Acura RSX 2004 User Manual

6,

t;,

a

General

Ghassis

-2002

Chassis

-2003

ldentification Warning/Caution

Under-hood

Control

Lift and Towing

Parts

Marking

Information

Paint

and Model

Paint

and Model

Number

Emission

Label

Support

........."......"..................

Points

Locations

Godes

Codes

Locations

Label

Locations

...'..

...".

1-2

1-3 1-4

1-5

1-7 1-8 1'9

1-1 0

"""""'.""'

....'............

........

'.................'.....

.....'.............."

F

General

Information

Chassis

Vehicle

JH4

r-

and

ldentif

DC538*2

[

tr[t[

cdef gh

a. Manufacturer.

JH4:

HONDA

ACURA

b. Line,

c. Body

d.

6. f.

g.

h.

Body

and

DCs;

ACURA

Type

and

3: 2-door

2-door

4:

2-door Vehicle 0: Type

6: RSX 8: RSX

Premium Check Digit ModelYear 2i

2002 Factory

C:

Saitama

Serial Number U.S.: Canada:

Hatchbacld5-speed

Hatchbacld6-speed

Hatchbacldb-speed

Grade

S

(Canada

Code

Factory

000001

800001

Paint

ication

Make MOTOR

Passenger

Engine

RSX/K20A2,

Transmission

(Series)

onlv)

(Canada

onlv)

in

Codes

Number

C 000001

and Type

CO.,

Type

Japan

of Vehicle

LTD.

vehicle

K2OA3

Type

Manual Manual Automatic

(Sayama)

-

2002

Model

Engine

l<20a2

l

Number

1400001

a

a. Engine

K20A2: K20A3:

b.

Serial Number K20A2: K20A3:1100001

Type

2.0

0 DOHC

Fuel-injected

2.0 0 Fuel-inlected

1400001-

Transmission

MRMA

I

1000001

a

a. Transmission

MRMA; W2M5: X2M5:

b.

Serial Number

5-speed s-speed 6-speed

VTEC

200

DOHC VTEC

160

Number

Type

Automatic Manual Manual

Sequentiat

Hp

engine

Sequentiat

Hp

engine

ua

Muttiport

Multipon

€,la

1-2

Vehicle

ldontification and Federal Saf

ety Standard

Certif

Number

ication.

Motor Vehicle

Paint

Code

B

5O7P

B-92P

B-96P NH-578 NH-623M NH-624P

NH-636P

R-81

R-507P

YR-534t\4

Color

Arctic

Blue Pearl Nighthawk Eternal Taffeta Satin Premium Brilliant Milano

Fire Pepper Desen

Black

Blue

White

Silver

White

Red

Silver

Pearl

Metallic

Pearl

lvletal

I ic

u.s.

_l

al

C

c

Canada

(_)

o

Chassis

and

Paint

Codes

-

2003

Model

Vehicle

ldentif

DCs38*3

JH4

[ri

cdef

b

a

r. Manufacturer.

HONDA

JH4:

ACURA

b. Line,

c.

d.

e.

f. Model g.

h. Serial

Body

ACURA

DC5:

Type and

Body 3: 2-door

2-door 4: Vehicle Grade 0:Type

6: RSX 8:

Check

3:

Factory C: Saitama

U.S.:

Canada:

Hatchback/5-speed

Hatchbacld6-sPeed

Hatchbaclds-speed

2'door

S

(Canada

RSX Premium

Digit

Year

2003

Code

Number

000001

800001

ication

ti lr

Make and

MOTOR

Passenger

Engine

and

RSX/K20A2,

Transmission

(Series)

onlY)

(Canada

Factory

in Japan

-

Number

C 000001

gh

Type of

LTD

CO.,

vehicle

TYPe

K20A3

TYPe Manual Manual Automatic

onlY)

(Sayama)

Vehicle

Engine

Number

t<2042

2400001

I

a

Engine

a.

K2OA2:

b.

Transmission

MRMA

I

a

a.

b.

TyPe

2.0 Fuel-iniected

K20A3:

Serial

K20A2: K20A3:

Transmission MRMA: W2M5: X2M5: Serial

2.0 0 DOHC Fuel-injected

Number

2400001 2100001

.2000001

s-speed 5-speed 6-sPeed

Number

0 DOHC

-

Number

TYPe

Automatic

Manual Manual

Sequential

VTEC

HP engine

200

VTEC Sequential

160 HP engine

Multiport Multiport

Vehiclo

Federal

and

Safety

ication

ldentif

Motor

Standard

Number

Vehicle

Certitication.

Paint

Code B-507P B-92P

B-96P NH-578 NH.623M

NH.624P NH-636P R-81

n-5zz

YR-534M

Code

Color

Blue

Arctic

Niohthawk Eternal Taffeta Satin

Premium Brilliant

Milano

Redondo

Desert

Black

Blue

white

Silver

White

Red

Red Pearl

Silver

.-<mA'

q-)'ff

Pearl

Pearl C

Pearl

Metallic

Pearl o

Pearl

Metallic

w

U.S.

c

o

Canada

c

C

o o

o

1-3

General

Information

ldentification

Vohicle

Number

ld6ntif

lVlN)

Number

ication

Locations

Vehicle

ldentif

Numbe.

