLU •
+B-P
PUMP MOTOR
RELAY
• RED -
CAN1-H CAN
15 CONTROLLER
•WHT •
CAN1-L
45
• BLU/ORN -
F L S <+)
RIGHT-FRONT
46
• BRN/WHT •
FLS (-)
34
WHEEL SPEED > GRN/BLK -
SENSOR FRS (+) ELECTRIC
RIGHT-FRONT CURRENT
33
— BLU — LIMITATION
FRS { - )
36
> YEL/RED -
RLS (+)
GND
1
37
• GRY/RED -
RLS (-)
43
• GRN/WHT •
RRS (+}
42
. BLU/YEL -
RRS (-)
-h^±7T
2
— GRY —
PUMP
IP MOTOR
MOT
BLK >
(M)
HB-:12V
-O :5V
(cont'd)
19-87
MAIN UNDER-HOOD FUSE/RELAY BOX BRAKE FLUID LEVEL SWITCH BRAKE PEDAL POSITION SWITCH
CONNECTOR A (18P) 2P CONNECTOR 4P CONNECTOR
. r T r
7 /
2 3 1—1 4 6
CUD X 2
r
/
j
8 9 /\\ 12 / // 4 ]
3 4 C
MAIN UNDER-HOOD FUSE/RELAY BOX VSA OFF SWITCH 6P CONNECTOR STEERING ANGLE SENSOR
CONNECTOR B (7P) 5P CONNECTOR
1 i
1 2 3 1 2 3 J
4 5 6 7
/ 6
1
2 1X1 4
GAUGE ASSEMBLY CONNECTOR A (22P) GAUGE ASSEMBLY CONNECTOR B (30P)
1 2 3 4 5 7 8 9 10
/15 126 137 148 195 206 271x22 X 23 248 259 2610 2711 1282 2913 3014
11 12 13 14 15 16
X 17 18 19 20
//
SENSOR CLUSTER 6P CONNECTOR VSA MODULATOR-CONTROL UNIT 47P CONNECTOR
1 2 3
2 7 / 29 31
/ / 5
33134135136 j 371/^|/^|X1/^142143 [ 4 4 [ 45 [ 46
1
/ ' 3 4 5 u 8 9
/ •11 12 13 14 15 16 17 18 19 20 21
n/n
2 2 23 24 25 27 28 29 30
/
DATA LINK CONNECTOR (DLC) WHEEL SPEED SENSOR 2P CONNECTOR
„ivsru
12 14 16
T e r m i n a l s i d e of f e m a l e t e r m i n a l s T e r m i n a l s i d e of m a l e t e r m i n a l s
19-88
DTC Troubleshooting
DTC 11,13,15,17: Wheel Speed Sensor 6. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d the

(Short to Power/Short to Body Ground/Open) a p p r o p r i a t e w h e e l s p e e d s e n s o r ( + ) a n d (—)
t e r m i n a l s of t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P
1. T u r n the ignition s w i t c h to L O C K (0). connector individually (see table).
2. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P DTC Appropriate Terminal

connector. (+) Side {-> Side
11 (Right-front) FRS (+): FRS ( - ) :
3. Start t h e e n g i n e . No. 34 No. 33
13 (Left-front) FLS (+): FLS (-):
4. M e a s u r e t h e v o l t a g e b e t w e e n b o d y g r o u n d a n d the No. 45 No. 46
a p p r o p r i a t e w h e e l s p e e d s e n s o r ( + ) a n d (—) 15 (Right-rear) RRS (+): RRS (-):
t e r m i n a l s of the V S A m o d u l a t o r - c o n t r o l unit 4 7 P No. 43 N o . 42
c o n n e c t o r individually ( s e e table). 17 (Left-rear) RLS (+): RLS(-):
No. 36 N o . 37
(+) Side ( - ) Side
11 (Right-front) F R S (+>: FRS (-):
16
No. 34 No. 3 3
13 (Left-front) F L S (+): FLS (-): 1331341351361371/1/1/1/1421431441451^
47
No. 4 5 No. 46
15 (Right-rear) RRS (+): RRS(-):
No. 43 No. 42
17 (Left-rear) R L S (+): RLS (-):
No. 3 6 No. 37
16
1T g5|>12T|^l29lxTtT
|y|Si|a5|y|y|/T/|/1/l42|48|44
Y E S — R e p a i r s h o r t to p o w e r in the w i r e b e t w e e n
t h e V S A modulator-control unit a n d the a p p r o p r i a t e
(cont'd)
19-89
7. D i s c o n n e c t the a p p r o p r i a t e w h e e l s p e e d s e n s o r 2 P 9. D i s c o n n e c t t h e a p p r o p r i a t e w h e e l s p e e d s e n s o r 2 P
connector. connector.
8. C h e c k f o r continuity b e t w e e n b o d y g r o u n d a n d t h e 10. C h e c k for continuity b e t w e e n t h e a p p r o p r i a t e

a p p r o p r i a t e w h e e l s p e e d s e n s o r ( + ) a n d (•—) w h e e l s p e e d s e n s o r ( + ) a n d (•—) t e r m i n a l s of t h e
t e r m i n a l s of the V S A m o d u l a t o r - c o n t r o l unit 4 7 P V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r ( s e e
connector individually (see table). table).
DTC Appropriate Terminal DTC Appropriate Terminal

(+) Side ( - ) Side {+) Side ( - ) Side
11 (Right-front) FRS (+): FRS (-): 11 (Right-front) FRS (+): FRS (-):
No. 34 No. 33 No. 34 No. 3 3
13 (Left-front) FLS (+): FLS (-): 13 (Left-front) FLS(+): FLS (-):
No. 45 N o . 46 No. 4 5 N o . 46
15 (Right-rear) RRS (+): RRS (-): 15 (Right-rear) RRS (+): RRS (-):
No. 43 N o . 42 No. 43 N o . 42
17 (Left-rear) RLS (+): RLS(-): 17 (Left-rear) RLS (+): RLS (-):
No. 36 N o . 37 No. 36 No. 37
VSA M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R VSA M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R
1V l^l^l^l^l^l^l^l 251>| Z7|>| 2g|7UT

16
16
*VV\A/VVV\KV\VV\*V\*\
32 47
3 3 1 3 4 1 3 5 1 3 6 1 3 ] \ / \ A A A w . |43144J45146~
FRS ( - ) FLS (-)

(BLU) (BRN/WHT)
FRS (+) FLS (+)

(GRN/BLK) (BLU/WHT)
RLS (+) RRS (+)

(YEL/RED) (GRN/WHT)
RLS (-) RRS (-)

(GRY/RED) (BLU/YEL)
Is there continuity? Y E S — R e p a i r s h o r t in t h e w i r e s b e t w e e n t h e V S A
m o d u l a t o r - c o n t r o l unit a n d the w h e e l s p e e d
Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e sensor. •
b e t w e e n t h e V S A m o d u l a t o r - c o n t r o l unit a n d t h e
wheel speed sensor. • N O — G o to s t e p 11.
N O — R e p l a c e the w h e e l s p e e d s e n s o r (see page

19-129).•
19-90
VSA
11. C o n n e c t w h e e l s p e e d s e n s o r 2 P c o n n e c t o r 12. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d the

t e r m i n a l s N o . 1 a n d No. 2 to b o d y g r o u n d w i t h a a p p r o p r i a t e w h e e l s p e e d s e n s o r ( + ) a n d (—)
jumper wire. t e r m i n a l s of the V S A m o d u l a t o r - c o n t r o l unit 4 7 P
connector individually (see table).
DTC Appropriate Wheel S p e e d S e n s o r
11 Right-front DTC Appropriate Terminal
13 Left-front (+) Side (-) Side
15 Right-rear 11 (Right-front) FRS (+): FRS (-):
17 Left-rear No. 34 No. 3 3
13 (Left-front) FLS (+): FLS (-):
No. 45 No. 46
W H E E L S P E E D S E N S O R 2P C O N N E C T O R
15 (Right-rear) RRS (+): RRS (-):
No. 43 No. 42
am
17 (Left-rear) RLS (+): R L S <-):
+ B G N D
No. 36 No. 37
JUMPER WIRE JUMPER WIRE V S A M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R
16
17Km/M/l/|25M^K|29|/l3T
N O — R e p a i r o p e n in t h e w i r e s b e t w e e n t h e V S A
m o d u l a t o r - c o n t r o l unit a n d t h e w h e e l s p e e d
sensor. •
(cont'd)
19-91

13. O n the s e n s o r s i d e , m e a s u r e t h e r e s i s t a n c e DTC 12,14,16,18: Wheel Speed Sensor
b e t w e e n t h e ( + ) a n d (—) t e r m i n a l s of the (Electrical Noise/Intermittent Interruption)
appropriate w h e e l s p e e d sensor.
N O T E : If t h e A B S indicator a n d V S A indicator c o m e o n
DTC Appropriate Wheel S p e e d S e n s o r b e c a u s e of e l e c t r i c a l n o i s e , t h e i n d i c a t o r s g o off w h e n
11 Right-front y o u t e s t - d r i v e the v e h i c l e at 19 m p h (30 k m / h ) .
13 Left-front
15 Right-rear 1. T u r n t h e ignition s w i t c h to L O C K (0).
17 Left-rear
2. C h e c k t h e a p p r o p r i a t e w h e e l s p e e d s e n s o r a n d
W H E E L S P E E D S E N S O R 2P C O N N E C T O R p u l s e r ( s e e p a g e 19-129).
DTC Appropriate Wheel S p e e d Sensor

12 Right-front
14 Left-front
r-<iny—] 16 Right-rear
18 Left-rear
Are they OK?
N O — R e i n s t a l l or replace the appropriate w h e e l
s p e e d s e n s o r or pulser. •
Is the resistance between 450—2,000 Q ?
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A connector.
substitute a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l
unit ( s e e p a g e 19-127), a n d retest. •
N O — R e p l a c e the w h e e l s p e e d s e n s o r (see page

19-129).•
19-92
4. C h e c k for continuity b e t w e e n t h e a p p r o p r i a t e 5. S u b s t i t u t e a k n o w n - g o o d w h e e l s p e e d s e n s o r for
w h e e l s p e e d s e n s o r (—) t e r m i n a l a n d other w h e e l t h e a p p r o p r i a t e w h e e l s p e e d s e n s o r ( s e e table).
s p e e d s e n s o r (—) t e r m i n a l s of t h e V S A m o d u l a t o r -
control unit 4 7 P c o n n e c t o r ( s e e table). DTC Appropriate Wheel S p e e d Sensor
12 Right-front
DTC Appropriate Other Terminals 14 Left-front
Terminal 16 Right-rear
12 FRS(-): No. 46 No. 42 No. 37 18 Left-rear
No. 33
14 FLS ( - ) : No. 33 No. 42 No. 37 6. R e c o n n e c t all of t h e d i s c o n n e c t e d c o n n e c t o r s .
No. 46
16 RRS ( - } : No. 33 No. 46 No. 37 7. T u r n the ignition s w i t c h to O N (II).
No. 42
18 RLS(-): No. 33 No. 46 No. 42 8. C l e a r t h e D T C w i t h the H D S .
No. 37
9. T u r n the ignition s w i t c h to L O C K (0), t h e n
V S A M O D U L A T O R - C O N T R O L U N I T 47P C O N N E C T O R
disconnect the H D S .
l33[34|35l36l37|/V1/1/42|43|44l45T46l Is DTC 12, 14, 16, or 18 indicated?
Y E S — C h e c k for l o o s e t e r m i n a l s in the V S A
s u b s t i t u t e a k n o w n - g o o d V S A modulator-control
W i r e s i d e of f e m a l e terminals unit ( s e e p a g e 19-127), a n d r e t e s t . B
N O — R e p l a c e the original w h e e l s p e e d s e n s o r or
Is there continuity? p u l s e r ( s e e p a g e 19-129). •
Y E S — R e p a i r s h o r t in the w i r e s b e t w e e n the
a p p r o p r i a t e w h e e l s p e e d s e n s o r a n d the other
19-93
DTC 21,22,23,24: Pulser DTC 25: Yaw Rate Sensor
1. T u r n t h e ignition s w i t c h to O N (II). DTC 26: Lateral Acceleration Sensor
2. C l e a r the D T C w i t h the H D S . DTC 104: Sensor Cluster
3. T u r n the ignition s w i t c h to L O C K (0), t h e n 1. C h e c k the s i z e , air p r e s s u r e , a n d a m o u n t of w e a r of

disconnect the H D S . all f o u r t i r e s , a n d the w h e e l a l i g n m e n t ( s e e p a g e
18-7).
4. T e s t - d r i v e t h e v e h i c l e at 19 m p h (30 k m / h ) or m o r e .
Is the tire condition and wheel alignment OK?
Is DTC 21,22,23, or 24 indicated?
N O — M a k e s u r e the s u s p e n s i o n is not m o d i f i e d ,
Y E S — G o t o s t e p 6. a n d a d j u s t the w h e e l a l i g n m e n t c o r r e c t l y , a n d
recheck by test-driving. •
6. C h e c k the a p p r o p r i a t e p u l s e r ( s e e table) ( s e e p a g e
19-129). 3. D i s c o n n e c t the s e n s o r c l u s t e r 6 P c o n n e c t o r .
DTC Appropriate Pulser 4. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P

21 Right-front connector.
22 Left-front
23 Right-rear 5. T u r n t h e ignition s w i t c h to O N (II).
24 Left-rear
Is the pulser OK?
substitute a known-good V S A modulator-control
unit ( s e e p a g e 19-127), a n d r e t e s t . B
N O — R e p l a c e the p u l s e r . •
19-94
6. M e a s u r e t h e v o l t a g e b e t w e e n b o d y g r o u n d a n d 9. C h e c k for c o n t i n u i t y b e t w e e n V S A m o d u l a t o r -
V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r c o n t r o l unit 4 7 P c o n n e c t o r t e r m i n a l s N o . 6, N o . 2 5 ,
t e r m i n a l s N o . 6 , N o . 2 5 , N o . 2 9 , a n d N o . 31 N o . 2 9 , a n d N o . 31 a n d s e n s o r c l u s t e r 6 P c o n n e c t o r
individually. t e r m i n a l s N o . 1, N o . 3 , N o . 2 , a n d N o . 5.
V S A MODULATOR-CONTROL UNIT 47P CONNECTOR V S A M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R

| CLST-IG (GRN/WHT)
CLST-IG (GRN/WHT)
16 |2|/|4|/|e|/|/|9|/|ll|/|l3|/|l5|
1 16
" l / l / l / l / l / l / l / l 25|/| 27|/l2
|33|34|35|36|371X1/1/17l42|43|44l45|46! 32 47
| 3 3 | 3 4 | 3 5 | 3 6 | 3 7 | / 1 / | / 1/|42|43|44 45|46
CAN2-L CAN2-H CLST-GND
(RED) (WHT) (LTGRN) CAN2-L CAN2-H CLST-GND
(RED) (WHT) (LTGRN)
CAN2-L
CLST-IG (GRN/WHT) (RED)
M I2|3
0 5 0
t h e V S A m o d u l a t o r - c o n t r o l unit a n d t h e s e n s o r CAN2-H (WHT)
cluster. • CLST-GND (LTGRN)
SENSOR CLUSTER 6P CONNECTOR

7. T u r n t h e ignition s w i t c h to L O C K (0). Is there continuity?
8. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d Y E S — G o t o s t e p 10.

V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r
t e r m i n a l s N o . 6, N o . 2 5 , N o . 2 9 , a n d N o . 31 N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A
individually. m o d u l a t o r - c o n t r o l unit a n d t h e s e n s o r c l u s t e r . !
CLST-IG (GRN/WHT)
2 4 6 |X|111x113 v
' yy vy w) ?
\i\/\/\A/\/\/\/\^v\ziV\SO%\
^
133I34I35136137I/I/I/T7142143I44 i i p i F
(RED) (WHT) (LTGRN)
sensor cluster. •
(cont'd)
19-95
10. S u b s t i t u t e a k n o w n - g o o d s e n s o r c l u s t e r ( s e e p a g e DTC 27: Steering Angle Sensor
19-125).
1. C h e c k t h e s i z e , air p r e s s u r e , a n d a m o u n t of w e a r of
N O T E : C h e c k that t h e s e n s o r c l u s t e r m o u n t i n g all four t i r e s , a n d t h e w h e e l a l i g n m e n t ( s e e p a g e
bracket is not bent or t w i s t e d , a n d m a k e s u r e t h e 18-7).
s e n s o r c l u s t e r is m o u n t e d p r o p e r l y a n d f i x e d .
Is the tire condition and wheel alignment OK?
11. R e c o n n e c t all of the d i s c o n n e c t e d c o n n e c t o r s .
N O — M a k e s u r e t h e s u s p e n s i o n is not m o d i f i e d ,
13. C l e a r t h e D T C w i t h t h e H D S . a n d adjust the w h e e l alignment correctly, and
recheck by test-driving. •
14. D o the V S A s e n s o r neutral p o s i t i o n m e m o r i z a t i o n
( s e e p a g e 19-125). 2. T u r n t h e ignition s w i t c h to O N (II).
15. T u r n the ignition s w i t c h to L O C K (0), t h e n 3. C l e a r t h e D T C w i t h t h e H D S .

4. S l o w l y d r i v e t h e v e h i c l e straight a h e a d w i t h o u t
16. T e s t - d r i v e t h e v e h i c l e a r o u n d a n u m b e r of c o r n e r s . t u r n i n g t h e s t e e r i n g w h e e l for 10 ft (3 m) or m o r e ,
t h e n park t h e v e h i c l e w h i l e h o l d i n g t h e s t e e r i n g
17. C h e c k for D T C s w i t h t h e H D S . w h e e l in t h e straight a h e a d p o s i t i o n .
Is DTC 25,26, or 104 indicated? 5. C h e c k t h e S T E E R I N G A N G L E in t h e V S A D A T A L I S T

with the H D S .
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A
m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y , Is it 0° ±3 °?
unit ( s e e p a g e 19-127), a n d r e t e s t . B Y E S — G o t o s t e p 7.
N O — I f a n y D T C s a r e i n d i c a t e d , g o to t h e i n d i c a t e d N O — G o to s t e p 6.
D T C s t r o u b l e s h o o t i n g . If D T C is not i n d i c a t e d ,
r e p l a c e t h e s e n s o r c l u s t e r ( s e e p a g e 19-125). • 6. D o the V S A s e n s o r neutral position m e m o r i z a t i o n
( s e e p a g e 19-125).
7. T u r n t h e ignition s w i t c h to L O C K (0), t h e n
19-96
8. T e s t - d r i v e t h e v e h i c l e a r o u n d a n u m b e r of c o r n e r s . 19. S u b s t i t u t e a k n o w n - g o o d s e n s o r c l u s t e r ( s e e p a g e
19-125).
9. C h e c k t h e D T C s w i t h t h e H D S .
N O T E : C h e c k that t h e s e n s o r c l u s t e r m o u n t i n g
Is DTC 27 Indicated? bracket is not bent or t w i s t e d , a n d m a k e s u r e t h e
s e n s o r c l u s t e r is m o u n t e d p r o p e r l y a n d f i x e d .
N O — I f t h e D T C 8 6 is i n d i c a t e d , d o the D T C 8 6
t r o u b l e s h o o t i n g ( s e e p a g e 19-105). If n o D T C s a r e 21. Clear the D T C with the H D S .
i n d i c a t e d , t h e s y s t e m i s O K at t h i s t i m e . B
2 2 . D o the V S A s e n s o r neutral p o s i t i o n m e m o r i z a t i o n
10. T u r n the ignition s w i t c h to L O C K (0). (see p a g e 19-125).
11. Substitute a k n o w n - g o o d s t e e r i n g a n g l e s e n s o r 2 3 . T u r n t h e ignition s w i t c h to L O C K (0), t h e n

(see p a g e 19-124). disconnect the HDS.
N O T E : Make s u r e the steering angle s e n s o r and 24. T e s t - d r i v e t h e v e h i c l e a r o u n d a n u m b e r of c o m e r s .

combination switch are mounted properly
(see p a g e 19-124). 2 5 . C h e c k for D T C s w i t h t h e H D S .
12. T u r n t h e ignition s w i t c h to O N (II). 'Is DTC 27 indicated?
13. C l e a r t h e D T C w i t h t h e H D S . Y E S — C h e c k for l o o s e t e r m i n a l s in the V S A

14. Do t h e V S A s e n s o r neutral position m e m o r i z a t i o n substitute a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l
( s e e p a g e 19-125). unit ( s e e p a g e 19-127), a n d retest. •
15. T u r n t h e ignition s w i t c h to L O C K (0), t h e n N O — R e p l a c e t h e original s e n s o r c l u s t e r ( s e e p a g e

disconnect the H D S . 19-125). •
16. T e s t - d r i v e t h e v e h i c l e a r o u n d a n u m b e r of c o r n e r s .
17. C h e c k for D T C s with the H D S .
N O — R e p l a c e t h e original s t e e r i n g a n g l e s e n s o r
(see p a g e 19-124). •
19-97
DTC 31,32,33,34,35,36,37,38: ABS DTC 51: Motor Lock

Solenoid DTC 52: Motor Stuck ON/OFF
1. T u r n t h e ignition s w i t c h to O N (II). 1. T u r n t h e ignition s w i t c h to L O C K (0).
2. C l e a r t h e D T C w i t h t h e H D S . 2. C h e c k t h e N o . 50 (30 A ) f u s e in t h e m a i n u n d e r -
3. T u r n t h e ignition s w i t c h to L O C K (0), t h e n t u r n it to hood f u s e / r e l a y box.
Is the fuse blown?
Y E S — I n s t a l l t h e n e w N o . 50 (30 A ) f u s e , a n d
Is DTC 31, 32, 33, 34, 35, 36, 37, or 38 indicated? r e c h e c k . If t h e f u s e c o n t i n u e s to b l o w , c h e c k for
s h o r t to b o d y g r o u n d in t h e w i r e b e t w e e n t h e
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A No. 50 (30 A ) f u s e in t h e m a i n u n d e r - h o o d f u s e /
m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y , r e l a y b o x a n d t h e V S A m o d u l a t o r - c o n t r o l unit. If
substitute a known-good V S A modulator-control n e c e s s a r y , substitute a known-good V S A
unit ( s e e p a g e 19-127), a n d r e t e s t . B m o d u l a t o r - c o n t r o l unit ( s e e p a g e 19-127), a n d
retest. •
N O — T h e s y s t e m is O K at t h i s t i m e . B
N O — R e i n s t a l l the c h e c k e d f u s e , t h e n g o to s t e p 3.
connector.
4. M e a s u r e t h e v o l t a g e b e t w e e n V S A m o d u l a t o r -
control unit 4 7 P c o n n e c t o r t e r m i n a l N o . 1 a n d b o d y
ground.
+ B - P (WHT/BLU)
I 2 M 4 M 6 M^l 9 Mil M13M15| 16
171/1/1/1/1/1X1X1251/1271X1291X131
32 47
|33|34|35|36|37|XIXIXIXl42|43|44|45|46|
Y)
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e N o . 50
(30 A) f u s e in t h e m a i n u n d e r - h o o d f u s e / r e l a y b o x
and the V S A modulator-control unit.B
19-98
VSA
5. C h e c k f o r continuity b e t w e e n V S A m o d u l a t o r - DTC 54: Fail-safe Relay

body ground. 1. T u r n t h e ignition s w i t c h t o O N (II).

VSA MODULATOR-CONTROL UNIT 47P C O N N E C T O R
3 . T u r n t h e ignition s w i t c h t o L O C K (0), t h e n
|2M4|/|6M/|9M11|/|13|/|15|
1 16
32
17MXI/1XIXIXI/|25|X|27|X|29|X|31 47 4. T e s t - d r i v e t h e v e h i c l e .
|33|34|35|36|37|/|/|/|/|42|43|44|45|46|
G N D - P (BLK) 5. C h e c k f o r D T C s w i t h t h e H D S .
W i r e side of f e m a l e t e r m i n a l s Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A
Is there continuity? unit ( s e e p a g e 19-127), a n d retest. •
Y E S — G o to s t e p 6. N O — I n t e r m i t t e n t failure; t h e v e h i c l e i s O K at t h i s
time.B
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A
m o d u l a t o r - c o n t r o l unit a n d b o d y g r o u n d ( G 3 0 3 ) . B
6. R e c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P
connector.
7. T u r n t h e ignition s w i t c h t o O N (II).
9. T u r n t h e ignition s w i t c h t o L O C K (0), t h e n
disconnect the HDS.
10. T e s t - d r i v e t h e v e h i c l e a t 10 m p h (15 k m / h ) o r m o r e .
11. C h e c k f o r D T C s w i t h t h e H D S .
Is DTC 51 or DTC 52 indicated?
Y E S — C h e c k f o r l o o s e t e r m i n a l s in t h e V S A
N O — T h e s y s t e m i s O K at t h i s t i m e . •
19-99
DTC 61: Low + B - F S R Voltage DTC 64: Sensor Power Voltage
DTC 62: High + B - F S R Voltage 1. T u r n t h e ignition s w i t c h to O N (II).
N O T E : If t h e v e h i c l e h a s h i g h e l e c t r i c l o a d or a w e a k 2. C l e a r t h e D T C with t h e H D S .
battery, D T C 61 m a y b e s t o r e d w h e n starting t h e e n g i n e .
1. T u r n t h e ignition s w i t c h to O N (II). disconnect the H D S .
2. C l e a r t h e D T C w i t h t h e H D S . 4. T e s t - d r i v e t h e v e h i c l e .
3. T u r n t h e ignition s w i t c h to L O C K (0), t h e n t u r n it to 5. C h e c k for D T C s with the H D S .

Y E S — G o to s t e p 4. m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
IMO—The s y s t e m is O K at t h i s t i m e . • unit ( s e e p a g e 19-127), a n d retest. •
4. C h e e k for D T C s w i t h t h e H D S . N O — T h e s y s t e m is O K at t h i s t i m e . •
Y E S — C h e c k t h e c h a r g i n g s y s t e m ( s e e p a g e 4-36).
•
N O — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e
D T C indicated. •
19-100
DTC 65: Brake Fluid Level 11. C h e c k for c o n t i n u i t y b e t w e e n brake fluid l e v e l
s w i t c h 2 P c o n n e c t o r t e r m i n a l No. 2 a n d b o d y
1. C h e c k t h e brake fluid level in t h e m a s t e r c y l i n d e r ground.
reservoir.
B R A K E FLUID L E V E L S W I T C H 2P C O N N E C T O R
Is brake fluid level OK ?
N O — I n s p e c t the b r a k e p a d s : F r o n t ( s e e p a g e 19-13),
GRN/RED
rear ( s e e p a g e 19-22), a n d r e p l a c e w o r n out b r a k e
pads, then recheck. •
3. C l e a r t h e D T C w i t h t h e H D S . W i r e s i d e of f e m a l e t e r m i n a l s
5. D i s c o n n e c t the b r a k e fluid level s w i t c h 2 P
connector. Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e
b e t w e e n t h e g a u g e a s s e m b l y or the V S A
6. T u r n the ignition s w i t c h to O N (II). m o d u l a t o r - c o n t r o l unit a n d t h e brake fluid level
switch. •
N O — C h e c k for l o o s e t e r m i n a l s in t h e V S A
Is DTC 65 indicated? m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
Y E S — G o t o s t e p 8. unit ( s e e p a g e 19-127), a n d r e t e s t . H
N O — R e p l a c e t h e r e s e r v o i r (brake fluid level s w i t c h

is i n c l u d e d ) o n t h e m a s t e r c y l i n d e r ( s e e p a g e 19-18).
•
9. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P
connector.
10. D i s c o n n e c t the g a u g e a s s e m b l y c o n n e c t o r B (30P).
19-101
DTC 66: VSA Pressure Sensor (Inside of V S A DTC 68: Brake Pedal Position Switch
Modulator-control Unit)
2. C h e c k for other D T C s .
Is another DTC indicated?
disconnect the H D S . Y E S — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e
DTC.B
4. Test-drive the v e h i c l e .
5 . C h e c k for D T C s w i t h t h e H D S .
Is DTC 66 Indicated?
4. C h e c k t h e brake p e d a l p o s i t i o n s w i t c h ( s e e p a g e
Y E S — R e p l a c e t h e V S A m o d u l a t o r - c o n t r o l unit 2 2 - 1 4 4 ) , a n d a d j u s t m e n t ( s e e p a g e 19-6).
(see page 19-127).B
Is the switch and adjustment OK?
N O — T h e s y s t e m is O K at t h i s t i m e . B
N O — A d j u s t the b r a k e p e d a l p o s i t i o n s w i t c h . If
n e c e s s a r y , r e p l a c e t h e s w i t c h ( s e e p a g e 19-6). B
5 . T u r n t h e ignition s w i t c h t o O N (II).
8 . Test-drive the vehicle.
19-102
VSA
9. C h e c k for D T C s w i t h the H D S . DTC 81: Central Processing Unit (CPU)
Is DTC 68 indicated? 1. T u r n t h e ignition s w i t c h to O N (II).
Y E S — G o to s t e p 10. 2. C h e c k for o t h e r D T C s .
N O — T h e s y s t e m is O K at t h i s t i m e . • Is another DTC indicated?
10. T r o u b l e s h o o t t h e brake p e d a l p o s i t i o n s w i t c h s i g n a l Y E S — D o t h e a p p r o p r i a t e t r o u b l e s h o o t i n g for t h e

circuit ( s e e p a g e 11-460). DTC.B
Is the brake pedal position switch circuit OK? N O — G o to s t e p 3.
Y E S — C h e c k for l o o s e t e r m i n a l s in t h e E C M 3. C l e a r t h e D T C w i t h t h e H D S .
c o n n e c t o r , if the c o n n e c t i o n s a r e O K , substitute a
k n o w n - g o o d E C M a n d r e c h e c k . If t h e p r o b l e m is 4. T u r n t h e ignition s w i t c h to L O C K (0), t h e n
g o n e , r e p l a c e t h e original E C M . If t h e p r o b l e m disconnect the H D S .
c o n t i n u e s , r e p l a c e the V S A m o d u l a t o r - c o n t r o l unit
( s e e p a g e 19-127). • 5. T e s t - d r i v e t h e v e h i c l e .
N O — R e p a i r t h e brake p e d a l p o s i t i o n s w i t c h 6. C h e c k f o r D T C s w i t h t h e H D S .
circuit. •
N O — I n t e r m i t t e n t f a i l u r e ; the s y s t e m is O K at this
time.B
19-103
DTC 83: ECM Communication DTC 84: VSA Sensor Neutral Position
1. T u r n t h e ignition s w i t c h to O N (II). N O T E : If D T C 8 4 is s t o r e d , the V S A activation indicator

d o e s not g o off until d o i n g t h e V S A s e n s o r neutral
2 . C h e c k for D T C s w i t h t h e H D S . position m e m o r i z a t i o n ( s e e p a g e 19-125).
Is DTC 86 indicated? 1. D o t h e V S A s e n s o r neutral position m e m o r i z a t i o n

( s e e p a g e 19-125).
Y E S — D o t h e t r o u b l e s h o o t i n g for D T C 8 6 . •
3. T u r n t h e ignition s w i t c h to L O C K (0), t h e n turn it to
3. C l e a r t h e D T C w i t h t h e H D S . O N (II) a g a i n .
4. T u r n t h e ignition s w i t c h to L O C K (0), t h e n 4. C h e c k for D T C s w i t h t h e H D S .

6. C h e c k for D T C s w i t h t h e H D S . m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
Is DTC 83 indicated? unit ( s e e p a g e 19-127), a n d retest. •
Y E S — G o to s t e p 7. N O — T h e s y s t e m is O K at t h i s t i m e . •
7. C h e c k for fuel a n d e m i s s i o n s y s t e m s ( P G M - F I )
D T C s w i t h t h e H D S ( s e e p a g e 11-213).
Are any ECM DTCs indicated ?
Y E S — D o t h e a p p l i c a b l e t r o u b l e s h o o t i n g for t h e
ECM.B
19-104
VSA
DTC 86: F-CAN Communication 13. T u r n t h e ignition s w i t c h to O N (II).
1. T u r n the ignition s w i t c h to O N (II). 14. M e a s u r e the v o l t a g e b e t w e e n b o d y g r o u n d a n d

2. C l e a r t h e D T C w i t h the H D S . t e r m i n a l s N o . 11 a n d N o . 15 individually.
3. T u r n the ignition s w i t c h to L O C K (0), t h e n turn it to

CAN1-H (RED) CAN1-L (WHT)
4. C h e c k for D T C s with the H D S . 1 I

16
v\/\A/\A/\/W
32 47
|33|34l35|36l37M/|/|/l42|43|44|45|46l
5. C l e a r the D T C w i t h the H D S . W i r e s i d e of f e m a l e terminals
6. S t a r t a n d run the e n g i n e for at l e a s t 5 s e c o n d s .

Y E S — R e p a i r s h o r t to p o w e r in the w i r e b e t w e e n
Is DTC 86 indicated? t h e V S A modulator-control unit a n d t h e E C M . B
NO—Intermittent failure; t h e F - C A N
c o m m u n i c a t i o n line is O K at t h i s t i m e . •
9. S h o r t the S C S line w i t h the H D S .
11. D i s c o n n e c t the s t e e r i n g a n g l e s e n s o r 5 P c o n n e c t o r .
12. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P

connector.
(cont'd)
19-105
15. T u r n t h e ignition s w i t c h to L O C K (0). 17. C h e c k for continuity b e t w e e n V S A m o d u l a t o r -
control unit 4 7 P c o n n e c t o r t e r m i n a l s N o . 11, N o . 15
16. C h e c k f o r c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d a n d E C M c o n n e c t o r E (31P) t e r m i n a l s N o . 11, N o . 24
V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r individually.
t e r m i n a l s N o . 11 a n d N o . 15 i n d i v i d u a l l y .
V S A M O D U L A T O R - C O N T R O L U N I T 4 7 P C O N N E C T O R

V S A M O D U L A T O R - C O N T R O L UNIT 47P C O N N E C T O R C A N 1 - H ( R E P ) C A N 1 - L ( W H T )
CAN1-H (RED) CAN1-L (WHT)

17|/l>l/l>l/l/MÎ>|27|>|29|>|a
|33l34|35|36|37|/|/l/l/l42|43|44|45l46]
47
l33l34l35|36l37|/|/|XI/|42l43|44l45|46|
C A N 1 - H ( R E D )
1 3| 4 /IVIUIels
| 5
/22 2311 2412 n13 2514 15 16n 2717 2818 2919 3020 21
W i r e side of f e m a l e terminals /
C A N 1 - L ( W H T )
/
E C M C O N N E C T O R E ( 3 1 P )
Is there continuity? Wire side of female terminals
Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e Is there continuity?
between the V S A modulator-control u n i t the
steering angle sensor, a n d the E C M . B Y E S — G o to s t e p 18.
N O — G o to s t e p 17. N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A
m o d u l a t o r - c o n t r o l unit a n d t h e E C M . •
18. C h e c k for continuity b e t w e e n t h e s t e e r i n g a n g l e

s e n s o r 5P connector terminals No. 2, No. 4 and
body ground individually.
S T E E R I N G A N G L E S E N S O R 5 P C O N N E C T O R
C A N 1 - L
1
( W H T )
2
I
/ 4 5
[ C A N 1 - H ( R E D )
(H) (a)
Y E S — T r a c e and repair short to body ground on the

C A N 1 - L or C A N 1 - H w i r e s between the steering
a n g l e s e n s o r , the E C M , a n d t h e V S A m o d u l a t o r -
control u n i t . B
19-106
VSA
19. C h e c k t h e No. 6 (15 A ) f u s e in t h e u n d e r - d a s h f u s e / 2 2 . T u r n t h e ignition s w i t c h to L O C K (0).

relay box.
2 3 . R e c o n n e c t all of t h e d i s c o n n e c t e d c o n n e c t o r s .
Is the fuse blown?
2 4 . T u r n t h e ignition s w i t c h to O N (II).
Y E S — R e p l a c e the f u s e , a n d r e c h e c k . •
25. M e a s u r e the voltage between steering angle
N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o to s t e p 20. s e n s o r 5P connector terminal No. 1 and body
ground.
2 1 . M e a s u r e the v o l t a g e b e t w e e n s t e e r i n g a n g l e
s e n s o r 5P connector terminal No. 5 a n d body
ground.
1 2
/
G N D (BLK)
4 5
IG1 ( B L K / Y E L ) W i r e s i d e of f e m a l e t e r m i n a l s
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — R e p l a c e the steering angle s e n s o r (see page

19-124).•
Is there battery voltage? N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e s t e e r i n g

a n g l e s e n s o r a n d b o d y g r o u n d (G401). •
Y E S — G o to s t e p 2 2 .
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e No. 6
(15 A ) f u s e a n d the s t e e r i n g a n g l e s e n s o r . •
19-107
DTC 91: VSA Operation 10. M e a s u r e t h e v o l t a g e b e t w e e n b o d y g r o u n d a n d

1. T u r n t h e ignition s w i t c h t o O N (II). t e r m i n a l s N o . 6, N o . 2 5 , N o . 2 9 , a n d N o . 31
individually.
3. T u r n t h e ignition s w i t c h t o L O C K (0), t h e n
disconnect the HDS. |2M4|/|6|/|/|9|/|11|/|13|/|15|
1 16
17 l / l / l / l / l / l / l / l 2 5 1 / | 2 7 | / | 2 9 1 / | 31
32 47
4. T e s t - d r i v e t h e v e h i c l e . | 3 3 | 3 4 | 3 5 | 3 6 | 3 7 | / | / | / l / | 4 2 | 4 3 | 4 4 45|45|

(RED) (WHT) (LTGRN)
5. C h e c k f o r D T C s w i t h t h e H D S .
NO—If D T C 86 is indicated, do the D T C 86

t r o u b l e s h o o t i n g ( s e e p a g e 19-105). If n o D T C s a r e Is there 0.1 V or more?
i n d i c a t e d , t h e s y s t e m i s O K at t h i s t i m e . •
6. T u r n t h e ignition s w i t c h t o L O C K (0). t h e V S A m o d u l a t o r - c o n t r o l unit a n d t h e s e n s o r
cluster. •
7. D i s c o n n e c t t h e s e n s o r c l u s t e r 6 P c o n n e c t o r .
connector. 11. T u r n t h e ignition s w i t c h t o L O C K (0).
9. T u r n t h e ignition s w i t c h t o O N (II). 12. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d

t e r m i n a l s N o . 6, N o . 2 5 , N o . 2 9 , a n d N o . 31
individually.
I CLST-IG (GRN/WHT)
1
|2|/|4MeM/|9MllMl3MlB| 16
2 5 | / | 2 7 | / | 2 9 l / l 31
32 47
|33|34|35|36|37|/|/l/ 1/142143|44| 451461
(RED) (WHT) (LTGRN)
sensor c l u s t e r . !
19-108
13. C h e c k for continuity b e t w e e n V S A m o d u l a t o r - 19. T e s t - d r i v e t h e v e h i c l e a r o u n d a n u m b e r of c o r n e r s .
control unit 4 7 P c o n n e c t o r t e r m i n a l s N o . 6, N o . 2 5 ,
No. 29, No. 31, a n d s e n s o r cluster 6 P connector 2 0 . C h e c k for D T C s w i t h t h e H D S .
t e r m i n a l s N o . 1, N o . 3 , N o . 2 , N o . 5.
Y E S — G o to s t e p 2 1 .
CLST-IG (GRN/WHT)
I 2 | / l 4 \/\ 6 \ / \ / \ 9 | / h l 1/|13|/|15T N O — R e p l a c e t h e original s e n s o r c l u s t e r ( s e e p a g e
16
17^^1/1/1^15^2^^291/13 19-125).H
32 I33|34|35|36l37|/ly1yl7l42|43l44|45l46 47
CAN2-L CAN2-H CLST-GND 2 1 . T u r n t h e ignition s w i t c h to L O C K (0).

(RED) (WHT) (LTGRN)
22. Disconnect the steering angle sensor 5P connector.
2 3 . C h e c k for continuity b e t w e e n V S A m o d u l a t o r -
CAN2-L
(RED)
control unit 4 7 P c o n n e c t o r t e r m i n a l s N o . 11, N o . 15
CLST-IG (GRN/WHT)
and steering angle s e n s o r 5P connector terminals
71 No. 4, N o . 2.
CAN2-H (WHT) CAN1-H (RED) C A N 1 - L (WHT)

CLST-GND (LTGRN)
S E N S O R C L U S T E R 6P C O N N E C T O R ^]/V\/]/]/]/\/\^]/\^\/\^\/\k
W i r e s i d e of f e m a l e t e r m i n a l s 32
CAN1-H (RED)
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A
m o d u l a t o r - c o n t r o l unit a n d t h e s e n s o r c l u s t e r . •
I C A N 1 - L (WHT)
14. S u b s t i t u t e a k n o w n - g o o d s e n s o r c l u s t e r ( s e e p a g e
19-125).
15. R e c o n n e c t all of t h e d i s c o n n e c t e d c o n n e c t o r s . Is there continuity?
16. T u r n t h e ignition s w i t c h to O N (II). Y E S — G o t o s t e p 24.
17. C l e a r t h e D T C w i t h the H D S . N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e V S A
modulator-control unit a n d t h e s t e e r i n g a n g l e
18. T u r n the ignition s w i t c h to L O C K (0), t h e n sensor. •
(cont'd)
19-109
24. C h e c k the N o . 6 (15 A ) f u s e in t h e u n d e r - d a s h f u s e / 2 9 . T u r n t h e ignition s w i t c h to O N (II).

relay box.
30. M e a s u r e the voltage between steering angle
Is the fuse blown? s e n s o r 5P connector terminal No. 1 and body
ground.
Y E S — I n s t a l l the n e w N o . 6 (15 A ) f u s e , a n d r e c h e c k .
If the f u s e c o n t i n u e s to b l o w , c h e c k f o r s h o r t to
S T E E R I N G A N G L E S E N S O R 5P CONNECTOR
b o d y g r o u n d in the w i r e b e t w e e n t h e N o . 6 (15 A )
f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d t h e
steering angle s e n s o r , or the V S A modulator-
control u n i t . B j
N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o to s t e p 2 5 .
1 2
A
G N D (BLK)
4 5
2 5 . T u r n the ignition s w i t c h to O N (II). X
26. Measure voltage between steering angle s e n s o r 5P

connector terminal No. 5 and body ground. W i r e s i d e of f e m a l e t e r m i n a l s
STEERING ANGLE S E N S O R 5P CONNECTOR

Y E S — R e p l a c e the steering angle s e n s o r (see page

<; f 19-124). •
1 2
/ 4 5
I IG1 ( B L K / Y E L )
N O — R e p a i r o p e n in t h e w i r e b e t w e e n the s t e e r i n g
angle sensor and body ground ( G 4 0 D . B
X)
Y E S — G o to s t e p 2 7 .
(15 A) f u s e a n d t h e s t e e r i n g a n g l e s e n s o r . •
19-110
VSA
DTC 105: Hydraulic Unit Temperature Sensor DTC 121,122,123,124: V S A Solenoid
2. C l e a r t h e D T C w i t h t h e H D S . 2. C l e a r t h e D T C w i t h t h e H D S .
3. T u r n the ignition s w i t c h to L O C K (0), t h e n 3. T u r n t h e ignition s w i t c h to L O C K (0), t h e n

disconnect the H D S . disconnect the H D S .
4. T e s t - d r i v e t h e v e h i c l e . 4. T e s t - d r i v e t h e v e h i c l e .
5. C h e c k for D T C s w i t h the H D S . 5. C h e c k for D T C s w i t h t h e H D S .
Is DTC 105 indicated? Is DTC 121, 122, 123, or 124 indicated?
Y E S — R e p l a c e the V S A m o d u l a t o r - c o n t r o l unit Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A

( s e e p a g e 19-127). • m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
N O — T h e s y s t e m is O K at this t i m e . • unit ( s e e p a g e 19-127), a n d retest. •
N O — I n t e r m i t t e n t f a i l u r e ; t h e s y s t e m is O K at t h i s
time.!
19-111
A B S indicator does not c o m e on 7. T u r n t h e ignition s w i t c h to L O C K (0).
1. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h t h e 8. D i s c o n n e c t the V S A m o d u l a t o r - c o n t r o l unit 4 7 P

ABS indicator. connector.
Does the ABS indicator come on? 9. T u r n the ignition s w i t c h to O N (II).
Y E S — T h e s y s t e m is O K at t h i s t i m e . • Does the ABS indicator come on?
N O — G o to s t e p 2. Y E S — C h e c k for l o o s e t e r m i n a l s in the V S A
2. T u r n t h e ignition s w i t c h to L O C K (0), t h e n t u r n it to substitute a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l
O N (II) a g a i n . unit ( s e e p a g e 19-127), a n d retest. •
Does the brake system indicator come on? N O — G o to s t e p 10.
Y E S — G o to s t e p 7. 10. T u r n the ignition s w i t c h to L O C K (0).
N O — G o to s t e p 3. 11. C h e c k t h e A B S indicator b u l b in t h e g a u g e
a s s e m b l y ( s e e p a g e 22-58).
Is the bulb OK?
4. R e m o v e the g a u g e a s s e m b l y . Do not d i s c o n n e c t
t h e g a u g e a s s e m b l y c o n n e c t o r A (22P) a n d Y E S — G o t o s t e p 12.
c o n n e c t o r B (30P) ( s e e p a g e 22-89).
N O — R e p l a c e t h e A B S indicator bulb ( s e e p a g e
5. T u r n t h e ignition s w i t c h to O N (II). 22-58). •
6. M e a s u r e t h e v o l t a g e b e t w e e n g a u g e a s s e m b l y 12. D i s c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).
c o n n e c t o r A (22P) t e r m i n a l N o . 18 a n d b o d y g r o u n d .
13. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y
GAUGE ASSEMBLY CONNECTOR A (22?) c o n n e c t o r B (30P) t e r m i n a l No. 20 a n d b o d y g r o u n d .
1 2 3 4 5 7 8 9 10
11 12 13 14 15 16|Xh7 18 19 20
GND
// (BLK)
2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22|X|23 24 25 26 27 28 29 30
ABS (BLU/RED)
Wire s i d e of f e m a l e terminals Wire side of female terminals
Is there 0.1 V or less? Is there continuity ?
Y E S — D o the self-diagnostic function Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e

t r o u b l e s h o o t i n g for the g a u g e a s s e m b l y ( s e e p a g e b e t w e e n the g a u g e a s s e m b l y a n d the V S A
22-60). • modulator-control u n i t . B
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e g a u g e N O — C h e c k for l o o s e t e r m i n a l s in the V S A

assembly and body ground ( G 5 0 D . B m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
19-112
ABS indicator does not go off, and no DTCs 6. T u r n t h e ignition s w i t c h to O N (II).
are stored
1. T u r n t h e ignition s w i t c h to L O C K (0). c o n t r o l unit 4 7 P c o n n e c t o r t e r m i n a l N o . 4 a n d b o d y
ground.
2. C h e c k the N o . 4 8 (30 A ) f u s e in t h e m a i n u n d e r -
Is the fuse blown?

' IG1 ( B L K / Y E L )
|2M4M6M/|91/|11|/|13M15|
Y E S — C h e c k f o r a s h o r t to b o d y g r o u n d in t h e f u s e
17 l ^ l ^ L ^ I ^ L ^ I ^ I ^ I 251^>| 2 T | ^ | 2^ 31
circuit, t h e n r e p l a c e t h e f u s e , a n d r e c h e c k . •
l33l34|35[36|37M/V1X|42l43|44|45|46|
N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o to s t e p 3 .
3 . C h e c k the N o . 6 (15 A ) f u s e in t h e u n d e r - d a s h
fuse/relay box.
Is the fuse blown?
Y E S — C h e c k f o r a s h o r t to b o d y g r o u n d in t h e f u s e Is there battery voltage?

N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o t o s t e p 4.
4. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P (15 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d t h e
connector. V S A modulator-control unit.B
5. M e a s u r e t h e v o l t a g e b e t w e e n V S A m o d u l a t o r - 8. T u r n t h e ignition s w i t c h to L O C K (0).
control unit 4 7 P c o n n e c t o r t e r m i n a l N o . 3 2 a n d
body ground. 9. C h e c k f o r c o n t i n u i t y b e t w e e n V S A m o d u l a t o r -
c o n t r o l unit 4 7 P c o n n e c t o r t e r m i n a l N o . 16 a n d
body ground.
2 1/|4M61/|/|9L/|11|/113M15|
i7i/i/iAîA^ G N D - V (BLK) I
3 2
'33|34l35|36|37|XI>XU1^l42|43|44|45i46i j 4 7 12M4M6M/19M111/|13|/|15|
H-B-V ( W H T / R E D )
1331341351361371^1/1/1/1421431441451461
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e N o . 4 8 Y E S - G o t o s t e p 10.
(30 A ) f u s e in t h e m a i n u n d e r - h o o d f u s e / r e l a y b o x
and the V S A modulator-control u n i t . B N O — R e p a i r o p e n in t h e w i r e b e t w e e n the V S A
(cont'd)
19-113
10. T u r n t h e ignition s w i t c h to O N (II). 12. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P)

terminal No. 20 and body ground with a jumper
11. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r wire.
terminal No. 4 4 a n d body ground with a j u m p e r
wire. G A U G E A S S E M B L Y C O N N E C T O R B (30P)
2 3 4 5 6 7 8 9 10 11 12 13 14
1
|2M4|/|6|/|/|9|/|11|/|13|/|15| 16
/
15 16 17 18 19 20 21
22|X|23
24 25 26 27 28 29 30
\i\AAAAAAA7^zM*V\* ABS (BLU/RED)

32 47
|33|34|35|36|37|/|/|/|/|42|43|44|45|46|
JUMPER WIRE
ABS (BLU/RED)
JUMPER WIRE

Does the ABS indicator go off?
Does the ABS indicator go off? Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e

a s s e m b l y and the V S A modulator-control unit.B
m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y , N O — C h e c k f o r l o o s e t e r m i n a l s in t h e g a u g e
substitute a known-good V S A modulator-control a s s e m b l y c o n n e c t o r B (30P). If n e c e s s a r y ,
unit ( s e e p a g e 19-127), a n d r e t e s t . H substitute a known-good g a u g e a s s e m b l y
(see page 22-89), and r e t e s t . B
19-114
Brake system indicator does not come on 10. M e a s u r e t h e v o l t a g e b e t w e e n g a u g e a s s e m b l y
1. A p p l y t h e p a r k i n g b r a k e .
2. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h the
b r a k e s y s t e m indicator.
£=2L
Does the brake system indicator come on and stay 1 2 3 4 5 7 8 9 10
11 12 13 14 15 161X117 18 19 20
on?
//
G N D (BLK)
X
3. T u r n t h e ignition s w i t c h to L O C K (0). W i r e s i d e of f e m a l e t e r m i n a l s
4. R e l e a s e t h e parking b r a k e .
5. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h t h e
b r a k e s y s t e m indicator. Y E S — D o the self-diagnostic function
t r o u b l e s h o o t i n g for t h e g a u g e a s s e m b l y ( s e e p a g e
Does the brake system indicator come on for 22-60). •
several seconds?
Y E S — T h e s y s t e m is O K at t h i s t i m e . • a s s e m b l y and body ground ( G 5 0 D . B
N O — G o to s t e p 14. 11. T u r n t h e ignition s w i t c h to L O C K (0).
6. T u r n t h e ignition s w i t c h to L O C K (0), t h e n turn it to 12. R e l e a s e t h e p a r k i n g b r a k e .

Does the ABS indicator come on for several
seconds? Does the brake system indicator come on for
several seconds?
Y E S — D o the parking brake s w i t c h test (see page
N O — G o to s t e p 7. 19-12).•
7. T u r n t h e ignition s w i t c h to L O C K (0). N O — G o t o s t e p 14.
8. R e m o v e the g a u g e a s s e m b l y . D o not d i s c o n n e c t 14. T u r n t h e ignition s w i t c h to L O C K (0).

t h e g a u g e a s s e m b l y c o n n e c t o r A (22P) a n d
c o n n e c t o r B (30P). 15. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P
connector.
(cont'd)
19-115
16. T u r n t h e ignition s w i t c h to O N (II). 2 1 . C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y

c o n n e c t o r B (30P) t e r m i n a l No. 2 5 a n d b o d y g r o u n d .
Does the brake system indicator come on for
several seconds? G A U G E A S S E M B L Y C O N N E C T O R B (30P)
Y E S — C h e c k f o r l o o s e t e r m i n a l s in t h e V S A
2 3 4 5 6 7 8 9 10 11 12 13 14
unit ( s e e p a g e 19-127), a n d r e t e s t . B /15 16 17 18 19 20 21 22|X|23 24 25 26 27 28 29 30
W L - E B D (PNK)
18. R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89). W i r e s i d e of f e m a l e t e r m i n a l s
19. C h e c k t h e b r a k e s y s t e m i n d i c a t o r b u l b in t h e g a u g e
a s s e m b l y ( s e e p a g e 22-58). Is there continuity?
Is the bulb OK? Y E S — R e p a i r s h o r t to b o d y g r o u n d b e t w e e n t h e

g a u g e a s s e m b l y a n d the V S A modulator-control
Y E S — G o to s t e p 20. unit.B
N O — R e p l a c e the brake s y s t e m indicator bulb N O — C h e c k for l o o s e t e r m i n a l s in the g a u g e

(see page 22-58). • a s s e m b l y c o n n e c t o r B (30P). If n e c e s s a r y ,
substitute a known-good gauge a s s e m b l y
20. D i s c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P). (see page 22-89), a n d r e t e s t . B
19-116
VSA
Brake system indicator does not go off, and 6. D o t h e parking b r a k e s w i t c h t e s t ( s e e p a g e 19-12).

no DTCs are stored
Is the switch OK ?
1. R e l e a s e the parking brake.
N O — R e p l a c e the parking brake switch (see page
Does the brake system indicator goes off after 19-30). •
several seconds?
Y E S — T h e s y s t e m is O K at t h i s t i m e . •
8. R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).
3. C h e c k t h e brake fluid level in t h e m a s t e r c y l i n d e r
reservoir. 10. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r B (30P) t e r m i n a l N o . 2 3 a n d b o d y g r o u n d .
Is brake fluid level OK ?
N O — I n s p e c t the b r a k e p a d s : F r o n t ( s e e p a g e 19-13),
r e a r ( s e e p a g e 19-22), a n d r e p l a c e w o r n out p a d s , 4 7
2 3 5 6 8 9 10 11 12 13 14
then recheck. • /
15 16 17 18 19 20 21 22|X|23 24 25 26 27 28 29 30
GRN/WHT
4. C h e c k t h e A B S indicator.
(Q)
Does ABS indicator stay on?
Y E S — C h e c k for D T C s a n d d o t h e indicated D T C W i r e s i d e of f e m a l e t e r m i n a l s
N O — G o to s t e p 5. Is there continuity?
5. D o t h e brake fluid level s w i t c h t e s t ( s e e p a g e 19-12). Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e

b e t w e e n t h e g a u g e a s s e m b l y a n d t h e parking brake
Is the switch OK ? switch. •
N O — R e p l a c e t h e r e s e r v o i r (brake fluid level s w i t c h

is i n c l u d e d ) o n t h e m a s t e r c y l i n d e r ( s e e p a g e 19-18).
(cont'd)
19-117
11. R e c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P). 14. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P)

terminal No. 25 and body ground with a jumper
12. T u r n t h e ignition s w i t c h to O N (II). wire.
13. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r
wire.
2 3 4 5 6 7 8 9 10 11 12 13 14
W L - E B D (PNK)
/
15 16 17 18 19 20 21 22|X|23 24 25 26 27 28 29 30
W L - E B D (PNK)
|2|/|4M6|/M9|/|11M13|/|15| 16
1 JUMPER WIRE
32
1 7 M X M / | X | / | / | 2 5 | / | 2 7 L X | 2 9 | / | 3 1 47
|33|34|35|36|37|/|/l/l/|42|43|44|45|46|

JUMPER
WIRE
Does the brake system indicator go off?

Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e
Does the brake system indicator go off?
Y E S - ^ C h e c k f o r l o o s e t e r m i n a l s in t h e V S A a s s e m b l y c o n n e c t o r B (30P). If n e c e s s a r y ,
m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y , substitute a known-good gauge a s s e m b l y
substitute a known-good V S A modulator-control ( s e e p a g e 22-89), a n d r e t e s t . B
19-118
VSA
VSA indicator does not come on 7. T u r n the ignition s w i t c h to L O C K (0).
1. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h the 8. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P

V S A indicator. connector.
Does the VSA indicator come on? 9. T u r n the ignition s w i t c h to O N (II).
Y E S — T h e s y s t e m is O K at t h i s t i m e . • Does the VSA indicator come on?
N O — G o to s t e p 2. Y E S — C h e c k for l o o s e t e r m i n a l s in t h e V S A
2. T u r n t h e ignition s w i t c h to L O C K (0), t h e n turn it to substitute a known-good V S A modulator-control
O N (II) a g a i n . unit ( s e e p a g e 19-127), a n d retest. •
Does the brake system indicator come on? N O — G o to s t e p 10.
Y E S — G o to s t e p 7. 10. T u r n the ignition s w i t c h to L O C K (0).
N O — G o t o s t e p 3. 11. C h e c k the V S A indicator bulb in t h e g a u g e

a s s e m b l y ( s e e p a g e 22-58).
Is the bulb OK?
4. R e m o v e the g a u g e a s s e m b l y . D o not d i s c o n n e c t
t h e g a u g e a s s e m b l y c o n n e c t o r A (22P) a n d Y E S — G o to s t e p 12.
c o n n e c t o r B (30P) ( s e e p a g e 22-89).
N O — R e p l a c e t h e V S A indicator b u l b ( s e e p a g e
5. T u r n the ignition s w i t c h to O N (II). 22-58). •
6. M e a s u r e the v o l t a g e b e t w e e n g a u g e a s s e m b l y 12. D i s c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).

1 2 3 4 5 7 8 9 10
q~7 V S A (PNK/BLK)
11 12 13 14 15 161X117 18 19 20
//
G N D (BLK)
/15 162 173 184 195 206 217 22|X|23 248 259 2610 2711 1228 2913 3014

is there 0.1 V or less?
Y E S — D o the s e l f - d i a g n o s t i c f u n c t i o n b e t w e e n the g a u g e a s s e m b l y a n d t h e V S A
t r o u b l e s h o o t i n g for t h e g a u g e a s s e m b l y ( s e e p a g e modulator-control unit.B
22-60). •
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e g a u g e m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y ,
assembly and body ground ( G 5 0 D . H substitute a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l
19-119
V S A indicator does not go off, and no DTCs 6. T u r n t h e ignition s w i t c h to O N (II).

are stored
1. T u r n the ignition s w i t c h to L O C K (0). control unit 4 7 P c o n n e c t o r t e r m i n a l No. 4 a n d b o d y
ground.
2. C h e c k the N o . 48 (30 A ) f u s e in t h e m a i n u n d e r -
Is the fuse blown?

' IG1 ( B L K / Y E L )
Y E S — C h e c k for a s h o r t to b o d y g r o u n d in t h e f u s e
|33|34l35l36l37l/M/|Xl42l43|44l45|46l
N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o to s t e p 3.
3. C h e c k the N o . 6 (15 A ) f u s e in t h e u n d e r - d a s h
fuse/relay box.
Is the fuse blown?
Y E S — C h e c k for a s h o r t to b o d y g r o u n d in t h e f u s e Is there battery voltage?

N O — R e i n s t a l l t h e c h e c k e d f u s e , t h e n g o to s t e p 4.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e No. 6
4. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P (15 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d t h e
connector. V S A modulator-control u n i t . B
5. M e a s u r e t h e v o l t a g e b e t w e e n V S A m o d u l a t o r - 8. T u r n t h e ignition s w i t c h to L O C K (0).
body ground. 9. C h e c k for continuity b e t w e e n V S A m o d u l a t o r -
body ground.
16
G N D - V (BLK) [
3 2 l
33|34|35|36|37ly0^ya/|42|43|44l45|46l | 4 7
|2|/|4|/|6|/|/|9|/|11|/|13|/|15| 16
1
+ B - V (WHT/RED) MV\/\/\/\/\/\/\7L\/\ll\/\^\/\^
32 47
|33|34|35|36|37|/|/|/|/|42|43|44|45|46|
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 48 Y E S — G o t o s t e p 10.
(30 A ) f u s e in t h e m a i n u n d e r - h o o d f u s e / r e l a y b o x
a n d the V S A modulator-control unit.B N O — R e p a i r o p e n in t h e w i r e b e t w e e n the V S A
19-120
VSA
TO. T u r n the ignition s w i t c h to O N (II). 12. C o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P)

11. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r wire.
wire.
<T-? V S A ( P N K / B L K )
V S A (PNK/BLK) 2 3 4 5 6 7 8 9 10 11 12 13 14
1
| 2 M 4 | / | 6 / M 9 | / | 1 1 | / | 1 3 | / | 1 5 | 16 /15 16 17 18 19 20 21 22 [ X I 2 3 24 25 26 27 28 29 30
17|/|/|/l/l/l/l/|25|/|27|/|29|/|31
32 47
|33|34|35|36|37|/VVVl42|43|44|45|46| JUMPER
WIRE
JUMPER
WIRE
Does the VSA indicator go off?
Does the VSA indicator go off? Y E S — R e p a i r o p e n in the w i r e b e t w e e n t h e g a u g e

m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r . If n e c e s s a r y , N O — C h e c k for l o o s e t e r m i n a l s in t h e g a u g e
substitute a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l a s s e m b l y c o n n e c t o r B (30P). If n e c e s s a r y ,
unit ( s e e p a g e 19-127), a n d retest. • substitute a known-good gauge a s s e m b l y
(see p a g e 2 2 - 8 9 ) , a n d retest. •
19-121
V S A activation indicator does not come on V S A activation indicator does not go off, and
at start-up (bulb check) no DTCs are stored
1. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h t h e N O T E : D o t h e V S A neutral p o s i t i o n m e m o r i z a t i o n

V S A a c t i v a t i o n indicator. ( s e e p a g e 19-125) first, if the indicator r e m a i n s o n ,
proceed with this flow chart.
Does the VSA activation indicator come on for
several seconds? 1. T u r n t h e ignition s w i t c h to O N (II), a n d w a t c h t h e
V S A a c t i v a t i o n indicator.
Does the VSA activation indicator go off?
N O — G o to s t e p 2 .
2. A p p l y t h e p a r k i n g b r a k e .
N O — G o to s t e p 2 .
3. C h e c k t h e V S A O F F s w i t c h ( s e e p a g e 19-126).
N O — D o the self-diagnostic function
t r o u b l e s h o o t i n g for t h e g a u g e a s s e m b l y ( s e e p a g e Is the switch OK?
22-60). •
N O — R e p l a c e the V S A O F F switch (see page
4. D i s c o n n e c t t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P 19-126).•
connector.
4. R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 2 2 - 8 9 ) .
5. C o n n e c t V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r
terminal No. 35 and body ground with a jumper 5. D i s c o n n e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (30P).
w i r e , a n d t u r n t h e ignition s w i t c h to O N (II).
connector.
| 2 M 4 L / | 6 | / | / | 9 | / | 1 1 ^ | 1 3 ^ | 1 5 | 16
1
1 7 | X I X M X I X I X I X l 2 5 | X | 2 7 M 291X131
32 47
|33|34|35|36|37|/i/l/|/|42|43|44|45|46|
A C T (GRN)
JUMPER WIRE
Does the VSA activation indicator come on?
a s s e m b l y a n d the V S A modulator-control u n i t . B
19-122
VSA
7. C h e c k for continuity b e t w e e n V S A m o d u l a t o r - 10. S u b s t i t u t e a k n o w n - g o o d V S A m o d u l a t o r - c o n t r o l

control unit 4 7 P c o n n e c t o r t e r m i n a l N o . 3 5 a n d unit ( s e e p a g e 19-127).
body ground.
11. R e c o n n e c t all of t h e d i s c o n n e c t e d c o n n e c t o r s .
1 |2|/|4|/|6M/|9M11|/H3L/|15| 16
17M/|/|/|/M/|25|/|27|/|29|/l31
32 47 14. T e s t - d r i v e t h e v e h i c l e .
|33|34|35|36|37|/|/|/|/|42|43|44|45|46|
A C T (GRN) Does the VSA activation indicator go off?
Y E S — R e p l a c e t h e original V S A m o d u l a t o r - c o n t r o l
unit ( s e e p a g e 19-127). •
a s s e m b l y c o n n e c t o r s . If n e c e s s a r y , s u b s t i t u t e a
Is there continuity? known-good gauge a s s e m b l y (see page 22-89), a n d
retest. •
b e t w e e n t h e g a u g e a s s e m b l y a n d the V S A
modulator-control unit.B
8. D i s c o n n e c t the V S A O F F s w i t c h 6 P c o n n e c t o r .
9. C h e c k for continuity b e t w e e n V S A m o d u l a t o r -
body ground.
|2|X|4|/|6|/|/|9|/|11|/|13L/|15| 16
1
17|/|/|/|/H/l/|25|/|27|/|29M31
32 47
|33|34|35|36|37|y1/|/|/|42 43|44|45|46|
V S A O F F S W (WHT)
b e t w e e n the V S A O F F s w i t c h a n d t h e V S A
modulator-control unit.B
19-123
Steering Angle Sensor Replacement
N O T E : D o not d a m a g e or d r o p t h e c o m b i n a t i o n s w i t c h a s t h e s t e e r i n g a n g l e s e n s o r i s s e n s i t i v e to s h o c k a n d v i b r a t i o n .
1. R e m o v e t h e s t e e r i n g w h e e l ( s e e p a g e 17-6).
2. R e m o v e t h e s t e e r i n g c o l u m n c o v e r s ( s e e p a g e 17-9) a n d t h e c a b l e reel ( s e e p a g e 23-174).
3. R e m o v e t h e c o m b i n a t i o n s w i t c h a s s e m b l y ( s e e p a g e 17-9).
4. R e m o v e t h e c o m b i n a t i o n light s w i t c h (A) a n d t h e w i p e r / w a s h e r s w i t c h (B).
5. R e p l a c e t h e c o m b i n a t i o n s w i t c h b o d y (C).
6. Install t h e c o m b i n a t i o n s w i t c h in the r e v e r s e o r d e r of r e m o v a l .
NOTE:
• Do not r e m o v e t h e s t e e r i n g a n g l e s e n s o r f r o m t h e c o m b i n a t i o n s w i t c h b o d y .
• W h e n installing t h e c a b l e r e e l , s e t t h e t u r n s i g n a l c a n c e l i n g s l e e v e p o s i t i o n ( s e e p a g e 23-177).
7. D o t h e V S A s e n s o r n e u t r a l p o s i t i o n m e m o r i z a t i o n ( s e e p a g e 19-125).
19-124
VSA
Sensor Cluster Replacement VSA Sensor Neutral Position

Memorization
NOTE:
• Do not d a m a g e or d r o p t h e s e n s o r a s it is s e n s i t i v e .
• Do not u s e p o w e r t o o l s . N O T E : D o not p r e s s t h e b r a k e p e d a l d u r i n g t h i s
procedure.
1. S l o w l y run t h e v e h i c l e straight w i t h o u t o p e r a t i n g
2. R e m o v e the rear c o n s o l e ( s e e p a g e 20-82). t h e s t e e r i n g w h e e l for 10 ft (3 m ) or m o r e , t h e n park
t h e v e h i c l e o n a flat a n d l e v e l s u r f a c e w h i l e h o l d i n g
3. D i s c o n n e c t the s e n s o r c l u s t e r 6 P c o n n e c t o r (A). t h e s t e e r i n g w h e e l at straight p o s i t i o n .
6 x 1.0 m m
9.8 N-m 2. W i t h t h e ignition s w i t c h at L O C K (0), c o n n e c t the
(1.0 k g f m , 7.2 Ibf-ft) H D S to t h e d a t a link c o n n e c t o r ( D L C ) (A) u n d e r the
4. R e m o v e t h e s e n s o r c l u s t e r (B). 4. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h t h e v e h i c l e
a n d t h e V S A m o d u l a t o r - c o n t r o l unit. If it d o e s n ' t ,
5. Install the s e n s o r in t h e r e v e r s e o r d e r of r e m o v a l . t r o u b l e s h o o t t h e D L C circuit ( s e e p a g e 11-367).
6. D o t h e V S A s e n s o r neutral position m e m o r i z a t i o n 5. D o t h e V S A s e n s o r neutral position m e m o r i z a t i o n

( s e e p a g e 19-125). in t h e V S A A D J U S T M E N T w i t h t h e H D S .
N O T E : S e e t h e H D S H e l p m e n u for s p e c i f i c
instructions.
19-125
VSA OFF Switch Test
1. R e m o v e the i n s t r u m e n t p a n e l ( s e e p a g e 20-84). 4. C h e c k for continuity b e t w e e n V S A O F F s w i t c h 6 P

c o n n e c t o r t e r m i n a l s N o . 2 a n d No. 3. T h e r e s h o u l d
2. R e m o v e the V S A O F F s w i t c h (A) b y p u s h i n g f r o m be continuity at all t i m e s .
t h e b a c k s i d e of the i n s t r u m e n t p a n e l .
V S A O F F S W I T C H 6P C O N N E C T O R
ILL ( + ) ILL (-)
3. C h e c k for continuity b e t w e e n V S A O F F s w i t c h 6 P
c o n n e c t o r t e r m i n a l s N o . 1 a n d No. 6. T h e r e s h o u l d
be c o n t i n u i t y w h e n t h e s w i t c h is p r e s s e d , a n d no
c o n t i n u i t y w h e n the s w i t c h is r e l e a s e d .
V S A O F F S W I T C H 6P C O N N E C T O R
VSA OFF SW
1 2
3 f
// 6
GND
T e r m i n a l side of f e m a l e t e r m i n a l s
19-126
VSA Modulator-Control Unit Removal and Installation
NOTE:
• D o not s p i l l b r a k e fluid o n t h e v e h i c l e ; it m a y d a m a g e t h e paint; if b r a k e fluid g e t s o n t h e paint, w a s h it off
• B e c a r e f u l not to d a m a g e or d e f o r m t h e brake lines d u r i n g r e m o v a l a n d i n s t a l l a t i o n .
• T o p r e v e n t t h e brake fluid f r o m f l o w i n g , p l u g a n d c o v e r t h e h o s e e n d s a n d j o i n t s w i t h a s h o p t o w e l or e q u i v a l e n t
material.
Removal
2. Pull d o w n t h e lock (A) o n the V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r (B), a n d r e m o v e t h e c o n n e c t o r .
15 N m T o left f r o n t
(1.5 k g f m ,
T o master cylinder 11Ibfft) T o right front
T o master cylinder
22 N m
(2.2 k g f m , 16 Ibf ft)
15 N-m
(1.5 k g f m ,
11 I b f f t )
left r e a r
9.8 N m
(1.0 k g f m , 7.2 I b f f t )
9.8 N - m
(1.0 k g f m , 7.2 I b f f t )
3. D i s c o n n e c t the s i x brake l i n e s f r o m t h e V S A m o d u l a t o r - c o n t r o l unit (C).
4. R e m o v e t h e V S A m o d u l a t o r - c o n t r o l unit w i t h t h e bracket (D) f r o m t h e b o d y .
5 . R e m o v e t h e V S A m o d u l a t o r - c o n t r o l unit f r o m t h e bracket.
(cont'd)
19-127
VSA Modulator-Control Unit Removal and Installation (cont'd)
Installation
1. Install t h e V S A m o d u l a t o r - c o n t r o l unit o n t h e b r a c k e t .
2. Install t h e b r a c k e t w i t h t h e V S A m o d u l a t o r - c o n t r o l unit to t h e b o d y .
3. R e c o n n e c t t h e s i x b r a k e l i n e s , t h e n t i g h t e n t h e f l a r e n u t s to t h e s p e c i f i e d t o r q u e .
4. A l i g n t h e c o n n e c t i n g s u r f a c e of t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r to the V S A m o d u l a t o r - c o n t r o l unit.
5. Pull up t h e lock of t h e V S A m o d u l a t o r - c o n t r o l unit 4 7 P c o n n e c t o r , t h e n c o n f i r m t h e c o n n e c t o r is fully s e a t e d .
6. B l e e d t h e b r a k e s y s t e m ( s e e p a g e 19-9).
7. D o t h e V S A s e n s o r neutral p o s i t i o n m e m o r i z a t i o n ( s e e p a g e 19-125).
8. S t a r t t h e e n g i n e , a n d c h e c k that t h e A B S a n d V S A i n d i c a t o r s g o off.
9. T e s t - d r i v e t h e v e h i c l e , a n d c h e c k that t h e A B S a n d V S A i n d i c a t o r s d o not c o m e o n .
N O T E : If t h e b r a k e p e d a l is s p o n g y , t h e r e m a y b e air t r a p p e d in t h e m o d u l a t o r a n d t h e n i n d u c e d in to t h e n o r m a l
b r a k e s y s t e m d u r i n g m o d u l a t i o n . B l e e d t h e b r a k e s y s t e m a g a i n ( s e e p a g e 19-9).
19-128
Wheel Speed Sensor Inspection Wheel Speed Sensor Replacement
1. I n s p e c t t h e front a n d r e a r p u l s e r s for c h i p p e d or N O T E : Install t h e s e n s o r s c a r e f u l l y to a v o i d t w i s t i n g t h e

d a m a g e d teeth. wires.
2 . M e a s u r e t h e air g a p b e t w e e n t h e w h e e l s p e e d Front
s e n s o r a n d p u l s e r all t h e w a y a r o u n d w h i l e rotating
9 . 8 N - m (1.0 k g f m , 7.2 Ibf ft)
t h e p u l s e r . R e m o v e t h e r e a r b r a k e d i s c to m e a s u r e
t h e g a p o n t h e rear w h e e l s p e e d s e n s o r . If t h e g a p
e x c e e d s 1.0 m m (0.04 in.), c h e c k for a bent
suspension arm.
Standard:
F r o n t / R e a r : 0 . 4 — 1 . 0 m m (0.02—0.04 in.)
Front/Rear
0.4—1.0 m m
( 0 . 0 2 - 0 . 0 4 in.)
9 . 8 N - m (1.0 k g f m , 7.2 Ibf-ft)
Rear
9.8 N-m
(1.0 k g f - m , 7.2 Ibf-ft)
(1.0 k g f m ,
7.2 I b f f t l
WHEEL SPEED SENSOR
19-129
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If body maintenance is required)
T h e S 2 0 0 0 S R S i n c l u d e s a d r i v e r ' s a i r b a g in t h e s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in t h e d a s h b o a r d a b o v e t h e
g l o v e b o x , a n d s e a t belt t e n s i o n e r s in t h e s e a t belt retractors. I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e t h e S R S is
S R S c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , or replacing t h e s e items requires special precautions a n d tools, and
should be done by a n authorized Honda dealer.
• T o a v o i d r e n d e r i n g t h e S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury o r d e a t h in t h e e v e n t of a s e v e r e frontal
c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d be d o n e by a n a u t h o r i z e d H o n d a d e a l e r .
• I m p r o p e r s e r v i c e p r o c e d u r e s , i n c l u d i n g i n c o r r e c t r e m o v a l a n d installation of t h e S R S , c o u l d l e a d to p e r s o n a l injury
• D o not b u m p or i m p a c t t h e S R S unit, or front i m p a c t s e n s o r s w h e n t h e ignition s w i t c h is O N (II), or for at l e a s t 3
• S R S e l e c t r i c a l c o n n e c t o r s a r e identified by y e l l o w c o l o r c o d i n g . R e l a t e d c o m p o n e n t s a r e l o c a t e d in t h e s t e e r i n g
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e b o x . D o not u s e e l e c t r i c a l
Body
Special T o o l s ... 20-2 Convertible T o p Lock Handle
Replacement 20-50
Doors Convertible T o p Lock Handle
C o m p o n e n t Location Index 20-3 Operation Load Adjustment 20-50
Door Panel Removal/Installation 20-5 Convertible T o p Motor Replacement 20-51
Door Outer Handle Replacement 20-6 Convertible T o p Striker Replacement 20-51
Door Latch Replacement 20-8 A-Pillar-Header Weatherstrip and
Door G l a s s and Regulator A-Pillar Molding Replacement 20-52
Replacement 20-9 B-PNIar Outer Weatherstrip
Door G l a s s Adjustment 20-12 Replacement 20-53
Door S a s h Holder Replacement 20-16 Drain Tank and L o w e r Drain Hose
Door S a s h Holder Adjustment 20-17 Replacement 20-53
Door G l a s s Outer Weatherstrip Convertible T o p C o v e r S n a p
Replacement 20-17 Replacement 20-54
Door Weatherstrip Replacement 20-18
Door W e d g e and Door W e d g e Holder Removable Hardtop
Replacement 20-18 C o m p o n e n t Location Index 20-55
Door Position a n d Door Striker Interior T r i m Removal/Installation 20-56
Adjustment 20-19 Headliner Removal/Installation 20-57
Roof Molding Replacement 20-58
Mirrors Hardtop L o w e r Weatherstrip
C o m p o n e n t Location Index 20-21 Replacement 20-61
Power Mirror Replacement 20-22 Roof Front Trim Replacement 20-62
Mirror Holder Replacement 20-22 Hardtop Lock Handle Replacement 20-62
R e a r v i e w Mirror Replacement 20-23 Roof S i d e Lock Replacement 20-63
Hardtop Striker Replacement 20-64
Glass Body S i d e Catch A s s e m b l y
C o m p o n e n t Location Index 20-24 Replacement 20-64
G l a s s Replacement Process 20-26 Body S i d e Catch Replacement 20-65
Windshield Replacement 20-30 Roof Position Adjustment 20-66
Rear W i n d o w Replacement 20-33
Interior Trim
Convertible Top C o m p o n e n t Location Index 20-68
C o m p o n e n t Location Index 20-36 Trim Removal/Installation
Convertible T o p A s s e m b l y -Front Roof A r e a 20-70
Replacement 20-39 Trim Removal/Installation
Convertible T o p Cloth Replacement 20-41 -Door A r e a s 20-71
Rear W i n d o w Replacement 20-44 T r i m Removal/Installation
Rear W i n d o w L o w e r Molding/ -Seat Side Area 20-72
Rear W i n d o w Harness Holder T r i m Removal/Installation
Replacement 20-48 -Rear T r a y A r e a 20-73
Convertible T o p Cloth Repair 20-49 Trim Removal/Installation
-Trunk A r e a 20-77
Carpet Replacement 20-78
* Center Carpet Replacement 20-79
Consoles Exterior Trim
Center Console Removal/Installation 20-80 Cowl Cover Replacement 20-119
W i n d Deflector Replacement 20-81 Rear T r a y Opening Molding
Rear Console Removal/Installation 20-82 Replacement 20-120
Rear Console Box Replacement 20-83 Rear W i n d o w Lower Molding
Replacement 20-120
Dashboard Trunk Lid Spoiler Replacement 20-121
Instrument Panel Removal/Installation .... 20-84 E m b l e m Replacement 20-124
Radio Panel Removal/Installation 20-84 A-Pillar Exterior T r i m Replacement 20-126
Front Console Cover
Removal/Installation 20-85 Fenderwell
Driver's Dashboard Lower Cover Inner Fender Replacement 20-127
Removal/Installation 20-85 Strake Replacement 20-128
Passenger's Dashboard Lower C o v e r Fenderwell Trim Replacement 20-129
Removal/Installation 20-86 Rear Air Outlet Replacement 20-129
P a s s e n g e r ' s Side Vent
Removal/Installation 20-87 Openers
* Dashboard Removal/Installation 20-87 Component Location Index 20-130
Hood Opener Cable Replacement 20-131
Seats Fuel Fill Door Opener C a b l e
Component Location Index 20-90 Replacement 20-132
* S e a t Removal/Installation 20-92 Hood Release Handle Replacement 20-133
* Seat Disassembly/Reassembly Hood Latch Replacement 20-133
-Driver's 20-95 Trunk Lid Latch Replacement 20-134
* Seat Disassembly/Reassembly Trunk Lid Lock Cylinder Replacement 20-135
-Passenger's 20-97
S e a t Cover Replacement 20-99 Frame
Front S u b f r a m e Replacement 20-136
Bumpers Rear S u b f r a m e Replacement 20-137
Front Bumper Removal/Installation 20-104 F r a m e Brace Replacement 20-138
Front Air Spoiler Replacement 20-107 Frame Repair Chart 20-140
Front Grille Replacement 20-108
Rear Bumper Removal/Installation 20-110
Hood
Hood Adjustment 20-111
Hood Insulator Replacement 20-113
Trunk Lid
Trunk Lid Adjustment 20-114
Trunk Lid Torsion Bar Replacement 20-115
Trunk Lid Rubber Protector
Replacement 20-116
Trunk Lid Weatherstrip Replacement 20-117
Fuel Fill Door

Fuel Fill Door Adjustment 20-118
Body
Special Tools

© 07 A A F - S N A A 1 0 0 Torsion Bar A s s e m b l y Tool 1
20-2
Doors
Component Location index
DOOR GLASS OUTER

WEATHERSTRIP
HINGE
HINGE
PLASTIC COVER
COLLAR
'04-08 m o d e l s )
SWITCH PANEL Jx^>
POWER WINDOW
SWITCH POWER MIRROR
SWITCH
NET DOOR PANEL

('04-08 m o d e l s ) ('04-08 m o d e l s s h a p e )
(cont'd)
20-3
Doors
IMMOBILIZER LABEL DOOR G L A S S

('00-01 m o d e l s ) R e p l a c e m e n t page 20-9
A d j u s t m e n t , page 20-12
IMMOBILIZER LABEL
('02-08 m o d e l s )
DOOR S A S H HOLDER
Replacement
page 20-16
Adjustment
STABILIZER page 20-17
G L A S S STABILIZER
DOOR GLASS
REGULATOR
Replacement
p a g e 20-9
REGULATOR
LOWER PATCH
DOOR OUTER HANDLE
OUTER HANDLE
PROTECTOR ROD ROD CRANK
FRONT LOCK ROD
DOOR STRIKER
Adjustment
p a g e 20-19
DOOR LATCH
Replacement
p a g e 20-8
POWER DOOR
INNER HANDLE
LOCK ACTUATOR
INNER HANDLE C A S E
20-4
Door Panel Removal/Installation
• K T C trim tool set S O J A T P 2 0 1 4 *
• T r i m p a d r e m o v e r , S n a p - o n A 177A or e q u i v a l e n t , c o m m e r c i a l l y a v a i l a b l e
• A v a i l a b l e t h r o u g h the A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; c a l l 8 8 8 - 4 2 4 - 6 8 5 7
NOTE:
• T a k e c a r e not to s c r a t c h t h e d o o r panel a n d d o o r .
• U s e the a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to a v o i d d a m a g e w h e n p r y i n g c o m p o n e n t s .
1. R e m o v e t h e d o o r p a n e l in t h e n u m b e r e d s e q u e n c e . R e m o v e t h e d o o r p a n e l w i t h a s little b e n d i n g a s p o s s i b l e to
a v o i d c r e a s i n g or b r e a k i n g it.
2. Install t h e p a n e l in the r e v e r s e order of r e m o v a l , a n d note t h e s e i t e m s :
• C h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s - w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h n e w o n e s .
• M a k e s u r e the c o n n e c t o r s a r e p l u g g e d in properly.
• P u s h t h e c l i p s into p l a c e s e c u r e l y .
• C h e c k t h e w i n d o w a n d p o w e r d o o r lock o p e r a t i o n s .
• W h e n reinstalling the d o o r p a n e l , m a k e s u r e t h e plastic c o v e r i s i n s t a l l e d p r o p e r l y a n d s e a l e d a r o u n d its o u t s i d e
p e r i m e t e r to s e a l out w a t e r .
• C h e c k for water leaks.
Fastener Locations
A ^ : Screw, 1 : Screw, 1 C ^ : Screw, 1 D|>:Clip, 1 E>:Clip, 6
(D Pull the inner

handle.
CD CAP
20-5
Doors
Door Outer Handle Replacement
NOTE:
• Put o n g l o v e s to protect y o u r h a n d s .
• T a k e c a r e not to s c r a t c h t h e d o o r .
• T a k e c a r e not to b e n d t h e r o d s .
1. R e m o v e t h e s e i t e m s :
• D o o r p a n e l ( s e e p a g e 20-5)
• P l a s t i c c o v e r , a s n e c e s s a r y ( s e e p a g e 20-3)
2 . R e m o v e the d o o r outer h a n d l e in t h e n u m b e r e d s e q u e n c e .
3. Install the outer h a n d l e in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :

• M a k e s u r e t h e c y l i n d e r s w i t c h h a r n e s s is r o u t e d p r o p e r l y .
• M a k e s u r e t h e c y l i n d e r s w i t c h c o n n e c t o r is p l u g g e d in p r o p e r l y , a n d t h e r o d s a r e c o n n e c t e d s e c u r e l y .
• W h e n installing t h e lock c y l i n d e r , l e a v e the o u t e r h a n d l e bolts l o o s e s o the o u t e r h a n d l e protector d o e s not
interfere w i t h the lock c y l i n d e r installation, t h e n t i g h t e n t h e h a n d l e bolts.
• Install t h e retainer c l i p o n the outer h a n d l e , t h e n install the lock c y l i n d e r . B e s u r e t h e retainer clip is fully s e a t e d
in the s l o t o n the lock c y l i n d e r .
• Make s u r e the door locks a n d o p e n s properly.
• W h e n r e i n s t a l l i n g t h e d o o r p a n e l , m a k e s u r e t h e p l a s t i c c o v e r is i n s t a l l e d p r o p e r l y a n d s e a l e d a r o u n d its o u t s i d e
• C h e c k for w a t e r l e a k s .
Fastener Locations
20-6
Fastener Locations
C#:Nut,1 D^»:Bolt,1 E^:Bolt,1 F • :Screw, 1 G • :Screw, 2
(%»)»)»»)»)) fib»
• ® T u r n the outer handle,

a n d r e m o v e it f r o m t h e o u t e r h a n d l e r o d .
OUTER HANDLE
Before r e m o v i n g the joint, m a r k
the outer h a n d l e rod to s h o w the
original adjustment.
OUTER HANDLE ROD
OUTER HANDLE
PROTECTOR ROD
6 x 1.0 m m
9.8 N - m
(1.0 k g f m ,
7.2 I b f f t )
6 x 1.0 m m
9.8 N - m (1.0 k g f m ,
7.2 I b f f t )
6 x 1.0 m m
9.8 N - m (1.0 k g f m ,
7.2 I b f f t )
)6x1.0 mm
6 N - m (0.6 k g f m
4 Ibfft)
LATCH
20-7
Doors
Door Latch Replacement
NOTE:
• T a k e c a r e not to s c r a t c h the d o o r .
• T a k e c a r e not to b e n d t h e r o d s .
1. R e m o v e t h e outer h a n d l e ( s e e p a g e 20-6).
2. R e m o v e t h e d o o r latch In t h e n u m b e r e d s e q u e n c e .
3. Install t h e latch in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e a c t u a t o r c o n n e c t o r s a r e p l u g g e d in p r o p e r l y , a n d e a c h rod is c o n n e c t e d s e c u r e l y .
• Make s u r e the door locks a n d o p e n s properly.
• W h e n reinstalling t h e d o o r p a n e l , m a k e s u r e t h e p l a s t i c c o v e r is i n s t a l l e d p r o p e r l y a n d s e a l e d a r o u n d its o u t s i d e
p e r i m e t e r to s e a ! out w a t e r .
lock r o d .
20-8
Door Glass and Regulator Replacement
NOTE:
• T a k e c a r e not to d r o p t h e w i n d o w g l a s s i n s i d e t h e d o o r .
• I n n e r h a n d l e a n d rod c r a n k ( s e e p a g e 20-8)
• P l a s t i c c o v e r ( s e e p a g e 20-3)
2. R e m o v e the d o o r g l a s s a n d regulator in n u m b e r e d s e q u e n c e :
• H o l d t h e a d j u s t i n g bolts w i t h a h e x w r e n c h w h e n r e m o v i n g t h e l o c k n u t s .
• M a r k a line a r o u n d t h e stabilizer m o u n t i n g bolt, t h e g l a s s m o u n t i n g bolts, a n d t h e r e g u l a t o r m o u n t i n g n u t s to
s h o w the original l o c a t i o n s .
4 Ibf ft)
(cont'd)
20-9
Doors
Door Glass and Regulator Replacement (cont'd)
Fastener Locations
B • : Bolt, 3
20-10
Fastener Locations
C#:Nut,2 D#:Nut,2 E ^ :Bolt,3 F ^ : Bolt,2
M a r k a line a r o u n d t h e n u t s
8 x 1.25 m m
12 N - m (1.2 k g f m ,
8.7 I b f f t )
REGULATOR
LOWER PATCH
6x1.0 mm
8 N m (0.8 k g f i
6 Ibfft)
6 x 1.0 m m
8 N m
(0.8 k g f m ,
6 Ibfft)
Loosen.
) HARNESS
CLIP
Detach.
)LOCKNUT
8 x 1.25 m m
12 N-m (1.2 k g f m ,
ADJUSTING BOLT
8.7 I b f f t )
3. Install t h e g l a s s a n d regulator in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• Hold t h e a d j u s t i n g bolts w i t h a h e x w r e n c h w h e n installing t h e l o c k n u t s .