(VlN)

ication

Engine

Numbgr

Transmi53ion (Automaticl

Numbsl

Transmi53ion lManual)

i,a

Number

1-4

ua

&,oWarning/Gaution

Label

Locations

,tre

FRONT

NOTE; (CHILD

model. Passenger's

SEAT)

FRONT MODULE

PASSENGER

is equipped

ComPartment:

WARNING

SRS INFORMATION

PASSENGER

DANGER

AIRBAG

on the

WARNING

glove

box

INFORMATION

SRS

model

U.S.

on

TAG

the

U S'

Steering

CABLE CAUTION

Wheel:

REEL

'to

STEERING COLUMN NOTICE

MODULE

SIDE

DANGER

SIDE

FRONT SEAT AND TENSIONER CAUTION

driver's

on

CAUTION

and

AIRBAG

Located passenger's doorjamb

BELT

BUCKLE

(cont'd)

1-5

General

Information

Warning/Caution

SERVICE {Undgr-hood

Informrtion COOLANT

INFORMATION

Embsion

labol)

and ENGINE

INFORMATION

LAAEL

Control

Label

Locations

SRS WARNING LABEL

(cont'd)

TIRE

INFORMATION

6,'

BATTERY

CAUTION

i3a

1-6

&,o

Under-hood

Emission

Control

Label

Emission

Example:

GrouP

ldentification

Engine

2

HNX

FamilY:

Engine

EvaPorative

and

V O2.O

VBP

Families:

TI-it-l--

ab

a.

model:

2002

VEHICLE

THIS

REGULATIONS

BIN

NEW REGULATIONS

LEV

NEW

mod€l:

2003

VEHICLE

THIS

REGULATIONS

BIN

NEW

t

REGULATIONS

LEV

NEW

CONFORMS

APPLICABLE

5 PASSENGER

APPLICABLE

PASSENGER

II LEV

CONFORMS

APPLICABLE

5 PASSENGER

APPLICABLE

LEV PASSENGER

II

TO U.S.

CARS

TO

CARS

EPA

TO 2OO2

CALIFORNIA

AND

TO 2OO2

CARS.

EPATIER

U'S.

2OO3

TO

CALIFORNIA

AND

TO 2OO3

CARS.

MODEL

MODEL MODEL

TIER

2

YEAR YEAR

2

YEAR YEAR

b.

c. d.

e.

Evaporative

cd

Yeal

Model 2:2O02 3: 2003 Manufacturer

HONDA

HNX: Family V:

TYPe

LDV Displacement Ssquence VBP

XKC

Characters

(H1):

2002

(P5,

PO), SKC-Tvpe

FamilY:

Subcode

model

S

(P7,

P8):

2003

model

OO!I9

R

HNX

2

tt-rrI

ab

c.

d.

a,

cd

Year

Model

2002

2i 2'.2003 Manufasturer

HONDA

HNX:

Type

Family

EVAP/ORVR

R: Canistsr Sequence AAH:

A./M:

Work

Charact€rs

model

2002

model

2003

AAH

e

Subcode

CaPacity

F

1-7

General

Lift

and

Information

Support

Points

NOTE: such vehicle, safety

from change

Frame

1. Position

you

lf

as suspension

first

stands.

the rear

and

Hoist

under support

going

are

or the

support

of the

cause

the hoist

the vehicle,s

points (C).

the front

When

substantialweight

vehicle,

the vehicle

Iift

to

remove

fuel

blocks

front

heavy

tank from

of

the vehicle

the

center

to

tip forward

(A),

support

components

the rear

with

is

removed

gravity

of

on

or safety

points

{B)

of

tall

can

the hoist.

stands,

and

the

rear

Floor

Jack

1.

Set the

2.

Block

3.

When gearshift

transmission

4.

Position bracket

jacking

up the

under

parking

the

wheels

lifting

lever

the floor

(A)

or rear

bracket

vehicle

it.

'/-

a

brake.

that

the

rear

in reverse,

position.

in

E

jack

jacking

in

the

high

enough

are

not

being

of

the vehicle,

or the

under

the front

bracket

jack

platform

lift

to fit

lifted. put

the

automatic

jacking

(B),

center

{C),

the

safety

the

jack

and

stands

2.

Raise gently

3.

Raise

points

Safety

To support use safety

vehicle

Stands

support

points

that

the

hoist

a few

to be

sure it

the

hoist

to full

for

solid

contact

the vehicle

and

{B

stands

when

is

supported

inches,

is firmly

height,

on

safety

C) as

for

working

only

supponed.

with

the lift

stands,

a frame

on

by

a

and rock

and inspect

jack.

the vehicle

blocks.

use

hoist.

or unoer

the same

the lift

Always

any

Position

and

adjust

Lower

the

the safety

them

so the

vehicle

stands

vehicle

onto

the stands.

under

the suppon pornts

will

level.

i"'O

1-8

',

s-.

e.o

Towing

vehicle

lf the

towing

vehicle Emergency

TherJare

Flat-bed on the transporting

To accommodate equipped

The towing

vehicle

be used

needs

service.

with

back

onto

Never

just

Towing

ihree

Equipment

of a

the

with towing

hook

the

secure

to

popular

truck.

be

to

tow

rope or

a

The

This

vehicle.

Jlat-bed

hooks

be used

can

and

truck,

vehicle

the

towed,

methods

call

vehicle

the

lt is

chain.

operator

best

is the

equipment,

(A)

and

with a

tie

the

to truck'

professional

a

the

hooks

another

a vehicle'

the

of

vehicle

to

behind

very dangerous'

of towing

loads

way

tie down

winch

down

vehicle

is

hooks

pull

the

slots

(B)'

can

Equipment

Lift

Wheel

pivoting iifts

on the vehicle.