• B e f o r e installing t h e regulator, a p p l y m u l t i p u r p o s e g r e a s e to all t h e s l i d i n g s u r f a c e s of t h e regulator.
• M a k e s u r e t h e c o n n e c t o r is p l u g g e d in p r o p e r l y .
• Roll t h e g l a s s u p a n d d o w n to s e e if it m o v e s f r e e l y w i t h o u t b i n d i n g .
• M a k e s u r e that t h e r e i s n o c l e a r a n c e b e t w e e n t h e g l a s s a n d roof w e a t h e r s t r i p s w h e n t h e g l a s s i s c l o s e d .
• A d j u s t t h e position of t h e g l a s s a s n e c e s s a r y ( s e e p a g e 20-12).
• W h e n reinstalling the d o o r p a n e l , m a k e s u r e t h e p l a s t i c c o v e r is i n s t a l l e d p r o p e r l y a n d s e a l e d a r o u n d its o u t s i d e
• C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15).
• T e s t - d r i v e a n d c h e c k for w i n d n o i s e a n d rattles.
20-11
Doors
Door Glass Adjustment
NOTE:
• C h e c k t h e A - p i l l a r - h e a d e r w e a t h e r s t r i p , roof M e a s u r i n g Point A
w e a t h e r s t r i p s a n d B-pillar w e a t h e r s t r i p for d a m a g e or
d e t e r i o r a t i o n , a n d r e p l a c e t h e m if n e c e s s a r y .
• W i p e e a c h w e a t h e r s t r i p a n d t h e front l o w e r c h a n n e l
clean with a s h o p towel.
• L u b r i c a t e t h e front l o w e r c h a n n e l w i t h S h i n - E t s u
s i l i c o n e g r e a s e P/N 0 8 7 9 8 - 9 0 1 3 .
1. P l a c e t h e v e h i c l e o n a f i r m , l e v e l s u r f a c e .
2. S e c u r e t h e c o n v e r t i b l e top w i t h both c o n v e r t i b l e
t o p lock h a n d l e s . M a k e s u r e t h e y a r e l o c k e d
securely.
3. L o w e r t h e g l a s s fully.
• D o o r p a n e l ( s e e p a g e 20-5)
• P l a s t i c c o v e r ( s e e p a g e 20-3)
• A - p i l l a r - h e a d e r w e a t h e r s t r i p , pillar portion
( s e e p a g e 20-52)
• R o o f s i d e w e a t h e r s t r i p ( s e e p a g e 20-41)
" B " Clearance
• R o o f c o r n e r w e a t h e r s t r i p ( s e e p a g e 20-36)
• B-pillar w e a t h e r s t r i p ( s e e p a g e 20-41) M e a s u r i n g Point C
5. C l o s e t h e door. C h e c k t h e d o o r fit to t h e b o d y
opening.
6. R a i s e t h e g l a s s fully.
7. A t t h e m e a s u r i n g p o i n t s (A, B , C ) , m e a s u r e a n d
record c l e a r a n c e s " H " and " B " between the g l a s s
" H " Clearance
(D) a n d t h e m o l d i n g (E) a n d t h e g l a s s a n d t h e
r e t a i n e r (F). A d j u s t t h e c l e a r a n c e a s d e s c r i b e d in
s t e p s 9 thru 10. Clearance (Standard clearance)
Unit: m m (in.)
B
M e a s u r i n g Point A B C
Clearance "H" 4 3 8
(0.16) (0.11) (0.31)
"B" 11 14 18
(0.43) (0.55) (0.71)
8. M o v e t h e d o o r s a s h h o l d e r all the w a y f o r w a r d
( s e e p a g e 20-16).
20-12
9. Adjust clearance " H " a s follows:
-1 L o o s e n the bolts (A) s e c u r i n g the s t o p p l a t e s (B).

- 2 L o o s e n the bolts (C) s e c u r i n g the g l a s s (D).
-3 M o v e the g l a s s u p or d o w n , a s w e l l a s , f o r w a r d a n d r e a r w a r d t o a l i g n it w i t h t h e retainer a n d m o l d i n g . M o v e
t h e g l a s s until c l e a r a n c e " H " is within the s p e c i f i e d limits.
-4 T i g h t e n the bolts s e c u r i n g t h e g l a s s .
-6 P r e s s the s t o p p l a t e s a g a i n s t the g l a s s s t o p s ( E ) .
- 6 F a s t e n the s t o p p l a t e s . C h e c k that the s t o p p l a t e s c o n t a c t t h e g l a s s s t o p s e v e n l y .
(cont'd)
20-13
Doors
Door Glass Adjustment (cont'd)
10. A d j u s t c l e a r a n c e "B" a s f o l l o w s :
-1 P u s h t h e g l a s s (A) o u t w a r d 10 m m (0.39 in.), t h e n lightly p u s h t h e stabilizer ( B ) a g a i n s t the g l a s s .

-2 T i g h t e n t h e bolt (C) s e c u r i n g t h e stabilizer. C h e c k t h a t the g l a s s m o v e s s m o o t h l y .
-3 L o o s e n t h e l o c k n u t s (D).
-4 T u r n t h e a d j u s t i n g bolts (E) until t h e c l e a r a n c e "B" is w i t h i n the s p e c i f i e d limits. T u r n t h e front a n d rear
a d j u s t i n g bolts t h e s a m e a m o u n t to k e e p t h e r e g u l a t o r (F) parallel w i t h t h e s e a t i n g s u r f a c e of t h e door.
-5 T i g h t e n t h e l o c k n u t s . M a k e s u r e t h a t the e n d s of t h e a d j u s t i n g bolts still project o u t of t h e l o c k n u t s .
-6 M o v e the g l a s s u p a n d d o w n to s e a t it, t h e n m e a s u r e c l e a r a n c e "B" at t h e d e s i g n a t e d l o c a t i o n s .
-7 M e a s u r e c l e a r a n c e " H " a g a i n to m a k e s u r e it is still w i t h i n t h e s p e c i f i e d limits at t h e d e s i g n a t e d l o c a t i o n s .
R e p e a t t h e a b o v e s t e p s until the c o r r e c t c l e a r a n c e s a r e o b t a i n e d .
Adjusting Bolt T o p E d g e of G l a s s
Clockwise Moved out
Counterclockwise •=> M o v e d in
20-14
11. A l i g n the d o o r s a s h holder w i t h t h e g l a s s u s i n g t h e 15. A t t a c h t h e p l a s t i c c o v e r m a k i n g s u r e it is s e a l e d
a d j u s t i n g bolt at t h e bottom of t h e d o o r s a s h h o l d e r a r o u n d its o u t s i d e p e r i m e t e r to s e a l out w a t e r , t h e n
( s e e p a g e 20-17). install t h e d o o r p a n e l ( s e e p a g e 20-5).
12. After the c l e a r a n c e s h a v e b e e n a d j u s t e d p r o p e r l y , 16. M a k e s u r e that t h e top is l o c k e d s e c u r e l y , t h e n r a i s e

reinstall e a c h w e a t h e r s t r i p . t h e g l a s s fully, a n d c l o s e the d o o r s .
13. C h e c k that t h e g l a s s m o v e s s m o o t h l y . 17. C h e c k for w a t e r l e a k s . R u n w a t e r o v e r t h e roof a n d

o n the s e a l i n g a r e a a s s h o w n , a n d note t h e s e i t e m s :
14. R a i s e the g l a s s (A) fully, a n d c h e c k that t h e g l a s s
c o n t a c t s e a c h w e a t h e r s t r i p (B) e v e n l y . M e a s u r i n g • U s e a 12 m m (1/2 in.) d i a m e t e r h o s e (A).
p o i n t s a r e d e s c r i b e d at s t e p 7. • A d j u s t t h e rate of w a t e r f l o w (B).
• D o not u s e a nozzle.
F r o n t roof pillar • Hold t h e h o s e a b o u t 300 m m (12 in.) a w a y f r o m
the door.
12 m m ( 1 / 2 in.) f'i
1 5 0 m m (6 in.)
Roof
3 0 0 m m ( 1 2 in.)
B-pillar
18. If t h e r e a r e l e a k s , r e c h e c k the w o r k p e r f o r m e d , a n d
check the door g l a s s , weatherstrip, A-pillar molding,
a n d retainer a d j u s t m e n t .
19. T e s t - d r i v e a n d c h e c k for w i n d n o i s e .
20-15
Doors
Door Sash Holder Replacement
NOTE:
•1. R e m o v e t h e s e i t e m s :
• D o o r g l a s s ( s e e p a g e 20-9)
• D o o r w e a t h e r s t r i p , a s n e c e s s a r y ( s e e p a g e 20-18)
2. R e m o v e t h e d o o r s a s h h o l d e r in t h e n u m b e r e d s e q u e n c e :
• H o l d t h e a d j u s t i n g bolt w i t h a h e x w r e n c h w h e n r e m o v i n g t h e locknut.
• M a r k a line a r o u n d t h e locknut to s h o w t h e o r i g i n a l a d j u s t m e n t .
3. Install t h e h o l d e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• A d j u s t t h e p o s i t i o n of t h e d o o r s a s h h o l d e r ( s e e p a g e 20-17).
• W h e n reinstalling t h e d o o r p a n e l , m a k e s u r e t h e p l a s t i c c o v e r i s i n s t a l l e d p r o p e r l y a n d s e a l e d a r o u n d its o u t s i d e
Fastener Locations
A • : Screw, 4 B • : Bolt, 2 C # . Nut, 1
©SPEAKER
20-16
Door Sash Holder Adjustment Door Glass Outer Weatherstrip
Replacement
1. R a i s e the g l a s s fully.
2. L o o s e n t h e locknut (A) w h i l e holding t h e a d j u s t i n g NOTE:

bolt (B) w i t h a h e x w r e n c h . • Put o n g l o v e s to protect y o u r h a n d s .
• T a k e c a r e not to s c r a t c h t h e d o o r a n d d o o r m o l d i n g .
A d j u s t i n g Bolt T o p E d g e of Holder
1. R e m o v e t h e d o o r s a s h h o l d e r ( s e e p a g e 2 0 - 1 6 ) .
Clockwise —• Moved out
Counterclockwise •=> M o v e d in 2. S t a r t i n g at t h e r e a r , pry t h e o u t e r w e a t h e r s t r i p (A)

u p , a n d d e t a c h the c l i p s ( B , C ) .
Fastener Locations
B [> : Clip, 1 C>:Clip,6
3. A l i g n t h e d o o r s a s h h o l d e r (C) w i t h t h e g l a s s u s i n g
t h e a d j u s t i n g bolt at t h e bottom of t h e d o o r s a s h
holder. M a k e s u r e that t h e r e is no c l e a r a n c e
b e t w e e n t h e e n d of c h a n n e l (D) a n d g l a s s s u r f a c e .
4. T i g h t e n t h e locknut s e c u r e l y . 3. Install t h e w e a t h e r s t r i p in t h e r e v e r s e o r d e r of
5. R e i n s t a l l all r e m a i n i n g r e m o v e d parts.
• C h e c k if the c l i p s a r e d a m a g e d or s t r e s s -
6. C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15). w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h
new ones.
7. T e s t - d r i v e a n d c h e c k for w i n d n o i s e a n d rattles. • P u s h t h e c l i p s into p l a c e s e c u r e l y .
20-17
Doors
Door Weatherstrip Replacement Door Wedge and Door Wedge
Holder Replacement
NOTE:
• U s e a clip r e m o v e r , to r e m o v e t h e c l i p s . N O T E : T a k e c a r e not to s c r a t c h t h e d o o r a n d body.
1. R e m o v e t h e d o o r p a n e l ( s e e p a g e 20-5). 1. R e m o v e t h e d o o r w e d g e a n d t h e d o o r w e d g e
holder a s s h o w n .
2. R e m o v e t h e d o o r w e a t h e r s t r i p a s s h o w n .
2. Install t h e w e d g e a n d w e d g e h o l d e r in t h e r e v e r s e
3. Install t h e w e a t h e r s t r i p in t h e r e v e r s e o r d e r of o r d e r of r e m o v a l , a n d w h e n installing t h e d o o r
r e m o v a l , a n d note t h e s e i t e m s : w e d g e h o l d e r , a d j u s t it u p o r d o w n until t h e d o o r
w e d g e i s c e n t e r e d in t h e h o l d e r .
• C h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s -
Fastener Locations
w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h
new ones. A • : Screw, 2 B • : Screw, 2
• If t h e o l d w e a t h e r s t r i p w i l l b e r e i n s t a l l e d , s c r a p e to
off all t r a c e s of o l d E P T s e a l e r a n d butyl t a p e ,
then clean the weatherstrip surface with 6 x 1.0 m m
isopropyl alcohol. 9.8 N m (1.0 k g f m ,
• A t t a c h t h e n e w w e a t h e r s t r i p into p l a c e u s i n g E P T 7.2 I b f f t )
s e a l e r a n d butyl t a p e .
• T e s t - d r i v e a n d c h e c k f o r w i n d n o i s e a n d rattles.
Fastener Locations
A ^ : Screw, 2 B>:Clip,2 C > : Clip, 17
EPT SEALER
Thickness: 5 mm (0.2 in.)
Width: 5 mm (0.2 in.)
DOOR WEDGE
DOOR WEDGE
HOLDER
6 x 1.0 m m
9.8 N m
(1.0 k g f m ,
7.2 I b f f t )
DOOR
WEATHERSTRIP
20-18
Door Position and Door Striker Adjustment
NOTE:
• C h e c k for a f l u s h fit w i t h t h e b o d y , t h e n c h e c k for e q u a l g a p s b e t w e e n t h e front, r e a r , a n d bottom d o o r e d g e s a n d t h e
b o d y . C h e c k that t h e d o o r a n d b o d y e d g e s a r e p a r a l l e l .
• P l a c e t h e v e h i c l e o n a f i r m , level s u r f a c e w h e n a d j u s t i n g t h e d o o r .
• S u p p o r t t h e d o o r w i t h a floor j a c k , a n d p l a c e a s h o p t o w e l o n t h e j a c k to p r e v e n t d a m a g e to the door.
1. R e m o v e the d o o r w e d g e h o l d e r (A) ( s e e p a g e 20-18).

D
2. S l i g h t l y l o o s e n the striker m o u n t i n g s c r e w s (B).
3. If n e c e s s a r y , r e p l a c e the d o o r m o u n t i n g bolts (C) a n d h i n g e m o u n t i n g bolts (D) w i t h a d j u s t i n g bolts

(P/N 9 0 1 0 1 - S Z 3 - 0 0 0 ) m a d e s p e c i f i c a l l y for d o o r a d j u s t m e n t .
4. A d j u s t the d o o r a l i g n m e n t in t h i s s e q u e n c e :
• A d j u s t at t h e h i n g e s (E):
- L o o s e n t h e d o o r m o u n t i n g bolts slightly, a n d m o v e the d o o r in or out until it's f l u s h w i t h the b o d y .
- R e m o v e the i n n e r f e n d e r ( s e e p a g e 2 0 - 1 2 6 ) , t h e n slightly l o o s e n t h e h i n g e m o u n t i n g bolts, a n d m o v e the d o o r
b a c k w a r d or f o r w a r d , up or d o w n a s n e c e s s a r y to e q u a l i z e t h e g a p s .
• T u r n the d o o r c u s h i o n s (F) a s n e c e s s a r y to m a k e t h e rear of the d o o r f l u s h w i t h t h e body.
5. M a k e s u r e the d o o r a n d b o d y e d g e s a r e parallel a n d the d o o r is f l u s h w i t h the b o d y . T i g h t e n the d o o r a n d h i n g e

m o u n t i n g bolts, a n d r e c h e c k .
(cont'd)
20-19
Doors
Door Position and Door Striker Adjustment (cont'd)
6. A d j u s t t h e striker (A):
• M o v e t h e striker In or O u t to m a k e t h e latch fit tighter o r l o o s e r .

• M o v e t h e striker U p or D o w n to a l i g n it w i t h t h e latch o p e n i n g .
7. M a k e s u r e t h e d o o r l a t c h e s p r o p e r l y . T i g h t e n t h e s c r e w s ( B ) , a n d r e c h e c k .
8. A l i g n t h e d o o r w e d g e h o l d e r (C) u p or d o w n until t h e d o o r w e d g e (D) is c e n t e r e d in t h e holder. T i g h t e n t h e s c r e w s

(E), a n d recheck.
9. A p p l y m u l t i p u r p o s e g r e a s e to t h e pivot p o r t i o n s of t h e h i n g e s (A) i n d i c a t e d b y t h e a r r o w s .
10. A p p l y t o u c h - u p paint to t h e h i n g e a n d d o o r m o u n t i n g bolts, a n d a r o u n d t h e h i n g e s .
11. C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15).
12. T e s t - d r i v e a n d c h e c k for w i n d n o i s e a n d rattles.
20-20
Mirrors
REARVIEW MIRROR
20-21
Mirrors
Power Mirror Replacement Mirror Holder Replacement
N O T E : T o a v o i d s c r a t c h i n g t h e d o o r , be s u r e to h o l d t h e Special Tools Required

m i r r o r w h i l e r e m o v i n g or installing t h e nuts. K T C t r i m tool s e t S O J A T P 2 0 1 4 *
• Available through the A m e r i c a n Honda Tool a n d
1. R e m o v e t h e s e i t e m s : E q u i p m e n t P r o g r a m ; call 8 8 8 - 4 2 4 - 6 8 5 7
• D o o r s a s h h o l d e r ( s e e p a g e 20-16) NOTE:
• P l a s t i c c o v e r , a s n e c e s s a r y ( s e e p a g e 20-3) • Put o n g l o v e s to protect y o u r h a n d s .
• U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to
2. D i s c o n n e c t the c o n n e c t o r (A), a n d d e t a c h it f r o m avoid d a m a g e w h e n prying c o m p o n e n t s .
the door.
1. C a r e f u l l y p u s h o n the top e d g e of the m i r r o r h o l d e r
Fastener Locations
(A) by h a n d .
C#:Nut,3
2. Put a s h o p t o w e l (B) in the o p e n i n g b e t w e e n t h e

l o w e r e d g e of t h e m i r r o r h o l d e r a n d the m i r r o r
h o u s i n g (C) to p r e v e n t s c r a t c h e s , a n d d e t a c h the
6 x 1.0 m m b o t t o m c l i p s (D) w i t h a t r i m tool.
9.8 N m
(1.0 k g f m , 7.2 Ibf ft)
3. C a r e f u l l y pull out t h e b o t t o m e d g e of t h e m i r r o r
3. S u p p o r t t h e m i r r o r (B) w i t h o n e h a n d , r e m o v e t h e h o l d e r to s e p a r a t e the butyl t a p e ( E ) , a n d t h e n
n u t s ( C ) , t h e n r e m o v e t h e mirror. r e l e a s e t h e s i d e c l i p s (F).
4. Install t h e m i r r o r in t h e r e v e r s e o r d e r of r e m o v a l , 4. S e p a r a t e t h e m i r r o r h o l d e r f r o m t h e a c t u a t o r (G) b y
a n d note t h e s e i t e m s : r e l e a s i n g t h e h o o k s (H).
• M a k e s u r e t h e c o n n e c t o r is p l u g g e d in p r o p e r l y . 5. S c r a p e off old butyl t a p e s , t h e n c l e a n t h e a c t u a t o r

• A d j u s t t h e p o s i t i o n of t h e d o o r s a s h h o l d e r s u r f a c e w i t h i s o p r o p y l a l c o h o l , a n d a p p l y the n e w
( s e e p a g e 20-17). butyl t a p e s to t h e actuator.
• W h e n reinstalling the door panel, make s u r e the
p l a s t i c c o v e r is i n s t a l l e d p r o p e r l y a n d s e a l e d Butyl tape: T h i c k n e s s 1.5 m m (0.059 in.)
a r o u n d its o u t s i d e p e r i m e t e r to s e a l out w a t e r .
• C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15), 6. Insert t h e h o o k s o n t h e m i r r o r h o l d e r into t h e s l o t s
• T e s t - d r i v e a n d c h e c k for w i n d n o i s e a n d rattles. o n t h e actuator. P o s i t i o n t h e m i r r o r h o l d e r o n t h e
a c t u a t o r , a n d c a r e f u l l y p u s h t h e c l i p s into p l a c e .
7. C h e c k t h e actuator o p e r a t i o n .
20-22
Rearview Mirror Replacement

K T C t r i m tool s e t S O J A T P 2 0 1 4 *
• A v a i l a b l e t h r o u g h the A m e r i c a n H o n d a T o o l a n d
E q u i p m e n t P r o g r a m ; call 888-424-6857
NOTE:
• T a k e c a r e not to s c r a t c h the c o v e r a n d mirror s t a y .
• U s e the a p p r o p r i a t e tool f r o m the K T C t r i m tool s e t to
a v o i d d a m a g e w h e n prying c o m p o n e n t s .
1. R e m o v e t h e r e a r v i e w mirror a s s h o w n .
2. Install the m i r r o r in the r e v e r s e o r d e r of r e m o v a l .
MOUNTING LUG
BRACKET COVER
20-23
Glass
Glass Replacement Process, page 20-26

20-24
R e m o v a b l e Hardtop
MOLDING
REAR WINDOW
G l a s s R e p l a c e m e n t Process, page 20-26
20-25
Glass
Glass Replacement Process

NOTE: 6. U s i n g a n a w l , m a k e a hole t h r o u g h t h e a d h e s i v e
• T h i s is g e n e r a l d e s c r i p t i o n of t h e g l a s s r e p l a c e m e n t f r o m i n s i d e the v e h i c l e at the c o r n e r of t h e g l a s s .
process using the windshield a s an e x a m p l e . For the
l o c a t i o n of c l i p s , r u b b e r d a m s , a n d o t h e r d e t a i l s , g o 7. P u s h a p i e c e of p i a n o w i r e t h r o u g h the h o l e , a n d
to t h e part of t h i s m a n u a l that c o v e r s t h e s p e c i f i c w r a p e a c h e n d a r o u n d a p i e c e of w o o d .
glass you are replacing:
- W i n d s h i e l d ( s e e p a g e 20-30) 8. W i t h a h e l p e r o n the o u t s i d e , pull t h e p i a n o w i r e (A)
- R e a r w i n d o w ( s e e p a g e 20-33) b a c k a n d forth in a s a w i n g m o t i o n . Hold the p i a n o
• Put o n g l o v e s to protect y o u r h a n d s . w i r e a s c l o s e to the w i n d s h i e l d a s p o s s i b l e to
• W h e n replacing a broken windshield, a c o m m e r c i a l l y p r e v e n t d a m a g e to t h e b o d y a n d d a s h b o a r d .
a v a i l a b l e w i n d s h i e l d cutter c a n b e efficiently u s e d for C a r e f u l l y cut t h r o u g h the r u b b e r d a m a n d a d h e s i v e
cutting t h e a d h e s i v e . F o r d e t a i l s , f o l l o w t h e a r o u n d t h e entire w i n d s h i e l d .
i n s t r u c t i o n s of t h e tool m a n u f a c t u r e r .
• W e a r e y e protection w h i l e cutting t h e g l a s s a d h e s i v e
with a piano wire.
• C o v e r interior s u r f a c e s to a v o i d d a m a g i n g t h e m .
1. R e m o v e related p a r t s a s n e c e s s a r y ( s e e t h e part of
t h i s m a n u a l that c o v e r s t h e s p e c i f i c g l a s s y o u a r e
replacing).
2. D i s c o n n e c t a n y c o n n e c t o r s f r o m t h e g l a s s
terminals.
3. R e m o v e the m o l d i n g (A) f r o m t h e e d g e of t h e g l a s s
(B). If n e c e s s a r y , c u t t h e m o l d i n g w i t h a utility knife.
4. If t h e old g l a s s will b e r e i n s t a l l e d , m a k e a l i g n m e n t
m a r k s a c r o s s the g l a s s a n d body with a g r e a s e
p e n c i l at f o u r p o i n t s .
5. A p p l y protective t a p e a l o n g t h e e d g e of t h e b o d y
a n d related p a r t s .
20-26
9. C a r e f u l l y r e m o v e the g l a s s . 14. A t t a c h t h e m o l d i n g (A) w i t h a d h e s i v e t a p e (B) to t h e
e d g e of t h e g l a s s (C). B e c a r e f u l not to t o u c h the
10. W i t h a knife, s c r a p e t h e old a d h e s i v e s m o o t h to a g l a s s w h e r e a d h e s i v e will be a p p l i e d .
t h i c k n e s s of a b o u t 2 m m (0.08 in.) o n the b o n d i n g
s u r f a c e a r o u n d t h e entire g l a s s o p e n i n g f l a n g e :
• D o not s c r a p e d o w n to t h e p a i n t e d s u r f a c e of t h e
b o d y ; d a m a g e d paint w i l l interfere with p r o p e r
bonding.
• R e m o v e a n y r e m a i n i n g f a s t e n e r s f r o m the b o d y .
11. C l e a n t h e b o d y b o n d i n g s u r f a c e w i t h a s p o n g e
d a m p e n e d in i s o p r o p y l a l c o h o l . After c l e a n i n g ,
k e e p o i l , g r e a s e a n d w a t e r f r o m getting o n t h e
clean surface.
12. If t h e old g l a s s will be r e i n s t a l l e d , u s e a putty knife

to s c r a p e off all of t h e old a d h e s i v e a n d a n y
r e m a i n i n g parts f r o m the g l a s s . C l e a n t h e i n s i d e
f a c e of the g l a s s with i s o p r o p y l a l c o h o l w h e r e n e w
a d h e s i v e will b e a p p l i e d . M a k e s u r e the b o n d i n g
s u r f a c e is kept f r e e of w a t e r , oil a n d g r e a s e .
13. A t t a c h r u b b e r d a m s (A), f a s t e n e r s (B), a n d other

p a r t s to t h e i n s i d e f a c e of t h e g l a s s (C). B e c a r e f u l
not to t o u c h the g l a s s w h e r e a d h e s i v e will be
applied.
15. Install t h e f a s t e n e r s (A) o n the b o d y .
(cont'd)
20-27
Glass
Glass Replacement Process (cont'd)
16. If n e w g l a s s w i l l b e i n s t a l l e d , s e t t h e g l a s s (A) in t h e 19. W i t h a s p o n g e , c a r e f u l l y a p p l y a light c o a t of b o d y

o p e n i n g , a n d c e n t e r it. M a k e a l i g n m e n t m a r k s (B) p r i m e r to a n y e x p o s e d paint a r o u n d t h e f l a n g e
a c r o s s the g l a s s a n d body with a g r e a s e pencil at w h e r e n e w a d h e s i v e w i l l b e a p p l i e d . L e t the p r i m e r
t h e f o u r p o i n t s s h o w n . B e c a r e f u l not to t o u c h t h e d r y for at l e a s t 10 m i n u t e s :
g l a s s w h e r e a d h e s i v e will be applied.
• D o not a p p l y p r i m e r to a n y r e m a i n i n g original
adhesive on the flange.
• B e c a r e f u l not to m i x u p t h e b o d y a n d g l a s s
primer sponges.
• Never touch the primed surface with your hands.
2 0 . C u t a " V " in t h e e n d of t h e nozzle (A) o n t h e

adhesive cartridge a s s h o w n .
1 0 m m (0.39 in.)
17. R e m o v e t h e g l a s s .
18. W i t h a s p o n g e , a p p l y a light c o a t of g l a s s p r i m e r
a r o u n d t h e e d g e of t h e g l a s s (A), t h e n lightly w i p e it
off w i t h g a u z e o r c h e e s e c l o t h :
• A p p l y g l a s s p r i m e r to t h e m o l d i n g . 7 m m (0.28 in.)
• D o not a p p l y b o d y p r i m e r to t h e g l a s s , a n d d o not
get b o d y a n d g l a s s p r i m e r s p o n g e s m i x e d u p .
• Never touch the primed surfaces with your hands.
If y o u d o , t h e a d h e s i v e m a y not b o n d to t h e g l a s s
p r o p e r l y , c a u s i n g a leak after t h e g l a s s is
installed.
• Keep water, dust, and abrasive materials a w a y
from the primed surfaces.
: Apply glass primer here.
20-28
2 1 . Put t h e c a r t r i d g e in a c a u l k i n g g u n , a n d r u n a b e a d 2 5 . R e i n s t a l l all r e m a i n i n g r e m o v e d p a r t s . Install t h e
of a d h e s i v e (A) a r o u n d t h e e d g e of t h e g l a s s (B) r e a r v i e w m i r r o r after t h e a d h e s i v e h a s d r i e d
b e t w e e n t h e r u b b e r d a m (C) a n d m o l d i n g (D) a s thoroughly.
s h o w n . A p p l y the a d h e s i v e w i t h i n 3 0 m i n u t e s after
a p p l y i n g t h e g l a s s p r i m e r . M a k e a slightly t h i c k e r N O T E : A d v i s e t h e c u s t o m e r not to d o t h e f o l l o w i n g
b e a d at e a c h c o r n e r . t h i n g s for 2 to 3 d a y s :
• S l a m the d o o r s w i t h all t h e w i n d o w s rolled u p .
• Twist the body e x c e s s i v e l y (such a s w h e n going
D in a n d out of d r i v e w a y s at a n a n g l e or d r i v i n g
over rough, uneven roads).
2 2 . U s e s u c t i o n c u p s to hold t h e g l a s s o v e r t h e o p e n i n g ,
a l i g n it w i t h t h e a l i g n m e n t m a r k s m a d e in s t e p 4 or
16, a n d s e t it d o w n o n t h e a d h e s i v e . Lightly p u s h
o n t h e g l a s s until its e d g e s a r e fully s e a t e d o n t h e
a d h e s i v e all t h e w a y a r o u n d .
N O T E : Do not o p e n or c l o s e a n y of the d o o r s for

a b o u t a n h o u r until the a d h e s i v e is dry.
2 3 . S c r a p e or w i p e a n y e x c e s s a d h e s i v e off w i t h a
putty knife o r t o w e l . T o r e m o v e a d h e s i v e f r o m a
painted s u r f a c e o r the g l a s s , w i p e w i t h a soft s h o p
towel d a m p e n e d with isopropyl alcohol.
2 4 . After the a d h e s i v e h a s d r i e d , s p r a y w a t e r o v e r t h e
w i n d s h i e l d a n d c h e c k for l e a k s . M a r k t h e l e a k i n g
a r e a , let the w i n d s h i e l d d r y , t h e n s e a l w i t h s e a l a n t :
• Let the v e h i c l e s t a n d for at l e a s t 4 h o u r s after

w i n d s h i e l d installation. If t h e v e h i c l e h a s to b e
u s e d w i t h i n the first 4 h o u r s , it m u s t be d r i v e n
slowly.
• K e e p the g l a s s d r y for t h e first h o u r after
installation.
20-29
Glass
Windshield Replacement
NOTE:
• Familiarize yourself with the g l a s s replacement p r o c e s s (see page 20-26).
• W h e n r e p l a c i n g a b r o k e n w i n d s h i e l d , a c o m m e r c i a l l y a v a i l a b l e w i n d s h i e l d cutter c a n be efficiently u s e d for cutting
t h e a d h e s i v e . F o r d e t a i l s , f o l l o w t h e i n s t r u c t i o n s of t h e t o o l m a n u f a c t u r e r .
Parts Removal
First r e m o v e t h e s e i t e m s :
• R e a r v i e w m i r r o r ( s e e p a g e 20-23)
• F r o n t roof rail t r i m ( s e e p a g e 20-70)
• W i n d s h i e l d wiper a r m s (see page 22-185)
• C o w l c o v e r (see page 20-119)
Cutting Positions
S l i p p i a n o w i r e t h r o u g h t h e a d h e s i v e at e a c h position a s s h o w n , a n d pull it b a c k a s i n d i c a t e d by the a r r o w s .
20-30
Rubber Dams and Fastener Installation, and Primer Application
• B e s u r e t h e r u b b e r d a m s a n d f a s t e n e r s line up w i t h the a l i g n m e n t m a r k s .
• Attach the rubber d a m s and f a s t e n e r s with a d h e s i v e tape.
• T o attach t h e m o l d i n g , a p p l y p r i m e r to t h e a r e a s b e t w e e n t h e a l i g n m e n t m a r k s of t h e w i n d s h i e l d .
Rubber d a m adhesive tape: T h i c k n e s s 0.16 m m (0.006 in.)

Fastener adhesive tape: T h i c k n e s s 0.4 m m (0.016 in.)
Molding Installation
• B e s u r e t h e a l i g n m e n t m a r k s o n t h e m o l d i n g line up w i t h t h e a l i g n m e n t m a r k s o n t h e w i n d s h i e l d .
• A t t a c h the m o l d i n g w i t h a d h e s i v e t a p e .
• A t t a c h t h e m o l d i n g s e a l s to t h e m o l d i n g .
Molding adhesive tape: T h i c k n e s s 0.8 m m (0.03 in.)
WINDSHIELD MOLDING
(cont'd)
20-31
Glass
Windshield Replacement (cont'd)
Fastener (body side) Installation/Body Primer Application

N O T E : A p p l y b o d y p r i m e r to e x p o s e d painted s u r f a c e s only.
16 m m
: Apply body primer here.
(0.63 in.)
6 m m (0.24 in.)
16 m m (0.63 in,
FASTENER
Glass Primer and Adhesive Application

: Apply glass primer here.
9 m m (0.35 in.)
13 m m (0.51 in.) MOLDING

MOLDING
UPPER RUBBER
DAM
UPPER RUBBER
DAM
1 mm
(0.04 in.)
WINDSHIELD
20-32
Rear Window Replacement
Removable Hardtop
NOTE:
• T o r e m o v e a n d install t h e r e a r w i n d o w , r e m o v e the roof f r o m t h e b o d y .
• P l a c e t h e roof o n p a d d e d s u p p o r t s to p r e v e n t d a m a g e .
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e r e a r w i n d o w .
• F a m i l i a r i z e y o u r s e l f w i t h t h e g l a s s r e p l a c e m e n t p r o c e s s ( s e e p a g e 20-26).
• R e m o v e t h e r e a r w i n d o w a n d m o l d i n g a s a n a s s e m b l y . If t h e m o l d i n g is d a m a g e d , r e p l a c e it.
Parts Removal
R e m o v e these items, and disconnect the rear w i n d o w defogger connectors:
• H e a d l i n e r ( s e e p a g e 20-57)
• R e a r w i n d o w l o w e r t r i m ( s e e p a g e 20-56)
Cutting Positions
S l i p p i a n o w i r e t h r o u g h t h e a d h e s i v e at e a c h position a s s h o w n , a n d pull it b a c k a s i n d i c a t e d b y t h e a r r o w s . F o r t h e
u p p e r p o r t i o n , c u t t h e a d h e s i v e w i t h a utility knife f r o m i n s i d e w h i l e p u s h i n g t h e r e a r w i n d o w out.
(cont'd)
20-33
Glass
Rear Window Replacement (cont'd)
Rubber Dams, Fasteners, and Spacers Installation
• B e s u r e t h e r u b b e r d a m s , f a s t e n e r s , a n d s p a c e r s line u p w i t h t h e a l i g n m e n t m a r k s .
• Attach the upper fastener a n d lower fastener with a d h e s i v e tape.
• Attach the rubber d a m s a n d s p a c e r s with a d h e s i v e tape.
Upper fastener adhesive tape: T h i c k n e s s 0.4 m m (0.016 in.)

Lower fastener adhesive tape: T h i c k n e s s 0.6 m m (0.024 in.)
Rubber d a m a n d spacer adhesive tape: T h i c k n e s s 0.16 m m (0.006 in.)
Molding Installation
T o a t t a c h t h e m o l d i n g , a p p l y a light c o a t of p r i m e r to t h e b o t t o m a r e a o n t h e o u t s i d e of t h e r e a r w i n d o w , a n d attach t h e
molding with urethane a d h e s i v e .
20-34
Fastener (roof side) Installation/Body Primer Application
NOTE:
• A p p l y b o d y p r i m e r to e x p o s e d p a i n t e d s u r f a c e s o n l y .
• Attach the lower fasteners with a d h e s i v e tape.
Lower fastener adhesive tape: T h i c k n e s s 1.6 m m (0.06 in.)
W///// '• Apply body primer here.

Unit: mm (in.)
ALIGNMENT
MARKS
Glass Primer and Adhesive Application

W////> '• PPlY glass primer here.
A
[A] Portion ADHESIVE
MOLDING \ 13(0.51)
Unit: mm (in.)
[A] REAR WINDOW S 2 (0.08)
14 2 --~
(0.55) (0.08) f 8 (0.31)
2 (0.08)
[B] Portion 2 (0.08)

SIDE RUBBER DAM
Inside
4r
MOLDING
[C] Portion
/ALIGNMENT
Inside MARK
12 (0.47)
33.5 35.5
(1.32) (1.4)
SPACER
ICER V /
MOLDING
MOLDING REAR WINDOW
20-35
Convertible Top
'00-01 M o d e l s
CONVERTIBLE TOP CLOTH

Repair, page 20-49
REPAIR C L O T H REAR WINDOW

(P/N 86321-S2A-003) Replacement, CONVERTIBLE TOP
page 20-44 COVER
CONVERTIBLE TOP
COVER SNAP
Replacement,
page 20-54
RAIN RAIL
SIDE CONVERTIBLE TOP

RETAINER
CONVERTIBLE TOP
LOCK HANDLE
Replacement,
page 20-50
Operation Load Adjustment B-PILLAR
page 20-50
WEATHERSTRIP
CONVERTIBLE TOP
ASSEMBLY
Replacement,
page 20-39
CONVERTIBLE ROOF CORNER

TOP MOTOR WEATHERSTRIP
Replacement,
p a g e 20-51 ROOF RETAINER
ROOF SIDE
WEATHERSTRIP
20-36
'02-08 M o d e l s
f CONVERTIBLE TOP CLOTH

Repair, page 20-49
REAR WINDOW
REPAIR CLOTH HARNESS HOLDER COVER
(P/N86321-S2A-003)
CONVERTIBLE TOP
COVER
CONVERTIBLE TOP
COVER SNAP
Replacement,
page 20-54
REAR LOWER
CONVERTIBLE TOP
RETAINER
RAIN RAIL
SIDE CONVERTIBLE TOP

RETAINER
CONVERTIBLE TOP
LOCK HANDLE
Replacement,
page 20-50
Operation Load Adjustment, B-PILLAR
page 20-50 WEATHERSTRIP
CONVERTIBLE TOP
ASSEMBLY
Replacement,
page 20-39
CONVERTIBLE ROOF CORNER

TOP MOTOR WEATHERSTRIP
Replacement,
p a g e 20-51 ROOF RETAINER
ROOF SIDE
WEATHERSTRIP
(cont'd)
20-37
Convertible Top
A-PILLAR MOLDING
20-38
Convertible Top Assembly Replacement
NOTE:
• Have an assistant help y o u r e m o v e the convertible top a s s e m b l y .
• T a k e c a r e not to s c r a t c h t h e t o p cloth a n d b o d y .
• If the top d o e s not m o v e w i t h t h e c o n v e r t i b l e top s w i t c h , d i s c o n n e c t the e m e r g e n c y c o n n e c t o r n e a r t h e p a s s e n g e r ' s
kick p a n e l ( s e e p a g e 22-245), a n d m o v e t h e t o p b y h a n d .
1. R e m o v e both r e a r t r a y s i d e t r i m s ( s e e p a g e 20-73).
2. R e m o v e t h e top in the n u m b e r e d s e q u e n c e .
3. Install the c o n v e r t i b l e top in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e the c o n n e c t o r s a r e p l u g g e d in p r o p e r l y .
• C h e c k o p e r a t i o n of the top.
• C h e c k t h a t e a c h top lock h a n d l e w o r k s s m o o t h l y . If n e c e s s a r y , a d j u s t t h e h o o k position ( s e e p a g e 20-50).
• C h e c k that e a c h d o o r g l a s s c o n t a c t s t h e w e a t h e r s t r i p s e v e n l y .
Fastener Locations
A ^ : Bolt,2 B ^ : B o l t , 12 C#:Nut,11 D>:Clip,2

(Body color) (Gold)
(cont'd)
20-39
Convertible Top
Convertible Top Assembly Replacement (cont'd)
Fastener Locations
E ^ : B o l t , 10 F>:Clip,2 G>:Clip,2
'00 m o d e l '01-08 m o d e l s J®
REAR WINDOW
RAIN RAIL
RAIN RAIL
MOLDING
(DCONNECTOR
Disconnect
and detach.
8x1.25 mm
2 9 N-m
(3.0 k g f - m , 2 2 Ibf-ft)
REAR TRAY
OPENING MOLDING
REAR WINDOW DEFOGGER

SUBHARNSS CONNECTOR
('02-08 m o d e l s )
(ft) Release the top rain
rail from the body, and
remove the top assembly.
©CONNECTOR
Disconnect and
detach.
F U E L FILL D O O R
OPENER BRACKET
20-40
Convertible Top Cloth Replacement

KTC t r i m tool s e t S O J A T P 2 0 1 4 *
NOTE:
• T a k e c a r e not to s c r a t c h t h e t o p f r a m e .
• W e a r e y e protection w h e n r e m o v i n g t h e rivets w i t h a drill.
• W h e n r e m o v i n g the rivets, drill h o l e s in t h e rivets with a 4 m m (0.16 in.) drill.
• U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to a v o i d d a m a g e w h e n p r y i n g c o m p o n e n t s .
• T h i s illustration s h o w s t h e left s i d e of t h e v e h i c l e , repeat t h e p r o c e d u r e o n the right s i d e in t h e s a m e m a n n e r .
Cloth Replacement
1. R e m o v e t h e c o n v e r t i b l e top a s s e m b l y ( s e e p a g e 20-39).
2. R e m o v e the c o n v e r t i b l e t o p cloth in t h e n u m b e r e d s e q u e n c e .
3. Install t h e cloth in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :

• T o p r e v e n t w r i n k l e s w h e n installing t h e c l o t h , m a k e s u r e t h e m a t e r i a l i s s t r e t c h e d e v e n l y o v e r the f r a m e before
s e c u r i n g the s c r e w s a n d r i v e t s .
• After installing the c l o t h , reinstall t h e top a s s e m b l y . C h e c k t h e o p e r a t i o n of the t o p , a n d i n s p e c t the cloth for
wrinkles.
• C h e c k that the w e a t h e r s t r i p fits f l u s h .
• C h e c k that e a c h d o o r g l a s s c o n t a c t s the w e a t h e r s t r i p s e v e n l y . If n e c e s s a r y , a d j u s t e a c h retainer ( s e e p a g e 20-12).
Fastener Locations
A • : Screw, 7 B • : Screw, 2 C • : Screw, 12 D>:Clip,2
r Before removing the screws,

scribe a line around the screws.
When reinstalling the retainers,
align them with these marks.
RETAINER
©B-PILLAR
WEATHERSTRIP
(cont'd)
20-41
Convertible Top
Convertible Top Cloth Replacement (cont'd)
Fastener Locations
C • : Screw, 4 E • :Screw, 2 F-*:Rivet,6

(Silver) Removal Installation
RIVET
O u t e r d i a m e t e r : 4 m m ( 0 . 1 6 in.)
Center punch
t h e rivet. DRILL RIVET TOOL
R e m o v e the rivet then

r e m o v e the tension wire.
R e m o v e the screw, and

slip the tension wire through
t h e h o l e in t h e f r a m e .
TENSION
WIRE
® Release the Velcro fastener and

cloth f r o m the rear b o w
('00-01 m o d e l s o n l y ) .
SPRING
(D R e l e a s e t h e t e n s i o n c l o t h b y
releasing the Velcro fastener from ADHESIVE \$
the c e n t e r b o w ('02-08 m o d e l s ) . TAPE
TRIM TOOL
BOW RETAINER
SET PLATE B
CONVERTIBLE TOP CLOTH
CONVERTIBLE TOP FRAME
20-42
Reinstalling the Cloth to each Bow
M a k e s u r e the a l i g n m e n t notch of t h e cloth is in the c e n t e r portion of t h e retainer. After r e i n s t a l l i n g , p r e s s o n t h e

retainers securely.
Center portion
RETAINERS
Cloth and Weatherstrip Check

T h e w e a t h e r s t r i p s h o u l d fit f l u s h .
20-43
Convertible Top
Rear Window Replacement
'00-01 Models 6. O p e n t h e roof, a n d lift u p t h e c e n t e r c o n s o l e

( s e e p a g e 20-80).
NOTE:
• T a k e c a r e not to s c r a t c h t h e t o p f r a m e . 7. R e m o v e t h e r e a r c o n s o l e ( s e e p a g e 20-82) a n d t h e
• W e a r e y e protection w h e n r e m o v i n g t h e r i v e t s w i t h a r e a r c o n s o l e b o x ( s e e p a g e 20-83).
drill.
8. C l o s e t h e roof. R e m o v e t h e r e a r t r a y s i d e t r i m a n d
1. O p e n t h e roof, a n d r e m o v e t h e s e i t e m s : both roll b a r s ( s e e p a g e 20-73).
• S e a t , both s i d e s ( s e e p a g e 20-92) 9. R e m o v e t h e n u t s , t h e n r e m o v e t h e r e a r l o w e r
• D o o r sill t r i m , both s i d e s ( s e e p a g e 20-71) c o n v e r t i b l e top retainer (A), right s i d e c o n v e r t i b l e
• R e a r s i d e t r i m , both s i d e s ( s e e p a g e 20-72) t o p r e t a i n e r (B), a n d left s i d e c o n v e r t i b l e t o p
• Roll b a r l o w e r t r i m , both s i d e s ( s e e p a g e 20-72) retainer (C).
Fastener Locations
2 . C l o s e t h e roof. R e m o v e t h e c l i p s that h o l d t h e r e a r
tray trim, the rear tray side trim, and the rear tray • :Nut,11
(see p a g e 20-73).
3. R e m o v e t h e s p a r e tire c o v e r a n d t h e s p a r e tire.
4. R e m o v e the rear tray a n d the rear tray trim through

the trunk o p e n i n g .
5. Lift t h e c o n v e r t i b l e t o p c l o t h (A) that o v e r l a p s t h e

t o p of t h e r e a r w i n d o w ( B ) , a n d r e m o v e t h e p a t c h
(C) f r o m t h e roof z i p p e r .
20-44
10. O p e n t h e roof h a l f - w a y , a n d r e m o v e t h e c l i p s (A, B) 14. Pull t h e rain rail (A) u p , a n d t u r n it i n s i d e - o u t . W i t h
o n e a c h s i d e of t h e top b e t w e e n t h e q u a r t e r p a n e l t h e rain rail r e s t i n g o n t h e roof ( B ) , drill out t h e
a n d t h e roof. r i v e t s (C) w i t h a 4 m m (0.16 in.) drill (D). T h e
w a s h e r s (E) o n t h e rain rail a r e not r e u s e d .
Fastener Locations
A P>: Clip, 2 B>:Clip,2
15. R e m o v e t h e r a i n rail.
11. P l a c e a f e n d e r c o v e r (A) o n t h e trunk. 16. U s i n g a flat-tip s c r e w d r i v e r , p r y a p a r t t h e

t w o - p i e c e b r a s s rivets (A) h o l d i n g t h e l o w e r roof
(B) to t h e l o w e r part of t h e w i n d o w (C).
12. Lift u p t h e rain rail ( B ) , a n d p l a c e it o n t o p of t h e

fender cover.
13. U s i n g a m a r k e r or w h i t e - o u t , d r a w a c i r c l e (C)
a r o u n d e a c h of t h e 11 a l u m i n u m rivets.
(cont'd)
20-45
Convertible Top
Rear Window Replacement (cont'd)
17. R e l e a s e t h e V e l c r o f a s t e n e r s (A) to e x p o s e t h e 19. Zip t h e n e w w i n d o w (A) onto t h e roof ( B ) , m a k i n g
z i p p e r ( B ) , a n d r e m o v e t h e e n d s t o p s (C) f r o m both s u r e t h e a l i g n m e n t n o t c h e s (C) line u p .
e n d s of t h e z i p p e r . It m a y take s e v e r a l a t t e m p t s to line up the m a r k s .
20. T u r n t h e c o n v e r t i b l e t o p cloth (A) i n s i d e out, a n d

a p p l y a n e w p a t c h (B) o n t h e z i p p e r (C).
M a k e s u r e t h e a l i g n m e n t n o t c h e s (D) a l i g n w i t h t h e
m i d d l e of the r e a r w i n d o w ( E ) .
18. C a r e f u l l y unzip t h e r e a r w i n d o w (D) f r o m t h e roof

( E ) , t h e n r e m o v e t h e w i n d o w . H o l d t h e z i p p e r tight
to k e e p it f r o m falling into a n y c r e v i c e s .
2 1 . P l a c e t h e c o n v e r t i b l e t o p cloth o n t h e r e a r w i n d o w .
20-46
2 2 . S e c u r e t h e l o w e r part of t h e r e a r w i n d o w (A) to t h e 2 4 . S e t the rain rail in p o s i t i o n , a n d install t h e c l i p s
l o w e r part of t h e c o n v e r t i b l e t o p cloth (B) w i t h n e w b e t w e e n t h e q u a r t e r p a n e l a n d t h e roof.
t w o - p i e c e b r a s s rivets (C).
2 5 . R e i n s t a l l t h e left s i d e c o n v e r t i b l e t o p retainer (A),
right s i d e c o n v e r t i b l e top retainer ( B ) , a n d r e a r
l o w e r c o n v e r t i b l e t o p retainer ( C ) .
Fastener Locations
# : N u t , 11
2 3 . A t t a c h t h e c o n v e r t i b l e t o p c l o t h , rear w i n d o w , a n d
rain rail t o g e t h e r w i t h n e w p o p rivets a n d w a s h e r s .
M a k e s u r e the c r u s h e n d of e a c h rivet is f a c i n g t h e
rear of t h e c a r w h e n the rain rail is sitting in p l a c e .
A C
2 6 . R e i n s t a l l all r e m a i n i n g interior c o m p o n e n t s a n d
trim pieces.
2 7 . C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15).
20-47
Convertible Top
Rear Window Lower Molding/Rear Window Harness Holder Replacement
'02-08 Models 4 . A p p l y p r i m e r to t h e a r e a s of t h e r e a r w i n d o w (A)
w h e r e t h e m o l d i n g a n d h a r n e s s h o l d e r will be
NOTE: a t t a c h e d , a n d a p p l y p r i m e r to t h e g r o o v e of t h e
• Put o n g l o v e s to protect y o u r h a n d s . m o l d i n g (B) a n d to t h e h a r n e s s h o l d e r ( C ) . B e s u r e
• T a k e c a r e not to s c r a t c h t h e t o p c l o t h . the h a r n e s s holder lines up with the alignment
• U s e s e a t c o v e r s to a v o i d d a m a g i n g a n y s u r f a c e s . m a r k s (D).
1. L o w e r t h e c o n v e r t i b l e t o p c l o t h b y o p e r a t i n g t h e W///// : Apply primer here.
convertible top.
2 . F r o m outside the rear w i n d o w , r e m o v e the molding

(A) f r o m t h e e d g e of t h e r e a r w i n d o w (B). F r o m
inside the rear w i n d o w , r e m o v e the rear w i n d o w
h a r n e s s h o l d e r c o v e r (C) f r o m t h e r e a r w i n d o w
h a r n e s s h o l d e r (D), a n d d i s c o n n e c t t h e r e a r w i n d o w
defogger connectors (E). R e m o v e the rear w i n d o w
h a r n e s s h o l d e r f r o m t h e i n s i d e f a c e of t h e r e a r
w i n d o w . If n e c e s s a r y , c u t t h e m o l d i n g w i t h a utility
knife.
5 . A t t a c h t h e m o l d i n g a n d h a r n e s s h o l d e r to t h e r e a r
w i n d o w with urethane adhesive.
6. S c r a p e o r w i p e t h e e x c e s s a d h e s i v e off w i t h a putty
knife o r t o w e l . T o r e m o v e a d h e s i v e f r o m t h e r e a r
w i n d o w , u s e a soft s h o p t o w e l d a m p e n e d w i t h
isopropyl alcohol.
3. C l e a n t h e e d g e of t h e r e a r w i n d o w w i t h i s o p r o p y l
alcohol w h e r e n e w molding and h a r n e s s holder are
to b e i n s t a l l e d . M a k e s u r e t h e b o n d i n g s u r f a c e is
kept f r e e of w a t e r , o i l , a n d g r e a s e .
20-48
Convertible Top Cloth Repair
1. T h e f o l l o w i n g t o o l s a n d s u p p l i e s a r e r e q u i r e d to 4. C l e a n t h e r e p a i r c l o t h w h e r e a d h e s i v e w i l l b e
r e p a i r t h e top c l o t h . applied.
• R e p a i r cloth (P/N 8 6 3 2 1 - S 2 A - 0 0 3 ) 5. A p p l y t h e a d h e s i v e (A) t o t h e repair cloth (B) a n d

• Adhesive t o p cloth (C) a s i n d i c a t e d b y t h e a r r o w s .
• Utility knife
• Ruler
• Sandpaper
2 . A p p l y a p i e c e of t h e repair cloth (A) to t h e i n s i d e

s u r f a c e of t h e top cloth at t h e d a m a g e d a r e a . C u t
t h r o u g h both t h e d a m a g e d cloth (B) a n d t h e repair
cloth u s i n g a ruler (C) a n d a utility knife (D).
A B
6. P u s h f i r m l y o n t h e r e p a i r c l o t h .
REPAIR CLOTH
3. C u t a p i e c e of r e p a i r cloth (A) s o it o v e r l a p s t h e
repair opening a s s h o w n .
30—50 m m
( 1 . 2 - 2 . 0 in.)
7. S c r a p e o r w i p e t h e e x c e s s a d h e s i v e off w i t h a soft
s h o p towel d a m p e n e d with isopropyl alcohol.
8. L e t t h e a d h e s i v e d r y . F o l l o w t h e m a n u f a c t u r e r ' s
recommendations for drying time.
9. C h e c k for w a t e r l e a k s ( s e e s t e p 17 o n p a g e 20-15).
20-49
Convertible Top
Convertible Top Lock Handle Convertible Top Lock Handle
Replacement Operation Load Adjustment
N O T E : T a k e c a r e not to s c r a t c h the top f r a m e . N O T E : T a k e c a r e not to s c r a t c h t h e interior p a r t s .
1. R e m o v e t h e c o n v e r t i b l e t o p lock h a n d l e a s s h o w n . 1. R e m o v e both rear t r a y s i d e t r i m s ( s e e p a g e 20-73).
2 . Install t h e h a n d l e in t h e r e v e r s e o r d e r of r e m o v a l , 2. C l o s e t h e t o p , t h e n lock it s e c u r e l y w i t h both lock

a n d a p p l y m u l t i p u r p o s e g r e a s e to t h e s p r i n g s a n d h a n d l e s (A).
moving parts.
Fastener Locations
A • : Screw, 1 B • : Screw, 1
'00 m o d e l '01-08 m o d e l s
3. L o o s e n t h e locknut (B) o n t h e link s t o p (C) o n e a c h

side.
4. A d j u s t the link s t o p o n e a c h s i d e until it m a k e s

c o n t a c t w i t h t h e link s e t b r a c k e t (D). T h e r e s h o u l d
be n o c l e a r a n c e b e t w e e n t h e c o n v e r t i b l e top striker
(E) a n d t h e h o o k (F).
5. T i g h t e n t h e locknut, a n d c h e c k that the lock h a n d l e

works smoothly on each side.
6. R e i n s t a l l all r e m o v e d p a r t s .
20-50
HWM*
Convertible Top Motor Convertible Top Striker

Replacement Replacement
NOTE: N O T E : T a k e c a r e not to s c r a t c h t h e interior parts.

• T a k e c a r e not to s c r a t c h the interior p a r t s .
• Put o n g l o v e s to protect y o u r h a n d s . 1. R e m o v e the w i n d s h i e l d h e a d e r interior t r i m
( s e e p a g e 20-70).
2 . R e m o v e the c o n v e r t i b l e top striker a s s h o w n .
• Roll b a r u p p e r t r i m ( s e e p a g e 2 0 - 7 3 )
•. C o r n e r g u s s e t ( s e e p a g e 20-39) 3. Install t h e striker in t h e r e v e r s e o r d e r of r e m o v a l .
Fastener Locations
2. R e m o v e the c o n v e r t i b l e t o p m o t o r a s s h o w n .
• : Screw, 2
3. Install the m o t o r in the r e v e r s e o r d e r of r e m o v a l ,
a n d note t h e s e i t e m s :
• M a k e s u r e t h e c o n n e c t o r i s p l u g g e d in p r o p e r l y .
• A p p l y m u l t i p u r p o s e g r e a s e to t h e g e a r portion.
• C h e c k the m o t o r o p e r a t i o n .
Fastener Locations
#:Nut,3
M O T O R
CONVERTIBLE TOP
STRIKER
('02-08 m o d e l s s h a p e )
20-51
Convertible Top
A-Pillar-Header Weatherstrip and A-Pillar Molding Replacement
NOTE:
• T a k e c a r e not to s c r a t c h the b o d y .
• U s e a clip r e m o v e r to r e m o v e t h e c l i p s .
1. R e m o v e t h e A - p i l l a r - h e a d e r w e a t h e r s t r i p a n d A - p i l l a r - m o l d i n g a s s h o w n .
2. Install t h e w e a t h e r s t r i p a n d m o l d i n g in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• If the old m o l d i n g will be r e i n s t a l l e d , s c r a p e off the d o u b l e - s i d e d a d h e s i v e t a p e , t h e n c l e a n t h e m o l d i n g s u r f a c e

w i t h i s o p r o p y l a l c o h o l . A t t a c h n e w d o u b l e - s i d e d a d h e s i v e t a p e to t h e m o l d i n g .
• W h e n installing t h e m o l d i n g , first tighten t h e s c r e w at t h e top of t h e m o l d i n g .
• If t h e old w e a t h e r s t r i p will b e r e i n s t a l l e d , s c r a p e off ail t r a c e s of o l d E P T s e a l e r a n d butyl t a p e , t h e n c l e a n t h e
w e a t h e r s t r i p s u r f a c e w i t h i s o p r o p y l a l c o h o l . A t t a c h n e w E P T s e a l e r a n d butyl t a p e to t h e w e a t h e r s t r i p .
• W h e n installing t h e w e a t h e r s t r i p , a l i g n t h e roof clip h o l e o n t h e w e a t h e r s t r i p w i t h t h e hole o n the m o l d i n g .
• B e f o r e installing t h e w e a t h e r s t r i p , fold t h e s e p a r a t o r of t h e butyl t a p e at t h e roof portion. After installing the
w e a t h e r s t r i p , c a r e f u l l y pull t h e s e p a r a t o r a w a y .
• P r e s s t h e butyl t a p e p o r t i o n s to m a k e t h e a d h e s i v e stick.
• C h e c k that e a c h d o o r g l a s s c o n t a c t s t h e w e a t h e r s t r i p e v e n l y .
Fastener Locations
A > : Clip, 4 B ^ : Screw, 5
20-52
B-Pillar Outer Weatherstrip Drain Tank and Lower Drain Hose
NOTE: NOTE:
• T a k e c a r e not to s c r a t c h t h e b o d y . • T a k e c a r e not to s c r a t c h t h e b o d y .
• U s e a c l i p r e m o v e r to r e m o v e t h e c l i p s . • T a k e c a r e not t o d r o p t h e s c r e w .
1. R e m o v e t h e B-pillar outer w e a t h e r s t r i p a s s h o w n . 1. R e m o v e t h e c o n v e r t i b l e t o p a s s e m b l y ( s e e p a g e
20-39).
2. Install t h e w e a t h e r s t r i p in t h e r e v e r s e o r d e r of
r e m o v a l , a n d note t h e s e i t e m s : 2. R e m o v e t h e d r a i n t a n k a n d l o w e r d r a i n h o s e a s
shown.
w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h 3. Install in t h e r e v e r s e o r d e r of r e m o v a l , a n d note
new ones. these items:
• If t h e old w e a t h e r s t r i p will b e r e i n s t a l l e d , s c r a p e • R e p l a c e t h e c l i p if it's d a m a g e d .
off all t r a c e s of old E P T s e a l e r a n d butyl t a p e , • P u s h t h e c l i p into p l a c e s e c u r e l y .
then clean the weatherstrip surface with • M a k e s u r e t h e l o w e r d r a i n h o s e is i n s e r t e d in t h e
isopropyl alcohol. Attach n e w E P T s e a l e r a n d drain valve properly.
butyl t a p e into p o s i t i o n . • M a k e s u r e t h e d r a i n tank i s c o n n e c t e d to t h e
lower drain h o s e properly.
Fastener Locations
Fastener Locations
: Screw, 1 B>:Clip,1 C>:Clip,1
A ^ : Screw, 1 B t > : Clip, 1
B-PILLAR O U T E R
WEATHERSTRIP
DRAIN T A N K
BUTYLTAPE
T h i c k n e s s : 1.51
LOWER
EPT SEALER HOSE
Thickness: 5 m m
(0.2 in.)
W i d t h : 5 m m (0.2 in.)
DRAIN V A L V E
20-53
Convertible Top
Convertible Top Cover Snap Replacement
N O T E : T a k e c a r e not to s c r a t c h t h e c o n v e r t i b l e t o p
cover.
1. U s i n g s n a p ring p l i e r s (A), r e m o v e t h e nut (B) f r o m

the s n a p (C), then r e m o v e the s n a p from the
c o n v e r t i b l e t o p c o v e r (D).
2 . Install t h e c o v e r s n a p in t h e r e v e r s e o r d e r of
removal.
20-54
Removable Hardtop
/ROOF
REAR WINDOW Position Adjustment, REAR WINDOW
DEFOGGER GROUND page 20-66 C o m p o n e n t Location index, page 20-24
G l a s s R e p l a c e m e n t Process, page 20-26
HARDTOP LOWER
WEATHERSTRIP
REAR WINDOW
ROOF FRONT TRIMS DEFOGGER HARNESS
REAR WINDOW
LOWER TRIM
page 20-56
REAR WINDOW
BRACKET
page 20-56
REAR WINDOW
LOWER TRIM
page 20-56
HEADLINER
Removal/Installation,
page 20-57
ROOF SIDE LOCK

Replacement,
HARDTOP STRIKER page 20-63
Replacement,
page 20-64
CUSHION
HARDTOP LOCK
HANDLE
Replacement,
page 20-62
UPPER DOOR G L A S S BODY SIDE CATCH

WEATHERSTRIP ASSEMBLY
page 20-58 Replacement, page 20-64
B o d y S i d e Catch Replacement, page 20-65
Hardtop S w i t c h Test, page 22-248
20-55
Removable Hardtop
Interior Trim Removal/Installation
• Available through the A m e r i c a n Honda T o o l a n d E q u i p m e n t P r o g r a m ; call 888-424-6857
NOTE:
• T o r e m o v e a n d install t h e interior t r i m , r e m o v e t h e roof f r o m t h e b o d y .
• U s e a c l i p r e m o v e r to r e m o v e t h e r e a r w i n d o w l o w e r t r i m c l i p s .
• T a k e c a r e not to b e n d or s c r a t c h t h e interior t r i m .
1. R e m o v e t h e t r i m a s s h o w n .
2. Install t h e t r i m in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• R e p l a c e t h e d a m a g e d a d h e s i v e t a p e , a n d c h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s - w h i t e n e d , a n d if n e c e s s a r y ,
replace t h e m with n e w o n e s .
• B e f o r e p e e l i n g a w a y t h e a d h e s i v e b a c k i n g f r o m t h e a d h e s i v e t a p e o n t h e e n d c a p , install t h e roof s i d e t r i m o n
t h e roof t e n t a t i v e l y to c h e c k t h e p o s i t i o n of t h e t r i m e n d .
• W h e n i n s t a l l i n g t h e roof s i d e t r i m , first install t h e front e n d , a n d i n s e r t t h e l o w e r e n d into t h e e n d c a p , t h e n p u s h
t h e c o r n e r portion a g a i n s t t h e roof s e c u r e l y . M a k e s u r e t h e r e i s n o c l e a r a n c e b e t w e e n t h e t r i m a n d c a p .
Fastener Locations
A>:Clip,8 B[>.CIip,3 C ^ : Bolt, 4
(Both sides)
20-56
Headliner Removal/Installation
NOTE:
• T o r e m o v e a n d install t h e h e a d l i n e r , r e m o v e t h e roof f r o m t h e b o d y .
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e h e a d l i n e r .
• T a k e c a r e not to b e n d or s c r a t c h t h e h e a d l i n e r .
• B-pillar t r i m , both s i d e s ( s e e p a g e 20-56)

• Hardtop lock h a n d l e , both s i d e s ( s e e p a g e 20-62)
• U p p e r d o o r g l a s s w e a t h e r s t r i p , front e d g e p o r t i o n s f r o m both s i d e s a s n e c e s s a r y ( s e e p a g e 20-58)
2. R e m o v e both front e d g e p o r t i o n s of t h e u p p e r d o o r g l a s s w e a t h e r s t r i p s (A) ( s e e p a g e 20-58).
Fastener Locations
B>:Clip,8
3. R e l e a s e t h e c l i p s (B) b y s l i d i n g t h e h e a d l i n e r (C) f o r w a r d , t h e n r e m o v e t h e h e a d l i n e r .
4. Install t h e h e a d l i n e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d c h e c k that t h e c l i p s a r e s e c u r e l y a t t a c h e d to t h e roof.
20-57
Removable Hardtop
Roof Molding Replacement
NOTE:
• T o r e m o v e a n d install t h e roof m o l d i n g , r e m o v e t h e roof f r o m t h e b o d y .
• T a k e c a r e not to s c r a t c h t h e roof.
• U s e a c l i p r e m o v e r to r e m o v e t h e c l i p .
• If t h e o l d r e t a i n e r i s to b e i n s t a l l e d , s c r i b e a line a r o u n d t h e m o u n t i n g s c r e w s b e f o r e r e m o v i n g t h e retainer.
Removal
R e m o v e t h e B-pillar t r i m ( s e e p a g e 2 0 - 5 6 ) , t h e n r e m o v e t h e roof m o l d i n g a s s h o w n .
Fastener Locations
A>:Clip,1 B^:Screw,1 C ••Screw,! • • . S c r e w , 6 E^:Screw, 1 F#:Nut,2

(Silver) *
^r: C O R R O S I O N - R E S I S T A N T S C R E W
ROOF MOLDING
Before r e m o v i n g the s c r e w s , mark

a line a r o u n d t h e m (six p l a c e s ) .
UPPER DOOR G L A S S
WEATHERSTRIP
UPPER DOOR G L A S S
WEATHERSTRIP
HARDTOP LOWER
WEATHERSTRIP
20-58
film*
Installation
Install t h e roof m o l d i n g in t h e n u m b e r e d s e q u e n c e , a n d note t h e s e i t e m s :
• B e f o r e reinstalling t h e roof m o l d i n g , u s e i s o p r o p y l a l c o h o l to c l e a n t h e roof s u r f a c e w h e r e t h e s e a l a n t w i l l b e

applied.
• W h e n r e i n s t a l l i n g t h e roof retainer, align it w i t h t h e m a r k s m a d e d u r i n g r e m o v a l .
• C h e c k t h a t t h e w e a t h e r s t r i p is s e c u r e l y i n s t a l l e d to t h e retainer.
• C h e c k that t h e d o o r g l a s s c o n t a c t s t h e w e a t h e r s t r i p e v e n l y . If n e c e s s a r y , a d j u s t t h e retainer.
Fastener Locations
A>:Clip,1 B^:Screw,1 C ^ : Screw, 1 D ^ : Screw, 6 E ^ : Screw, 1 F< Nut, 2

(Silver) *
Jr. C O R R O S I O N - R E S I S T A N T S C R E W
: S e a l a n t (Cemedine 336, or equivalent)
(DApply sealant to the back
edge of the roof molding
ana the roof as shown.
© A p p l y sealant to the
edge of the roof
as shown.
(DROOF MOLDING
4x0.7 mm
3 N m (0.3 k g f m , 2 I b f f t )
UPPER DOOR GLASS

WEATHERSTRIP
® Apply sealant to the edge of

the roof molding, to the roof,
into the holder of the roof retainer,
and into the gap under the molding
as shown.
©UPPER DOOR GLASS
WEATHERSTRIP
HARDTOP LOWER
WEATHERSTRIP
(cont'd)
20-59
Removable Hardtop
Roof Molding Replacement (cont'd)
Weatherstrip Check
NOTE:
• M a k e s u r e t h e h a r d t o p i s l o c k e d s e c u r e l y w i t h both lock h a n d l e s a n d both roof s i d e l o c k s .
• C h e c k that t h e w e a t h e r s t r i p is s e c u r e l y i n s t a l l e d to t h e retainer.
• R a i s e t h e g l a s s fully.
• C h e c k that t h e d o o r g l a s s c o n t a c t s t h e w e a t h e r s t r i p e v e n l y .
• C h e c k for w a t e r l e a k s ( s e e s t e p l i o n p a g e 2 0 - 6 7 ) .
• Test-drive a n d c h e c k for w i n d noise.
ROOF SIDE DOOR
20-60
Hardtop Lower Weatherstrip Replacement
NOTE:
• T o r e m o v e a n d install t h e h a r d t o p l o w e r w e a t h e r s t r i p , r e m o v e t h e roof f r o m t h e b o d y .
• U s e a clip r e m o v e r to r e m o v e t h e c l i p s .
1. R e m o v e t h e r e a r w i n d o w l o w e r t r i m ( s e e p a g e 20-56).
2. R e m o v e t h e hardtop l o w e r w e a t h e r s t r i p a s s h o w n .
3. Install t h e w e a t h e r s t r i p in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• B e f o r e installing the w e a t h e r s t r i p , c l e a n t h e roof b o n d i n g s u r f a c e w i t h i s o p r o p y l a l c o h o l .

• If t h e old w e a t h e r s t r i p w i l l b e i n s t a l l e d , s c r a p e off t h e d o u b l e - s i d e d a d h e s i v e t a p e , t h e n c l e a n t h e w e a t h e r s t r i p
s u r f a c e w i t h i s o p r o p y l a l c o h o l . A t t a c h n e w d o u b l e - s i d e d a d h e s i v e t a p e to t h e w e a t h e r s t r i p .
• B e f o r e installing the w e a t h e r s t r i p , fold the e d g e of t h e a d h e s i v e b a c k i n g f r o m t h e d o u b l e - s i d e d a d h e s i v e t a p e .
After installing the w e a t h e r s t r i p , c a r e f u l l y pull t h e a d h e s i v e b a c k i n g a w a y .
• P r e s s t h e d o u b l e - s i d e d a d h e s i v e t a p e portion to m a k e t h e a d h e s i v e stick.
Fastener Locations
A • :Screw,2 B > : Clip, 2 C > : C l i p , 18
HARDTOP LOWER HARDTOP LOWER

WEATHERSTRIP WEATHERSTRIP
20-61
Removable Hardtop
Roof Front Trim Replacement Hardtop Lock Handle Replacement
NOTE: NOTE:
• T o r e m o v e a n d install t h e roof front t r i m , r e m o v e t h e • T o r e m o v e a n d install t h e h a r d t o p lock h a n d l e ,
roof f r o m t h e b o d y . r e m o v e t h e roof f r o m t h e b o d y .
• T a k e c a r e not to s c r a t c h t h e roof. • T a k e c a r e not to s c r a t c h t h e h e a d l i n e r .
1. S c r a p e off all t r a c e s of t h e old t r i m , t h e n c l e a n t h e 1. R e m o v e t h e h a r d t o p lock h a n d l e a s s h o w n .

roof b o n d i n g s u r f a c e w i t h a s p o n g e d a m p e n e d in
i s o p r o p y l a l c o h o l . After c l e a n i n g , k e e p o i l , g r e a s e , 2. Install t h e h a n d l e in t h e r e v e r s e o r d e r of r e m o v a l ,
a n d w a t e r f r o m getting o n t h e s u r f a c e . a n d note t h e s e i t e m s :
2. A p p l y P P p r i m e r to t h e a r e a s w h e r e t h e roof front • A p p l y m u l t i p u r p o s e g r e a s e to t h e s p r i n g s a n d t h e
t r i m will b e a p p l i e d . m o v i n g portions.
• A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to
3. A p p l y t h e roof front t r i m (A, B ) . t h e t h r e a d of t h e s c r e w (A) b e f o r e reinstallation.
Fastener Locations
-1 P e e l t h e a d h e s i v e b a c k i n g (C) f r o m t h e front
e d g e of t h e t r i m . A • : Screw, 1 B • : Screw, 1
-2 C e n t e r a n d fit t h e t r i m a g a i n s t t h e roof. MEDIUM STRENGTH TYPE
-3 A p p l y t h e t r i m to t h e roof w h i l e p e e l i n g t h e LIQUID T H R E A D L O C K
r e m a i n i n g a d h e s i v e b a c k i n g (D) f r o m it a little
at a t i m e . C h e c k that t h e t r i m i s p a r a l l e l a n d
f r e e of w r i n k l e s .
6mm 2mm
-4 R e m o v e t h e a p p l i c a t i o n t a p e .
( 0 . 2 4 in.) (0.08 in.)
D D 6 x 1.0 m m
12 N m
(1.2 k g f - m ,
8.7 Ibf ft)
20-62
Roof Side Lock Replacement
NOTE: G r e a s e Application
• Put o n g l o v e s t o protect y o u r h a n d s .
• T o r e m o v e a n d install t h e roof s i d e lock, r e m o v e the
roof f r o m t h e b o d y .
• If t h e o l d lock will b e i n s t a l l e d , m a r k a line a r o u n d t h e
m o u n t i n g bolts before r e m o v i n g t h e lock.
1. R e m o v e t h e B-pillar t r i m ( s e e p a g e 20-56).
2. R e m o v e t h e roof s i d e lock a s s h o w n .
3. Install t h e lock in t h e r e v e r s e o r d e r of r e m o v a l , a n d
note t h e s e i t e m s :
• If reinstalling t h e o l d lock, align t h e lock w i t h the

marks made during removal.
• A p p l y m u l t i p u r p o s e g r e a s e to t h e s p r i n g s a n d t h e
m o v i n g portions.
• If n e c e s s a r y , a d j u s t t h e lock a l i g n m e n t ; refer to
t h e roof position a d j u s t m e n t ( s e e p a g e 20-66).
Fastener Locations
• :Bolt,3
(1.0 k g f m , 7.2 Ibf-ft)
20-63
Removable Hardtop
Hardtop Striker Replacement Body Side Catch Assembly
Replacement
NOTE:
• T o r e m o v e a n d install t h e h a r d t o p striker, r e m o v e t h e
roof f r o m t h e b o d y . N O T E : Put o n g l o v e s to protect y o u r h a n d s .
• T a k e c a r e not to s c r a t c h t h e interior parts.
1. R e m o v e the roof f r o m the b o d y . T a k e c a r e not to
1. R e m o v e t h e w i n d s h i e l d h e a d e r interior t r i m b e n d or s c r a t c h t h e t r i m a n d p a n e l s .
(see page 20-70).
2 . R e m o v e t h e r e a r s i d e t r i m ( s e e p a g e 20-72).
2 . R e m o v e t h e h a r d t o p striker a s s h o w n .
3 . O n t h e left s i d e , d e t a c h a n d d i s c o n n e c t t h e
3 . Install t h e striker in t h e r e v e r s e o r d e r of r e m o v a l . c o n n e c t o r (A), t h e n d e t a c h t h e h a r n e s s clip (B).
Fastener Locations Fastener Locations
• : Screw, 2 C ^ : Bolt 2 D ^ : Bolt, 2
HARDTOP STRIKER
i / ra-m
(1.7 k g f m , 1 2 I b f f t )
A \
4 . R e m o v e t h e bolts ( C , D), t h e n r e m o v e the b o d y s i d e

catch a s s e m b l y (E).
20-64
Body Side Catch Replacement
5. R e m o v e t h e l o w e r c l i p (A) f a s t e n i n g t h e B-pillar 1. R e m o v e t h e b o d y s i d e c a t c h a s s e m b l y f r o m t h e
o u t e r w e a t h e r s t r i p (B) f r o m o u t s i d e of t h e front b o d y ( s e e p a g e 20-64).
d o o r o p e n i n g . M a k e s u r e t h e c e n t e r of the c l i p h o l e
a l i g n s w i t h t h e c e n t e r of t h e hole in t h e c o n v e r t i b l e 2. R e m o v e t h e b o d y s i d e c a t c h a s s h o w n .
t o p f r a m e (C). If n e c e s s a r y , l o o s e n t h e m o u n t i n g
bolt (D), a n d m o v e t h e c o n v e r t i b l e t o p f r a m e 3. Install t h e c a t c h in t h e r e v e r s e o r d e r of r e m o v a l ,
slightly until t h e h o l e s a l i g n . T h e n tighten t h e bolt, a n d note t h e s e i t e m s :
a n d install t h e c l i p .
• A p p l y m u l t i p u r p o s e g r e a s e to e a c h l o c a t i o n a s
Fastener Locations
i n d i c a t e d by t h e a r r o w s .
G ^ : Bolt,2 H ^ : Bolt,2 • A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to
the s c r e w before reinstallation.
Fastener Location
G r e a s e Application
6. G r e a s e t h e c a t c h .
7. R e i n s t a l l t h e c a t c h a s s e m b l y (E) o n t h e c o r n e r
g u s s e t (F) a n d t h e c o n v e r t i b l e t o p f r a m e ; tighten
t h e bolts ( G , H). O n left s i d e , r e c o n n e c t t h e
c o n n e c t o r (I).
8. R e i n s t a l l all of t h e r e m o v e d p a r t s .
20-65
Removable Hardtop
Roof Position Adjustment
N O T E : H a v e a n a s s i s t a n t h e l p y o u a d j u s t t h e roof p o s i t i o n .
1. R e m o v e t h e B-pillar t r i m f r o m both s i d e s ( s e e p a g e 2 0 - 5 6 ) , a n d m a k e s u r e both lock h a n d l e s (A) a n d roof s i d e

l o c k s (B) a r e u n l o c k e d .
2. S e t t h e roof (C) o n t o t h e b o d y (D):
• M a k e s u r e t h e l o c k p i n s (E) of both roof s i d e l o c k s a r e s e c u r e l y i n s e r t e d into t h e b o d y s i d e c a t c h e s (F).

• M a k e s u r e t h e r e a r w i n d o w d e f o g g e r h a r n e s s e s a r e not p i n c h e d .
3. A d j u s t t h e roof a l i g n m e n t .
-1 C h e c k that t h e r e is n o c l e a r a n c e b e t w e e n t h e striker (G) a n d t h e b o s s (H) of t h e lock h a n d l e at t h e m e a s u r i n g

p o i n t s [ A ] , a n d c h e c k that t h e c l e a r a n c e is w i t h i n s p e c i f i c a t i o n at t h e m e a s u r i n g p o i n t s [ B ] o n t h e b o t t o m
of both B - p i l l a r s .
-2 T o fit t h e b o s s into t h e striker, a n d to a d j u s t t h e v e r t i c a l c l e a r a n c e to t h e s p e c i f i c a t i o n , l o o s e n t h e roof s i d e
lock m o u n t i n g b o l t s (I), t h e n m o v e t h e roof u p o r d o w n , a s w e l l a s , f o r w a r d a n d r e a r w a r d .
-3 T o a d j u s t t h e horizontal c l e a r a n c e b e t w e e n both s i d e e d g e s of t h e roof a n d t h e r e a r t r a y o p e n i n g m o l d i n g (J)
t o t h e s p e c i f i c a t i o n , l o o s e n t h e h o l d e r plate m o u n t i n g b o l t s ( K ) , t h e n m o v e t h e roof to t h e right o r left.
-4 F a s t e n both roof s i d e l o c k s .
-5 L o c k t h e roof s e c u r e l y w i t h both lock h a n d l e s a n d roof s i d e l o c k s .
-6 R e c h e c k t h e roof a l i g n m e n t .
20-66
4. If t h e roof a l i g n m e n t is still not w i t h i n s p e c i f i c a t i o n , u n l o c k t h e roof, a n d r e p e a t t h e p r e c e d i n g s t e p s .
5. If t h e roof a l i g n m e n t is not w i t h i n s p e c i f i c a t i o n , c h e c k t h e b o d y s i d e c a t c h e s , a n d c h e c k for b o d y d e f o r m a t i o n .
6. L o c k t h e roof (A) s e c u r e l y w i t h both lock h a n d l e s (B) a n d roof s i d e l o c k s ( C ) . C h e c k t h e level d i f f e r e n c e b e t w e e n

t h e roof a n d b o d y (D) at t h e m e a s u r i n g point [ A ] . If t h e d i f f e r e n c e is not w i t h i n s p e c i f i c a t i o n , r e m o v e t h e roof
f r o m t h e b o d y , a n d a d j u s t t h e d i f f e r e n c e w i t h t h e s p a c e r s (E) that a r e i n s t a l l e d b e t w e e n t h e lock h a n d l e a n d t h e
roof.
S P A C E R : T h i c k n e s s = 1 m m (0.04 in.) Measuring Point [A]

N u m b e r s T h r e e pieces (standard)
7. S e t t h e roof onto t h e b o d y , a n d lock it s e c u r e l y . C h e c k that t h e w e a t h e r s t r i p fits f l u s h , a n d c h e c k that e a c h d o o r

g l a s s c o n t a c t s t h e w e a t h e r s t r i p e v e n l y . If n e c e s s a r y , a d j u s t t h e retainer; refer to t h e roof m o l d i n g r e p l a c e m e n t
( s e e p a g e 20-58).
8. R e m o v e t h e roof f r o m t h e b o d y , a n d reinstall t h e B-pillar t r i m o n t h e roof.
9. S e t t h e roof onto t h e b o d y , a n d lock it s e c u r e l y . R e c o n n e c t t h e r e a r w i n d o w d e f o g g e r c o n n e c t o r s s e c u r e l y .
10. M a k e s u r e that t h e roof i s l o c k e d s e c u r e l y , t h e n r a i s e t h e d o o r g l a s s fully, a n d c l o s e t h e d o o r s .
11. C h e c k for w a t e r l e a k s . R u n w a t e r o v e r t h e roof a n d o n t h e s e a l i n g a r e a a s s h o w n , a n d note t h e s e i t e m s :
• U s e a 12 m m (1/2 in.) d i a m e t e r h o s e (A).

• A d j u s t t h e rate of w a t e r f l o w (B).
• Do not u s e a nozzle.
• Hold t h e h o s e a b o u t 2 0 0 m m (7.9 in.) a w a y f r o m t h e d o o r .
2 0 0 m m (7.9 in.)
12. T e s t - d r i v e a n d c h e c k for w i n d n o i s e .
20-67
Interior Trim
Except C R Model
C O N V E R T I B L E T O P C O V E R PIN
p a g e 20-72
REAR TRAY
page 20-73
ROLL BAR
UPPER TRIM
page 20-72
REAR TRAY
REAR TRIM
page 20-73
REAR TRAY
SIDE TRIM
page 20-73
A-PILLAR INTERIOR
TRIM CONVERTIBLE TOP COVER
page 20-70 PIN
page 20-72
REAR SIDE TRIM

WINDSHIELD HEADER page 20-72
INTERIOR TRIM
p a g e 20-70
ROLL BAR LOWER TRIM
p a g e 20-72
CENTER CARPET
CARPETS R e p l a c e m e n t p a g e 20-79
Replacement
p a g e 20-78
KICK P A N E L DOOR SILL TRIM
p a g e 20-71 p a g e 20-71
CR Model
R I G H T R E A R C O V E R LID ROLL BAR

p a g e 20-75 UPPER TRIM
page 20-72
REAR COVER
p a g e 20-75
L E F T R E A R C O V E R LID
p a g e 20-75
WINDSHIELD HEADER
REAR SIDE TRIM
INTERIOR TRIM
p a g e 20-72
p a g e 20-70
ROOL BAR LOWER TRIM

p a g e 20-72
CARPETS
Replacement CENTER CARPET
p a g e 20-78 R e p l a c e m e n t p a g e 20-79
KICK PANEL DOOR SILL TRIM

p a g e 20-71 p a g e 20-71
20-68
SPARE TIRE C O V E R
page 20-77
TRUNK FLOOR TRIM PANEL

p a g e 20-77
T O O L B O X LID
page 20-77
TOOL BOX
page 20-77
REAR TRIM PANEL

p a g e 20-77
TRUNK SIDE TRIM PANEL

page 20-77
20-69
Interior Trim
Trim Removal/Installation - Front Roof Area

• Available through the A m e r i c a n Honda Tool and E q u i p m e n t P r o g r a m ; call 888-424-6857
NOTE:
• Put o n g l o v e s to p r o t e c t y o u r h a n d s .
• T a k e c a r e not to b e n d o r s c r a t c h t h e t r i m a n d p a n e l s .
1. R e m o v e the t r i m in t h e n u m b e r e d s e q u e n c e .
• C h e c k if t h e c l i p s a r e d a m a g e d o r s t r e s s - w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h n e w o n e s .
• M a k e s u r e t h e c o n n e c t o r is p l u g g e d in p r o p e r l y .
• If t h e t h r e a d s o n t h e v i s o r s c r e w s a r e w o r n out, u s e a n o v e r s i z e d s c r e w ( P / N 9 0 1 3 2 - S Z 3 - 0 0 3 ) m a d e s p e c i f i c a l l y
for t h i s a p p l i c a t i o n .
Fastener Locations
A ^ : Screw, 2 B^:Screw,2 C>:Clip,4 D>:Clip,2
(D W I N D S H I E L D H E A D E R
INTERIOR TRIM
20-70
Trim Removal/Installation - Door Areas

NOTE:
• U s e t h e a p p r o p r i a t e tool f r o m the K T C t r i m tool s e t to a v o i d d a m a g e w h e n p r y i n g c o m p o n e n t s .
• T a k e c a r e not to b e n d or s c r a t c h t h e t r i m a n d p a n e l s .
• C h e c k if the c l i p s a r e d a m a g e d or s t r e s s - w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h n e w o n e s .
Fastener Locations
A > : Clip, 3 B>:Clip,1 C>:Clip,1 D>:Clip,1
TAB
20-71
Interior Trim
Trim Removal/Installation - Seat Side Area

• A v a i l a b l e t h r o u g h t h e A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; c a l l 888-424-6857
NOTE:
• T a k e c a r e not to b e n d o r s c r a t c h t h e t r i m a n d p a n e l s .
1. R e m o v e t h e d o o r sill t r i m ( s e e p a g e 20-71).
2 . R e m o v e the t r i m a s s h o w n .
3. Install the t r i m in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• P u s h the c l i p s into p l a c e s e c u r e l y .
• F o r r e m o v a b l e hardtop: M a k e s u r e the r e a r w i n d o w d e f o g g e r c o n n e c t o r i s p l u g g e d in p r o p e r l y (left s i d e o n l y ) .
Fastener Locations
A ^ : Screw, 1 B ^ : Screw, 2 C>:Clip,7 D>:Clip,1 CAP
L O W E R TRIM 4 N-m (0.4 k g f m , 3 Ibfft)
20-72
Trim Removal/Installation - Rear Tray Area

• A v a i l a b l e t h r o u g h t h e A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; call 8 8 8 - 4 2 4 - 6 8 5 7
Except CR Model
NOTE:
• T a k e c a r e not to b e n d or s c r a t c h t h e t o p c l o t h , r e a r w i n d o w , t r i m a n d p a n e l s .
1. R e m o v e t h e t r i m in n u m b e r e d s e q u e n c e .
2 . Install the t r i m in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to t h e a n c h o r bolts before r e i n s t a l l a t i o n .
• B e f o r e installing t h e a n c h o r b o l t s , m a k e s u r e t h e r e a r e n o t w i s t s or kinks in t h e s e a t belt.
Fastener Locations
A > : Clip, 4 B>:Clip,7
(cont'd)
20-73
Interior Trim
Trim Removal/Installation - Rear Tray Area (cont'd)
Fastener Locations © ROLL BAR AND UPPER TRIM ASSEMBLY

N O T E : T h e roll b a r c a n n o t b e s e p a r a t e d f r o m
C • : Bolt 8 :Screw,4 the upper trim a s s e m b l y .
First r e m o v e t h e s e items:
© SEAT BELT UPPER ANCHOR BOLT
•Rear console
7/16-20 U N F
•Rear side trim
3 2 N - m (3.3 k g f - m , 2 4 I b f f t )
© UPPERANCHOR CAP
© S l i p the s e a t belt
t h r o u g h t h e h o l e in
t h e roll b a r u p p e r t r i m .
© H A R N E S S CLIP
CONVERTIBLE TOP
('06-08 m o d e l s )
C O V E R PIN
Detach.
('00-01 m o d e l s : O u t s i d e a n d m i d d l e )
('02-08 m o d e l s : O u t s i d e o n l y )
'02-08 m o d e l s
shape
TRIM CLIP
('02-08 m o d e l s ) ©SEAT BELT
LOWER ANCHOR BOLT
7/16-20 U N F
3 2 N m (3.3 k g f - m ,
24 Ibfft)
'00-01 m o d e l s s h a p e
First r e m o v e the seat.
20-74
CR Model
NOTE:
1. R e m o v e t h e r e a r c o v e r in n u m b e r e d s e q u e n c e .
2. If n e c e s s a r y , r e m o v e the r e a r c o v e r b r a c k e t a n d t h e rear c o v e r r e t a i n e r s .
3. Install t h e r e a r c o v e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• A p p l y m e d i u m strength t y p e liquid t h r e a d lock to t h e a n c h o r bolts before r e i n s t a l l a t i o n .
• B e f o r e installing the a n c h o r b o l t s , m a k e s u r e t h e r e a r e n o t w i s t s o r kinks in t h e s e a t belt.
• P u s h t h e cFastener Locations
l i p s into place securely.
A^:Bolt,2 B^:Bolt,3 C#:Nut,7 D>:Clip,6 E>:Clip,2 F >:Striker,6
Interior Trim
Trim Removal/Installation - Rear Tray Area (cont'd)
Fastener Locations
G • : Bolt 9 H • : Screw, 4
® S E A T BELT UPPER ANCHOR BOLT

7/16-20 U N F
3 2 N - m (3.3 k g f m , 2 4 Ibf-ft)
UPPER ANCHOR CAP
® S l i p the s e a t belt
t h r o u g h t h e h o l e in
t h e roll b a r u p p e r t r i m .
® HARNESS CUP
Detach.
TRIM CLIP
© S E A T BELT
8 x 1.25 m m LOWER ANCHOR BOLT
22 N m 7/16-20 U N F
(2.2 k g f - m , 3 2 N-m
1 6 Ibf-ft) (3.3 k g f - m , 2 4 Ibf-ft)
First r e m o v e the seat.
20-76
Trim Removal/Installation - Trunk Area

• Available through the A m e r i c a n Honda Tool a n d Equipment Program; call 888-424-6857
NOTE:
• T a k e c a r e not to b e n d or s c r a t c h the t r i m a n d p a n e l s .
Fastener Locations
A > : Clip, 18 B>:Clip,4 C[>:Clip,3
20-77
Interior Trim
Carpet Replacement
NOTE:
• T a k e c a r e not to d a m a g e , w r i n k l e , o r t w i s t t h e c a r p e t s .
• B e c a r e f u l not to d a m a g e t h e d a s h b o a r d o r o t h e r interior t r i m p i e c e s .
1. R e m o v e t h e s e i t e m s , t h e n r e m o v e the c a r p e t a s s h o w n :
• S e a t s , both s i d e s ( s e e p a g e 20-92)
• Kick p a n e l s , both s i d e s ( s e e p a g e 20-71)
• F r o n t c o n s o l e c o v e r s , both s i d e s ( s e e p a g e 2 0 - 8 5 )
• R e a r s i d e t r i m s , both s i d e s ( s e e p a g e 20-72)
2. Install t h e c a r p e t in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e s e a t h a r n e s s is r o u t e d c o r r e c t l y .
• A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to t h e a n c h o r bolts a n d s e a t m o u n t i n g bolts before reinstallation.
• B e f o r e installing t h e l o w e r a n c h o r b o l t s , m a k e s u r e t h e r e a r e n o t w i s t s or kinks in t h e s e a t belts.
Fastener Locations
A • : Bolt, 2 B • : Screw, 4 C • : Nut, 2 D > : C l i p , 14 E > : C l i p , 10 F > : Clip, 2
SEAT BELT LOWER CENTER

ANCHOR BOLT CARPET -ACCELERATOR
7/16-20 U N F PEDAL STOP
32 N m FOOTREST
(3.3 k g f m , 2 4 I b f f t )
FASTENER
CENTER CARPET
Pull back a s
necessary.
FASTENER
DRIVER'S CARPET
TUNNEL
SIDE CLIP
TUNNEL SIDE
DOUBLE-SIDED
ADHESIVE TAPE
FLOOR MAT HOLDER

('02-08 m o d e l s )
If n e c e s s a r y , r e m o v e it.
(3.3 kgf-i
('00-05 m
n odels)
20-78
Center Carpet Replacement
S R S c o m p o n e n t s a r e l o c a t e d in this a r e a . R e v i e w the S R S c o m p o n e n t l o c a t i o n s for t h e a p p r o p r i a t e m o d e l :

• '00-05 m o d e l s ( s e e p a g e 23-11)
• ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-12)
A l s o r e v i e w t h e p r e c a u t i o n s a n d p r o c e d u r e s ( s e e p a g e 23-13) before d o i n g r e p a i r s o r s e r v i c e .
NOTE:
• T a k e c a r e not to d a m a g e , w r i n k l e , o r t w i s t the c a r p e t .
• B e c a r e f u l not to d a m a g e t h e d a s h b o a r d or other interior t r i m p i e c e s .
• B e f o r e d i s c o n n e c t i n g t h e n e g a t i v e c a b l e f r o m the battery/ m a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e a u d i o
s y s t e m , then write d o w n the audio presets.
• D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery, t h e n w a i t for 3 m i n u t e s before starting w o r k .
1. R e m o v e t h e s e i t e m s , t h e n r e m o v e t h e c e n t e r c a r p e t a s s h o w n :
• D a s h b o a r d ( s e e p a g e 20-87)
• R e a r c o n s o l e ( s e e p a g e 20-82)
• T h e h a r n e s s clips securing the S R S wire h a r n e s s and steering hanger b e a m wire h a r n e s s .
• C u t t h e c a r p e t in the a r e a s s h o w n .
2. Install the c e n t e r c a r p e t in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e S R S w i r e h a r n e s s a n d s t e e r i n g h a n g e r b e a m w i r e h a r n e s s a r e routed c o r r e c t l y , a n d c l i p p e d into
place.
• Refasten the cut a r e a s with wire ties.
• R e c o n n e c t t h e n e g a t i v e c a b l e to t h e battery.
• E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m , t h e n e n t e r t h e a u d i o p r e s e t s .
• S e t the clock.
• ' 0 2 - 0 5 m o d e l s : D o the E C M idle l e a r n p r o c e d u r e ( s e e p a g e 11-140).
Fastener Locations
A ^ : Bolt,2 B > : C l i p , 14 C>:Clip,2
DASHBOARD
CENTER FRAME
Cut here.
STEERING HANGER
BEAM WIRE HARNESS
FASTENERS Cut here.
20-79
Consoles
Center Console Removal/Installation

• Available through the A m e r i c a n Honda Tool a n d E q u i p m e n t P r o g r a m ; call 888-424-6857
NOTE:
• T a k e c a r e not to s c r a t c h the front s e a t , d a s h b o a r d a n d related p a r t s .
• R e m o v e t h e shift k n o b b y t u r n i n g it c o u n t e r c l o c k w i s e .
1. R e m o v e the c e n t e r c o n s o l e a s s h o w n .
2. Install t h e c e n t e r c o n s o l e in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e c o n n e c t o r s a r e p l u g g e d in p r o p e r l y .
• P u s h the c l i p s a n d h o o k s into p l a c e s e c u r e l y .
• Install t h e shift k n o b in n u m b e r e d s e q u e n c e .
Fastener Locations
A>:Clip B>:Hook,2 C[>:Clip,1
'00-03 models, 5 '00-03 models
'04-08 models, 6
*f
yd)SHIFT KNOB
By hand, thread
the shift knob ) Move to proper position.
on the shaft.
CENTER CONSOLE
('06-08 models)
PIN
CONVERTIBLE TOP SWITCH

CONNECTOR
REAR WINDOW
DEFOGGER SWITCH HAZARD WARNING
CONNECTOR SWITCH CONNECTOR
('06-08 models)
20-80
Wind Deflector Replacement

'01-08 Models
NOTE:
• T a k e c a r e not to s c r a t c h the r e a r c o n s o l e u p p e r lid a n d related p a r t s .
1. R e m o v e the w i n d deflector a s s h o w n .
2 . Install the w i n d deflector in t h e r e v e r s e o r d e r of r e m o v a l .
• A p p l y m e d i u m strength t y p e liquid t h r e a d lock to t h e t h r e a d of t h e s c r e w s b e f o r e r e i n s t a l l a t i o n .

• M a k e s u r e t h e c a p s a r e i n s t a l l e d s e c u r e l y onto t h e s c r e w s .
Fastener Locations
• : Screw, 2
MEDIUM STRENGTH TYPE
LIQUID T H R E A D L O C K
20-81
Consoles
Rear Console Removal/Installation

• A v a i l a b l e t h r o u g h t h e A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; call 8 8 8 - 4 2 4 - 6 8 5 7
NOTE:
• T a k e c a r e not to s c r a t c h t h e front s e a t a n d r e l a t e d p a r t s .
• C e n t e r c o n s o l e ( s e e p a g e 20-80)
• R e a r tray (except C R model) (see page 20-73)
• R e a r c o v e r ( C R m o d e l ) ( s e e p a g e 20-75)
• Roll b a r l o w e r t r i m , both s i d e s ( s e e p a g e 2 0 - 7 2 )
2 . R e m o v e the r e a r c o n s o l e a s s h o w n .
3. Install t h e r e a r c o n s o l e in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• P u s h t h eFastener
c l i p s into place securely.
Locations
A • : Screw, 4 B • : Screw, 10
20-82
Rear Console Box Replacement
N O T E : T a k e c a r e not to s c r a t c h t h e front s e a t a n d related parts.
1. R e m o v e t h e s e i t e m s , t h e n r e m o v e the rear c o n s o l e b o x a s s h o w n :
• Roll bar u p p e r t r i m , both s i d e s ( s e e p a g e 20-72)

• S p a r e tire (except C R m o d e l )
2. R e m o v e the rear c o n s o l e b o x a s s h o w n .
3. Install the rear c o n s o l e b o x in the r e v e r s e o r d e r of r e m o v a l .
Fastener Locations
• : Screw, 4
REAR CONSOLE BOX
4 N m (0.4 k g f m , H A R N E S S CLIP
3 Ibfft) Detach.
20-83
Dashboard
Instrument Panel Removal/ Radio Panel Removal/Installation
Installation
Special Tools Required • Available through the A m e r i c a n Honda Tool a n d
K T C t r i m tool s e t S O J A T P 2 0 1 4 * E q u i p m e n t P r o g r a m ; call 888-424-6857
Equipment Program; call 888-424-6857 NOTE:
NOTE: avoid d a m a g e w h e n prying components.
• U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to • T a k e c a r e not to s c r a t c h t h e d a s h b o a r d a n d related
avoid d a m a g e w h e n prying c o m p o n e n t s . parts.
• T a k e c a r e not to s c r a t c h t h e d a s h b o a r d a n d related
parts. 1. R e m o v e t h e r a d i o p a n e l a s s h o w n .
1. R e m o v e t h e i n s t r u m e n t p a n e l a s s h o w n . 2. Install t h e p a n e l in t h e r e v e r s e o r d e r of r e m o v a l ,
2. Install t h e p a n e l in t h e r e v e r s e o r d e r of r e m o v a l ,
a n d note t h e s e i t e m s : • C h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s -
• C h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s - new ones.
w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h • P u s h t h e c l i p s into p l a c e s e c u r e l y .
new ones.
• M a k e s u r e t h e c o n n e c t o r s a r e p l u g g e d in '00-05 m o d e l s
properly. Fastener Locations
• P u s h t h e c l i p s into p l a c e s e c u r e l y . A>:Clip,5 B>:Clip,2
Fastener Locations
A^:Screw,2 B>:Clip,2 C>:Clip,4
D>:Clip,2 E>:Clip,2 TRIM TOOL
RADIO PANEL
'06-08 m o d e l s
Fastener Locations
A > : Clip, 5 B>:Clip,2 PASSENGER'S AIRBAG

CUTOFF INDICATOR
HEATER CONTROL
UNIT CONNECTOR
'02-05 models:
REAR WINDOW
AUDIO CONTROL DEFOGGER SWITCH
UNIT CONNECTOR CONNECTOR
'06-08 models:
VSA OFF SWITCH
CONNECTOR
RADIO PANEL
20-84
Front Console Cover Removal/ Driver's Dashboard Lower Cover
Installation Removal/Installation

K T C t r i m tool s e t S O J A T P 2 0 1 4 * K T C t r i m tool s e t S O J A T P 2 0 1 4 *
• Available through the A m e r i c a n Honda Tool and • Available through the A m e r i c a n Honda Tool a n d
Equipment Program; call 888-424-6857 Equipment Program; call 888-424-6857
NOTE: '06-08 Models

• U s e t h e a p p r o p r i a t e tool f r o m the K T C t r i m tool s e t to
avoid d a m a g e w h e n prying c o m p o n e n t s . NOTE:
• T a k e c a r e not to s c r a t c h t h e d a s h b o a r d a n d related • U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to
parts. avoid d a m a g e w h e n prying components.
1. R e m o v e t h e front c o n s o l e c o v e r a s s h o w n . parts.
2 . Install t h e c o v e r in t h e r e v e r s e o r d e r of r e m o v a l , 1. R e m o v e t h e d r i v e r ' s d a s h b o a r d l o w e r c o v e r (A).

-4 T u r n t h e lock k n o b (B) 9 0 °.
• C h e c k if t h e c l i p s a r e d a m a g e d or s t r e s s - -2 G e n t l y pull out o n t h e b o t t o m e d g e to r e l e a s e
w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h t h e c l i p s ( C , D).
new ones.
Fastener Locations
C>:Clip,8 D>:Clip,1
Fastener Locations
• : Screw, 1 >:Clip,2
FRONT CONSOLE
COVER
2. Install t h e c o v e r in t h e r e v e r s e o r d e r of r e m o v a l ,
• C h e c k if the c l i p s a r e d a m a g e d or s t r e s s -
new ones.
20-85
Dashboard
Passenger's Dashboard Lower Cover Removal/Installation
Special Tools Required '06-08 m o d e l s
Fastener Locations
Equipment Program; call 888-424-6857 A|>:Clip,6 B>:Clip,2 C>:Clip,2 D ^ S c r e w , 1
NOTE:
avoid d a m a g e w h e n prying components.
parts.
1. R e m o v e t h e p a s s e n g e r ' s d a s h b o a r d l o w e r c o v e r a s
shown.
2. Install t h e c o v e r in t h e r e v e r s e o r d e r of r e m o v a l ,
• C h e c k if t h e c l i p s a r e d a m a g e d o r s t r e s s -
new ones.
PASSENGER'S DASHBOARD
'00-05 m o d e l s LOWER COVER
Fastener Locations
>:Clip,6
& T-A. M
PASSENGER'S DASHBOARD
LOWER COVER
20-86
Passenger's Side Vent Removal/ Dashboard Removal/Installation
Installation
Special Tools Required • A v a i l a b l e through the A m e r i c a n Honda Tool a n d
K T C t r i m tool s e t S O J A T P 2 0 1 4 * E q u i p m e n t P r o g r a m ; call 888-424-6857
* A v a i l a b l e t h r o u g h the A m e r i c a n H o n d a T o o l a n d
E q u i p m e n t P r o g r a m ; call 888-424-6857 S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e
N O T E : U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool • ' 0 0 - 0 5 m o d e l s ( s e e p a g e 23-11)
s e t to a v o i d d a m a g e w h e n p r y i n g c o m p o n e n t s . • ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-12)
A l s o review the precautions and procedures (see page
1. C a r e f u l l y i n s e r t a t r i m tool next to t h e c l i p s , a n d 23-13) b e f o r e d o i n g r e p a i r s o r s e r v i c e .
detach the clips by prying on the p a s s e n g e r ' s side
v e n t (A). T a k e c a r e not to s c r a t c h t h e d a s h b o a r d NOTE:
a n d related p a r t s . • U s e t h e a p p r o p r i a t e tool f r o m t h e K T C t r i m tool s e t to
avoid d a m a g e w h e n prying c o m p o n e n t s .
Fastener Locations
• Have an assistant help y o u w h e n y o u r e m o v e and
>:Clip,2 install t h e d a s h b o a r d .
• T a k e c a r e not to s c r a t c h t h e d a s h b o a r d , b o d y a n d
o t h e r related p a r t s .
2. D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery,
t h e n w a i t for 3 m i n u t e s b e f o r e s t a r t i n g w o r k .
• R a d i o p a n e l ( s e e p a g e 20-84)
• A u d i o unit ( s e e p a g e 22-288)
• S t e e r i n g c o l u m n ( s e e p a g e 17-9)
• '06-08 m o d e l s : Driver's d a s h b o a r d lower c o v e r
TRIM T O O L A
( s e e p a g e 20-85)
• Passenger's dashboard lower cover (see page
2. R e m o v e t h e v e n t b y r e l e a s i n g t h e h o o k s (B). 20-86)
• F r o n t c o n s o l e c o v e r , both s i d e s ( s e e p a g e 20-85)
3. R e i n s t a l l t h e hook p o r t i o n s of t h e v e n t first, t h e n • P a s s e n g e r ' s a i r b a g a s s e m b l y ( s e e p a g e 23-166)
p u s h t h e c l i p s into p l a c e s e c u r e l y . • Kick p a n e l , both s i d e s ( s e e p a g e 20-71)
• A - p i l l a r t r i m , both s i d e s ( s e e p a g e 20-70)
(cont'd)
20-87
Dashboard
Dashboard Removal/Installation (cont'd)
4 . D i s c o n n e c t t h e e n g i n e w i r e h a r n e s s c o n n e c t o r (A), e n g i n e c o m p a r t m e n t w i r e h a r n e s s c o n n e c t o r s (B), d o o r w i r e
h a r n e s s c o n n e c t o r s ( C ) , rear w i r e h a r n e s s c o n n e c t o r (D), s t e e r i n g h a n g e r b e a m w i r e h a r n e s s c o n n e c t o r s ( E ) , S R S
m a i n h a r n e s s c o n n e c t o r (F), front i m p a c t s e n s o r h a r n e s s c o n n e c t o r ( G ) , radio a n t e n n a h a r n e s s c o n n e c t o r (H), E C M
c o n n e c t o r (I), k e y l e s s entry control unit c o n n e c t o r ( J ) , a n d c o n v e r t i b l e top control unit c o n n e c t o r (K).
5 . R e m o v e t h e g r o u n d bolts (L).
6 . D e t a c h all of t h e h a r n e s s a n d c o n n e c t o r c l i p s .
20-88
7. O p e n t h e d o o r s , r e m o v e t h e c a p s (A), t h e n r e m o v e the bolts ( B , C , D) a n d s c r e w s ( E ) a n d lift up o n t h e d a s h b o a r d
r
(F) to r e l e a s e it f r o m the g u i d e p i n s ( G ) . T a k e c a r e not to s c r a t c h t h e c e n t e r c o n s o l e a n d shift knob.
Fastener Locations
B ^ : Bolt, 2 C ^ : Bolt,2 D ^ : Bolt, 2 E^:Screw,2
6x1.0 mm
9.8 N-m (1.0 k g f m ,
7.2 Ibf-ft)
8. C a r e f u l l y r e m o v e the d a s h b o a r d t h r o u g h t h e front d o o r o p e n i n g .
9. Install t h e d a s h b o a r d in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e d a s h b o a r d fits onto t h e g u i d e p i n s c o r r e c t l y .
• B e f o r e tightening the bolts, m a k e s u r e t h e d a s h b o a r d w i r e h a r n e s s a n d s t e e r i n g h a n g e r b e a m w i r e h a r n e s s a r e
not p i n c h e d .
• E n t e r t h e anti-theft c o d e for the a u d i o s y s t e m , t h e n enter the a u d i o p r e s e t s .
• '02-05 m o d e l s : Do t h e E C M idle learn p r o c e d u r e ( s e e p a g e 11-140).
20-89
Seats
'00-05 M o d e l s
20-90
'06-08 Models
SEAT
(Driver's)
D i s a s s e m b l y / R e a s s e m b l y , page 20-96
S e a t C o v e r R e p l a c e m e n t , page 20-99
20-91
Seats
Seat Removal/Installation
'00-05 Models
N O T E : T a k e c a r e not to s c r a t c h t h e b o d y or t e a r t h e s e a t c o v e r s .
1. R e m o v e the s e a t a s s h o w n .
2 . Install t h e s e a t in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
S l i p the s e a t belt t h r o u g h t h e slits in the s e a t belt g u i d e p r o p e r l y .

M a k e s u r e t h e s e a t belt s w i t c h c o n n e c t o r i s p l u g g e d in p r o p e r l y .
A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to t h e s e a t m o u n t i n g bolts b e f o r e reinstallation.
T i g h t e n the s e a t m o u n t i n g bolts to t h e s p e c i f i e d t o r q u e in t h e s e q u e n c e s h o w n . S l i d e t h e s e a t all t h e w a y b a c k
a n d tighten © a n d (D, t h e n s l i d e it f o r w a r d a n d tighten ® a n d ® . T h e d r i v e r ' s s e a t is s h o w n ; t h e p a s s e n g e r ' s
seat is similar.
T i g h t e n the bolts by h a n d first, t h e n t i g h t e n t h e m to s p e c i f i c a t i o n w i t h a t o r q u e w r e n c h .
Fastener Locations
A>-:Bolt,2 B^:Bort,2
SEAT BELT GUIDE
SEAT BELT
Remove from the
seat belt guide.
10x1
29 N m
(3.0 kgf
SEAT
SEAT BELT
SWITCH HARNESS
(Driver's)
SEAT BELT
8x1.25 mm SWITCH CONNECTOR
22 N-m Disconnect (driver's).
(2.2 kgf.m, 16 Ibf-ft)
20-92
Special Tools Required 4. P a s s e n g e r ' s : R e m o v e t h e s e a t track a n d c o v e r s (A)
K T C t r i m tool s e t S O J A T P 2 0 1 4 * f r o m t h e front of both s e a t t r a c k s .
• Available through the A m e r i c a n Honda Tool and
E q u i p m e n t Program; call 888-424-6857 Outer
'06-08 Models
S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 23-11)
• ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-12)
A l s o r e v i e w the precautions a n d p r o c e d u r e s (see page
23-13) b e f o r e d o i n g r e p a i r s o r s e r v i c e .
NOTE:
avoid d a m a g e w h e n prying c o m p o n e n t s .
• T a k e c a r e not to s c r a t c h t h e b o d y o r t e a r t h e s e a t
covers.
2. D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery,
t h e n w a i t for 3 m i n u t e s before s t a r t i n g w o r k .
3. P a s s e n g e r ' s : D e t a c h t h e front s e a t belt l o w e r

a n c h o r ( s e e s t e p 4 o n p a g e 23-5).
(cont'd)
20-93
Seats
Seat Removal/Installation (cont'd)
5. R e m o v e the seat a s s h o w n .
6 . Install t h e s e a t in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• S l i p t h e s e a t belt t h r o u g h t h e slits in t h e s e a t belt g u i d e p r o p e r l y .

• M a k e s u r e t h e s e a t belt s w i t c h , p a s s e n g e r ' s w e i g h t s e n s o r unit a n d d r i v e r ' s s e a t position s e n s o r c o n n e c t o r a r e
p l u g g e d in properly.
• A p p l y m e d i u m s t r e n g t h t y p e liquid t h r e a d lock to t h e s e a t m o u n t i n g bolts b e f o r e reinstallation.
• T i g h t e n t h e s e a t m o u n t i n g bolts t o t h e s p e c i f i e d t o r q u e in t h e s e q u e n c e s h o w n . S l i d e t h e s e a t all t h e w a y b a c k
a n d t i g h t e n © a n d ® , t h e n s l i d e it f o r w a r d a n d t i g h t e n ® a n d ® .
• T i g h t e n t h e bolts b y h a n d first, t h e n t i g h t e n t h e m t o s p e c i f i c a t i o n w i t h a t o r q u e w r e n c h .
• P a s s e n g e r ' s : B e f o r e a t t a c h i n g t h e front s e a t belt l o w e r a n c h o r , m a k e s u r e t h e r e a r e n o t w i s t s o r kinks in t h e belts.
• E n t e r t h e anti-theft c o d e f o r t h e a u d i o s y s t e m , t h e n e n t e r t h e a u d i o p r e s e t s .
Fastener Locations
A^:Bort,4 B ^ : Bolt, 4
SEAT BELT GUIDE
SEAT BELT
Remove from the
s e a t belt g u i d e . SEAT BELT GUIDE
10x1.25 m m
39 N-m
(4.0 k g f m , 2 9 I b f f t )
SEAT BELT
Remove from the
s e a t belt g u i d e .
8 x 1.25 m m
22 N-m
(2.2 k g f m , 1 6 I b f f t )
PASSENGER'S
WEIGHT SENSOR
UNIT CONNECTOR DRIVER'S SEAT
Disconnect.
HARNESS
CLIP
Detach.
SEAT BELT
SEAT BELT SWITCH CONNECTOR
SWITCH CONNECTOR Disconnect.
Disconnect.
DRIVER'S S E A T POSITION
SENSOR CONNECTOR
Disconnect.
20-94
Seat Disassembly/Reassembly - Driver's

• Available through the A m e r i c a n Honda Tool and E q u i p m e n t P r o g r a m ; call 888-424-6857
'00-05 Models
NOTE:
• M a k e s u r e the b u s h i n g a n d pivot w a s h e r a r e i n s t a l l e d c o r r e c t l y .
• A p p l y m u l t i p u r p o s e g r e a s e to t h e m o v i n g portion of t h e s e a t track.
• T o p r e v e n t w r i n k l e s in t h e s e a t - b a c k c o v e r , stretch t h e m a t e r i a l e v e n l y o v e r t h e p a d .
• R e i n s t a l l the c o n n e c t i n g w i r e t h r o u g h t h e h o l e s in t h e h o o k s .
HOOK
10x1.25 mm
47 N-m (4.8 kgf-m, 35 Ibf-ft)
20-95
Seats
Seat Disassembly/Reassembly - Driver's (cont'd)

• A v a i l a b l e t h r o u g h t h e A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; c a l l 888-424-6857
'06-08 Models
• S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e S R S c o m p o n e n t l o c a t i o n s for t h e a p p r o p r i a t e m o d e l :
- ' 0 0 - 0 5 m o d e l s ( s e e p a g e 23-11)
- ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-13)
• A l s o r e v i e w t h e p r e c a u t i o n s a n d p r o c e d u r e s ( s e e p a g e 2 3 - 1 3 ) b e f o r e d o i n g r e p a i r s or s e r v i c e .
• T h e o p e r a t i o n of t h e d r i v e r ' s s e a t p o s i t i o n s e n s o r m u s t b e c h e c k e d after a n y of t h e s e a c t i o n s ( s e e p a g e 23-32):
- Driver's s e a t position s e n s o r replacement
NOTE:
• T a k e c a r e not to s c r a t c h t h e b o d y o r t e a r t h e s e a t c o v e r s .
• M a k e s u r e t h e b u s h i n g a n d pivot w a s h e r a r e i n s t a l l e d c o r r e c t l y .
• A p p l y m u l t i p u r p o s e g r e a s e t o t h e m o v i n g portion of t h e s e a t track.
• T o p r e v e n t w r i n k l e s in t h e s e a t - b a c k c o v e r , s t r e t c h t h e m a t e r i a l e v e n l y o v e r t h e p a d .
• Adjust the connecting cable a s necessary.
• Make s u r e the connecting cable is connected properly.
47 N-m 22 N-m
(4.8 kgfm, 35 Ibfft) (2.2 kgfm, 16 Ibfft)
20-96
Seat Disassembly/Reassembly - Passenger's
'00-05 Models
NOTE:
• M a k e s u r e t h e b u s h i n g a n d pivot w a s h e r a r e i n s t a l l e d c o r r e c t l y .
• A p p l y m u l t i p u r p o s e g r e a s e to the m o v i n g portion of t h e s e a t track.
• Adjust the connecting cable a s n e c e s s a r y .
• M a k e s u r e the c o n n e c t i n g c a b l e i s c o n n e c t e d p r o p e r l y .
HOOK
RECLINE KNOB
20-97
Seats
Seat Disassembly/Reassembly - Passenger's (cont'd)

K T C t r i m too! s e t S O J A T P 2 0 1 4 *
'06-08 Models
• S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e S R S c o m p o n e n t l o c a t i o n s for t h e a p p r o p r i a t e m o d e l :
- ' 0 0 - 0 5 m o d e l s ( s e e p a g e 23-11)
- ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-12)
• A l s o review the precautions and p r o c e d u r e s (see page 23-13) before doing repairs or service.
• T h e p a s s e n g e r ' s w e i g h t s e n s o r unit m u s t b e c a l i b r a t e d after a n y of t h e s e a c t i o n s ( s e e p a g e 23-31):
- R e p l a c e m e n t of t h e s e a t w e i g h t s e n s o r s
- R e p l a c e m e n t of t h e s e a t w e i g h t s e n s o r unit
NOTE:
• T a k e c a r e not to s c r a t c h t h e b o d y o r t e a r t h e s e a t c o v e r s .
• M a k e s u r e the b u s h i n g a n d pivot w a s h e r a r e i n s t a l l e d c o r r e c t l y .
• A p p l y m u l t i p u r p o s e g r e a s e to t h e m o v i n g portion of t h e s e a t track.
• A d j u s t the c o n n e c t i n g c a b l e a s n e c e s s a r y .
• M a k e s u r e the c o n n e c t i n g c a b l e i s c o n n e c t e d p r o p e r l y .
HOOK
RECUNE KNOB
20-98
Seat Cover Replacement
• A v a i l a b l e t h r o u g h the A m e r i c a n H o n d a T o o l a n d E q u i p m e n t P r o g r a m ; call 8 8 8 - 4 2 4 - 6 8 5 7
NOTE:
• T a k e c a r e not to tear the s e a m s or d a m a g e t h e s e a t c o v e r s .
• U s e the a p p r o p r i a t e tool f r o m the K T C t r i m tool s e t to a v o i d d a m a g e w h e n p r y i n g c o m p o n e n t s .
Seat-back Cover '00-05 Models
1. R e m o v e t h e s e a t - b a c k c o v e r in n u m b e r e d s e q u e n c e .
2. Install the c o v e r in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :

• T o p r e v e n t w r i n k l e s w h e n installing a s e a t - b a c k c o v e r , m a k e s u r e the m a t e r i a l is s t r e t c h e d e v e n l y o v e r t h e p a d
before s e c u r i n g the c l i p s , V e l c r o f a s t e n e r s a n d h o o k s .
• R e p l a c e the r e l e a s e d c l i p s w i t h n e w o n e s u s i n g c o m m e r c i a l l y a v a i l a b l e u p h o l s t e r y p l i e r s .
• R e p l a c e a n y d a m a g e d h e a d restraint c o v e r c l i p s .
Fastener Locations
A • : Screw, 4 B• : Screw, 2 C |> : Clip, 4
RESTRAINT
(cont'd)
20-99
Seats
Seat Cover Replacement (cont'd)
20-100
Seat-back Cover '06-08 Models
1. R e m o v e the s e a t - b a c k c o v e r in n u m b e r e d s e q u e n c e .
2. Install the c o v e r in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• T o p r e v e n t w r i n k l e s w h e n installing a s e a t - b a c k c o v e r , m a k e s u r e t h e m a t e r i a l is s t r e t c h e d e v e n l y o v e r the p a d
before s e c u r i n g the c l i p s , V e l c r o f a s t e n e r s a n d h o o k s .
• R e p l a c e the r e l e a s e d c l i p s w i t h n e w o n e s u s i n g c o m m e r c i a l l y a v a i l a b l e u p h o l s t e r y p l i e r s .
Fastener Locations
• : Screw, 2
(cont'd)
20-101
Seats
Seat Cover Replacement (cont'd)
20- 102
Seat Cushion Cover
1. R e m o v e the s e a t ; ' 0 0 - 0 5 m o d e l s ( s e e p a g e 2 0 - 9 2 ) , ' 0 6 - 0 8 m o d e l s ( s e e p a g e 20-93).
2. R e m o v e t h e s e a t c u s h i o n , d r i v e r ' s ; ' 0 0 - 0 5 m o d e l s ( s e e p a g e 20-95), ' 0 6 - 0 8 m o d e l s ( s e e p a g e 2 0 - 9 6 ) ,

p a s s e n g e r ' s ; ' 0 0 - 0 5 m o d e l s ( s e e p a g e 20-97), ' 0 6 - 0 8 m o d e l s ( s e e p a g e 20-98).
3. R e m o v e t h e s e a t c u s h i o n c o v e r in n u m b e r e d s e q u e n c e .
4. Install the c o v e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• T o p r e v e n t w r i n k l e s w h e n installing a s e a t c u s h i o n c o v e r , m a k e s u r e the m a t e r i a l i s s t r e t c h e d e v e n l y o v e r t h e
p a d before s e c u r i n g the c l i p s .
• R e p l a c e the r e l e a s e d c l i p s w i t h n e w o n e s u s i n g c o m m e r c i a l l y a v a i l a b l e u p h o l s t e r y ring p l i e r s .
0 CLIPS
Release from under the seat cushion. ® CLIPS
WIRE
(Pad side)
20-103
Bumpers
Front Bumper Removal/Installation
'00-03 Models
NOTE:
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e front b u m p e r .
• T a k e c a r e not to s c r a t c h t h e front b u m p e r a n d b o d y .
1. R e m o v e t h e front b u m p e r a s s h o w n .
2. Install t h e b u m p e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d m a k e s u r e t h e front b u m p e r e n g a g e s t h e h o o k s of the

c o r n e r u p p e r b e a m s a n d front f e n d e r s s e c u r e l y .
Fastener Locations
A^:Bolt,5 B ^ : Bolt 9 C ^ : Bolt,2 D ^ : Screw,2
UPPER STIFFENER
20-104
'04-08 Models (Except CR Model)
NOTE:
• H a v e a n a s s i s t a n t help y o u r e m o v e a n d install t h e front b u m p e r .
• T a k e c a r e not to s c r a t c h the front b u m p e r a n d b o d y .
2 . Install t h e b u m p e r in the r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e front b u m p e r e n g a g e s the h o o k s of the c o r n e r u p p e r b e a m s a n d front f e n d e r s s e c u r e l y .

Fastener Locations
A^:Bolt,5 B ^ : Bolt, 6 C ^ : Bolt, 2 D ^ : Screw, 2 E>:Clip,3
FRONT BUMPER
UPPER STIFFENER
20-105
Bumpers
Front Bumper Removal/Installation (cont'd)
CR Model
NOTE:
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e front b u m p e r .
2 . Install t h e b u m p e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e front b u m p e r e n g a g e s t h e h o o k s of t h e c o r n e r u p p e r b e a m s a n d front f e n d e r s s e c u r e l y .
Fastener Locations
A ^ : Bolt, 5 B^:BoK,6 C^:Bort,2 D ^ : Screw, 2 E>:Clip,3
UPPER STIFFENER
20-106
Front Air Spoiler Replacement
CR Model
NOTE:
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e s p o i l e r .
1. R e m o v e t h e front b u m p e r ( s e e p a g e 2 0 - 1 0 6 ) .
2. R e m o v e t h e bolts (A, B) a n d s c r e w s (C) s e c u r i n g t h e front a i r s p o i l e r , t h e n r e m o v e t h e front a i r s p o i l e r .
3. Install t h e front air s p o i l e r in t h e r e v e r s e o r d e r of r e m o v a l .
Fastener Locations
A^:Bort,8 B^:Bolt,7 C^:Screw,4
20-107
Bumpers
F r o n t Grille R e p l a c e m e n t
'04-08 Models S p e e d nut removal
N O T E : T a k e c a r e not to s c r a t c h t h e front b u m p e r .
1. R e m o v e t h e front b u m p e r .
• E x c e p t C R m o d e l ( s e e p a g e 20-105)
• CR m o d e l (see page 20-106)
2. R e m o v e t h e clip s e c u r i n g the l i c e n s e plate b a s e (A).
Fastener Location
4. Pull the top e d g e of the grille (A) out to r e l e a s e the

p i n s (B) of the front b u m p e r (C), a n d t h e n r e l e a s e
t h e t a b s (D) o n both s i d e s , a n d r e l e a s e the d o u b l e -
s i d e d a d h e s i v e t a p e (E) a n d p i n s (F), t h e n r e m o v e
t h e grille f r o m t h e b u m p e r .
C B
3. F r o m the b a c k of the front b u m p e r (A), r e l e a s e the

s p e e d nuts s e c u r i n g t h e front b u m p e r grille (B) by
u s i n g pliers (C) a s s h o w n .
Fastener Locations
t>: S p e e d nut, 6
20-108
5 . R e m o v e t h e bolt, t h e n r e m o v e t h e l i c e n s e plate
b a s e b r a c k e t (A) f r o m the grille (B).
Fastener Location
• : Bolt, 1
6 . Install t h e grille in t h e r e v e r s e o r d e r of r e m o v a l ,
• B e f o r e installing t h e grille, c l e a n t h e grille

bonding surface with isopropyl alcohol, and
apply primer.
• B e f o r e installing t h e grille, s c r a p e off t h e d o u b l e -
s i d e d a d h e s i v e t a p e , t h e n c l e a n t h e front b u m p e r
s u r f a c e with i s o p r o p y l a l c o h o l , a n d attach n e w
d o u b l e - s i d e d a d h e s i v e t a p e to t h e b u m p e r .
Adhesive tape: T h i c k n e s s 0.8 m m (0.03 in.)

W i d t h 10 m m (0.39 in.)
• After installing t h e grille to the b u m p e r , p r e s s t h e

double-sided a d h e s i v e tape portions s e c u r e l y .
• R e p l a c e the s p e e d nuts w i t h n e w o n e s .
20-109
Bumpers
Rear Bumper Removal/Installation
NOTE:
• H a v e a n a s s i s t a n t h e l p y o u r e m o v e a n d install t h e r e a r b u m p e r .
• T a k e c a r e not to s c r a t c h t h e r e a r b u m p e r a n d b o d y .
1. R e m o v e t h e r e a r b u m p e r a s s h o w n . F o r ' 0 4 - 0 8 m o d e l s , to r e l e a s e t h e s p e e d n u t s , refer to front grille r e p l a c e m e n t

(see page 20-108).
2. Install t h e b u m p e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• M a k e s u r e t h e r e a r b u m p e r e n g a g e s t h e h o o k s ( b u m p e r s p a c e r s a n d u n d e r t h e taillight) o n e a c h s i d e s e c u r e l y .
• M a k e s u r e t h e l i c e n s e plate light c o n n e c t o r i s p l u g g e d in p r o p e r l y .
• C h e c k if t h e c l i p s a r e d a m a g e d o r s t r e s s - w h i t e n e d , a n d if n e c e s s a r y / r e p l a c e t h e m w i t h n e w o n e s .
• R e p l a c e t h e s p e e d n u t s w i t h n e w o n e s ('04-08 m o d e l s ) .
• F o r ' 0 4 - 0 8 m o d e l s : If t h e r e a r b u m p e r p r o t e c t o r i s r e i n s t a l l e d , c l e a n it a n d t h e b u m p e r w i t h a s p o n g e d a m p e n e d
in i s o p r o p y l a l c o h o l . A p p l y p r i m e r to t h e p r o t e c t o r s u r f a c e , a n d t h e n a p p l y n e w d o u b l e - s i d e d t a p e .
Double-sided adhesive tape: T h i c k n e s s 0.8 m m (0.03 in.)

W i d t h 10 m m (0.39 in.)
Fastener Locations
A ^ : Screw, 2 B^:Screw,2 C>:Cllp,2 D>:Clip,5 E > : Speed nut, 2

('01-08 models) ('00 model) ('04-08 models)
REAR BUMPER
20-110
Hood
Hood Adjustment
1. S l i g h t l y l o o s e n e a c h h o o d h i n g e bolt.
2 . A d j u s t the hood alignment:
• A d j u s t t h e h o o d right a n d left, a s w e l l a s f o r w a r d a n d r e a r w a r d , by u s i n g t h e e l o n g a t e d h o l e s o n t h e h o o d
h i n g e s (A).
• T u r n the h o o d e d g e c u s h i o n s (B), a s n e c e s s a r y , to m a k e t h e h o o d fit f l u s h w i t h t h e b o d y at front a n d s i d e e d g e s .
6 x 1.0 m m
9 . 8 N m (1.0 k g f m ,
7.2 Ibf-ft)
3. A d j u s t the h o o d latch (C) to o b t a i n the p r o p e r height at the f o r w a r d e d g e , a n d m o v e t h e h o o d latch right or left

until t h e striker (D) is c e n t e r e d in the h o o d l a t c h .
4. T i g h t e n e a c h bolt s e c u r e l y .
(cont'd)
20-111
Hood
Hood Adjustment (cont'd)
5. C h e c k t h a t t h e h o o d o p e n s p r o p e r l y a n d l o c k s
securely.
6. A p p l y t o u c h - u p paint to t h e h i n g e m o u n t i n g bolts
and around the hinges.
7. R e m o v e t h e air g u i d e plate c o v e r ( s e e p a g e 2 0 - 1 3 2 ) ,
t h e n r e m o v e t h e latch c o v e r (A). A p p l y
m u l t i p u r p o s e g r e a s e to e a c h location of t h e h o o d
latch (R) a n d h o o d h i n g e (C) a s i n d i c a t e d by t h e
arrows.
20-112
Hood Insulator Replacement
NOTE:
• T a k e c a r e not to s c r a t c h the h o o d .
• U s e a c l i p r e m o v e r to r e m o v e t h e c l i p s .
1. R e m o v e t h e h o o d i n s u l a t o r i n n u m b e r e d s e q u e n c e .
2 . Install t h e i n s u l a t o r in t h e r e v e r s e o r d e r of r e m o v a l , a n d n o t e t h e s e i t e m s :
• Make s u r e the windshield w a s h e r tubes are connected properly.
Fastener Locations
A>:Clip,10 B [ > : Clip, 2 C>:Clip,2

(Except C R model) (Except C R model) (CR model)
® HOOD
INSULATOR
(Except C R model)
® CLIPS
(Except C R model)
(?) H O O K
®HOOK
Except C R model: B
CR model: C
(DY-JOINTCLIP ® WINDSHIELD WASHER T U B E S

Detach. Release from the clips (B, C)
and disconnect.
20-113
Trunk Lid
Trunk Lid Adjustment
1. S l i g h t l y l o o s e n e a c h bolt.
2 . A d j u s t t h e trunk lid a l i g n m e n t :
• A d j u s t t h e trunk lid right a n d left, a s w e l l a s f o r w a r d a n d r e a r w a r d , b y u s i n g t h e e l o n g a t e d h o l e s o n t h e trunk lid

h i n g e s (A).
• T u r n t h e trunk lid e d g e c u s h i o n s (B) in o r o u t a s n e c e s s a r y to m a k e t h e trunk lid fit f l u s h w i t h t h e b o d y at t h e r e a r
and side edges.
• A d j u s t t h e fit b e t w e e n t h e trunk lid a n d t h e t r u n k lid o p e n i n g b y m o v i n g t h e striker ( C ) .
3. T i g h t e n e a c h bolt s e c u r e l y .
4 . M a k e s u r e t h e trunk lid o p e n s p r o p e r l y a n d l o c k s s e c u r e l y .
5 . A p p l y t o u c h - u p paint to t h e trunk lid m o u n t i n g bolts a n d a r o u n d t h e h i n g e s .
20-114
Trunk Lid Torsion Bar Replacement

T o r s i o n b a r a s s e m b l y tool 0 7 A A F - S N A A 1 0 0
NOTE:
• T a k e c a r e not to s c r a t c h t h e b o d y .
• U s e a t o r s i o n bar tool to r e m o v e a n d install the t o r s i o n b a r s .
• R e m o v e the right t o r s i o n b a r first, a n d t h e n r e m o v e t h e left t o r s i o n bar.
1. R e m o v e the trunk lid t o r s i o n b a r s a s s h o w n .
2. Install the t o r s i o n b a r s in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• T h e right t o r s i o n b a r h a s a p i e c e of r u b b e r o n it a s s h o w n . Install t h e right a n d left t o r s i o n b a r s in their p r o p e r

locations.
• M a k e s u r e the trunk lid o p e n s p r o p e r l y a n d l o c k s s e c u r e l y .
L E F T TORSION BAR RIGHT TORSION BAR
20-115
Trunk Lid
Trunk Lid Rubber Protector Replacement
NOTE: 2. C R m o d e l : If n e c e s s a r y , r e m o v e t h e trunk s i d e
• T a k e c a r e not to s c r a t c h t h e trunk lid. p r o t e c t o r s (B).
* U s e a c l i p r e m o v e r to r e m o v e t h e c l i p s .
Fastener Locations
1. R e m o v e t h e t r u n k lid r u b b e r p r o t e c t o r s (A) a s >:Clip,4

shown.
warn
Except C R model
Fastener Locations
[ > : Clip, 8
3. Note t h e s e items w h e n reinstalling the protectors:
• C h e c k if t h e c l i p s a r e d a m a g e d o r s t r e s s -
CR model w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h
new ones.
Fastener Locations
>:Clip,4 •:Nut,4
20-116
Trunk Lid Weatherstrip Replacement
1. R e m o v e t h e trunk lid w e a t h e r s t r i p b y pulling it off.
2 . L o c a t e t h e p a i n t e d a l i g n m e n t m a r k (A) o n t h e trunk
lid w e a t h e r s t r i p (B). A l i g n the p a i n t e d m a r k w i t h t h e
a l i g n m e n t t a b in t h e c e n t e r of t h e trunk, a n d install
t h e w e a t h e r s t r i p all t h e w a y a r o u n d f a c i n g in t h e
d i r e c t i o n s h o w n . M a k e s u r e t h e r e a r e n o w r i n k l e s in
the weatherstrip.
3 . C h e c k for w a t e r l e a k s .
20-117
Fuel Fill Door
Fuel Fill Door Adjustment
1. S l i g h t l y l o o s e n t h e h i n g e m o u n t i n g bolts (A). 5 . A p p l y m u l t i p u r p o s e g r e a s e to e a c h location

i n d i c a t e d b y the a r r o w s .
6 . A p p l y t o u c h - u p paint to t h e h i n g e m o u n t i n g bolts
a n d a r o u n d the h i n g e s .
A
6 x 1.0 m m
9 . 8 N - m (1.0 k g f m ,
7 . 2 Ibf-ft)
2 . A d j u s t t h e fuel fill d o o r (B) in o r out until it's f l u s h

w i t h the b o d y , a n d up or d o w n a s n e c e s s a r y to
equalize the g a p s .
3. T i g h t e n t h e h i n g e m o u n t i n g b o l t s .
4 . C h e c k that t h e fuel fill d o o r o p e n s p r o p e r l y a n d

locks securely.
20-118
Exterior Trim
Cowl Cover Replacement
NOTE:
• U s e a clip r e m o v e r to r e m o v e the c l i p s .
1. R e m o v e the w i n d s h i e l d w i p e r a r m s ( s e e p a g e 2 2 - 1 8 5 ) .
2. R e m o v e the c o w l c o v e r a s s h o w n .
3. Install the c o v e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
Fastener Locations
A > : Clip, 7 B>:Clip,9
COWL COVER
20-119
Exterior Trim
Rear Tray Opening Molding Rear Window Lower Molding
NOTE: N O T E : T a k e c a r e not to s c r a t c h the b o d y .

• B e c a r e f u l not to pry t o o f a r or y o u m a y b e n d t h e 1. R e m o v e t h e r e a r w i n d o w l o w e r m o l d i n g a s s h o w n .
molding.
• Put o n g l o v e s to protect y o u r h a n d s . 2 . Install t h e m o l d i n g in t h e r e v e r s e o r d e r of r e m o v a l ,
a n d c h e c k if t h e clip i s d a m a g e d or s t r e s s - w h i t e n e d ,
1. R e m o v e t h e s e i t e m s , t h e n r e m o v e t h e r e a r t r a y a n d if n e c e s s a r y , r e p l a c e it w i t h a n e w o n e .
opening molding a s s h o w n :
Fastener Locations
• C o n v e r t i b l e t o p a s s e m b l y ( s e e p a g e 20-39) • : Screw, 1 > : Clip, 1

• B-pillar outer w e a t h e r s t r i p s , both s i d e s ( s e e p a g e
20-53)
• D r a i n tank, both s i d e s ( s e e p a g e 2 0 - 5 3 )
2 . R e m o v e t h e rear t r a y o p e n i n g m o l d i n g a s s h o w n .
Fastener Locations
• : Bolt, 12
REAR WINDOW
LOWER MOLDING
(1.0 k g f m , 7 . 2 I b f f t )
3. Install t h e m o l d i n g in t h e r e v e r s e o r d e r o f r e m o v a l .
20-120
Trunk Lid Spoiler Replacement
CR model 2 . C l o s e t h e t r u n k lid, t h e n r e m o v e t h e trunk lid

spoiler.
NOTE:
• T a k e c a r e not to s c r a t c h t h e trunk lid.
1. O p e n t h e trunk lid, a n d r e m o v e t h e nuts (A) a n d

bolts (B) f r o m i n s i d e t h e trunk lid.
Fastener Locations
A * : Nut, 2 B^:Bolt,4
6x1.0 mm
6x1.0 mm 9.8 N - m
9.8 N-m (1.0 k g f m , 7 . 2 Ibf-ft)
(1.0 k g f m , 7 . 2 Ibf-ft)
(cont'd)
20-121
Exterior Trim
Trunk Lid Spoiler Replacement (cont'd)
3. If n e c e s s a r y , s e p a r a t e t h e trunk lid s p o i l e r i n n e r foot (A) a n d t h e trunk lid s p o i l e r o u t e r foot (B).
-A R e m o v e t h e s c r e w s ( C ) .
-2 R e l e a s e t h e h o o k s (D) w i t h a flat-tip s c r e w d r i v e r w r a p p e d w i t h protective t a p e , t h e n s e p a r a t e t h e trunk lid
s p o i l e r i n n e r foot a n d t h e trunk lid s p o i l e r o u t e r foot.
- 3 R e m o v e t h e n u t s (E) a n d t h e bolts ( F ) , t h e n r e m o v e t h e t r u n k lid s p o i l e r foot stiffener (G) f r o m t h e trunk lid
s p o i l e r (H).
N O T E : T h i s illustration s h o w s t h e left s i d e of t h e t r u n k lid s p o i l e r , r e p e a t t h e p r o c e d u r e o n t h e right s i d e in t h e

s a m e manner.
Fastener Locations
C^:Screw,3 E # : N u t , 4 F ^ : Bolt, 1
4 . Install t h e trunk lid s p o i l e r in t h e r e v e r s e o r d e r of r e m o v a l .
20-122
Emblem Replacement
N O T E : W h e n r e m o v i n g t h e e m b l e m s , t a k e c a r e not to s c r a t c h t h e b o d y . U s e d e n t a l f l o s s to c u t t h e a d h e s i v e s a f e l y .
A p p l y the e m b l e m s w h e r e s h o w n , a n d note t h e s e items:
• C l e a n t h e b o d y s u r f a c e w i t h a s p o n g e d a m p e n e d in a l c o h o l .
• A f t e r c l e a n i n g , k e e p o i l , g r e a s e a n d w a t e r f r o m getting o n t h e s u r f a c e .
FRONT " H " EMBLEM
S2000 E M B L E M (Both sides)
CR EMBLEM
(Both sides, C R model)
A d h e s i v e tape: T h i c k n e s s 0.8 m m (0.03 in.)
U n i t : m m (in.) FRONT BUMPER
FRONT BUMPER
'00-01 m o d e l s '02-08 m o d e l s
ADHESIVE EMBLEM. ADHESIVE
TAPE
TAPE \V
CUP
CUP
H3 II y*t a*x i i l f l
m II *"/^ ^v'' If ift
=a GUIDE
GUIDE
PIN
PIN
FRONT " H " EMBLEM FRONT " H " EMBLEM
B O D Y LINE BODY LINE

Left s i d e Right side
FRONT SIDE TURN S2000 E M B L E M FRONT SIDE TURN

SIGNAL LIGHT SIGNAL LIGHT
ADHESIVE CREMBLEM 135.8(5.35) / / C RE M B L E M ADHESIVE

TAPE (CR model) / / (CR model) TAPE
1 9 9 . 3 (7.85)
2 1 7 . 5 (8.56)
(cont'd)
20-123
Exterior Trim
Emblem Replacement (cont'd)
REAR " H " EMBLEM
A d h e s i v e t a p e : T h i c k n e s s 0.8 m m (0.03 in.)

REAR CR EMBLEM
U n i t : m m (in.)
(CR model)
T R U N K LID
T R U N K LID
'00-01 m o d e l s '02-08 m o d e l s
ADHESIVE EMBLEM. ADHESIVE EMBLEM
TAPE TAPE
CLIP
CLIP
*v—U"^ iTill
yj ==
fc *S' II III GUIDE
GUIDE
PIN
PIN
/
R E A R ' H" E M B L E M REAR "H" EMBLEM
ADHESIVE
TAPE
7 2 . 5 (2.85)
zzzzzzz
42 '////////&
(1.65) 9 . 6 (0.38)
REAR CR EMBLEM
(CR model)
E d g e of t h e t r u n k lid
20-124
A-Pillar Exterior Trim Replacement
NOTE:
• K e e p dust a w a y from the working a r e a .
• W h e n w o r k i n g at l o w e r t e m p e r a t u r e s , h e a t t h e b o d y a n d t r i m w i t h a h a i r d r y e r .
B o d y : a b o u t 59 °F ( 1 5 * 0
T r i m : a b o u t 8 6 °F (30 °C)
• W h e n h e a t i n g t h e t r i m , heat it e v e n l y a n d g r a d u a l l y to p r e v e n t d e f o r m a t i o n .
• C l e a n t h e b o d y b o n d i n g s u r f a c e w i t h a s p o n g e d a m p e n e d in i s o p r o p y l a l c o h o l .
• After c l e a n i n g , k e e p o i l , g r e a s e a n d w a t e r f r o m getting o n the s u r f a c e .
1. R e m o v e t h e s e i t e m s , t h e n p e e l up t h e old t r i m w h i l e h e a t i n g it w i t h a hair d r y e r :
• A - p i l l a r - h e a d e r w e a t h e r s t r i p ( s e e p a g e 20-52)
• A - p i l l a r m o l d i n g , both s i d e s ( s e e p a g e 20-52)
2. A p p l y t h e t r i m in t h e n u m b e r e d s e q u e n c e , a n d note t h e s e i t e m s :
• Align the application tape with the A-pillar a s s h o w n .

• W h e n p r e s s i n g t h e t r i m , s l o w l y p r e s s it f r o m t h e c o r n e r to p r e v e n t air b u b b l e s a n d w r i n k l e s .
• If t h e r e a r e air b u b b l e s in t h e t r i m , p e e l u p the t r i m , t h e n r e a p p l y it.
• After r e i n s t a l l i n g all r e m o v e d p a r t s , c h e c k that t h e b o d y c o l o r is c o v e r e d b y t h e t r i m .
20-125
Fenderwell
Inner Fender Replacement
N O T E : T a k e c a r e not to s c r a t c h t h e b o d y .
2 . R e m o v e the inner fender a s s h o w n .
3 . Install t h e i n n e r f e n d e r in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
Fastener Locations
A ^ : Bolt,5 B^:Screw,2 C > : C l i p , 17
L<3C
20-126
Strake Replacement
N O T E : T a k e c a r e not to s c r a t c h t h e b o d y .
1. R e m o v e t h e s t r a k e s a s s h o w n .
2 . Install the s t r a k e s in the r e v e r s e o r d e r of r e m o v a l .
Fastener Locations
A ^ : Bolt, 2 B ^ : Bolt,4 C ^ : Screw, 3
REAR 9 . 8 N - m (1.0 k g f - m ,
STRAKE A 7.2 Ibf-ft)
20-127
Fenderwell
Fenderwell Trim Replacement Rear Air Outlet Replacement
N O T E : T h e s t e e l c o r e in t h e f e n d e r w e l l t r i m c a n n o t b e N O T E : T a k e c a r e not to s c r a t c h t h e b o d y .
r e s t o r e d to its o r i g i n a l s h a p e o n c e it i s bent. R e p l a c e t h e
f e n d e r w e l l t r i m w h e n the s t e e l c o r e i s bent. 1. R e m o v e t h e s e i t e m s :
1. R e m o v e t h e f e n d e r w e l l t r i m b y pulling it out. • R e a r t r i m p a n e l ( s e e p a g e 20-77)
2 . Install t h e f e n d e r w e l l t r i m , a n d note t h e s e i t e m s : • R e a r b u m p e r ( s e e p a g e 20-110)
• C l e a n the body bonding surface with a s p o n g e 2 . R e m o v e t h e r e a r a i r outlet a s s h o w n .

d a m p e n e d in i s o p r o p y l a l c o h o l .
• After c l e a n i n g , k e e p o i l , g r e a s e a n d w a t e r f r o m 3. Note t h e s e i t e m s w h e n reinstalling t h e air outlet:
getting o n t h e c l e a n s u r f a c e . • C h e c k if t h e c l i p s a r e d a m a g e d o r s t r e s s -
• A p p l y c l e a r s e a l a n t in t h e g r o o v e of t h e t r i m at w h i t e n e d , a n d if n e c e s s a r y , r e p l a c e t h e m w i t h
the area indicated by the arrow. new ones.
• S c r a p e o r w i p e t h e e x c e s s s e a l a n t off w i t h a soft • P u s h t h e c l i p s into p l a c e s e c u r e l y .
s h o p t o w e l d a m p e n e d in i s o p r o p y l a l c o h o l .
Fastener Locations
Sealant: C e m e d i n e P / N 08712-0004, or equivalent

>:Clip,2
FENDERWELL TRIM
20-128
Openers
HOOD OPENER CABLE

20-129
Openers
Hood Opener Cable Replacement
NOTE:
• T a k e c a r e not to s c r a t c h t h e b o d y a n d r e l a t e d p a r t s .
• T a k e c a r e not t o kink t h e c a b l e .
• Inner fender (see page 20-126)

• K i c k p a n e l ( s e e p a g e 20-71)
• Front b u m p e r , '00-03 m o d e l s (see p a g e 20-104), '04-08 m o d e l s (except C R model) (see page 20-105), C R model
( s e e p a g e 20-106)
• A i r g u i d e plate c o v e r ( s e e p a g e 20-132)
2 . D i s c o n n e c t t h e h o o d o p e n e r c a b l e (A) f r o m t h e h o o d latch (B) a n d h o o d r e l e a s e h a n d l e (C) ( s e e p a g e 20-132).
Fastener Locations
D>:Clip,1 E>:Clip,6
3 . U s i n g a c l i p r e m o v e r , d e t a c h t h e c l i p s (D, E ) a n d r e m o v e t h e g r o m m e t (F) f r o m t h e b o d y , t h e n r e m o v e t h e h o o d
o p e n e r c a b l e . T a k e c a r e not to kink t h e c a b l e .
4. Install t h e c a b l e in t h e r e v e r s e o r d e r of r e m o v a l , a n d note t h e s e i t e m s :
• R o u t e t h e c a b l e t h r o u g h t h e h o l e (G) in t h e b o d y .
20-130
Fuel Fill Door Opener Cable Replacement
NOTE:
• T a k e c a r e not t o s c r a t c h t h e b o d y a n d related p a r t s .
• T a k e c a r e not t o kink t h e c a b l e .
• R e a r s i d e t r i m ( s e e p a g e 20-72)
• R e a r tray ( e x c e p t C R m o d e l ) ( s e e p a g e 20-73)
• R e a r c o v e r ( C R m o d e l ) ( s e e p a g e 20-75)
• T r u n k s i d e t r i m p a n e l , left s i d e ( s e e p a g e 20-77)
2. R e m o v e t h e fuel fill d o o r o p e n e r k n o b (A) f r o m t h e f u e l fill d o o r o p e n e r b r a c k e t (B) b y t u r n i n g it 9 0 °, a n d r e m o v e

t h e fuel fill d o o r latch (C) f r o m t h e b o d y in the s a m e w a y .
Fastener Location
[ > : Cable cushiontape, 1
3. R e m o v e t h e fuel fill d o o r o p e n e r c a b l e (D).
4. Install t h e c a b l e in t h e r e v e r s e o r d e r of r e m o v a l w i t h a n e w p i e c e of c a b l e c u s h i o n t a p e .
20-131
Openers
Hood Release Handle Replacement Hood Latch Replacement
N O T E : T a k e c a r e not to kink t h e c a b l e . N O T E : T a k e c a r e not to kink t h e c a b l e .
1. R e m o v e t h e kick p a n e l ( s e e p a g e 20-71). Replacement
2. R e m o v e t h e h o o d r e l e a s e h a n d l e a s s h o w n . 1. R e m o v e t h e a i r g u i d e plate c o v e r , t h e n r e m o v e t h e
h o o d latch a s s h o w n .
3. Install t h e h a n d l e in t h e r e v e r s e o r d e r of r e m o v a l ,
a n d note t h e s e i t e m s : 2. Install t h e latch in t h e r e v e r s e o r d e r of r e m o v a l , a n d
• M a k e s u r e t h e h o o d o p e n e r c a b l e is c o n n e c t e d
properly. • A p p l y m u l t i p u r p o s e g r e a s e to t h e h o o d latch.
• M a k e s u r e t h e h o o d o p e n e r c a b l e is c o n n e c t e d
• Make s u r e the hood o p e n s properly.
properly.
Fastener Locations • M a k e s u r e t h e c a b l e a c t u a t e s t h e latch before y o u
• :Bort,2 close the hood.
• A d j u s t t h e h o o d latch a l i g n m e n t ( s e e s t e p 3 o n
page 20-111).
• Make s u r e the hood locks s e c u r e l y .
new ones.
• P u s h t h e c o v e r c l i p s into p l a c e s e c u r e l y .
Fastener Locations
• :Bolt,3 >:Clip,3
HOOD RELEASE HANDLE
PLATE COVER
20-132
Trunk Lid Latch Replacement
Grease Application NOTE:

N O T E : R e m o v e t h e latch c o v e r , a n d a p p l y m u l t i p u r p o s e • T a k e c a r e not to s c r a t c h t h e b o d y .
g r e a s e to e a c h location of t h e h o o d latch indicated b y • T a k e c a r e not to b e n d t h e c y l i n d e r r o d .
the a r r o w s .
1. R e m o v e t h e trunk lid latch a s s h o w n .
2 . Install t h e latch in t h e r e v e r s e o r d e r of r e m o v a l , a n d
• M a k e s u r e the c o n n e c t o r is p l u g g e d in p r o p e r l y
a n d the opener cable is connected properly.
• M a k e s u r e the rod a c t u a t e s t h e latch before y o u
c l o s e t h e trunk lid.
• M a k e s u r e t h e trunk lid o p e n s p r o p e r l y a n d l o c k s
securely.
Fastener Locations
HOOD LATCH • :Bolt,2
T R U N K LID L A T C H
ACTUATOR CONNECTOR
Disconnect.
CYLINDER R O D
LATCH COVER
T R U N K LID L A T C H
6x1.0 mm
9.8 N m '00-08 m o d e l s s h a p e
(1.0 k g f - m , 7.2 I b f f t ) (With handle)
20-133
Openers
Trunk Lid Lock Cylinder Replacement
NOTE:
• T a k e c a r e not to b e n d the c y l i n d e r r o d .
1. R e m o v e the trunk lid lock c y l i n d e r a s s h o w n .
2 . Install the c y l i n d e r in the r e v e r s e o r d e r of r e m o v a l ,

• M a k e s u r e the c y l i n d e r rod is c o n n e c t e d p r o p e r l y .
• M a k e s u r e the trunk lid o p e n s p r o p e r l y .
Fastener Locations
• : Bolt, 2
6 x 1.0 m m
9.8 N m (1.0 k g f - m ,
7.2 Ibf-ft)
20-134
Frame
Front Subframe Replacement
A f t e r l o o s e n i n g t h e s u b f r a m e m o u n t i n g b o l t s , b e s u r e to r e p l a c e t h e m w i t h n e w o n e s
Reference hole alignment
FRONT SUBFRAME
SUBFRAME REFERENCE HOLE

(Body side)
INSTALLATION
REFERENCE HOLE
S C R E W D R I V E R or (Subframe side)
TAPERED PUNCH
8 x 1.0 m m
2 2 N-m (2.2 k g f m .
3 8 N - m (3.9 k g f - m , BRACE
2 8 Ibf-ft)
20-135
Frame
Rear Subframe Replacement
A f t e r l o o s e n i n g t h e s u b f r a m e m o u n t i n g bolts, be s u r e to r e p l a c e t h e m w i t h n e w o n e s .
Reference hole alignment
1 4 x 1.5 m m
1 0 3 N m (10.5 k g f m , 7 5 . 9 Ibf-ft)
Replace.
20-136
Frame Brace Replacement
6 x 1.0 m m
9 . 8 N m (1.0 k g f m , 7.2 Ibf ft)
20-137
Frame
Frame Repair Chart
Top View
Unit: mm (in.) a For bumper beam 010 (0.4) f Damper center

0: Inner diameter b For tie down 023X30 (0.9X1.2) g For subframe 017 (0.7)
c For stabilizer 024 (0.9) h For upper arm 013 (0.5)
d For stabilizer 024 (0.9) i For subframe 017 (0.7)
e For upper arm 013 (0.5) j For subframe 017 (0.7)
POINT i POINT k
POINT
POINT c
POINT b
POINT a
CENTER SI t\ §
LINE
VERTICAL
LINE
20-138
k Locate hole 025 (1.0) P For rear subframe 016 (0.63)
1 For transmission mount bracket 013 (0.5) q For rear subframe 016 (0.63)
m For transmission mount bracket 013 (0.5) r Rear damper center 050 (2.0)
n For transmission mount bracket e13 (0.5) s For rear subframe 0 I 6 (0.63)
o Locate hole 015 (0.59) t Locate hole 020 (0.8)
722 (28.4)
Frame
Frame Repair Chart (cont'd)
Side View
Unit: mm (in.) a For bumper beam 010 (0.4) f Damper center

0: Inner diameter b For tie down 023X30 (0.9X1.2) g For subframe 017 (0.7)
c For stabilizer 024 (0.9) h For upper arm 013 (0.5)
d For stabilizer 024 (0.9) i For subframe 017 (0.7)
e For upper arm 013 (0.5) j For subframe 017 (0.7)
POINT e
[SECTION: AA] [SECTION: BB]
M12X1.25
BASE
LINE
20-140
k Locate hole 025 (1.0) P For rear subframe 016 (0.63)
I For transmission mount bracket 013 (0.5) q For rear subframe 016 (0.63)
m For transmission mount bracket 013 (0.5) r Rear damper center 050 (2.0)
n For transmission mount bracket 013 (0.5) s For rear subframe 016 (0.63)
o Locate hole 015 (0.59) t Locate hole 020 (0.8)
POINT r
[SECTION: D D ]
20-141
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If HVAC maintenance is required)
T h e S 2 0 0 0 S R S i n c l u d e s a d r i v e r ' s a i r b a g in t h e s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in t h e d a s h b o a r d a b o v e the

g l o v e b o x , a n d s e a t belt t e n s i o n e r s in t h e s e a t belt r e t r a c t o r s . I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e the S R S is
S R S c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , or replacing t h e s e items requires special precautions and tools, and
• T o a v o i d r e n d e r i n g the S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury or d e a t h in t h e e v e n t of a s e v e r e frontal

c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d b e d o n e b y a n a u t h o r i z e d H o n d a d e a l e r .
• Do not b u m p or i m p a c t the S R S unit, o r front i m p a c t s e n s o r s w h e n the ignition s w i t c h is O N (II), or for at l e a s t 3
m i n u t e s after the ignition s w i t c h is t u r n e d O F F ; o t h e r w i s e , t h e s y s t e m m a y fail in a c o l l i s i o n , or a i r b a g s m a y d e p l o y .
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e box. D o not u s e electrical
test e q u i p m e n t o n t h e s e c i r c u i t s .
HVAC (Heating, Ventilation, and Air Conditioning)
HVAC (Heating. Ventilation, and Air S y m p t o m Troubleshooting Index 21-37
Conditioning) S y s t e m Description 21-38
Special T o o l s 21-2 Circuit Diagram 21-40
D T C Troubleshooting 21-42
Heating Recirculation Control Motor Circuit
C o m p o n e n t Location Index 21-3 Troubleshooting 21-50
General Troubleshooting Information . 21-4 H V A C Control Power a n d G r o u n d Circuit
D T C Troubleshooting Index 21-6 Troubleshooting 21-51
S y m p t o m Troubleshooting Index 21-7 A / C C o n d e n s e r F a n Circuit
S y s t e m Description . 21-8 Troubleshooting 21-53
Circuit Diagram . 21-9 Radiator and A / C C o n d e n s e r F a n C o m m o n
D T C Troubleshooting 21-10 Circuit Troubleshooting 21-54
Recirculation Control Motor Circuit A / C C o m p r e s s o r Clutch Circuit
Troubleshooting 21-16 Troubleshooting 21-55
Heater Control Power and G r o u n d Circuit A / C Pressure S w i t c h Circuit
Troubleshooting 21-18 Troubleshooting 21-58
Power Transistor T e s t 21-19 Evaporator Temperature S e n s o r T e s t 21-60
Air Mix Control Motor T e s t 21-20 H V A C Control Unit
Air Mix Control Motor Replacement 21-20 Removal/Installation 21-60
Mode Control Motor Test 21-21 Blower/Evaporator Unit
Mode Control Motor Replacement . 21-21 Removal/Installation 21-61
Recirculation Control Motor T e s t 21-22 Blower/Evaporator Unit Component
Recirculation Control Motor Replacement 21-62
Replacement 21-22 E x p a n s i o n Valve Replacement 21-63
Heater Control Panel * Heater Unit/Core Replacement 21-63
Removal/Installation 21-23 A / C C o m p r e s s o r Replacement 21-66
Blower Unit Removal/Installation 21-23 A / C C o m p r e s s o r Clutch Check 21-68
Blower Unit Component Replacement 21-24 A / C C o m p r e s s o r Clutch Overhaul 21-69
* Heater Unit/Core Replacement 21-24 A / C C o m p r e s s o r T h e r m a l Protector
Dust and Pollen Filter Replacement 21-27 Replacement 21-71
Heater V a l v e Cable Adjustment 21-27 A / C C o m p r e s s o r Relief Valve
Replacement 21-71
Heating/Air Conditioning A / C C o n d e n s e r Replacement 21-72
C o m p o n e n t Location Index 21-29 Refrigerant Recovery 21-73
A / C S e r v i c e T i p s and Precautions 21-32 S y s t e m Evacuation 21-74
A / C S y s t e m Inspection 21-32 S y s t e m Charging 21-75
A / C Refrigerant Oil Replacement 21-33 Refrigerant Leak T e s t 21-76
A / C Line Replacement 21-34 A / C System Test 21-77
D T C Troubleshooting Index 21-36
on
HVAC (Heating, Ventilation, and Air Conditioning)
Special Tools

© 07SAZ-001000A Backprobe Set 2
21-2
Heating
'08 model
(confd)
21-3
Heating
'08 model
D U S T AND POLLEN FILTER

, HEATER VALVE CABLE

A d j u s t m e n t p a g e 21-27 BLOWER UNIT
Removal/Installation,
page 21-23
BLOWER UNIT COMPONENT
Replacement,
p a g e 21-24
RECIRCULATION
CONTROL MOTOR
T e s t page 21-22
Replacement
page 21-22
POWER TRANSISTOR
Test, page 21-19
AIR MIX C O N T R O L M O T O R
T e s t p a g e 21-20
MODE CONTROL MOTOR
T e s t , p a g e 21-21
HEATER CONTROL PANEL
21-4
How to Retrieve a DTC
T h e h e a t e r control p a n e l h a s a s e l f - d i a g n o s t i c f u n c t i o n . T o run t h e s e l f - d i a g n o s t i c f u n c t i o n , d o t h e f o l l o w i n g :
1. S e t the m o d e control dial o n the V e n t p o s i t i o n .
3. W i t h i n 5 s e c o n d s after turning t h e ignition s w i t c h o n , p r e s s t h e r e c i r c u l a t i o n control s w i t c h the r e q u i r e d n u m b e r of

t i m e s d e p e n d i n g o n t h e recirculation indicator s t a t u s :
• if the indicator is O N , p r e s s the r e c i r c u l a t i o n control s w i t c h 5 t i m e s .

• If the indicator is O F F , p r e s s the r e c i r c u l a t i o n control s w i t c h 6 t i m e s .
T h e recirculation indicator will c o m e o n for 2 s e c o n d s , t h e n blink t h e D i a g n o s t i c T r o u b l e C o d e ( D T C ) to indicate a

faulty c o m p o n e n t . If no D T C s a r e f o u n d , the indicator will not blink after the initial 2 s e c o n d s light.
RECIRCULATION INDICATOR LIGHT
E x a m p l e of D T C I n d i c a t i o n P a t t e r n ( D T C 2 )
Recirculation
indicator
light o n
Recirculation
indicator
l i g h t off
0.3 s e c
2 sec
W i t h i n five s e c o n d s after t h e
i g n i t i o n s w i t c h i s t u r n e d O N (II),
press the recirculation control
s w i t c h t h e r e q u i r e d n u m b e r of 1.5 s e c 0.3 s e c
t i m e s depending on t h e recirculation
indicator light s t a t u s
Canceling the Self-diagnosis Function
4. T u r n the ignition s w i t c h to L O C K (0) to c a n c e l the s e l f - d i a g n o s t i c f u n c t i o n . After c o m p l e t i n g repair w o r k , run the

s e l f - d i a g n o s t i c f u n c t i o n a g a i n to m a k e s u r e that t h e r e a r e no other m a l f u n c t i o n s .
21-5
Heating
DTC Detection Item Page

(Recirculation
Indicator Blinks)
1 A p r o b l e m in t h e air m i x c o n t r o l m o t o r c i r c u i t ( s e e p a g e 21-10)
2 A p r o b l e m in t h e m o d e control m o t o r c i r c u i t ( s e e p a g e 21-11)
3 A p r o b l e m in t h e b l o w e r m o t o r circuit ( s e e p a g e 21-13)
• In c a s e of multiple p r o b l e m s , t h e r e c i r c u l a t i o n i n d i c a t o r will i n d i c a t e o n l y t h e D T C w i t h t h e l e a s t n u m b e r of b l i n k s .
• In c a s e of a n intermittent f a i l u r e , t h e h e a t e r c o n t r o l p a n e l w i l l s t o r e t h e D T C until t h e ignition s w i t c h is in L O C K (0).
21-6
F o r electrical m a l f u n c t i o n s w h i c h a r e indicated by t h e s e l f - d i a g n o s t i c s y s t e m , refer to s e l f - d i a g n o s t i c f u n c t i o n

( s e e p a g e 21-5).