Sling-type

cablis Darts end

suspension method

lf the should due front

Manual

. .

arms

off

them

ground. This

with

the

of

the

of

vehicle

be

to damage,

wheels

Transmission

Release

the

Shift

go

that

the

Equipment

hooks frame

vehicle

and

towing

cannot

towed

on the

the

transmission

under

ground

is an

-

on the

suspension

or

the

off

can

body

is attemPted.

be

the

with

vehicle

the

ground, do the

Parking

truck

tow

The

the tires

other

The acceptable

The tow ends.

ground. The

be

transported

front

brake.

in

truck

These

and the

seriously

wheels

be

must

Neutral.

uses

(front

or

wheels

two

way of

uses

hooks

cables

vehicle's

damaged

flat-bed,

by

off the

with

towed

following:

wvo

rear)

remain

towing

metal go

around

lift that

if this

it

ground' lf

the

and

the

c.

Automatic

.

Release

.

Start

.

Shift

.

Turn

It is best km), and

the the to

E

off the

to

keep the

mrlieA

.

lmproper transmission.

you

cannot iautomatic transPorted

.

to

Trying

serious

cause

designed

Transmission

Parking

engine.

position,

engine.

tow

towing

shift

transmission).

on

lift or

to support

brake.

then E

vehicle

the

speed

preparation will

F;llowthe

transmission

the

flat-bed.

a

the

tow

damage.

position'

farther

no

35

below

above

vehicle

the

vehicle

The bumpers

vehicle's

the

miles

50

than

(55

mph

procedure exactly

by

km/h)'

damage

or start

must

bumpers

the

are

weight'

the

be

not

engine

will

(80

lf

$

1-9

:l

I

Generaf

Parts

To

deter vehicle

parts

have

transmission NoTE:

Be

Information

Marking

theft,

self-adhesive

vlN

careful

certain

plate

is

not

to damage

ma.ior

labels.

Replacement

transferred

the

components

body

to

a replacement

parts

marking

are marked

parts

have

engine

labels

during

with

the vehicle

generic

or

self-adhesive

transmission body repair.

identification

labels.

and

attached

Mask

the labels

number

The

with

(VlN).

original

break-off

before repairing

engine or

Original

bolts.

the

&rrl

part.

L,.

1-10

Specifications

.uO

Standards

Engine Engine Cylinder Engine

Engine Cooling Fuel and

C1utch..........."

Manual Automatic Steering

Susoension

8rakes..........'..

ConditioninS

Air

Design

Dimensions

weisht

Weight

En9ine............

Starter............

Clutch Manual

w2M5

x2M5

Automatic

Steering SusPension Wheel

and

Electrical

Assembly'.....'......""""

Head Block Lubrication

Emissions

Transmission

Specifications

(u.s.A.)

(CANADA) .'.

.............

Transmission

............

.............

Transmission

Alignment

Service

....'.....'............

..........'....

.'......'............'

Limits

....'..'..'...""'

Differential

and

Differential

and

....."..

...'..'......".....

"""""'

2-2 2-2

z-5

2-4 2-5 2-6 z-o 2-7

2-8 2-10 2-15

2-15 2-16 2-16

2-17 2-17

2-17

2-'17

2-17

2-14 2-18 2-18

2-18 2-18 2-18

2-18 2-19 2-19

Body

Specifications

lllustration

2-20

Standards

ngtne

Engine

lgnition

Spark

lgnition

Altelnator (MITSUBISHI}

Alternator (DENSO)

Starter (MITSUBA)

Starter (DENSO)

Compression

hom

coil

plug

timing

ne

Assem

Item

Electrical

and

Rated

voltaoe

Firing

order

Type

Gap

Outpr.lt

(rotor)

Coil Slip

ring

Brush

length

Brush

spring

Output

Coil(rotod Slip

ring

Erush

lenoth

Erush

sprinq

._-__:-

Uutput

LOmmutator

Commutator Brush

length Output Commutalor

Brush

length

Urush

spring

Pressure open ratio)

check

throttle.

Service

Measurefn€nt

resistance

O.D.

tension

resistance

O.D.

tension

mica denth

O.D.

mica denrh

tension

M€asuremont

at 250

rpm

(See

Design

with

wr.de

Specs

Limits

At 13.5 normalengine temperature At

At 13.5 normalenglne temperature

At

Oualific.tion

Minimum

for

lvlaximum

ou!{@!g!

K20A3

K20A2

At

idle

red

matk)

68 F"

68"F

engine

(check

V

and

(20

C")

V

and

(20.C)

|

Standard

12V

or

New

1-3-4-2 NGK:

|ZFR6K11

I

DENSO:

I

the

M/r 650+

ryr ![r

90A

1.84

19.0

1?-rrN/n2l_

95A

2.2

ru,e

SKJ20DR-M11

NGKi

IFRTG-1

DENSO:

SK22PR-Ml

1'o

1.1

mm

(in

neurrat):

50 rpm

r!] ur

2.10

mm

{0.75

3.O

I

mm

lu.4t

jFR7G.11Ks

1K,

t,

SK22pR-tvll1S

-0.043

{0.039

8a2.

BfOt

{K2OA3 enqine}

l!1,: d:tz'ts

()

in.)