R e c i r c u l a t i o n control d o o r s d o not Recirculation Control Motor Circuit • B l o w n No. 20 (7.5 A ) f u s e in t h e
change between Fresh and T r o u b l e s h o o t i n g ( s e e p a g e 21-16) under-dash fuse/relay box
Recirculate • C l e a n l i n e s s a n d t i g h t n e s s of all
connectors
B l o w e r a n d h e a t e r c o n t r o l s d o not Heater C o n t r o l P o w e r a n d G r o u n d • B l o w n No. 56 (40 A ) f u s e in the
work Circuit T r o u b l e s h o o t i n g ( s e e p a g e main under-hood fuse/relay box,
21-18) a n d No. 20 (7.5 A ) f u s e in the
• P o o r g r o u n d at N o . G 2 0 1 , G 4 0 2
• C l e a n l i n e s s a n d t i g h t n e s s of all
connectors
Insufficient h e a t i n g 1. C h e c k t h e c o o l a n t level ( s e e p a g e D a m a g e d cylinder head gasket
10-9)
2. C h e c k t h e radiator c a p ( s e e p a g e
10-6)
3. Check the coolant temperature
4. C h e c k t h e o p e r a t i o n of t h e air m i x
control m o t o r a n d d o o r ( s e e p a g e
21-20)
5. C h e c k t h e o p e r a t i o n of t h e h e a t e r
v a l v e ( s e e p a g e 21-27)
6. C h e c k t h e b l o w e r m o t o r for
obstructions
7. C h e c k for air l e a k s a r o u n d t h e
ducts a n d vents
8. C h e c k t h e inlet h e a t e r h o s e
temperature
• If it i s C O L D , c h e c k for
r e s t r i c t i o n s in t h e h o s e , a
d a m a g e d or leaking t h e r m o s t a t ,
a n d a d a m a g e d or leaking w a t e r
pump.
• If it i s H O T , c h e c k for
r e s t r i c t i o n s in t h e h e a t e r c o r e .
B a c k f l u s h the h e a t e r c o r e u s i n g
standard commercially
a v a i l a b l e e q u i p m e n t , or r e p l a c e
the heater core.
21-7
Heating
System Description
H E A T E R C O N T R O L P A N E L 30P C O N N E C T O R
szz.
Cavity W i r e color Signal

1 PNK AIR MIX C O O L OUTPUT
2 PNK/BLU AIR MIX HOT OUTPUT
3 YEL/BLU MODE DEF OUTPUT
4 YEL/RED MODE VENT OUTPUT
5 GRY AIR MIX P O T E N T I A L + 5 V OUTPUT
6 PNK/BLK AIR MIX P O T E N T I A L OUTPUT
8 YEL/GRN MODE 2 OUTPUT
9 BRN/WHT MODE 1 OUTPUT
10 LTGRN SENSOR COMMON GROUND INPUT
11 BLU/RED BLOWER FEEDBACK INPUT
13 BLU/YEL POWER TRANSISTOR BASE OUTPUT
15 GRN/WHT FRESH INPUT
16 GRN/YEL RECIRCULATE INPUT
21 YEL MODE 4 OUTPUT
22 BLK/WHT MODE 3 OUTPUT
23 BLK/WHT GAUGE ASSEMBLY OUTPUT
26 BLK GROUND INPUT
27 RED GAUGE ASSEMBLY OUTPUT
28 RED/BLK TAILLIGHTS RELAY INPUT
29 WHT/RED + B (Power) INPUT
30 BLK/YEL IG2(Power) INPUT
21-8
[
Circuit Diagram
21-9
Heating
DTC Troubleshooting
DTC 1: A Problem in the Air Mix Control 5. T u r n t h e ignition s w i t c h to O N (II), a n d m e a s u r e t h e
Motor Circuit s a m e t e r m i n a l s for v o l t a g e .
1. D i s c o n n e c t the air m i x control m o t o r 7 P c o n n e c t o r .
GRY PNK/BLK
2. T e s t t h e air m i x c o n t r o l m o t o r ( s e e p a g e 2 1 - 2 0 ) .
PNK/BLU LTGRN
Is the air mix control motor OK?
1 1 1 8
H K
PNK
3. D i s c o n n e c t t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r .
4. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d t h e W i r e s i d e of f e m a l e t e r m i n a l s
heater control panel 30P connector No. 1,2, 5 , 6 ,

a n d 10 t e r m i n a l s individually. Is there any voltage?
Y E S — R e p a i r s h o r t to p o w e r in t h e w i r e ( s ) b e t w e e n
t h e h e a t e r c o n t r o l p a n e l a n d t h e air m i x control
GRY PNK/BLK
motor. T h i s short m a y also d a m a g e the heater
PNK/BLU LTGRN c o n t r o l p a n e l . R e p a i r t h e s h o r t to p o w e r before
| J - r e p l a c i n g t h e h e a t e r control p a n e l . •
1 2 8 4 6 6
21 221X128
8 9 10 11 /
16 16
PNK
//// // 26 27 » 29 80
Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e ( s )
b e t w e e n t h e h e a t e r control p a n e l a n d t h e air m i x
control m o t o r . •
21-10
6. T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k for DTC 2: A Problem in the Mode Control Motor
c o n t i n u i t y b e t w e e n the f o l l o w i n g t e r m i n a l s of t h e Circuit
h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d t h e air m i x
control motor 7P connector. 1. D i s c o n n e c t t h e m o d e control m o t o r 7 P c o n n e c t o r .
30P: 7P:
No. 1 No. 2 2. T e s t the m o d e c o n t r o l m o t o r ( s e e p a g e 21-21).
No. 2 No. 1
No. 5 No. 5 Is the mode control motor OK ?
No. 6 No. 3
No. 10 N o . 7 Y E S — G o to s t e p 3.
GRY PNK/BLK 3. D i s c o n n e c t t h e h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r .
PNK/BLU LTGRN
4. C h e c k for c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d the
JL 1
2 9 4 i 0
1^1 9 9 10 11 / / 13 h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r N o . 3, 4 , 8 , 9 ,
PNK
16 IB
/ /, / y 21
// 2d 27 23 29 80
1 0 , 2 1 , a n d 22 terminals individually.
YEL/GRN
YEL/RED BRN/WHT
PNK/BLK
PNK YEL/BLU LTGRN
PNK/BLU Bazn
GRY
LTGRN 1 2 8
...
4 6 8
"IXI*
8
J -
9 10 11
/ / 13
16 18
// / 21
// 28 27 28 29 89
AIR MIX C O N T R O L M O T O R 7P C O N N E C T O R
Y E S — C h e c k for l o o s e w i r e s o r p o o r c o n n e c t i o n s at W i r e s i d e of f e m a l e t e r m i n a l s
t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d at t h e
air m i x control m o t o r 7 P c o n n e c t o r . If t h e Is there continuity?
connections are g o o d , substitute a known-good
h e a t e r control p a n e l , a n d r e c h e c k . If t h e s y m p t o m / Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e ( s )
indication g o e s a w a y , r e p l a c e t h e original h e a t e r b e t w e e n t h e h e a t e r control p a n e l a n d t h e m o d e
control panel. • control m o t o r . •
N O — R e p a i r o p e n in t h e w i r e ( s ) b e t w e e n the h e a t e r N O — G o to s t e p 5.
c o n t r o l p a n e l a n d t h e air m i x control m o t o r . •
7. R e m o v e the air m i x control m o t o r ( s e e p a g e 21-20).
8. C h e c k t h e air m i x c o n t r o l linkage a n d d o o r s for

smooth movement.
Do the air mix control linkage and doors move

smoothly?
Y E S — R e p l a c e t h e air m i x control m o t o r . •
N O — R e p a i r t h e air m i x control linkage or d o o r s . •
(cont'd)
21-11
Heating

5. T u r n the ignition s w i t c h to O N (II), a n d m e a s u r e t h e T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k for
s a m e terminals for voltage. continuity b e t w e e n t h e f o l l o w i n g t e r m i n a l s of t h e
h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d t h e m o d e
HEATER C O N T R O L P A N E L 30P C O N N E C T O R
control m o t o r 7 P c o n n e c t o r .
YEL/GRN 30P: 7P:
YEL/RED No. 3 No. 2
No. 4 No. 1
No. 8 No. 5
No. 9 No. 6
N o . 10 N o . 7
N o . 21 No. 3
NoJ 2 2 No. 4
YEL/GRN
YEL/RED BRN/WHT
Is there any voltage? YEL/BLU LTGRN
1 2 3 4 6 6
>< / / 8 9 10 11
/ /
18
t h e h e a t e r control p a n e l a n d t h e m o d e control
16 16
/// 21 *IXI» 29 27 28 29 30
motor. T h i s s h o r t m a y a l s o d a m a g e the h e a t e r
control p a n e l . R e p a i r t h e s h o r t to p o w e r before
replacing the heater control panel. •
M O D E C O N T R O L M O T O R 7P C O N N E C T O R
Y E S — C h e c k for l o o s e w i r e s o r p o o r c o n n e c t i o n s at
t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d at t h e
m o d e control m o t o r 7 P c o n n e c t o r . If t h e
h e a t e r control p a n e l , a n d r e c h e c k . If the s y m p t o m /
indication g o e s a w a y , r e p l a c e t h e original heater
control p a n e l . •
N O — R e p a i r o p e n in the w i r e ( s ) b e t w e e n the h e a t e r
control p a n e l a n d m o d e c o n t r o l m o t o r . •
21-12
7. R e m o v e t h e m o d e control m o t o r ( s e e p a g e 21-21). DTC 3: A Problem in the Blower Motor Circuit
8. C h e c k t h e m o d e c o n t ro l linkage a n d d o o r s for 1. C h e c k t h e No. 5 6 ( 4 0 A ) f u s e in t h e m a i n

smooth movement. u n d e r - h o o d f u s e / r e l a y b o x , a n d t h e N o . 2 0 (7.5 A )
f u s e in t h e u n d e r - d a s h f u s e / r e l a y box.
Do the mode control linkage and doors move
smoothly? Are the fuses OK?
Y E S — R e p l a c e the m o d e control m o t o r . • Y E S — G o to s t e p 2.
N O — R e p a i r the m o d e control linkage or d o o r s . • N O — R e p l a c e the fuse(s), a n d recheck. •
2. C o n n e c t t h e No. 2 t e r m i n a l of the b l o w e r m o t o r 2 P
c o n n e c t o r to b o d y g r o u n d w i t h a j u m p e r w i r e .
B L O W E R MOTOR 2P C O N N E C T O R
JUMPER BLU/BLK
WIRE
Does the blower motor run?
6. D i s c o n n e c t t h e p o w e r t r a n s i s t o r 5 P c o n n e c t o r .
(cont'd)
21-13
Heating
•7. C h e c k for continuity b e t w e e n t h e N o . 5 t e r m i n a l of 12. D i s c o n n e c t t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r .
the power transistor 5P connector and body ground.
13. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 11 a n d No. 13
P O W E R T R A N S I S T O R 5P C O N N E C T O R t e r m i n a l s of t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r
a n d body ground individually.
HEATER CONTROL PANEL 30P CONNECTOR

1 3
BLU/RED BLU/YEL
4
D 5
1 2 3 4 5 6 8 9 10 11
/ / 13
15 16
/// 21
// 26 27 28 29 30

N O — C h e c k for a n o p e n in t h e w i r e b e t w e e n t h e b e t w e e n t h e h e a t e r control p a n e l a n d t h e p o w e r
p o w e r t r a n s i s t o r a n d b o d y g r o u n d . If t h e w i r e is O K , transistor. •
c h e c k for p o o r g r o u n d at G 4 0 2 . •
8. C o n n e c t t h e N o . 4 a n d N o . 5 t e r m i n a l s of t h e p o w e r
transistor 5P connector with a j u m p e r wire. 14. C h e c k for c o n t i n u i t y b e t w e e n t h e f o l l o w i n g
t e r m i n a l s of t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r
P O W E R T R A N S I S T O R 5P C O N N E C T O R
and the power transistor 5P connector.
30P: 5P:
XL N o . 11 N o . 1
N o . 13 N o . 3
1
D
tJ
BLU/RED BLU/YEL
BLU/BLK BLK
1 2 3 4 5 6
/ 8 9 10 11
/ / 13
JUMPER WIRE
15 16
//// 21
// 26 27 28 29 30
BLU/RED BLU/YEL
Does the blower motor run at high speed?

POWER TRANSISTOR 5P CONNECTOR
Y E S — G o to s t e p 10. Wire side of female terminals
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e p o w e r Is there continuity?
transistor and blower motor. •
N O — R e p a i r o p e n in t h e w i r e ( s ) b e t w e e n t h e h e a t e r
11. D i s c o n n e c t t h e j u m p e r w i r e . control p a n e l a n d t h e p o w e r t r a n s i s t o r . •
21-14
IB
15. R e c o n n e c t the heater control p a n e l 3 0 P c o n n e c t o r . 2 3 . M e a s u r e t h e v o l t a g e b e t w e e n t h e No. 4 t e r m i n a l of
the blower motor relay 4P socket a n d body ground.
16. T e s t t h e p o w e r t r a n s i s t o r ( s e e p a g e 21-19).
BLOWER MOTOR R E L A Y 4P S O C K E T
Is the power transistor OK? n
Y E S — C h e c k for l o o s e w i r e s or p o o r c o n n e c t i o n s at
t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r , b l o w e r
m o t o r 2 P c o n n e c t o r a n d at the p o w e r t r a n s i s t o r 5 P
c o n n e c t o r . If the c o n n e c t i o n s a r e g o o d , substitute a
k n o w n - g o o d heater control p a n e l , a n d r e c h e c k . If
the symptom/indication g o e s a w a y , replace the
original heater control p a n e l . •
N O — R e p l a c e the power transistor. •

18. D i s c o n n e c t the j u m p e r w i r e .
19. D i s c o n n e c t the b l o w e r motor 2 P c o n n e c t o r .
N O — R e p l a c e the main under-hood fuse/relay
20. M e a s u r e the v o l t a g e b e t w e e n t h e No. 1 t e r m i n a l of box.B
the b l o w e r motor 2 P c o n n e c t o r a n d b o d y g r o u n d .
B L O W E R MOTOR 2P C O N N E C T O R
2 5 . M e a s u r e the v o l t a g e b e t w e e n t h e N o . 1 t e r m i n a l of
t h e b l o w e r m o t o r relay 4 P s o c k e t a n d b o d y g r o u n d .
BLU/WHT
BLOWER MOTOR RELAY 4P S O C K E T
BLK/YEL
2 1

4
a 3
Y E S — R e p l a c e the b l o w e r motor. •
2 2 . R e m o v e the b l o w e r motor r e l a y f r o m the m a i n
u n d e r - h o o d f u s e / r e l a y box, a n d test it ( s e e p a g e N O — R e p a i r o p e n in the w i r e b e t w e e n the No. 2 0
22-48). (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e b l o w e r m o t o r relay. •
Is the relay OK?
Y E S — G o to s t e p 2 3 .
N O — R e p l a c e the b l o w e r m o t o r relay. •
(cont'd)
21-15
Heating
DTC Troubleshooting (cont'd) Recirculation Control Motor Circuit
Troubleshooting
2 6 , T u r n the ignition s w i t c h to L O C K (0).
2 7 . C h e c k for continuity b e t w e e n the No. 2 t e r m i n a l of 1. C h e c k the N o . 20 (7.5 A ) f u s e in the u n d e r - d a s h

the blower motor relay 4P socket and body ground. fuse/relay box.

Is the fuse OK?
BLK Y E S — G o to s t e p 2.
2 1
N O — R e p l a c e the f u s e , a n d r e c h e c k . •
4
[ 3
2. D i s c o n n e c t t h e recirculation control m o t o r 7 P
connector.
4. M e a s u r e t h e voltage b e t w e e n t h e N o . 1 t e r m i n a l of
the r e c i r c u l a t i o n control m o t o r 7 P c o n n e c t o r a n d
body ground.
RECIRCULATION CONTROL MOTOR
Y E S — R e p a i r o p e n in t h e B L U / W H T w i r e b e t w e e n
the blower motor relay and the blower motor. •
N O — C h e c k for a n o p e n in the w i r e b e t w e e n the 1
b l o w e r m o t o r r e l a y a n d b o d y g r o u n d . If the w i r e is BLK/YEL
O K , c h e c k for p o o r g r o u n d at G 2 0 1 . •
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e N o . 20
(7.5 A ) f u s e in the u n d e r - d a s h f u s e / r e l a y b o x a n d
the r e c i r c u l a t i o n control motor. •
6. T e s t the recirculation control m o t o r ( s e e p a g e

21-22).
Is the recirculation control motor OK?
7. D i s c o n n e c t t h e heater control p a n e l 3 0 P c o n n e c t o r .
21-16
DB
8. C h e c k for continuity b e t w e e n t h e N o . 15 a n d N o . 16 10. T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k f o r
t e r m i n a l s of t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r c o n t i n u i t y b e t w e e n t h e f o l l o w i n g t e r m i n a l s of t h e
and body ground individually. h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d t h e
r e c i r c u l a t i o n control m o t o r 7 P c o n n e c t o r .
HEATER C O N T R O L PANEL 30P C O N N E C T O R
30P: 7P:
N o . 15 N o . 5
N o . 16 N o . 7
1 2 3 4 5 6 8 9 10 11 / 13
2 1 26 27 28 29 30
GRN/
ZZZZ ^LZ-^ZZ W i r e s i d e of f e m a l e t e r m i n a l s
WHT 1 2 3 4 5 6
/ 8 9 10 11
/ / 13
GRN/
15 16
////
| GRN/YEL
21 22 ) x ( 23
// 26 27 28 29 30
WHT
a) Co)
GRN/WHT GRN/YEL
/ s ffrere continuity?

b e t w e e n t h e h e a t e r control p a n e l a n d t h e W i r e s i d e of f e m a l e t e r m i n a l s
recirculation control motor. •
9. T u r n t h e ignition s w i t c h to O N (II), a n d m e a s u r e t h e t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d at t h e
s a m e t e r m i n a l s for v o l t a g e . recirculation control m o t o r 7 P c o n n e c t o r . If t h e
c o n n e c t i o n s a r e g o o d , substitute a k n o w n - g o o d
h e a t e r control p a n e l , a n d r e c h e c k . If t h e s y m p t o m /
indication g o e s a w a y , r e p l a c e t h e original h e a t e r
<T-?
I>/
1 2 3 4 5 8 9 10 11
/ / 13
N O — R e p a i r o p e n in t h e w i r e ( s ) b e t w e e n t h e h e a t e r
GRN/
15 16
/ / //
GRN/YEL
'a 2Z
X 23
// 26 27 28 29 30
control p a n e l a n d t h e r e c i r c u l a t i o n control m o t o r . •
WHT
11. R e m o v e t h e r e c i r c u l a t i o n control m o t o r ( s e e p a g e
21-22).
12. C h e c k t h e r e c i r c u l a t i o n control linkage a n d d o o r s

for s m o o t h m o v e m e n t .
Do the recirculation control linkage and doors

Is there any voltage? move smoothly?
Y E S — R e p a i r s h o r t to p o w e r in t h e w i r e ( s ) b e t w e e n Y E S — R e p l a c e t h e recirculation control motor. •

the heater control p a n e l a n d t h e recirculation
control m o t o r . T h i s s h o r t m a y a l s o d a m a g e t h e N O — R e p a i r t h e recirculation control linkage o r
heater c o n t r o l p a n e l . R e p a i r t h e s h o r t to p o w e r doors. •
before r e p l a c i n g t h e h e a t e r control p a n e l . •
21-17
Heating
Heater Control Power and Ground Circuit Troubleshooting
1. C h e c k t h e N o . 54 (30 A ) f u s e in t h e m a i n M e a s u r e t h e v o l t a g e b e t w e e n the No. 29 t e r m i n a l

u n d e r - h o o d f u s e / r e l a y b o x , a n d t h e N o . 20 (7.5 A ) of the h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r a n d b o d y
a n d N o . 2 5 (7.5 A ) f u s e s in t h e u n d e r - d a s h f u s e / ground.
relay box.
Are the fuses OK?

<r~?
1 2 3 4 5 6 8 9 10 11
26 27 28 29 30
N O — R e p l a c e the fuse(s), and recheck. • WHT/RED
2. D i s c o n n e c t t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r .
4. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 3 0 t e r m i n a l Wire s i d e of female terminals
of the h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r a n d b o d y
ground. Is there battery voltage?
1 2 3 4 5 6
/ X
8 9 10 11
/ /
13 (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e h e a t e r control p a n e l . •
15 16
//// 21
22 23
// 26 27 26 29 30
BLK/YEL C h e c k for c o n t i n u i t y b e t w e e n the No. 26 t e r m i n a l of

t h e h e a t e r control p a n e l 3 0 P c o n n e c t o r a n d b o d y
ground.
1 2 3 4 5 6 8 9 10 11
Is there battery voltage ? 26 27 28 29 30
BLK
(7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d
the heater control panel. •
Y E S — C h e c k for l o o s e w i r e s or poor c o n n e c t i o n s at
t h e h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r . If t h e
h e a t e r control p a n e l , a n d r e c h e c k . If t h e s y m p t o m
indication g o e s a w a y , r e p l a c e t h e original heater
N O — C h e c k for a n o p e n in t h e w i r e b e t w e e n the
h e a t e r control p a n e l a n d b o d y g r o u n d . If t h e w i r e is
O K , c h e c k for p o o r g r o u n d at G 4 0 2 . B
21-18
Power Transistor Test
1. D i s c o n n e c t the 5 P c o n n e c t o r f r o m t h e p o w e r 3. C a r e f u l l y r e l e a s e t h e lock t a b o n t h e N o . 3 t e r m i n a l
transistor. ( B L U / Y E L ) (A) in t h e 5 P c o n n e c t o r , t h e n r e m o v e the
t e r m i n a l a n d i n s u l a t e it f r o m b o d y g r o u n d .
2. M e a s u r e the r e s i s t a n c e b e t w e e n t h e N o . 1 a n d
No. 4 t e r m i n a l s of the p o w e r t r a n s i s t o r . It s h o u l d b e
a b o u t 1.4—1.5 k £ .
N O T E : A l s o c h e c k t h e b l o w e r motor. P o w e r
t r a n s i s t o r failure c a n b e c a u s e d by a d e f e c t i v e
b l o w e r motor.
• If t h e r e s i s t a n c e is w i t h i n t h e s p e c i f i c a t i o n s , g o to
s t e p 3.
JUMPER
• If t h e r e s i s t a n c e i s not w i t h i n t h e s p e c i f i c a t i o n s , WIRE
replace the power transistor.
V
(To 12 V p o w e r
POWER TRANSISTOR source on vehicle)
4. R e c o n n e c t t h e 5 P c o n n e c t o r to t h e p o w e r t r a n s i s t o r .
5. S u p p l y 12 V to the N o . 3 c a v i t y w i t h a j u m p e r w i r e .
1
4 1 6. T u r n t h e ignition s w i t c h to O N (II), a n d c h e c k that
the b l o w e r motor runs.
I—I
\
• If t h e b l o w e r m o t o r d o e s not r u n , r e p l a c e t h e
5 3
power transistor.
I
N O T E : A faulty b l o w e r m o t o r c a n c a u s e t h e
p o w e r t r a n s i s t o r to fail. If t h e p o w e r t r a n s i s t o r is
r e p l a c e d , a l s o c h e c k t h e b l o w e r m o t o r for
b i n d i n g , a n d r e p l a c e it if n e c e s s a r y .
• If t h e b l o w e r m o t o r r u n s , t h e p o w e r t r a n s i s t o r is
OK.
21-19
Heating
Air Mix Control Motor Test Air Mix Control Motor Replacement
1. D i s c o n n e c t t h e IP c o n n e c t o r f r o m t h e air m i x 1. R e m o v e t h e a u d i o unit ( s e e p a g e 22-288).
control motor.
2. R e m o v e t h e p a s s e n g e r ' s d a s h b o a r d l o w e r c o v e r
INOTICEl ( s e e p a g e 20-86).
I n c o r r e c t l y a p p l y i n g p o w e r a n d g r o u n d to
t h e air m i x control m o t o r w i l l d a m a g e it. 3. D i s c o n n e c t t h e 7 P c o n n e c t o r (A) f r o m t h e air m i x
Follow the instructions carefully. c o n t r o l m o t o r (B). R e m o v e t h e s e l f - t a p p i n g s c r e w s
a n d t h e air m i x control m o t o r f r o m t h e h e a t e r unit.
2. C o n n e c t battery p o w e r to t h e . N o . 1 t e r m i n a l of t h e
air m i x control m o t o r , a n d g r o u n d t h e N o . 2
t e r m i n a l ; t h e air m i x c o n t r o l m o t o r s h o u l d r u n , a n d
s t o p at M a x Hot. If it d o e s n ' t , r e v e r s e t h e
c o n n e c t i o n s ; t h e air m i x c o n t r o l m o t o r s h o u l d r u n ,
a n d s t o p at M a x C o o l .
3. If t h e air m i x control m o t o r d o e s not run in s t e p 2 ,

r e m o v e it, t h e n c h e c k t h e air m i x c o n t r o l l i n k a g e
a n d d o o r s for s m o o t h m o v e m e n t .
• If t h e linkage a n d d o o r s m o v e s m o o t h l y , r e p l a c e
t h e air m i x control motor.
• If t h e linkage or d o o r s stick o r b i n d , r e p a i r t h e m
as needed.
• If t h e air m i x control m o t o r r u n s s m o o t h l y , g o to
s t e p 4.
4. Install the m o t o r in t h e r e v e r s e o r d e r of r e m o v a l .
M a k e s u r e t h e pin o n t h e m o t o r is p r o p e r l y
e n g a g e d w i t h t h e linkage. After installation, m a k e
s u r e the m o t o r r u n s s m o o t h l y .
1 2 3 4 5 6 7
4. M e a s u r e t h e r e s i s t a n c e b e t w e e n t h e N o . 5 a n d
N o . 7 t e r m i n a l s . It s h o u l d b e b e t w e e n 4.2 to 7.8 k Q .
5. R e c o n n e c t t h e air m i x c o n t r o l m o t o r 7 P c o n n e c t o r ,
t h e n turn the ignition s w i t c h to O N (II).
6. U s i n g t h e b a c k p r o b e s e t , m e a s u r e t h e v o l t a g e
b e t w e e n t h e No. 3 a n d N o . 7 t e r m i n a l s .
Max Cool: about 1 V

M a x Hot: a b o u t 4 V
7. If either t h e r e s i s t a n c e or v o l t a g e r e a d i n g a r e not a s
s p e c i f i e d , r e p l a c e the air m i x c o n t r o l m o t o r .
21-20
BD
Mode Control Motor Test Mode Control Motor Replacement
1. D i s c o n n e c t the 7 P c o n n e c t o r f r o m t h e m o d e control T. S e t the m o d e c o n t r o l dial o n D E F w i t h t h e ignition

motor. s w i t c h to O N (II).
INOTICEI 2. R e m o v e t h e d r i v e r ' s h e a t e r outlet.

Incorrectly a p p l y i n g p o w e r a n d g r o u n d to
t h e m o d e control m o t o r will d a m a g e it. 3. D i s c o n n e c t the 7 P c o n n e c t o r (A) f r o m t h e m o d e
F o l l o w the i n s t r u c t i o n s c a r e f u l l y . c o n t r o l m o t o r (B). R e m o v e t h e r o d s (C) f r o m t h e
m o d e control linkage (D). R e m o v e t h e s e l f - t a p p i n g
2. C o n n e c t battery p o w e r to t h e N o . 1 t e r m i n a l of t h e s c r e w s a n d the m o d e control m o t o r f r o m t h e h e a t e r
m o d e control m o t o r , a n d g r o u n d t h e No. 2 unit.
t e r m i n a l ; t h e m o d e control m o t o r s h o u l d run
D
s m o o t h l y , a n d s t o p at V e n t . If it d o e s n ' t , r e v e r s e t h e
c o n n e c t i o n s ; the m o d e control m o t o r s h o u l d run
s m o o t h l y , a n d s t o p at Defrost. W h e n t h e m o d e
control m o t o r s t o p s r u n n i n g , d i s c o n n e c t battery
power immediately.
MODE CONTROL MOTOR
1 2 3 4 5 6 7
4. Install the m o t o r in t h e r e v e r s e o r d e r of r e m o v a l .
M a k e s u r e the pin o n t h e linkage i s p r o p e r l y
e n g a g e d with t h e m o t o r . After installation, m a k e
3. If t h e m o d e control m o t o r d o e s not run in s t e p 2 , s u r e t h e motor r u n s s m o o t h l y .
r e m o v e it, t h e n c h e c k the m o d e c o n tro l linkage a n d
d o o r s for s m o o t h m o v e m e n t .
• If t h e linkage a n d d o o r s m o v e s m o o t h l y , r e p l a c e
t h e m o d e control motor.
• If t h e linkage or d o o r s stick or b i n d , repair t h e m
as needed.
• If t h e m o d e c o n t ro l m o t o r r u n s s m o o t h l y , g o to
s t e p 4.
4. U s e a digital m u l t i m e t e r w i t h a n output of 1 m A o r
l e s s at the 20 k Q, r a n g e . W i t h t h e m o d e control
m o t o r r u n n i n g a s in s t e p 2 , c h e c k for continuity
b e t w e e n t h e No. 7 t e r m i n a l a n d t h e N o . 3, 4, 5, a n d
6 t e r m i n a l s in d iv id u a lly . T h e r e s h o u l d b e continuity
for a m o m e n t at e a c h t e r m i n a l a s t h e m o t o r m o v e s
past each switch terminal.
5. If t h e r e is no continuity for a m o m e n t at e a c h
t e r m i n a l , r e p l a c e t h e m o d e c o n t ro l m o t o r .
21-21
Heating
Recirculation Control Motor Test Recirculation Control Motor
Replacement
D i s c o n n e c t t h e IP c o n n e c t o r f r o m t h e r e c i r c u l a t i o n
control m o t o r .
INQTICE1 ( s e e p a g e 20-86).
Incorrectly a p p l y i n g p o w e r a n d g r o u n d to
t h e r e c i r c u l a t i o n c o n t r o l m o t o r w i l l d a m a g e it. 2 . R e m o v e t h e p a s s e n g e r ' s a i r b a g ( s e e p a g e 23-166).
Follow the instructions carefully.
3. R e m o v e t h e c o n v e r t i b l e t o p c o n t r o l unit ( s e e p a g e
2. C o n n e c t battery p o w e r to t h e N o . 1 t e r m i n a l of t h e 22-242).
r e c i r c u l a t i o n control m o t o r , a n d g r o u n d t h e N o . 5
and No. 7 terminals; the recirculation control motor 4. D i s c o n n e c t t h e d a s h b o a r d w i r e h a r n e s s B
should run smoothly. T o avoid d a m a g i n g the c o n n e c t o r s C 2 0 1 , C 2 0 2 , C 2 0 3 , a n d C451 ( s e e p a g e
r e c i r c u l a t i o n c o n t r o l m o t o r , d o not r e v e r s e p o w e r 22-24).
a n d g r o u n d . D i s c o n n e c t t h e N o . 5 or N o . 7
terminals from ground; the recirculation control 5. D i s c o n n e c t t h e 7 P c o n n e c t o r (A) f r o m t h e
m o t o r s h o u l d s t o p at F r e s h ( w h e n t h e N o . 7 r e c i r c u l a t i o n control m o t o r ( B ) . R e m o v e t h e
terminal is disconnected) or Recirculate (when the self-tapping s c r e w s a n d the recirculation control
N o . 5 t e r m i n a l is d i s c o n n e c t e d ) . Don't c y c l e t h e m o t o r f r o m t h e b l o w e r unit.
r e c i r c u l a t i o n control m o t o r f o r a l o n g t i m e .
3. If t h e r e c i r c u l a t i o n c o n t r o l m o t o r d o e s not r u n in
s t e p 2 , r e m o v e it, t h e n c h e c k t h e r e c i r c u l a t i o n
control l i n k a g e a n d d o o r s for s m o o t h m o v e m e n t . 6. Install t h e m o t o r in t h e r e v e r s e o r d e r of r e m o v a l .
M a k e s u r e t h e pin o n t h e m o t o r i s p r o p e r l y
• If t h e l i n k a g e a n d d o o r s m o v e s m o o t h l y , r e p l a c e e n g a g e d w i t h t h e linkage. After installation, m a k e
t h e r e c i r c u l a t i o n c o n t r o l motor. s u r e the motor runs s m o o t h l y .
• If t h e l i n k a g e o r d o o r s stick o r b i n d , r e p a i r t h e m
as needed.
21-22
un
Heater Control Panel Removal/ Blower Unit Removal/Installation
Installation
a n d t h e right kick p a n e l ( s e e p a g e 20-86).
1. R e m o v e t h e i n s t r u m e n t p a n e l t o g e t h e r w i t h t h e
h e a t e r control p a n e l ( s e e p a g e 20-84). 2. D i s c o n n e c t t h e d a s h b o a r d w i r e h a r n e s s c o n n e c t o r
from the p a s s e n g e r ' s door wire h a r n e s s connector,
2. R e m o v e the self-tapping s c r e w s a n d the heater t h e n r e m o v e it. R e m o v e t h e w i r e h a r n e s s
c o n t r o l p a n e l (A) f r o m t h e i n s t r u m e n t p a n e l (B). c o n n e c t o r s a n d t h e c o n v e r t i b l e t o p c o n t r o l unit
from the steering hanger b e a m .
3. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m t h e b l o w e r
m o t o r , t h e p o w e r t r a n s i s t o r a n d t h e recirculation
control m o t o r , t h e n r e m o v e t h e w i r e h a r n e s s c l i p s
(B). R e m o v e t h e s e l f - t a p p i n g s c r e w , t h e m o u n t i n g
b o l t s , t h e m o u n t i n g n u t s a n d t h e b l o w e r unit (C).
3. Install t h e control p a n e l in t h e r e v e r s e o r d e r of
r e m o v a l . After installation, o p e r a t e t h e control
p a n e l c o n t r o l s to s e e w h e t h e r it w o r k s properly.
4. R u n t h e s e l f - d i a g n o s t i c f u n c t i o n to c o n f i r m that
t h e r e a r e n o p r o b l e m s in t h e s y s t e m ( s e e p a g e
21-5).
B
4. Install in t h e r e v e r s e o r d e r of r e m o v a l . M a k e s u r e
that there is no air leakage.
21-23
Heating
Blower Unit Component Heater Unit/Core Replacement
Replacement
S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e
S R S c o m p o n e n t locations: '00-05 m o d e l s (see page
Note t h e s e i t e m s w h e n o v e r h a u l i n g t h e b l o w e r unit: 2 3 - 1 1 ) , ' 0 6 - 0 8 m o d e l s ( s e e p a g e 23-12) a n d t h e
p r e c a u t i o n s a n d p r o c e d u r e s ( s e e p a g e 23-13) b e f o r e
• T h e r e c i r c u l a t i o n control m o t o r (A), t h e p o w e r doing repairs or service.
t r a n s i s t o r (B) a n d t h e b l o w e r m o t o r (C) c a n be
r e p l a c e d w i t h o u t r e m o v i n g t h e b l o w e r unit. 1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e
• B e f o r e r e a s s e m b l y , m a k e s u r e that t h e r e c i r c u l a t i o n audio s y s t e m , then write d o w n the audio preset.
control d o o r s a n d linkage m o v e s m o o t h l y w i t h o u t
binding. 2 . D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery.
• After r e a s s e m b l y , m a k e s u r e t h e r e c i r c u l a t i o n c o n t r o l
m o t o r r u n s s m o o t h l y ( s e e p a g e 21-22). 3. R e m o v e t h e h e a t s h i e l d of t h e e x h a u s t m a n i f o l d .
• M a k e s u r e that t h e r e is no a i r l e a k a g e .
4. F r o m u n d e r t h e h o o d , o p e n t h e c a b l e c l a m p (A),
t h e n d i s c o n n e c t t h e h e a t e r v a l v e c a b l e (B) f r o m t h e
h e a t e r v a l v e a r m (C). T u r n t h e h e a t e r v a l v e a r m to
t h e fully o p e n e d p o s i t i o n a s s h o w n .
c
5. W h e n t h e e n g i n e i s c o o l , d r a i n t h e e n g i n e c o o l a n t
f r o m t h e radiator ( s e e p a g e 10-9).
21-24
DB
6. R e m o v e t h e m o u n t i n g bolt f r o m t h e h e a t e r v a l v e . 8. R e m o v e t h e d a s h b o a r d ( s e e p a g e 2 0 - 8 7 ) .
S l i d e t h e c l a m p s (A) b a c k , t h e n d i s c o n n e c t t h e inlet
a n d outlet h e a t e r h o s e s (B) f r o m t h e h e a t e r unit. 9. R e m o v e t h e b l o w e r unit ( s e e p a g e 2 1 - 2 3 ) .
E n g i n e c o o l a n t will r u n out w h e n t h e h o s e s a r e
d i s c o n n e c t e d ; d r a i n it into a c l a n d r i p p a n . B e s u r e 10. R e m o v e t h e m o u n t i n g b o l t s , t h e c e n t e r b r a c k e t s (A)
not to let c o o l a n t spill o n t h e electrical p a r t s o r t h e a n d the audio brackets (B).
p a i n t e d s u r f a c e s . If a n y c o o l a n t s p i l l s , r i n s e it off
immediately.
u A i.v n u n
9 . 8 N m (1.0 k g f m , 7 . 2 I b f f t )
A
7. R e m o v e t h e m o u n t i n g nut f r o m t h e h e a t e r unit. 11. R e m o v e t h e S R S unit ( s e e p a g e 2 3 - 1 7 9 ) .

T a k e c a r e not to d a m a g e o r b e n d t h e fuel a n d b r a k e
lines, etc.. 12. R e m o v e t h e s e l f - t a p p i n g s c r e w s a n d t h e d e f r o s t e r
outlet (A), t h e n r e m o v e t h e w i r e h a r n e s s c l i p s (B).
8 x 1.25 m m
13 N m
(1.3 k g f - m , 9 . 4 I b f f t )
(cont'd)
21-25
Heating
Heater Unit/Core Replacement (cont'd)
13. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m t h e m o d e 15. Install t h e h e a t e r c o r e in t h e r e v e r s e o r d e r of

control m o t o r a n d t h e air m i x control m o t o r , t h e n removal.
r e m o v e t h e w i r e h a r n e s s c l i p (B). R e m o v e t h e
m o u n t i n g n u t s , t h e m o u n t i n g bolt a n d t h e h e a t e r 16. Install t h e h e a t e r unit in t h e r e v e r s e o r d e r of
unit ( C ) . r e m o v a l , a n d note t h e s e i t e m s :
• D o not i n t e r c h a n g e t h e inlet a n d outlet h e a t e r

h o s e s , a n d install t h e h o s e c l a m p s s e c u r e l y .
• Refill t h e c o o l i n g s y s t e m w i t h e n g i n e c o o l a n t
( s e e p a g e 10-9).
• A d j u s t t h e h e a t e r v a l v e c a b l e ( s e e p a g e 21-27).
• M a k e s u r e that t h e r e i s n o c o o l a n t l e a k a g e .
• M a k e s u r e that t h e r e i s n o air l e a k a g e .
• E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m ,
then enter the audio presets.
6x1.0 mm
9.8 N m ( 1 . 0 k g f m , 7 . 2 Ibf-ft)
6 x 1.0 m m
9 . 8 N - m (1.0 k g f m , 7 . 2 Ibf-ft)
14. R e m o v e t h e s e l f - t a p p i n g s c r e w a n d t h e p a s s e n g e r ' s
h e a t e r outlet (A), t h e n r e m o v e t h e s e l f - t a p p i n g
s c r e w a n d t h e c l a m p (B). B e c a r e f u l not to b e n d t h e
inlet a n d outlet p i p e s d u r i n g t h e h e a t e r c o r e (C)
r e m o v a l , a n d pull out t h e h e a t e r c o r e .
21-26
Dust and Pollen Filter Replacement Heater Valve Cable Adjustment
DD
1. O p e n t h e h o o d . 1. F r o m u n d e r t h e h o o d , o p e n t h e c a b l e c l a m p (A),
2. R e m o v e t h e c l i p s (A) a n d t h e h o o d s e a l (B). Lift t h e h e a t e r v a l v e a r m (C).
right s i d e of the c o w l c o v e r (C) u p , a n d r e m o v e t h e
d u s t a n d pollen filter (D) a s s h o w n . B e c a r e f u l not to
d a m a g e the hood seal w h e n removing the clips.
C B
3. W i t h t h e h e a t e r v a l v e c a b l e d e t a c h e d at both e n d s ,
make s u r e the cable m o v e s freely with no binding.
R e p l a c e t h e h e a t e r v a l v e c a b l e if it d o e s not m o v e
4. Install t h e filter in the r e v e r s e o r d e r of r e m o v a l . freely.
4. S e t t h e t e m p e r a t u r e control dial o n M a x C o o l w i t h
t h e ignition s w i t c h to O N (II).
5. A t t a c h t h e h e a t e r v a l v e c a b l e to the air m i x control

linkage a s s h o w n . Hold t h e e n d of t h e h e a t e r v a l v e
c a b l e h o u s i n g a g a i n s t t h e s t o p (D), t h e n s n a p the
h e a t e r v a l v e c a b l e h o u s i n g into t h e c a b l e c l a m p .
(cont'd)
21-27
Heating
Heater Valve Cable Adjustment (cont'd)
6. F r o m u n d e r t h e h o o d , turn t h e h e a t e r v a l v e a r m (A)
to t h e fully c l o s e d position a s s h o w n , a n d h o l d it.
A t t a c h t h e h e a t e r v a l v e c a b l e (B) to t h e h e a t e r v a l v e
a r m , a n d g e n t l y pull o n the h e a t e r v a l v e c a b l e
h o u s i n g to take up a n y s l a c k , t h e n install t h e h e a t e r
v a l v e c a b l e h o u s i n g into the c a b l e c l a m p ( C ) .
21-28
Heating/Air Conditioning DB
D U S T AND POLLEN FILTER

B L O W E R / E V A P O R A T O R UNIT
B L O W E R / E V A P O R A T O R UNIT C O M P O N E N T
SERVICE VALVE EXPANSION VALVE

(HIGH-PRESSURE SIDE) R e p l a c e m e n t page 21-63
A/C CONDENSER A/C COMPRESSOR

R e p l a c e m e n t page 21-72 R e p l a c e m e n t page 21-66
Clutch C h e c k , page 21-68
Clutch O v e r h a u l , page 21-69
T h e r m a l Protector C h e c k , page 21-68
T h e r m a l P r o t e c t o r R e p l a c e m e n t p a g e 21-71
RECEIVER/DRYER R e l i e f V a l v e R e p l a c e m e n t , p a g e 21-71
DESICCANT
(cont'd)
21-29
Heating/Air Conditioning
Component Location Index (confd)
A/C CONDENSER FAN
21-30
HB
/HEATER UNIT/CORE B L O W E R / E V A P O R A T O R UNIT

R e p l a c e m e n t , page 21-63 R e m o v a l / I n s t a l l a t i o n , p a g e 21-61
BLOWER/EVAPORATOR UNIT COMPONENT
/HEATER VALVE CABLE R e p l a c e m e n t page 21-62
A d j u s t m e n t , page 21-27

T e s t page 21-22
POWER TRANSISTOR
T e s t page 21-19
T e s t page 21-20
EVAPORATOR TEMPERATURE SENSOR

T e s t page 21-60
HVAC CONTROL UNIT

MODE CONTROL MOTOR

T e s t , p a g e 21-21
21-31
A / C Service Tips and Precautions A / C System Inspection
B e f o r e t r o u b l e s h o o t i n g a n y p r o b l e m with t h e air
A WARNING conditioning s y s t e m , do the following:
• C o m p r e s s e d air m i x e d w i t h R-134a f o r m s a
combustible vapor. 1. W i t h t h e ignition s w i t c h in t h e L O C K (0), i n s p e c t t h e
• T h e v a p o r c a n b u r n or e x p l o d e c a u s i n g s e r i o u s A / C c o m p o n e n t s , p r e s s u r e l i n e s a n d h o s e s for
injury. s t a i n s that m a y indicate a refrigerant or a
• N e v e r u s e c o m p r e s s e d air to p r e s s u r e t e s t c o m p r e s s o r oil leak.
R-134a s e r v i c e e q u i p m e n t or v e h i c l e air
conditioning s y s t e m s ,
ACAUTION
• A i r c o n d i t i o n i n g refrigerant or l u b r i c a n t v a p o r
c a n irritate y o u r e y e s , n o s e , or t h r o a t
• Be careful w h e n connecting service equipment.
• D o not b r e a t h e refrigerant or v a p o r .
T h e air c o n d i t i o n i n g s y s t e m u s e s H F C - 1 3 4 a ( R - 1 3 4 a )
refrigerant a n d p o l y a l k y l e n e g l y c o l ( P A G ) refrigerant o i l ,
w h i c h a r e not c o m p a t i b l e w i t h C F C - 1 2 (R-12) refrigerant
a n d m i n e r a l oil. D o not u s e R-12 refrigerant or m i n e r a l 2. C h e c k t h e A / C c o n d e n s e r for m a t e r i a l c l o g g i n g t h e
oil in t h i s s y s t e m , a n d d o not attempt to u s e R-12 f i n s or f o r d a m a g e to t h e f i n s :
s e r v i c i n g e q u i p m e n t ; d a m a g e to the air c o n d i t i o n i n g
s y s t e m or y o u r s e r v i c i n g e q u i p m e n t w i l l r e s u l t . • C a r e f u l l y c l e a n a n y m a t e r i a l f r o m the A / C
U s e o n l y s e r v i c e e q u i p m e n t that is U . L - l i s t e d a n d i s c o n d e n s e r (A) f i n s w i t h w a t e r a n d detergent.
certified to m e e t the r e q u i r e m e n t s of S A E J 2 2 1 0 to • B e s u r e to d r y t h e A / C c o n d e n s e r c o m p l e t e l y .
r e m o v e R - 1 3 4 a f r o m t h e air c o n d i t i o n i n g s y s t e m .
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , v e n t i l a t e t h e
work area before resuming service.
R-134a s e r v i c e e q u i p m e n t or v e h i c l e air c o n d i t i o n i n g
s y s t e m s s h o u l d not b e p r e s s u r e t e s t e d or leak t e s t e d
w i t h c o m p r e s s e d air.
Additional health a n d safety information m a y be

o b t a i n e d f r o m t h e refrigerant a n d l u b r i c a n t
manufacturers.
• A l w a y s d i s c o n n e c t the negative cable from the

battery w h e n e v e r r e p l a c i n g air c o n d i t i o n i n g p a r t s .
• K e e p m o i s t u r e a n d dirt out of the s y s t e m . W h e n 3. I n s p e c t t h e d r i v e belt ( s e e p a g e 4-42).
d i s c o n n e c t i n g a n y l i n e s , plug or c a p t h e fittings
i m m e d i a t e l y ; d o n ' t r e m o v e the c a p s or p l u g s until 4. M a k e s u r e n o m a t e r i a l is b l o c k i n g t h e air f l o w to t h e
j u s t b e f o r e y o u r e c o n n e c t e a c h line. A/C condenser.
• B e f o r e c o n n e c t i n g a n y h o s e or line, a p p l y a f e w d r o p s
of refrigerant oil to t h e O - r i n g .
• W h e n t i g h t e n i n g or l o o s e n i n g a fitting, u s e a s e c o n d
w r e n c h to s u p p o r t t h e m a t c h i n g fitting.
• W h e n discharging the s y s t e m , u s e a n R-134a
refrigerant r e c o v e r y / r e c y c l i n g / c h a r g i n g s t a t i o n ; d o n ' t
r e l e a s e refrigerant into t h e a t m o s p h e r e .
21-32
A / C Refrigerant Oil Replacement
5. S t a r t t h e e n g i n e , t u r n t h e a i r c o n d i t i o n i n g s y s t e m R e c o m m e n d e d P A G oil: S P - 1 0 :
o n , a n d a l l o w it to n o r m a l i z e for a f e w m i n u t e s :
• P/N 3 8 8 9 7 - P 1 3 - A 0 1 A H : 120 m L (4 fl-oz)
• C h e c k that t h e A / C o p e r a t e s at e a c h p o s i t i o n of • P/N 3 8 8 9 9 - P 1 3 - A 0 1 : 40 m L (1 1/3 fl-oz)
the blower fan switch (except O F F ) .
• C h e c k that t h e A / C c o m p r e s s o r c l u t c h (A) is A d d t h e r e c o m m e n d e d refrigerant oil in t h e a m o u n t
e n g a g e d . T h e p r e s s u r e plate s h o u l d b e rotating listed if y o u r e p l a c e a n y of t h e f o l l o w i n g p a r t s .
at t h e s a m e s p e e d a s t h e p u l l e y .
• C h e c k that t h e radiator f a n (B) a n d A / C c o n d e n s e r • T o a v o i d c o n t a m i n a t i o n , d o not return t h e oil to t h e
f a n (C) o p e r a t e w h e n t h e A / C c o m p r e s s o r c l u t c h c o n t a i n e r o n c e d i s p e n s e d , a n d n e v e r m i x it w i t h o t h e r
is e n g a g e d . refrigerant o i l s .
• C h e c k that t h e e n g i n e idle s p e e d i s c o r r e c t l y • I m m e d i a t e l y after u s i n g t h e o i l , reinstall t h e c a p o n
m a i n t a i n e d w h e n t h e A / C is s w i t c h e d o n a n d off t h e c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e
a n d t h e A / C c o m p r e s s o r c l u t c h is e n g a g e d a n d absorption.
disengaged. • D o not spill t h e refrigerant oil o n t h e v e h i c l e ; it m a y
d a m a g e t h e paint. If t h e refrigerant oil c o n t a c t s t h e
paint, w a s h it off i m m e d i a t e l y .
A/C Condenser 2 5 m L (5/6 fl-oz)

Evaporator 40 m L ( 1 1/3 fl-oz)
Line or h o s e 10 m L (1/3 fl-oz)
Receiver/Dryer 10 m L (1/3 fl-oz)
L e a k a g e repair 2 5 m L (5/6 fl-oz)
A/C Compressor For A / C compressor replacement,
s u b t r a c t t h e v o l u m e of oil d r a i n e d
from the removed A / C
c o m p r e s s o r f r o m 130 m L
( 4 1 / 3 fl-oz), a n d d r a i n t h e
c a l c u l a t e d v o l u m e of oil f r o m t h e
n e w A / C c o m p r e s s o r : 130 m L
(4 1/3 fl-oz) — V o l u m e of r e m o v e d
A / C c o m p r e s s o r = V o l u m e to
drain from n e w A / C c o m p r e s s o r .
N O T E : E v e n if n o oil is d r a i n e d
from the removed A / C
c o m p r e s s o r , don't drain m o r e
t h a n 50 m L (1 2/3 fl-oz) f r o m t h e
new A/Ccompressor.
REMOVED NEW
A/C COMPRESSOR A / C COMPRESSOR
]• DRAINING
SAME LEVEL - J
VOLUME h A
A : 130 m L ( 4 1 / 3 fl-oz)
21-33
A / C Line Replacement
® D i s c h a r g e h o s e t o t h e A / C c o m p r e s s o r (6 x 1.0 m m ) : 9 . 8 N - m (1.0 k g f m , 7.2 Ibf ft)

® D i s c h a r g e h o s e t o t h e A / C c o n d e n s e r (6 x 1.0 m m ) : 9 . 8 N - m (1.0 k g f - m , 7 . 2 Ibf ft)
© A / C c o n d e n s e r l i n e t o t h e A / C c o n d e n s e r (6 x 1.0 m m ) : 9.8 N - m (1.0 k g f m , 7.2 Ibf ft)
© A / C c o n d e n s e r l i n e t o t h e r e c e i v e r / d r y e r (6 x 1.0 m m ) : 9 . 8 N - m (1.0 k g f m , 7.2 Ibf-ft)
@ R e c e i v e r l i n e A t o t h e r e c e i v e r / d r y e r (6 x 1.0 m m ) : 9 . 8 N - m (1.0 k g f - m , 7 . 2 Ibf ft)
© R e c e i v e r l i n e A t o r e c e i v e r l i n e B : 1.3 N - m (1.3 k g f - m , 9 . 4 Ibf-ft)
© R e c e i v e r l i n e B a n d t h e s u c t i o n l i n e t o t h e e v a p o r a t o r (6 x 1.0 m m ) : 9.8 N - m (1.0 k g f - m , 7.2 Ibf ft)
© S u c t i o n h o s e t o t h e s u c t i o n l i n e (6 x 1.0 m m ) : 9.8 N - m (1.0 k g f - m , 7 . 2 Ibf-ft)
© S u c t i o n h o s e t o t h e A / C c o m p r e s s o r (6 x 1.0 m m ) : 9 . 8 N - m (1.0 k g f m , 7 . 2 Ibf-ft)
(S) A / C c o m p r e s s o r t o t h e A / C c o m p r e s s o r b r a c k e t ( 1 0 x 1.25 m m ) : 4 4 N - m (4.5 k g f - m , 3 3 Ibf ft)
® A / C c o m p r e s s o r b r a c k e t t o t h e e n g i n e b l o c k (8 x 1.25 m m ) : 2 2 N - m (2.2 k g f m , 1 6 Ibf ft)
21-34
ma
G e n e r a l T r o u b l e s h o o t i n g Information
H o w to Retrieve a D T C
T h e H V A C control unit h a s a s e l f - d i a g n o s t i c f u n c t i o n . T o run t h e s e l f - d i a g n o s t i c f u n c t i o n , d o t h e f o l l o w i n g :
1. S e t t h e m o d e control dial o n the V e n t p o s i t i o n .
3. W i t h i n 5 s e c o n d s after t u r n i n g the ignition s w i t c h o n , p r e s s t h e r e c i r c u l a t i o n control s w i t c h t h e r e q u i r e d n u m b e r of

t i m e s d e p e n d i n g o n the recirculation indicator s t a t u s :
• If t h e indicator is O N , p r e s s the r e c i r c u l a t i o n control s w i t c h 5 t i m e s .

• If t h e indicator is O F F , p r e s s the r e c i r c u l a t i o n control s w i t c h 6 t i m e s .
T h e recirculation indicator will c o m e o n for 2 s e c o n d s , t h e n blink t h e D i a g n o s t i c T r o u b l e C o d e ( D T C ) to i n d i c a t e a

faulty c o m p o n e n t . If no D T C s a r e f o u n d , the indicator will not blink after the initial 2 s e c o n d s light.
RECIRCULATION INDICATOR LIGHT
E x a m p l e of D T C I n d i c a t i o n P a t t e r n ( D T C 2 )
Recirculation
indicator
light o n
Recirculation
indicator
light off
0.3 s e c
\
2 sec
W i t h i n five s e c o n d s after t h e
i g n i t i o n s w i t c h i s t u r n e d O N (II),
p r e s s the recirculation control
1.5 s e c 0.3 s e c
s w i t c h t h e r e q u i r e d n u m b e r of
t i m e s depending on t h e recirculation
indicator light s t a t u s
Canceling the Self-diagnostic Function
4. T u r n the ignition s w i t c h to L O C K (0) to c a n c e l t h e s e l f - d i a g n o s t i c f u n c t i o n . After c o m p l e t i n g repair w o r k , run the

s e l f - d i a g n o s t i c f u n c t i o n a g a i n to m a k e s u r e that t h e r e a r e no other m a l f u n c t i o n s .
21-35
DTC Detection Item Page

(Recirculation
Indicator Blinks)
1 A p r o b l e m in t h e a i r m i x c o n t r o l m o t o r circuit (see page 21-42)
2 A p r o b l e m in t h e m o d e c o n t r o l m o t o r circuit (see page 21-43)
3 A p r o b l e m in t h e b l o w e r m o t o r circuit (see page 21-45)
4 A p r o b l e m in t h e e v a p o r a t o r t e m p e r a t u r e s e n s o r circuit (see page 21-48)
• In c a s e of m u l t i p l e p r o b l e m s , t h e r e c i r c u l a t i o n i n d i c a t o r will indicate o n l y t h e D T C w i t h t h e l e a s t n u m b e r of blinks.

• In c a s e of a n intermittent f a i l u r e , t h e h e a t e r c o n t r o l p a n e l will s t o r e t h e D T C until t h e ignition s w i t c h to L O C K (0).
21-36

R e c i r c u l a t i o n control d o o r s d o not R e c i r c u l a t i o n control m o t o r circuit • H V A C D T C s (see page 21-35)
change between Fresh and t r o u b l e s h o o t i n g ( s e e p a g e 21-50) • B l o w n N o . 2 0 (7.5 A ) f u s e in the
Recirculate under-dash fuse/relay box
connectors
B l o w e r , heater c o n t r o l s , a n d A / C H V A C control p o w e r a n d g r o u n d • H V A C D T C s ( s e e p a g e 21-35)
d o not w o r k circuit t r o u b l e s h o o t i n g ( s e e p a g e • B l o w n N o . 5 4 (30 A ) f u s e in t h e
21-51) main under-hood fuse/relay box,
a n d N o . 20 (7.5 A ) a n d N o . 2 5
(7.5 A ) f u s e s in the u n d e r - d a s h
fuse/relay box
• P o o r g r o u n d at G 4 0 2
connectors
T h e A / C c o n d e n s e r f a n d o e s not A / C c o n d e n s e r f a n circuit • H V A C D T C s ( s e e p a g e 21-35)
run at all (but radiator fan r u n s t r o u b l e s h o o t i n g ( s e e p a g e 21-53) • B l o w n N o . 58 (20 A ) f u s e in the
w i t h the A / C on) main under-hood fuse/relay box,
a n d N o . 20 (7.5 A ) f u s e in the
• P o o r g r o u n d at G201
connectors
Both f a n s do not run w i t h the A / C Radiator and A / C c o n d e n s e r fan • H V A C D T C s ( s e e p a g e 21-35)
on (but the A / C c o m p r e s s o r r u n s c o m m o n circuit t r o u b l e s h o o t i n g • B l o w n N o . 57 (20 A ) a n d N o . 58
w i t h the A / C on) ( s e e p a g e 21-54) (20 A ) f u s e s in the m a i n u n d e r -
h o o d f u s e / r e l a y b o x , a n d N o . 20
(7.5 A ) f u s e in the u n d e r - d a s h
fuse/relay box
• P o o r g r o u n d at G201
connectors
T h e A / C c o m p r e s s o r clutch d o e s A / C c o m p r e s s o r c l u t c h circuit • H V A C D T C s ( s e e p a g e 21-35)
not e n g a g e (but both f a n s run t r o u b l e s h o o t i n g ( s e e p a g e 21-55) • B l o w n N o . 5 8 (20 A ) f u s e in the
w i t h the A / C on) main under-hood fuse/relay box,
a n d No. 20 (7.5 A ) f u s e in t h e
connectors
A / C s y s t e m d o e s not c o m e o n A / C p r e s s u r e s w i t c h circuit • H V A C D T C s ( s e e p a g e 21-35)
(both f a n s a n d the A / C t r o u b l e s h o o t i n g ( s e e p a g e 21-58) • C l e a n l i n e s s a n d t i g h t n e s s of all
c o m p r e s s o r d o not w o r k ) ; heater connectors
is O K
21-37
System Description
T h e air c o n d i t i o n i n g s y s t e m r e m o v e s heat f r o m t h e p a s s e n g e r c o m p a r t m e n t b y t r a n s f e r r i n g h e a t f r o m t h e a m b i e n t air
to t h e e v a p o r a t o r . T h e e v a p o r a t o r c o o l s t h e air w i t h t h e r e f r i g e r a n t t h a t is c i r c u l a t i n g t h r o u g h t h e e v a p o r a t o r . T h e
refrigerant e x p a n d s in t h e e v a p o r a t o r , a n d t h e e v a p o r a t o r b e c o m e s v e r y c o l d a n d a b s o r b s t h e h e a t f r o m t h e a m b i e n t
air. T h e b l o w e r f a n p u s h e s air a c r o s s t h e e v a p o r a t o r w h e r e t h e h e a t is a b s o r b e d , a n d t h e n it b l o w s t h e c o o l air into t h e
passenger compartment.
BLOWER FAN
EVAPORATOR
( A b s o r p t i o n of h e a t )
EXPANSION VALVE
(Meters the required
a m o u n t of r e f r i g e r a n t
into t h e evaporator) EVAPORATOR TEMPERATURE
SENSOR
THERMAL PROTECTOR
A / C PRESSURE SWITCH ( O p e n s t h e A / C c o m p r e s s o r clutch circuit
W h e n t h e refrigerant is b e l o w w h e n the compressor temperature
2
196 kPa (2.0 k g f / c m , 28 psi) b e c o m e s t o o high)
or a b o v e 3,140 k P a (32 kgf/cm
455 psi), the A / C p r e s s u r e RELIEF VALVE
s w i t c h o p e n s t h e circuit to (Relieves pressure at the A / C c o m p r e s s o r
the A / C switch and stops the w h e n t h e p r e s s u r e i s t o o high)
air c o n d i t i o n i n g to protect t h e
A/C compressor.
A/C COMPRESSOR
RECEIVER/DRYER (Suction and compression)
DESICCANT
(Traps debris, and
removes moisture)
HIGH P R E S S U R E V A P O R
] HIGH P R E S S U R E LIQUID
A/C CONDENSER
( R a d i a t i o n of h e a t )
1 L O W P R E S S U R E LIQUID
LOW PRESSURE VAPOR
T h i s v e h i c l e u s e s H F C - 1 3 4 a (R-134a) refrigerant w h i c h d o e s not c o n t a i n c h l o r o f l u o r o c a r b o n s . P a y attention to t h e

following service items:
• D o not m i x refrigerants C F C - 1 2 ( R - 1 2 ) a n d H F C - 1 3 4 a ( R - 1 3 4 a ) . T h e y a r e not c o m p a t i b l e .

• U s e o n l y t h e r e c o m m e n d e d p o l y a l k y l e n e g l y c o l ( P A G ) refrigerant oil ( S P - 1 0 ) d e s i g n e d for t h e R-134a A / C
c o m p r e s s o r . I n t e r m i x i n g t h e r e c o m m e n d e d ( P A G ) refrigerant oil w i t h a n y other refrigerant oil will result in A / C
c o m p r e s s o r failure.
• All A / C s y s t e m parts ( A / C c o m p r e s s o r , d i s c h a r g e line, s u c t i o n l i n e , e v a p o r a t o r , A / C c o n d e n s e r , r e c e i v e r / d r y e r ,
e x p a n s i o n v a l v e , O - r i n g s for joints) a r e d e s i g n e d for refrigerant R - 1 3 4 a . D o not e x c h a n g e w i t h R-12 p a r t s .
• U s e a h a l o g e n g a s leak d e t e c t o r d e s i g n e d for refrigerant R - 1 3 4 a .
• R-12 a n d R - 1 3 4 a refrigerant s e r v i c i n g e q u i p m e n t a r e not i n t e r c h a n g e a b l e . U s e o n l y a r e c o v e r y / r e c y c l i n g / c h a r g i n g
station t h a t is U . L - l i s t e d a n d is certified to m e e t t h e r e q u i r e m e n t s of S A E J 2 2 1 0 to s e r v i c e R-134a air c o n d i t i o n i n g
systems.
• A l w a y s r e c o v e r refrigerant R-134a w i t h a n a p p r o v e d r e c o v e r y / r e c y c l i n g / c h a r g i n g station before d i s c o n n e c t i n g a n y
A / C fitting.
21-38
DB
HVAC Control Unit Inputs and Outputs
HVAC C O N T R O L UNIT 30P C O N N E C T O R
10 11 12 13
15 16 21 22 23 26 27 28 29 30
Cavity Wire color Signal

1 PNK AIR MIX C O O L OUTPUT
2 PNK/BLU AIR MIX HOT OUTPUT
3 YEL/BLU MODE DEF OUTPUT
4 YEL/RED MODE VENT OUTPUT
5 GRY AIR MIX P O T E N T I A L + 5 V OUTPUT
6 PNK/BLK AIR MIX P O T E N T I A L INPUT
7 BRN EVAPORATOR TEMPERATURE SENSOR INPUT
8 YEL/GRN MODE 2 INPUT
9 BRN/WHT MODE 1 INPUT
10 LTGRN SENSOR COMMON GROUND OUTPUT
11 BLU/RED BLOWER FEEDBACK INPUT
12 BLU/WHT A/C PRESSURE SWITCH OUTPUT
13 BLU/YEL POWER TRANSISTORCONTROL OUTPUT
15 GRN/WHT FRESH OUTPUT
16 GRN/YEL RECIRCULATE OUTPUT
21 YEL MODE 4 INPUT
22 BLK/WHT MODE 3 INPUT
23 BLK/WHT GAUGE ASSEMBLY OUTPUT
26 BLK G R O U N D (G402) INPUT
27 RED/BLK TAILLIGHT RELAY INPUT
28 RED GAUGE ASSEMBLY OUTPUT
29 WHT/RED + B (Power) INPUT
30 BLK/YEL IG2 (Power) INPUT
21-39
Circuit Diagram

BATTERY
21-40
[
*1:'00-05 models
*2:'00-07 models
*3: '06-08 models
M:'08 model
BLU/WHT
1
® BLOWER
MOTOR
2
BLU/BLK
POWER
TRANSISTOR
12 V
3 1 > — BLU/RED
-AAAr >
D — BLU/YEL
X
5V EVAPORATOR
TEMPERATURE
SENSOR
2,
LTGRN BLK
• BLK/YEL —@->HA/H 5V 5V
51 17 1
GRY OS5V S-COM C>- LTGRN
"WHT/RED — @ • ! W H
§ ) — PNK/BLK —hmD-P m m
21 CONTROL
MOTOR
PNK/BLU <>M-HOT
YEL/RED - )M-VENT
YEL/BLU - 2 >M-DEF
1 S-COM -LTGRN
BRN/WHT - 6,)M0DE1
YEL/GRN - 5 )MODE2 MODE
4 CONTROL
BLK/WHT " )MODE3 MOTOR
— YEL 3 )MODE4
/
$ 5 ) — GRN/WHT -OFRS RECIRCULATION

7I CONTROL
GRN/YEL >REC MOTOR IG2 BLK/YEL
HVAC CONTROL UNIT
G402
21
DTC Troubleshooting
DTC 1: A Problem in the Air Mix Control 5. T u r n the ignition s w i t c h to O N (II), a n d m e a s u r e the
Motor Circuit s a m e t e r m i n a l s for v o l t a g e .
H V A C C O N T R O L UNIT 30P C O N N E C T O R
1. D i s c o n n e c t t h e air m i x control m o t o r 7 P c o n n e c t o r .
GRY PNK/BLK
2. T e s t t h e air m i x c o n t r o l m o t o r ( s e e p a g e 21-20).
PNK/BLU LTGRN
Is the air mix control motor OK? -L
1 2 3 4 ; 6 7 8 9 10 11 12 18
/
16 18
PNK
/ /V 21
*IXI» / / 26 27 28 29 30
3. D i s c o n n e c t t h e H V A C control unit 3 0 P c o n n e c t o r .
4. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d t h e W i r e s i d e of f e m a l e t e r m i n a l s
H V A C c o n t r o l unit 3 0 P c o n n e c t o r N o . 1, 2 , 5, 6, a n d
10 t e r m i n a l s individually. Is there any voltage?
t h e H V A C c o n t r o l unit a n d t h e air m i x control motor.
GRY PNK/BLK
T h i s s h o r t m a y a l s o d a m a g e the H V A C control unit.
PNK/BLU LTGRN R e p a i r the s h o r t to p o w e r before r e p l a c i n g the
H V A C control u n i t . B
1 2 6 A 6 6 7 !><: 8 9 10 11 12 13
/
16 16
PNK
//// 21 22
M *
// 26 27 28 29 80
b e t w e e n t h e H V A C control unit a n d t h e air m i x
c o n t r o l motor. •
21-42
6. T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k for DTC 2: A Problem in the Mode Control Motor
c o n t i n u i t y b e t w e e n the f o l l o w i n g t e r m i n a l s of the Circuit
H V A C control unit 3 0 P c o n n e c t o r a n d t h e air m i x
c o n t r o l motor 7 P c o n n e c t o r . 1. D i s c o n n e c t t h e m o d e c o n t r o l m o t o r 7 P c o n n e c t o r .
30P: 7P:
No. 1 No. 2 2. T e s t the m o d e control m o t o r ( s e e p a g e 21-21).
No. 2 No. 1
No. 5 No. 5 Is the mode control motor OK ?
No. 6 No. 3
N o . 10 No. 7 Y E S — G o to s t e p 3.
GRY PNK/BLK 3. D i s c o n n e c t the H V A C c o n t r o l unit 3 0 P c o n n e c t o r .

PNK/BLU LTGRN
4. C h e c k for continuity b e t w e e n b o d y g r o u n d a n d the
1 2 3 A 7 8 9 10 11 12 13
/ h e a t e r c o n t r o l p a n e l 3 0 P c o n n e c t o r No. 3 , 4 , 8 , 9,
PNK
16 16
/ // V 21
// 2B 27 28 29 30
10, 2 1 , a n d 22 t e r m i n a l s i n d i v i d u a l l y .
YEL/GRN
YEL/RED BRN/WHT
PNK/BLK
PNK YEL/BLU LTGRN
| 1,
PNK/BLU
GRY
LTGRN 1 2 3 4 6 6 7 8 9 10 11 12 13
/
////
90
16 ie 21
// 28 27 28 29
AIR MIX C O N T R O L M O T O R 7P C O N N E C T O R
Y E S — C h e c k for l o o s e w i r e s or p o o r c o n n e c t i o n s at W i r e s i d e of f e m a l e t e r m i n a l s
t h e H V A C control unit 3 0 P c o n n e c t o r a n d at t h e air

m i x control m o t o r 7 P c o n n e c t o r . If t h e c o n n e c t i o n s is- there continuity?
a r e g o o d , substitute a k n o w n - g o o d H V A C control
unit, a n d r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e ( s )
a w a y , r e p l a c e the original H V A C c o n t r o l u n i t . H b e t w e e n t h e H V A C control unit a n d t h e m o d e
c o n t r o l motor. •
N O — R e p a i r o p e n in t h e w i r e ( s ) b e t w e e n t h e H V A C
control unit a n d t h e air m i x control motor. • N O — G o to s t e p 5.
7. R e m o v e the air m i x control motor ( s e e p a g e 21-20).
N O — R e p a i r the air m i x control linkage or d o o r s . •
(cont'd)
21-43

5. T u r n t h e ignition s w i t c h to O N (II), a n d m e a s u r e t h e T u r n t h e ignition s w i t c h to L O C K (0), a n d c h e c k for
s a m e t e r m i n a l s for v o l t a g e . c o n t i n u i t y b e t w e e n t h e f o l l o w i n g t e r m i n a l s of t h e
H V A C c o n t r o l unit SOP c o n n e c t o r a n d t h e m o d e
control m o t o r 7 P c o n n e c t o r .
YEL/GRN 30P: 7P:
YEL/RED BRN/WHT No. 3 No. 2
No. 4 No. 1
YEL/BLU LTGRN
No. 8 No. 5
I <r-p 1
1 2 8 4 6 6 7 8 9 10 11 12 13 / No. 9 No. 6
16 16
zzzz YEL
21
// 26 27 28 29 30 N o . 10 N o . 7
N o . 21 N o . 3
N o . 22 N o . 4
(V)(X)
<J)(I)<J H V A C C O N T R O L UNIT 30P C O N N E C T O R
YEL/GRN
YEL/RED
Is there any voltage?
t h e H V A C control unit a n d t h e m o d e control m o t o r .
T h i s s h o r t m a y a l s o d a m a g e t h e H V A C control unit.
R e p a i r t h e s h o r t to p o w e r b e f o r e r e p l a c i n g t h e
H V A C control u n i t . B
YEL/GRN
M O D E C O N T R O L M O T O R 7P C O N N E C T O R
t h e H V A C control unit 3 0 P c o n n e c t o r a n d at the
m o d e control m o t o r 7 P c o n n e c t o r . If t h e
connections are good, substitute a known-good
H V A C control unit, a n d r e c h e c k . If the s y m p t o m /
i n d i c a t i o n g o e s a w a y , r e p l a c e t h e original H V A C
control u n i t . B
control unit a n d m o d e control motor, fl
21-44
7. R e m o v e t h e m o d e control m o t o r ( s e e p a g e 21-21). DTC 3: A Problem in the Blower Motor Circuit
8. C h e c k t h e m o d e control linkage a n d d o o r s for 1. C h e c k the N o . 5 6 (40 A ) f u s e in t h e m a i n

smooth movement. u n d e r - h o o d f u s e / r e l a y b o x , a n d t h e N o . 2 0 (7.5 A )
f u s e in the u n d e r - d a s h f u s e / r e l a y b o x .
Do the mode control linkage and doors move
smoothly? Are the fuses OK?
Y E S — R e p l a c e t h e m o d e control m o t o r . • Y E S — G o t o step2.
N O — R e p a i r t h e m o d e control linkage o r d o o r s . • N O — R e p l a c e the fuse(s), and recheck. •
2. C o n n e c t t h e N o . 2 t e r m i n a l of t h e b l o w e r m o t o r 2 P
c o n n e c t o r to b o d y g r o u n d w i t h a j u m p e r w i r e .
B L O W E R M O T O R 2P C O N N E C T O R
JUMPER BLU/BLK
WIRE
Does the blower motor run?
6. D i s c o n n e c t t h e p o w e r t r a n s i s t o r 5 P c o n n e c t o r .
(cont'd)
21-45
7. C h e c k for continuity b e t w e e n t h e N o . 5 t e r m i n a l of 12. D i s c o n n e c t the H V A C control unit 3 0 P c o n n e c t o r .

the p o w e r transistor 5P connector a n d body ground.
13. C h e c k for c o n t i n u i t y b e t w e e n t h e No. 11 a n d N o . 13
P O W E R T R A N S I S T O R 5P C O N N E C T O R t e r m i n a l s of the H V A C control unit 3 0 P c o n n e c t o r
a n d b o d y g r o u n d individually.
HVAC CONTROL UNIT 30P CONNECTOR

1 3
BLU/RED BLU/YEL
4 D 5
2 3 5 6 7 8 9 10 11 12 1
L ™,
BLK 15 16
//// 21
// 26 27 28 29 30
N O — C h e c k for a n o p e n in t h e w i r e b e t w e e n t h e b e t w e e n t h e H V A C control unit a n d the p o w e r
p o w e r t r a n s i s t o r a n d b o d y g r o u n d . If t h e w i r e is O K , transistor. •
8. C o n n e c t t h e No. 4 a n d No. 5 t e r m i n a l s of t h e p o w e r
t r a n s i s t o r 5 P c o n n e c t o r with a j u m p e r w i r e . 14. C h e c k for c o n t i n u i t y b e t w e e n the f o l l o w i n g
t e r m i n a l s of the H V A C control unit 3 0 P c o n n e c t o r
P O W E R T R A N S I S T O R 5P C O N N E C T O R
a n d the p o w e r transistor 5P connector.
30P: 5P:
XL N o . 11 No. 1
N o . 13 No. 3
1
D Wire side of female terminals

BLU/RED BLU/YEL
BLU/BLK BLK
1 2 3 4 5 6 7 8 9 10 11 12 13
/
JUMPER WIRE
15 16
//// 21
2*1X1 *
// 26 27 28 29 30
BLU/RED BLU/YEL
Does the blower motor run at high speed?

POWER TRANSISTOR 5P CONNECTOR
Y E S — G o to s t e p 10. Wire side of female terminals
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e p o w e r Is there continuity?
t r a n s i s t o r a n d b l o w e r motor. •
11. D i s c o n n e c t t h e j u m p e r w i r e . control unit a n d t h e p o w e r t r a n s i s t o r . •
21-46
ma
15. R e c o n n e c t t h e H V A C control unit 3 0 P c o n n e c t o r . 2 2 . M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 4 t e r m i n a l of

16. T e s t the p o w e r t r a n s i s t o r ( s e e p a g e 21-19).
B L O W E R M O T O R R E L A Y 4P S O C K E T
Is the power transistor OK ? n

1
Y E S — C h e c k for l o o s e w i r e s o r poor c o n n e c t i o n s at
t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r , b l o w e r m o t o r
2 P c o n n e c t o r a n d at t h e p o w e r t r a n s i s t o r 5 P
c o n n e c t o r . If t h e c o n n e c t i o n s a r e g o o d , substitute a
D
k n o w n - g o o d H V A C control unit, a n d r e c h e c k . If t h e
s y m p t o m / i n d i c a t i o n g o e s a w a y , r e p l a c e the
original H V A C control unit. •
N O — R e p l a c e the power transistor. •
18. D i s c o n n e c t the b l o w e r m o t o r 2 P c o n n e c t o r .
Y E S — G o to s t e p 2 3 .
19. M e a s u r e t h e v o l t a g e b e t w e e n t h e No. 1 t e r m i n a l of
the blower motor 2P connector a n d body ground. N O — R e p l a c e the m a i n under-hood fuse/relay
box.m
BLOWER MOTOR 2P CONNECTOR
2 3 . T u r n the ignition s w i t c h to O N (II).

I 1
BLU/WHT 2 4 . M e a s u r e t h e v o l t a g e b e t w e e n t h e No. 1 t e r m i n a l of
B L O W E R MOTOR RELAY 4P S O C K E T
XL
BLK/YEL
o
Y E S — R e p l a c e the blower m o t o r . B
20. T u r n the ignition s w i t c h to L O C K (0). Is there battery voltage?
2 1 . R e m o v e t h e b l o w e r m o t o r r e l a y f r o m the m a i n Y E S — G o t o s t e p 25.
u n d e r - h o o d f u s e / r e l a y b o x , a n d test it ( s e e p a g e
22-48). N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 20
Is the relay OK ? t h e b l o w e r motor relay. •
N O — R e p l a c e the b l o w e r m o t o r relay. •
(cont'd)
21-47
2 5 . T u r n t h e ignition s w i t c h to L O C K (0). DTC 4: A Problem in the Evaporator

Temperature Sensor Circuit
2 6 . C h e c k for continuity b e t w e e n t h e N o . 2 t e r m i n a l of
the blower motor relay 4P socket and body ground. 1. D i s c o n n e c t t h e e v a p o r a t o r t e m p e r a t u r e s e n s o r 2 P
connector.
2. M e a s u r e the r e s i s t a n c e b e t w e e n the N o . 1 a n d
BLK No. 2 t e r m i n a l s of t h e e v a p o r a t o r t e m p e r a t u r e
sensor.
D
tJ
L. p
1 2
U U
40
30
Y E S — R e p a i r o p e n in t h e B L U / W H T w i r e b e t w e e n RESISTANCE
(kQ) 20
t h e b l o w e r m o t o r r e l a y a n d t h e b l o w e r motor. •
10
N O — C h e c k for a n o p e n in t h e w i r e b e t w e e n t h e
b l o w e r m o t o r r e l a y a n d b o d y g r o u n d . If t h e w i r e is
O K , c h e c k for p o o r g r o u n d at G 2 0 1 . • 32 50 68 86 T
0 10 20 3 0 <€
TEMPERATURE
Is the resistance within the specifications shown

on the graph?
N O — R e p l a c e the e v a p o r a t o r t e m p e r a t u r e
sensor. •
3. D i s c o n n e c t t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r .
21-48
HI
4. C h e c k for continuity b e t w e e n t h e N o . 7 t e r m i n a l of 6. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 10 t e r m i n a l of
t h e H V A C control unit 3 0 P c o n n e c t o r a n d b o d y t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r a n d the N o . 1
ground. t e r m i n a l of t h e e v a p o r a t o r t e m p e r a t u r e s e n s o r 2 P
connector.
BRN
1 2 3 4 5 6 7 ^ ^ ^
IX
• ^
8 9 10 11 12 13
/ 1 2 3 4 5 6 7 8 9 10 11 12 13
/
15 16
//// 21 22 23
// 26 27 28 29 30 15 16
/ // 21 23
// 26 27 28 29 30
W i r e s i d e of f e m a l e t e r m i n a l s EVAPORATOR TEMPERATURE SENSOR

Y E S — R e p a i r s h o r t to b o d y g r o u n d in t h e w i r e Is there continuity?
b e t w e e n t h e H V A C control unit a n d t h e e v a p o r a t o r
temperature sensor. • Y E S — C h e c k for l o o s e w i r e s o r p o o r c o n n e c t i o n s at
t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r a n d at t h e
N O — G o to s t e p 5. e v a p o r a t o r t e m p e r a t u r e s e n s o r 2 P c o n n e c t o r . If the
connections are good, substitute a k n o w n - g o o d
5. C h e c k f o r continuity b e t w e e n t h e N o . 7 t e r m i n a l of H V A C control unit, a n d r e c h e c k . If t h e s y m p t o m /
t h e H V A C control unit 3 0 P c o n n e c t o r a n d t h e N o . 2 indication g o e s a w a y , r e p l a c e t h e original H V A C
t e r m i n a l of t h e e v a p o r a t o r t e m p e r a t u r e s e n s o r 2 P control u n i t . B
connector.
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e H V A C
control unit a n d t h e e v a p o r a t o r t e m p e r a t u r e
sensor.B
1 2 3 4 5 6 7
(XI 23
8 9 10 11 12 13
/
15 16
//// 21 22
// 26 27 28 29 30
BRN

c o n t r o l unit a n d t h e e v a p o r a t o r t e m p e r a t u r e
sensor.B
21-49
Recirculation Control Motor Circuit Troubleshooting
1. C h e c k t h e N o . 2 0 (7.5 A ) f u s e in the u n d e r - d a s h 8. C h e c k for continuity b e t w e e n the N o . 15 a n d No. 16
f u s e / r e l a y box. t e r m i n a l s of the H V A C control unit 3 0 P c o n n e c t o r
a n d b o d y g r o u n d individually.
Is the fuse OK?
N O — R e p l a c e the f u s e , and recheck. • 1 2 3 4 5 6 7

x 8 9 10 11 12 13
/
2. D i s c o n n e c t the recirculation control m o t o r 7 P
connector.
GRN/
15 16
////
GRN/YEL
21 22
X 23
// 26 27 28 29 30
WHT
4. M e a s u r e t h e v o l t a g e b e t w e e n the N o . 1 t e r m i n a l of
t h e r e c i r c u l a t i o n control m o t o r 7 P c o n n e c t o r a n d
body ground. W i r e s i d e of f e m a l e t e r m i n a l s

Y E S — R e p a i r s h o r t to b o d y g r o u n d in the w i r e ( s )
b e t w e e n t h e H V A C control unit a n d the
1 r e c i r c u l a t i o n control m o t o r . •
BLK/YEL
9. T u r n the ignition s w i t c h to O N (II), a n d m e a s u r e the

s a m e t e r m i n a l s for v o l t a g e .
<T"?
Is there battery voltage? 1 2 3 4 5 6 7 8 9 10 11 12 13
/
GRN/
15 16
//// 21 22
X 23
// 26 27 28 29 30
WHT
N O — R e p a i r o p e n in the w i r e b e t w e e n the N o . 20
t h e r e c i r c u l a t i o n control m o t o r . •
6. T e s t t h e r e c i r c u l a t i o n control m o t o r ( s e e p a g e
21-22). Is there any voltage?
Is the recirculation control motor OK? Y E S — R e p a i r s h o r t to p o w e r in t h e w i r e ( s ) b e t w e e n

the H V A C control unit a n d the r e c i r c u l a t i o n control
Y E S — G o to s t e p 7. motor. T h i s s h o r t m a y a l s o d a m a g e the H V A C
control unit. R e p a i r the s h o r t to p o w e r before
N O — G o to s t e p 11. r e p l a c i n g the H V A C control u n i t . B
7. D i s c o n n e c t t h e H V A C control unit 3 0 P c o n n e c t o r . N O — G o to s t e p 10.
21-50
HVAC Control Power and Ground
Circuit Troubleshooting
10. T u r n the ignition s w i t c h to L O C K (0), a n d c h e c k for
continuity b e t w e e n the f o l l o w i n g t e r m i n a l s of the
H V A C control unit 3 0 P c o n n e c t o r a n d the 1. C h e c k t h e No. 5 4 (30 A ) f u s e in the m a i n
recirculation control m o t o r 7 P c o n n e c t o r . u n d e r - h o o d f u s e / r e l a y b o x , a n d the No. 2 0 (7.5 A )
30P: 7P: a n d N o . 2 5 (7.5 A ) f u s e s in t h e u n d e r - d a s h f u s e /
N o . 15 N o . 5 relay box.
N o . 16 No. 7
Are the fuses OK?
1 2 3 4 5 6 7
x 8 9 10 11 12 13
/ N O — R e p l a c e the fuse(s), and recheck. •
GRN/
15 16
////
I GRN/YEL
21 2 2 ^ 2 3
// 26 27 28 29 30
2. D i s c o n n e c t the H V A C control unit 3 0 P c o n n e c t o r .
0
WHT
Sv ( u 3. T u r n the ignition s w i t c h to O N (II).

GRN/WHT GRN/YEL
4. M e a s u r e the v o l t a g e b e t w e e n t h e No. 3 0 t e r m i n a l
of the H V A C control unit 3 0 P c o n n e c t o r a n d b o d y
ground.
7P C O N N E C T O R H V A C C O N T R O L UNIT 30P C O N N E C T O R
1 2 3 4 5 6 7 8 9 10 11 12 13
/
t h e H V A C control unit 3 0 P c o n n e c t o r a n d at the
recirculation control m o t o r 7 P c o n n e c t o r . If the
15 16
//// 21 22
X 23
// 26 27 28 29 30
BLK/YEL
H V A C control unit, a n d r e c h e c k . If t h e s y m p t o m /
indication g o e s a w a y , r e p l a c e the original H V A C
control unit. •
N O — R e p a i r o p e n in the w i r e ( s ) b e t w e e n the H V A C W i r e s i d e of f e m a l e t e r m i n a l s
control unit a n d the recirculation control motor. •

11. R e m o v e the recirculation control m o t o r ( s e e p a g e
21-22). Y E S — G o to s t e p 5.
12. C h e c k the recirculation control linkage a n d d o o r s N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e N o . 20

for s m o o t h m o v e m e n t . (7.5 A ) f u s e in the u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e H V A C control u n i t . B
Do the recirculation control linkage and doors
move smoothly? 5. T u r n t h e ignition s w i t c h to L O C K (0).
Y E S — R e p l a c e the recirculation c o n t r o l m o t o r . B
N O — R e p a i r the recirculation control linkage or

doors. •
(cont'd)
21-51
HVAC Control Power and Ground Circuit Troubleshooting (cont'd)
6. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 29 t e r m i n a l
of the H V A C control unit 3 0 P c o n n e c t o r a n d b o d y
ground.
1 2 3 4 5 6 7
x 8 9 10 11 12 13
/
15 16
/ // 21 22
X 23
// 26 27 28 29 30
WHT/RED
(7.5 A ) f u s e in the u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e H V A C control unit. •
7. C h e c k for continuity b e t w e e n t h e N o . 2 6 t e r m i n a l of
t h e H V A C control unit 3 0 P c o n n e c t o r a n d b o d y
ground.
1 2 3 4 5 6 7 8 9 10 11 12 13
/
15 16
//// 21 22
X 23
// 26 27 28 29 30
RLK
t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r . If t h e
connections are good, substitute a known-good
H V A C c o n t r o l unit, a n d r e c h e c k . If t h e s y m p t o m
indication g o e s a w a y , replace the original H V A C
control u n i t . B
N O — C h e c k for a n o p e n in the w i r e b e t w e e n the

H V A C control unit a n d b o d y g r o u n d . If t h e w i r e is
O K , c h e c k for p o o r g r o u n d at G 4 0 2 . B
21-52
A / C Condenser Fan Circuit Troubleshooting
NOTE: 4. C o n n e c t t h e No. 1 a n d No. 2 t e r m i n a l s of t h e A / C

• D o not u s e this t r o u b l e s h o o t i n g p r o c e d u r e if t h e c o n d e n s e r fan relay 4P socket with a j u m p e r wire.
radiator f a n a n d / o r t h e A / C c o m p r e s s o r is i n o p e r a t i v e .
R e f e r to t h e s y m p t o m t r o u b l e s h o o t i n g . A / C C O N D E N S E R F A N R E L A Y 4P S O C K E T
• Before performing s y m p t o m troubleshooting, check
for p o w e r t r a i n D T C s : '00-05 m o d e l s ( s e e p a g e
11-3); '06-08 m o d e l s ( s e e p a g e 11-213).
JUMPER
WIRE
1. C h e c k the No. 58 (20 A ) f u s e in t h e m a i n
u n d e r - h o o d f u s e / r e l a y box, a n d t h e No. 20 (7.5 A )
BLU/YEL
f u s e in the u n d e r - d a s h f u s e / r e l a y box.
Are the fuses OK?
N O — R e p l a c e the fuse(s), and recheck. • Does the A/C condenser fan run?
2. R e m o v e the A / C c o n d e n s e r f a n r e l a y f r o m t h e m a i n Y E S — G o to s t e p 5.
u n d e r - h o o d f u s e / r e l a y box, a n d t e s t it ( s e e p a g e
22-48). N O — G o to s t e p 8.
Is the relay OK ? 5. D i s c o n n e c t t h e j u m p e r w i r e .
Y E S — G o to s t e p 3. 6. T u r n t h e ignition s w i t c h to O N (II).
N O — R e p l a c e t h e A / C c o n d e n s e r f a n relay. • 7. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 3 t e r m i n a l of
the A / C c o n d e n s e r fan relay 4P socket a n d body
3. M e a s u r e the v o l t a g e b e t w e e n t h e No. 1 t e r m i n a l of ground.
the A / C c o n d e n s e r fan relay 4P socket and body
ground. A / C C O N D E N S E R F A N R E L A Y 4P S O C K E T
r
A / C C O N D E N S E R F A N R E L A Y 4P S O C K E T 1
2
1
4 3
2 J
BLK/YEL
4 3
Y E S — R e p l a c e the m a i n u n d e r - h o o d f u s e / r e l a y
Is there battery voltage? box.B
Y E S — G o t o s t e p 4. N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e No. 20
N O — R e p l a c e the m a i n u n d e r - h o o d f u s e / r e l a y t h e A / C c o n d e n s e r f a n relay. •
box.B
(cont'd)
21-53
A / C Condenser Fan Circuit Radiator and A / C Condenser Fan
Troubleshooting (cont'd) Common Circuit Troubleshooting
9. D i s c o n n e c t t h e A / C c o n d e n s e r f a n 2 P c o n n e c t o r . NOTE:
• D o not u s e t h i s t r o u b l e s h o o t i n g p r o c e d u r e if o n l y o n e
10. C h e c k for c o n t i n u i t y b e t w e e n the No. 2 t e r m i n a l of f a n is i n o p e r a t i v e , or if t h e A / C c o m p r e s s o r is
the A / C c o n d e n s e r f a n r e l a y 4 P s o c k e t a n d t h e N o . 2 i n o p e r a t i v e . R e f e r to t h e s y m p t o m t r o u b l e s h o o t i n g .
t e r m i n a l of t h e A / C c o n d e n s e r f a n 2 P c o n n e c t o r . • Before performing s y m p t o m troubleshooting, check
for p o w e r t r a i n D T C s : ' 0 0 - 0 5 m o d e l s ( s e e p a g e
A / C C O N D E N S E R F A N R E L A Y 4P S O C K E T 11-3); ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-213).
1
BLU/YEL 1. C h e c k t h e N o . 57 (20 A ) a n d No. 58 (20 A ) f u s e s in
t h e m a i n u n d e r - h o o d f u s e / r e l a y b o x , a n d the No. 20
4 3 (7.5 A ) f u s e in the u n d e r - d a s h f u s e / r e l a y b o x .
Are the fuses OK ?
BLU/YEL N O — R e p l a c e the f u s e ( s ) , a n d r e c h e c k . •
A / C C O N D E N S E RF A N 2P C O N N E C T O R
W i r e s i d e of f e m a l e t e r m i n a l s 2. R e m o v e t h e A / C c o n d e n s e r f a n r e l a y f r o m t h e m a i n
under-hood fuse/relay box.
4. M e a s u r e t h e v o l t a g e b e t w e e n the No. 3 t e r m i n a l of
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e A / C t h e A / C c o n d e n s e r f a n r e l a y 4P s o c k e t a n d b o d y
condenser fan relay a n d the A / C c o n d e n s e r fan. • ground.
11. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 1 t e r m i n a l of A / C C O N D E N S E R F A N R E L A Y 4P S O C K E T
the A / C c o n d e n s e r f a n 2 P c o n n e c t o r a n d b o d y
A
ground. r
1
A / C C O N D E N S E RFAN 2P C O N N E C T O R
2
r 4 3
1 2
V J
I BLK/YEL
BLK
N O — C h e c k for a n o p e n in t h e w i r e b e t w e e n the A / C
c o n d e n s e r f a n a n d b o d y g r o u n d . If the w i r e is O K , 5. T u r n t h e ignition s w i t c h to L O C K (0).
21-54
A / C Compressor Clutch Circuit
Troubleshooting
6. R e i n s t a l l the A / C c o n d e n s e r f a n relay.
7. M a k e s u r e the A / C s w i t c h i s O F F . NOTE:
• Do not u s e t h i s t r o u b l e s h o o t i n g p r o c e d u r e if t h e f a n s
8. T u r n the ignition s w i t c h t o O N (II). a r e a l s o i n o p e r a t i v e w i t h t h e A / C o n . R e f e r to the
s y m p t o m troubleshooting.
9. U s i n g a b a c k p r o b e s e t , m e a s u r e the v o l t a g e • Before performing s y m p t o m troubleshooting, check
b e t w e e n the N o . 2 0 t e r m i n a l of E C M c o n n e c t o r A for p o w e r t r a i n D T C s : ' 0 0 - 0 5 m o d e l s ( s e e p a g e
(32P) a n d b o d y g r o u n d w i t h t h e E C M c o n n e c t o r s 11-3); ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-213).
c o n n e c t e d {'00-05 m o d e l s ) or b e t w e e n t h e No. 12
t e r m i n a l of E C M c o n n e c t o r E (31P) a n d b o d y 1. C h e c k the No. 58 (20 A ) f u s e in the m a i n
g r o u n d w i t h the E C M c o n n e c t o r s c o n n e c t e d u n d e r - h o o d f u s e / r e l a y b o x , a n d t h e N o . 20 (7.5 A )
('06-08 m o d e l s ) . f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x .
'00-05 m o d e l s Are the fuses OK?
ECM C
ONN
ECT
ORA (32P)
N O — R e p l a c e the fuse(s), and recheck. •

1 2 3 4
/ / / 6 9 10
12 13
/ /
25
15
26 27
18
28
19
29
20
30
21
/ 32
24
2. U s i n g t h e H D S , c o n f i r m t h e f o l l o w i n g v a l u e s in t h e
P G M - F I Data L i s t at idle.
ECT Sensor 1 6 9 - 1 9 4 °F ( 7 6 - 9 0 °C)

TP Sensor A b o u t 0.5 V
RPM More than 800
A / C Switch ON
'06-08 m o d e l s A / C Clutch ON
ECM C
ONN
ECT
ORE (31P) Are all the values within specifications?
1H 3 I 4 I 5X I 7 | | 8 | a Y E S — G o to s t e p 3.
/ 11 12 13 14 15 16 17 18 19 20 21
/
22 24 25
GRN
27 28 29 30
/ / N O — T r o u b l e s h o o t i n g t h e v a l u e that is not w i t h i n
the specifications. •
3 . R e m o v e the A / C c o m p r e s s o r c l u t c h r e l a y f r o m t h e
Wire side of female terminals m a i n u n d e r - h o o d f u s e / r e l a y b o x , a n d test it
( s e e p a g e 22-48).
Is there battery voltage? Is the relay OK ?
Y E S — C h e c k for l o o s e w i r e s or poor c o n n e c t i o n s at Y E S — G o to s t e p 4.
E C M c o n n e c t o r A (32P) ('00-05 m o d e l s ) , or E C M
c o n n e c t o r E (31P) ('06-08 m o d e l s ) . If the N O — R e p l a c e the A / C c o m p r e s s o r c l u t c h relay. •
E C M , a n d r e c h e c k . If the s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e t h e original E C M : ' 0 0 - 0 5 m o d e l s
( s e e p a g e 11-115); '06-08 m o d e l s ( s e e p a g e 11-389).
N O — R e p a i r o p e n in the w i r e b e t w e e n t h e radiator
fan relay, t h e A / C c o n d e n s e r f a n r e l a y a n d t h e
ECM.B
(cont'd)
21-55
A / C Compressor Clutch Circuit Troubleshooting (cont'd)
4. M e a s u r e the v o l t a g e b e t w e e n the N o . 1 t e r m i n a l of 6. D i s c o n n e c t t h e j u m p e r w i r e .
the A / C c o m p r e s s o r c l u t c h r e l a y 4 P s o c k e t a n d
body ground. 7. T u r n t h e ignition s w i t c h to O N (II).
A / C C O M P R E S S O R C L U T C H R E L A Y 4P S O C K E T
8. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 4 t e r m i n a l of
the A / C c o m p r e s s o r c l u t c h r e l a y 4 P s o c k e t a n d
r body ground.
1
2 A / C C O M P R E S S O R C L U T C H R E L A Y 4P S O C K E T
4 3 1
4 3
BLK/YEL
N O — R e p l a c e the m a i n u n d e r - h o o d f u s e / r e l a y Is there battery voltage ?

box.B
5. C o n n e c t the N o . 1 a n d N o . 2 t e r m i n a l s of t h e A / C
c o m p r e s s o r clutch relay 4P socket with a j u m p e r N O — R e p a i r o p e n in the w i r e b e t w e e n the No. 20
wire. (7.5 A ) f u s e in t h e u n d e r - d a s h f u s e / r e l a y b o x a n d
t h e A / C c o m p r e s s o r c l u t c h relay. •
10. R e i n s t a l l t h e A / C c o m p r e s s o r c l u t c h relay.
"\ JUMPER
1 WIRE
11. M a k e s u r e t h e A / C s w i t c h i s O F F .
2
BLU/RED
4 3
Does the A/C compressor clutch click?
21-56
13. U s i n g a b a c k p r o b e s e t , m e a s u r e t h e v o l t a g e 14. D i s c o n n e c t the j u m p e r w i r e .
b e t w e e n t h e No. 17 t e r m i n a l of E C M c o n n e c t o r A
(32P) a n d b o d y g r o u n d w i t h the E C M c o n n e c t o r s 15. D i s c o n n e c t the A / C c o m p r e s s o r c l u t c h 1P c o n n e c t o r .
c o n n e c t e d ('00-05 m o d e l s ) or b e t w e e n t h e N o . 18
t e r m i n a l of E C M c o n n e c t o r E (31P) a n d b o d y 16. C h e c k for continuity b e t w e e n t h e N o . 2 t e r m i n a l of
g r o u n d w i t h the E C M c o n n e c t o r s c o n n e c t e d t h e A / C c o m p r e s s o r c l u t c h relay 4 P s o c k e t a n d the
('06-08 m o d e l s ) . N o . 1 t e r m i n a l of t h e A / C c o m p r e s s o r c l u t c h 1P
connector.
'00-05 m o d e l s
1
BLU/RED
1 2 3 4 6 9 10
12 13 15 / / /
17 18 19 20 21 24
/ /
25 26 27 28 29 30 32
RED
BLK/RED
A / C C O M P R E S S O RC L U T C H I P C O N N E C T O R
'06-08 m o d e l s
Y E S — C h e c k the A / C c o m p r e s s o r c l u t c h c l e a r a n c e ,
the t h e r m a l protector, a n d the A / C c o m p r e s s o r
clutch field coil ( s e e p a g e 21-68). •
1 \/ 3 | 4 | 5 / I T 8 I 9 N O — R e p a i r o p e n in the w i r e b e t w e e n t h e A / C
c o m p r e s s o r c l u t c h relay a n d the A / C c o m p r e s s o r
/ 11 12 13 14 15 16 17 18 19 20 21
clutch. •
22
/ 24 25
/ 2 7 2 3 2 9 30
RED
/
Y E S — C h e c k for l o o s e w i r e s or poor c o n n e c t i o n s at
E C M c o n n e c t o r A (32P) ('00-05 m o d e l s ) , or E C M
c o n n e c t o r E (31P) ('06-08 m o d e l s ) . If t h e
E C M , a n d r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e the original E C M : ' 0 0 - 0 5 m o d e l s
( s e e p a g e 11-115); ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-389).
N O — R e p a i r o p e n in t h e w i r e b e t w e e n t h e A / C
c o m p r e s s o r c l u t c h r e l a y a n d the E C M . B
21-57
A / C Pressure Switch Circuit Troubleshooting
NOTE: 4. T u r n t h e ignition s w i t c h to L O C K (0).

• D o not u s e t h i s t r o u b l e s h o o t i n g p r o c e d u r e if a n y of
the following items are operative; A / C c o n d e n s e r f a n , 5. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 1 a n d N o . 2
radiator f a n , A / C c o m p r e s s o r , o r if t h e h e a t e r i s t e r m i n a l s of t h e A / C p r e s s u r e s w i t c h .
inoperative. Refer to the s y m p t o m troubleshooting.
• Before performing s y m p t o m troubleshooting, c h e c k A / C PRESSURE SWITCH
for p o w e r t r a i n D T C s : ' 0 0 - 0 5 m o d e l s ( s e e p a g e
11-3); ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-213).
1. D i s c o n n e c t t h e A / C p r e s s u r e s w i t c h 2 P c o n n e c t o r .
2 . T u r n t h e ignition s w i t c h t o O N (II).
3. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 2 t e r m i n a l of
the A / C pressure switch 2 P connector and body
ground.
A / C P R E S S U R E S W I T C H 29 C O N N E C T O R
BLU/RED
6. R e c o n n e c t t h e A / C p r e s s u r e s w i t c h 2 P c o n n e c t o r .
7. D i s c o n n e c t t h e H V A C control unit 3 0 P c o n n e c t o r .
9. M e a s u r e t h e v o l t a g e b e t w e e n t h e N o . 12 t e r m i n a l
Is there about 5 V? of t h e H V A C c o n t r o l unit 3 0 P c o n n e c t o r a n d b o d y
ground.
<T? BLU/WHT
1 2 3 4 5 6 7 >< 8 9 10 11 12 13
/
15 16
//// 21 22
A 2 3
// 26 27 28 29 30
Is there about 5 V?
YES-Gotostep10.
control unit a n d t h e A / C p r e s s u r e s w i t c h . •
21-58
10. T u r n the ignition s w i t c h to L O C K (0). 16. U s i n g a b a c k p r o b e s e t , m e a s u r e t h e v o l t a g e
b e t w e e n t h e N o . 2 7 t e r m i n a l of E C M c o n n e c t o r A
11. M e a s u r e the r e s i s t a n c e b e t w e e n t h e N o . 7 a n d (32P) a n d b o d y g r o u n d w i t h the E C M c o n n e c t o r s
N o . 10 t e r m i n a l s of t h e H V A C control unit 3 0 P c o n n e c t e d ('00-05 m o d e l s ) or b e t w e e n t h e N o . 2 8
connector. t e r m i n a l of E C M c o n n e c t o r E (31P) a n d b o d y
ground with the E C M connectors connected
('06-08 m o d e l s ) .
'00-05 m o d e l s
ECM CONNECTOR A (32P)
2 3 4
/ / / 6 9 10 ~^?>
1 2 3 4 5 6 7 8 9 10 11 12 13
/ 12 13
/ / 15 17 18 19 20 21 24
15 16
//// 21 2 2 ^ 2 3
// 26 27 28 29 30 25 26 27 28
BLU/RED
29 30
/ 32
W i r e s i d e of f e m a l e t e r m i n a l s Wire side of female terminals
'06-08 m o d e l s
Is the resistance less than 24 k 0,?
N O — R e p a i r c a u s e of high r e s i s t a n c e in the 11 M 31415 M v i inn

e v a p o r a t o r t e m p e r a t u r e circuit. • |22|X|24| |25|XI |Z7|28|29|30|/|
IBLU/RED
12. R e c o n n e c t t h e H V A C control unit 3 0 P c o n n e c t o r .

t
14. C h e c k t h e b l o w e r m o t o r o p e r a t i o n at s e v e r a l
speeds. Is there about 5V ?
Does the blower motor operate at all speeds? Y E S — R e p a i r o p e n in t h e w i r e b e t w e e n the E C M

and the A / C pressure switch. •
t h e H V A C control unit 3 0 P c o n n e c t o r a n d at t h e A / C N O — C h e c k for l o o s e w i r e s or p o o r c o n n e c t i o n s at
p r e s s u r e s w i t c h 2 P c o n n e c t o r . If t h e c o n n e c t i o n s E C M c o n n e c t o r A (32P) ('00-05 m o d e l s ) , or E C M
a r e g o o d , s u b s t i t u t e a k n o w n - g o o d H V A C control c o n n e c t o r E (31P) ('06-08 m o d e l s ) . If t h e
unit, a n d r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s c o n n e c t i o n s a r e g o o d , substitute a k n o w n - g o o d
a w a y , r e p l a c e t h e original H V A C control unit. • E C M , a n d r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s
a w a y , r e p l a c e the o r i g i n a l E C M : ' 0 0 - 0 5 m o d e l s
N O — R e p a i r t h e p r o b l e m in t h e b l o w e r m o t o r ( s e e p a g e 11-115); ' 0 6 - 0 8 m o d e l s ( s e e p a g e 11-389).
circuit.!
15. M a k e s u r e the A / C s w i t c h is O F F . 17. C h e c k for p r o p e r A / C s y s t e m p r e s s u r e .
Is the pressure within specifications?
Y E S — R e p l a c e the A / C p r e s s u r e s w i t c h . •
N O — R e p a i r the A / C p r e s s u r e problem. •
21-59
Evaporator Temperature Sensor HVAC Control Unit Removal/
Test Installation
1. R e m o v e t h e e v a p o r a t o r c o r e a n d t h e e v a p o r a t o r 1. R e m o v e t h e i n s t r u m e n t p a n e l t o g e t h e r w i t h t h e
t e m p e r a t u r e s e n s o r ( s e e p a g e 21-62). H V A C c o n t r o l unit ( s e e p a g e 20-84).
2 . Dip t h e s e n s o r in i c e w a t e r , a n d m e a s u r e t h e 2. R e m o v e t h e s e l f - t a p p i n g s c r e w s a n d t h e H V A C
r e s i s t a n c e b e t w e e n its t e r m i n a l s . control unit (A) f r o m t h e i n s t r u m e n t p a n e l (B).
I 1 —p
1 ?
u u
3. T h e n p o u r w a r m w a t e r o n t h e s e n s o r , a n d c h e c k f o r
a c h a n g e in r e s i s t a n c e .
4. C o m p a r e t h e r e s i s t a n c e r e a d i n g s w i t h t h e
s p e c i f i c a t i o n s s h o w n in t h e g r a p h ; t h e r e s i s t a n c e
s h o u l d be within the specifications.
3. Install t h e control unit in t h e r e v e r s e o r d e r of

r e m o v a l . After installation, o p e r a t e t h e c o n t r o l unit
c o n t r o l s to s e e w h e t h e r it w o r k s p r o p e r l y .
RESISTANCE
4. R u n t h e s e l f - d i a g n o s t i c f u n c t i o n to c o n f i r m that
(k£) 20
t h e r e a r e no p r o b l e m s in t h e s y s t e m ( s e e p a g e
21-35).
32 50 68 86 T
0 10 20 3 0 <€
TEMPERATURE
5. If t h e r e s i s t a n c e is not a s s p e c i f i e d , r e p l a c e t h e
e v a p o r a t o r t e m p e r a t u r e s e n s o r ( s e e p a g e 21-62).
21-60
Blower/Evaporator Unit Removal/Installation
1. R e c o v e r t h e refrigerant w i t h a r e c o v e r y / r e c y c l i n g / Disconnect the d a s h b o a r d wire h a r n e s s connector

c h a r g i n g station ( s e e p a g e 21-73). from the p a s s e n g e r ' s door wire h a r n e s s connector,
t h e n r e m o v e it. R e m o v e the w i r e h a r n e s s
2. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e c o n n e c t o r s a n d t h e c o n v e r t i b l e t o p control unit
audio s y s t e m , then write d o w n the audio presets. f r o m the steering hanger b e a m .
3. R e m o v e t h e battery. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m t h e b l o w e r
motor, the power transistor, the evaporator s e n s o r ,
4. Pull out t h e g r o m m e t s , t h e n c a r e f u l l y s e p a r a t e t h e a n d t h e r e c i r c u l a t i o n control m o t o r , t h e n r e m o v e
u p p e r g r o m m e t (A) f r o m t h e l o w e r g r o m m e t (B) b y t h e w i r e h a r n e s s c l i p s (B). R e m o v e t h e d r a i n h o s e
r e l e a s i n g t h e locktabs ( C ) . ( C ) , t h e s e l f - t a p p i n g s c r e w , t h e m o u n t i n g bolts, t h e
m o u n t i n g n u t s , a n d t h e b l o w e r / e v a p o r a t o r unit (D).
R e m o v e t h e bolt, t h e n d i s c o n n e c t t h e s u c t i o n line
(A) a n d t h e r e c e i v e r line (B) f r o m t h e b l o w e r /
e v a p o r a t o r unit. P l u g or c a p t h e l i n e s i m m e d i a t e l y
after d i s c o n n e c t i n g t h e m to a v o i d m o i s t u r e a n d
dust contamination. 9. Install t h e unit in t h e r e v e r s e o r d e r of r e m o v a l , a n d
• If y o u ' r e installing a n e w b l o w e r / e v a p o r a t o r unit,

a d d refrigerant oil ( S P - 1 0 ) ( s e e p a g e 21-33).
• R e p l a c e the O - r i n g s w i t h n e w o n e s at e a c h fitting,
a n d a p p l y a thin c o a t of refrigerant oil before
installing t h e m . B e s u r e to u s e t h e c o r r e c t O - r i n g s
f o r H F C - 1 3 4 a (R-134a) to a v o i d l e a k a g e .
• I m m e d i a t e l y after u s i n g t h e o i l , reinstall the c a p
o n t h e c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e
absorption.
• D o not spill t h e refrigerant oil o n the v e h i c l e ; it
m a y d a m a g e t h e paint. If t h e refrigerant oil
c o n t a c t s t h e paint, w a s h it off i m m e d i a t e l y .
6x1.0 m m
9.8 N - m (1.0 k g f m , 7.2 Ibf-ft) • M a k e s u r e that t h e r e is no air l e a k a g e .
• C h a r g e t h e s y s t e m ( s e e p a g e 21-75).
6. R e m o v e t h e p a s s e n g e r ' s d a s h b o a r d l o w e r c o v e r • D o t h e E C M idle l e a r n p r o c e d u r e : '00-05 m o d e l s
( s e e p a g e 20-86) a n d t h e right kick p a n e l ( s e e p a g e ( s e e p a g e 11-140); '06-08 m o d e l s ( s e e p a g e
20-71). 11-462).
t h e n enter t h e a u d i o p r e s e t s .
21-61
Blower/Evaporator Unit Component Replacement
Note t h e s e i t e m s w h e n o v e r h a u l i n g t h e b l o w e r / e v a p o r a t o r unit:
• T h e r e c i r c u l a t i o n c o n t r o l m o t o r ( A ) , t h e p o w e r t r a n s i s t o r ( B ) , a n d t h e b l o w e r m o t o r (C) c a n be r e p l a c e d w i t h o u t
removing the blower/evaporator u n i t
• If y o u ' r e installing a n e w e v a p o r a t o r c o r e (D), a d d r e f r i g e r a n t oil ( S P - 1 0 ) ( s e e p a g e 21-33).
• R e p l a c e the O - r i n g s w i t h n e w o n e s at e a c h fitting a n d a p p l y a thin c o a t of refrigerant oil b e f o r e installing t h e m .
B e s u r e to u s e t h e c o r r e c t O - r i n g s for H F C - 1 3 4 a ( R - 1 3 4 a ) to a v o i d l e a k a g e .
• I m m e d i a t e l y after u s i n g t h e o i l , reinstall t h e c a p o n t h e c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e a b s o r p t i o n .
• R e i n s t a l l t h e e v a p o r a t o r t e m p e r a t u r e s e n s o r (E) in its o r i g i n a l l o c a t i o n .
• B e f o r e r e a s s e m b l y , m a k e s u r e t h a t t h e r e c i r c u l a t i o n c o n t r o l linkage a n d d o o r s m o v e s m o o t h l y .
• After r e a s s e m b l y , m a k e s u r e t h e r e c i r c u l a t i o n c o n t r o l m o t o r r u n s s m o o t h l y ( s e e p a g e 21-22).
• M a k e s u r e n o air i s l e a k i n g f r o m t h e u p p e r h o u s i n g (F) a n d t h e l o w e r h o u s i n g (G) fitting.
21-62
Expansion Valve Replacement Heater Unit/Core Replacement
1. R e m o v e t h e b l o w e r / e v a p o r a t o r unit ( s e e p a g e S R S c o m p o n e n t s a r e l o c a t e d in t h i s a r e a . R e v i e w t h e
21-61). S R S c o m p o n e n t locations: '00-05 m o d e l s (see page
2 3 - 1 1 ) , '06-08 m o d e l s ( s e e p a g e 23-12) a n d t h e
2. R e m o v e t h e e v a p o r a t o r c o r e ( s e e p a g e 21-62). p r e c a u t i o n s a n d p r o c e d u r e s ( s e e p a g e 23-13) b e f o r e
d o i n g r e p a i r s or s e r v i c e .
3. R e m o v e t h e bolts (A).
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e f o r t h e
2 . D i s c o n n e c t t h e n e g a t i v e c a b l e f r o m t h e battery.
3 . R e m o v e t h e h e a t s h i e l d of t h e e x h a u s t m a n i f o l d
( s e e s t e p 2 3 o n p a g e 6-29).
4. F r o m u n d e r t h e h o o d , o p e n t h e c a b l e c l a m p (A),
h e a t e r v a l v e a r m (C). T u r n t h e h e a t e r v a l v e a r m to
t h e fully o p e n e d p o s i t i o n a s s h o w n .
4. R e m o v e t h e outer s e a l (B) a n d e x p a n s i o n v a l v e ( C ) .
5. Install t h e e x p a n s i o n v a l v e in t h e r e v e r s e o r d e r of
r e m o v a l a n d note t h e s e i t e m s :
• If y o u ' r e installing a n e w e x p a n s i o n v a l v e , a d d
refrigerant oil ( S P - 1 0 ) ( s e e p a g e 21-33).
• R e p l a c e t h e O - r i n g s with n e w o n e s at e a c h fitting,
a n d a p p l y a thin c o a t of refrigerant oil b e f o r e
installing t h e m . B e s u r e to u s e t h e c o r r e c t O - r i n g s
for H F C - 1 3 4 a (R-134a) to a v o i d l e a k a g e .
• I m m e d i a t e l y after u s i n g t h e o i l , reinstall t h e c a p
o n t h e c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e 5. W h e n t h e e n g i n e i s c o o l , d r a i n t h e e n g i n e c o o l a n t
absorption, f r o m t h e radiator ( s e e p a g e 10-9).
• D o not spill t h e refrigerant oil o n t h e v e h i c l e ; it
m a y d a m a g e t h e paint; if t h e refrigerant oil
• M a k e s u r e that there is n o air l e a k a g e .
(cont'd)
21-63
Heater Unit/Core Replacement (cont'd)
6. R e m o v e t h e m o u n t i n g bolt f r o m t h e h e a t e r v a l v e . 8. R e m o v e t h e d a s h b o a r d ( s e e p a g e 2 0 - 8 7 ) .
S l i d e t h e h o s e c l a m p s (A) b a c k , t h e n d i s c o n n e c t t h e
inlet h e a t e r h o s e (B) a n d t h e outlet h e a t e r h o s e (C) 9 . R e m o v e t h e b l o w e r / e v a p o r a t o r unit ( s e e p a g e
f r o m t h e h e a t e r unit. E n g i n e c o o l a n t w i l l r u n o u t 21-61).
w h e n t h e h o s e s a r e d i s c o n n e c t e d ; d r a i n it into a
c l e a n drip p a n . B e s u r e not to let c o o l a n t s p i l l o n 10. R e m o v e t h e m o u n t i n g bolts, t h e c e n t e r b r a c k e t s ( A ) ,
t h e e l e c t r i c a l p a r t s o r t h e p a i n t e d s u r f a c e s . If a n y a n d the audio brackets (B).
c o o l a n t s p i l l s , r i n s e it off i m m e d i a t e l y .
8x1.25 mm
2 2 N - m (2.2 k g f - m , 1 6 I b f f t )
6x1.0 mm
9.8 N-m
(1.0 k g f - m ,
7.2 I b f f t )
8x1.25 mm
22 N-m
6 x 1.0 m m (2.2 k g f m , 1 6 I b f f t )
9 . 8 N m (1.0 k g f - m , 7 . 2 Ibf ft)
7. R e m o v e t h e m o u n t i n g nut f r o m t h e h e a t e r unit.
T a k e c a r e not to d a m a g e o r b e n d t h e f u e l l i n e s , t h e 11. R e m o v e t h e S R S unit ( s e e p a g e 23-179).
b r a k e l i n e s , etc..
12. R e m o v e t h e s e l f - t a p p i n g s c r e w s a n d t h e d e f r o s t e r
8 x 1.25 m m
1 3 N m (1.3 k g f - m , 9 . 4 I b f f t )
outlet ( A ) , t h e n r e m o v e t h e w i r e h a r n e s s c l i p s ( B ) .
21-64
BD
13. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m the m o d e 15. Install t h e h e a t e r c o r e in t h e r e v e r s e o r d e r of
control m o t o r a n d the air m i x control m o t o r , t h e n removal.
r e m o v e t h e w i r e h a r n e s s c l i p (B). R e m o v e t h e
m o u n t i n g n u t s , the m o u n t i n g bolt, a n d t h e h e a t e r 16. Install t h e h e a t e r unit in t h e r e v e r s e o r d e r of
unit ( C ) . r e m o v a l , a n d note t h e s e i t e m s :
• D o not i n t e r c h a n g e t h e inlet a n d outlet h e a t e r

h o s e s , a n d install t h e h o s e c l a m p s s e c u r e l y .
• Refill t h e c o o l i n g s y s t e m w i t h e n g i n e c o o l a n t
( s e e p a g e 10-9).
• A d j u s t t h e h e a t e r v a l v e c a b l e ( s e e p a g e 21-27).
• M a k e s u r e that t h e r e i s n o e n g i n e c o o l a n t l e a k a g e .
• M a k e s u r e that t h e r e is no air l e a k a g e .
• F o r e v a p o r a t o r a n d A / C - r e l a t e d i n f o r m a t i o n , refer
to b l o w e r / e v a p o r a t o r unit r e m o v a l a n d
installation ( s e e p a g e 21-61).
• D o t h e E C M idle l e a r n p r o c e d u r e : ' 0 0 - 0 5 m o d e l s
( s e e p a g e 11-140); ' 0 6 - 0 8 m o d e l s ( s e e p a g e
11-462).
then enter the audio presets.
14. R e m o v e t h e self-tapping s c r e w s a n d t h e p a s s e n g e r ' s

h e a t e r outlet (A), t h e n r e m o v e t h e s e l f - t a p p i n g
s c r e w a n d t h e c l a m p (B). B e c a r e f u l not to b e n d t h e
inlet a n d outlet p i p e s d u r i n g t h e h e a t e r c o r e (C)
r e m o v a l , a n d pull out t h e h e a t e r c o r e .
21-65
A / C Compressor Replacement
1. If t h e A / C c o m p r e s s o r i s m a r g i n a l l y o p e r a b l e , r u n 8. D i s c o n n e c t t h e A / C c o m p r e s s o r c l u t c h c o n n e c t o r ,
t h e e n g i n e at idle s p e e d , a n d let t h e a i r t h e n r e m o v e t h e m o u n t i n g bolts a n d t h e A / C
conditioning w o r k for a f e w m i n u t e s , then shut the compressor.
e n g i n e off.
2 . M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e
4. R e c o v e r t h e refrigerant w i t h a r e c o v e r y / r e c y c l i n g /
charging station (see page 21-73).
5. R e m o v e t h e air c l e a n e r h o u s i n g ( s e e p a g e 6-25).
6. R e m o v e t h e a l t e r n a t o r ( s e e p a g e 4-45).
7. R e m o v e t h e n u t s , t h e n d i s c o n n e c t t h e s u c t i o n line
(A) a n d t h e d i s c h a r g e line (B) f r o m t h e A / C
10x1.25 mm
c o m p r e s s o r . P l u g o r c a p t h e l i n e s i m m e d i a t e l y after 4 4 N - m (4.5 k g f . m ,
d i s c o n n e c t i n g t h e m to a v o i d m o i s t u r e a n d d u s t 3 3 Ibf ft)
contamination.
9 . If n e c e s s a r y , r e m o v e t h e m o u n t i n g bolts a n d t h e
A / C c o m p r e s s o r bracket.
21-66
HB
10. Install the A / C c o m p r e s s o r in t h e r e v e r s e o r d e r of
• If y o u ' r e installing a n e w A / C c o m p r e s s o r , y o u
m u s t c a l c u l a t e t h e a m o u n t of refrigerant oil to be
r e m o v e d f r o m it ( s e e p a g e 21-33).
• R e p l a c e the O - r i n g s with n e w o n e s at e a c h fitting,
a n d a p p l y a thin c o a t of refrigerant oil before
installing t h e m . B e s u r e to u s e the c o r r e c t O - r i n g s
• U s e refrigerant oil ( S P - 1 0 ) for H F C - 1 3 4 a K E I H I N
s p i r a l type A / C c o m p r e s s o r o n l y .
• T o a v o i d c o n t a m i n a t i o n , d o not return t h e oil to
the c o n t a i n e r o n c e d i s p e n s e d , a n d n e v e r m i x it
with other refrigerant oils.
o n the c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e
absorption.
• D o not spill t h e refrigerant oil o n t h e v e h i c l e ; it
c o n t a c t s the paint, w a s h it off i m m e d i a t e l y .
• D o the E C M idle l e a r n p r o c e d u r e : '00-05 m o d e l s
( s e e p a g e 11-140); '06-08 m o d e l s ( s e e p a g e
11-462).
t h e n enter t h e a u d i o p r e s e t s .
21-67
A / C Compressor Clutch Check
1. C h e c k t h e a r m a t u r e plate for d i s c o l o r a t i o n , p e e l i n g , 4. R e l e a s e t h e field c o i l c o n n e c t o r f r o m the holder,

o r o t h e r d a m a g e . If t h e r e i s d a m a g e , r e p l a c e t h e t h e n d i s c o n n e c t it. C h e c k t h e t h e r m a l protector for
c l u t c h s e t ( s e e p a g e 21-69). continuity. If t h e r e i s no continuity, r e p l a c e t h e
t h e r m a l protector ( s e e p a g e 21-71).
2 . C h e c k t h e rotor p u l l e y b e a r i n g p l a y a n d d r a g b y
rotating t h e rotor p u l l e y b y h a n d . R e p l a c e t h e N O T E : T h e t h e r m a l protector will h a v e n o
c l u t c h s e t w i t h a n e w o n e if it i s n o i s y o r h a s c o n t i n u i t y a b o v e 2 5 2 to 2 6 2 °F (122 to 128 *C>.
e x c e s s i v e play/drag (see page 21-69). W h e n t h e t e m p e r a t u r e d r o p s b e l o w 241 to 219 °F
(116 to 104 * € ) , t h e t h e r m a l protector will h a v e
continuity.
3. M e a s u r e t h e c l e a r a n c e b e t w e e n t h e rotor p u l l e y (A)
a n d t h e a r m a t u r e plate (B) all t h e w a y a r o u n d . If t h e
c l e a r a n c e i s not w i t h i n s p e c i f i e d l i m i t s , r e m o v e t h e
a r m a t u r e plate ( s e e p a g e 21-69) a n d a d d o r r e m o v e
s h i m s a s n e e d e d to i n c r e a s e o r d e c r e a s e c l e a r a n c e .
5. C h e c k r e s i s t a n c e of t h e field c o i l . If r e s i s t a n c e is not
Clearance: 0 . 3 5 — 0 . 6 5 m m ( 0 . 0 1 4 ± 0 . 0 2 6 in.) w i t h i n s p e c i f i c a t i o n s , r e p l a c e t h e coil ( s e e p a g e
21-69).
N O T E : T h e s h i m s a r e a v a i l a b l e in f o u r t h i c k n e s s e s :
0.1 m m , 0.2 m m , 0.4 m m , a n d 0.5 m m . Field Coil Resistance: 3.05—3.35 Q at
6 8 °F (20 <€)
A
a
21-68
DD
A / C Compressor Clutch Overhaul
Special Tools Required 3. If y o u a r e r e p l a c i n g t h e field c o i l , r e m o v e the s n a p

A / C c l u t c h holder, R o b i n a i r 10204 or K e n t - M o o r e ring (A) w i t h s n a p ring p l i e r s , t h e n r e m o v e t h e rotor
J 3 7 8 7 2 , or H o n d a T o o l a n d E q u i p m e n t K M T - J 3 3 9 3 9 , p u l l e y (B). B e c a r e f u l not to d a m a g e t h e p u l l e y a n d
commercially available A/C compressor.
1. R e m o v e t h e c e n t e r nut (A) w h i l e holding t h e

a r m a t u r e plate w i t h a c o m m e r c i a l l y a v a i l a b l e A / C
c l u t c h h o l d e r (B).
4. R e m o v e t h e bolt a n d h o l d e r (A), t h e n d i s c o n n e c t
t h e field coil c o n n e c t o r (B). L o o s e n t h e c l a m p s c r e w
(C) to f r e e t h e field coil w i r e . R e m o v e t h e s n a p ring
(D) w i t h s n a p ring p l i e r s , t h e n r e m o v e t h e field coil
2. R e m o v e t h e a r m a t u r e plate (A) a n d s h i m ( s ) ( B ) , (E) . B e c a r e f u l not to d a m a g e the field coil a n d A / C
taking c a r e not to l o s e the s h i m ( s ) . If the c l u t c h compressor.
n e e d s adjustment, increase or d e c r e a s e the
n u m b e r a n d t h i c k n e s s of s h i m s a s n e c e s s a r y , t h e n
reinstall the a r m a t u r e plate, a n d r e c h e c k its
c l e a r a n c e ( s e e p a g e 21-68).
N O T E : T h e s h i m s a r e a v a i l a b l e in four t h i c k n e s s e s :
0.1 m m , 0.2 m m , 0.4 m m , a n d 0.5 m m .
(cont'd)
21-69
A / C Compressor Clutch Overhaul (cont'd)
5 . R e a s s e m b l e t h e c l u t c h in t h e r e v e r s e o r d e r of
d i s a s s e m b l y , a n d note t h e s e i t e m s :
• Install t h e field coil w i t h t h e w i r e s i d e f a c i n g

d o w n , a n d a l i g n t h e b o s s o n t h e A / C field c o i l
w i t h t h e h o l e in t h e A / C c o m p r e s s o r .
• C l e a n t h e rotor p u l l e y a n d A / C c o m p r e s s o r
sliding s u r f a c e s with contact cleaner or other
non-petroleum solvent.
• Install n e w s n a p r i n g s , note t h e installation
d i r e c t i o n , a n d m a k e s u r e t h e y a r e fully s e a t e d in
the groove.
• M a k e s u r e that t h e rotor p u l l e y t u r n s s m o o t h l y
after it's r e a s s e m b l e d .
• Route a n d c l a m p the w i r e s properly or they c a n
b e d a m a g e d b y t h e rotor p u l l e y .
21-70
A / C Compressor Thermal Protector A / C Compressor Relief Valve
1. R e m o v e t h e bolt, the g r o u n d t e r m i n a l (A), a n d the N O T E : If t h e A / C c o m p r e s s o r relief v a l v e r e l e a s e d

h o l d e r (B). D i s c o n n e c t t h e field coil c o n n e c t o r ( C ) , refrigerant to t h e a t m o s p h e r e , d e t e r m i n e a n d c o r r e c t
t h e n r e m o v e t h e t h e r m a l protector (D). t h e c a u s e of t h e e x c e s s i v e s y s t e m p r e s s u r e , t h e n
r e p l a c e t h e relief v a l v e .
7.4 N m (0.75 k g f m , 5 Ibf-ft)
1. R e c o v e r t h e refrigerant w i t h a r e c o v e r y / r e c y c l i n g /
c h a r g i n g station ( s e e p a g e 21-73).
2. R e m o v e t h e relief v a l v e ( A ) , a n d t h e O - r i n g (B). P l u g
t h e o p e n i n g to k e e p f o r e i g n m a t t e r f r o m e n t e r i n g
t h e s y s t e m a n d t h e A / C c o m p r e s s o r oil f r o m
r u n n i n g out.
2. R e p l a c e t h e t h e r m a l protector (A) w i t h a n e w o n e ,
B
a n d a p p l y s i l i c o n e s e a l a n t (B) to t h e b o t t o m of t h e
t h e r m a l protector.
3. C l e a n the m a t i n g s u r f a c e s .
4. R e p l a c e t h e O - r i n g w i t h a n e w o n e at t h e relief
v a l v e , a n d a p p l y a thin c o a t of refrigerant oil before
installing it.
5. R e m o v e the p l u g , a n d install a n d tighten t h e relief

valve.
6. C h a r g e the s y s t e m ( s e e p a g e 21-75).
3. Install t h e t h e r m a l protector in t h e r e v e r s e o r d e r of
removal.
21-71
A / C Condenser Replacement
1. R e c o v e r t h e refrigerant w i t h a r e c o v e r y / r e c y c l i n g / 5. R e m o v e t h e bolts a n d t h e u p p e r m o u n t b r a c k e t s (A),
c h a r g i n g s t a t i o n ( s e e p a g e 21-73). t h e n r e m o v e t h e A / C c o n d e n s e r (B) b y lifting it u p .
B e c a r e f u l not to d a m a g e t h e radiator o r t h e A / C
2. R e m o v e t h e a i r c l e a n e r h o u s i n g ( s e e p a g e 6-25). condenser fins w h e n removing the A / C condenser.
A
3. R e m o v e t h e b o l t s , t h e n r e m o v e t h e u p p e r m o u n t
b r a c k e t s f r o m t h e radiator.
6 x 1.0 m m
9 . 8 N - m (1.0 k g f m , 7 . 2 Ibf-ft)
4. R e m o v e t h e b o l t s , t h e n d i s c o n n e c t t h e d i s c h a r g e
line (A) a n d t h e A / C c o n d e n s e r line (B) f r o m t h e A / C
c o n d e n s e r . P l u g o r c a p t h e l i n e s i m m e d i a t e l y after
d i s c o n n e c t i n g t h e m to a v o i d m o i s t u r e a n d d u s t
contamination.
6. Install t h e A / C c o n d e n s e r in t h e r e v e r s e o r d e r of
• If y o u ' r e installing a n e w A / C c o n d e n s e r , a d d
refrigerant oil ( S P - 1 0 ) ( s e e p a g e 21-33).
• R e p l a c e t h e O - r i n g s w i t h n e w o n e s at e a c h fitting,
a n d a p p l y a thin c o a t of refrigerant oil b e f o r e
i n s t a l l i n g t h e m . B e s u r e to u s e t h e c o r r e c t O - r i n g s
o n t h e c o n t a i n e r , a n d s e a l it to a v o i d m o i s t u r e
absorption.
• D o not s p i l l t h e refrigerant oil o n t h e v e h i c l e ; it
• B e c a r e f u l not to d a m a g e t h e radiator o r t h e A / C
c o n d e n s e r f i n s w h e n installing t h e A / C c o n d e n s e r .
6 x 1.0 m m
9 . 8 N - m (1.0 k g f m , 7 . 2 Ibf-ft)
21-72
Refrigerant Recovery
2. M e a s u r e t h e a m o u n t of refrigerant oil r e m o v e d
ACAUTION f r o m t h e A / C s y s t e m after t h e r e c o v e r y p r o c e s s is
• A i r c o n d i t i o n i n g refrigerant or lubricant v a p o r c o m p l e t e d . B e s u r e to put t h e s a m e a m o u n t of n e w
c a n irritate y o u r e y e s , n o s e , or throat. r e f r i g e r a n t oil b a c k into t h e A / C s y s t e m b e f o r e
• B e careful w h e n connecting service equipment. charging.
U s e o n l y s e r v i c e e q u i p m e n t that is U . L - l i s t e d a n d is
certified to m e e t the r e q u i r e m e n t s of S A E J 2 2 1 0 to
r e m o v e H F C - 1 3 4 a (R-134a) f r o m the air c o n d i t i o n i n g
system.
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , ventilate the
w o r k a r e a before r e s u m i n g s e r v i c e .
A d d i t i o n a l health a n d s a f e t y i n f o r m a t i o n m a y be
o b t a i n e d f r o m t h e refrigerant a n d lubricant
manufacturers.
1. C o n n e c t a n R-134a refrigerant r e c o v e r y / r e c y c l i n g /
c h a r g i n g station (A) to the h i g h - p r e s s u r e s e r v i c e
port (B) a n d the l o w - p r e s s u r e s e r v i c e port ( C ) , a s
s h o w n , following the equipment manufacturer's
instructions.
21-73
System Evacuation
2. C o n n e c t a n R-134a refrigerant r e c o v e r y / r e c y c l i n g /
ikCAUTION c h a r g i n g station (A) to t h e h i g h - p r e s s u r e s e r v i c e
• A i r c o n d i t i o n i n g refrigerant or l u b r i c a n t v a p o r port (B) a n d the l o w - p r e s s u r e s e r v i c e port ( C ) a s
r
c a n irritate y o u r e y e s , n o s e , o r throat. s h o w n , following the equipment manufacturer's

• Be careful w h e n connecting service equipment. instructions. E v a c u a t e the s y s t e m .
U s e o n l y s e r v i c e e q u i p m e n t that is U . L - l i s t e d a n d is
certified to m e e t the r e q u i r e m e n t s of S A E J 2 2 1 0 to
r e m o v e H F C - 1 3 4 a (R-134a) f r o m t h e a i r c o n d i t i o n i n g
system.
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , v e n t i l a t e t h e
w o r k area before r e s u m i n g service.
A d d i t i o n a l health a n d s a f e t y i n f o r m a t i o n m a y b e
manufacturers.
1. W h e n a n A / C s y s t e m h a s b e e n o p e n e d to t h e
a t m o s p h e r e , s u c h a s d u r i n g installation or r e p a i r , it
m u s t b e e v a c u a t e d u s i n g a n R - 1 3 4 a refrigerant
r e c o v e r y / r e c y c l i n g / c h a r g i n g s t a t i o n (If t h e s y s t e m
h a s b e e n o p e n for s e v e r a l d a y s , t h e r e c e i v e r / d r y e r
s h o u l d be r e p l a c e d , a n d t h e s y s t e m s h o u l d be
e v a c u a t e d for s e v e r a l h o u r s . )
3. If t h e l o w - p r e s s u r e d o e s not r e a c h m o r e t h a n
9 3 . 3 k P a (700 m m H g , 27.6 in.Hg) w i t h i n 15 m i n u t e s ,
t h e r e is p r o b a b l y a leak in the s y s t e m . Partially
c h a r g e t h e s y s t e m , a n d c h e c k for l e a k s ( s e e s t e p 3
o n p a g e 21-76).
21-74
System Charging
2. E v a c u a t e t h e s y s t e m ( s e e p a g e 2 1 - 7 4 ) .
^CAUTION
A i r c o n d i t i o n i n g refrigerant o r lu b rican t v a p o r 3. A d d t h e s a m e a m o u n t of n e w refrigerant oil to the
c a n irritate y o u r e y e s , n o s e , o r throat. s y s t e m that w a s r e m o v e d d u r i n g r e c o v e r y . U s e
Be careful w h e n connecting service equipment. o n l y S P - 1 0 refrigerant o i l .
D o not b r e a t h e refrigerant or v a p o r .
4. C h a r g e t h e s y s t e m w i t h t h e s p e c i f i e d a m o u n t of
R - 1 3 4 a refrigerant. D o not o v e r c h a r g e t h e s y s t e m ;
U s e o n l y s e r v i c e e q u i p m e n t that i s U . L . - l i s t e d a n d is t h e A / C c o m p r e s s o r will be d a m a g e d .
certified to m e e t t h e r e q u i r e m e n t s of S A E J 2 2 1 0 to
r e m o v e HFC-134a (R-134a) from the air conditioning S e l e c t t h e a p p r o p r i a t e units of m e a s u r e for y o u r
system. refrigerant c h a r g i n g s t a t i o n .
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , ventilate the Refrigerant Capacity:

w o r k a r e a before r e s u m i n g s e r v i c e . 550 to 600 g
0.55 t o 0.60 k g
A d d i t i o n a l health a n d s a f e t y i n f o r m a t i o n m a y b e 1.2 t o 1.3 l b s
o b t a i n e d f r o m t h e refrigerant a n d l u b r i c a n t 19.4 t o 2 1 . 2 o z
manufacturers.
5. C h e c k for refrigerant l e a k s ( s e e p a g e 21-76).
1. C o n n e c t a R - 1 3 4 a refrigerant r e c o v e r y / r e c y c l i n g /
c h a r g i n g station (A) to the h i g h - p r e s s u r e s e r v i c e 6. C h e c k for s y s t e m p e r f o r m a n c e ( s e e p a g e 21-78).
port (B) a n d the l o w - p r e s s u r e s e r v i c e port ( C ) , a s
instructions.
21-75
Refrigerant Leak Test

Special Tools Required 1. C o n n e c t a n R - 1 3 4 a refrigerant r e c o v e r y / r e c y c l i n g /
L e a k detector, H o n d a T o o l a n d E q u i p m e n t Y G K - H - 1 O P M c h a r g i n g s t a t i o n (A) to t h e h i g h - p r e s s u r e s e r v i c e
commercially available port (B) a n d t h e l o w - p r e s s u r e s e r v i c e port ( C ) , a s
instructions.
^WARNING
• C o m p r e s s e d air m i x e d w i t h R - 1 3 4 a f o r m s a
combustible vapor.
• T h e vapor c a n burn or explode c a u s i n g s e r i o u s
injury.
• N e v e r u s e c o m p r e s s e d a i r to p r e s s u r e t e s t
R-134a s e r v i c e e q u i p m e n t or v e h i c l e air
conditioning s y s t e m s .
^CAUTION
c a n irritate y o u r e y e s , n o s e , o r throat.
• Be careful w h e n connecting service equipment.
U s e o n l y s e r v i c e e q u i p m e n t that i s U . L . - l i s t e d a n d i s
certified to m e e t t h e r e q u i r e m e n t s of S A E J 2 2 1 0 t o
r e m o v e H F C - 1 3 4 a (R-134a) f r o m t h e a i r c o n d i t i o n i n g
system.
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , ventilate t h e
work area before r e s u m i n g service.
2. O p e n t h e high p r e s s u r e v a l v e to c h a r g e t h e s y s t e m
R-134a s e r v i c e e q u i p m e n t o r v e h i c l e air c o n d i t i o n i n g to t h e s p e c i f i e d c a p a c i t y , t h e n c l o s e t h e s u p p l y
s y s t e m s s h o u l d not b e p r e s s u r e t e s t e d o r leak t e s t e d v a l v e , a n d r e m o v e t h e c h a r g i n g station fittings.
w i t h c o m p r e s s e d air.
S e l e c t t h e a p p r o p r i a t e units of m e a s u r e m e n t for
A d d i t i o n a l health a n d s a f e t y i n f o r m a t i o n m a y b e y o u r refrigerant c h a r g i n g s t a t i o n .
manufacturers. Refrigerant Capacity:
550 to 600 g
0.55 t o 0.60 k g
1.2 t o 1.3 l b s
19.4 t o 2 1 . 2 o z
3. C h e c k t h e s y s t e m for l e a k s u s i n g a n R-134a
refrigerant leak d e t e c t o r w i t h a n a c c u r a c y of 14 g
(0.5 oz) p e r y e a r or better.
4. If y o u find l e a k s that r e q u i r e t h e s y s t e m to b e
o p e n e d (to r e p a i r o r r e p l a c e h o s e s , fittings, etc.), d o
t h e refrigerant r e c o v e r y t h e s y s t e m .
5. After c h e c k i n g a n d r e p a i r i n g l e a k s , t h e s y s t e m
m u s t be e v a c u a t e d .
21-76
A / C System Test
B§j
Pressure Test
T e s t results Related symptoms Probable c a u s e Remedy
Driver's and Poor A / C performance. Discharge L o w refrigerant c h a r g e R e c o v e r , e v a c u a t e ( s e e page 21-73),
p a s s e n g e r ' s side (high) and suction (low) p r e s s u r e are a n d recharge w i t h specified a m o u n t
vent temperature low. (see page 21-75).
v a r y by m o r e than Air mix door inoperable Repair or replace.
2 0 ° F ( 2 0 °C)
Discharge (high) After stopping A / C c o m p r e s s o r , Air in s y s t e m R e c o v e r , e v a c u a t e ( s e e p a g e 21-73),
pressure p r e s s u r e drops to about 196 kPa a n d recharge with specified a m o u n t
2
abnormally high (2.0 k g f / c m , 2 8 psi) quickly, a n d then (see page 21-75).
falls gradually.
R e d u c e d or no airflow through A / C • C l o g g e d A / C c o n d e n s e r or • Clean.
condenser. radiator fins • C h e c k voltage a n d fan r p m .
• A / C c o n d e n s e r or radiator fan • C h e c k fan direction.
not w o r k i n g properly
Line to A / C c o n d e n s e r is e x c e s s i v e l y Restricted f l o w of refrigerant in R e p l a c e restricted lines.
hot. system
Discharge pressure High and low p r e s s u r e s are balanced • Faulty A / C c o m p r e s s o r R e p l a c e the A / C c o m p r e s s o r .
abnormally low s o o n after stopping A / C c o m p r e s s o r . discharge valve
L o w side is higher than normal. • Faulty A / C c o m p r e s s o r s e a l
Outlet of e x p a n s i o n valve is not • Faulty e x p a n s i o n v a l v e • Replace.
frosted, l o w - p r e s s u r e gauge indicates • Moisture in s y s t e m • R e c o v e r , e v a c u a t e , a n d recharge
vacuum. with specified a m o u n t .
S u c t i o n (low) E x p a n s i o n v a l v e is not frosted, and • Frozen e x p a n s i o n v a l v e • R e c o v e r , e v a c u a t e , a n d recharge
pressure l o w - p r e s s u r e line is not cold. L o w - (Moisture in s y s t e m ) with specified a m o u n t .
abnormally low p r e s s u r e g a u g e indicates v a c u u m . • Faulty e x p a n s i o n v a l v e • Replace.
Discharge temperature is low, a n d the Frozen evaporator R u n the fan with A / C c o m p r e s s o r off,
airflow from v e n t s is restricted. then c h e c k evaporator temperature
sensor.
E x p a n s i o n v a l v e is frosted. Clogged expansion valve C l e a n or replace.
Receiver/dryer outlet is c o o l , and inlet C l o g g e d receiver/dryer Replace.
is w a r m (should be w a r m during
operation).
Suction pressure L o w - p r e s s u r e h o s e and check joint are E x p a n s i o n v a l v e o p e n too long Repair or replace.
abnormally high cooler than the temperature a r o u n d
evaporator.
S u c t i o n p r e s s u r e is lowered w h e n A / C E x c e s s i v e refrigerant in s y s t e m R e c o v e r , e v a c u a t e , a n d recharge with
c o n d e n s e r is cooled by water. specified a m o u n t .
High and l o w - p r e s s u r e s are equalized • Faulty gasket R e p l a c e the A / C c o m p r e s s o r .
a s s o o n a s the A / C c o m p r e s s o r is • Faulty h i g h - p r e s s u r e v a l v e
s t o p p e d , a n d both g a u g e s fluctuate • Foreign particle stuck in high-
w h i l e running. pressure valve
S u c t i o n and R e d u c e d airflow through A / C • C l o g g e d A / C c o n d e n s e r or • Clean.
discharge condenser. radiator fins • C h e c k voltage a n d fan r p m .
pressures • A / C c o n d e n s e r or radiator fan • C h e c k fan direction.
abnormally high not working properly
Suction and L o w - p r e s s u r e h o s e a n d metal e n d C l o g g e d or kinked l o w - p r e s s u r e Repair or replace.
discharge a r e a s are cooler than evaporator. h o s e parts
pressures Temperature around expansion valve C l o g g e d h i g h - p r e s s u r e line Repair or replace.
a b n o r m a l l y low is too low c o m p a r e d with that a r o u n d
receiver/dryer.
Refrigerant leaks A / C c o m p r e s s o r clutch is dirty. A / C c o m p r e s s o r shaft s e a l leaking R e p l a c e the A / C c o m p r e s s o r .
A / C c o m p r e s s o r bolt(s) are dirty. Leaking around bolt(s) Tighten bolt(s) or replace the A / C
compressor.
A / C c o m p r e s s o r gasket is w e t with oil. G a s k e t leaking R e p l a c e the A / C c o m p r e s s o r .
A / C fitting is dirty. Leaking O-ring C l e a n A / C fitting a n d replace O-ring.
(cont'd)
21-77
A / C System Test (cont'd)
Performance Test R e m o v e the passenger's dashboard lower c o v e r

( s e e p a g e 20-86).
i i WARNING Insert a t h e r m o m e t e r (A) in the c e n t e r v e n t , a n d

C o m p r e s s e d air m i x e d w i t h R - 1 3 4 a f o r m s a p l a c e a n o t h e r t h e r m o m e t e r (B) n e a r t h e b l o w e r unit.
combustible vapor.
T h e v a p o r c a n b u r n or e x p l o d e c a u s i n g s e r i o u s
injury.
N e v e r u s e c o m p r e s s e d air to p r e s s u r e t e s t
R - 1 3 4 a s e r v i c e e q u i p m e n t or v e h i c l e air
conditioning s y s t e m s .
^CAUTION
c a n irritate y o u r e y e s , n o s e , or throat.
• Be c a r e f u l w h e n connecting service equipment.
• Do not b r e a t h e refrigerant or v a p o r .
T h e p e r f o r m a n c e t e s t w i l l h e l p d e t e r m i n e if t h e air 5. T e s t c o n d i t i o n s :
c o n d i t i o n e r s y s t e m is o p e r a t i n g w i t h i n s p e c i f i c a t i o n s .
• A v o i d direct s u n l i g h t , put t h e t o p up.
U s e o n l y s e r v i c e e q u i p m e n t that is U . L . - l i s t e d a n d is • O p e n the hood.
certified to m e e t t h e r e q u i r e m e n t s of S A E J 2 2 1 0 to • O p e n t h e front d o o r s .
r e m o v e H F C - 1 3 4 a (R-134a) f r o m t h e air c o n d i t i o n i n g • S e t t h e t e m p e r a t u r e control dial o n M a x C o o l , t h e
system. m o d e control dial o n V e n t , a n d t h e r e c i r c u l a t i o n
control switch on Recirculate.
If a c c i d e n t a l s y s t e m d i s c h a r g e o c c u r s , ventilate t h e • T u r n the A / C switch on and the fan switch on Max.
work area before r e s u m i n g service. • R u n t h e e n g i n e s p e e d at 1,500 r p m .
• N o d r i v e r or p a s s e n g e r s in v e h i c l e .
R-134a s e r v i c e e q u i p m e n t or v e h i c l e air c o n d i t i o n i n g
s y s t e m s s h o u l d not b e p r e s s u r e t e s t e d or leak t e s t e d 6. After r u n n i n g the air c o n d i t i o n i n g for 10 m i n u t e s
w i t h c o m p r e s s e d air. under the a b o v e test conditions, read the delivery
t e m p e r a t u r e f r o m t h e t h e r m o m e t e r in the c e n t e r
Additional health a n d safety information m a y be v e n t , t h e intake t e m p e r a t u r e n e a r t h e b l o w e r unit,
o b t a i n e d f r o m t h e refrigerant a n d l u b r i c a n t a n d the high a n d low s y s t e m p r e s s u r e from the A / C
manufacturers. gauges.
1. C o n n e c t a n R - 1 3 4 a refrigerant r e c o v e r y / r e c y c l i n g /
c h a r g i n g s t a t i o n to t h e h i g h - p r e s s u r e s e r v i c e port
a n d t h e l o w - p r e s s u r e s e r v i c e port, f o l l o w i n g t h e
equipment manufacturer's instructions.
2 . D e t e r m i n e the relative h u m i d i t y a n d a i r
temperature.
21-78
HB
7. T o c o m p l e t e t h e v e n t ( d e l i v e r y ) / a m b i e n t air (intake) t e m p e r a t u r e chart:
• M a r k t h e v e n t (delivery) t e m p e r a t u r e o n t h e v e r t i c a l line.
• M a r k t h e a m b i e n t air (intake) t e m p e r a t u r e o n t h e b o t t o m line.
• D r a w a v e r t i c a l line f r o m t h e a m b i e n t air (intake) t e m p e r a t u r e m a r k .
• D r a w a horizontal line f r o m t h e v e n t (delivery) t e m p e r a t u r e m a r k until it i n t e r s e c t s the v e r t i c a l line.
N O T E : T h e l o w s i d e a n d intake t e m p e r a t u r e s s h o u l d i n t e r s e c t in t h e s h a d e d a r e a w i t h i n a b o u t 10 % of t h e
m e a s u r e d h u m i d i t y l e v e l . A n y m e a s u r e m e n t s o u t s i d e t h e line m a y indicate t h e n e e d for further i n s p e c t i o n .
A m b i e n t (Intake) T e m p e r a t u r e v s . V e n t (Delivery) T e m p e r a t u r e
HUMIDITY
LEVEL
i°C)
92 80%
(33)
87
(31)
82
(28)
77
(25)
72
(22)
20%
67
(19)
VENT
(DELIVERY) 62
TEMPERATURE (17)
57
(14)
52 -
(11)
47
(8)
42
(6)
37 -
(3)
32
(0)
60 65 70 75 80 85 90 95 100 105 110 115 120 °F
(16) (18) (21) (24) (27) (29) (32) (30) (38) (41) (43) (46) (49) (<€)
A M B I E N T (INTAKE) T E M P E R A T U R E
(cont'd)
21-79
A / C System Test (cont'd)
8 . T o c o m p l e t e t h e h ig h s i d e ( d i s c h a r g e p r e s s u r e ) / a m b i e n t air (intake) t e m p e r a t u r e c h a r t :
• M a r k the h i g h s i d e ( d i s c h a r g e p r e s s u r e ) t e m p e r a t u r e o n t h e v e r t i c a l line.
• M a r k t h e a m b i e n t air (intake) t e m p e r a t u r e o n t h e b o t t o m line.
• D r a w a v e r t i c a l line f r o m t h e high s i d e ( d i s c h a r g e p r e s s u r e ) t e m p e r a t u r e m a r k .
• D r a w a horizontal line f r o m t h e v e n t (delivery) t e m p e r a t u r e m a r k until it i n t e r s e c t s t h e v e r t i c a l line.
N O T E : T h e l o w s i d e a n d intake t e m p e r a t u r e s s h o u l d i n t e r s e c t in t h e s h a d e d a r e a w i t h i n a b o u t 1 0 % of t h e
m e a s u r e d h u m i d i t y l e v e l . A n y m e a s u r e m e n t s o u t s i d e t h e line m a y indicate t h e n e e d for further i n s p e c t i o n .
A m b i e n t (Intake) T e m p e r a t u r e v s . High S i d e (Discharge) P r e s s u r e
psi
(kPa)
450
(3103) HUMIDITY
LEVEL
400 80%
(2758)
350
(2413)
300 20%
(2068)
250
HIGH SIDE (1724)
(DISCHARGE)
PRESSURE
200
(1379)
150
(1034)
100
(689)
50
(345)
0
(0)
60 65 70 75 80 85 90 95 100 105 110 115 1 2 0 °F
(16) (18) (21) (24) (27) (29) (32) (30) (38) (41) (43) (46) (49) («C)
21-80
DO
9 . T o c o m p l e t e t h e l o w s i d e ( s u c t i o n p r e s s u r e ) / a m b i e n t air (intake) t e m p e r a t u r e c h a r t :
• M a r k t h e l o w s i d e ( s u c t i o n p r e s s u r e ) t e m p e r a t u r e a l o n g the v e r t i c a l line.
• M a r k t h e a m b i e n t air (intake) t e m p e r a t u r e a l o n g t h e bottom line.
• D r a w a v e r t i c a l line f r o m t h e a m b i e n t air (intake) t e m p e r a t u r e m a r k .
• D r a w a horizontal line f r o m t h e v e n t (delivery) t e m p e r a t u r e m a r k until it i n t e r s e c t s the v e r t i c a l l i n e .
N O T E : T h e l o w s i d e a n d intake t e m p e r a t u r e s s h o u l d i n t e r s e c t in t h e s h a d e d a r e a w i t h i n a b o u t 1 0 % of t h e
m e a s u r e d h u m i d i t y l e v e l . A n y m e a s u r e m e n t s o u t s i d e t h e line m a y i n d i c a t e t h e n e e d for further i n s p e c t i o n .
A m b i e n t (Intake) T e m p e r a t u r e v s . L o w S i d e ( S u c t i o n ) P r e s s u r e
psi HUMIDITY
(kPa) LEVEL
100
(689) 80%
90
(621)
80
(552)
20%
70
(483)
60
(414)
LOW SIDE
(SUCTION) 50
PRESSURE (345)
40
(276)
30
(207)
20
(138)
10
(69)
0
(0)
60 65 70 75 80 85 90 95 100 105 110 115 1 2 0 °F
(16) (18) (21) (24) (27) (29) (32) (30) (38) (41) (43) (46) (49) C C )
21-81
SUPPLEMENTAL RESTRAINT S Y S T E M (SRS) (If electrical maintenance is required)

g l o v e b o x , a n d s e a t belt t e n s i o n e r s in the s e a t belt retractors. I n f o r m a t i o n n e c e s s a r y to s a f e l y s e r v i c e the S R S i s
i n c l u d e d in this S e r v i c e M a n u a l . I t e m s m a r k e d w i t h a n a s t e r i s k ( * ) o n t h e c o n t e n t s p a g e i n c l u d e o r a r e l o c a t e d n e a r
s h o u l d be d o n e by a n a u t h o r i z e d H o n d a d e a l e r .
• T o a v o i d r e n d e r i n g the S R S i n o p e r a t i v e , w h i c h c o u l d l e a d to p e r s o n a l injury or d e a t h in the e v e n t of a s e v e r e frontal

c a u s e d b y unintentional activation of the a i r b a g s a n d s e a t belt t e n s i o n e r s .
• D o not b u m p or i m p a c t the S R S unit, or front i m p a c t s e n s o r s w h e n t h e ignition s w i t c h is O N (II), or for at least 3
m i n u t e s after the ignition s w i t c h is t u r n e d O F F ; o t h e r w i s e , t h e s y s t e m m a y fail in a c o l l i s i o n , or a i r b a g s m a y d e p l o y .
• S R S electrical c o n n e c t o r s a r e identified by y e l l o w c o l o r c o d i n g . R e l a t e d c o m p o n e n t s a r e l o c a t e d in t h e s t e e r i n g
c o l u m n , c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in the d a s h b o a r d a b o v e the g l o v e b o x . D o not u s e electrical
Body Electrical
B o d y Electrical Exterior Lights
Special T o o l s . . 22-2 C o m p o n e n t Location Index 22-110
General Troubleshooting Information 22-3 Circuit Diagram 22-113
Back-up Lights Circuit Diagram 22-124
Relay and Control Unit Brake Lights Circuit Diagram 22-124
Locations 22-7 Combination Light Switch
Test/Replacement 22-126
Connectors and Harnesses 22-11 Daytime Running Lights Control
Unit Input T e s t 22-127
Fuse/Relay Boxes 22-38 Daytime Running Lights Subcontrol
Unit Input T e s t 22-131
P o w e r Distribution 22-41 HID L a m p S y s t e m Troubleshooting 22-133
HID Bulb R e m o v a l 22-136
G r o u n d Distribution 22-45 HID Unit Replacement 22-138
Bulb Replacement 22-138
Under-hood Fuse/Relay Box Headlight Replacement 22-139
Removal a n d Installation 22-46 Headlight Adjustment 22-140
S i d e T u r n Signal Light Replacement 22-141
Battery Taillight Replacement 22-142
Battery T e s t 22-47 Taillight/Brake Light L E D Replacement .... 22-142
High Mount Brake Light Replacement 22-143
Relays L i c e n s e Plate Light Replacement 22-143
Power Relay T e s t 22-48 Brake Pedal Position Switch T e s t 22-144
*Ignition Switch Turn Signal/Hazard Warning Lights

Test 22-51 C o m p o n e n t Location Index 22-145
* Gauges T u r n Signal/Hazard Relay Input T e s t 22-147
C o m p o n e n t Location Index 22-52 Hazard Warning Switch T e s t /
G a u g e Bulb R e p l a c e m e n t 22-56 Replacement 22-148
Self-diagnostic Function 22-60
Circuit Diagram 22-63 Interior Lights
DTC Troubleshooting Index 22-78 C o m p o n e n t Location Index 22-149
S y m p t o m Troubleshooting Index 22-79 Circuit Diagram 22-150
DTC Troubleshooting 22-80 Ceiling Light/Spotlight Test 22-151
S y m p t o m Troubleshooting 22-86 Trunk Light T e s t 22-152
Rewriting the O D O Data and Trunk Lid Latch Switch T e s t 22-152
Transferring the Maintenance Minder
Data to a N e w G a u g e A s s e m b l y 22-88 Dash Lights Brightness Controller
Gauge Assembly Replacement 22-89 Circuit Diagram 22-153
Outside Air Temperature Indicator Controller Input Test 22-155
Calibration 22-90
Outside Air Temperature S e n s o r T e s t 22-92 Accessory Power Sockets
Outside Air Temperature S e n s o r C o m p o n e n t Location Index 22-159
Replacement 22-92 Circuit Diagram 22-160
VSS Replacement 22-93 A c c e s s o r y Power Socket
Vehicle S p e e d Signal Circuit Test/Replacement 22-161
Troubleshooting 22-94
Resetting the Maintenance Horns
Required Indicator 22-97 C o m p o n e n t Location Index 22-162
T a c h o m e t e r Circuit Troubleshooting 22-98 Circuit Diagram 22-163
Coolant Temperature G a u g e Horn Test/Replacement 22-164
Circuit Troubleshooting 22-101 Horn Switch T e s t 22-165
Reminder Systems
C o m p o n e n t Location Index 22-103
S y s t e m Input T e s t 22-106
Trunk Lid Opener Keyless/Power Door Lock System
Component Location Index 22-166 C o m p o n e n t Location Index 22-227
Circuit D i a g r a m 22-167 Circuit Diagram 22-228
T r u n k Lid O p e n e r S w i t c h T e s t 22-168 Keyless D o o r Lock C o n t r o l U n i t
T r u n k Lid O p e n e r S o l e n o i d T e s t 22-168 Input Test 22-229
I g n i t i o n Key S w i t c h T e s t 22-232
Power Mirrors D r i v e r ' s D o o r Lock K n o b S w i t c h T e s t 22-232
Component Location Index 22-169 D r i v e r ' s D o o r Lock A c t u a t o r T e s t 22-233
Circuit D i a g r a m 22-170 P a s s e n g e r ' s D o o r Lock A c t u a t o r T e s t 22-233
Function Test 22-171 D r i v e r ' s D o o r Key C y l i n d e r S w i t c h T e s t ... 22-234
Power Mirror Switch Test 22-172 T r a n s m i t t e r Test 22-234
Power Mirror Actuator Test 22-172 Keyless T r a n s m i t t e r P r o g r a m m i n g /
Power Mirror Actuator Replacement 22-173 Deleting-Manual Method 22-235
Wipers/Washers Convertible Top

Component Location Index 22-174 C o m p o n e n t Location Index 22-236
I n t e r m i t t e n t W i p e r Circuit I n p u t T e s t 22-180 System Description 22-240
Wiper/Washer Switch Convertible T o p Switch Test 22-241
Test/Replacement 22-182 Convertible Top Control Unit
W i p e r M o t o r Test .. 22-183 Input Test 22-242
W a s h e r M o t o r Test 22-183 Convertible T o p M o t o r Test 22-245
Washer Reservoir Replacement 22-184
Wiper Motor Replacement 22-185 Removable Hardtop
Washer Tube Replacement 22-186 Component Location Index 22-247
C o n v e r t i b l e T o p Disable S w i t c h T e s t 22-248
Immobilizer System
Component Location Index 22-187 Rear Window Defogger
System Description 22-188 C o m p o n e n t Location Index 22-249
Troubleshooting 22-194 S w i t c h Test 22-254
S y s t e m Check 22-213 Function Test 22-256
Status L o g 22-214 D e f o g g e r W i r e Repair 22-257
Imoes Unit Input Test/Replacement 22-215
I m m o b i l i z e r Receiver U n i t * Audio System
Replacement 22-217 C o m p o n e n t Location Index 22-258
Immobilizer Control Unit-Receiver S y m p t o m Troubleshooting Index 22-259
Replacement 22-217 System Description 22-260
I m m o b i l i z e r Key R e g i s t r a t i o n 22-218 Circuit D i a g r a m 22-264
Self-diagnostic Function 22-266
Power Windows Symptom Troubleshooting 22-267
Component Location Index 22-219 S o u n d Quality Diagnosis 22-281
Circuit D i a g r a m 22-220 A u d i o Remote Switch Replacement 22-287
M a s t e r S w i t c h Test 22-221 A u d i o Remote Switch Test 22-287
Power W i n d o w Master Switch A u d i o Unit Removal/Installation 22-288
Input Test 22-222 D o o r Speaker R e p l a c e m e n t 22-288
Passenger's P o w e r W i n d o w S w i t c h Rear Speaker R e p l a c e m e n t 22-289
Test/Replacement 22-225 Tweeter Replacement 22-289
Driver's Power W i n d o w M o t o r Test 22-226 A M / F M Antenna Replacement 22-290
Passenger's P o w e r W i n d o w M o t o r
Test 22-226
Body Electrical
Special Tools
Ref. No. Tool Number Description Qty

© 07AAZ-SDBA100 Diagnostics C D 1
® 07AAZ-SDBA200 (ABEX-TCD-725B) Skip Test C D 1
(D 07AAZ-SDBA300 (ABEX-TCD-721) Skip Test C D 1
® 07AAJ-S3MA100 HID B u l b T e s t Light 1
® 07TAZ-001020A Back Probe Adaptor 1
22-2
Tips and Precautions • S o m e c o n n e c t o r s h a v e a c l i p o n their s i d e u s e d to

attach t h e m to a m o u n t b r a c k e t o n t h e b o d y or o n
Before Troubleshooting a n o t h e r c o m p o n e n t . T h i s c l i p h a s a pull t y p e lock.
• S o m e mounted connectors cannot be disconnected
1. C h e c k a p p l i c a b l e f u s e s in t h e a p p r o p r i a t e f u s e / r e l a y u n l e s s y o u first r e l e a s e t h e lock a n d r e m o v e t h e
box/ c o n n e c t o r f r o m its m o u n t b r a c k e t (A).
2 . C h e c k t h e battery for d a m a g e , state of c h a r g e , a n d

c l e a n a n d tight c o n n e c t i o n s .
INOTICEI
• D o not q u i c k - c h a r g e a battery u n l e s s t h e
battery g r o u n d c a b l e h a s b e e n
disconnected, otherwise y o u will d a m a g e
the alternator d i o d e s .
• D o not attempt to c r a n k t h e e n g i n e w i t h
the battery g r o u n d c a b l e l o o s e l y
c o n n e c t e d or y o u w i l l s e v e r e l y d a m a g e t h e
wiring.
3. C h e c k t h e a l t e r n a t o r - c o m p r e s s o r belt t e n s i o n .
• N e v e r try to d i s c o n n e c t c o n n e c t o r s b y pulling o n their
Handling C o n n e c t o r s w i r e s ; pull o n t h e c o n n e c t o r h a l v e s i n s t e a d .
• A l w a y s reinstall plastic c o v e r s .
• M a k e s u r e the c o n n e c t o r s a r e c l e a n a n d h a v e no
loose wire terminals.
• M a k e s u r e multiple c a v i t y c o n n e c t o r s a r e p a c k e d w i t h
dielectric g r e a s e (except w a t e r t i g h t c o n n e c t o r s ) .
• All c o n n e c t o r s h a v e p u s h - d o w n r e l e a s e t y p e l o c k s (A).
• Before connecting connectors, make sure the

t e r m i n a l s (A) a r e in p l a c e a n d not bent.
(cont'd)
22-3
Body Electrical
G e n e r a l T r o u b l e s h o o t i n g I n f o r m a t i o n (cont'd)
• C h e c k for l o o s e r e t a i n e r s (A) a n d r u b b e r s e a l s (B). Handling W i r e s a n d H a r n e s s e s

• S e c u r e w i r e s a n d w i r e h a r n e s s e s to t h e f r a m e w i t h
their r e s p e c t i v e w i r e t i e s at t h e d e s i g n a t e d l o c a t i o n s .
A • R e m o v e c l i p s c a r e f u l l y ; d o n ' t d a m a g e their l o c k s (A).
• T h e b a c k s of s o m e c o n n e c t o r s a r e p a c k e d w i t h
d i e l e c t r i c g r e a s e . A d d g r e a s e if n e c e s s a r y . If t h e
g r e a s e is c o n t a m i n a t e d , r e p l a c e it.
• After installing h a r n e s s c l i p s , m a k e s u r e t h e h a r n e s s
d o e s n ' t interfere w i t h a n y m o v i n g p a r t s .
• Keep wire h a r n e s s e s a w a y from exhaust pipes and
other hot p a r t s , f r o m s h a r p e d g e s of b r a c k e t s a n d
h o l e s , a n d f r o m e x p o s e d s c r e w s a n d bolts.
• S e a t g r o m m e t s in t h e i r g r o o v e s p r o p e r l y (A). D o not
l e a v e g r o m m e t s distorted (B).
• Insert t h e c o n n e c t o r all t h e w a y a n d m a k e s u r e it is
securely locked.
• P o s i t i o n w i r e s s o that t h e o p e n e n d of t h e c o v e r f a c e s
down.
22-4
Testing and Repairs Five-step Troubleshooting
• D o not u s e w i r e s o r h a r n e s s e s w i t h b r o k e n i n s u l a t i o n .
Replace t h e m or repair t h e m by w r a p p i n g the break 1. V e r i f y T h e C o m p l a i n t
with electrical tape. T u r n o n all t h e c o m p o n e n t s in t h e p r o b l e m c i r c u i t
• After installing t h e p a r t s , m a k e s u r e t h a t n o w i r e s a r e to v e r i f y t h e c u s t o m e r c o m p l a i n t . N o t e t h e
pinched under them. s y m p t o m s . D o not b e g i n d i s a s s e m b l y or t e s t i n g
• W h e n using electrical test equipment, follow the until y o u h a v e n a r r o w e d d o w n the p r o b l e m a r e a .
m a n u f a c t u r e r ' s i n s t r u c t i o n s a n d t h o s e d e s c r i b e d in
this m a n u a l . 2. A n a l y z e T h e S c h e m a t i c
• If p o s s i b l e , i n s e r t t h e p r o b e of the t e s t e r f r o m t h e w i r e L o o k u p t h e s c h e m a t i c f o r t h e p r o b l e m circuit.
side (except waterproof connector). D e t e r m i n e h o w t h e c i r c u i t is s u p p o s e d t o w o r k b y
t r a c i n g t h e c u r r e n t p a t h s f r o m the p o w e r f e e d
t h r o u g h t h e circuit c o m p o n e n t s to g r o u n d . If
s e v e r a l c i r c u i t s fail at t h e s a m e t i m e , t h e f u s e or
g r o u n d i s a likely c a u s e .
B a s e d o n t h e s y m p t o m s a n d y o u r u n d e r s t a n d i n g of
t h e c i r c u i t o p e r a t i o n , identify o n e or m o r e p o s s i b l e
c a u s e s of t h e p r o b l e m .
3. Isolate T h e P r o b l e m B y T e s t i n g T h e C i r c u i t
M a k e circuit t e s t s t o c h e c k t h e d i a g n o s i s y o u m a d e
in s t e p 2 . K e e p in m i n d t h a t a l o g i c a l , s i m p l e
p r o c e d u r e i s t h e k e y t o efficient t r o u b l e s h o o t i n g .
T e s t for t h e m o s t likely c a u s e of f a i l u r e first. T r y to
m a k e t e s t s at p o i n t s t h a t a r e e a s i l y a c c e s s i b l e .
• U s e back probe adapter 07TAZ-001020A.
4. F i x T h e P r o b l e m
O n c e t h e s p e c i f i c p r o b l e m i s identified, m a k e the
repair. B e s u r e to u s e p r o p e r t o o l s a n d s a f e
procedures.
5. M a k e S u r e T h e C i r c u i t W o r k s
T u r n o n all c o m p o n e n t s in t h e r e p a i r e d circuit in all
m o d e s to m a k e s u r e y o u ' v e fixed t h e entire
p r o b l e m . If t h e p r o b l e m w a s a b l o w n f u s e , be s u r e
to t e s t all of t h e c i r c u i t s o n t h e f u s e . M a k e s u r e n o
n e w p r o b l e m s turn u p a n d t h e o r i g i n a l p r o b l e m
d o e s not r e c u r .
• R e f e r to t h e i n s t r u c t i o n s in t h e H o n d a T e r m i n a l Kit for
identification a n d r e p l a c e m e n t of c o n n e c t o r t e r m i n a l s .
(cont'd)
22-5
Body Electrical
Wire Color Codes How to Check for DTCs with the Honda
Diagnostic System (HDS) ('06-08 models)
T h e f o l l o w i n g a b b r e v i a t i o n s a r e u s e d to identify w i r e
c o l o r s in t h e circuit s c h e m a t i c s : 1. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to the
Data Link C o n n e c t o r ( D L C ) (A) located b e h i n d t h e
WHT . White d r i v e r ' s s i d e of the front c o n s o l e .
YEL Yellow
BLK Black N O T E : F o r s p e c i f i c o p e r a t i o n s , refer to t h e u s e r ' s
BLU Blue m a n u a l t h a t c a m e w i t h the H o n d a D i a g n o s t i c
GRN . Green S y s t e m (HDS).
RED Red
ORN Orange
PNK Pink
BRN.. Brown
GRY Gray
PUR Purple
LT B L U Light B l u e
LTGRN Light G r e e n
T h e w i r e i n s u l a t i o n h a s o n e c o l o r or o n e c o l o r w i t h
a n o t h e r c o l o r s t r i p e . T h e s e c o n d c o l o r is t h e s t r i p e .
2. M a k e s u r e t h e H D S c o m m u n i c a t e s w i t h the v e h i c l e
a n d t h e g a u g e a s s e m b l y . If it d o e s n ' t t r o u b l e s h o o t
t h e D L C circuit ( s e e p a g e 11-367).
3. S e l e c t t h e T E S T M O D E M E N U a n d c h e c k for
D i a g n o s t i c T r o u b l e C o d e ( D T C s ) , a n d note t h e m .
R e f e r to t h e T r o u b l e s h o o t i n g Index a n d b e g i n t h e
appropriate troubleshooting procedure.
22-6
Relay and Control Unit Locations
Engine Compartment
'00-05 m o d e l s
INTERMITTENT WIPER RELAY