In.)

tuu

,G ^Yr,

; ; ;i_Y!!q_r!9ir1!r:!.qrEl

l^-u.c

mm

0.02

mm

28.0

28.1

,

i. i

I r.J

0.50-0.80

0.02

mm

28.0

mm

14.0-

14.5

(9.5

930 kPa 200

kPa

12.0

IU.u

{0.00'1 in.)

(1.102-

mm

r,

ru.44 u.4c

(0.020

mm

in.)

10.00't (1.10

in.)

mm

10.55 0_57inl

, 1 '._v

Standard

kqf/cm,,

kg7cm,,

tb

max.

r.w

of New

135

28

u.o20in.)

1.106 in I

0.031

^v.,

osi)

psi)

in.)

"t

Zoot

at 650+50

v.,

e.r rosl

tn.)

in.)

,,ur

J.r/

T------_-

soi",

pm

21.7

5.0

14.0

1.5

0.15

i.05

225

4.3

0.2 mm

0.05 mm

27.0

9.0

tos,

Service

ffzOaz

mm

{0.20 in.i

mm

(0.06

mm

mm mm mm

(0.17

mm

(0.008

(0.002 (1.06In.)

mm

{0.35 in.)

Service

Limh

"^gir,"L

{0.85 in.)

(0.55

in.)

(0.006

in.)

{0.002 in.)

in.)

11.083 in.)

in.)

Limh

1;O

2-2

|*

o

h.m

Head

Camshaft

Valve seats

springs

Valve

guides LD.

Valve

Eocker

Head

arms

Maaa0aomcm

Warpage

Height

End olav Camshaft-to-holder

Totalrunout

height

lobe

Cam

engine)

{K20A3

height

lobe

Cam

(K20A2

engine)

Clearance

Stem

Stem-to-guide

width

Stem

Free (K20A3

Free lK20A2

Installed

Arm-to-shaft

{cold)

O.D.

installed

length

engine)

length

engine)

height

clearance

height

clearance

oil

Ou.liilcation

journal

I

No.

4, 5

2, 3,

No. iournals

primary

Intake,

Intake.

Exhaust

pramary 32.791

lnlake,

mid

Intake, lntake, secondary

Exhaust, Exhaust, Exhaust,

lntake Exhaust (K20A3

Exhaust (K20A2

lntake

llntake

I Exhaust

primarY mid

engine)

Exhaust

Intal(e Exhaust

lntake exheust

lntake

Exhaust

lntake Exhaust

Inlake

Exhaust

Intake

Exhaust

lntake

Exhaust

(K20A3

engine)

Exhaust (K20A2

engane)

mm

104.05

103.95-

(4,093 o.o5

0.030-0.069 {0.001

0.060{0.002-0.004

mm

O.O3

33.925

29.638

34.092

35.534

32.678

nn;^rt

34.768

32.661

0.21-0.25

0.28-0.32

0.25-0.29

5.475

5.450-5.460

0.030-0.055

0.055

1.25-1.55

1.25-

40.8-

54.6-51.8

49.64

49.63

49.77

50.39

5.515 l'0.2171-

5.515-5.530 \0.2111-0.2177

15.2

15.5

0.025-0.052

1.096 mm

0.20

0.003

0.099

(0.001

mm mm

mm

mm mm mm

mm mm

5.485

0.080

1.55 mm

41.0

rnm mm

mm mm

5.530

0.2177

16.2

16.5

in

)

{0

mm

in.)

mm

in

)

in

(1.3356

11.1658

(1.3422 (1.2910 (1.3990

{1.2865

\L110,

{1.3688 (1.2859

mm

10.00ts (0.011

mm

(0.010-0.011

mm

mm mm mm mm {0

mm

mm mm

(1.954

11.954 {1.959

11.984 mm

mm

mm mm

mm

10.0010-0.0020

0.018-0.056 (0.0007

0.025-0.052 (0.0010

mm

-0.0022 mm

0.0020

in.)

0.008

002

max.

)

in.) in.)

in.) in

) in.l in

)

L) in.} in.)

rn.l

Iu

U.u

in

0 013

in.)

(0.2156 {0.2146

(0.0012

(0049 (0.049 (1.606(2.150-2.157 in

in.) in

in.} in.)

in.l

i^.1

10.598 {0.610-0

0022-0

0.061

-0

061

1.614

)

0.638 650

0.2159 0 2150

0.0022in l 0031

in) an in.l

in.)

in

)

in

)

in in

)

in.) in

)

inJ

)

Limit

Service

(0.002

mm

0.05

(0.02

mm

mm mm mm mm mm

mm

in

(0.006

(0.002

(0.214

(0.213 {0.003

(0.004

10.079 (0.079

{0.219

(0.219

10.003

(0.003

mm

0.4

0.15 mm {0-006

0.15

0.04

5.445

5.42

0.08

0.'l1

2.00

2.00 mm

5.55

0.08

in.)

) in.)

in.)

in.) in.) in in

in.)

in

in.)

in.l

in.)

) )

)

ot

2-3

Standards

and

Block

hem

Block

Piston

ring

Piston

Connecting

rod

Warpage

Bore

diameter

Eore

taper

Reboring J^rrr

u.u.

bottom

Clearance

groove

Bing

Ring-lo groove

Ring

end

o.D.

jston

Pin-to-p

Pin-to-rod Small-end Large-end

play

End

Service

Mc$urGmant

ofd€ck

limit

ar | | mm

of skirt

in

gap

clearence

bore bore

(u,4

cylinder

width

clearance

diameter

In,l

Limits

trom

Ou.llficd[ion

Aor

I

Borll

No

letter

or A

Letter

B

Top (K20A3

engine) Top (K20A2

engine) Second (K20A3

engine) Second {K20A2 ensine) oir

Top

engine}

{K20A3 Top (K20A2

engine)

Second (K20A3

engine)

Second (K20A2

engine)

Top Second

(K20A3

engine)

Second (K20A2

engine)

oil

engine}

{K20A3

oil (K20A2

engine)

K20A3

engine

K20A2

engine

Standard

mm

l.230

1.245

1.230

1.240

2.025

0.060 mm

0.065 mm

0.055

0.35 mm

0.55 mm

0.65

0.70

21.965

in.)

0.015

21.976 (1.89

mm mm

12.01

0.30

(0.003

86.010

3.3862

85.990

85.980

mm

0.07

86.010-86.020

13.3862 3.3866

86.000 (3.3858-

85.980 81970-

0.020-0.040

1.220-

1.235

1.220

11.230 l

2.005

I

0.035

0.040

0.030-

0.045-0.070

0.20

0.40

0.50

0.25-0.65

0.20

21.961

0.005 +0.002

0.00008

0.005

21.970-

48.0

51.0

015

or New

in.)

max.

mm

in.)

mm

in.)

(3.3850-3.3854

mm mm

{3.3846-3.3850

mm

{0.0008*0.0016

mm

(0.008-0.014

(0.016-0.022

(0.020

(0.010

(0.008-0.028

mm

{0.0002 0.0006

mm in.) in.)

{0.006-0.012

-

10.0481

(0.0{86

(0.0481

(0.0484

{0.0789 {0.0014 0.0024 in.)

{0.0016 0.0026

-

(0.0012

{0.0018-0.0028

-0.026

0.026

(0.8646-0.8648

(-

0.OOO2O-

{0.8650,0.8652

in.)

0.0484 in.)

0.0490

in.)

0.0484 in.)

O.o488in.)

0.0797 in.}

in.)

O.OO22

in.l

in.)

+

in.)

in.

in.)

Service Limit

mm

mm mm

mm

10.016 in.)

(0.004

(0.002 (0.01

(0.002

10.049

(0.0498

(0.049

(0.0496

(0.081 (0.005

(0.005

(0.005;n.)

(0.005

(0.024 (0.028

{0.030

(0.030

{0.031

(0.8643

{0.0008

0.10 mm

86.070

86.070 mm

0.05

0.25 mm

in.)

85.930

in.)

85.920 mm

0.05 mm

1.25

1.265

1.25

1.260

2.05

0.13 mm

0.13

0.60

0.70

0.75 mm

0.80

21.953

0.005

0.02 mm {0 oooa in )

0.40

in.l

(3.3886

jn.)

in.)

(3.3831

in.l

(3.3827

in.

in.)

in

)

in.)

in.) in.)

in.)

in,l

2-4

hem

Crankshaft

Deanngs

journal

lvlain

Bod

iournal

Rod/main Rod/main End Runout

Main

Bod

iournaltaper journal

play

bearing-to-iournal

bearing

M€asurement

diameter

out'of_round

clearance

oil clearance

Oualilication

journal

l

No.

journal

2

No. No.4journal No.5iournal

engine)

{K20A3

journal

l

No.

journal

2

No.

journal

No. 4

journal

5

No. (K20A2

engine)

journal

No. 3 (K20A3

engine)

No.3journal (K20A2

engine)

engine

K20A3

engine

K20A2

K20A3 engine

K20A2 engine

journal

l

No-

journal

No. 2

journal

No. 4 No.5journal

No. 3

iournal

engine

K20A3

€ngine

K20A2

Standard

55.008

54.984

55.004

54.980

54.976

55.000

54.996

54.974

44.9?6-45.000

48.000

47.976 (0.0002

mm

0.005

(0.0002

mm

0.005

mm

0.35

0.10

0.03

0.02

0.017-0.041

0.025

0.021-0.049

0.033

mm

0.049

(0.0012 (0.0008

mm

0.061

New

or

mm

(2.1648

12

in

2.1657

'!646-2

(2.1644-2.1654

(2.

1644 - 2.1652

(1.7107 1'1.8888

)

in.)

10.004-0.014 max

in.) in

)max.

(0

0007

0 0016

(0.0010-0

{0.0008 (0.0013

0.00'19 0 0024

in.)

1655

1.1117 1 8a98

in

)

in

0019

in.) inJ

in

4n.)

in.l

in)

in.)

)

0.010

0.45

0.04 mm

0.03

0.050

0.055

0.060

0.072

Service

mm mm

mm

{0.018 (0.0016

mm

{0.0012

mm

mm mm mm

Limit

(0.0004

in.) in.)

{0.0004

in

in.) in

(o.oozu

(0.0022

(0.0024 (0.0028

)

In.l

in.) in.) in

)

ro

Belief

valve,

oil

Pressure

with oil

(5.6

tJS

0

5.3 0

14.4 (4.2

016.1 (5.0

{4.8

0.15

0.07

kPa

{0.7

US US US

US

4.2

4.0 0

5.8

4.7 4

4.5 4

0.02

0.15-0.21 O.O2 7o

qtlfor

engine

qt)lor

engine, qt) qt)for qtlfor engine,

qt)

mm mm mm

kqvcm',

change,

for oil

engine

for oilchange

(0.001

10.006 (0.001

10

Psi)

overhaul

including

overhaul

including

0.006

0.008

0.003 min

filter

without

filtet

without'ilter

4n.) in

)

in.)