('02-05 m o d e l s )
HEADLIGHT RELAY 2 ELECTRICAL LOAD

(LEFT) D E T E C T O R (ELD)
22-7
Engine Compartment (cont'd)
'06-08 models
AUXILIARY
UNDER-HOOD FUSE BOX
VSA MODULATOR-
CONTROL UNIT
22-8
Dashboard
HIGH B E A M C U T R E L A Y (Canada models)

TWire colors: RED/BLU, ORN, 1
[BLU/RED, and BLU J
INTERMITTENT WIPER RELAY K E Y L E S S DOOR LOCK CONTROL UNIT
('00-01 m o d e l s )
TWire colors: GRN/RED, GRN, ]
[GRN/BLK, BLK, and BLU/WHT J
REAR WINDOW DEFOGGER RELAY
('02-08 m o d e l s )
[Wire colors: WHT/GRN, BLK/RED, 1
[YEL/BLU, and Y E L / B L K J
THROTTLE ACTUATOR
CONTROL MODULE
('06-08 m o d e l s )
IMOES UNIT
('08 m o d e l )
THROTTLE ACTUATOR CONTROL

MODULE RELAY TURN SIGNAL/HAZARD RELAY
('06-08 m o d e l s ) [Wire colors: BLK/RED, GRN/WHT,
[Wire colors: Y E L / G R N , BLU/WHT, 1 Land BLK
[BRN, and Y E L / G R N J
ACCESSORY POWER SOCKET RELAY
(CR m o d e l )
[Wire colors: WHT, B L U , B L K
Land WHT/RED
TAILLIGHT RELAY
UNDER-DASH FUSE/RELAY B O X [Wire colors: RED/BLK, WHT/GRN,
LWHT/GRN, and BLU
STARTER CUT RELAY

[Wire colors: ORN, BLK/WHT, 1
LBLU/WHT, and LT BLU J
REAR WINDOW DEFOGGER RELAY

( W i t h h a r d t o p ) ('00-01 m o d e l s )
[Wire colors: BLK/RED, WHT/GRN, 1
[YEL/BLK, and BLK/YEL J
22-9
Dashboard and Door
( ' 0 6 - 0 8 m o d e l s ) (Fl M A I N )
I G N I T I O N C O I L R E L A Y ('06-08 m o d e l s ) rWire c o l o r s : W H T / G R N , Y E I 7 B L K , ]
TWire c o l o r s : B L K / Y E L , 1 [GRN, and WHT/GRN J
[GRN/YEL, G R N , and B L K / Y E L J PGM-FI MAIN R E L A Y 2
A / F S E N S O R R E L A Y ('06-08 m o d e l s ) ('06-08 m o d e l s ) ( F U E L P U M P )
TWire c o l o r s : W H T / R E D , 1 [Wire colors: B L K / Y E L , Y E L / G R N , 1
[WHT, O R N , and Y E L / B L U J [GRN/YEL, and Y E L / B L K J
DAYTME RUNNING
LIGHTS C O N T R O L UNIT
( E x c e p t '00-05 U S A m o d e l s )
DAYTIME RUNNING
LIGHTS SUBCONTROL
U N I T ('06-08 U S A m o d e l s )
CONVERTIBLE TOP
C O N T R O L UNIT
(Except C R model)
IG2 C U T RELAY
TWire c o l o r s : B L K / R E D , 1
[LT B L U , Y E L , and B L U / W H T J
ACC CUT RELAY
fWIre c o l o r s : W H T / R E D , 1
[LT B L U , Y E L / R E D , and B L U / W H T J
22-10
Connectors and Harnesses
Connector Index
Identification n u m b e r s h a v e been a s s i g n e d to in-line c o n n e c t o r s , junction c o n n e c t o r s , a n d t e r m i n a l s . T h e n u m b e r is p r e c e d e d by the letter "C"
for c o n n e c t o r s , " G " for g r o u n d t e r m i n a l s , o r " T " for n o n - g r o u n d t e r m i n a l s .
Harness Location
Engine Dashboard O t h e r s (Floor, D o o r , Notes
Compartment T r u n k a n d Roof)
A n t e n n a amplifier C551 ( s e e p a g e 22-32)
subharness
Battery g r o u n d cable G1and(-) (see p a g e 22-12)
3
CKP sensor subharness* C105 (see p a g e 22-16)
Dashboard wire harness A C101 through C 1 0 3 , (see p a g e 22-26)
C204, C 3 0 3 C 3 0 4
f f
C 4 0 2 through C 4 0 4 f
C451,C453,
C501 through C 5 0 6
G501 a n d G 5 0 2
Dashboard wire harness B C301,C302, (see p a g e 22-22)
(left branch) C401 through C 4 0 4
G401
Dashboard wire harness B C201 through C 2 0 3 , ( s e e p a g e 22-24)
(right branch) C451 through C 4 5 3
G402
Driver's d o o r w i r e h a r n e s s C502 (see p a g e 22-34)
E n g i n e g r o u n d cable T5 ( s e e p a g e 22-12)
G2
Engine wire harness* 4
T101 t hrough T 1 0 3 C101 through C 1 0 4 ( s e e p a g e 22-14)
G101
Engine wire harness* 3
C105 C101 through C 1 0 4 (see p a g e 22-16)
T101andT103
G101
E P S g e a r b o x ground cable T4 (see p a g e 22-12)
G4
EPS subharness C351 (see p a g e 22-12)
T 1 , T 6 , and (+)
G351
1
Hardtop s u b h a r n e s s * C601 a n d C901 ( s e e p a g e 22-36)
1
Hardtop w i r e h a r n e s s * C901 (see p a g e 22-36)
G901
Ignition s w i t c h lead (see p a g e 22-33)
Left e n g i n e c o m p a r t m e n t C351 C301 through C 3 0 5 (see p a g e 22-20)
wire harness G301 through G 3 0 5
P a s s e n g e r ' s door w i r e C504 (see p a g e 22-35)
harness
Rear w i n d o w defogger G902 (see p a g e 22-36)
1
ground wire*
Rear w i n d o w defogger C602 (see p a g e 22-37)
2
subharness*
Rear w i r e h a r n e s s C401,C501,C505 C601 t h r o u g h C 6 0 3 (see p a g e 22-30)
(left branch) G601
Rear w i r e h a r n e s s G602 (see p a g e 22-32)
(right branch)
Right e n g i n e c o m p a r t m e n t G201 C201 through C 2 0 5 (see p a g e 22-18)
wire harness
Roof w i r e h a r n e s s C452 (see p a g e 22-32)
S R S main harness C205, C305, C503 C 6 0 3 , G801 (see p a g e 22-33)
Starter c a b l e T 2 , T 3 , and 77 (see p a g e 22-12)
G3
* 1 : W i t h hardtop
* 2: '02-08 m o d e l s
* 3: '06-08 m o d e l s
* 4: '00-05 m o d e l s
22-11
Connector to Harness Index
EPS Subharness
C o n n e c t o r or T e r m i n a l Ref Cavities Location Connects to Notes

E P S control unit connector C 2 2 Right s i d e of e n g i n e c o m p a r t m e n t
C351 8 2 Left side of e n g i n e c o m p a r t m e n t Left engine c o m p a r t m e n t w i r e
h a r n e s s (see p a g e 22-20)
T1 1 Right s i d e of e n g i n e c o m p a r t m e n t Main u n d e r - h o o d f u s e / r e l a y
box
T6 7 Left side of e n g i n e c o m p a r t m e n t Auxiliary u n d e r - h o o d f u s e
box
G351 3 Right side of e n g i n e c o m p a r t m e n t Body ground, via E P S
subharness
(+) Battery Battery positive terminal
Battery Ground Cable

G1 4 Right s i d e of e n g i n e c o m p a r t m e n t B o d y g r o u n d , v i a battery
g r o u n d cable
(-) Battery Battery negative terminal
Starter Cable

T2 9 Left s i d e of e n g i n e c o m p a r t m e n t Starter motor
T3 11 Left side of e n g i n e c o m p a r t m e n t E n g i n e block
T7 6 Left s i d e of e n g i n e c o m p a r t m e n t Auxiliary u n d e r - h o o d f u s e
box
G3 5 Left s i d e of e n g i n e c o m p a r t m e n t B o d y g r o u n d , via starter c a b l e
Engine Ground Cable

T5 10 Left s i d e of e n g i n e c o m p a r t m e n t E n g i n e block
G2 12 Rear beam Rear b e a m g r o u n d , via e n g i n e
g r o u n d cable
E P S Gearbox Ground Cable

T4 13 Left s i d e of e n g i n e c o m p a r t m e n t E P S gearbox
G4 14 Front b e a m Front b e a m g r o u n d , via E P S
gearbox ground cable
22-12
22-13
Connector to Harness Index (cont'd)
E n g i n e W i r e H a r n e s s ('00-05 m o d e l s )

A/C compressor 25 1 Left s i d e of e n g i n e c o m p a r t m e n t
Alternator 26 4 Left s i d e of e n g i n e c o m p a r t m e n t
Back-up light s w i t c h 10 2 M i d d l e of t r a n s m i s s i o n
CKP sensor 31 3 Middle of e n g i n e
C M P (TDC) s e n s o r A 13 2 M i d d l e of e n g i n e
C M P (TDC) s e n s o r B 6 2 Right s i d e of e n g i n e c o m p a r t m e n t
E C M connector B 15 25 B e h i n d left kick panel
E C M connector C 16 31 B e h i n d left kick panel
E n g i n e coolant t e m p e r a t u r e ( E C T ) 34 2 Middle of e n g i n e
sensor
Idle air control (IAC) v a l v e 20 3 Left s i d e of e n g i n e c o m p a r t m e n t
Intake air temperature (IAT) s e n s o r 21 2 Left s i d e of e n g i n e c o m p a r t m e n t
Knock sensor 28 1 M i d d l e of e n g i n e
MAP sensor 24 3 Left s i d e of e n g i n e c o m p a r t m e n t
No. 1 ignition coil 3 3 Middle of e n g i n e
No. 3 ignition coil 5 3 M i d d l e of e n g i n e
No. 1 injector 32 2 M i d d l e of e n g i n e
No. 4 injector 22 2 Middle of engine
P r i m a r y heated o x y g e n s e n s o r 9 4 M i d d l e of t r a n s m i s s i o n
(PH02S)
Rocker a r m oil control s o l e n o i d ( V T E C 36 1 Right s i d e of e n g i n e c o m p a r t m e n t
s o l e n o i d valve)
Rocker a r m oil p r e s s u r e s w i t c h ( V T E C 2 2 Right s i d e of e n g i n e c o m p a r t m e n t
oil p r e s s u r e switch)
S e c o n d a r y heated o x y g e n s e n s o r 11 4 Middle of t r a n s m i s s i o n
(SH02S)
Starter s o l e n o i d 23 1 Left s i d e of e n g i n e c o m p a r t m e n t
Throttle position (TP) s e n s o r 29 3 Left s i d e of engine c o m p a r t m e n t
Vehicle speed sensor ( V S S ) 12 3 Middle of t r a n s m i s s i o n
C101 14 16 B e h i n d left kick panel Dashboard wire harness A
(see p a g e 22-26)
C 1 0 2 (Junction connector) 18 20 B e h i n d left kick panel
C 1 0 3 ( C o n n e c t to C104) 17 2 B e h i n d left kick panel
C 1 0 4 ( C o n n e c t to C103) 19 2 B e h i n d left kick panel
T101 1 Main u n d e r - h o o d f u s e / r e l a y box
T102 27 Alternator
T103 35 Oil p r e s s u r e s w i t c h
G101 8 R e a r of e n g i n e E n g i n e g r o u n d , v i a engine
wire harness
22-14
22-15
E n g i n e W i r e H a r n e s s {'06-08 m o d e l s )

A/C compressor 23 1 Left s i d e of engine c o m p a r t m e n t *
A/F sensor 9 4 Middle of t r a n s m i s s i o n
Back-up light s w i t c h 10 2 Middle of t r a n s m i s s i o n
CMP sensor 6 3 Right s i d e of e n g i n e c o m p a r t m e n t
E C M connector A 15 31 B e h i n d left kick panel
E C M connector B 16 24 B e h i n d left kick panel
E n g i n e coolant temperature ( E C T ) 32 2 Middle of e n g i n e
sensor 1
Knock s e n s o r 26 1 Middle of e n g i n e
MAP sensor 22 3 Left s i d e of e n g i n e c o m p a r t m e n t
N o . 2 ignition coil 4 3 Middle of engine
No. 4 ignition coil 7 3 Middle of engine
No. 1 injector 30 2 Middle of e n g i n e
Output shaft (countershaft) s p e e d 12 3 Middle of t r a n s m i s s i o n
sensor
Rocker a r m oil control s o l e n o i d ( V T E C 2 1 Right s i d e of e n g i n e c o m p a r t m e n t
s o l e n o i d valve)
Rocker a r m oil p r e s s u r e s w i t c h ( V T E C 34 2 Right s i d e of e n g i n e c o m p a r t m e n t
oil p r e s s u r e switch)
S e c o n d a r y heated o x y g e n s e n s o r 11 4 Middle of t r a n s m i s s i o n
(SH02S)
Starter s o l e n o i d 20 1 Left s i d e of e n g i n e c o m p a r t m e n t
Throttle body 21 6 Left s i d e of e n g i n e c o m p a r t m e n t
(see p a g e 22-26)
(see p a g e 22-26)
(see p a g e 22-26)
C 1 0 4 (Junction connector) 18 20 B e h i n d left kick panel
C105 28 3 Middle of e n g i n e CKP sensor subharness
T101 1 Main u n d e r - h o o d f u s e / r e l a y box
T103 33 Oil p r e s s u r e s w i t c h
G101 8 R e a r of e n g i n e E n g i n e g r o u n d , via e n g i n e
wire harness
*: With A / C
C K P S e n s o r S u b h a r n e s s ('06-08 m o d e l s )

CKP sensor 29 3 Middle of engine
C105 28 3 Middle of engine Engine wire harness
22-16
CKP SENSOR SUBHARNESS
22-17
Right Engine C o m p a r t m e n t W i r e Harness

A / C pressure switch 4 2 Middle of e n g i n e c o m p a r t m e n t *
A / C c o n d e n s e r fan motor 1 2 Left s i d e of e n g i n e c o m p a r t m e n t *
Electrical load detector ( E L D ) 15 3 Under-hood fuse/relay box
(see page 22-38)
E P S control unit c o n n e c t o r A 16 2 Right s i d e of e n g i n e c o m p a r t m e n t
E P S control unit c o n n e c t o r B 18 14 Right s i d e of e n g i n e c o m p a r t m e n t
E P S torque s e n s o r 2 3 Left s i d e of e n g i n e c o m p a r t m e n t
E P S motor 3 2 Left s i d e of e n g i n e c o m p a r t m e n t
Horn (low) 6 1 Middle of e n g i n e c o m p a r t m e n t
Horn (high) 29 1 Right s i d e of e n g i n e c o m p a r t m e n t '02-08 m o d e l s
Main u n d e r - h o o d f u s e / r e l a y box 28 18 Right s i d e of e n g i n e c o m p a r t m e n t
c o n n e c t o r A (see p a g e 22-38)
Main u n d e r - h o o d f u s e / r e l a y box 27 7 Right s i d e of e n g i n e c o m p a r t m e n t
c o n n e c t o r B (see p a g e 22-38)
M a i n u n d e r - h o o d f u s e / r e l a y box 26 3 Right s i d e of e n g i n e c o m p a r t m e n t
c o n n e c t o r C (see p a g e 22-38)
M a i n u n d e r - h o o d f u s e / r e l a y box 25 16 Right s i d e of e n g i n e c o m p a r t m e n t
connector D ( s e e p a g e 22-38)
O u t s i d e air t e m p e r a t u r e s e n s o r 5 2 B e h i n d front bumper '06-08 m o d e l s
Radiator fan motor 7 2 Right s i d e of engine compartment
Right front i m p a c t s e n s o r 12 2 Right s i d e of engine compartment '06-08 m o d e l s
Right front parking light 14 2 B e h i n d right headlight '00-03 m o d e l s
Right front parking/side m a r k e r light 14 2 B e h i n d right headlight '04-08 m o d e l s
Right front turn signal light 13 2 B e h i n d right headlight
Right front w h e e l s p e e d s e n s o r 11 2 Right s i d e of engine compartment
Right headlight (high b e a m ) 9 3 B e h i n d right headlight
Right headlight (low b e a m ) 10 2 B e h i n d right headlight
Right s i d e turn s i g n a l light 19 2 Right s i d e of engine compartment
W i n d s h i e l d w a s h e r motor 17 2 Right s i d e of engine compartment
C201 22 16 B e h i n d right s i d e of d a s h Dashboard wire harness B
(See p a g e 22-24)
C202 23 6 B e h i n d right s i d e of d a s h Dashboard wire harness B '00-05 m o d e l s
(see p a g e 22-24)
C202 23 8 B e h i n d right s i d e of d a s h Dashboard wire harness B '06-08 m o d e l s
(see p a g e 22-24)
C203 21 7 B e h i n d right s i d e of d a s h Dashboard wire harness B
(see p a g e 22-24)
C204 20 18 B e h i n d right s i d e of d a s h Dashboard wire harness A '00-05 m o d e l s
(see p a g e 22-26)
C204 20 20 B e h i n d right s i d e of d a s h Dashboard wire harness A '06-08 m o d e l s
(see p a g e 22-26)
C205 24 4 B e h i n d right s i d e of d a s h S R S main harness '06-08 m o d e l s
(see p a g e 22-33)
G201 8 Right s i d e of e n g i n e c o m p a r t m e n t B o d y g r o u n d , v i a right
engine compartment wire
harness
*: With A / C
22-18
22-19
Left E n g i n e C o m p a r t m e n t W i r e H a r n e s s

A B S modulator-control unit 30 25 Left side of engine compartment '00-05 m o d e l s
A c c e l e r a t o r pedal position s e n s o r 13 6 Left side of engine compartment '06-08 m o d e l s
A i r control solenoid v a l v e 33 2 Left side of engine compartment
A i r p u m p electric current s e n s o r 16 2 Left side of engine compartment '00-05 m o d e l s
connector A
A i r p u m p electric current s e n s o r 17 3 Left s i d e of e n g i n e c o m p a r t m e n t '00-05 m o d e l s
connector B
A i r p u m p motor 5 2 Left s i d e of e n g i n e c o m p a r t m e n t '00-05 m o d e l s
A i r p u m p relay connector A 7 2 Left s i d e of e n g i n e c o m p a r t m e n t '00-05 m o d e l s
Air p u m p relay connector B 4 2 Left s i d e of e n g i n e c o m p a r t m e n t '00-05 m o d e l s
Auxiliary u n d e r - h o o d f u s e box 28 2 Auxiliary u n d e r - h o o d f u s e box
c o n n e c t o r A (see page 22-40)
A u x i l i a r y u n d e r - h o o d f u s e box 14 3 A u x i l i a r y u n d e r - h o o d f u s e box
c o n n e c t o r B (see p a g e 22-40)
Brake fluid level s w i t c h 21 2 Left s i d e of e n g i n e c o m p a r t m e n t
C r u i s e control actuator 32 4 Left s i d e of e n g i n e c o m p a r t m e n t '00-05 m o d e l s
E n g i n e c o o l a n t temperature ( E C T ) 1 2 Left s i d e of e n g i n e c o m p a r t m e n t '06-08 m o d e l s
sensor 2
E V A P c a n i s t e r purge v a l v e 31 2 Left s i d e of e n g i n e c o m p a r t m e n t
Intake air t e m p e r a t u r e (IAT) s e n s o r 34 2 Middle of e n g i n e c o m p a r t m e n t '06-08 models
Intermittent w i p e r relay 19 5 Left s i d e of e n g i n e c o m p a r t m e n t '02-08 models
Left front i m p a c t s e n s o r 9 2 Left s i d e of e n g i n e c o m p a r t m e n t '06-08 models
Left front parking light 12 2 B e h i n d left headlight '00-03 models
Left front parking/side m a r k e r light 12 2 B e h i n d left headlight '04-08 models
Left front turn signal light 10 2 B e h i n d left headlight
Left front w h e e l s p e e d s e n s o r 11 2 Left s i d e of e n g i n e c o m p a r t m e n t
Left headlight (high beam) 6 3 B e h i n d left headlight
Left headlight (low b e a m ) 8 2 B e h i n d left headlight
Left s i d e turn signal light 18 2 Left s i d e of e n g i n e c o m p a r t m e n t
Radiator f a n s w i t c h 1 2 Left s i d e of engine c o m p a r t m e n t '00-05 m o d e l s
T e s t t a c h o m e t e r connector 20 2 Left s i d e of e n g i n e c o m p a r t m e n t
V S A modulator-control unit 30 47 Left s i d e of engine c o m p a r t m e n t '06-08 m o d e l s
W i n d s h i e l d w i p e r motor 27 5 Left s i d e of e n g i n e c o m p a r t m e n t
C301 22 14 U n d e r left s i d e of d a s h Dashboard wire harness B
(see page 22-22)
(see page 22-22)
C303 25 14 U n d e r left s i d e of d a s h Dashboard wire harness A '00-05 m o d e l s
(see page 22-26)
(see page 22-26)
C304 23 8 U nder left s i d e of d a s h Dashboard wire harness A '06-08 m o d e l s
(see p a g e 22-26)
C305 24 4 U nder left s i d e of d a s h S R S main harness '06-08 m o d e l s
(see p a g e 22-33)
C351 29 2 Left s i d e of e n g i n e c o m p a r t m e n t E P S s u b h a r n e s s (see page
22-12)
G301 2 Left s i d e of e n g i n e c o m p a r t m e n t B o d y g r o u n d , v i a left
harness
G302 3 Left s i d e of e n g i n e c o m p a r t m e n t B o d y g r o u n d , v i a left
harness
G303 13 Left s i d e of engi ne c o m p a r t m e n t B o d y g r o u n d , v i a left
harness
22-20
22-21
D a s h b o a r d W i r e H a r n e s s B (Left b r a n c h )

A c c e s s o r y p o w e r socket relay 8 4 Under left s i d e of d a s h *2
Brake pedal position s w i t c h 16 4 Under left s i d e of d a s h
C a b l e reel 21 4 Under left s i d e of d a s h
Clutch pedal position s w i t c h 11 2 Under left s i d e of d a s h
Clutch interlock s w i t c h 13 2 Under left s i d e of d a s h
C o m b i n a t i o n light switch 20 16 Under left s i d e of d a s h
C r u i s e control unit 12 14 Under left s i d e of d a s h
High b e a m cut relay 9 4 Under left s i d e of d a s h * 1
Ignition key s w i t c h 3 7 U nder left s i d e of d a s h
Intermittent w i p e r relay 10 5 Under left s i d e of d a s h '00-01 models
Immobilizer receiver unit 2 5 Under left s i d e of d a s h '00-05 models
Immobilizer control unit-receiver 2 7 Under left s i d e of d a s h '06-08 models
R e a r w i n d o w defogger relay 10 5 Under left s i d e of d a s h '02-08 models
Throttle actuator control m o d u l e 7 4 Under left s i d e of d a s h '06-08 models
relay
T P M S control unit 4 20 U n d e r left s i d e of d a s h '08 m o d e l
Wiper/washer switch 1 14 U n d e r left s i d e of d a s h
C301 14 14 U n d e r left s i d e of d a s h Left e n g i n e c o m p a r t m e n t w i r e
C302 15 16 U n d e r left s i d e of d a s h Left e n g i n e c o m p a r t m e n t w i r e
h a r n e s s (see page 22-20)
C401 6 22 Behind left kick panel R e a r w i r e h a r n e s s (see page
22-30)
(see p a g e 22-26)
( s e e p a g e 22-26)
C402 18 6 U n d e r left s i d e of d a s h Dashboard wire harness A '08 m o d e l
(see p a g e 22-26)
(see p a g e 22-26)
C403 19 16 U n d e r left s i d e of d a s h Dashboard wire harness A '08 m o d e l
(see p a g e 22-26)
G404 17 24 U n d e r left s i d e of d a s h Dashboard wire harness A
(see p a g e 22-26)
G401 5 U n d e r left s i d e of d a s h Body ground, via dashboard
wire harness B
* 1: E x c e p t '00-05 U S A m o d e l s
* 2: C R m o d e l
22-22
22-23
D a s h b o a r d Wire H a r n e s s B (Right branch)
Connector or Terminal Ref Cavities Location Connects to Notes

A / F s e n s o r relay 2 5 Under m i d d l e of d a s h '06-08 m o d e l s
A C C c u t relay 32 5 Under m i d d l e of d a s h
A i r m i x control motor 9 7 Under m i d d l e of d a s h
B l o w e r motor 13 2 Under right s i d e of d a s h
Convertible top motor e m e r g e n c y 22 2 Under right side of d a s h
connector A
Convertible top motor e m e r g e n c y 23 2 U n d e r right side of d a s h
connector B
Convertible top control unit c o n n e c t o r A 12 14 U n d e r right s i d e of d a s h
Convertible top s w i t c h 30 6 Middle of floor b e t w e e n
seats
Daytime running lights control unit 5 14 U n d e r middle of d a s h E x c e p t '00-05
U S A models
Daytime running lights subcontrol unit 6 14 U n d e r m i d d l e of d a s h '06-08 U S A
models
Data link connector ( D L C ) 8 16 U n d e r m i d d l e of d a s h '00-01 m o d e l s
Data link connector ( D L C ) 30 16 U n d e r m i d d l e of d a s h '02-08 m o d e l s
Diode (DRL) 4 2 U n d e r m i d d l e of d a s h Canada
models
E v a p o r a t o r temperature s e n s o r 10 2 U n d e r right s i d e of d a s h
Hazard w a r n i n g s w i t c h 26 10 Middle of floor between
seats
IG2 cut relay 33 5 U n d e r middle of d a s h
Ignition coil relay 1 5 U n d e r m i d d l e of d a s h '06-08 m o d e l s
I m o e s unit 19 5 U n d e r right s i d e of d a s h '08 m o d e l
M o d e control motor 7 7 U n d e r m i d d l e of d a s h
Parking brake s w i t c h 25 1 Middle of floor b e t w e e n '00-03 m o d e l s
seats
Parking brake s w i t c h 25 2 Middle of floor b e t w e e n '04-08 m o d e l s
seats
PGM-FI m a i n relay 31 7 U n d e r m i d d l e of d a s h '00-05 m o d e l s
P G M - F I m a i n relay 1 (Fl main) 3 4 U n d e r m i d d l e of d a s h '06-08 m o d e l s
P G M - F I m a i n relay 2 (fuel p u m p ) 31 4 U n d e r middle of d a s h '06-08 m o d e l s
P o w e r transistor 11 5 U n d e r right s i d e of d a s h
R e a r w i n d o w defogger s w i t c h 28 5 Middle of floor between Hardtop*
seats
Rear w i n d o w defogger s w i t c h 27 6 Middle of floor between '06-08 m o d e l s
seats
Recirculation control motor 14 7 U n d e r right s i d e of d a s h
C201 17 16 U n d e r right s i d e of d a s h Right e n g i n e c o m p a r t m e n t
w i r e h a r n e s s (see p a g e 22-18)
C202 24 6 U n d e r right s i d e of d a s h Right e n g i n e c o m p a r t m e n t '00-05 m o d e l s
C202 24 8 U n d e r right s i d e of d a s h Right e n g i n e c o m p a r t m e n t '06-08 m o d e l s
C203 16 7 U n d e r right s i d e of d a s h Right e n g i n e c o m p a r t m e n t
C451 18 16 U n d e r right s i d e of d a s h Dashboard wire harness A
( s e e p a g e 22-26)
C452 21 2 U n d e r right s i d e of d a s h Roof w i r e h a r n e s s ( s e e p a g e
22-32)
C453 15 12 U n d e r right s i d e of d a s h Dashboard wire harness A '06-08 m o d e l s
( s e e p a g e 22-26)
G402 20 U n d e r right s i d e of d a s h Body ground, via dashboard
wire harness B
*: '00-01 m o d e l s
22-24
22-25
Dashboard Wire Harness A

A u d i o r e m o t e switch 10 6 U n d e r left s i d e of d a s h
A u d i o unit c o n n e c t o r A 22 20 B e h i n d a u d i o unit
A u d i o unit c o n n e c t o r B 30 14 B e h i n d audio unit Option' 1
Convertible top control unit connector B 25 10 U n d e r right s i d e of d a s h

C r u i s e control m a i n s w i t c h 13 6 U n d e r left s i d e of d a s h
E C M connector A 11 32 B e h i n d left kick panel '00-05 m o d e l s
E C M connector D 11 17 B e h i n d left kick panel '06-08 m o d e l s
E C M connector E 12 31 B e h i n d left kick panel '06-08 m o d e l s
E n g i n e start s w i t c h 7 5 U n d e r left s i d e of d a s h
G a u g e assembly connector A 19 14 Behind gauge assembly '00-03 models
G a u g e assembly connector B 18 12 Behind gauge assembly '00-03 models
Gauge assembly connector C 17 20 Behind gauge assembly '00-03 models
G a u g e assembly connector D 16 16 Behind gauge assembly '00-03 models
G a u g e assembly connector A 19 22 Behind gauge assembly '04-08 models
G a u g e assembly connector B 16 30 Behind gauge assembly '04-08 models
Heater control panel 20 30 U n d e r middle of d a s h
K e y l e s s door lock control unit 9 18 U n d e r left s i d e of d a s h
R e a r w i n d o w defogger s w i t c h 31 6 U n d e r middle of d a s h '02-05 m o d e l s
Security L E D connector 8 2 U n d e r left s i d e of d a s h Option* 1
Throttle actuator control m o d u l e 29 16 B e h i n d right kick panel '06-08 m o d e l s

V S A O F F switch 31 6 U n d e r middle of d a s h '06-08 m o d e l s
C101 4 16 B e h i n d left kick panel Engine wire harness
(see page 22-14)
C102 5 6 B e h i n d left kick panel Engine wire harness '06-08 m o d e l s
(see page 22-16)
C103 6 13 B e h i n d left kick panel Engine wire harness '06-08 m o d e l s
(see page 22-16)
C204 27 18 U n d e r left s i d e of d a s h Right engine c o m p a r t m e n t '00-05 m o d e l s
w i r e h a r n e s s (see page 22-18)
C204 27 20 U n d e r left s i d e of d a s h Right engine c o m p a r t m e n t '06-08 m o d e l s
C303 33 14 U n d e r left s i d e of d a s h Left e n g i n e c o m p a r t m e n t w i r e '00-05 m o d e l s
C303 33 20 U n d e r left s i d e of d a s h Left engine c o m p a r t m e n t w i r e '06-08 m o d e l s
C304 32 8 U n d e r left s i d e of d a s h Left e n g i n e c o m p a r t m e n t w i r e '06-08 m o d e l s
C402 34 4 U n d e r left s i d e of d a s h Dashboard wire harness B '00-01 m o d e l s
(see p a g e 22-22)
(see page 22-22)
C402 14 6 U n d e r left s i d e of d a s h Dashboard wire harness B '08 m o d e l
(see page 22-22)
(see page 22-22)
C403 34 16 U n d e r left s i d e of d a s h Dashboard wire harness B '08 m o d e l
(see page 22-22)
(see p a g e 22-22)
C451 26 16 U n d e r right s i d e of d a s h Dashboard wire harness B
(see page 22-24)
C453 24 12 U n d e r right s i d e of d a s h Dashboard wire harness B '06-08 m o d e l s
(see page 22-24)
* 1:'04-08 m o d e l s
22-26
(cont'd)
22-27
D a s h b o a r d W i r e H a r n e s s A (cont'd)
Connector or Terminal Ref Cavities Location Connects to Notes

C501 2 14 B e h i n d left kick panel Rear wire harness (see page '00-03 m o d e l s
22-30)
C501 2 17 B e h i n d left kick panel R e a r w i r e h a r n e s s (see p a g e '04-05 m o d e l s
22-30)
C501 2 21 B e h i n d left kick panel Rear wire harness (see page '06-08 m o d e l s
22-30)
C502 3 18 B e h i n d left kick panel Driver's d o o r w i r e h a r n e s s '00-03 m o d e l s
( s e e p a g e 22-34)
C502 3 20 B e h i n d left kick panel Driver's d o o r w i r e h a r n e s s '04-08 m o d e l s
(see p a g e 22-34)
C503 35 3 U n d e r left s i d e of d a s h S R S main harness (see page '00-05 m o d e l s
22-33)
C503 35 6 U n d e r left s i d e of d a s h S R S m a i n h a r n e s s (see p a g e '06-08 m o d e l s
22-33)
C504 28 14 B e h i n d right kick panel P a s s e n g e r ' s door w i r e '00-03 m o d e l s
h a r n e s s ( s e e p a g e 22-35)
C504 28 16 B e h i n d right kick panel P a s s e n g e r ' s door w i r e '04-08 m o d e l s
h a r n e s s ( s e e p a g e 22-35)
C505 1 6 B e h i n d left kick panel Rear w i r e h a r n e s s (see p a g e '04-05 m o d e l s
22-30)
C505 1 12 B e h i n d left kick panel R e a r w i r e h a r n e s s (see page '06-08 m o d e l s
22-30)
1
C506 21 4 B e h i n d a u d i o unit Headrest s p e a k e r s u b h a r n e s s Option*
C551 23 2 B e h i n d a u d i o unit A n t e n n a amplifier s u b h a r n e s s
(see p a g e 22-32)
G501 37 Body ground, via dashboard
wire harness A
G502 36 Body ground, via dashboard
wire harness A
* 1:'04-08 m o d e l s
22-28
22-29
R e a r W i r e H a r n e s s (Left b r a n c h )

Driver's door s w i t c h 4 1 B e h i n d left c o r n e r g u s s e t
Driver's left rear s p e a k e r 28 3 U n d e r driver's roll bar '06-08 m o d e l s
Driver's right rear s p e a k e r 29 2 U n d e r driver's roll bar '06-08 m o d e l s
D r i v e r ' s s e a t belt buckle s w i t c h 3 2 Under driver's seat
D r i v e r ' s s e a t position s e n s o r 30 2 U n d e r driver's s e a t '06-08 m o d e l s
E V A P bypass solenoid valve 9 2 Left s i d e of under floor
E V A P canister vent s h u t v a l v e 10 2 Left s i d e of under floor
Fuel pump/fuel g a u g e s e n d i n g unit 25 5 Middle of fuel tank
Fuel tank p r e s s u r e s e n s o r 8 3 Left s i d e of under floor
High m o u n t brake light 21 2 Middle of trunk lid
Left convertible top motor 5 2 B e h i n d left c o r n e r g u s s e t
Left back-up light 17 2 B e h i n d left taillight a s s e m b l y '00-03 models
Left back-up light 19 2 B e h i n d left taillight a s s e m b l y '04-08 models
Left brake/taillight 16 3 B e h i n d left taillight a s s e m b l y '00-03 models
Left brake/side marker/taillight 16 3 B e h i n d left taillight a s s e m b l y '04-08 models
Left rear side marker light 15 2 B e h i n d left taillight a s s e m b l y '00-03 models
Left rear turn signal light 18 2 B e h i n d left taillight a s s e m b l y
Left rear w h e e l s p e e d s e n s o r 7 2 Left s i d e of trunk
Noise condenser 11 2 Left s i d e of trunk '02-08 models
R e a r w i n d o w defogger c h a n g e relay 13 5 Left s i d e of trunk '02-08 models
R e a r w i n d o w defogger diode 12 2 Left s i d e of trunk '02-08 models
S e n s o r cluster 27 6 B e h i n d rear c o n s o l e '06-08 models
T r u n k light 23 2 Middle of trunk
T r u n k lid o p e n e r solenoid/latch 20 3 Middle of trunk lid
switch
T r u n k lid o p e n e r s w i t c h 26 2 B e h i n d rear c o n s o l e b e t w e e n
seat-back
1
X M receiver 22 14 Left s i d e of trunk Option*
C401 1 22 B e h i n d left kick panel Dashboard wire harness B
(see p a g e 22-22)
C501 2 14 B e h i n d left kick panel Dashboard wire harness A '00-03 m o d e l s
(see p a g e 22-26)
(see p a g e 22-26)
(see p a g e 22-26)
(see p a g e 22-26)
(see p a g e 22-26)
C601 6 4 Left s i d e of trunk Hardtop s u b h a r n e s s '00-05 m o d e l s
( s e e p a g e 22-36)
C601 6 3 Left s i d e of trunk Hardtop s u b h a r n e s s '06-08 m o d e l s
(see p a g e 22-36)
C602 14 2 Left s i d e of trunk Rear w i n d o w defogger '02-08 m o d e l s
s u b h a r n e s s ( s e e page 22-37)
C603 27 8 B e h i n d rear c o n s o l e S R S m a i n h a r n e s s (see p a g e '06-08 m o d e l s
22-33)
G601 24 B o d y g r o u n d , via rear w i r e
harness
* 1:'04-08 m o d e l s
22-30
22-31
R e a r W i r e H a r n e s s (Right b r a n c h )

A c c e s s o r y p o w e r socket 1 2 B e h i n d rear c o n s o l e b e t w e e n s e a t -
back
L i c e n s e plate light 18 2 B e h i n d rear b u m p e r
Passenger's door switch 9 1 B e h i n d right c o r n e r g u s s e t
P a s s e n g e r ' s left rear s p e a k e r 8 2 U n d e r p a s s e n g e r ' s roll bar '06-08 models
P a s s e n g e r ' s right rear s p e a k e r 2 3 U n d e r p a s s e n g e r ' s roll bar '06-08 models
P a s s e n g e r ' s s e a t belt buckle s w i t c h 6 3 Under passenger's seat '06-08 models
P a s s e n g e r ' s w e i g h t s e n s o r unit 7 6 Under passenger's seat '06-08 models
Right convertible top motor 10 2 B e h i n d right c o r n e r g u s s e t
Right back-up light 15 2 B e h i n d right taillight '00-03 models
Right back-up light 17 2 B e h i n d right taillight '04-08 models
Right brake/taillight 14 3 B e h i n d right taillight '00-03 models
Right brake/side marker/taiMight 14 3 B e h i n d right taillight '04-08 models
Right rear s i d e m a r k e r light 13 2 B e h i n d right taillight '00-03 models
Right rear turn signal light 16 2 B e h i n d right taillight
Right rear w h e e l s p e e d s e n s o r 11 2 Right s i d e of trunk
G602 19 B o d y g r o u n d , v i a rear w i r e
harness
Roof Wire H a r n e s s

Ceiling light/spotlight 3 4 Roof area
C452 5 2 U n d e r right s i d e of d a s h Dashboard wire harness B
(see page 22-24)
A n t e n n a Amplifier S u b h a r n e s s

A n t e n n a amplifier 12 2 Right front of trunk
C551 4 2 B e h i n d a u d i o unit Dashboard wire harness A
(see p a g e 22-26)
22-32
S R S Main Harness

C a b l e reel 5 2 U nder left s i d e of d a s h '00-05 m o d e l s
C a b l e reel 5 4 U n d e r left s i d e of d a s h '06-08 m o d e l s
Driver's s e a t belt tensioner 12 2 Behind driver's seat-back
M e m o r y e r a s e signal ( M E S ) connector 1 2 U n d e r - d a s h f u s e / r e l a y box
P a s s e n g e r ' s airbag inflator 8 2 U n d e r right s i d e of d a s h '00-05 m o d e l s
P a s s e n g e r ' s airbag inflator 8 4 U n d e r right s i d e of d a s h '06-08 m o d e l s
P a s s e n g e r ' s s e a t belt tensioner 10 2 B e h i n d p a s s e n g e r ' s seat-back
S R S unit 6 18 Middle of floor '00-05 m o d e l s
S R S unit connector A 6 28 Middle of floor '06-08 m o d e l s
S R S unit connector B 7 28 Middle of floor '06-08 m o d e l s
U n d e r - d a s h fuse/relay box connector 2 2 U n d e r - d a s h f u s e / r e l a y box
A (see page 22-39)
C205 9 4 U n d e r right s i d e of d a s h Right engine c o m p a r t m e n t '06-08 m o d e l s
C305 14 4 U n d e r left s i d e of d a s h Left engine c o m p a r t m e n t '06-08 m o d e l s
(see page 22-26)
(see page 22-26)
C603 11 8 Behind rear c o n s o l e R e a r w i r e h a r n e s s (see p a g e '06-08 m o d e l s
22-30)
G801 13 Middle of floor B o d y g r o u n d , via S R S m a i n
harness
Ignition S w i t c h L e a d

U n d e r - d a s h fuse/relay box connector 3 7 U n d e r left s i d e of d a s h
B (see page 22-39)
13
22-33
Driver's Door Wire Harness

Driver's door key cylinder s w i t c h 7 2 Driver's door
Driver's door lock actuator 8 2 D r i v e r ' s door
Driver's door lock knob s w i t c h 9 3 D r i v e r ' s door
Driver's door s p e a k e r 3 2 Driver's door
Driver's p o w e r w i n d o w motor 6 4 Driver's door
Left p o w e r mirror actuator 1 3 Driver's door
Left tweeter 10 2 Driver's door '02-08 m o d e l s
P o w e r mirror s w i t c h 5 10 Driver's door
Power w i n d o w master switch 4 14 Driver's door
(see page 22-26)
(see page 22-26)
DRIVER'S DOOR WIRE HARNESS
22-34
P a s s e n g e r ' s Door Wire H a r n e s s

P a s s e n g e r ' s door lock actuator 6 2 Passenger's door
P a s s e n g e r ' s door s p e a k e r 3 2 P a s s e n g e r ' s door
Passenger's power window motor 5 2 Passenger's door
Passenger's power window switch 4 6 Passenger's door
Right p o w e r mirror actuator 1 3 Passenger's door
Right tweeter 7 2 P a s s e n g e r ' s door '02-08 m o d e l s
C504 2 14 B e h i n d right kick panel Dashboard wire harness A '00-03 m o d e l s
(see p a g e 22-26)
C504 2 16 B e h i n d right kick panel Dashboard wire harness A '04-08 m o d e l s
(see page 22-26)
1 7
22-35
HARDTOP

Convertible top d i s a b l e s w i t c h 5 2 B e h i n d left corner g u s s e t
C601 3 4 B e h i n d left rear s i d e trim Rear w i r e h a r n e s s (see page '00-05 m o d e l s
22-30)
C601 3 3 B e h i n d left rear s i d e trim Rear w i r e h a r n e s s (see page '06-08 m o d e l s
22-30)
C901 7 3 B e h i n d left rear s i d e trim Hardtop w i r e h a r n e s s
Hardtop Wire Harness

C o n n e c t o r or T e r m i n a l Ref Cavities Location C o n n e c t s to Notes
Rear w i n d o w defogger c o n n e c t o r ( + ) 4 1 Left s i d e of hardtop
C901 8 3 Left s i d e of hardtop Hardtop s u b h a r n e s s
G901 6 Left C-pillar B o d y g r o u n d , v i a hardtop
wire harness

R e a r w i n d o w defogqer c o n n e c t o r (•—) 2 1 Right s i d e of hardtop
G902 1 Right s i d e of hardtop B o d y g r o u n d , v i a rear w i n d o w
defogger g r o u n d w i r e
HARDTOP WIRE HARNESS
DEF0GGER
§Rmw
HARDTOP S U B H A R N E S S
22-36
• BODY •
CONVERTIBLE TOP

Rear w i n d o w defogger c o n n e c t o r ( + ) 1 1 Left s i d e of rear w i n d o w
R e a r w i n d o w defogger c o n n e c t o r (—) 2 1 Left s i d e of rear w i n d o w
C602 3 2 Left s i d e of trunk Rear wire harness
(see p a g e 22-30)
22-37
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index
Main Under-hood Fuse/Relay Box
Socket Ref Terminal Connects to

A 15 18 Right e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-18)
A / C c o m p r e s s o r clutch relay 3 4
A / C c o n d e n s e r fan relay 1 4
B 14 7 Right e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-18)
Blower motor relay 11 4
C 13 3 Right e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-18)
D 12 16 Right e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-18)
Diode 9 2
Electrical l o a d detector ( E L D ) 4 3 R i g h t e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-18)
Horn r e l a y 10 4
Headlight relay 1 7 4
Headlight relay 2 8 4
R a d i a t o r f a n relay 2 4
T1 6 E P S s u b h a r n e s s ( s e e p a g e 22-12)
T101 5 Engine wire harness (see page 22-14,22-16)
1 2 3
22-38
•BODY •
Under-dash Fuse/Relay Box

A 3 2 S R S m a i n h a r n e s s ( s e e p a g e 22-33)
B 1 7 Ignition s w i t c h h a r n e s s ( s e e p a g e 22-33)
C 7 1 Optional connector
D 8 1 Optional connector
E 9 1 Optional connector
Memory erase signal ( M E S ) 5 2 S R S m a i n h a r n e s s ( s e e p a g e 22-33)
connector
Rear w i n d o w defogger relay 6 4
('00-01 m o d e l s )
Starter cut relay 4 4
Taillight r e l a y 2 4
T u r n signal/hazard relay 10 3
22-39
Fuse/Relay Boxes
Connector to Fuse/Relay Box Index (cont'd)
Auxiliary Under-hood F u s e B o x

A 2 2 Left e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-20)
B 1 3 Left e n g i n e c o m p a r t m e n t w i r e h a r n e s s ( s e e p a g e 22-20)
22-40
Power Distribution
Fuse to Components Index
Main Under-hood Fuse/Relay Box
Fuse Amps Wire Color C o m p o n e n t ( s ) or C i r c u i t ( s ) P r o t e c t e d

Number
41 100 A Battery, P o w e r distribution
42 40 A WHT Ignition s w i t c h ( B A T )
3
43 20 A RED/WHT D a y t i m e r u n n i n g lights control u n i t * , R i g h t headlight ( h i g h / l o w b e a m )
44 Not u s e d
3
45 20 A RED/YEL D a y t i m e r u n n i n g lights control u n i t * , G a u g e a s s e m b l y , High b e a m
3
indicator, High b e a m c u t r e l a y * , Left h e a d l i g h t ( h i g h / l o w b e a m )
46 15A WHT/GRN Data link c o n n e c t o r ( D L C ) , P G M - F I m a i n r e l a y ('00-05 m o d e l s ) , C M P s e n s o r
('06-08 m o d e l s ) , C K P s e n s o r ('06-08 m o d e l s ) , E C M ('06-08 m o d e l s )
47 10A* 1
WHT/GRN A B S m o d u l a t o r - c o n t r o l unit ('00-05 m o d e l s ) , B r a k e lights, C r u i s e control
15A* 2
unit ('00-05 m o d e l s ) , E C M , High m o u n t b r a k e light, Horn(s)
48 20 A WHT/RED A B S m o d u l a t o r - c o n t r o l unit ('00-05 m o d e l s ) , V S A m o d u l a t o r - c o n t r o l unit
('06-08 m o d e l s )
49 10A WHT/BLK H a z a r d w a r n i n g lights
50 30 A WHT/BLU A B S m o d u l a t o r - c o n t r o l unit ('00-05 m o d e l s ) , V S A m o d u l a t o r - c o n t r o l unit
('06-08 m o d e l s )
51 40 A WHT/BLK No. 17 a n d 18 f u s e s (in t h e u n d e r - d a s h f u s e / r e l a y box)
52 20 A GRY/RED Right c o n v e r t i b l e top m o t o r
53 20 A * 5
BLU A c c e s s o r y p o w e r s o c k e t (CR m o d e l )
54 30 A YEL N o . 2 2 , 2 3 , 2 4 , 2 5 , 2 6 , a n d 27 f u s e s (in t h e u n d e r - d a s h f u s e / r e l a y box)
55 20 A GRY Left c o n v e r t i b l e top m o t o r
56 40 A BLU/WHT Blower motor
57 20 A * 4
BLU/BLK Radiator fan motor
5
30 A *
58 20 A BLU/YEL A / C c o n d e n s e r f a n m o t o r (with A / C )
BLU/RED A / C c o m p r e s s o r c l u t c h (with A / C )
59 20 A YEL No. 1 4 , 1 5 , 1 6 , a n d 21 f u s e s (in the u n d e r - d a s h f u s e / r e l a y box)
* 1:'00-01 m o d e l s
* 2: '02-07 m o d e l s
* 4: '00-07 m o d e l s
* 5: '08 m o d e l
(cont'd)
22-41
Power Distribution
Fuse to Components Index (cont'd)
Under-dash Fuse/Relay Box
Fuse Amps Wire Color C o m p o n e n t ( s ) or Circuit(s) P r o t e c t e d

Number
1 10A G R N or P N K S R S unit (VB)
2 15A G R N or S R S unit (VA)
BLK/YEL
BLK/YEL Fuel p u m p , Immobilizer control unit-receiver ('06-08 m o d e l s ) , P G M - F I m a i n relay
('00-05 m o d e l s ) , I m o e s unit ('08 m o d e l ) , P a s s e n g e r ' s w e i g h t s e n s o r ('06-08 m o d e l s ) ,
P a s s e n g e r ' s airbag cut off indicator ('08 m o d e l )
3 7.5 A BLK/WHT A C C cut relay ('08 m o d e l ) , E n g i n e start s w i t c h
4 15A BLK/YEL Ignition coils ('00-05 m o d e l s )
5 7.5 A YEL B a c k - u p lights. C h a r g i n g s y s t e m light ('04-05 m o d e l s ) , D R L indicator, E P S control unit.
G a u g e a s s e m b l y . K e y l e s s door lock control unit, Convertible top control unit, T P M S control
unit ('08 m o d e l )
6 15A BLK/YEL Air control s o l e n o i d v a l v e , Alternator, C h a r g i n g s y s t e m indicator ('00-03 m o d e l s ) , C r u i s e
control unit. C r u i s e c o n t r o l m a i n s w i t c h , E L D , E V A P b y p a s s s o l e n o i d v a l v e , E V A P c a n i s t e r
v e n t s h u t v a l v e , E V A P c a n i s t e r purge v a l v e , P r i m a r y a n d s e c o n d a r y heated o x y g e n s e n s o r s ,
R e a r w i n d o w d e f o g g e r c h a n g e relay ('02-05 m o d e l s )
7 7.5 A RED/BLU T u r n s i g n a l / h a z a r d relay
8 20 A GRN/BLK P o w e r w i n d o w m a s t e r s w i t c h , W i n d s h i e l d w i p e r motor. Intermittent w i p e r relay
9 10A YEL/RED A c c e s s o r y p o w e r s o c k e t (Except '08 m o d e l without s p a r e tire), A c c e s s o r y p o w e r socket
relay ('08 m o d e l without s p a r e tire), A u d i o unit, A u d i o r e m o t e s w i t c h , Convertible top
s w i t c h light
10 7.5 A YEL/BLU A / F s e n s o r relay ( L A F ) ('06-08 m o d e l s )
11 7.5 A YEL/GRN Throttle actuator control m o d u l e relay ('06-08 m o d e l s )
12 15A BLK/WHT W i n d s h i e l d w a s h e r motor. Convertible top s w i t c h
13 7.5 A BLU/ORN Intermittent w i p e r driving circuit (in t h e g a u g e a s s e m b l y )
14 15A BLU/WHT Throttle actuator control m o d u l e ('06-08 m o d e l s )
15 20 A * 2
WHT/RED A / F s e n s o r ( s e n s o r 1) ('06-08 m o d e l s ) , E V A P c a n i s t e r vent s h u t v a l v e ('06-08 m o d e l s )
3
15A*
16 15A BLK/YEL Ignition coils ('06-08 m o d e l s ) , ignition coil relay ('06-08 m o d e l s )
17 20 A GRN/WHT Driver's p o w e r w i n d o w motor
18 20 A BLU/BLK P a s s e n g e r ' s p o w e r w i n d o w motor. Convertible top control unit
1
19 7.5 A YEL/BLK A B S modulator-control unit ('00-05 m o d e l s ) , D a y t i m e running lights control unit* , D a y t i m e
r u n n i n g lights s u b c o n t r o l unit ('06-08 U S A m o d e l s ) , P o w e r mirror actuator, R e a r w i n d o w
d e f o g g e r relay
20 7.5 A BLK/YEL A / C c o m p r e s s o r clutch relay, A / C c o n d e n s e r f a n relay, B l o w e r motor relay, Heater control
p a n e l . Radiator f a n relay. Recirculation control motor
21 7.5 A BLU/ORN* 2
E C M , P G M - F I m a i n relay ('00-05 m o d e l s ) , T P M S control unit ('08 model)
3
RED*
22 15A WHT/BLU A u d i o unit
23 10A WHT/GRN A u d i o r e m o t e s w i t c h lights, A u d i o unit light, Convertible top s w i t c h lights. C r u i s e control,
m a i n s w i t c h light, Front parking lights. G a u g e lights. Hazard w a r n i n g s w i t c h light, Heater
control panel lights, K e y l e s s d o o r lock control unit, L i c e n s e plate light, Option c o n n e c t o r ,
R e a r s i d e m a r k e r lights, Taillights, R e a r w i n d o w defogger s w i t c h light, P a s s e n g e r ' s airbag
cutoff indicator illumination light ('06-08 m o d e l s ) , V S A O F F s w i t c h light
24 7.5 A WHT/BLU Ceiling/spotlights, T r u n k light
25 7.5 A WHT/RED E C M , G a u g e a s s e m b l y , Heater control p a n e l , Immobilizer indicator light. Convertible top
control unit, Immobilizer control unit-receiver ('06-08 m o d e l s ) , I m o e s unit ('08 m o d e l )
26 15A WHT K e y l e s s d o o r lock control unit, T r u n k lid o p e n e r s o l e n o i d
1
27 10A RED/BLU D a y t i m e r u n n i n g lights control unit*
28 Not u s e d
* 2: '00-07 m o d e l s
* 3: '08 m o d e l
22-42
J BODY J
UNDER-DASH FUSE/RELAY BOX
(cont'd)
22-43
Power Distribution
Fuse to Components Index (cont'd)
Auxiliary Under-hood F u s e B o x
Fuse Amps Wire Color C o m p o n e n t ( s ) or Circuit(s) Protected

Number
32 60 A WHT A i r p u m p e l e c t r i c c u r r e n t s e n s o r ('00-05 m o d e l s )
33 70 A WHT/RED E P S c o n t r o l unit
34 20 A WHT/GRN Rear w i n d o w defogger
35 Not u s e d
36 Not u s e d
36
30
© 33 KG
© 32
©
© ©
o o
U-Jy p i
22-44
Ground Distribution
Ground to Components Index
Ground C o m p o n e n t or circuit grounded

G1 Battery
G2 E n g i n e block
G3 E n g i n e block
G4 E P S gearbox
G101 C K P s e n s o r , Data link c o n n e c t o r ( D L C ) ('00-05 m o d e l s ) , E C M (PG1 a n d P G 2 a r e B L K ; L G 1 a n d L G 2 a r e
B R N / Y E L ) , I A C v a l v e ('00-05 m o d e l s ) , Ignition c o i l s , I m m o b i l i z e r control u n i t - r e c e i v e r , P G M - F I m a i n
r e l a y ('00-05 m o d e l s ) , R o c k e r a r m oil p r e s s u r e s w i t c h ( V T E C oil p r e s s u r e s w i t c h ) , Throttle a c t u a t o r
control m o d u l e , V S S ('00-05 m o d e l s )
Shielding between the E C M a n d these c o m p o n e n t s have B R N / Y E L wires: C K P s e n s o r , T D C s e n s o r 1
a n d 2 ( C M P s e n s o r A a n d B) ('00-05 m o d e l s ) , P r i m a r y H 0 2 S ('00-05 m o d e l s ) , S e c o n d a r y H 0 2 S , K n o c k
sensor
G201 A / C c o n d e n s e r f a n m o t o r (with A / C ) , B l o w e r m o t o r r e l a y , E L D , E P S control unit, R a d i a t o r f a n m o t o r ,
Right front parking light ('00-03 m o d e l s ) . Right front p a r k i n g / s i d e m a r k e r light ('04-08 m o d e l s ) , Right
front turn s i g n a l light, Right headlight ( l o w b e a m ) ('00-03 m o d e l s ) , Right s i d e turn s i g n a l light,
Windshield w a s h e r motor
G301 A i r p u m p r e l a y , B r a k e fluid level s w i t c h . C r u i s e control a c t u a t o r , Intermittent w i p e r r e l a y ('02-08
m o d e l s ) , Left front parking light ('00-03 m o d e l s ) , Left front p a r k i n g / s i d e m a r k e r light ('04-08 m o d e l s ) ,
Left front turn s i g n a l light, Left h e a d l i g h t ( l o w b e a m ) ('00-03 m o d e l s ) , Left s i d e t u r n s i g n a l light,
R a d i a t o r f a n s w i t c h ('00-05 m o d e l s ) . W i n d s h i e l d w i p e r m o t o r
G302 A i r p u m p ('00-05 m o d e l s )
G303 A B S m o d u l a t o r - c o n t r o l unit ('00-05 m o d e l s ) (2 w i r e s ) , V S A m o d u l a t o r - c o n t r o l unit ('06-08 m o d e l s )
G351 E P S control unit
G401 A c c e s s o r y p o w e r s o c k e t r e l a y (CR m o d e l ) , C l u t c h interlock s w i t c h , C l u t c h p e d a l p o s i t i o n s w i t c h ,
C o m b i n a t i o n light s w i t c h , Data link c o n n e c t o r ( D L C ) , D a y t i m e r u n n i n g lights s u b c o n t r o l unit ('06-08
U S A m o d e l s ) (2 w i r e s ) , Ignition k e y s w i t c h , Intermittent w i p e r r e l a y ('00-03 m o d e l s ) , R e a r w i n d o w
d e f o g g e r s w i t c h ('00-01 m o d e l s ) , T P M S control unit ('08 m o d e l s ) , T u r n s i g n a l / h a z a r d r e l a y , W i n d s h i e l d
wiper/washer switch
G402 C o n v e r t i b l e t o p control unit (3 w i r e s ) , C r u i s e control unit ('00-05 m o d e l s ) . D a y t i m e r u n n i n g lights
control unit ( E x c e p t '00-05 U S A m o d e l s ) (2 w i r e s ) , E P S c o n t r o l unit, H e a t e r control p a n e l , P o w e r
t r a n s i s t o r , R e a r w i n d o w d e f o g g e r s w i c t h ('06-08 m o d e l s )
G501 A u d i o r e m o t e s w i t c h , C o n v e r t i b l e t o p control unit, C r u i s e m a i n s w i t c h , D r i v e r ' s d o o r k e y c y l i n d e r
s w i t c h , D r i v e r ' s d o o r lock actuator, E n g i n e start s w i t c h , G a u g e a s s e m b l y (2 w i r e s ) , H e a d l i g h t s ( l o w
b e a m ) ('04-08 m o d e l s ) , K e y l e s s d o o r lock control unit, P a s s e n g e r ' s p o w e r w i n d o w s w i t c h , P o w e r m i r r o r
s w i t c h , P o w e r w i n d o w m a s t e r s w i t c h , R e a r w i n d o w d e f o g g e r s w i t c h ('02-05 m o d e l s )
G502 A u d i o unit
G601 A c c e s s o r y p o w e r s o c k e t , C o n d e n s e r ('02-08 m o d e l s ) , C o n v e r t i b l e t o p d i s a b l e s w i t c h , D r i v e r ' s s e a t belt
buckle s w i t c h , F u e l g a u g e s e n d i n g unit ('00-05 m o d e l s ) (2 w i r e s ) , F u e l p u m p , High m o u n t brake light,
P a s s e n g e r ' s s e a t belt buckle s w i t c h , P a s s e n g e r ' s w e i g h t s e n s o r unit, R e a r w i n d o w d e f o g g e r
(convertible t o p f o r '02-08 m o d e l s ) , R e a r w i n d o w d e f o g g e r (with h a r d top), R e a r w i n d o w d e f o g g e r
s u b h a r n e s s c o n n e c t o r (option) ('00-01 m o d e l s ) , T r u n k lid o p e n e r s o l e n o i d / l a t c h s w i t c h , p l u s e v e r y t h i n g
grounded through G901
G602 B a c k - u p lights, L i c e n s e plate light, R e a r s i d e m a r k e r lights, R e a r turn s i g n a l lights, T a i l l i g h t s
G801 S R S unit (2 w i r e s )
G901 C o n v e r t i b l e t o p d i s a b l e s w i t c h , R e a r w i n d o w d e f o g g e r r e l a y ('00-01 m o d e l s ) , p l u s e v e r y t h i n g g r o u n d e d
through G601
G902 Rear w i n d o w defogger
22-45
Under-hood Fuse/Relay Box
Removal and Installation
Removal Installation
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e f o r t h e 1. Install t h e r e l a y s a n d c o n n e c t the c o n n e c t o r s to t h e

audio s y s t e m , then write d o w n the audio p r e s e t s . u n d e r - h o o d f u s e / r e l a y b o x , t h e n install t h e u n d e r -
h o o d f u s e / r e l a y b o x in t h e r e v e r s e o r d e r of r e m o v a l .
2 . M a k e s u r e t h e ignition s w i t c h is O F F .
2 . Install the r e m o v e d p a r t s in the r e v e r s e o r d e r of
3 . D i s c o n n e c t t h e n e g a t i v e battery c a b l e , t h e n removal.
d i s c o n n e c t t h e p o s i t i v e c a b l e , a n d w a i t at l e a s t
3 minutes. 3 . C o n n e c t t h e p o s i t i v e c a b l e to t h e battery, t h e n
c o n n e c t t h e n e g a t i v e c a b l e to the battery.
4 . R e m o v e t h e bolts (A) for t h e E P S s u b h a r n e s s a n d
engine w i r e h a r n e s s terminals from the m a i n 4 . E n t e r t h e anti-theft c o d e for t h e a u d i o s y s t e m , t h e n
u n d e r - h o o d f u s e / r e l a y box. e n t e r t h e a u d i o p r e s e t s , a n d s e t the c l o c k .
5 . C o n f i r m that all s y s t e m s w o r k p r o p e r l y .
5 . R e m o v e t h e bolts (B) s e c u r i n g t h e m a i n u n d e r - h o o d
fuse/relay box.
6. R e m o v e the bottom c o v e r from the m a i n under-

h o o d f u s e / r e l a y box.
7 . Disconnect the connectors from the main under-

8 . C a r e f u l l y r e m o v e t h e r e l a y s by p r y i n g u n d e r t h e
b a s e of t h e r e l a y .
N O T E : D o not u s e p l i e r s . P l i e r s will d a m a g e t h e
r e l a y s , w h i c h c o u l d c a u s e t h e e n g i n e to stall or not
start.
22-46
Battery
Battery Test
A WARNING
A battery c a n e x p l o d e if y o u d o not follow t h e
p r o p e r p r o c e d u r e , c a u s i n g s e r i o u s injury to a n y o n e
n e a r b y . F o l l o w all p r o c e d u r e s c a r e f u l l y a n d k e e p
s p a r k s a n d o p e n f l a m e s a w a y f r o m the battery.
U s e either a J C I or B e a r A R B S T t e s t e r , a n d f o l l o w t h e
m a n u f a c t u r e r ' s p r o c e d u r e s . If y o u don't h a v e o n e of
t h e s e c o m p u t e r i z e d t e s t e r s , f o l l o w this c o n v e n t i o n a l
test procedure:
1. B e s u r e the t e m p e r a t u r e of t h e electrolyte is
b e t w e e n 70 °F (21 <€) a n d 100 °F (38 °C).
2. I n s p e c t the battery c a s e for c r a c k s or l e a k s .
• If the c a s e is d a m a g e d , r e p l a c e the battery. •

• If the c a s e looks O K , g o to s t e p 3.
3. C h e c k the indicator E Y E .
• If t h e E Y E i n d i c a t e s the battery is c h a r g e d , g o to
s t e p 4.
• If the E Y E i n d i c a t e s a l o w c h a r g e , go to s t e p 7.
4. A p p l y a 300 A load for 15 s e c o n d s to r e m o v e t h e

surface charge.
5. W a i t 15 s e c o n d s , t h e n a p p l y a test load of 2 8 0 A for

15 s e c o n d s .
6. R e c o r d battery v o l t a g e .
• If v o l t a g e is a b o v e 9.6 V , t h e battery is O K . •
• If v o l t a g e is b e l o w 9.6 V , g o to s t e p 7.
7. C h a r g e t h e battery o n High (40 A ) until the E Y E

s h o w s the battery is c h a r g e d , p l u s a n additional
30 m i n u t e s . If t h e battery c h a r g e is v e r y l o w , it m a y
be n e c e s s a r y to b y p a s s the c h a r g e r ' s polarity
protection circuitry.
• If the E Y E i n d i c a t e s t h e battery is c h a r g e d w i t h i n
3 h o u r s , t h e battery is O K . B
• If the E Y E i n d i c a t e s t h e battery is not c h a r g e d
within 3 h o u r s , r e p l a c e t h e battery. •
22-47
Relays
Power Relay Test
U s e t h i s c h a r t to identify t h e t y p e of r e l a y , t h e n d o t h e Normally-open type A
t e s t listed for it.
C h e c k for c o n t i n u i t y b e t w e e n t h e t e r m i n a l s .
N O T E : F o r t h e t u r n s i g n a l / h a z a r d r e l a y input t e s t
(see page 22-147). • T h e r e s h o u l d b e continuity b e t w e e n t h e No. 1 a n d
N o . 2 t e r m i n a l s w h e n battery p o s i t i v e t e r m i n a l is
Relay Test c o n n e c t e d to t h e N o . 4 t e r m i n a l , a n d battery n e g a t i v e
A c c e s s o r y power socket Normally open t e r m i n a l is c o n n e c t e d to t h e N o . 3 t e r m i n a l .
relay* 4
type A • T h e r e s h o u l d b e n o continuity b e t w e e n t h e N o . 1 a n d
A / C c o m p r e s s o r clutch relay N o . 2 t e r m i n a l s w h e n p o w e r is d i s c o n n e c t e d .
A / C c o n d e n s e r fan relay
3
A/F sensor relay*
Throttle a c t u a t o r control
module relay*
Headlight relay 1
3
e 4
• 2
• © 4 2
Headlight relay 2
High b e a m c u t r e l a y
(Except '00-05 U S A models)
Horn relay
3
Ignition coil r e l a y *
3 1 3
e e
3
P G M - F I m a i n r e l a y I*
3
PGM-FI main relay 2 *
Radiator fan relay
Starter cut relay
Taillight relay
Rear w i n d o w defogger relay
Blower motor relay Normally open
typeB
Intermittent w i p e r r e l a y * 2
Five terminal
type A
A C C cut relay Five terminal
IG2 cut relay typeB
1
Intermittent w i p e r r e l a y *
Rear w i n d o w defogger
2
change relay*
Rear w i n d o w defogger relay
* 1:'00-01 m o d e l s
* 2: ' 0 2 - 0 8 m o d e l s
* 3: ' 0 6 - 0 8 m o d e l s
* 4: C R m o d e l
22-48
Normally-open type B
C h e c k for c o n t i n u i t y b e t w e e n t h e t e r m i n a l s .
• T h e r e s h o u l d b e continuity b e t w e e n the No. 3 a n d

N o . 4 t e r m i n a l s w h e n battery p o s i t i v e t e r m i n a l is
c o n n e c t e d to the No. 1 t e r m i n a l , a n d battery n e g a t i v e
t e r m i n a l is c o n n e c t e d to t h e N o . 2 t e r m i n a l .
• T h e r e s h o u l d b e no continuity b e t w e e n t h e N o . 3 a n d
No. 4 t e r m i n a l s w h e n p o w e r is d i s c o n n e c t e d .
e1 3
2 4
Relays
Power Relay Test (cont'd)
Five-terminal type A Five-terminal type B
C h e c k for c o n t i n u i t y b e t w e e n t h e t e r m i n a l s . C h e c k for continuity b e t w e e n t h e t e r m i n a l s .
• T h e r e should be continuity between the No. 1 a n d • T h e r e s h o u l d b e c o n t i n u i t y b e t w e e n t h e No. 1 a n d

No. 2 t e r m i n a l s w h e n battery p o s i t i v e t e r m i n a l i s N o . 2 t e r m i n a l s w h e n battery p o s i t i v e t e r m i n a l is
c o n n e c t e d to t h e N o . 5 t e r m i n a l , a n d battery n e g a t i v e c o n n e c t e d to t h e N o . 5 t e r m i n a l , a n d battery n e g a t i v e
t e r m i n a l is c o n n e c t e d to t h e N o . 3 t e r m i n a l . t e r m i n a l is c o n n e c t e d to t h e No. 3 t e r m i n a l .
• T h e r e should be continuity between the No. 1 a n d • T h e r e s h o u l d b e c o n t i n u i t y b e t w e e n t h e No. 1 a n d
No. 4 terminals w h e n p o w e r is disconnected. N o . 4 t e r m i n a l s w h e n p o w e r is d i s c o n n e c t e d .
1
e 5
© ©
1 5 1 5
4 2 3 4 2 3 4 2 3
e e e
I n t e r m i t t e n t w i p e r r e l a y ('02-08 m o d e l s ) • Intermittent w i p e r r e l a y ('00-01 m o d e l s )

• R e a r w i n d o w d e f o g g e r r e l a y ('02-08 m o d e l s )
• R e a r w i n d o w d e f o g g e r c h a n g e r e l a y ('02-08 m o d e l s )
22-50
•BODY •
Ignition Switch
Test
S R S c o m p o n e n t s a r e l o c a t e d in this a r e a . R e v i e w t h e 4. C h e c k for continuity b e t w e e n t h e t e r m i n a l s in e a c h
S R S c o m p o n e n t locations (see page 23-11), and s w i t c h p o s i t i o n a c c o r d i n g to t h e t a b l e .
p r e c a u t i o n s , a n d p r o c e d u r e s ( s e e p a g e 23-13) b e f o r e
p e r f o r m i n g r e p a i r s or s e r v i c e . ^Terminal WHT/ WHT/ BLK/ WHT BLK/
BLK RED (BAT- YEL ORN
RED (BAT- (IG1-A) (IG2-A)
Position \^ (ACC) (IG2-B) A)
B) (IG1-B)
1. M a k e s u r e y o u h a v e the anti-theft c o d e for t h e
0 (LOCK)
1 (ACC) O — —O
II (ON) r\ r\ r\
2. D i s c o n n e c t t h e battery n e g a t i v e c a b l e .
3. D i s c o n n e c t t h e 7 P c o n n e c t o r f r o m t h e u n d e r - d a s h 5. If t h e c o n t i n u i t y c h e c k s d o not a g r e e w i t h t h e t a b l e ,
fuse/relay box. r e p l a c e t h e electrical s w i t c h .
6. After r e c o n n e c t i n g t h e battery, e n t e r the anti-theft

c o d e for t h e a u d i o s y s t e m , t h e n e n t e r t h e a u d i o
p r e s e t s . S e t t h e clock.
22-51
Gauges
V E H I C L E S P E E D S E N S O R (VSS) (00-05 models)

Troubleshooting, page 22-94
S P E E D S E N S O R ('06-08 m o d e l s )
Troubleshooting, page 22-95
FUEL GAUGE
SENDING UNIT
T e s t , page 11-494
GAUGE ASSEMBLY
Bulb Replacement, page 22-56
Self-diagnostic Function, s e e page 22-60
Rewriting the O D O Data and Transferring
the M a i n t e n a n c e M i n d e r Data to a
N e w G a u g e A s s e m b l y , s e e page 22-88
O u t s i d e Air T e m p e r a t u r e Indicator Calibration,
s e e page 22-90
BRAKE FLUID L E V E L SWITCH

T e s t , p a g e 19-12
OIL P R E S S U R E SWITCH
T e s t , page 8-5
O U T S I D E A I R T E M P E R A T U R E S E N S O R ('06-08 m o d e l s )
T e s t , page 22-92
22-52
G a u g e / T e r m i n a l L o c a t i o n I n d e x ('00-03 m o d e l s )
CONNECTOR A CONNECTOR D
(Viewed f r o m the back side)
CONNECTOR B CONNECTOR C
FUELGAUGE
(cont'd)
22-53
Gauges
G a u g e / T e r m i n a l L o c a t i o n I n d e x ('04-07 m o d e l s )
CONNECTOR A CONNECTOR B
(Viewed from the back side)
22-54
G a u g e / T e r m i n a l L o c a t i o n I n d e x ('08 m o d e l )
CONNECTOR A CONNECTOR B
22-55
Gauges
Gauge Bulb Replacement
'00-03 m o d e l s
G A U G E L I G H T S (3.0 W )
G A U G E L I G H T S (2.0 W )
G A U G E LIGHTS
(3.0 W x 3 )
SEAT BELT
REMINDER (Viewed from the back side)
I N D I C A T O R (1.12 W )
LEFT TURN SIGNAL

INDICATOR
(1.12 W )
A B S INDICATOR
S R S INDICATOR
(1.12 W )
(1.12 W )
BRAKE SYSTEM
I N D I C A T O R (1.12 W )
L O W F U E L INDICATOR
(1.12 W ) CHARGING SYSTEM
I N D I C A T O R (1.12 W )
L O W OIL P R E S S U R E
DRL INDICATOR I N D I C A T O R (1.12 W )
(1.12 W )
(Canada models) MALFUNCTION INDICATOR
L A M P ( M I L ) (1.12 W )
IMMOBILIZER INDICATOR
(1.12 W )
DOOR INDICATOR
(1.12 W ) MAINTENANCE REQUIRED INDICATOR (REMINDER)
12 W )
T R U N K INDICATOR CRUISE C O N T R O L INDICATOR
(1.12 W ) (1.4 W )
HIGH B E A M E P S INDICATOR
INDICATOR (1.12 W )
(1.12 W )
22-56
| BODY J
'04-05 m o d e l s
G A U G E L I G H T S (3.0 W x 2 )
LEFT TURN SIGNAL

INDICATOR
RIGHT T U R N SIGNAL (1.12 W )
INDICATOR
(1.12 W ) SEAT BELT
REMINDER INDICATOR
(1.12 W )
HIGH B E A M INDICATOR
(1.12 W ) A B S INDICATOR
,12 W )
(1.12 W ) INDICATOR
12 W )
DRL INDICATOR
(1.12 W ) BRAKE SYSTEM
(Canada models) I N D I C A T O R (1.12 W )
DOOR INDICATOR INDICATOR

(1.12 W )
TRUNK INDICATOR CHARGING S Y S T E M

(1.12 W ) I N D I C A T O R (1.12 W )
G A U G E L I G H T (3.0 W )
(1.12 W )
CRUISE CONTROL MALFUNCTION INDICATOR

I N D I C A T O R (1.4 W ) L A M P ( M I L ) (1.12 W )
MAINTENANCE REQUIRED INDICATOR (REMINDER)

(1.12 W )
22-57
Gauges
Gauge Bulb Replacement (cont'd)
'06-07 m o d e l s
G A U G E L I G H T S (3.0 W x 2)
LEFT TURN SIGNAL

I N D I C A T O R (1.12 W )
RIGHT TURN SIGNAL
A B S INDICATOR
INDICATOR
(1.12 W )
(1.12 W )
V S A I N D I C A T O R (1.12 W )
V S A ACTIVATION
(1.12 W )
I N D I C A T O R (1.12 W )
(1.12 W ) E P S I N D I C A T O R (1.12 W )
S E A T BELT REMINDER
DRL INDICATOR
I N D I C A T O R (1.12 W )
(1.12 W )
BRAKE SYSTEM
I N D I C A T O R (1.12 W )
DOOR INDICATOR
(1.12 W ) I N D I C A T O R (1.12 W )
TRUNK INDICATOR SYSTEM

(1.12 W ) (1.12 W )
G A U G E LIGHT 0W)
(1.12 W )
CRUISE CONTROL MALFUNCTION INDICATOR

I N D I C A T O R (1.4 W ) L A M P (MIL) (1.12 W )
MAINTENANCE MINDER INDICATOR

(1.12 W )
22-58
'08 model
G A U G E L I G H T S (3.0 W x 2 )
T P M S INDICATOR
(1.12 W ) LEFT TURN SIGNAL
I N D I C A T O R (1.12 W )
RIGHT TURN SIGNAL A B S INDICATOR
INDICATOR (1.12 W )
(1.12 W )
V S A I N D I C A T O R (1.12 W )
L O W TIRE P R E S S U R E
V S A ACTIVATION
I N D I C A T O R (1.12 W )
I N D I C A T O R (1.12 W )
(1.12W) E P S I N D I C A T O R (1.12 W )
SEAT BELT REMINDER
D R L I N D I C A T O R (1.12 W ) I N D I C A T O R (1.12 W )
BRAKE SYSTEM
HIGH B E A M INDICATOR I N D I C A T O R (1.12 W )
(1.12 W )
S R S I N D I C A T O R (1.12 W )
DOOR INDICATOR CHARGING SYSTEM

(1.12 W ) I N D I C A T O R (1.12 W )
T R U N K INDICATOR G A U G E L I G H T (3.0 W )
(1.12 W )
L O W OIL P R E S S U R E
G A U G E LIGHT I N D I C A T O R (1.12 W )
IMMOBILIZER INDICATOR MALFUNCTION INDICATOR

(1.12 W ) L A M P ( M I L ) (1.12 W )
CRUISE CONTROL MAINTENANCE MINDER

I N D I C A T O R (1.4 W ) I N D I C A T O R (1.12 W )
22-59
Gauges
Self-diagnostic Function
'06-08 models
T h e g a u g e a s s e m b l y h a s a self-diagnostic function s h o w n , a n d a l s o h a s a customizeable reset function.
• T h e b e e p e r d r i v e circuit c h e c k .
• T h e indicator d r i v e circuit c h e c k .
• T h e s w i t c h input test.
• The L C D segments check.
• T h e c o m m u n i c a t i o n line c h e c k t h e e n g i n e c o o l a n t t e m p e r a t u r e s i g n a l , e n g i n e oil life i n d e x , fuel data r e q u e s t s i g n a l ,
C H E C K F U E L C A P s i g n a l , c h a r g i n g s y s t e m indicator O N / O F F s i g n a l , M I L O N / O F F s i g n a l , a n d c r u i s e control s y s t e m
O N / O F F s i g n a l line b e t w e e n the g a u g e a s s e m b l y a n d t h e E C M ) .
Entering the self-diagnostic function
B e f o r e d o i n g t h e s e l f - d i a g n o s t i c f u n c t i o n , c h e c k t h e No. 5 (7.5 A ) f u s e a n d t h e N o . 2 5 (7.5 A ) f u s e in t h e u n d e r - d a s h

f u s e / r e l a y box.
1. P u s h a n d h o l d t h e T R I P button.
2. T u r n t h e h e a d l i g h t s O N .
4. W i t h i n 5 s e c , turn t h e h e a d l i g h t s O F F , t h e n O N a n d O F F a g a i n .
5. W i t h i n 5 s e c , r e l e a s e t h e T R I P button, a n d t h e n p u s h a n d r e l e a s e the button t h r e e t i m e s r e p e a t e d l y .
NOTE:
• W h i l e in t h e s e l f - d i a g n o s t i c m o d e , t h e d a s h lights b r i g h t n e s s controller o p e r a t e s n o r m a l l y .
• W h i l e in t h e s e l f - d i a g n o s t i c m o d e , t h e T R I P button is u s e d to start the B e e p e r D r i v e Circuit T e s t .
• If the v e h i c l e s p e e d e x c e e d s 1.2 m p h (2 k m / h ) or t h e ignition s w i t c h is t u r n e d O F F , the s e l f - d i a g n o s t i c m o d e e n d s .
Ignition
Switch
Lighting
Switch
TRIP
Button
mm. ~ M o v e to self-diagnostic mode.
5 sec. 5 sec.
22-60
T h e Indicator Drive Circuit C h e c k
W h i l e in t h e s e l f - d i a g n o s t i c m o d e , t h e f o l l o w i n g i n d i c a t o r s blink:
B r a k e s y s t e m indicator, c h a r g i n g s y s t e m indicator, c r u i s e c o n t r o l indicator, l o w fuel indicator, l o w tire p r e s s u r e
1 2
i n d i c a t o r * , m a i n t e n a n c e m i n d e r indicator, m a l f u n c t i o n i n d i c a t o r l a m p (MIL), p e a k p o w e r i n d i c a t o r * , s e a t belt
1
r e m i n d e r indicator, a n d T P M S i n d i c a t o r * .
* 1:'08 m o d e l
* 2: ' 0 8 C R m o d e l
Switch Input Check

After the intermittent b e e p e r s o u n d s at t h e initial s t a g e of s e l f - d i a g n o s i s , a b e e p e r s o u n d s c o n t i n u o u s l y w h i l e a n y of
t h e f o l l o w i n g s w i t c h inputs a r e s w i t c h e d f r o m O F F to O N :
C L O C K button, d r i v e r ' s s e a t belt b u c k l e s w i t c h , i l l u m i n a t i o n ( + ) button, illumination (—) button, p a r k i n g brake s w i t c h ,
r e a r w i n d o w d e f o g g e r s w i t c h , S E L button, T R I P button, w i n d s h i e l d w a s h e r s w i t c h , a n d w i n d s h i e l d w i p e r I N T s w i t c h .
T h e Beeper Drive Circuit C h e c k

W h e n e n t e r i n g t h e s e l f - d i a g n o s t i c m o d e , t h e b e e p e r s o u n d s five t i m e s .
The LCD Segment Check