0.20

0.12

mm

(0.008

(0.005

in.)

2-5

Standards

and

Service

Limits

Rad;ator

and

Item Fuelpressure regulator

Fueltank Engine

idle

Coolantcapaciry,lncludeseng;ne.

Emissions

Measurement

Pressure

Capacity

ldle

fan

Fast

speed

off

idle

with

pressure

fuel

headlights

gauge

and radiator

Oualification

K20A2

engine neutral K20A3

engine neutral(M/T) K20A3

engine

p6s;s;on

or

E

P

(A/T) K2042

engine

neutral

K20A3

engine neutral{M/T) K20A3

engine

or

E

{Arr)

6.4 0

5.10

6.3

5.00

93 169

8.0 mm

196

Subtract

320.-370

I

s0 0

I

in

650450

I

in

650 t

in

ffi

in

1,600+200

in

ffi

(6.8

{5.4 US

(6.7

S

{5.3 US

123

kPa

176"F

1O.31

203"F

5

(13.2

rpm

50 rpm

ql)

US

qt)

q0

US

q0

{0.95- 1.25

(76-

80"C)

in.)

min.

95.C)

191

':5"F

(3

S"Clfrom

Standard

kPa

US

orNew

13.3 3.8 ks7cm,,

qat)

rpm

kgflcm:,

actuat

47

14.-

52

18

,ON,

I

psi)

Service

w

Limit

2-6

Clutch

nem

pedal Heiqht

Clutch

disc

Clutch

Pressure

from

Stroke

Play

Disenqaqement

on clutch

Bunout

head dePth

Rivet

Thickness

plate Warpage

if diaphragm

Height

M6asur€ment

lloor

the

lrom the

height

surface

mating

spring

floor

tingers

Oualification

Measured specialtooland {eeler

with

gauge

Standard

(7.76

140

2.25

8.9

{0.02

in.)

(5.1-

mm

{0.39

in.) min

14.53 (0.002

mm

(0.33

mm

in.)

mm

197

130

16 mm

10

mm

115

0.05 mm

1.65

8.3 0-03 mm {0.001

mm

0.6

or New

5 5

0 63

max.

in.)

10.065 0 35 in.)

in.) max.

max

in.)

in

)

0.089

in.) min

0.15 mm

0.7 mm

6.0

0.15 mm

0.8

Service

mm

{0.006

{0.03

(0.24

(0.001

mm

(0.03

Limit

in.) in.) 4n.)

in.) 'n.)

t

.-l

e,

2-7

Standards

Manual

u

Transmission

Item Transmission fluid Mainshaft

Mainshaft 4th gears

Mainshafr

geal

Countershatt

Counlershaft

LOUntershatt

2nd

Countershaft

lst drstance Countershaft 2nd distance

3rd,

and 5th

6th

gear

collar

gear

collar

and

Capacity

play

End

Diameter

{clutch housing

Diameter alea Diameter

(transmission

Hunout LD.

play

End

LD.

play

End Thickness

area

{ctutch

Diameter

area

Diameter (transmission

Run

out

35 mm

shim-to,bearing

t.D.

play

End Thickness LD.

play

End

Thickness ta)

Length

LD.

o.o.

Length

Service

and

Measurernent

of bushing

of

distance

side)

of needle

of

of ball

ball

bearing

housino

hogsing distance

bearing

housing

bearing

side)

collar

M

surface

co

at

r9

conraq

contact

side)

lng

conract

contact

side)

inner

Limits

Differential

area

race

Oualification

For

fluid

change:

Foroverhaul:

-0.17

U.I

I

mm

20.80

20.85

31.984

21.977

38.984-39.000

27.987

0.02

44.009

0.06

23.92

40.009-!0.025

0.06=0.16

23.92

40.000-40.015

39.937

30.020

0.02 mm

0.04

s2zo10

006

22.92

52.010-52.029

0.06

rv.v5

46.989

23.03

39.95

46.989

zd.ur

32.000

27.990

28.000

(0.001

mm

44.025

0.16 mm

23-97 mm lo cFl n

mm

23.97

mm

39.950

30.033

(0.001

0.10

mm

52.029 mm

0.16

mm

22.91

mm

0.16

mm

J9.9b

mm

47.000mm

23.08

mm

39.96 mm

47.000

zu.ud

mm

Standard

1.7

mm

(0.0016

(0.002

mm

{0.002 0.006 in )

mm

or New

1.5 0

011.8

(0.004

(0.819

(1.2594-

mm

\1.1015 1.1020an.)

mm

fi.5348- 1.5354

(1.1019

mm

in.)

max.

mm

{1.1326 1.j333in.|

{0.002-O 006 in.)

(1.5752

mm

(0.002

(0.981

(1.5748

mm

{1.5i23. i.572Ain.l

mm

fi.1819 1.i824

in.)

max.

(2.0476

10.902 0.904 in.) ?? R7 mh i^ on^,^ | (2.0476

('1.5728

(1.8499-

10.907 (1.5128

.8499

{1.104 1.106

{1.6 US

qt)

LJS

0.007in.)

0.821

I 2598

t.tO2a

qfu

-1.5758in.)

0.006 in.)