W h e n e n t e r i n g t h e s e l f - d i a g n o s t i c m o d e , t h e all s e g m e n t s blink five t i m e s .
(cont'd)
22-61
Gauges
Self-diagnostic Function (cont'd)
The Communication Line Check
'06-07 m o d e l s
W h i l e in t h e s e l f - d i a g n o s t i c m o d e , t h e C o m m u n i c a t i o n L i n e C h e c k s t a r t s after t h e L C D S e g m e n t s C h e c k .
If all s e g m e n t s c o m e o n , t h e c o m m u n i c a t i o n line is O K . If t h e r e is a c o m m u n i c a t i o n line e r r o r , t h e w o r d " E r r o r " w i l l b e
indicated on the L C D display.
Normal Faulty
8 8 8 8 8 8 8ii8i
If t h e c o m m u n i c a t i o n line e r r o r is f o u n d , g o to s y m p t o m t r o u b l e s h o o t i n g ( s e e p a g e 22-86).
'08 model
W h i l e in the s e l f - d i a g n o s t i c m o d e , t h e C o m m u n i c a t i o n L i n e C h e c k s t a r t s after t h e L C D S e g m e n t s C h e c k .
If all s e g m e n t s c o m e o n , t h e c o m m u n i c a t i o n line i s O K . If f a u l t y , the w o r d " E r r " will be i n d i c a t e d o n t h e o d o m e t e r
display followed by number(s).
Error C o d e List
Error code T y p e of c o m m u n i c a t i o n line(s) e r r o r
Err1 F-CAN communication
Err 3 E C M communication
E r r 13 F-CAN and E C M communication
E x a m p l e Indication
oooooo
N o r m a l (all s e g m e n t s c o m e o n . ) : F a u l t y ( E r r 13):
oooooo
OOOOOO OO009O
• If t h e w o r d " E r r 1" is i n d i c a t e d , t h e r e is a m a l f u n c t i o n in t h e c o m m u n i c a t i o n line b e t w e e n t h e g a u g e a s s e m b l y , the
f a s t - c o n t r o l l e r a r e a n e t w o r k ( F - C A N ) . C h e c k f o r D T C s in t h e E C M a n d t r o u b l e s h o o t a n y D T C s f o u n d .
If n o D T C s a r e f o u n d , g o to i n d i c a t e d t r o u b l e s h o o t i n g .
• If t h e w o r d " E r r 3 " is i n d i c a t e d , t h e r e is a m a l f u n c t i o n in t h e c o m m u n i c a t i o n line b e t w e e n t h e g a u g e a s s e m b l y , t h e
E C M . C h e c k for D T C s in t h e E C M a n d t r o u b l e s h o o t a n y D T C s f o u n d .
• If t h e w o r d " E r r 1 3 " is i n d i c a t e d , t h e r e is a m a l f u n c t i o n in t h e c o m m u n i c a t i o n line b e t w e e n t h e g a u g e a s s e m b l y , t h e
E C M a n d t h e f a s t - c o n t r o l l e r a r e a n e t w o r k ( F - C A N ) . C h e c k for D T C s in t h e E C M a n d t r o u b l e s h o o t a n y D T C s f o u n d .
If a n y F - C A N o r E C M c o m m u n i c a t i o n line e r r o r is f o u n d , g o to D T C c h e c k u s i n g H D S .
Ending the self-diagnostic function
T u r n t h e ignition s w i t c h O F F .
N O T E : If the v e h i c l e s p e e d e x c e e d s 1.2 m p h (2 k m / h ) , t h e s e l f - d i a g n o s t i c f u n c t i o n e n d s .
22-62
• BODY •
Circuit Diagram
'00-03 models

BATTERY
/BAT-A \
-WHT r O CH BLK/YEL
V V V
EPS
CONTROL
UNIT
(cont'd)
22-63
Gauges
C i r c u i t D i a g r a m (cont'd)
'00-03 models
INTERMITTENT
WPI ER RELAY
^— * WINDSHIELD _.1C
TAILLIGHT V» WP
I ERW
/ ASHER Nj. 45
RELAY 1 3
?U°S E ^H .
CRUISE
CONTROL
UNIT
YEL/BLUBLU/WHT CONTROL
1
UNIT
CRUISE
1 ] 2 CONTROL
rO————On UNIT
VSS
T
G101 G501
22-64
• BODY •
('02-03 models)
REAR KEYLESS
WINDOW DOOR LOCK
DEFOGGER CONTROL
RELAY UNIT
V V
YEL/BLU BLK/WHT
3) i> i)
GAUGE ASSEMBLY C10 B1
1}) LOW FUEL

INDICATOR
MAINTENANCE
REQUIRED
SEAT
BELT
DOOR
INDICATOR
(1.12 W) INDICATOR REMINDER (1.12 W)
(REMINDER) INDICATOR
11.12 W) (1.12 W)
DRIVING DRIVING
CIRCUIT CIRCUIT
CPU
I
H-
C2 KEYLESS C8 D5 A1 B7
v
DOORLOCK
Y
RED/WHT y N r r YEL/BLK BLK/YEL GRN BLU/RED LT GRN/RED
REAR
RED/WHT WINDOW
FUEL
FUEL DEFOGGER
GAUGE
GAUGE SWITCH
SENDING
UNIT UNIT
! I
1 DRIVER'S 1 DRIVER'S 1 PASSENGER'S

qr\ DOOR PIN SEAT BELT °J\ DOOR
J ? J / SWITCH BUCKLE SWITCH
(Closed: [2 SWITCH (Closed:
Door open) (Closed: When Dooropen)
unbuckled)
BLK
G401
1
G601 G601
(cont'd)
22-65
Gauges
'00-03 m o d e l s
TURN SIGNAL/
HAZARO WARNING
SWITCH
V V
GRN/YEL
A7 A8 GAUGE ASSEMBLY
® ® <5 $ $
LEFT TURN
SIGNAL
RIGHT TURN
SIGNAL
MALFUNCTION LOW
INDICATOR OIL
EPS
INDICATOR
INDICATOR INDICATOR LAMP PRESSURE (1.12 W)
(1.12 W) (1.12 W) (MIL) INDICATOR
(1.12 W) (1.12 W)
ABS
INDICATOR
CIRCUIT
D14 D13 A14
v
RED PNK BLK GRN ORN YEL/RED YEL/BLU
V V V
ECM EPS
MODULATOR- UNFT CONTROL
CONTROL UNIT
UNIT
^ OIL
( J ) SWITCH
Engine stopped
Open:
G501
22-66
•BODY m
(USA models) {Canada models)

^"DAYTIME
No. 6 (15 A) No. 45 (20 A) RUNNING LIGHTS
FUSE
Y
FUSE CONTROL UNIT
T Y
BLK/YEL
D12
RED/YEL j RED/WHT
.-J
GAUGE ASSEMBLY
A9
5) TRUNK
~3> BRAKE CHARGING HIGH
INDICATOR SYSTEM SYSTEM BEAM
(1.12 W) INDICATOR INDICATOR INDICATOR
(1.12 W) (1.12 W) (1.12 W)
-M-
A11 D11 A10

CONVERTIBLE
TOP CONTROL
BLU/BLK GRN WHT UNIT GRN 'RED WHT/BLU RED/BLU
DAYTIME
RUNNING
LIGHTS
CONTROL
V V
Y Y
UNIT
LIGHT (Canada models) ALTERNATOR COMBINATION
LIGHT SWITCH
BLU/ BLK
13
BLU/BLK
TRUNK
GRN/WHT
PARKING
GRN/WHT
GRN/RED
- GRN/RED
-< DAYTIME
RUNNING
LIGHTS
CONTROL
UNIT
(Canada models)
LID BRAKE
I A]) UTCH SWITCH
v
f f SWITCH (Closed:
2
I (Oosed: Lever pulled)
I Trunk open)
BLK
22-67
Gauges
'04-05 m o d e l s

BATTERY
GAUGE ASSEMBLY
LCD DISPLAY
• SPEEDOMETER
• TACHOMETER
• ODO/TRIP INDICATOR
• FUEL GAUGE
. COOLANT TEMPERATURE DRIVING
GAUGE CIRCUIT
• CLOCK
>
DRL IMMOBILIZER
INDICATOR INDICATOR
{1.12 W) (1.12 W)
CPU CPU
i — r i — r
DASH LIGHTS
•ODO/TRIP SWITCH CLOCK
BRIGHTNESS
•mph/km/h SWITCH SWITCH
CONTROLLER
BLU/WHT YEL/BLK
V V
ECM
DAYTIME FUEL
RUNNING FUEL GAUGE
LIGHTS GAUGE SENDING
CONTROL UNIT UNIT
|^ UNIT j
UNIT
{Canada models)
G601
22-68
• BODY •
INTERMITTENT
WIPER RELAY
> WINDSHIELD J C
Via WIPER/WASHER go.45

3
KJSE . S W T C >
? , RJSE
G301
(cont'd)
22-69
Gauges
'04-05 m o d e l s
REAR KEYLESS
WINDOW DOORLOCK
DEFOGGER CONTROL
RELAY UNIT
GAUGE ASSEMBLY
V
YEL/ BLU
B13
Y
BLK/WHT
A5
$ MAINTENANCE
REQUIRED
<h <b SEAT
BELT
DOOR
INDICATOR
INDICATOR REMINDER (1.12 W)
(REMINDER) INDICATOR
(1.12 W) (1.12 W)
DRIVING DRIVING
CIRCUIT CIRCUIT
CPU
-w-
-M-
-w-
KEYLESS , B5 B15 A14 B4 A13
DOOR LOCK
CONTROL V C I
UNIT Y E L
' GRN BLU BLK/YEL GRN BLU/RED LT GRN/RED
V V V
REAR
ECM
WINDOW
DEFOGGER
SWITCH
i DRIVER'S , J DRIVER'S 4 PASSENGER'S

DOOR qTN SEAT BELT ^ DOOR
SWITCH 01/ BUCKLE SWITCH
(Closed: 2 SWITCH (Closed:
Door open) (Closed: When Dooropen)
unbuckled)
BLK
_0_
G401 G601
22-70
• BODY •
TURN SIGNAL/
HAZARD WARNING
SWITCH
V V
GRN 'RED GRN/YEL
$ $ <5 3) S
B30 GAUGE ASSEMBLY
LEFT TURN RIGHT TURN MALFUNCTION LOW EPS

SIGNAL SIGNAL INDICATOR OIL INDICATOR
INDICATOR MDICATOR PRESSURE (1.12 W)
(1.12 W) (1.12 W) (ML) INDICATOR
(1.12 W) (1.12 W)
ABS
INDICATOR
CIRCUIT
B20 A18 B27 B21
vv
BLU/RED BLK GRN/ORN YEU RED YEL/BLU
ABS SRS UNIT

VECM
MODULATOR- CONTROL
CONTROL UNIT
UNIT
, OIL
o PRESSURE
SWITCH
(Closed:
Engine stopped
Open:
Engine running)
G501
(cont'd)
22-71
Gauges
'04-05 m o d e l s
(USA models) (Canada models)
^"DAYTIME
No. 45 (20 A) RUNNING UGHTS
FUSE CONTROL UNIT
V
RED/YEL
! 0
j
Y.
REDjWHT
GAUGE ASSEMBLY
TRUNK
INDICATOR
CHARGN
SYSTEM
IG
® HIGH
BEAM
(1.12 W) INDICATOR INDICATOR
(1.12 W) (1.12 W)
A16
BLU/BLK RED/BLU
TRUNK
Y
LIGHT
ALTERNATOR
V
COMBINATION
LIGHT SWITCH
BLU/BLK
BLU, BLK
3 TRUNK
] ) LATCH
f SWITCH
i
2
(Closed:
Trunk open)
G601
22-72
• BODY •
'06-08 m o d e l s

: CAN line
No. 41 (100 A) No. 42 (40 A)
— c r \ j o — -CTXJ3— -WHT BLK/YEL
No. 54 (30 A)
1
-YEL
UNDER-DASH
1 FUSE/RELAY
No. 25 ' No. 5
BOX
(7.5 A) (7.5 A)
WHT RED YEL
WHT/RED WHT RED
GAUGE ASSEMBLY
LCD DISPLAY
3
• SPEEDOMETER
• TACHOMETER
• ODO/TRIP INDICATOR
• FUELGAUGE
• COOLANTTEMPERATURE
GAUGE
-H-
• CHECK FUEL CAP
• CLOCK
• OUTSIDE AIRTEMPERATURE
• MAINTENANCE VOtTAGE DRIVING
MINDER INDICATOR FEED CIRCUIT
DRL IMMOBILIZER
MINI
INDICATOR INDICATOR
(1.12 W) (1.12 W)
1=^
F-CAN DASH LIGHTS
•ODO/TRIP SWITCH CLOCK
TRANCEIVER BRIGHTNESS
•mph/km/h SWITCH SWITCH
CAN2H CAN2L CONTROLLER
MA/V-* I i VW
•,A22
124Q I B10
l l YEL/BLK
WHT RED
V
DAYTIME
V
IMMOBILIZER
i vv
RUNNING CONTROL UNIT- FUEL
TPMS FUEL
LIGHTS RECEIVER GAUGE
CONTROL GAUGE
CONTROL SENDING
UNIT UNIT UNIT
L.._!?_.._
('08 model)
(cont'd)
22-73
Gauges
'06-08 m o d e l s
TAILLIGHT
RELAY
V
RED/BLK
A8
JL. TPMS LOLOW TIRE CHARGN IG GAUGE

(a\ INDICATOR (S) PRE ISSURE SYSTEM LIGHTS
V J y H.12W) Vjp/
IN DICATOR
INI12 W)
INDICATOR VX/ (3Wx2) VJp/ (3Wx2
.12 W) 2Wx5)
DRIVING DRIVING DRIVING FREQUENCY DRIVING DRIVING

CIRCUIT CIRCUIT CIRCUIT DIVIDING CIRCUIT CIRCUIT CIRCUIT
I
CPU 2 *
DRIVING DRIVING DRIVING
FILTER CIRCUIT CIRCUIT CIRCUIT
:B26 : A11 B7 A17 A19

ECM
GRY (WHT WHTB
]LK LK BLK/WHT RED
VA
V <7
DATA LINK
BLUl//W
V HT I
EPS
A A
HEATER DASH
CONNECTOR CONTROL CONTROL UGHTS
(DLC) UNIT PANEL
ECM CONVERTB
I LE
SRS UNIT TOP
TPMS YEL/BLU BLU/WHT CONTROL
CONTROL UNIT1 #
UNIT
VSA
MODULATOR-
CONTROL UNIT
|l
OUTPUT SHAFT
(COUNTERSHAFT)
3
IN
A23
ECM
G501
22-74
*1:'08 model
*2:CR model
: Other communication line
INTERMITTENT
WIPER RELAY
WINDSHIELD
Via WIPER/WASHER
No. 13 SWITCH
FUSE
W W
IB25 CONVERTIBLE B5 KEYLESS B15

TOP CONTROL DOORLOCK
CONTROL
PNK DAYTIME GRNTWHT GRN/RED BLK/YEL RED/WHT UNIT BLU BLK/YEL
RUNNING IMOES
LIGHTS UNIP1
CONTROL
UNIT
IMMOBIUZER
V Y V
ECM
V
REAR
CONTROL UNIT-
RECEIVER WINDOW
RED/WHT DEFOGGER
('06-08 models) I SWITCH
Y
GRN/WHT
RED/WHT
3
IGNITION
KEY
VSA
v GRN/WHT
1 PARKING V/J BRAKE
1
SWITCH
(Closed:
Key inserted)
MODULATOR- BRAKE N< FLUID
CONTROL I SWITCH 1
LEVEL
UNIT (Closed: '
B K SWITCH
Lever pulled) i (Closed:
I Float down)
G301 G401
(cont'd)
22-75
Gauges
'06-08 m o d e l s
22-76
TURN SIGNAL/
HAZARD WARNING DAYTIME
SWITCH RUNNING LIGHTS
CONTROL UNIT
V
GRN/RED
B29
V
GRN/YEL
Y
RED/WHT
GAUGE ASSEMBLY
® 2) 55 5>
A15
LEFT TURN RIGHT TURN LOW TRUNK HIGH

SIGNAL SIGNAL OIL INDICATOR BEAM
INDICATOR INDICATOR PRESSURE (1.12 W) INDICATOR
(1.12 W) (1.12 W) INDICATOR
(1.12 W)
(1.12 W|
A18 B27 A12 A16
r"
YEL/ RED
BLU/BLK YEL
TRUNK
Y
LIGHT
DIODE I
RED BLU
BLU/BLK
OIL BLU/BLK RED/BLU RED/ORN
| SWITCH
(Closed:
Engine stopped
Open:
Engine running)
V
COMBINATION
V
DAYTIME
v
COMBINATION
LIGHT SWITCH RUNNING LIGHT SWITCH
LIGHTS
CONTROL UNIT ^
(Canada models)
G501 G601 (USAinodels)
Gauges
DTC Description Note

B1152* 1
G a u g e a s s e m b l y C P U abnormality ( s e e p a g e 22-80)
B1173* 3
G a u g e a s s e m b l y lost c o m m u n i c a t i o n w i t h T P M S control unit ( T P M S ( s e e p a g e 22-80)
message)
B1175* 1
F u e l g a u g e unit circuit o p e n ( s e e p a g e 22-82)
B1176* 1
F u e l g a u g e unit circuit s h o r t ( s e e p a g e 22-83)
2
B1177* IG1 circuit l o w v o l t a g e ( s e e p a g e 22-84)
B1178* 3
F - C A N c o m m u n i c a t i o n line e r r o r ( s e e p a g e 22-80)
* 1:'06-08 m o d e l s
* 2: '06-07 m o d e l s
* 3: ' 0 8 m o d e l
22-78
'06-08 m o d e l s

E r r o r is i n d i c a t e d o n t h e L C D d i s p l a y S y m p t o m T r o u b l e s h o o t i n g ( s e e p a g e 22-86)
22-79
Gauges
DTC Troubleshooting
DTC B1152: Gauge Assembly CPU DTC B1173: Gauge Assembly Lost
Abnormality Communication with TPMS Control Unit
(TPMS message)
DTC B1178: F-CAN Communication Line Error
1. C l e a r t h e D T C s w i t h the H D S .
3. T u r n t h e ignition s w i t c h O F F , t h e n t u r n it O N (II).
2. T u r n t h e ignition s w i t c h O F F , a n d t h e n b a c k O N (II).
3. W a i t for 6 s e c o n d s or m o r e .
Is DTC B1152 indicated?
4. C h e c k f o r D T C s w i t h the H D S .
22-89). • Are DTCs B1173 or 1178 indicated?
N O — I n t e r m i t t e n t f a i l u r e , t h e s y s t e m is O K at t h i s Y E S — G o t o s t e p 5.
at the g a u g e a s s e m b l y . • N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m is O K at this
t i m e . C h e c k for l o o s e or p o o r c o n n e c t i o n s . •
5. C h e c k for T P M S D T C s w i t h the H D S .
Is any DTCs indicated?
Y E S — G o to t h e indicated D T C s , t h e n r e c h e c k .
7. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r A (22P).
8. D i s c o n n e c t t h e T P M S control unit 2 0 P c o n n e c t o r .
22-80
• BODY •
9. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y 11. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y

c o n n e c t o r A (22P) No. 21 a n d N o . 2 2 t e r m i n a l s a n d c o n n e c t o r A (22P) N o . 21 a n d No. 2 2 t e r m i n a l s a n d
b o d y g r o u n d individually. t h e T P M S control unit 2 0 P c o n n e c t o r No. 1 a n d
No. 11 t e r m i n a l s r e s p e c t i v e l y .
1 2 3 4 5 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
11 12 13 14 15 16
4 5 7 8
17 18 19 20 21 22
9 10
X CAN2L CAN2H
X CAN2L CAN2H
(RED) (WHT)
(RED) (WHT)
CAN2H
(WHT)
W i r e s i d e of f e m a l e t e r m i n a l s il/l/H/l/Haj/r
1
C A N 2 L (RED)
Is there continuity? T P M S C O N T R O L UNIT 20P C O N N E C T O R
Y E S — R e p a i r t h e s h o r t to b o d y g r o u n d o n t h e
appropriate write. • Is there continuity?
N O — G o to s t e p 10. Y E S — S u b s t i t u t e a k n o w n - g o o d T P M S control unit,

a n d r e c h e c k . If t h e i n d i c a t i o n g o e s a w a y , r e p l a c e
10. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y t h e original T P M S control unit. If t h e D T C is still
c o n n e c t o r A (22P) No. 21 a n d N o . 22 t e r m i n a l s . present, replace the g a u g e a s s e m b l y (see page
22-89). •
N O — R e p a i r a n o p e n in t h e w i r e . •
1 2 3 4 5 7 8 9 10 C A N 2 H
(WHT)
11 12 13 14 15 16 18 19 20 21 22
CAN2L
(RED)
Y E S — R e p a i r s h o r t in the w i r e b e t w e e n g a u g e
a s s e m b l y A (22P) c o n n e c t o r No. 21 ( C A N 2 L L i n e )
a n d No. 22 ( C A N 2 H Line) t e r m i n a l s . !
22-81
Gauges
DTC B1175: Fuel Gauge Unit Circuit Open 6. W i t h o u t d i s c o n n e c t i n g t h e g a u g e a s s e m b l y or f u e l

g a u g e s e n d i n g unit c o n n e c t o r , m e a s u r e the v o l t a g e
1. T u r n t h e ignition s w i t c h O N (II). b e t w e e n g a u g e a s s e m b l y c o n n e c t o r B (30P) N o . 10
t e r m i n a l a n d fuel g a u g e s e n d i n g unit 5 P c o n n e c t o r
2. C l e a r t h e D T C w i t h the H D S . No. 2 terminal, and between gauge a s s e m b l y
c o n n e c t o r B (30P) N o . 2 t e r m i n a l a n d f u e l g a u g e
3. T u r n t h e ignition s w i t c h O F F , t h e n t u r n it O N (II). s e n d i n g unit 5 P c o n n e c t o r No. 1 t e r m i n a l .
G A U G E A S S E M B L Y C O N N E C T O R B OOP)
4. W a i t m o r e t h a n 30 s e c o n d s .
E IL.IX

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N O — I n t e r m i t t e n t f a i l u r e , the s y s t e m i s O K at t h i s
BLK YEL/BLK
at t h e g a u g e a s s e m b l y a n d t h e f u e l g a u g e s e n d i n g
unit.B
\ZE7
F U E L G A U G E S E N D I N G UNIT 5P C O N N E C T O R
Is there less than 0.1 V?
N O — R e p a i r a n o p e n in the w i r e b e t w e e n the g a u g e
a s s e m b l y a n d the fuel gauge sending u n i t . B
7. T e s t t h e fuel g a u g e s e n d i n g unit ( s e e p a g e 11-494).
Is the fuel gauge sending unit normal?
22-89). •
N O — R e p l a c e the fuel g a u g e s e n d i n g unit ( s e e p a g e

11-488).B
22-82
DTC B1176: Fuel Gauge Unit Circuit Short 6. T u r n t h e ignition s w i t c h O F F .
1. T u r n t h e ignition s w i t c h O N (II). 7. D i s c o n n e c t t h e fuel g a u g e s e n d i n g unit 5 P

connector.
2. C l e a r t h e D T C with t h e H D S .
3. T u r n t h e ignition s w i t c h O F F , t h e n turn it O N (II).
9. C l e a r t h e D T C s w i t h t h e H D S .
4. W a i t m o r e t h a n 3 0 s e c o n d s .
10. W a i t m o r e t h a n 3 0 s e c o n d s .
t i m e . C h e c k for p o o r c o n n e c t i o n s o r l o o s e t e r m i n a l s N O — R e p l a c e t h e fuel g a u g e s e n d i n g unit ( s e e p a g e
at t h e g a u g e a s s e m b l y a n d t h e fuel g a u g e s e n d i n g 11-488).B
unit.B
13. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P).
(cont'd)
22-83
Gauges
14. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y DTC B1177: IG1 Circuit Low Voltage
c o n n e c t o r B (30P) N o . 10 t e r m i n a l a n d b o d y g r o u n d .
YEL/BLK 3 . T u r n t h e ignition s w i t c h O F F , t h e n turn it O N (II).
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30 4. C h e c k for D T C s w i t h t h e H D S .
W i r e side of f e m a l e t e r m i n a l s N O — G o to s t e p 5.
Y E S — R e p a i r a s h o r t to g r o u n d b e t w e e n t h e g a u g e
a s s e m b l y a n d t h e fuel g a u g e s e n d i n g unit. • 7. S t a r t t h e e n g i n e .
N O — R e p l a c e the g a u g e a s s e m b l y ( s e e p a g e 22-89). 8. C h e c k for D T C s w i t h t h e H D S .
at the g a u g e a s s e m b l y . •
22-84
9. C h e c k t h e battery c o n d i t i o n ( s e e p a g e 2 2 - 4 7 ) .
Is the battery normal?
N O — C h a r g e t h e battery, o r r e p l a c e it. •
10. T u r n t h e ignition s w i t c h O N (UK
11. W i t h the c o n n e c t o r s c o n n e c t e d , m e a s u r e t h e
voltage between gauge a s s e m b l y connector A
(22P) N o . 9 t e r m i n a l a n d b o d y g r o u n d .
1 2 3 4 5 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
X
22-89). •
N O — I n c r e a s e of circuit r e s i s t a n c e ; c h e c k t h e IG1
circuit b e t w e e n the ignition s w i t c h a n d t h e g a u g e
assembly. •
Gauges
Error is indicated on the LCD display 7. C h e c k f o r continuity b e t w e e n g a u g e a s s e m b l y

c o n n e c t o r B (30P) N o . 2 6 t e r m i n a l a n d E C M
1. T u r n t h e ignition s w i t c h O N (II). c o n n e c t o r E (31P) N o . 13 t e r m i n a l .
2. C h e c k for PGM-FI s y s t e m D T C s with the H D S . GAUGE ASSEMBLY CONNECTOR B (30P)

Are there PGM-FI system DTCs?

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Y E S — D o the D T C troubleshooting, then do the
JYEL
g a u g e a s s e m b l y self-diagnosis (see page 22-60). •
11
1
T
1 / s 4 5 7 8 9
4. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P). / 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
YEL / 27 28 29 30
/
6. D i s c o n n e c t E C M c o n n e c t o r E (31P). ECM CONNECTOR E (31P)
N O — R e p a i r a n o p e n in t h e w i r e b e t w e e n t h e g a u g e
a s s e m b l y and the E C M . H
22-86
c o n n e c t o r B (30P) No. 2 6 t e r m i n a l a n d b o d y g r o u n d .
G A U G E A S S E M B L Y C O N N E C T O R B OOP)
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Y E S — R e p a i r a s h o r t to g r o u n d in t h e w i r e b e t w e e n
the g a u g e a s s e m b l y a n d the E C M . B
9. R e c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P).
11. M e a s u r e t h e v o l t a g e b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r B (30P) N o . 2 6 t e r m i n a l a n d b o d y g r o u n d .
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YEL
Y E S — R e p l a c e the E C M . B
• ' 0 0 - 0 5 m o d e l s ( s e e p a g e 11-115)
• '06-08 m o d e l s ( s e e p a g e 11-389)
N O — R e p l a c e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).
Gauges
Rewriting the ODO Data and Transferring the Maintenance Minder Data to a
New Gauge Assembly
3 . W i t h t h e ignition s w i t c h O F F , r e c o n n e c t the original
NOTE: gauge assembly.
• O b t a i n a n e w g a u g e a s s e m b l y before starting the
rewriting p r o c e s s . 4 . C o m p l e t e l y re-boot the H D S .
• R e w r i t i n g is not p o s s i b l e o n a g a u g e a s s e m b l y that
w i l l not c o m m u n i c a t e w i t h t h e H D S . 5. Clear any stored D T C s .
• M a k e s u r e that the H D S s h o w s t h e c o r r e c t V I N for t h e
car you are working on. 6 . N a v i g a t e to B o d y E l e c t r i c / G a u g e s / A d j u s t m e n t /
• O n c e y o u have started this procedure, y o u m u s t Instrument Panel Replacement.
c o m p l e t e it b e f o r e r e m o v i n g t h e H D S f r o m t h e D L C .
• C o n n e c t a battery j u m p e r b o x (not a battery c h a r g e r ) 7. Select " 3 . Releasing Locked O D O Value."
to i n s u r e t h a t c o r r e c t battery v o l t a g e will be
maintained. 8 . F o l l o w the p r o m p t s a n d the O d o m e t e r m i l e a g e will
be restored.
1. B e f o r e r e p l a c i n g the g a u g e a s s e m b l y , c o n n e c t t h e
HDS. 9 . Start over and make sure the s c r e e n prompts are
followed.
2 . S e l e c t G A U G E S f r o m the B O D Y E L E C T R I C A L
s y s t e m s e l e c t m e n u w i t h the H D S .
3. Select "Gauge Assembly Replacement (ODO

Rewrite)" from the A D J U S T M E N T m e n u , a n d
f o l l o w t h e i n s t r u c t i o n s o n t h e d i s p l a y to retrieve t h e
O D O v a l u e a n d the M a i n t e n a n c e M i n d e r
Information.
4 . R e p l a c e the g a u g e a s s e m b l y .
5 . F o l l o w the i n s t r u c t i o n s o n the d i s p l a y to w r i t e the

n e w O D O v a l u e a n d M a i n t e n a n c e M i n d e r d a t a to
the n e w g a u g e a s s e m b l y . If t h e data t r a n s f e r f a i l s ,
refer to t h e i n s t r u c t i o n s b e l o w to r e l e a s e t h e l o c k e d
O D O value.
Release Locked odometer mileage to the

original gauge assembly.
If after y o u a t t e m p t to t r a n s f e r m i l e a g e , the n e w
odometer has dashes ( ), g a r b l e d , or a n i n c o r r e c t
v a l u e d i s p l a y e d , d o the f o l l o w i n g :
S t a r t o v e r . T h e o r i g i n a l g a u g e a s s e m b l y is g o i n g to be
u n l o c k e d a n d r e s t o r e d to its original state.
1. C o n f i r m that y o u h a v e the latest H D S v e r s i o n of

software.
2 . M a k e s u r e that the H D S s h o w s t h e c o r r e c t V I N for

the car y o u are working on.
22-88
Gauge Assembly Replacement
4. D i s c o n n e c t t h e c o n n e c t o r s (D), a n d r e m o v e the
N O T E : Before r e p l a c i n g t h e g a u g e a s s e m b l y , d o the gauge assembly.
" R e w r i t i n g the O D O Data a n d T r a n s f e r r i n g t h e
M a i n t e n a n c e M i n d e r Data to a N e w G a u g e a s s e m b l y " N O T E : '04-08 m o d e l s only have two connectors.
( s e e p a g e 22-88).
5. R e m o v e the s c r e w s a n d the g a u g e a s s e m b l y
1. L o w e r the s t e e r i n g c o l u m n , a n d r e m o v e t h e d r i v e r ' s brackets.
airbag, steering w h e e l , steering c o l u m n c o v e r s
cable reel, and combination switch a s s e m b l y
( s e e p a g e 17-9).
2. R e m o v e the i n s t r u m e n t p a n e l ( s e e p a g e 20-84).
3. R e m o v e the s c r e w s (A) f r o m the g a u g e a s s e m b l y

(B), a n d s p r e a d a protective cloth (C) o n the
steering column.
D B
6. Install in the r e v e r s e o r d e r of r e m o v a l .
22-89
Gauges
Outside Air Temperature Indicator Calibration
Description Update to the outside air temperature

indicator while driving
T h e o u t s i d e t e m p e r a t u r e s e n s o r is l o c a t e d b e h i n d t h e
c e n t e r of the front b u m p e r . T h e g a u g e a s s e m b l y u s e s If t h e t e m p e r a t u r e m e a s u r e d b y t h e o u t s i d e air
m e a s u r e m e n t s f r o m t h i s s e n s o r to d i s p l a y t h e o u t s i d e t e m p e r a t u r e s e n s o r is g r e a t e r t h a n t h e t e m p e r a t u r e o n
air t e m p e r a t u r e . t h e o u t s i d e air t e m p e r a t u r e indicator, t h e o u t s i d e
B e c a u s e of t h e l o c a t i o n of t h e s e n s o r , it m a y b e a f f e c t e d t e m p e r a t u r e indicator will i n c r e a s e b y 1 °F (1 *€) per
b y h e a t , reflection f r o m t h e r o a d , e n g i n e a n d r a d i a t o r 3 4 s e c o n d s (1 m i n u t e ) after t h e v e h i c l e s p e e d is g r e a t e r
h e a t or hot e x h a u s t f r o m s u r r o u n d i n g traffic. t h a n 19 m p h (30 k m / h ) for m o r e t h a n 3 0 s e c o n d s . It w i l l
T h e s e conditions c a n heat soak the outside air c o n t i n u e to i n c r e a s e until t h e c u r r e n t o u t s i d e air
temperature sensor and c a u s e inaccurate readings. t e m p e r a t u r e is i n d i c a t e d . S o , t h e first c h a n g e to the
L o g i c h a s b e e n w r i t t e n into t h e g a u g e a s s e m b l y to h e l p o u t s i d e air t e m p e r a t u r e indicator is 3 4 s e c o n d s
p r e v e n t a b n o r m a l of f l u c t u a t i n g o u t s i d e a i r t e m p e r a t u r e (1 m i n u t e ) after t h e v e h i c l e s p e e d is g r e a t e r t h a n
indicator r e a d i n g s . 19 m p h (30 k m / h ) . If t h e v e h i c l e s p e e d d r o p s b e l o w
19 m p h (30 k m / h ) , the i n d i c a t o r will not u p d a t e a g a i n
Outside Air Temperature Indicator Logic until t h e v e h i c l e s p e e d is i n c r e a s e d to 19 m p h (30 k m / h )
or m o r e for m o r e t h a n 30 s e c o n d s a g a i n .
Initial o u t s i d e air t e m p e r a t u r e i n d i c a t i o n after t h e
ignition s w i t c h is t u r n e d O N (II). If t h e o u t s i d e a i r t e m p e r a t u r e is l e s s t h a n 140 °F (60 °C),
t h e t e m p e r a t u r e i n c r e a s e s 1 °F (1 °C) e v e r y 2 s e c o n d s
• If t h e e n g i n e c o o l a n t t e m p e r a t u r e is 140 °F (60 °C) o r until the c u r r e n t o u t s i d e air t e m p e r a t u r e .
h i g h e r w h e n t h e ignition s w i t c h is t u r n e d O N (II), t h e
o u t s i d e air t e m p e r a t u r e w i l l b e i n d i c a t e d t h e last If t h e o u t s i d e a i r t e m p e r a t u r e is l e s s t h a n the i n d i c a t e d
r e a d i n g before t h e k e y w a s t u r n e d off r e g a r d l e s s of t e m p e r a t u r e , t h e t e m p e r a t u r e will d e c r e a s e 1 °F (1 *C)
t h e c u r r e n t t e m p e r a t u r e m e a s u r e d by t h e o u t s i d e air e v e r y 2 s e c o n d s until t h e c u r r e n t o u t s i d e air
temperature sensor. t e m p e r a t u r e is i n d i c a t e d r e g a r d l e s s of v e h i c l e s p e e d .
• If the e n g i n e c o o l a n t t e m p e r a t u r e is 139 °F (59 °C) o r
l o w e r w h e n t h e ignition s w i t c h i s t u r n e d O N (II), t h e Troubleshooting
current temperature m e a s u r e d by the outside air
temperature s e n s o r will be indicated. If t h e indicator d i s p l a y s " " for m o r e t h a n
2 s e c o n d s after s e l e c t i n g t h e o u t s i d e a i r t e m p e r a t u r e
d i s p l a y m o d e , c h e c k t h e o u t s i d e air t e m p e r a t u r e s e n s o r ,
o r g a u g e a s s e m b l y s e l f - d i a g n o s i s ( s e e p a g e 22-60).
22-90
Calibration N O T E : T o r e c a l i b r a t e t h e d i s p l a y to t h e t r u e
t e m p e r a t u r e , r e m o v e t h e o u t s i d e air t e m p e r a t u r e
T h e o u t s i d e air t e m p e r a t u r e i n d i c a t o r ' s d i s p l a y e d s e n s o r (A), but l e a v e it c o n n e c t e d . S u b m e r g e t h e
t e m p e r a t u r e c a n b e r e c a l i b r a t e d ± 5 °F (or ± 3 °C) to s e n s o r a n d a t h e r m o m e t e r (B) in a c o n t a i n e r of i c e
m e e t the c u s t o m e r ' s expectations. w a t e r (C). S e l e c t t h e c a l i b r a t i o n m o d e a s d e s c r i b e d
a b o v e , t h e n r e c a l i b r a t e t h e d i s p l a y to t h e true
1. T u r n the ignition s w i t c h O N (II). temperature.
2. S e l e c t the o u t s i d e air t e m p e r a t u r e d i s p l a y . B
3. P r e s s a n d h o l d t h e trip button for 10 s e c o n d s . W h i l e

y o u c o n t i n u e to hold t h e button, t h e d i s p l a y will
scroll through temperature settings from
+ 5 °F to —5 °F (or 4 3 °C to - 3 °C) a s s h o w n .
L r* i 3 3 I_I c _C _3 - D _ ' J
4 . W h e n the d e s i r e d c o r r e c t i o n v a l u e a p p e a r s o n t h e
d i s p l a y , r e l e a s e t h e button, a n d t h e r e c a l i b r a t e d
o u t s i d e air t e m p e r a t u r e will b e d i s p l a y e d .
Example:
Incorrect value = 6 8 °F (20 °C)
Desired correction value = + 2 °F ( + 1 *C)

Correct value = 7 0 T (21 °C)
Desired correction value = — 2 *F (—1 *€)

Correct value = 6 6 ° F (19 °C)
N O T E : T h e r e c a l i b r a t i o n t e m p e r a t u r e is not t h e
v a l u e the s e n s o r s e e s . T h e r e f o r e t h e t e m p e r a t u r e
c a n o n l y be a d j u s t e d ± 5 d e g r e e s f r o m the s e n s o r .
22-91
Gauges
Outside Air Temperature Sensor Outside Air Temperature Sensor
Test Replacement
1. R e m o v e t h e o u t s i d e a i r t e m p e r a t u r e s e n s o r 1. Lift t h e t a b (A) to r e l e a s e t h e lock, t h e n r e m o v e the

( s e e p a g e 22-92). o u t s i d e air t e m p e r a t u r e s e n s o r (B) f r o m t h e s e n s o r
c l i p . D i s c o n n e c t t h e 2 P c o n n e c t o r (C) f r o m t h e
2 . Dip t h e s e n s o r in i c e w a t e r , a n d m e a s u r e t h e o u t s i d e air t e m p e r a t u r e s e n s o r .
resistance. T h e n pour w a r m water on the s e n s o r ,
a n d c h e c k for a c h a n g e in r e s i s t a n c e .
3. C o m p a r e the resistance reading between the No. 1

a n d N o . 2 t e r m i n a l s of the o u t s i d e air t e m p e r a t u r e
s e n s o r w i t h t h e s p e c i f i c a t i o n s s h o w n in t h e g r a p h ;
t h e r e s i s t a n c e s h o u l d be w i t h i n t h e s p e c i f i c a t i o n s .
O U T S I D E AIR T E M P E R A T U R E S E N S O R
2. Install the s e n s o r in the r e v e r s e o r d e r of r e m o v a l .
14 32 50 68 8 6 104 T
-10 0 10 20 3 0 4 0 <C
TEMPERATURE
4. If t h e r e s i s t a n c e is not a s s p e c i f i e d , r e p l a c e t h e out
s i d e air t e m p e r a t u r e s e n s o r ( s e e p a g e 22-92).
22-92
V S S Replacement
'00-05 models
1. R a i s e t h e v e h i c l e , a n d m a k e s u r e it is s e c u r e l y
supported.
2. D i s c o n n e c t t h e 3 P c o n n e c t o r f r o m t h e v e h i c l e
speed sensor (VSS).
3. R e m o v e t h e m o u n t i n g bolt, t h e n r e m o v e t h e V S S .
4. Install in the r e v e r s e o r d e r of r e m o v a l .
22-93
Gauges
Vehicle Speed Signal Circuit Troubleshooting
'00-05 models 5. M e a s u r e the v o l t a g e b e t w e e n the V S S 3 P

connector No. 1 terminal and body ground.
N O T E : If the M I L is O N , t r o u b l e s h o o t the P G M - F I
p r o b l e m first. V S S 3P C O N N E C T O R
1. R a i s e the v e h i c l e w i t h t h e t r a n s m i s s i o n in n e u t r a l , JT_JT-L_n ,
a n d m a k e s u r e it is s e c u r e l y s u p p o r t e d .
2. D i s c o n n e c t t h e V S S 3 P c o n n e c t o r .
Is there about 5 V?
N O — R e p a i r s h o r t or o p e n in the Y E L / B L U w i r e
between the V S S and the E C M . •
6. R e c o n n e c t the V S S 3 P c o n n e c t o r .
4. C h e c k for continuity b e t w e e n t h e V S S 3 P c o n n e c t o r 7. S l o w l y rotate the p r o p e l l e r shaft.

No. 3 terminal and body ground.
V S S 3P C O N N E C T O R
_n_j—i__n_
N O — R e p a i r a n o p e n o r high r e s i s t a n c e in the B R N /
Y E L wire between the V S S a n d G 1 0 1 . B
22-94
8. M e a s u r e t h e v o l t a g e b e t w e e n g a u g e a s s e m b l y '06-08 models
c o n n e c t o r C (20P) N o . 3 t e r m i n a l a n d b o d y g r o u n d
('00-03 m o d e l s ) o r b e t w e e n g a u g e a s s e m b l y N O T E : If t h e M I L is O N , t r o u b l e s h o o t t h e P G M - F I
c o n n e c t o r B (30P) N o . 7 t e r m i n a l a n d b o d y g r o u n d p r o b l e m first.
('04-05 m o d e l s ) .
1. R a i s e t h e v e h i c l e w i t h t h e t r a n s m i s s i o n in n e u t r a l ,
'00-03 m o d e l s
a n d m a k e s u r e it i s s e c u r e l y s u p p o r t e d .
G A U G E A S S E M B L Y C O N N E C T O R C (20P)
2 . D i s c o n n e c t t h e output s h a f t (countershaft) s p e e d
sensor 3P connector.
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 3. T u r n t h e ignition s w i t c h O N (II).
BLU/WHT
'04-05 m o d e l s
/ 2 3 4
15 16 17 18 19 20 21
5 6 7
2xz 8
24
9 10
/ 12 13
26 27 28 29 30 /
BLU/WHT
/
X
Wire s i d e of female terminals
Does voltage pulse from 0 to about 5 V?
Y E S — C h e c k c o n n e c t i o n s , a n d if n e c e s s a r y , r e p l a c e
t h e printed circuit b o a r d . •
10. D i s c o n n e c t t h e 3 P c o n n e c t o r f r o m t h e v e h i c l e
speed sensor (VSS).
12. M e a s u r e the v o l t a g e b e t w e e n t h e V S S 3 P
Is there about 5 V?
Y E S — R e p l a c e the V S S . B
N O — R e p a i r a s h o r t to g r o u n d or o p e n in the B L U /
WHT wire.B
(cont'd)
22-95
Gauges
Vehicle Speed Signal Circuit Troubleshooting (cont'd)
4. C h e c k for continuity b e t w e e n the output s h a f t 5. M e a s u r e the v o l t a g e b e t w e e n the output shaft
(countershaft) s p e e d s e n s o r 3 P c o n n e c t o r No. 3 (countershaft) s p e e d s e n s o r 3 P c o n n e c t o r N o . 1
t e r m i n a l a n d E C M c o n n e c t o r A (31P) N o . 2 3 terminal and body ground.
terminal.
OUTPUT SHAFT (COUNTERSHAFT) SPEED SENSOR
OUTPUT SHAFT (COUNTERSHAFT) SPEED SENSOR
3PCONECTOR
T e r m i n a l s i d e of m a l e t e r m i n a l s n_r~i_rL_
JT_j—i__n_
YEL/BLU
GRN/YEL
1 2 4 5 6 "7
3 8. 9
10
23 24 /
13 14 15 16 17 is
25 26 / 20 21
30 31
Is there about 5 V?
J GRN/YEL
28
/ / Y E S — G o t o s t e p 6.
W i r e s i d e of f e m a l e t e r m i n a l s N O — R e p a i r s h o r t or o p e n in the Y E L / B L U w i r e
b e t w e e n t h e output s h a f t (countershaft) s p e e d
Is there continuity? s e n s o r a n d the E C M . •
Y E S — G o to s t e p 5. 6. R e c o n n e c t the output s h a f t (countershaft) s p e e d

sensor 3P connector.
N O — R e p a i r a n o p e n o r high r e s i s t a n c e in t h e G R N /
Y E L w i r e b e t w e e n the output s h a f t (countershaft) 7. S l o w l y rotate the p r o p e l l e r shaft.
s p e e d s e n s o r and the E C M . B
22-96
• BODY •
Resetting the Maintenance

Required Indicator
8. M e a s u r e the v o l t a g e b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r B (SOP) N o . 7 t e r m i n a l a n d b o d y g r o u n d .
How to Reset
P u s h a n d h o l d t h e trip button, turn t h e ignition s w i t c h
O N (II), a n d c o n t i n u e h o l d i n g the trip button for m o r e
BLU/WHT
t h a n 10 s e c o n d s .
/
15
2
16
3
17
4
18
5
19
6
20
7
21
22|X|23
8
24
9
25
10
26
11
27 28
12 13
29
14
30 Blinking Pattern:
M i l e s (km) Maintenance Reminder Light
A t 5,900 (9,440) Blinks for 10 s e c o n d s w h e n the
to 6 , 1 0 0 ( 9 , 7 6 0 ) ignition s w i t c h i s t u r n e d O N (II).
A t 7,400 (11,840) C o m e s on and stays on while
to 7 , 6 0 0 ( 1 2 , 1 6 0 ) the ignition s w i t c h is O N (II).
Does voltage pulse from 0 to about 5 V?
Y E S — C h e c k c o n n e c t i o n s , a n d if n e c e s s a r y , r e p l a c e
t h e printed circuit b o a r d . •
10. D i s c o n n e c t the 3 P c o n n e c t o r f r o m t h e output s h a f t

(countershaft) s p e e d s e n s o r .
12. M e a s u r e the v o l t a g e b e t w e e n t h e output shaft

(countershaft) s p e e d s e n s o r 3 P c o n n e c t o r No. 2
terminal and body ground.
Is there about 5 V?
Y E S — R e p l a c e the output shaft (countershaft)

speed sensor. •
N O — R e p a i r a s h o r t to g r o u n d o r o p e n in the B L U /
W H T wire. •
22-97
Gauges
Tachometer Circuit Troubleshooting
'00-03 models 5. C h e c k f o r c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y
c o n n e c t o r C (20P) N o . 5 t e r m i n a l a n d b o d y g r o u n d .
N O T E : If t h e M I L is o n , t r o u b l e s h o o t t h e P G M - F I
p r o b l e m first.
2. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r C (20P) a n d 1 2 3 4 5 6 7 8 9 10
E C M c o n n e c t o r A (32P).
11 12 13 14 15 16 17 18 19 20
3. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y BLU

c o n n e c t o r C (20P) N o . 5 t e r m i n a l a n d E C M
c o n n e c t o r A (32P) N o . 19 t e r m i n a l .
BLU H Z
1 2 3 5 6 7 8
11 12 13 / //15
/ /////
W i r e s i d e of f e m a l e t e r m i n a l s Y E S — R e p a i r a s h o r t to g r o u n d in t h e B L U w i r e
b e t w e e n t h e g a u g e a s s e m b l y , t h e E P S c o n t r o l unit
E C M C O N N E C T O R A (32P) and the E C M . B
6. R e c o n n e c t g a u g e a s s e m b l y c o n n e c t o r C (20P), E P S
control unit c o n n e c t o r B (14P) a n d E C M c o n n e c t o r
A(32P).
Is there continuity? 7. C h e c k t h e E P S s y s t e m for D T C 2 2 o r 2 3 .
Y E S — G o to s t e p 4. Is DTC 22 or 23 present?
N O — R e p a i r a n o p e n in t h e B L U w i r e b e t w e e n t h e Y E S — G o to t h e E P S s y s t e m T r o u b l e s h o o t i n g . If O K ,
gauge a s s e m b l y and the E C M . B s u b s t i t u t e a k n o w n - g o o d E C M a n d r e t e s t t h e circuit.
If O K , r e p l a c e t h e E C M . fl
4. D i s c o n n e c t E P S c o n t r o l unit c o n n e c t o r B (14P).
N O — C h e c k for continuity b e t w e e n t h e g a u g e
a s s e m b l y connector A 1 4 terminal and the E P S
c o n t r o l unit c o n n e c t o r B 1 2 t e r m i n a l , a n d t h e g a u g e
a s s e m b l y connector C 5 terminal and the E P S
c o n t r o l unit c o n n e c t o r B 5 t e r m i n a l . If O K , r e p l a c e
t h e m a i n printed circuit b o a r d in t h e g a u g e
assembly. •
22-98
• BODY •
'04-05 models 5. C h e c k for continuity b e t w e e n g a u g e a s s e m b l y

N O T E : If t h e M I L is o n , t r o u b l e s h o o t t h e P G M - F I
p r o b l e m first.
1. R e m o v e the g a u g e a s s e m b l y ( s e e p a g e 22-89).
2. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P) a n d
/ 2 3 4 5 6 7 8 9 10
/ 12 13
/
15 16 17 18 19 20 21
/X 23 24
/ 26 27 28 29 30
c o n n e c t o r B (30P) N o . 3 t e r m i n a l a n d E C M
c o n n e c t o r A (32P) No. 19 t e r m i n a l .
G A U G E A S S E M B L Y C O N N E C T O R B (30P) W i r e s i d e of f e m a l e t e r m i n a l s
/ 2 3 4 5 6 7
X 8 9 10
/ 12 13
/ Is there continuity?
15 16 17 18 19 20 21
/ 24
/ 26 27 28 29 30
Y E S — R e p a i r a s h o r t to g r o u n d in t h e B L U w i r e
W i r e s i d e of f e m a l e t e r m i n a l s b e t w e e n t h e g a u g e a s s e m b l y , t h e E P S control unit
and the E C M . •
10 N O — G o to s t e p 6.
12 13 15 17 18 19 20 21 24
6. R e c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P), E P S
25 26 27 28 29 30 32
c o n t r o l unit c o n n e c t o r B (14P) a n d E C M c o n n e c t o r
A(32P).
Is there continuity? 7. C h e c k the E P S s y s t e m for D T C 2 2 or 2 3 .
YES-Gotostep4. Is DTC 22 or 23 present?
N O — R e p a i r a n o p e n in t h e B L U w i r e b e t w e e n t h e Y E S — G o to the E P S s y s t e m T r o u b l e s h o o t i n g . If O K ,
gauge a s s e m b l y and the E C M . • s u b s t i t u t e a k n o w n - g o o d E C M a n d retest the circuit.
If O K , r e p l a c e t h e E C M . •
N O — C h e c k for c o n t i n u i t y b e t w e e n the g a u g e
a s s e m b l y c o n n e c t o r B21 t e r m i n a l a n d the E P S
control unit c o n n e c t o r B 1 2 t e r m i n a l , a n d t h e g a u g e
a s s e m b l y c o n n e c t o r B 3 t e r m i n a l a n d the E P S
control unit c o n n e c t o r B 5 t e r m i n a l . If O K , r e p l a c e
assembly. •
22-99
Gauges
Tachometer Circuit Troubleshooting (cont'd)

N O T E : If t h e M I L i s o n , t r o u b l e s h o o t t h e P G M - F I
p r o b l e m first. G A U G E A S S E M B L Y C O N N E C T O R B (30P)
2. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r R (30P).
/
15
2
16
3
17
4
18
5
19
6
20
7
21
8 9 10 11 12
2 2 | X l 2 3 24 25 26 27 28 29 30
13 14
3. J u m p t h e S C S line w i t h t h e H D S , t h e n d i s c o n n e c t
E C M c o n n e c t o r E (31P).
c o n n e c t o r B (30P) N o . 3 t e r m i n a l a n d E C M
c o n n e c t o r E (31P) N o . 2 5 t e r m i n a l . W i r e s i d e of f e m a l e t e r m i n a l s
BLU
Y E S — R e p a i r a s h o r t to g r o u n d in t h e B L U w i r e
/
16
2
16 17
3 4
18
5
19
6
20
7
21 2 2 ^ 2 3 24
8 9
25
10
26
11
27 28
12 13
29
14
30
b e t w e e n t h e g a u g e a s s e m b l y , t h e E P S control unit
and the E C M . •
1 8
1
7 3 4^ 5 X 9 7. R e c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P), E P S
/ 11 12 13 14 15 16 17 18 19 20 21 c o n t r o l unit c o n n e c t o r B (14P) a n d E C M c o n n e c t o r
22 23 24 25
J /
BLU
27 28 29 30
/ A(32P).
8. C h e c k t h e E P S s y s t e m for D T C 2 2 or 2 3 .
Is DTC 22 or 23 present?
Is there continuity? Y E S — G o to t h e E P S s y s t e m T r o u b l e s h o o t i n g . If O K ,
s u b s t i t u t e a k n o w n - g o o d E C M a n d retest t h e circuit.
Y E S — G o to s t e p 5. If O K , r e p l a c e t h e E C M . •
N O — R e p a i r a n o p e n in t h e B L U w i r e b e t w e e n t h e N O — C h e c k for continuity b e t w e e n t h e g a u g e
gauge a s s e m b l y a n d the E C M . • a s s e m b l y c o n n e c t o r B21 t e r m i n a l a n d t h e E P S
control unit c o n n e c t o r B 1 2 t e r m i n a l , a n d t h e g a u g e
5. D i s c o n n e c t E P S c o n t r o l unit c o n n e c t o r B (14P). a s s e m b l y connector B 3 terminal a n d the E P S
control unit c o n n e c t o r B 5 t e r m i n a l . If O K , r e p l a c e
assembly. •
22-100
[ BODY |
Coolant Temperature Gauge Circuit Troubleshooting
'00-03 models 5. C h e c k for c o n t i n u i t y b e t w e e n g a u g e a s s e m b l y

c o n n e c t o r C (20P) N o . 7 t e r m i n a l a n d b o d y g r o u n d .
Is DTC P0116, P0117, or P0118 Indicated?
YEL/GRN
Y E S — G o to t h e E C M D T C T r o u b l e s h o o t i n g . •
1 2 3 5 6 7 8
11 12 13 / //
15
2 . R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).
/ /////
3 . D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r C (20P) a n d
c o n n e c t o r C (20P) N o . 7 t e r m i n a l a n d E C M
c o n n e c t o r A (32P) N o . 1 t e r m i n a l . Is there continuity?
Y E S — C h e c k the output f r o m t h e E C M first, if O K ,
repair a s h o r t to g r o u n d in t h e Y E L / G R N w i r e
between the gauge a s s e m b l y a n d the E C M . B
1 2 3 5 6 7 8
11 12 13 / //
15
/ /////
N O — C h e c k c o n n e c t i o n s . If O K , substitute a k n o w n -
g o o d g a u g e a s s e m b l y . If t h e p r o b l e m g o e s a w a y ,
r e p l a c e t h e m a i n printed circuit b o a r d in t h e g a u g e
assembly. •
1
12 13
2 3
/ / / 7
4
15
6
17 18 19 20 21
9 10
24
/ /
25 26 27 // 28 29 30 32
/
N O — R e p a i r a n o p e n in t h e Y E L / G R N w i r e b e t w e e n
the gauge a s s e m b l y and the E C M . H
22-101
Gauges
Coolant Temperature Gauge Circuit Troubleshooting (cont'd)

c o n n e c t o r B (30P) No. 5 t e r m i n a l a n d b o d y g r o u n d .
Is DTC P0116, P0117, or P0118 indicated?
YEL/GRN
Y E S — G o to t h e E C M D T C T r o u b l e s h o o t i n g . •
2 3 4 15 6 7 8 9 10 12 13
/
15 16 17 18 19 20 21 24 /
26 27 28 29 30/
2. R e m o v e the g a u g e a s s e m b l y ( s e e p a g e 22-89).
/ /
3. D i s c o n n e c t g a u g e a s s e m b l y c o n n e c t o r B (30P) a n d
c o n n e c t o r B (30P) No. 5 t e r m i n a l a n d E C M
c o n n e c t o r A (32P) No. 1 t e r m i n a l . Is there continuity?
Y E S — C h e c k the output f r o m t h e E C M first, if O K ,
r e p a i r a s h o r t to g r o u n d in t h e Y E I V G R N w i r e
I *
/
/x *> / / / between the gauge a s s e m b l y and the E C M . B
2 5 6 7
3 4 8 9 10 12 13
15 16 17 18 19 20 21 24 26 27 28 29 30
N O — C h e c k c o n n e c t i o n s , If O K , s u b s t i t u t e a k n o w n -
g o o d g a u g e a s s e m b l y . If t h e p r o b l e m g o e s a w a y ,
r e p l a c e t h e m a i n printed circuit b o a r d in t h e g a u g e
E C M C O N N E C T O R A (32P) assembly. •
n n
1 2 3 4 6 9 10
12 13 15 / / /
17 18 19 20 21 24
/ /
25 26 27 28 29 30 32
N O — R e p a i r a n o p e n in t h e Y E I V G R N w i r e b e t w e e n
the gauge a s s e m b l y a n d the E C M . •
22-102
Reminder Systems
22-103
Reminder Systems
Circuit Diagram
'00-03 m o d e l s

BATTERY
No. 41 (100 A) No. 42 (40 A)
@- -—cooo f•
I
cr>oo-
cr>oO—
No. 54 (30 A)
I—crxjo—
No. 23 (10 A)
FUSE
V
RED/BLK
GAUGE ASSEMBLY
BEEPER
LCD DISPLAY
• SPEEDOMETER
• TACHOMETER
SEAT • ODO/TRIP INDICATOR
BELT • FUEL GAUGE
REMINDER • ENGINE COOLANT
TEMPERATURE (ECT) VOLTAGE DRIVING
INDICATOR FEED CIRCUIT
GAUGE
TTTTm
(1.12 W|
H
—H— ODO/TRIP SWITCH
•mph/km/h SWITCH
GRN BLK
DRIVER'S DRIVER'S IGNITION

DOOR SEAT BELT KEY
SWITCH BUCKLE SWITCH
(Closed: SWITCH 1 (Closed:
Door open) (Closed: Key inserted)
When unbuckled)
BLK BLK
-9r JUL.
G601 G501 G401
22-104
• BODY •
'04-08 m o d e l s

BATTERY
No. 41 (100 A) No. 42 (40 A) C2
-WHT BLK/YEL
No. 54 (30 A)
-YEL •
UNDER-DASH
FUSE/RELAY
No. 25 No. 5 BOX
(7.5 A) (7.5 A)
No. 23 (10 A)
FUSE
WHTJRED YEL
V
RED/BLK
GAUGE ASSEMBLY A10
BEEPER
LCD DISPLAY • PARKING BRAKE REMINDER
SEAT • SPEEDOMETER • SEAT BELT REMINDER
BELT • TACHOMETER • KEY-IN REMINDER
• ODO/TRIP INDICATOR • LIGHTS-ON REMINDER
REMINDER
INDICATOR
(1.12 W)
• FUELGAUGE
. COOLANT -N-
TEMPUTURE
GAUGE VOLTAGE DRIVING
DRIVING
• CLOCK FEED CIRCUIT
CIRCUIT
-J f
CPU
I I .. I I
DASH LIGHTS
BRIGHTNESS
CONTROLLER
ODO/TRIP SWITCH
mph/km/h SWITCH
CLOCK
SWITCH
-M-
A14 B4 B23 A17
GRN BLU/RED GRN/WHT RED/WHT
YEL
DRIVER'S 2 DRIVER'S PARKING IGNITION

DOOR SEAT BELT { BRAKE KEY
SWITCH BUCKLE SWITCH SWITCH
(Closed: 1 SWITCH (Closed: 1 (Closed:
Door open) (Closed: Lever pulled) Key inserted)
When
unbuckled)
-LL.
-~7
G601 G501 G401
22-105
Reminder Systems
System Input Test
'00-03 models
2. I n s p e c t all t h e c o n n e c t o r s a n d s o c k e t t e r m i n a l s to b e s u r e t h e y a r e all m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l a r e bent, l o o s e , or c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
• If t h e t e r m i n a l s look O K , g o to s t e p 3.
BLU/RED
1
// p 4 5 6 W i r e s i d e of
7 8 9 10
X // 11 14
female terminals
RED/BLK YEL WHT/RED
f l 2
1=1
3 4
M W i r e s i d e of
6 7 8 9 10 11
/ female terminals
/ /
GRN BLK
RED/WHT
W i r e s i d e of
female terminals
22-106
3. W i t h the c o n n e c t o r s c o n n e c t e d , b a c k p r o b e t h e c o n n e c t o r s a n d m a k e t h e s e input t e s t s .
• If a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m .
• If all t h e input t e s t s p r o v e O K , the g a u g e a s s e m b l y m u s t be faulty; r e p l a c e it.
Cavity Wire T e s t condition Test: Desired result P o s s i b l e c a u s e if d e s i r e d r e s u l t i s

not obtained
B4 YEL Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • B l o w n No. 5 (7.5 A ) f u s e in t h e
B5 WHT/RED U n d e r all M e a s u r e the v o l t a g e to g r o u n d : • B l o w n No. 2 5 (7.5 A ) f u s e in the
conditions T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
• A n o p e n in the w i r e
B3 RED/BLK Combination M e a s u r e the v o l t a g e to g r o u n d : • B l o w n No. 2 3 (10 A ) f u s e in t h e
light s w i t c h T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
ON • F a u l t y taillight r e l a y
• F a u l t y c o m b i n a t i o n light s w i t c h
B8 BLK U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • Poor ground (G501)
conditions T h e r e s h o u l d be l e s s t h a n 0,5 V- • A n o p e n in the w i r e
C2 RED/WHT Ignition key is M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y ignition key s w i t c h
i n s e r t e d into T h e r e s h o u l d be l e s s t h a n 1 V . • Poor ground (G401)
the ignition • A n o p e n in t h e w i r e
switch
Ignition key M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y ignition s w i t c h
not in ignition T h e r e s h o u l d be 5 V or m o r e . • A s h o r t to g r o u n d in t h e w i r e
A1 BLU/RED Ignition s w i t c h M e a s u r e t h e v o l t a g e to g r o u n d : • F a u l t y d r i v e r ' s s e a t belt b u c k l e
O N (II) a n d T h e r e s h o u l d be l e s s t h a n 1 V . switch
driver's seat • Poor ground (G601)
belt u n b u c k l e d • A n o p e n in the w i r e
Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y d r i v e r ' s s e a t belt b u c k l e
O N (II) a n d T h e r e s h o u l d be 5 V or m o r e . switch
driver's seat • A s h o r t to g r o u n d in the w i r e
belt b u c k l e d
B6 GRN Driver's door M e a s u r e the v o l t a g e to g r o u n d : • Faulty driver's door switch
open T h e r e s h o u l d be l e s s t h a n 1 V . • A n o p e n in the w i r e
Driver's door M e a s u r e the v o l t a g e to g r o u n d : • Faulty driver's door switch
closed T h e r e s h o u l d be 5 V or m o r e . • A s h o r t to g r o u n d in the w i r e
B4 YEL Ignition s w i t c h C h e c k the b e e p e r o p e r a t i o n : • Faulty beeper
B5 WHT/RED O N (II) a n d trip T h e beeper should c o m e on. • Poor ground (G501)
B8 BLK r e s e t button • A n o p e n in the w i r e
pressed • Faulty gauge a s s e m b l y
22-107
Reminder Systems
System Input Test (cont'd)
'04-08 models
2 . I n s p e c t all t h e c o n n e c t o r s a n d s o c k e t t e r m i n a l s to b e s u r e t h e y a r e all m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l a r e b e n t , l o o s e , or c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
RED/BLK YEL WHT/RED
1 2 3 4 5 7 8 9 10
11 ,12 13 14 15 16
X" 18 19 20 21 22
Wire side of
female terminals
GRN
7 BLK
/
BLU/RED RED/WHT
/ 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22
X 23 24 25 26 27 28 29 30
W i r e s i d e of
female terminals
22-108
3. W i t h t h e c o n n e c t o r s c o n n e c t e d , b a c k p r o b e the c o n n e c t o r s a n d m a k e t h e s e input t e s t s .
• If a n y t e s t i n d i c a t e s a p r o b l e m , find a n d c o r r e c t the c a u s e , t h e n r e c h e c k the s y s t e m .

• If all t h e input t e s t s p r o v e O K , the g a u g e a s s e m b l y m u s t be faulty; r e p l a c e it.

not obtained
A9 YEL Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • B l o w n N o . 5 (7.5 A ) f u s e in the
A10 WHT/RED U n d e r all M e a s u r e the v o l t a g e to g r o u n d : • B l o w n N o . 2 5 (7.5 A ) f u s e in the
conditions T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
A8 RED/BLK Combination M e a s u r e the v o l t a g e to g r o u n d : • B l o w n N o . 2 3 (10 A ) f u s e in the
light s w i t c h T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
ON • Faulty taillight r e l a y
A17 BLK U n d e r all M e a s u r e the v o l t a g e to g r o u n d : • Poor ground (G501)
conditions T h e r e s h o u l d be l e s s t h a n 1 V . • A n o p e n in t h e w i r e
B6 RED/WHT Ignition key is M e a s u r e the v o l t a g e to g r o u n d : • Faulty ignition key s w i t c h
i n s e r t e d into T h e r e s h o u l d be l e s s t h a n 1 V . • Poor ground (G401)
the ignition • A n o p e n in t h e w i r e
switch
Ignition key M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y ignition s w i t c h
not in ignition T h e r e s h o u l d be 5 V or m o r e . • A s h o r t to g r o u n d in the w i r e
B4 BLU/RED Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y d r i v e r ' s s e a t belt buckle
O N (II) a n d T h e r e s h o u l d be l e s s t h a n 1 V . switch
driver's seat • Poor ground (G601)
belt u n b u c k l e d • A n o p e n in the w i r e
Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y d r i v e r ' s s e a t belt buckle
O N (II) a n d T h e r e s h o u l d be 5 V or m o r e . switch
driver's seat • A s h o r t to g r o u n d in the w i r e
belt b u c k l e d
B23 GRN/WHT Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • Poor ground
O N (II) a n d T h e r e s h o u l d be l e s s t h a n 1 V . • F a u l t y parking brake s w i t c h
parking brake • A n o p e n in the w i r e
l e v e r pulled
Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • Faulty parking brake s w i t c h
O N (II) a n d T h e r e s h o u l d be battery v o l t a g e . • A s h o r t to g r o u n d in t h e w i r e
parking brake
lever released
A14 GRN Driver's door M e a s u r e the v o l t a g e to g r o u n d : • Faulty d r i v e r ' s d o o r s w i t c h
open T h e r e s h o u l d be l e s s t h a n 1 V . • A n o p e n in t h e w i r e
Driver's door M e a s u r e the v o l t a g e to g r o u n d : • Faulty driver's door switch
closed T h e r e s h o u l d be 5 V or m o r e . • A s h o r t to g r o u n d in the w i r e
A9 YEL Ignition s w i t c h C h e c k the b e e p e r o p e r a t i o n : • Faulty b e e p e r
A10 WHT/RED O N (II) a n d trip The beeper should c o m e on. • Poor g r o u n d (G501)
A17 BLK r e s e t button • A n o p e n in the w i r e
pressed • Faulty g a u g e a s s e m b l y
22-109
Exterior Lights
HID U N I T FRONT PARKING/SIDE MARKER/

Replacement, page 22-138 TURN SIGNAL LIGHTS
Bulb Replacement, page 22-138
22-110
SIDE MARKER LIGHT TAILLIGHT A S S E M B L Y
BACK-UP LIGHT
T U R N SIGNAL LIGHT
(cont'd)
22-111
Exterior Lights
/ D A S H LIGHTS BRIGHTNESSCONTROLLER
Input T e s t ('00-03 m o d e l s ) , p a g e 22-155
Input T e s t ('04-08 m o d e l s ) , page 22-157
B u l b L o c a t i o n s ('00-03 m o d e l s ) , p a g e 2 2 - 5 6
B u l b L o c a t i o n s ('04-05 m o d e l s ) , p a g e 22-57
B u l b L o c a t i o n s ('08 m o d e l ) , p a g e 2 2 - 5 9
D R L I N D I C A T O R (Except '00-05 U S A models)

Bulb L o c a t i o n s ('00-03 m o d e l s ) , p a g e 22-56
B u l b L o c a t i o n s ('08 m o d e l ) , p a g e 2 2 - 5 9
DAYTIME RUNNING
LIGHTS SUBCONTROL
U N I T ('06-08 U S A m o d e l s )
I n p u t T e s t , p a g e 22-131
DAYTIME RUNNING LIGHTS CONTROL

U N I T (Except '00-05 U S A models)
HIGH B E A M C U T R E L A Y Input T e s t , page 22-127
(Except '00-05 U S A models)
Test, page 22-48
TAILLIGHT RELAY
Test, page 22-48
UNDER-DASH
FUSE/RELAY BOX
22-112
J BODY |
Circuit Diagram
'00-03 U S A m o d e l s

No. 54 (30 A)
— « C T \ _ D — -
HEADLIGHT
RELAY 1 UNDER-DASH
FUSE/RELAY
BOX
03-
-WHT/GRN
I—WHT/GRN —
j -—J
-WHT/GRN
RED/YEL RED/WHT RED/WHT —WHT/GRN — - -nftRT*-

TAILLIGHT
RELAY
RIGHT
HEADLIGHT
(High beam)
(55 W)
)W \V' HIGH
LOW
DIMMER
iA»""fr
COMBINATION LIGHT SWITCH
RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK
© © © RIGHT LEFT
© © LEFT
© RIGHT
©
FRONT REAR TAILLIGHT TAILLIGHT PLATE
PARKING PARKING SIDE (5W) (5W) LIGHT
LIGHT LIGHT (5W)
(5W) 15 W) LIGHT LIGHT
15 W) (5W)
BUI DL.lv
I L
BLK BLK
1 1
22-113
Exterior Lights
'04-05 U S A m o d e l s
MAN UNDBI-H000 FUSE/RE1AV BOX
0-
No. 411100 A) No. 54 (30 A)
HEADLIGHT HEADLIGHT
RELAY 2 RELAY 1 UNDER-DASH
FUSE/RELAY
BOX
03-
) No. 45 > No. 43
. (20A) , {20 A) 3 No-23
CdOA)
r— -WHT/GRN
WHT/GRN — —J
h
-WHT/GRN -
RED/YEL RED/YEL RED/YEL RED/YEL RED/WHT RED/WHT -WHT/GRN •
I <j) <f)
TAILLIGHT
LEFT
v
GAUGE
RELAY
HIGH BEAM ASSEMBLY

HEADLIGHT INDICATOR HEADLIGHT
(High beam) LIGHT (High beam)
155 W) (1.12 W) (55 W)
-—-O INVERTER
>W V HIGH
< DIMMER
COMBINATION LIGHT SWITCH
LEFT RIGHT
HEADLIGHT HEADLIGHT
(Low beam) (Low beam)
(35 W) RED/BLU RED/BLU (35W) RED/BLU
1
G501
22-114
•BODY •
'06-08 U S A models
BATTERY
(cont'd)
22-115
Exterior Lights
UNDER-DASH
FUSE/RELAY BOX
No. 23 (10 A)
—cr\jo— " WHT/GRN -
No. 27 (10 A)
—cr>oo—
DRL
v
INDICATOR
No. 19 (7.5 A)
' BLU •
HIGH BEAM YEL BLK

CUT RELAY
- BLU/RED -
-RED/BLU • !:Q- •ORN-
BLU/RED - RED/BLU-
- BLU/RED- -BLU/RED-
- YEL/BLK -
BLUj - WHT — YEL/BLK BLU/RED RED/BLU
o —-O O 1
I 1: 1H—J>21——
DAYTIME RUNNING LIGHTS
) DAYTIME RUNNING LIGHTS SUBCONTROLUNIT
( CONTROL UNIT
\ Q
V
n
BLK
Q
GRN/WHT
1
BRAKE SYSTEM
T
GRN/WHT
5
TT
BLK BLK
INDICATOR
IMMOBILIZER CONTROL
UNIT-RECEIVER
CONVERTIBLE
Y
TOP CONTROL UNIT
GRN/WHT
GRN/WHT
1 PARKING
BLK BLK
BRAKE
SWITCH
(Closed:
Lever pulled)
G402 G401
22-116
UNDER-DASH
FUSE/RELAY BOX
- WHT/GRN - - WHT/GRN
- WHT/GRN
ORN
-BLU/RED-
G401 G301 G201 G602
22-117
Exterior Lights
'00-03 C a n a d a m o d e l s
RED/BLU
RIGHT
HEADLIGHT
(High beam)
(55 W)
PARKING
D BRAKE
SWITCH
(Closed:
BLK LEFT
HEADLIGHT
(Low beam)
RED/BLU
'
RED/BLU BLK RIGHT
HEADLIGHT
(Low beam)
RED/BLU
n c w / D L W
Lever pulled) 135 W) (35W)
.XL
G301 G201
22-118
[ BODY g
IGNITION SWITCH UNDER-DASH

FUSE/RELAY BOX
ÂT-B UNDER-DASH
• WHT/BLK BLK/RED - FUSE/RELAY BOX
IG2-B ,
>-
No. 23 (10 A)
— YEL - —CTVD—
- WHT/GRN t WHT/GRN
ENGINE
START
SWITCH
BLU/WHT
L WHT/GRN
CLUTCH No. 19 (7.5 A)

INTERLOCK LTBLU
SWITCH
• BLU/RED • BLU/RED
-BLU •
HIGH BEAM
CUT RELAY
• BLU/RED
* RED/BLU •Qj_r> ORN" BLU RED/BLK

BLU/RED YEL/BLK (Not used) 13
PASSING
-CJ-n-D- -K-
LOW \/ HIGH
GAUGE ' O
12 ASSEMBLY (axE)
O- i i
CONTROL UNIT COMBINATION UGHT SWITCH
-g
T
BLK BLK
RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK
i i >
® ® d) ® d) ® ®
LEFT
FRONT
RIGHT
FRONT
LEFT
REAR
RIGHT
REAR
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
LICENSE
PLATE
PARKING PARKING SIDE SIDE (5W) (5W) LIGHT
LIGHT LIGHT MARKER MARKER (3 CP)
(5W) (5W) LIGHT UGHT
(5W) (5W)
BLK BLK
BLK BLK BLK BLK BLK
BLK BLK
' ' ' I
-0_
G402 G301 G401 G301 G201 G602
22-119
Exterior Lights
'04-05 C a n a d a models
PARKING
BRAKE BLK RIGHT RED/BLU
©/ SWITCH HEADLIGHT
(Closed: (Low beam) (Low beam)
Lever pulled) (35W) (35 W)
GS01 G501
22-120
• BODY •
UNDER-DASH
FUSE/RELAY BOX
UNDER-DASH
FUSE/RELAY BOX TAILLIGHT
RELAY
No. 23 (10 A)
—o~\jo—
T
-WHT/GRN WHT/GRN — — •OTO-
-i
WHT/GRN <
No. 19 (7.5 A)
' BLU/RED • BLU/RED
-BLU •
HIGH BEAM
CUT RELAY
- BLU/RED
• RED/BLU -Q-LQ- RED/BLK
BLU/RED YEL/BLK (Not used)
PASSING
LOW V HIGH
(ED)
GAUGE 'DIMMER o
12 ASSEMBLY

CONTROL UNIT V COMBINATION LIGHT SWITCH
r r r GRN/RED GRN/RED RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK
BRAKE
6 FLUID
LEVEL
SWITCH
(Closed:
Float down)
BLK BLK BLK
G402 G301 G401 G301
22-121
Exterior Lights
'06-08 C a n a d a m o d e l s
22-122
IGNITION SWITCH
/BATB Y
•WHT/BLK rO O f BLK/RED
V IG2-B J
22-
Exterior Lights
Circuit Diagram - Back-up Lights Circuit Diagram - Brake Lights
'00-03 m o d e l s
MAIN UNDER-HOOD
FUSE/RELAY BOX
*10A.*00-01n
MAIN UNDER-HOOD 15 A: '02-03 models
FUSE/RELAY BOX
BRAKE PEDAL
POSITION SWITCH
(Closed: Pedal pressed)
WHT/BLK
BACK-UP
UGHT
SWITCH WHT
1
[On the transmission
housing]
(Closed: In position " R" }
•ABS MODUUTOR-CONTROL UNIT

•ECM
•CRUISE CONTROL UNIT
GRN
WHT/BLK
HIGH 1
MOUNT RIGHT
BRAKE
LIGHT UGHT
(LED) 3 (21W) 3^ (21W)
BLK
JL.
G601 G602
22-124
•BODY •
'04-08 models
MAIN UNDER-HOOD •1:'04-05 models

FUSE/RELAY BOX •2:'06-08 models
BRAKE PEDAL
POSITION SWITCH
(Closed: Pedal pressed)
WHT BLK
WHT BLK
1
ABS MODULATOR-CONTROL UNIT*
2
VSA MODULATOR-CONTROL UNIT*
ECM
CRUISE CONTROL UNIT*'
22-125
Exterior Lights
Combination Light Switch Test/Replacement
1. R e m o v e t h e s t e e r i n g c o l u m n c o v e r s ( s e e p a g e 17-9).
2. D i s c o n n e c t the 16P c o n n e c t o r (A) f r o m the c o m b i n a t i o n light s w i t c h (B).
3. R e m o v e t h e t w o s c r e w s , t h e n pull out t h e c o m b i n a t i o n light s w i t c h .
4. I n s p e c t t h e c o n n e c t o r t e r m i n a l s to be s u r e t h e y a r e all m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l s a r e bent, l o o s e or c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k the s y s t e m .
• If t h e t e r m i n a l s look O K , c h e c k for continuity b e t w e e n t h e t e r m i n a l s in e a c h s w i t c h position a c c o r d i n g to the
tables.
- If t h e continuity is not a s s p e c i f i e d , r e p l a c e t h e s w i t c h .
Light s w i t c h
Terminal
12 13
Position
OFF
Headlight s w i t c h
LOW
HIGH O
OFF
Passing switch
ON
Turn signal switch
\ Terminal
2 11 10
Position \
r\
LEFT \J
NEUTRAL vj
RIGHT r\
22-126
[ BODY |
Daytime Running Lights Control Unit Input Test
Canada models
1. D i s c o n n e c t t h e 1 4 P c o n n e c t o r (A) f r o m the d a y t i m e r u n n i n g lights c o n t r o l unit (B).
RED/BLU RED/WHT
RED/WHT \ RED/YEL BLK GRN/WHT
BLK 1 2 3 4 5 6
I 1
7 8 9 10 11 12 13
BLU/RED / RED/BLU RED/ORN \ GRN/RED*

BLU/WHT YEL/BLK
*: '00-05 m o d e l s
2. I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s to be s u r e t h e y a r e all m a k i n g g o o d contact.
• If t h e t e r m i n a l s a r e bent, l o o s e or c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k the s y s t e m .

• If t h e t e r m i n a l s look O K , go to s t e p 3.
(cont'd)
22-127
Exterior Lights
Daytime Running Lights Control Unit Input Test (cont'd)
3. Make t h e s e input tests at the connector.
• If a n y test indicates a p r o b l e m , find a n d correct the c a u s e , then recheck the s y s t e m .

• If all the input tests prove O K , the control unit m u s t be faulty; replace it.
Cavity Wire T e s t condition Test: Desired result P o s s i b l e c a u s e if d e s i r e d result is n o t

obtained
2 2
RED/BLU U n d e r all conditions M e a s u r e the voltage to g r o u n d : • B l o w n No. 54 (30 A ) f u s e in the m a i n
T h e r e s h o u l d be battery voltage. under-hood f u s e / r e l a y box
• B l o w n No. 27 (10 A ) f u s e in the under-
d a s h f u s e / r e l a y box
• A n open in the w i r e
12* 2
YEL/BLK Ignition switch O N (II) M e a s u r e the voltage to g r o u n d : • B l o w n No. 19 (7.5 A ) f u s e in the under-
T h e r e s h o u l d be battery voltage. d a s h f u s e / r e l a y box
• Faulty IG2 cut relay
4* 2
BLK U n d e r all conditions M e a s u r e the voltage to g r o u n d : • Poor ground (G402)
T h e r e s h o u l d be less t h a n 0.5 V . • A n open in the w i r e
7* 2
BLK U n d e r all conditions M e a s u r e the voltage to g r o u n d : • Poor ground (G402)
T h e r e s h o u l d be less than 0.5 V. • A n open in the w i r e
3 RED/YEL C o m b i n a t i o n light M e a s u r e the voltage to g r o u n d : • B l o w n No. 45 (20 A ) f u s e in the m a i n
switch ON (ID) T h e r e s h o u l d be battery voltage. under-hood f u s e / r e l a y box
• Faulty headlight relay 2
• Faulty combination light switch
• Faulty diode
• Poor ground (G401)
5 RED/WHT C o m b i n a t i o n light M e a s u r e the voltage to g r o u n d : • B l o w n No. 43 (20 A ) f u s e in the m a i n
switch O N (=D) T h e r e s h o u l d be battery voltage. under-hood f u s e / r e l a y box
• Faulty headlight relay 1
• Faulty combination light switch
• Faulty diode
1 RED/WHT C o m b i n a t i o n light C o n n e c t a j u m p e r w i r e b e t w e e n No. 3 • Blownbulb
s w i t c h O N (ID), a n d a n d No. 1 t e r m i n a l s : • Faulty high b e a m cut relay
d i m m e r switch in HIGH Left headlight (HIGH) a n d high b e a m • Faulty combination light switch
indicator s h o u l d c o m e o n . • Faulty diode
11 RED/ORN C o m b i n a t i o n light C o n n e c t a j u m p e r w i r e b e t w e e n No. 5 • B l o w n bulb
s w i t c h O N (ID)/ and a n d No. 11 t e r m i n a l s : • Faulty high b e a m cut relay
d i m m e r s w i t c h in HIGH Right headlight (HIGH) s h o u l d c o m e • Faulty combination light switch
on. • Faulty diode
10 RED/BLU C o m b i n a t i o n light C h e c k for continuity to g r o u n d : • Faulty high b e a m cut relay
s w i t c h O N (ID), a n d T h e r e s h o u l d be continuity. • Faulty combination light switch
d i m m e r s w i t c h in H I G H • Faulty diode
6 GRN/WHT Parking brake lever C h e c k for continuity to g r o u n d : • Faulty parking brake s w i t c h
pulled T h e r e s h o u l d be continuity. • A n o p e n in the w i r e
8 BLU/RED U n d e r all conditions M e a s u r e the voltage to g r o u n d : • Faulty headlight relays
T h e r e s h o u l d be battery voltage. • Faulty diode
9 BLU/WHT Ignition s w i t c h O N (II) Attach to g r o u n d : • B l o w n No. 5 (7.5 A ) f u s e in the under-
T h e D R L indicator s h o u l d c o m e o n . d a s h f u s e / r e l a y box
• B l o w n bulb
• A n o p e n in the wire
13* 1
GRN/RED Ignition s w i t c h O N (II) Attach to g r o u n d : • B l o w n No. 5 (7.5 A ) f u s e in the under-
T h e brake s y s t e m indicator s h o u l d d a s h f u s e / r e l a y box
come on. • B l o w n bulb
* 1:'00-05 m o d e l s
* 2: R e c o n n e c t the c o n n e c t o r
22-128
'06-08 USA models
1. D i s c o n n e c t the 14P c o n n e c t o r (A) f r o m the d a y t i m e r u n n i n g lights c o n t r o l unit (B).
BLU/RED RED/ORN \
YEL/BLK
2. I n s p e c t the c o n n e c t o r a n d s o c k e t t e r m i n a l s to b e s u r e t h e y a r e all m a k i n g g o o d c o n t a c t .
• If the t e r m i n a l s a r e bent, l o o s e or c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k the s y s t e m .