0.944

1.5754

O.OO39

2.O4B4in.)

0.006

in.)

2.0484

1.5732in.)

1 a5o4in )

0.909

1.5732in.) t.8504 in )

in.)

qt)

in \

in.)

in

in.)

)

20.75 31

93 mm

27.92

38.93

27.93

0.05 mm

44.08

0.25

mm

23.80

40.08

0.25 mm

23.80

39.95

39.883

29.97

0.05 mm Adjust

52.08

0.25

mm

52.08

27.87

mm

39.97

mm

39.97

mm

46.94

mm

Service

mm

(1.533

mm

{1.100

(0.002

mm

11.735 in.)

{0.0'10In.)

(0.937

mm

('1.578

mm

(0.010

(0.937

mm

(1.573

mm

{1.180

(0.002

(2.050

mm

{0.010 in.)

mm

{2.050

(1.097

11.574In.)

(1.574 (1.848

Limit

(0.817

in.)

(1.257

in.)

(1.099

in.)

in.) in.)

in.)

jn.) in.)

(1.5702

in.)

in.) in.)

w

jn.)

2-8

Manual

Mainshaft and distance

MBS d stance

Transmission

4th

gears

sth

collar

l.lj.

"d"

:'::i::r"t

'-""*;ffi

disrance

sear

(6

collar moder onlY

Reverse

qear Gear-to

Synchro 15 sDeed

nrodelonlY)

Double synchro

;;;

modelonly)

-riple Triple cone

svnchro

Reverse shift fork

Shift arm

Selecl

Selecl Shift

M/I differential

lrl.

o.p.

j

idler

ring

Length

1.0

Ring

Outer clearance

speed

*' "t";t*-,, "*"r""*-

cone

Fu"i;"*r*n""-;;;

puter synchro

I clearance

Ort"'

cone

Uuler

l

clpardn, Synch

uuter syncnro

t-#;;;.-"

clearance

Fork

l!gg!t!r!Ia":L

Fork

levet

lever

';-..'^j..*^*,^"

!:lll::li

r- : ..- ,

-

carrier

M/f differential

n*

*t"

80 mm shirn I

fllsr

Differential

and

Oualitication

32.01

32.00

39.000

38.e89

52.05

51.95

24.08

24.03

28.01

28.00

'" ""

L

.

24 03

24 08

*;

-

l

" ]on

gear

reverse

to_gear

syrchro

_-n

.yn"n,o

sYncnro

e

o cone

to-synchro

to reverse

diameter

fork

Shift

arm-to

Shift

widrh

wlorn

Frnge'

Frnger

ro select

Shaft

shift

shaft

pinion

to

select

:]1

Groove {to Shaft-lo

*,*^*;*. rn f 18-O1O

Pinion Carrier

or'ytrl"trsal!119"!

Backlash l.D.

g"jllstlrlga"!9tt

mm shim

80

clearance

in transm

st u!jl99Il!9

clearance

. , i-* i",; . *--,"""" n--'' rc3-n.(0or2iti

ri'19 ro svnch'o

-lfRts

co'1e

-

hlng dqa'n5t

llT

agalnstgear

F"s

rv LUric

l

area

I D

-pi"o

""n"

agalnsl

Rrng ous'Fd

--",-P-::^::

dgarnsl

I

R'no o"""4 againstgear

I;tr;H:,":

i

t

l

ring-to

o"-i.""

fing ro*u*-'o

rrng tu_svrrcr

'ledra'lce

to_gedr

ro_gear

nn9

-_

clearance

sleeve

idler

contact

at

lever clearance

shift

tever

.lpa'ance

lever)

earance

arm c

area

contacl

clearance

shaft

l!

*;;""*

ssron

";;-'

t

to-bearint

--:e".

Tlet

20.016

0.036

p,snet-

pusrreu

t-::::

p,.h"d f 50

n"r*d

-

noto

qear

- ^^ -

95

0

gear

.

/O 1

0

gear

0 50

|

r.*

7.4 7.6 o.ss

13.4

.

0.20

16.9

0.2

.

14.85

0 05 0

rsoo

15.00

0.013

0.027

--iq025

O.O5

18.042

o.oss

io

*,qoo

z43s

20.013

0.084

1/9 mm 10.028

1!4

1 68 mm

--19 mm

1 01

*,,,,"..*z

0.65

13 7

0.59

17.0 mm

0.5

14.95 '15.10

ls.ro

0-07

0.051

0.15

o oes

cj'ro

New

Standard

mm

mrn

rnm

mm

-.

mm

or

(1

mm

(2.045

(0.946

(1.102

rosro 0 e47

'1

2598

(1.53s0

2 049

0 947 in

1 103

0.947

1q:-r:

-d1:77:;

(03a6

0 947

/880 0.7891

{0.

mm

(0.0014

059

0

(0

0.041

oro

(0

o 066

037

r0

0 04/

028

r0

O 04'

020

in

2602

1 53s4

in )

)

in.)

)'.916

ir

rr.)

l:971s

in

)

0 0033ln

in

)

in.)

in

)

\

in

ir''

)

in

il

in.)

)

o-ooor"L

(0.29

30 in

0

mm

{0.014

(0.527

mm

m-r.

10.007

10.665

(0.008

mm

{0.58b 0 589

mm

mm r0 002

25

18.028

-.

mm

(0.591

10.591

(0.0005

10.0011

28045Trn!1'1931111041

(0.002

mm

mrn

18.066

(0

mm

ooos'

m--o

)

in.)