• If the t e r m i n a l s look O K , g o to s t e p 3.
Exterior Lights
Daytime Running Lights Control Unit Input Test (cont'd)
3. M a k e t h e s e input t e s t s at the c o n n e c t o r .
• if a n y test i n d i c a t e s a p r o b l e m , find a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m .
• If all t h e input t e s t s p r o v e O K , t h e c o ntro l unit m u s t b e faulty; r e p l a c e it.

not obtained
12* YEL/BLK Ignition s w i t c h M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 19 (7.5 A ) f u s e in t h e
• Faulty IG2 cut relay
4* BLK U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • Poor ground (G402)
conditions T h e r e s h o u l d b e l e s s t h a n 0.5 V . • A n o p e n in t h e w i r e
7* BLK U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • Poor ground (G402)
3* RED/YEL Combination M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 4 5 (20 A ) f u s e in t h e
light s w i t c h O N T h e r e s h o u l d b e battery v o l t a g e . main under-hood fuse/relay box
(ID) • Faulty headlight relay 2
• Faulty diode
5 RED/WHT Combination M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 4 3 (20 A ) f u s e in t h e
light s w i t c h O N T h e r e s h o u l d b e battery v o l t a g e . main under-hood fuse/relay box
(ID) • Faulty headlight relay 1
• Faulty diode
1 RED/WHT Combination Connect a jumper wire between • B l o w n bulb
light s w i t c h O N No. 3 and No. 1 terminals: • F a u l t y high b e a m c u t r e l a y
(ID), and Left h e a d l i g h t (HIGH) a n d high • F a u l t y c o m b i n a t i o n light s w i t c h
dimmer switch b e a m indicator s h o u l d c o m e o n . • Faulty diode
in H I G H • Poor ground (G401)
11 RED/ORN Combination Connect a jumper wire between • B l o w n bulb
light s w i t c h O N No. 5 a n d N o . 11 t e r m i n a l s : • F a u l t y high b e a m c u t r e l a y
(ID), and Right h e a d l i g h t (HIGH) s h o u l d • F a u l t y c o m b i n a t i o n light s w i t c h
dimmer switch come on. • Faulty diode
in H I G H • Poor ground (G401)
2 WHT Ignition s w i t c h M e a s u r e t h e v o l t a g e to g r o u n d : • F a u l t y d a y t i m e r u n n i n g lights
O N (II), a n d T h e r e s h o u l d b e a b o u t 6.5 V . s u b c o n t r o l unit
parking brake • A n o p e n in t h e w i r e
lever released
6 GRN/WHT Parking brake C h e c k for c o n t i n u i t y to g r o u n d : • Faulty parking brake switch
lever pulled T h e r e s h o u l d b e continuity. • A n o p e n in t h e w i r e
8 BLU/RED U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • Faulty headlight relays
conditions T h e r e s h o u l d b e battery v o l t a g e . • Faulty diode
* : Reconnect the connector
22-130
• BODY •
Daytime Running Lights Subcontrol Unit Input Test
'06-08 USA models
1. D i s c o n n e c t the 14P c o n n e c t o r (A) f r o m the d a y t i m e r u n n i n g lights s u b c o n t r o l unit (B).
YEL/BLK
1 1— 3 4 5 r
8 9
// / //
12 14
BLK BLU/RED
BLK RED/BLU
2. I n s p e c t the c o n n e c t o r a n d s o c k e t t e r m i n a l s to be s u r e t h e y a r e all m a k i n g g o o d contact.
• If t h e t e r m i n a l s a r e bent, l o o s e or c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k the s y s t e m .

(cont'd)
22-131
Exterior Lights
Daytime Running Lights Subcontrol Unit Input Test (cont'd)
3. M a k e t h e s e input t e s t s at t h e c o n n e c t o r .
• If all t h e input t e s t s p r o v e O K , t h e control unit m u s t b e faulty; r e p l a c e it.

not obtained
14* RED/BLU U n d e r all M e a s u r e the v o l t a g e to g r o u n d : • B l o w n No. 54 (30 A ) f u s e in the
conditions T h e r e s h o u l d be battery v o l t a g e . main under-hood fuse/relay box
• B l o w n N o . 27 (10 A ) f u s e in the
r YEL/BLK Ignition s w i t c h M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 19 (7.5 A ) f u s e in t h e
• F a u l t y I G 2 cut r e l a y
8* BLK U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • P o o r g r o u n d (G401)
conditions T h e r e s h o u l d be l e s s t h a n 0.5 V . • A n o p e n in the w i r e
9*
12 BLU/RED U n d e r all M e a s u r e t h e v o l t a g e to g r o u n d : • F a u l t y headlight r e l a y s
conditions T h e r e s h o u l d be battery v o l t a g e . • Faulty diode
3 BLU/WHT Ignition s w i t c h A t t a c h to g r o u n d : • B l o w n N o . 5 (7.5 A ) f u s e in the
O N (II) T h e D R L indicator s h o u l d c o m e under-dash fuse/relay box
oh. • B l o w n bulb
4 RED/BLU Combination C h e c k for continuity to g r o u n d : • F a u l t y high b e a m cut r e l a y
light s w i t c h O N T h e r e s h o u l d b e continuity. • F a u l t y c o m b i n a t i o n light s w i t c h
(ID), and • P o o r g r o u n d (G401)
dimmer switch • A n o p e n in the w i r e
in H I G H
5 GRN/WHT Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • F a u l t y parking brake s w i t c h
O N (II), a n d T h e r e should be less than 1 V. • A n o p e n in the w i r e
parking brake
lever pulled
Ignition s w i t c h M e a s u r e the v o l t a g e to g r o u n d : • B l o w n bulb
O N (II), a n d T h e r e s h o u l d b e battery v o l t a g e . • F a u l t y parking brake s w i t c h
parking brake • S h o r t to g r o u n d
lever released
7* WHT Ignition s w i t c h M e a s u r e the voltage between • F a u l t y d a y t i m e r u n n i n g lights
O N (II), a n d t h e d a y t i m e r u n n i n g lights control unit
parking brake c o n t r o l unit No. 2 t e r m i n a l a n d • S h o r t to g r o u n d
lever released ground:
T h e r e s h o u l d b e a b o u t 6.5 V .
* : R e c o n n e c t the connector
22-132
HID Lamp System Troubleshooting
i k WARNING
4. D i s c o n n e c t the n e g a t i v e battery c a b l e .
A t r a n s i e n t high t e n s i o n (25,000 V ) o c c u r s at the 5. R e m o v e t h e s o c k e t f r o m t h e HID bulb ( s e e p a g e

bulb s o c k e t s or the high intensity d i s c h a r g e (HID) 22-136).
l a m p s w h e n the c o m b i n a t i o n light s w i t c h is t u r n e d
O N , it m a y c a u s e s e r i o u s electrical s h o c k or 6. C h e c k for c o r r o s i o n (A) a n d t r a c e s of electrical
e l e c t r o c u t i o n if y o u d o not o b s e r v e the c a u t i o n s a r c i n g (B) at the s o c k e t m a t i n g part.
below.
ik CAUTION
• N e v e r turn o n the c o m b i n a t i o n light s w i t c h
B
before fitting the HID b u l b s to their bulb s o c k e t s
a n d c o m p l e t i n g the r e a s s e m b l y of the headlight
assembly.
• D o not s e r v i c e the h e a d l i g h t s a s s e m b l y in w e t
c o n d i t i o n s , s u c h a s rain or s n o w , n e a r a s p r i n k l e r
s y s t e m , or w h e n y o u r h a n d s a r e w e t to p r e v e n t
electrocution.
• D o not t o u c h the s u r f a c e of t h e HID b u l b s w i t h
y o u r b a r e h a n d s a n d d o not s t a i n it w i t h a n y oils
a n d fats. Is the socket corroded or burnt?
• D o not d i s a s s e m b l e the inverter unit a n d t h e
igniter unit. Y E S — G o to s t e p 7.
• D o not turn o n the HID bulb b y u s i n g a p o w e r
s o u r c e other t h a n the battery m o u n t e d o n y o u r N O — R e p l a c e the socket, a n d recheck. •
vehicle.

HID bulb test light 0 7 A A J - S 3 M A 1 0 0
1. C h e c k the No. 45 (20 A ) a n d N o . 43 (20 A ) f u s e s in

the m a i n u n d e r - h o o d f u s e / r e l a y box.
Are the fuses OK ?
N O — R e p l a c e the f u s e ( s ) , a n d r e c h e c k . •
2 . M a k e s u r e y o u h a v e t h e anti-theft c o d e for the

a u d i o s y s t e m , t h e n w r i t e d o w n the a u d i o p r e s e t s .
3. T u r n the c o m b i n a t i o n light s w i t c h O F F .
(cont'd)
22-133
Exterior Lights
HID Lamp System Troubleshooting (cont'd)
7. C o n n e c t t h e HID b u l b t e s t light (A) to t h e s o c k e t ( B ) . 16. C h e c k for continuity b e t w e e n t h e HID unit 2 P

H I D U N I T 2P C O N N E C T O R
07AAJ-S3MA100 W i r e s i d e of f e m a l e t e r m i n a l s
8. R e c o n n e c t t h e battery n e g a t i v e c a b l e .
7 s there continuity?
9. T u r n t h e c o m b i n a t i o n light (headlight) s w i t c h O N .
Does the bulb In the test light come on?
N O — R e p a i r a n o p e n i n the w i r e b e t w e e n t h e HID
Y E S — - R e p l a c e t h e o r i g i n a l HID b u l b ( s e e p a g e unit a n d b o d y g r o u n d . If the w i r e is O K , c h e c k for
22-136). • p o o r g r o u n d at G 2 0 1 (right)/G301 (left) ('00-03
m o d e l s ) or G 5 0 1 ('04-08 m o d e l s ) . •
N O T E : After t h e r e p a i r is c o m p l e t e , enter t h e anti-
10. T u r n t h e c o m b i n a t i o n light (headlight) s w i t c h O F F . theft c o d e for t h e a u d i o s y s t e m , t h e n e n t e r t h e
audio presets, a n d set the clock.
11. D i s c o n n e c t t h e battery n e g a t i v e c a b l e .
12. R e m o v e the HID b u l b t e s t light f r o m t h e b u l b s o c k e t .
13. R e c o n n e c t t h e battery n e g a t i v e c a b l e .
14. D i s c o n n e c t t h e HID unit 2 P c o n n e c t o r .
15. T u r n t h e c o m b i n a t i o n light (headlight) s w i t c h O N .
22-134
| BODY §
17. M e a s u r e t h e v o l t a g e b e t w e e n t h e HID unit 2 P 18. D i s c o n n e c t m a i n u n d e r - h o o d f u s e / r e l a y box

connector No. 2 terminal and body ground. c o n n e c t o r A (18P).
HID U N I T 2 P C O N N E C T O R
19. C h e c k f o r c o n t i n u i t y b e t w e e n m a i n u n d e r - h o o d
f u s e / r e l a y b o x c o n n e c t o r A (18P) N o . 3 (No. 4)
t e r m i n a l s a n d t h e HID unit 2 P c o n n e c t o r No. 2
terminal.

[LEFT. HEADLIGHT (RED/YEL) C O N N E C T O R A (18P)
[RIGHT. HEADLIGHT (RED/WHT) W i r e s i d e of f e m a l e t e r m i n a l s
RED/YEL RED/WHT
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 17 18

RED/YEL RED/WHT
1 1
Y E S — S u b s t i t u t e a k n o w n - g o o d HID unit, a n d 1 2
r e c h e c k . If t h e s y m p t o m / i n d i c a t i o n g o e s a w a y ,
r e p l a c e t h e original HID unit ( s e e p a g e 22-138). I L E F T . HID U N I T R I G H T . HID U N I T
2P C O N N E C T O R 2P C O N N E C T O R
Y E S — R e p l a c e t h e m a i n u n d e r - h o o d f u s e / r e l a y box.
( s e e p a g e 22-46). •
N O — R e p a i r a n o p e n in t h e w i r e b e t w e e n the m a i n
u n d e r - h o o d f u s e / r e l a y b o x a n d t h e HID u n i t . B
N O T E : After t h e r e p a i r is c o m p l e t e , e n t e r the anti-

theft c o d e for t h e a u d i o s y s t e m , t h e n enter t h e
audio presets, and set the clock.
22-135
Exterior Lights
HID Bulb Removal
A WARNING audio s y s t e m , then write d o w n the audio presets.
A t r a n s i e n t h i g h t e n s i o n (25,000 V ) o c c u r s at t h e
b u l b s o c k e t s of t h e h i g h intensity d i s c h a r g e (HID) 2 . T u r n t h e ignition s w i t c h O F F .
l a m p s w h e n t h e c o m b i n a t i o n light s w i t c h is t u r n e d
O N . It m a y c a u s e s e r i o u s e l e c t r i c a l s h o c k or 3. T u r n t h e c o m b i n a t i o n light s w i t c h O F F .
e l e c t r o c u t i o n if y o u d o not o b s e r v e the c a u t i o n s
below. 4. D i s c o n n e c t t h e battery n e g a t i v e c a b l e .
5. R e m o v e t h e front part of t h e i n n e r f e n d e r a s
ACAUTION
• N e v e r t u r n o n t h e c o m b i n a t i o n light s w i t c h 6. D i s c o n n e c t 2 P c o n n e c t o r (A) f r o m t h e inverter unit.
before fitting t h e HID b u l b s to t h e i r bulb s o c k e t s
a n d c o m p l e t i n g t h e r e a s s e m b l y of the h e a d l i g h t
assembly.
• D o not s e r v i c e t h e h e a d l i g h t s a s s e m b l y in w e t
c o n d i t i o n s , s u c h a s rain or s n o w , n e a r a s p r i n k l e r
s y s t e m , or w h e n y o u r h a n d s a r e w e t to p r e v e n t
electrocution.
• D o not t o u c h t h e s u r f a c e of t h e HID b u l b s w i t h
y o u r b a r e h a n d s a n d d o not s t a i n it w i t h a n y o i l s
a n d fats.
• D o not d i s a s s e m b l e t h e i n v e r t e r unit a n d t h e
igniter unit.
• D o not t u r n o n t h e HID bulb b y u s i n g a p o w e r
s o u r c e o t h e r t h a n t h e battery m o u n t e d in y o u r
vehicle.
7. R e m o v e t h e T O R X bolt u s i n g a t a m p e r - p r o o f T O R X
T 2 5 bit.
8. T u r n t h e c o v e r (B) 4 5 ° c o u n t e r c l o c k w i s e to r e m o v e
it f r o m t h e h e a d l i g h t a s s e m b l y .
22-136
9. Pull t h e retaining s p r i n g (A) a w a y f r o m t h e b u l b ( B ) ,
t h e n r e m o v e t h e s o c k e t a n d t h e bulb (C).
10. T u r n t h e b u l b 4 5 ° c o u n t e r c l o c k w i s e to r e m o v e it
f r o m the s o c k e t .
11. Install the n e w bulb in the r e v e r s e o r d e r of r e m o v a l .
12. After r e c o n n e c t i n g t h e battery, enter t h e anti-theft

c o d e for t h e a u d i o s y s t e m , t h e n enter the a u d i o
p r e s e t s , a n d s e t t h e clock.
22-137
Exterior Lights
HID Unit Replacement Bulb Replacement
1. M a k e s u r e y o u h a v e t h e anti-theft c o d e for t h e Headlight

1. D i s c o n n e c t t h e 3 P c o n n e c t o r (A) f r o m t h e headlight.
H e a d l i g h t (high b e a m ) : 5 5 W
3. T u r n t h e c o m b i n a t i o n light s w i t c h O F F .
4. D i s c o n n e c t t h e battery n e g a t i v e c a b l e , t h e n
disconnect the positive c a b l e .
5. R e m o v e t h e h e a d l i g h t a s s e m b l y ( s e e p a g e 2 2 - 1 3 9 ) .
6. R e m o v e t h e s o c k e t f r o m t h e HID b u l b ( s e e p a g e
22-136).
7. R e m o v e t h e t h r e e m o u n t i n g s c r e w s a n d t h e HID
unit.
2. R e m o v e t h e r u b b e r c o v e r (B).
3. Pull t h e retaining s p r i n g (C) a w a y f r o m t h e bulb (D),

t h e n r e m o v e t h e bulb.
4. Install a n e w b u l b in the r e v e r s e o r d e r of r e m o v a l .
Make s u r e the tabs on the bulb align with the
n o t c h e s in t h e headlight.
8. Install in t h e r e v e r s e o r d e r of r e m o v a l .
9. E n t e r the anti-theft c o d e for t h e a u d i o s y s t e m , t h e n

enter the audio presets, a n d set the clock.
22-138
Headlight Replacement
Front Turn Signal Light,

Front Parking Light ('00-03 models), ^CAUTION
Front Parking/Side Marker Light ('04-08 H e a d l i g h t s b e c o m e v e r y hot d u r i n g u s e ; d o not
models) t o u c h t h e m o r a n y attaching h a r d w a r e i m m e d i a t e l y
after t h e y h a v e b e e n t u r n e d off.
1. R e m o v e the i n n e r f e n d e r ( s e e p a g e 20-126).
2. D i s c o n n e c t the c o n n e c t o r s (A) f r o m t h e lights. 1. R e m o v e t h e front b u m p e r ' 0 0 - 0 3 m o d e l s ( s e e p a g e

20-104); ' 0 4 - 0 8 m o d e l s ( s e e p a g e 2 0 - 1 0 5 ) ; C R m o d e l
F r o n t t u r n s i g n a l lights: 21 W ( s e e p a g e 20-106).
F r o n t p a r k i n g light ('00-03 m o d e l s ) : 5 W
F r o n t p a r k i n g / S i d e m a r k e r light 2. R e m o v e t h e front part of the i n n e r f e n d e r a s
('04-08 m o d e l s ) : 5 W n e c e s s a r y ( s e e p a g e 20-126).
3. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m the h e a d l i g h t s .
3. T u r n the bulb s o c k e t s (B) 4 5 ° c o u n t e r c l o c k w i s e to

r e m o v e t h e m f r o m the h e a d l i g h t h o u s i n g .
4. Install the n e w bulb(s) in the r e v e r s e o r d e r of

removal.
4. R e m o v e t h e f o u r bolts, t h e n r e m o v e the c o r n e r
u p p e r b e a m (B).
H e a d l i g h t (High): 55 W
Headlight (Low): 35 W
Front T u r n S i g n a l Light: 21 W
F r o n t P a r k i n g L i g h t ('00-03 m o d e l s ) : 5 W
Front Parking/Side Marker Light
('04-08 m o d e l s ) : 5 W
5. R e m o v e t h e four bolts, t h e n r e m o v e the headlight

assembly.
6. Install t h e h e a d l i g h t in the r e v e r s e o r d e r of r e m o v a l .
7. After r e p l a c e m e n t , a d j u s t t h e h e a d l i g h t s to local
r e q u i r e m e n t s ( s e e p a g e 22-140).
22-139
Exterior Lights
Headlight A d j u s t m e n t
2. Park t h e v e h i c l e 2 5 ft (7.5 m ) a w a y f r o m a w a l l or a
^CAUTION s c r e e n (A).
H e a d l i g h t s b e c o m e v e r y hot d u r i n g u s e ; d o not
A
t o u c h t h e m or a n y a t t a c h i n g h a r d w a r e i m m e d i a t e l y
after t h e y h a v e b e e n t u r n e d off. / 2 5 ft (7.5 m )
Before adjusting the headlights:
• Park t h e v e h i c l e o n a level s u r f a c e .
• M a k e s u r e t h e tire p r e s s u r e s a r e c o r r e c t .
• T h e d r i v e r or s o m e o n e w h o w e i g h s t h e s a m e s h o u l d
sit in t h e d r i v e r ' s s e a t .
1. C l e a n the outer l e n s s o that y o u c a n s e e the c e n t e r

of t h e h e a d l i g h t s (A).
3. O p e n the h o o d .
22-140
• BODY •
Side Turn Signal Light Replacement
4. T u r n t h e l o w b e a m s o n . 1. P u s h the s i d e t u r n s i g n a l light (A) f o r w a r d , t h e n

r e m o v e it f r o m the f e n d e r .
5. D e t e r m i n e if the h e a d l i g h t s a r e a i m e d properly.
S i d e Turn Signal Light Bulb: 5W
Vertical adjustment:
B N
M e a s u r e the height of the h e a d l i g h t s (A). T h e lights

s h o u l d reflect 52 m m (2.1 in.) b e l o w h e a d l i g h t
h e i g h t (B).
2. D i s c o n n e c t t h e 2 P c o n n e c t o r (B) f r o m t h e light.
6. If n e c e s s a r y , a d j u s t t h e h e a d l i g h t s to local
r e q u i r e m e n t s by t u r n i n g the vertical a d j u s t e r (A).
22-141
Exterior Lights
Taillight Replacement Taillight/Brake Light LED
Replacement
1. O p e n t h e trunk lid a n d pull b a c k the trunk t r i m
p a n e l ( s e e p a g e 20-77).
'04-08 models
2. D i s c o n n e c t t h e c o n n e c t o r s (A) f r o m t h e t a i l l i g h t
1. R e m o v e the taillight ( s e e p a g e 22-142).
'00-03 m o d e l s
2 . R e m o v e the t w o s c r e w s a n d c o v e r (A).
Brake/Taillight: 21/5 W
B a c k - u p Light: 21 W
T u r n S i g n a l Light: 21 W
S i d e Marker Light: 5 W R
'04-08 models
3. R e m o v e the t w o s c r e w s (A) a n d the T O R X s c r e w (B),
t h e n pull out the L E D (C).
4. B e f o r e installing the taillight, c h e c k t h e g a s k e t . If it

3. R e m o v e the f o u r m o u n t i n g n u t s (B), t h e n pull out is d i s t o r t e d or s t a y s c o m p r e s s e d , r e p l a c e it.
t h e taillight.
5. Install the n e w bulb in the r e v e r s e o r d e r of r e m o v a l .
4. B e f o r e installing t h e taillight, c h e c k t h e g a s k e t . If it
i s d i s t o r t e d or s t a y s c o m p r e s s e d , r e p l a c e it.
5. Install t h e taillight in t h e r e v e r s e o r d e r of r e m o v a l .
6. After installing t h e taillight, run w a t e r o v e r it to

m a k e s u r e it d o e s not leak.
22-142
High Mount Brake Light License Plate Light Replacement
Replacement
1. R e m o v e t h e l i c e n s e plate light a s s e m b l y , a n d
d i s c o n n e c t the 2 P c o n n e c t o r f r o m it.
1. O p e n t h e trunk lid.
License Plate Light Bulb: 5 W
4 . Install t h e high m o u n t brake light in t h e r e v e r s e 2 . T a k e t h e l e n s off, t h e n r e p l a c e the b u l b ,

o r d e r of r e m o v a l .
5 . After installing t h e high m o u n t brake light, r u n

w a t e r o v e r it to m a k e s u r e it d o e s not leak.
22-143
Exterior Lights
Brake Pedal Position Switch Test
1. D i s c o n n e c t the b r a k e p e d a l p o s i t i o n s w i t c h 1. D i s c o n n e c t t h e b r a k e p e d a l p o s i t i o n s w i t c h
connector, and r e m o v e the s w i t c h . connector, and remove the switch.
2. C h e c k for continuity b e t w e e n t h e No. 1 a n d t h e 2. C h e c k for c o n t i n u i t y b e t w e e n t h e No. 1 a n d the

N o . 4 t e r m i n a l s of t h e b r a k e p e d a l position s w i t c h No. 2 t e r m i n a l s of t h e brake p e d a l position s w i t c h
c o n n e c t o r . T h e r e s h o u l d be continuity w h e n t h e c o n n e c t o r . T h e r e s h o u l d be c o n t i n u i t y w h e n the
button (A) is p r e s s e d , a n d no continuity w h e n t h e button (A) is p r e s s e d , a n d no c o n t i n u i t y w h e n t h e
button is r e l e a s e d . button is r e l e a s e d .
BRAKE PEDAL POSITION SWITCH CONNECTOR BRAKE PEDAL POSITION SWITCH CONNECTOR
1 2
3 4
T e r m i n a l s i d e of m a l e t e r m i n a l s T e r m i n a l s i d e of m a l e t e r m i n a l s
I )
\
3. C h e c k for c o n t i n u i t y b e t w e e n t h e No. 2 a n d t h e 3. C h e c k for c o n t i n u i t y b e t w e e n t h e N o . 3 a n d the
N o . 3 t e r m i n a l s . T h e r e s h o u l d be continuity w h e n No. 4 t e r m i n a l s . T h e r e s h o u l d b e continuity w h e n
t h e button is r e l e a s e d , a n d n o continuity w h e n t h e t h e button is r e l e a s e d , a n d n o c o n t i n u i t y w h e n t h e
button is p r e s s e d . button is p r e s s e d .
4. If t h e b r a k e p e d a l p o s i t i o n s w i t c h is faulty, r e p l a c e 4. If t h e brake p e d a l p o s i t i o n s w i t c h is faulty, r e p l a c e

it. it.
5. Install t h e b r a k e p e d a l p o s i t i o n s w i t c h , a n d a d j u s t it 5. Install t h e b r a k e p e d a l p o s i t i o n s w i t c h , a n d a d j u s t it
( s e e p a g e 19-6). ( s e e p a g e 19-6).
22-144
Turn Signal/Hazard Warning Lights
UNDER-DASH
FUSE/RELAY BOX
22-145
Circuit Diagram
UNDER-DASH
MAIN UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH FUSE/RELAY BOX
BATTERY
No. 41 (100 A} No. 42 (40 A)
C2 /BAT-A No. 7 (7.5 A)
0- —crxjD er\jo-
IG1-A A
BLK/YEL — C T X J O —
No.49(10A) RED/BLU
B4
- WHT/BLK
No. 23 (10 A)
FUSE
-GRN/RED
V
RED/BLK
GRNÊL HAZARD
TURN SIGNAL WARNING
SWITCH 4 (Not used) 8 SWITCH
0FF
O* , 0 -
Left | Right
ON& ZD 6 JO "J^ ZD% ^v/^ idK LIGHT
(0.85 W)
OLeft O Right 0 T
BLK/RED GRN/WHT RED
• BLK/RED
2
RED
1
GRN/RED TURN SIGNAL/

GRN/YEL HAZARD RELAY
V
DASHUGHTS
LEFT TURN SIGNAL LIGHT RIGHT TURN SIGNAL LIGHT BRIGHTNESS
CONTROLLER
(In the gauge
GRN/RED GRN/RED GRN/RED GRN/RED GRN/YEL GRN/YEL GRN/YEL GRN/YEL
REAR SIDE FRONT /TN FRONT SIDE REAR

(€0(21W)
(§J (&J (5W)
&)(21W) (§){5W)
(21W) ( j ^ ) (21W)
BLK BLK BLK
G602 G301 G301 G201 G401
22-146
Turn Signal/Hazard Relay Input Test
1. R e m o v e the t u r n s i g n a l / h a z a r d r e l a y (A) f r o m t h e u n d e r - d a s h f u s e / r e l a y b o x (B).
2 . I n s p e c t the c o n n e c t o r a n d s o c k e t t e r m i n a l s to be s u r e t h e y a r e all m a k i n g g o o d c o n t a c t .
• If the t e r m i n a l s a r e bent, l o o s e , or c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .

3. M a k e t h e s e input t e s t s at the f u s e / r e l a y box.
• If a n y t e s t i n d i c a t e s a p r o b l e m , find a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m .
• If all t h e input t e s t s p r o v e O K , the turn s i g n a l / h a z a r d r e l a y m u s t b e faulty; r e p l a c e it.
Cavity T e s t condition Test: Desired result P o s s i b l e c a u s e if d e s i r e d r e s u l t i s n o t

obtained
3 U n d e r all c o n d i t i o n s M e a s u r e t h e v o l t a g e to g r o u n d : • Poor ground (G401)
T h e r e s h o u l d be l e s s t h a n 0.5 V . • A n o p e n in t h e w i r e
2 Ignition s w i t c h O N (II) M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 7 (7.5 A ) f u s e in the u n d e r -
T h e r e s h o u l d be battery v o l t a g e . d a s h fuse/relay box
• Faulty hazard warning switch
Hazard warning switch M e a s u r e t h e v o l t a g e to g r o u n d : • B l o w n N o . 49 (10 A ) f u s e in the u n d e r -
O N , ignition s w i t c h T h e r e s h o u l d be battery v o l t a g e . hood fuse/relay box
OFF • Faulty hazard warning switch
1 Hazard warning switch Hazard lights s h o u l d c o m e o n . • Poor ground (G201, G301, G501,
O N a n d connect No. 1 G602)
a n d No. 2 terminals • Faulty hazard warning switch
Ignition s w i t c h O N (II) Right o r left turn s i g n a l lights • F a u l t y turn s i g n a l s w i t c h
a n d c o n n e c t No. 1 a n d should c o m e on. • A n o p e n in t h e w i r e
N o . 2 t e r m i n a l s ; turn
s i g n a l s w i t c h in right or
left position
22-147
Hazard Warning Switch Test/Replacement
1. R e m o v e t h e c e n t e r c o n s o l e ( s e e p a g e 20-80).
2. D i s c o n n e c t the 10P c o n n e c t o r (A) f r o m t h e h a z a r d

w a r n i n g s w i t c h (B).
1 2 F=3 3 4
5 6 9 10
/I-
3. R e m o v e t h e t w o s c r e w s a n d t h e h a z a r d w a r n i n g
switch.
4. C h e c k for c o n t i n u i t y b e t w e e n t h e t e r m i n a l s in e a c h
s w i t c h position a c c o r d i n g to t h e table.
\ Terminal
1 2 3 4 5 6 8 9 10
Position \
r\
OFF
o- -©- -o
/--\
o o o -o
r\
o- -©- -o
ON vj
5. If the continuity i s not a s s p e c i f i e d , r e p l a c e the

i l l u m i n a t i o n b u l b (C) o r t h e s w i t c h .
22-148
Interior Lights
Component Location index
22-149
Interior Lights
Circuit Diagram
*1:'00-03 models
UNDER-DASH *2: '04-08 models
BATTERY
No 41 (100 A) No. 54 (30 A) No. 24 (7.5 A)
' WHT/BLU
WHT/BLU WHT/BLU
TRUNK
LIGHT
(5W)
BLU/BLK
TRUNK
INDICATOR
LIGHT
GAUGE ASSEMBLY
GRN/YEL BLU/BLK
KEYLESS
DOOR LOCK
CONTROL UNIT
• BLK/WHT BLU/BLK
1 DRIVER'S i PASSENGER'S 3 TRUNK

6
l ^ DOOR DOOR LID
SJ SWITCH SWITCH LATCH
(Closed: (Closed: SWITCH
Door open) Door open) (Closed:
Trunk lid open)
BLK
XL.
G601
22-150
!,:V • • -:•
BODY
Celling Light/Spotlight Test
1. T u r n t h e c e i l i n g / s p o t l i g h t s s w i t c h O F F . 5. C h e c k f o r c o n t i n u i t y b e t w e e n t h e t e r m i n a l s i n e a c h
switch position according to the table.
2. P r y o f f t h e l e n s (A).
\ Terminal BODY
1 2 GROUND
Ceiling Light/Spotlight Bulb: 5 W Position \
OFF
CEILING LIGHT MIDDLE o -®- o
ON
KJ
R
ON o -©- —o
OFF
SPOTLIGHTS
ON
L
OFF
KJ
~— ~ ' '—'
© 1
m c
3. R e m o v e t h e t w o s c r e w s a n d t h e c e i l i n g / s p o t l i g h t
h o u s i n g (B).
4. D i s c o n n e c t t h e 4 P c o n n e c t o r (C) f r o m t h e h o u s i n g .
6. If t h e c o n t i n u i t y is n o t a s s p e c i f i e d , r e p l a c e t h e
bulbs or the light.
22-151
Interior Lights
Trunk Light Test Trunk Lid Latch S w i t c h Test
1. O p e n t h e t r u n k l i d . 1. O p e n t h e t r u n k l i d .
2. P r y o u t t h e t r u n k l i g h t a s s e m b l y . 2. D i s c o n n e c t t h e 3 P c o n n e c t o r f r o m t h e t r u n k l i d l a t c h .
T r u n k L i g h t Bulb: 5 W
Terminal side of
male terminals
3. Check f o r c o n t i n u i t y b e t w e e n t h e t e r m i n a l s in each
t r u n k lid p o s i t i o n a c c o r d i n g to t h e table.
3. D i s c o n n e c t t h e 2P c o n n e c t o r f r o m t h e h o u s i n g .
\ Terminal
2 3
4. O p e n t h e t r u n k l i g h t c o v e r . Position \^
5. C h e c k f o r c o n t i n u i t y b e t w e e n t h e N o . 1 a n d N o . 2 OPEN
terminals. CLOSED
6. If t h e r e is n o c o n t i n u i t y , r e p l a c e t h e b u l b o r t h e l i g h t .
t r u n k lid latch.
22-152
BODY
Dash Lights Brightness Controller
Circuit Diagram
'00-03 m o d e l s
: '02-03 models
UNDER-DASH
No. 41 (100 A) No. 54 (30 A) No. 23 (10 A)

—crvx>—-f crxjD—- WHT/GRN
No. 42 WHT/GRN WHT/GRN

(40 A)
No. 25 (7.5 A)
IGNITION
WHT SWITCH
No. 5 (7.5 A)
TAILLIGHT
BLK/YEL RELAY
RED/BLK
COMBINATION
YEL WHT/RED RED/BLK RED/BLK LIGHT SWITCH
[ON::C0; or =D J
B3 GAUGE ASSEMBLY
v
DASH LIGHTS LIGHTS
BRIGHTNESS HAZARD WARNING
VOLTAGE FEED CONTROLLER SWITCH LIGHT
fl CONVERTIBLE TOP
Mill SWITCH LIGHT
AUDIO REMOTE
CPU SWITCH LIGHTS
CRUISE CONTROL MAIN
SWITCH LIGHT
DRIVING CIRCUIT REAR WINDOW
DEFOGGER SWITCH
LIGHT*
BLK RED
JLL.
G501 G401
22-153
'04-08 m o d e l s
UNDER-DASH
No. 41 (100 A} No. 54 (30 A) No. 23 (10 A)
( ± >
3
YEL ' —crxj>— WHT/GRN
WHT/GRN AHT.CR.J
No 25 (7.5 A)
No 5 (7.5 A)
TAILLIGHT
BLK/YEL
-cru>- RELAY
RED/BLK BLU
COMBINATION
WHT/RED RED/BLK RED/BLK LIGHT SWITCH
[ON: HX>;or=D J
A10 A8 GAUGE ASSEMBLY
V
AUDIO REMOTE SWITCH
DASH LIGHTS LIGHT
BRIGHTNESS AUDIO UNIT
CONTROLLER CONVERTIBLE TOP SWITCH
LIGHT
CPU zzczrz CRUISE CONTROL MAIN

SWITCH LIGHT
HAZARD WARNING SWITCH
LIGHT
DRIVING CIRCUIT LIGHT
PASSENGER'S AIRBAG
CUTOFF INDICATOR
ILLUMINATION LIGHT
REAR WINDOW DEFOGGER
SWITCH LIGHT
VSA OFF SWITCH UGHT
BLK BLK
G501 G401
22-154
- +1:;
BODY U
C o n t r o l l e r Input T e s t
'00-03 models
1. R e m o v e t h e g a u g e a s s e m b l y (see p a g e 2 2 - 8 9 ) .
2. I n s p e c t t h e g a u g e a s s e m b l y c o n n e c t o r B (12P) t e r m i n a l s t o b e s u r e t h e y a r e a l l m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l s a r e b e n t , l o o s e , o r c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
• If t h e t e r m i n a l s l o o k O K , g o t o s t e p 3.
RED/BLK YEL WHT/RED
W i r e s i d e of
female terminals
(cont'd)
22-155
C o n t r o l l e r Input T e s t (cont'd}
3. R e c o n n e c t t h e c o n n e c t o r s t o t h e g a u g e a s s e m b l y .
4. B a c k p r o b e t h e c o n n e c t o r a n d m a k e t h e s e I n p u t t e s t s .
• If a l l t h e i n p u t t e s t s p r o v e O K , t h e c o n t r o l l e r s w i t c h b o a r d o r t h e m a i n p r i n t e d c i r c u i t b o a r d i n t h e g a u g e
assembly m u s t be faulty; replace i t , ^

not obtained
B3 RED/BLK Combination Measure the voltage to ground: • B l o w n N o . 2 3 (10 A ) f u s e i n t h e
light switch There s h o u l d be battery voltage. under-dash fuse/relay box
O N &Qz) o r " • Faulty taillight relay
(ID) • Faulty c o m b i n a t i o n light switch
• Poor g r o u n d (G401)
B4 YEL Ignition switch Measure the voltage to ground: • B l o w n N o . 5 (7.5 A ) f u s e i n t h e
O N (II) There should be battery voltage. under-dash fuse/relay box
B5 WHT/RED U n d e r ail Measure the voltage to ground: • B l o w n N o . 2 5 (7.5 A ) f u s e i n t h e
conditions There should be battery voltage. under-dash fuse/relay box
B8 BLK U n d e r all Measure the voltage to ground: • Poor g r o u n d (G501)
conditions T h e r e s h o u l d b e l e s s t h a n 0.5 V . • A n o p e n in the w i r e
B9 BLK U n d e r all Measure the voltage to ground: • Poor g r o u n d (G501)
conditions T h e r e s h o u l d b e l e s s t h a n 0.5 V . • A n o p e n in the w i r e
B10 RED Combination Connect to ground: A n o p e n in the w i r e
light switch , Dash lights should c o m e o n full
O N 6008 or bright.
(ID)
22-156
'04-08 models
2 . I n s p e c t t h e g a u g e a s s e m b l y c o n n e c t o r A ( 2 2 P ) t e r m i n a l s t o be s u r e t h e y a r e a l l m a k i n g g o o d c o n t a c t .
• If the t e r m i n a l s a r e b e n t l o o s e , or c o r r o d e d , repair t h e m a s n e c e s s a r y , a n d r e c h e c k the s y s t e m .

• If the t e r m i n a l s look O K , go to s t e p 3.
RED/BLX YEL WHT/RED

\
A1 A2 A 3 A4 A5 A7 A 8 A 9 A10
W i r e s i d e of
A11 A12 A 1 3 A 1 4 A 1 5 A16
X A17 A18 A19 A 2 0 A21 A 2 2 female terminals
(cont'd)
22-157
Dash Lights Brightness 0^^©^;=^
C o n t r o l l e r Input T e s t ( c o n t ' d )
3. R e c o n n e c t t h e c o n n e c t o r s t o t h e g a u g e a s s e m b l y .
4. B a c k p r o b e t h e c o n n e c t o r a n d m a k e t h e s e i n p u t t e s t s .
• If a l l t h e i n p u t t e s t s p r o v e O K , t h e c o n t r o l l e r s w i t c h b o a r d o r t h e m a i n p r i n t e d c i r c u i t b o a r d i n t h e g a u g e
a s s e m b l y m u s t b e f a u l t y ; r e p l a c e it.
Cavity Wire Test condition Test: Desired result P o s s i b l e c a u s e if d e s i r e d r e s u l t i s

not obtained
A8 RED/BLK Combination Measure the voltage to ground: • B l o w n N o . 2 3 (10 A ) f u s e i n t h e
light switch There should be battery voltage. under-dash fuse/relay box
ON (3><£) or • Faulty taillight relay
(ID) • Faulty c o m b i n a t i o n light switch
• Poor g r o u n d (G401)
A9 YEL Ignition switch Measure the voltage to ground: • B l o w n N o . 5 (7.5 A ) f u s e i n t h e
O N (il) There should be battery voltage. under-dash fuse/relay box
A10 WHT/RED U n d e r all Measure the voltage to ground: • B l o w n N o . 2 5 (7.5 A ) f u s e i n t h e
conditions There s h o u l d be battery voltage. under-dash fuse/relay box
A17 BLK U n d e r all Measure the voltage to ground: • Poor g r o u n d (G501)
A18 BLK U n d e r all Measure the voltage to ground: * Poor g r o u n d (G501)
A19 RED Combination Connect to ground: A n o p e n in the w i r e
light switch Dash lights should c o m e on full
O N izOOz) o r bright.
(ID)
22-158
Accessory Power Sockets
22-159
Accessory Power Sockets
Circuit Diagram
MAIN UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH *1:CR model

*2: Except CR model
/BAT-B \
-WHT/BLK * + 0 °T
A C C * WHT/RED '
"BLU "
UNDER-DASH
No. 9 FUSE/RELAY
(10 A) BOX
BLU/WHT
—BLU/WHT | YEL/RED
V / BLU/WHT
STARTER CUT RELAY

IG2 CUT RELAY
WHT/RED
CLUTCH
INTERLOCK
*1 SWITCH
r"
BLU *2
4' ACCESSORY
1
4
POWER WHT/RED
SOCKET
RELAY
WHT
WHT*1
WHT/RED*2
ACCESSORY
POWER
(J) SOCKET
BLK
1
G601
22-160
BODY
Accessory Power Socket Test/Replacement
1. R e m o v e t h e r e a r c o n s o l e (see p a g e 2 0 - 8 2 ) . 5. R e m o v e t h e h o u s i n g a n d s o c k e t .
2. D i s c o n n e c t t h e 2 P c o n n e c t o r .
3. I n s p e c t t h e c o n n e c t o r t e r m i n a l s t o b e s u r e t h e y a r e
all m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l s a r e b e n t l o o s e o r c o r r o d e d ,
r e p a i r t h e m as n e c e s s a r y , a n d r e c h e c k t h e
system.
• If t h e t e r m i n a l s l o o k O K , g o t o s t e p 4.
BLK
*: CR model
4. T u r n t h e i g n i t i o n s w i t c h A C C (I), a n d m e a s u r e t h e
voltage between t h e No. 1 and No. 2 terminals.
• There s h o u l d be battery v o l t a g e .
• If t h e r e Is n o v o l t a g e , c h e c k f o r :
- B l o w n N o . 9 (10 A ) f u s e i n t h e u n d e r - d a s h
fuse/relay box
- B l o w n N o . 53 (20 A ) f u s e i n t h e m a i n u n d e r -
h o o d f u s e / r e l a y b o x (CR m o d e l )
- Faulty ACC cut relay
- F a u l t y a c c e s s o r y p o w e r s o c k e t r e l a y (CR
model)
- P o o r g r o u n d (G 601)
- P o o r g r o u n d (G 401) (CR m o d e l )
- A n o p e n in the w i r e
22-161
Horns
HORN (high)
( ' 0 2 - 0 8 models)
Test/Replacement, page 22-164
22-162
Circuit Diagram
10 A:'00-01 models
15 A:'02-08 models
BATTERY
©
No. 47*
WHT/GRN HORN
RELAY
v
BRAKE
A11 A9
('02-08 models)
LIGHTS
i
ORN BLU/RED BLU/RED
ORN
V
KEYLESS
DOOR LOCK
CONTROL
UNIT
O" Y
HORN
(Low)
© HORN
(High)
V
• SET/ HORN
RESUME SWITCH SWITCH
{'00-03 models)
• SET/RESUME/
CANCEL SWITCH
{'04-08 models)
L7-. ...j
22-163
Horns
Horn T e s t / R e p l a c e m e n t
1. R e m o v e t h e f r o n t b u m p e r '00-03 m o d e l s (see p a g e
2 0 - 1 0 4 ) ; ' 0 4 - 0 8 m o d e l s (see p a g e 2 0 - 1 0 5 ) ; CR m o d e l
(see p a g e 20-106).
2 . O p e n t h e h o o d ('02-08 m o d e l s ) .
3. D i s c o n n e c t t h e 1 P c o n n e c t o r (A), a n d r e m o v e t h e
h o r n (B).
4. Test t h e h o r n by c o n n e c t i n g battery p o w e r t o the

t e r m i n a l (A) a n d g r o u n d i n g t o t h e b r a c k e t ( B ) . T h e
horn should sound.
5. If it f a i l s t o s o u n d , r e p l a c e it.
22-164
• BODY •
' orn S w i t c h T e s t
1, R e m o v e t h e s t e e r i n g c o l u m n u p p e r a n d l o w e r 4 R e m o v e t h e d r i v e r ' s a i r b a g ( s e e p a g e 23-164).
c o v e r ( s e e p a g e 17-9).
5 C h e c k for continuity b e t w e e n the c a b l e reel N o . 2
2. D i s c o n n e c t the d a s h b o a r d w i r e h a r n e s s B 4 P t e r m i n a l (A) a n d the horn s w i t c h p o s i t i v e t e r m i n a l
c o n n e c t o r (A) f r o m t h e c a b l e reel (B). (B).
• If t h e r e is n o continuity, r e p l a c e t h e c a b l e r e e l ,
'00-05 m o d e l s ( s e e p a g e 2 3 - 1 7 3 ) ; '06-08 m o d e l s
( s e e p a g e 23-174) a n d c h e c k for p r o p e r o p e r a t i o n .
• If t h e r e is continuity, r e p l a c e the h o r n s w i t c h .
1 2 3 4
3. C h e c k for continuity b e t w e e n the c a b l e reel N o . 2

t e r m i n a l a n d b o d y g r o u n d in e a c h s w i t c h position
a c c o r d i n g to the table.
• If t h e r e is continuity, the h o r n s w i t c h is O K .
• If t h e r e is no continuity, g o to s t e p 4.
\ Terminal
2 Body ground
Position \
Pushed o -o
Released
22-165
Trunk Lid Opener
22-166
Circuit Diagram
UNDER-DASH
M A I N UNDER-HOOD FUSE/RELAY B O X FUSE/RELAY BOX
No. 41(100 A) No. 54 (30 A) No. 26 (15 A)

3 1
YEL
WHT
KEYLESS
DOOR LOCK
CONTROL
TRUNK
UNIT LID
v 1
OPENER
SWITCH
TRUNK INDICATOR
BLK/YEL BLK/YEL
LIGHT
TRUNK UGHT
V
BLK/YEL BLU/BLK
TRUNK UD OPENER
SOLENOID/
LATCH SWITCH
BLK
G601
22-167
Trunk Lid Opener
Trunk Lid Opener S w i t c h T e s t Trunk Lid Opener Solenoid Test
1 . R e m o v e t h e r e a r c o n s o l e (see p a g e 2 0 - 8 2 ) . 1. O p e n t h e t r u n k l i d .
2. D i s c o n n e c t t h e 2P c o n n e c t o r f r o m t h e s w i t c h . 2. D i s c o n n e c t t h e 3P c o n n e c t o r f r o m t h e t r u n k l i d l a t c h .
Terminal side of
male terminals
3. C h e c k f o r c o n t i n u i t y b e t w e e n t h e N o . 1 a n d N o . 2
terminals.
• T h e r e s h o u l d b e c o n t i n u i t y w h e n t h e s w i t c h is 3. Check solenoid operation by connecting p o w e r and

pushed. g r o u n d according to the table. To prevent damage
• T h e r e s h o u l d b e n o c o n t i n u i t y w h e n t h e s w i t c h is to the solenoid, apply battery voltage only
released. momentarily.
4. If t h e c o n t i n u i t y c h e c k is n o t a s s p e c i f i e d , r e p l a c e \ Terminal
the switch. 1 2
Position \^
UNLOCK © 0
4 . If t h e s o l e n o i d d o e s n o t o p e r a t e as s p e c i f i e d ,
r e p l a c e it.
22-168
Power Mirrors
22-169
Power Mirrors
Circuit Diagram

BATTERY
22-170
mm
Function Test
1 . R e m o v e t h e d r i v e r ' s d o o r p a n e l (see p a g e 2 0 - 5 ) . 5. C h e c k f o r c o n t i n u i t y b e t w e e n t h e N o . 10 t e r m i n a l
and body ground.
2 . D i s c o n n e c t t h e , 10P c o n n e c t o r (A) f r o m t h e p o w e r M o v e t h e m i r r o r s e l e c t o r s w i t c h t o t h e left or r i g h t
m i r r o r s w i t c h (B), a n d i n s p e c t t h e t e r m i n a l s . If t h e a n d hold d o w n t h e m i r r o r s w i t c h in any direction.
t e r m i n a l s a r e O K , g o t o s t e p 3. T h e r e s h o u l d be less t h a n 1 V.
• If t h e r e is n o m o r e t h a n 1 V , c h e c k f o r :
- A n o p e n in t h e BLK w i r e .
- P o o r g r o u n d (G 5 0 1 ) .
• If t h e r e is l e s s t h a n 1 V , c h e c k b o t h m i r r o r s
i n d i v i d u a l l y as d e s c r i b e d .
Left mirror
6. C o n n e c t t h e N o . 9 t e r m i n a l t o t h e N o . 7 t e r m i n a l ,
a n d t h e N o . 5 ( o r N o . 4) t e r m i n a l t o b o d y g r o u n d
w i t h j u m p e r w i r e s . T h e left m i r r o r s h o u l d tilt d o w n
( o r s w i n g left) w i t h t h e i g n i t i o n s w i t c h O N (II).
• If t h e m i r r o r d o e s n o t t i l t d o w n ( o r d o e s n o t s w i n g
l e f t ) , c h e c k f o r a n o p e n i n t h e G R N / W H T (or RED)
w i r e b e t w e e n t h e l e f t m i r r o r a n d t h e 10P
c o n n e c t o r . If t h e w i r e is O K , c h e c k t h e l e f t m i r r o r
actuator.
• If t h e m i r r o r n e i t h e r t i l t s d o w n n o r s w i n g s l e f t ,
RED GRN/WHT RED/BLU YEL/BLK repair the RED/YEL w i r e .
• If t h e m i r r o r w o r k s p r o p e r l y , c h e c k t h e m i r r o r
3. C h o o s e t h e a p p r o p r i a t e test b a s e d o n t h e switch.
symptom:
Right mirror
• B o t h m i r r o r s d o n ' t w o r k , g o t o step 4.
• Left m i r r o r d o e s n ' t w o r k , g o t o s t e p 6. 7. C o n n e c t t h e N o . 9 t e r m i n a l t o t h e N o . 6 t e r m i n a l ,
• R i g h t m i r r o r d o e s n ' t w o r k , g o t o s t e p 7. a n d t h e N o . 5 ( o r N o . 3) t e r m i n a l t o b o d y g r o u n d
w i t h j u m p e r wires. The right m i r r o r should tilt
Both mirrors d o w n (or s w i n g left) w i t h t h e i g n i t i o n s w i t c h O N (II).
4 . R e c o n n e c t t h e 10P c o n n e c t o r , a n d m e a s u r e t h e • If t h e m i r r o r d o e s n o t t i l t d o w n ( o r d o e s n o t s w i n g
voltage between the No. 9 terminal and body l e f t ) , c h e c k f o r a n o p e n i n t h e G R N / W H T (or B L U /
g r o u n d w i t h t h e i g n i t i o n s w i t c h O N (II). W H T ) w i r e b e t w e e n t h e r i g h t m i r r o r a n d t h e 10P
There s h o u l d be battery v o l t a g e . connector.
M o v e t h e m i r r o r s e l e c t o r s w i t c h t o t h e left o r r i g h t If t h e w i r e is O K , c h e c k t h e r i g h t m i r r o r a c t u a t o r .
and hold d o w n the mirror switch in any direction. • If t h e m i r r o r n e i t h e r t i l t s d o w n n o r s w i n g s l e f t ,
repair the RED/BLU w i r e .
• If t h e r e is n o b a t t e r y v o l t a g e , c h e c k f o r ; • If t h e m i r r o r w o r k s p r o p e r l y , c h e c k t h e m i r r o r
- B l o w n N o . 19 (7.5 A ) f u s e i n t h e u n d e r - d a s h switch.
fuse/relay box.
- A n o p e n in the YEL/BLK w i r e .
• If t h e r e is b a t t e r y v o l t a g e , g o t o s t e p 5.
22-171
Power Mirrors
P o w e r Mirror S w i t c h T e s t Power Mirror Actuator Test
1 . R e m o v e t h e d r i v e r ' s d o o r p a n e l (see p a g e 2 0 - 5 ) . 1. R e m o v e t h e d o o r p a n e l (see p a g e 20-5).
2. D i s c o n n e c t t h e 10P c o n n e c t o r f r o m t h e p o w e r 2. D i s c o n n e c t t h e 3 P c o n n e c t o r f r o m t h e p o w e r m i r r o r .
mirror switch.
Terminal side o
male terminals
3. C h e c k f o r c o n t i n u i t y b e t w e e n t h e t e r m i n a l s i n e a c h
switch position according to the table.
\ Terminal 3. C h e c k a c t u a t o r o p e r a t i o n b y c o n n e c t i n g p o w e r a n d
3 4 5 6 7 9 10
Position \
ground according to the table.
o— ~o
UP r\ r\
KJ KJ KJ \ Terminal
DOWN /~~\
KJ
o— KJ 1 2 3 -
L. LEFT r~\ Position \
KJ KJ
RIGHT o— r\
-o r~\
TILT U P
0 ©
KJ KJ KJ ©
OFF
KJ
c\
KJ
TILT D O W N
0
UP o— r\ - o r\ SWING LEFT
0 ©
DOWN
KJ
—
KJ— —o
KJ
r\
SWING RIGHT
0
H
~~©~1
KJ - o KJ
R. LEFT c\
KJ
O— - o
KJ 4. If t h e m i r r o r f a i l s t o w o r k p r o p e r l y , r e p l a c e t h e
RIGHT r\ mirror actuator.
o—
KJ
OFF -o
switch.
22-172
Power Mirror Actuator Replacement
1 . R e m o v e t h e p o w e r m i r r o r f r o m t h e d o o r (see p a g e 6. R e m o v e t h e s c r e w s a n d t h e a c t u a t o r f r o m t h e
20-22). housing.
2. Record t h e t e r m i n a l locations a n d w i r e colors.
3. C u t t h e w i r e h a r n e s s w i t h a w i r e c u t t e r .
7. R o u t e t h e w i r e h a r n e s s o f t h e n e w a c t u a t o r t h r o u g h
t h e hole of t h e m i r r o r h o u s i n g , t h e n install t h e n e w
a c t u a t o r in t h e r e v e r s e o r d e r o f r e m o v a l .
4. C a r e f u l l y p u l l o u t t h e b o t t o m e d g e o f t h e m i r r o r
holder by hand. 8. I n s e r t t h e t e r m i n a l s i n t o t h e c o n n e c t o r i n t h e
o r i g i n a l a r r a n g e m e n t as s h o w n .
5. S e p a r a t e t h e m i r r o r h o l d e r f r o m t h e a c t u a t o r b y
slowly pulling t h e m apart.
Left a n d right
2 3
YEL BRN BLU
Terminal side of m a l e terminals
9. R e a s s e m b l e t h e m i r r o r i n t h e r e v e r s e o r d e r o f
disassembly.
Be c a r e f u l n o t t o b r e a k t h e m i r r o r h o l d e r w h e n
r e i n s t a l l i n g it t o t h e a c t u a t o r .
10. O p e r a t e t h e p o w e r m i r r o r t o c h e c k t h a t t h e a c t u a t o r
works smoothly.
22-173
Wipers/Washers
C o m p o n e n t Location index
; W I N D S H I E L D WASHER TUBE
' Replacement page 22-186
, WINDSHIELD WIPER A R M S
a n d LINKAGE
WIPER/WASHER SWITCH
Test/Replacement, page 22-182

('00-01 m o d e l s )
Test, page 22-48
INTERMITTENT WIPER CIRCUIT

(In t h e gauge a s s e m b l y )
Input Test, page 22-180

('02-08 models)
Test, page 22-48
WINDSHIELD WIPER MOTOR

Test, page 22-183
Replacement, page 2 2 - 1 8 5
W A S H E R RESERVOIR
WINDSHIELD W A S H E R MOTOR
Test, page 22-183
22-174
22-175
Wipers/Washers
Circuit Diagram
'00-03 models
MAIN UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH : '02-03 models

UNDER-DASH
BATTERY FUSE/RELAY BOX
No. 41 (100 A) No. 42 (40 A)
No. 8 (20 A)
BLK/YEL • GRN/BLK
No. 12 (15 A)
_T>>No.5(7.5A)
BLK/YEL ^ > ^ F U S E ' GRN/BLK
No. 54 (30 A)
BLK/WHT GRN/BLK
WINDSHIELD WIPER/WASHER SWITCH
SWITCH
6
INT
m OFF/INT
12
O
LO
MIST MIST
WHT 'BLK • BLU/BLK

• WHT/BLK
• BLU/ORN
GRN/BLK GRN/RED BLK BLU/YEL —GRN —
1 [2]
INTERMITTENT
WIPER
RELAY
2 [1]|4
GRN/BLK WHT/BLK BLU/WHT
• BLK •
WINDSHIELD WIPER MOTOR
WINDSHIELD , Rfl
WASHER I M
MOTOR
UNDER-DASH
BLK BLU/WHT BLK BLK FUSE/RELAY BOX
No. 13 (7.5 A)
• BLU/WHT
G201 G301 G401
22-176
UNDER-DASH
FUSE/RELAY BOX
IGNITION No. 5 (7.5 A)

SWITCH BLK/YEL —CTVJ>-
(IG1-A)
No. 25 (7.5 A)
No. 54 (30 A)
— C T X J O —
FUSE
WHT/RED YEL
X L
G501
22-177
Wipers/Washers
C i r c u i t D i a g r a m (cont'd)
"04-08 m o d e l s

UNDER-DASH
BATTERY FUSE/RELAY BOX
No. 41 (100 A) No. 42 (40 A)
@-
C2
—crv£>— —cr\j>- -WHT No. 8 (20 A)
BLK/YEL CRN/BLK
- BLK/YEL _J>>No.5(7,
1>^FUSE
.5 A)
No. 12 (15 A)
GRN/BLK J
No.54(30A)
BLK/WHT GRN/BLK
WINDSHIELD WIPER/WASHER SWITCH
GRN/BLK WHT/BLK
WINDSHIELD , „
WASHER I M
MOTOR
22-178
UNDER-DASH
FUSE/RELAY BOX
mow i v .
IGNITION No. 5 (7.5 A}
ITCH A j > -
SWITCH BLK/YEL
(IG1l-A) ^
No. 25 (7.5 A)
No. 54 (30 A) r^s^ -YEL •
FUSE
BLU/BLK YEL WHT/RED

WHT/BLK
BLU/ORN
GRN —
B12 B18 B17 A1G
VOLTAGE FEED
» I > GAUGE
ASSEMBLY
CPU
WIPER/WASHER
DRIVING CIRCUIT
BLK
BLK
G501
22-179
Wipers/Washers
i n t e r m i t t e n t Wiper C i r c u i t Input T e s t
'00-03 models
1 . R e m o v e t h e g a u g e a s s e m b l y ( s e e p a g e 22-89).
2. Inspect t h e all connectors a n d socket t e r m i n a l s t o b e sure t h e y are all m a k i n g g o o d contact.
• If t h e t e r m i n a l s a r e b e n t l o o s e , o r c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
• If t h e t e r m i n a l s l o o k O K , g o t o s t e p 3 .
G A U G E A S S E M B L Y C O N N E C T O R B (12P) G A U G E A S S E M B L Y C O N N E C T O R C (20P)
YEL WHT/RED
V BLK
/
GRN
/
BLU/ORN
\ \
\ WHT/BLK
BLU/BLK
Wire side of female terminals Wire side of female terminals
3. R e c o n n e c t t h e g a u g e a s s e m b l y .
4. M a k e t h e s e i n p u t t e s t s a t t h e c o n n e c t o r .
• If a l l t h e i n p u t t e s t s p r o v e O K , t h e g a u g e a s s e m b l y m u s t b e f a u l t y ; r e p l a c e i t .
Cavity Wire Test condition Test: Desired result P o s s i b l e c a u s e if d e s i r e d r e s u l t i s

not obtained
B4 YEL Ignition switch Measure the voltage to ground: • B l o w n N o . 5 (7.5 A ) f u s e i n t h e
• A nopen inthe wire
B5 WHT/RED U n d e r all Measure the voltage to ground: • B l o w n N o . 5 4 (30 A ) f u s e in t h e
conditions There should be battery voltage. main under-hood fuse/relay b o x
• B l o w n N o . 2 5 (7.5 A ) f u s e i n t h e
:
• A n open inthe wire
B8 BLK Under all Measure the voltage to ground: • Poor g r o u n d (G501)
B9 conditions T h e r e s h o u l d b e less t h a n 0.5 V . • A n open inthe wire
B11 GRN Ignition switch Measure the voltage to ground: • B l o w n N o . 8 (20 A ) f u s e i n t h e
• Faulty Intermittent w i p e r relay
• A nopen inthe wire
C11 BLU/ORN Ignition switch Measure the voltage to ground: • B l o w n N o . 13 (7.5 A ) f u s e i n t h e
O N (II), w i p e r There should be battery voltage. under-dash fuse/relay box
switch OFF • Faulty w i p e r m o t o r
(PARKED) * open int h e w i r e
C12 BLU/BLK Ignition switch Measure the voltage t o ground: ° B l o w n N o . 12 (15 A ) f u s e i n t h e
O N (II) a n d w i p e r There should be battery voltage. under-dash fuse/relay box
switch at INT • Faulty w i p e r switch
• A n open in t h e w i r e
C13 WHT/BLK Ignition switch Measure the voltage t o ground: >wn N o . 12 ( 1 5 A ) f u s e i n t h e
O N (II) a n d There should be battery voltage. under-dash fuse/relay box
washer switch • Faulty w a s h e r switch
c
ON A n open in t h e wire
22-180
n
I B0DY
'04-08 models
1 . R e m o v e t h e g a u g e a s s e m b l y (see p a g e 2 2 - 8 9 ) .
2 . Inspect t h e all c o n n e c t o r s a n d socket t e r m i n a l s t o be s u r e t h e y are all m a k i n g g o o d c o n t a c t .
• If t h e t e r m i n a l s a r e b e n t l o o s e , o r c o r r o d e d , r e p a i r t h e m a s n e c e s s a r y , a n d r e c h e c k t h e s y s t e m .
• If t h e t e r m i n a l s look O K , g o t o s t e p 3.
G A U G E A S S E M B L Y CONNECTOR A (22P) G A U G E A S S E M B L Y CONNECTOR B (30P)
•- •' •-•YEL WHT/RED
1 2 3 4 5 7 8 9 10
/ 2 3 4 5 6 7
x 8 9 10 11 12 13 14
M ,7
23 2 4
11 12 13 14 15 18 19 20 21 22 15 16 17 18 13 20 21
22 |XI 25 26 27 28 29 30
/ \
16
BLK BLK
BLU/BLK
Wire side of female terminals Wire side of female terminals
3. R e c o n n e c t t h e g a u g e a s s e m b l y .
4 . M a k e t h e s e i n p u t t e s t s at t h e c o n n e c t o r .
• If a l l t h e i n p u t t e s t s p r o v e O K , t h e g a u g e a s s e m b l y m u s t b e f a u l t y ; r e p l a c e it.
T
Cavity Wire T e s t condition '3?ii: D ^ s f r a d irosuit P o s s i b l e c a u s e if d e s i r e d r e s u l * °^
- -• • not obtained
A9 YEL Ignition switch Measure the voltage to ground: •> B l o w n N o . 5 (7.5 A ) f u s e i n t h e
A10 WHT/RED U n d e r all Measure the voltage to ground: • B l o w n N o . 5 4 (30 A ) f u s e i n t h e
conditions There s h o u l d be battery voltage. main under-hood fuse/relay box
• B l o w n N o . 2 5 (7.5 A ) f u s e i n t h e
: under-dash fuse/relay box
• A n open in the wire
A17 BLK U n d e r all Measure the voltage to ground: • Poor g r o u n d (G501)
A18 conditions T h e r e s h o u l d b e l e s s t h a n 0.5 V . • A n o p e n in the w i r e
B12 GRN Ignition switch Measure the voltage to ground: • B l o w n N o . 8 (20 A ) f u s e in t h e
• Faulty Intermittent w i p e r relay
B16 BLU/ORN Ignition switch Measure the voltage to ground: • B l o w n N o . 13 (7.5 A ) f u s e i n t h e
O N (II), w i p e r T h e r e s h o u l d be battery v o l t a g e . under-dash fuse/relay box
s w i t c h OFF • Faulty w i p e r m o t o r
(PARKED) • A n o p e n in the w i r e
B17 BLU/BLK Ignition switch Measure the voltage to ground: • B l o w n N o , 12 (15 A ) f u s e i n t h e
O N (II) a n d w i p e r There s h o u l d be battery voltage. under-dash fuse/relay box
s w i t c h at I N T • Faulty w i p e r switch
B18 WHT/BLK ignition switch Measure the voltage to ground: • B l o w n N o . 12 (15 A ) f u s e i n t h e
O N (II) a n d T h e r e s h o u l d be b a t t e r y v o l t a g e . under-dash fuse/relay box
washer switch • Faulty w a s h e r switch
ON • A n o p e n in t h e w i r e
22-181
Wipers/Washers
Wiper/Washer Switch Test/Replacement
1. L o w e r t h e s t e e r i n g c o l u m n , a n d r e m o v e t h e s t e e r i n g c o l u m n c o v e r s ( s e e p a g e 1 7 - 9 ) .
2 . D i s c o n n e c t t h e 14P c o n n e c t o r f r o m t h e w i p e r / w a s h e r s w i t c h .
3. R e m o v e t h e t w o s c r e w s , t h e n p u l l o u t t h e w i p e r / w a s h e r s w i t c h .
4. C h e c k f o r c o n t i n u i t y b e t w e e n t h e t e r m i n a l s i n e a c h s w i t c h p o s i t i o n a c c o r d i n g t o t h e t a b l e . If t h e c o n t i n u i t y is n o t a s
specified, replace the s w i t c h .
\ y Terminal
6 s 4 14 13 12 11
Position \ ^
OFF O -~o
INT O— —o
o - -o
LO
\J LJ
HI
o— - o
Mist switch O N o - -o
Washer switch O N
22-182
....
BODY
Wiper Motor Test W a s h e r Motor T e s t
1. O p e n t h e h o o d a n d r e m o v e t h e c a p n u t s a n d t h e 1. R e m o v e t h e right i n n e r f e n d e r (see page 20-126).

w i p e r a r m s (see p a g e 2 2 - 1 8 5 ) .
2. D i s c o n n e c t t h e 2 P c o n n e c t o r (A) f r o m t h e w a s h e r
2. R e m o v e t h e h o o d s e a l a n d c o w l c o v e r (see p a g e m o t o r (B).
22-185).
3. D i s c o n n e c t t h e 5 P c o n n e c t o r f r o m t h e w i p e r m o t o r .
3. T e s t t h e w a s h e r m o t o r b y c o n n e c t i n g b a t t e r y
power to terminal No. 1 and ground to terminal
No. 2.
4. T e s t t h e m o t o r b y c o n n e c t i n g b a t t e r y p o w e r a n d 4. If t h e m o t o r d o e s n o t r u n o r f a i l s t o r u n s m o o t h l y ,
g r o u n d a c c o r d i n g t o t h e t a b l e . If t h e m o t o r d o e s n o t replace the motor.
run or fails to run s m o o t h l y , replace the motor.
\ Terminal
1 2 4
Position \
LOW SPEED 0 e
HIGH S P E E D e e
5. C o n n e c t t h e b a t t e r y p o w e r t o t h e N o . 4 t e r m i n a l ,
and g r o u n d to the No. 2 and No. 3 terminals of the
5P c o n n e c t o r . T h e n c o n n e c t a n a n a l o g v o l t m e t e r
b e t w e e n t h e N o . 4 ( + ) t e r m i n a l a n d t h e N o . 5 (—)
t e r m i n a l . W h e n the park switch contacts, the
p o i n t e r s h o u l d s w i n g . If n o t , r e p l a c e t h e m o t o r .
22-183
Wipers/Washers
Washer Reservoir Replacement
1 . Pull away the right inner fender (see page 2 0 - 1 2 6 ) . 3. Remove t h e bolts, t h e n separate a n d remove t h e
f i l l e r n e c k (C) f r o m t h e w a s h e r r e s e r v o i r ( D ) .
2 . -Disconnect the washer tube (A) and washer motor
2P connector ( B ) . Washer reservoir capacity
U S A models: 2.5 L (2.6 U S qt)
USA models C a n a d a m o d e l s : 6.0 L (6.3 U S qt)
6 M 1.0 mm
9.8 N m (1.0 k g f m , 7.2 Ibfft)
4. R e m o v e t h e w a s h e r reservoir.
5. I n s t a l l i n t h e r e v e r s e o r d e r o f r e m o v a l . C h e c k t h e
washer motor operation.
22-184
H B 0 D Y
Wiper Motor Replacement
1. O p e n t h e h o o d , a n d r e m o v e t h e c a p n u t s a n d t h e 5. R e m o v e the three m o u n t i n g bolts a n d nut f r o m the

wiper arms. w i p e r l i n k a g e (A) t o r e m o v e t h e w i p e r m o t o r (B).
10 x 1.25 m m 8 x 1.25 m m
Ibf-ft)
18 N m (1.8 k g f m , 1 3 Ibf-ft) 15 N m
(1.5 k g f m , 11
2 . R e m o v e t h e h o o d seal a n d c o w l cover.
3. D i s c o n n e c t t h e 5 P c o n n e c t o r ( A ) f r o m t h e w i p e r
motor (B). 6. I n s t a l l i n t h e r e v e r s e o r d e r o f r e m o v a l , a n d n o t e
these items:
6 x 1.0 m m
9.8 N m (1.0 k g f m , 7.2 ibf-ft)
• Grease all m o v i n g parts.
• Before reinstalling the wiper arms, turn the wiper
s w i t c h O N , t h e n OFF t o r e t u r n t h e w i p e r shafts t o
the park position.
• If n e c e s s a r y , r e p l a c e a n y d a m a g e d c l i p s .
• Check t h e w i p e r m o t o r operation.
4. R e m o v e t h e b o l t s , t h e n r e m o v e w i n d s h i e l d w i p e r
l i n k a g e a s s e m b l y (C).
22-185
Wipers/Washers
Washer Tube Replacement
1. R e m o v e t h e f r o n t b u m p e r a n d t h e r i g h t i n n e r f e n d e r { s e e p a g e 2 0 - 1 2 6 ) .
2 . R e m o v e the w a s h e r n o z z l e s a n d c l i p s , t h e n r e m o v e the t u b e .
3. Install in t h e r e v e r s e o r d e r of r e m o v a l . T a k e c a r e not to p i n c h the w a s h e r t u b e . C h e c k t h e w i n d s h i e l d w a s h e r

operation.
22-186
Immobilizer System
I M M O B I L I Z E R RECEIVER UNIT ('00-05 models) IMOES UNIT ('08 model)

Troubleshooting, page 22-194 Input Test/Replacement, page 22-215
IMMOBILIZER CONTROL U N I T - R E C E I V E R ('08-08 models)
Troubleshooting ('06-07 models), page 22-200
Troubleshooting ('08 model), page 22-206
Replacement, page 22-217 ( m § 5 m o d e | s )
(Master and valef k e f s)
22- 187
Immobilizer System
S y s t e m Description
'00-05 models
T h e v e h i c l e is e q u i p p e d w i t h t y p e 11 i m m o b i l i z e r s y s t e m t h a t w i l l d i s a b l e t h e v e h i c l e u n l e s s t h e p r o p e r i g n i t i o n k e y is
used. This s y s t e m consists of a t r a n s p o n d e r located in t h e ignition key, an immobilizer receiver unit, an indicator, a n d
the ECM.
The vehicle has t w o kinds of keys.
• T h e black m a s t e r key for.

- Ignition switch.
- Door locks.
- T r u n k lock.
- Center console lock
• The gray valet key for:
- Ignition switch.
- Door locks.
W h e n t h e i m m o b i l i z e r k e y is i n s e r t e d i n t o t h e i g n i t i o n s w i t c h a n d t u r n e d t o t h e O N (II) p o s i t i o n , t h e i m m o b i l i z e r
receiver unit sends p o w e r t o t h e transponder in t h e ignition key. T h e transponder t h e n sends a coded signal back
through the immobilizer receiver unit to the ECM.
• T h e i m m o b i l i z e r s y s t e m can store u p t o six key codes.

• If it is n e c e s s a r y t o r e w r i t e t h e E C M , t h e d e a l e r n e e d s t h e c u s t o m e r ' s v e h i c l e , a l l i t s m a s t e r k e y s a n d v a l e t k e y s , a n d
t h e H D S e q u i p p e d w i t h t h e l a t e s t v e r s i o n o f H D S s o f t w a r e . A n y k e y t h a t is n o t l e a r n e d d u r i n g r e w r i t i n g w i l l n o
longer start t h e e n g i n e , except T 5 keys duplicated w i t h t h e llco Code Key Duplicator.
• It is p o s s i b l e t o a d d O N E n e w k e y w i t h o u t r e p r o g r a m m i n g a l l o f t h e k e y s ( f o l l o w t h e p r o m p t s i n t h e H D S I M M O B I
menu).
22-188
• If t h e p r o p e r k e y h a s b e e n u s e d , t h e i m m o b i l i z e r i n d i c a t o r w i l l c o m e o n f o r a b o u t 2 s e c o n d s , t h e n g o off. W h e n t h e
i g n i t i o n s w i t c h is t u r n e d O F F , t h e i n d i c a t o r w i l l b l i n k f o r a b o u t 5 s e c o n d s t o s i g n a l t h a t t h e i m m o b i l i z e r s y s t e m h a s
b e e n set correctly, t h e n t h e indicator w i l l g o off.
• If t h e w r o n g k e y h a s b e e n u s e d o r t h e c o d e w a s n o t r e c e i v e d o r r e c o g n i z e d b y t h e E C M , t h e i n d i c a t o r w i l l c o m e o n
- f o r a b o u t 2 s e c o n d s , t h e n it w i l l b l i n k u n t i l t h e i g n i t i o n s w i t c h is t u r n e d O F F . F o r a c c u r a t e i m m o b i l i z e r s y s t e m
d i a g n o s i s , get as m u c h i n f o r m a t i o n f r o m t h e c u s t o m e r as possible. A b l i n k i n g indicator m e a n s the key w a s not
recognized.
NOTE: Large metal objects, key fobs, other immobilizer keys, a n d other transponders can interfere w i t h the
i m m o b i l i z e r s i g n a l . If a n i n t e r m i t t e n t p r o b l e m is s u s p e c t e d , r e m o v e t h e i g n i t i o n k e y f r o m t h e k e y r i n g .
Problem Part s e t HDS

required ?
CD Master or valet key has been lost or additional Blank key YES*
m a s t e r o r v a l e t k e y is r e q u i r e d .
CD All master and valet keys have been l o s t B l a n k k e y x 2, o r 3 YES
(D Immobilizer receiver unit does not w o r k . Immobilizer receiver unit NO
© ECM does not w o r k . ECM YES
® Ignition switch does not work. Ignition switch YES
M a s t e r keys, a n d valet key (rekey all lock
c y 1 inders t o the n e w key).
(D D o o r k e y c y l i n d e r is b r o k e n . Door key cylinder (rekey the cylinder) NO
* : Duplicate keys can be m a d e w i t h llco Code Key Duplicator
22-189
Immobilizer System
S f s t e m Description ( c o n t ' d )
'06-08 models
T h e v e h i c l e is e q u i p p e d w i t h a t y p e IV i m m o b i l i z e r s y s t e m t h a t w i l l d i s a b l e the v e h i c l e u n l e s s a p r o g r a m m e d i g n i t i o n
k e y is u s e d . •
This system consists of a transponder located in t h e ignition key, an immobilizer control unit-receiver, an indicator, the
i m o e s u n i t ('08 m o d e l ) , a n d t h e E C M .
'06-07 models
W h e n t h e i m m o b i l i z e r k e y is i n s e r t e d i n t o t h e i g n i t i o n s w i t c h a n d t u r n e d t o t h e O N (II) p o s i t i o n , t h e i m m o b i l i z e r c o n t r o l
unit-receiver sends p o w e r t o t h e t r a n s p o n d e r in t h e ignition key. T h e t r a n s p o n d e r t h e n sends a c o d e d signal back
t h r o u g h t h e i m m o b i l i z e r c o n t r o l u n i t - r e c e i v e r t o t h e E C M . T h e c o d e is a r o l l i n g t y p e e m b e d d e d i n t h e r e c e i v e r i n s t e a d
o f t h e E C M . A h a n d s h a k e w i t h t h e H D S is r e q u i r e d a t E C M r e p a i r a n d r e p l a c e m e n t , a n d a l l k e y s a r e r e q u i r e d a t c o n t r o l
unit-receiver repair a n d replacement.
#
08 model
W h e n t h e i m m o b i l i z e r k e y is i n s e r t e d i n t o t h e i g n i t i o n s w i t c h a n d t u r n e d to the O N (II) p o s i t i o n , the i m m o b i l i z e r c o n t r o l

unit-receiver sends p o w e r t o t h e t r a n s p o n d e r in t h e ignition key. T h e t r a n s p o n d e r t h e n sends a c o d e d signal back t o
the immobilizer control unit-receiver w h i c h sends a coded signal t o the i m o e s unit, w h i c h confirms the code and
signals the ECM to supply p o w e r t o the fuel p u m p circuit.
A c o m m u n i c a t i o n a g r e e m e n t w i t h t h e H D S i s r e q u i r e d i f t h e E C M o r t h e i m o e s u n i t is r e p l a c e d .
W h e n r e p l a c i n g t h e i m m o b i l i z e r c o n t r o l u n i t - r e c e i v e r , all keys are r e q u i r e d t o be r e g i s t e r e d in t o t h e n e w c o n t r o l unit-
receiver w i t h t h e HDS. A n y keys that w e r e n o t registered in t h e control unit-receiver w i l l not start the vehicle.
, IMMOBILIZER CONTROL UNIT-RECEIVER
22-190
J~\
BOOT
• If a p r o g r a m m e d k e y h a s b e e n u s e d , t h e i m m o b i l i z e r indicator will c o m e o n for a b o u t 2 s e c o n d s , t h e n g o off. W h e n

the ignition s w i t c h is t u r n e d O F F , the indicator will blink for a b o u t 5 s e c o n d s to s i g n a l t h a t the unit h a s b e e n s e t
c o r r e c t l y , t h e n the indicator will g o off.
• If t h e w r o n g key h a s b e e n u s e d w h o s e c o d e w a s not r e c e i v e d or r e c o g n i z e d by the s y s t e m , t h e indicator will c o m e
o n for a b o u t 2 s e c o n d s , t h e n it will blink until the ignition s w i t c h is t u r n e d O F F .
IMMOBILIZER INDICATOR BUNKING PATTERN
I G N I T I O N SWITCH O N fill
OFF •j
2 sec. 5 sec.
PROPER KEY ON
INDICATOR
INSERTED
OFF
WRONG KEY ON
Mil
INDICATOR
INSERTED
OFF
22-191
Immobilizer System
Circuit D i a g r a m
'00-05 m o d e l s
UNDER-DASH *1: '04—05 models

MAIN UNDER-HOOD FUSE/RELAY BOX FUSE/RELAY BOX *2: '00-03 models
No. 41 (100 A) No. 54 (30 A) No. 25 (7.5 A)
(±> -HTNJD-
No. 46
(15 A)
No. 2 (15 A} Mo. 21 (7.5 Aj WHT/RED

FUSE FUSE
A3*'
D16* 2
WHT/CRN BLK/YEL BLU/ORN IMMOBILIZER

INDICATOR
7 (1.12W)
YEL/BLK D15*
YEL/BLK
;
—f-
A4*'
KEY
IMMOBILIZER
RECEIVER UNIT •<=Q
1
Q Q—
No. 25 (7.5 A)
PGM-FI FUSE
MAIN
RELAY
4
YEL/GRN GRN/YEL YEL/BLK YEL/BLK RED/BLU PNK/BLU BRN WHT/RED PNK
{BI) (m)
A
(A25>- -<B21> •© j
IMOFLR IGP1 IGP2 IMOCD IMOEN IMOLMP
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G101 G601 G101
22-192
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I m
'06-08 models

BATTERY
No. 41 (100 A) No. 54 (30 A)
& IGNITION SWITCH
No. 42 (40 A) ^BAT-A
UNDER-DASH
j No.2 ) No. 25
FUSE/RELAY
(15 A) C. (7.5 A)
BOX
BLK/YEL WHT/RED
{'08 model)
r
WHT/RED
GAUGE
ASSEMBLY
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IMOES UNIT
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IMMOBILIZER CONTROL UNIT-RECEIVER
LG3 DIAG-H H/BRKSW
T
g
RED/WHT
GAUGE ASSEMBLY
GRN/WHT RED/BLU
I 2
GRN/WHT
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GRN/WHT
4
RED/BLU
KEYLESS
DOOR LOCK
CONTROL UNIT
i
RED/BLU
\
GRN/WHT
• GAUGE ASSEMBLY
• SOFT TOP
CONTROL UNIT
Y
RED/WHT
/
/
) IMOCD
(S-Net)
ECM
u
LG3
v
DATA
Y
GRN/WHT
PG2 PG1 LINK
CONNECTOR
^ 0
TA4
QY A 5 , (DLC)
RED/WHT
IGNITION KEY BLK BLK

3
^ PARKING BRAKE
SWITCH SWITCH
(Closed: Key inserted) (Closed: Lever pulled)
1 (Open: Lever released)
i
G101
G401
...J
22-193
Immobilizer System

2000-08 Honda S2000 SM

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2000-08 Honda S2000 SM

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2000-08 Honda S2000 SM

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INTRODUCTION

- How to Use This Manual

T h e S2000 SRS Includes a d r i v e r ' s a i r b a g in t h e steering w h e e l h u b , a passenger's airbag in the d a s h b o a r d a b o v e t h e

Identification Number Locations 1-11

Danger/Warning/Caution Label Locations .... 1-12

Under-hood Emission Control Label 1-14

Lift and Support Points 1-18

Parts Marking 1-21

Service Precaution 1-22

Revised Component T e r m s 1-23

'00 Model Engine Number

Vehicle Identification Number

Vehicle Identification Number

Code Color USA Canada

Chassis and Paint Codes (cont'd)

'02 Model Engine Number

Vehicle Identification Number

Code Color USA Canada

Vehicle Identification Number

Code Color USA Canada

'04 Model Engine Number

Vehicle Identification Number

Code Color USA Canada

Vehicle Identification Number

Code Color USA Canada

'06 Model Engine Number

Vehicle Identification Number

Code Color USA Canada

Vehicle Identification Number

JHM AP2 1 4 * 7 S 000001

Code Color USA Canada

'08 Model Engine Number

Vehicle Identification Number

JHM AP2 1 2 * 8 S 000001

CABLE REEL CAUTION MODULE DANGER

Emission Group Identification Test Group and Evaporative Family

VEHICLE EMISSION CONTROL INFORMATION z H N X V 02.0 DYC

Emission Group Identification - Test Group and Evaporative Family

Example: Test Group:

Emission Group Identification Test Group and Evaporative Family

Example: Test Group:

Honda Motor Co.

'05 Model 5 H N X R 0130 AAA

Emission Group Identification Test Group and Evaporative Family

Example: Test Group:

f VEHICLE EMISSION CONTROL INFORMATION! Evaporative Family:

TWC, A/F SENSOR, H02S, SFI

'00-05 models '06-08 models

'00-05 m o d e l s '06-08 models

To s u p p o r t the vehicle on safety stands, use the s a m e

Towing Hook Installation W h e e l Lift E q u i p m e n t — T h e t o w truck u s e s t w o

1MOTICE1 S l i n g - t y p e E q u i p m e n t — T h e t o w truck u s e s metal

1. R e m o v e the c o v e r (A) f r o m t h e b u m p e r . T h e o n l y r e c o m m e n d e d w a y of t o w i n g the v e h i c l e is o n

4. S c r e w t h e t o w i n g h o o k (A) into the e x t e n s i o n , a n d

T o deter v e h i c l e theft, certain m a j o r c o m p o n e n t s are m a r k e d w i t h t h e v e h i c l e i d e n t i f i c a t i o n n u m b e r (VIN). Original

Adhesive Wheel Balance Weight

T h e w h e e l s o n t h i s m o d e l a r e not d e s i g n e d to m o u n t t h e b a l a n c e w e i g h t o n the outer s i d e of the w h e e l . I n s t e a d , m o u n t

There must be clearance. BALANCE WEIGHT

Beginning w i t h '01 m o d e l , the f o l l o w i n g c o m p o n e n t t e r m s have been c h a n g e d to c o n f o r m w i t h t h e standards in SAE

'00 and Earlier Models ^ '01 or Later Models