0.026

)

in

0 539

'

02a i1

0

in

0.669

)

in

0.020

)

in )

I

in

0 010

in

0 594

in

0.003

(0.7091

(0

0023

0 7098

00022in)

in

0.006

)

7103 07113in)

0 0037

i"J

)

in

in)

)

(1.261

mm

32.02

slllqlf1E]

3e

mm

28.02

11?lzrrlllmr')

lqj10

mm

34.940

rn. C

!os0;;io€32

mm

0.16

i

mm

0 4

o.3 mm

mm

0 6

mm

0.3

mm

0 3

\-

-

'.\*ot"l

1.0 mm 'l

mm {o

1.3 mm

3

mm

0.62

mm

0.50

mm

0.1

mm

0.1

mm

0.15 Adjust

in.)

(1.103

in.)

(1.3756

JZlq

in.i

(0.006

in.)

(0

in )

016

(0

in.)

012

(0

024 in

)

(0.012

in.)

r0

in )

012

(0

inj

039

(0.051

in.)

(0.024

in.)

{0.020

(0.0041n.)

(0.004

in.)

(0.006

in.)

2-9

Standards

and

Service

Limits

h6m

ATF

lAutomatic Transmission Fluid)

pressure

ltF

I

Clutch

Automatic

Capacity Use

Honda

pressure

Lrne

'I

st

2nd

3rd

4th

sth

Stallspeed Check Clutch

I

Clutch

CIutch.lic. rhi.r.^-..

iv!!rr

sr

clutch

pressure

clutch

with vehicle

end

return

P.drc

and

3rd

ctutch

cru

pressure

pressore

pressure

ptate-to_top

uIu(ness

Transmission

Measuremonl

genuine

ATF-Z1

on

ground

level

disc

ctearance

spring

free

length

plale

end

prare

thickness

rntc(ness

and

Oualification

Fluid

Overhaul

At

2,000 rpm or E position

E

Ar

2,000

gear

1st

posrtron

At

2,000 2nd gear position

At

2,000

gearin

3rd position

At 2,000 4th gear posrtron

At

2,000

gear

5th

lst

2nd

3rd

4th

and

1st,2nd,

4th

and

Mark I fV"rf

Z

Mark

3

i

Mark

4

I

Mark

s

Mark

6

Mark

7

Mark

8 g

Mark

10

Mark

11

Mark

12

Mark

1

Mark

2

Mark

3

Mark

4

Mark

5

Mark

6

M""

?

Mark

8

r,,1"fi_-f

Diffarantial

change

in

rpm

in

M

rpm

in

E

rpm

in

E

rpm

in

E

rpm

in

El

5th

and

3rd

sth

I

Standard

(2.9

2.7 0

6.5 416.9

-

900 (9.2

490

19.1

-970

890 {9.1 9.9

890 (9.1

-970

890 (9.1

E90 (9.1

2.32O

q0

US

q0

US

960

kPa

9.8 kgTcm', 970 kPa 9-9

kg7cm,,

kPa

kg7cm',

970 kPa

9.9 ksf/cm',

kPa

9.9

kg?cm,,

970 kPa

9.9 kgtcm',

tpm

--

(rno,'t

."'

lso"e

33.5

mm

1.94

mm

2.00

mm

2.3

mm

2.4

mm

2.5

mm

2.6

mm

2.7

mm

2.8_.Il!.11!l

2.9

mm

3.0

mm

3.1

mm

3.2

mm

i

3.3

mm

-.4

rn.

2.6

mm

2.7

mm

2.8

mm

2.9

mm

3.0

mm

3.1

mm

in.)

{1.32 (0.076

(0.079

(0.090

in.)

(0.094

in.)

10.098 in.l jn.)

(0.102 (0.106

in.)

(0.114

in.)

(0.'118

in.)

(0-122

in.)

(0.126

in.)

(0.130

in.)

(0134,

itj

(0.102

in.)

(0.'106

in.)

(0.110

in.)

10.114 in.) (0.'t

18

in.)

(0-122

in.)

in.) in.)

)

3.2_ry1q1?qI.) x ..191!j]tl

!

(0.134

3.4

mm

in.)

130-

t30

130

or New

140

j40

140

?40

t40

-

t40

osi)

psi)

Se.vice

850 kPa (8.7

kg7cml,

840

kPa

(8.6

kgf/cm,,

840 kPa (8.6

kgTcm',

840 kPa {8.6 kgflcm','t20

840

kPa

(8.6

kgtcm',

840

kPa

(8.6

kg7cm',

2,110

2,470

1.23-

1.43

(0.048

0.056

0.75

0.95

(0.030

0.037

0.83

1.03

(0.033

0.041

0.73

0.93

yllr1al

Y:al

48.8

31.5 mm

When

When When When

When

When When When

When

When When

When

(1.92

mm

(1.24

discolored

discolored discolored

discolored

discolo.ed

discoiored discolored discolored discolored

discolored

discolored discotored

discolored

Limit

120

120 psa)

em

mm

in.)

mm

in.)

mm

in.)

mm

in.)

psi)

14,

I

2-10

Item

Clutch

N/ta;nshaft

Countershaft

sth

4th and

Diameter alea

LD- ofgears

play

End

mm thrust

41 x 68

gear

4th

of 4th

Length

end

Sealing

of sealang

Width

feed

Clutch

feed

Clutch

Diameter

gears

LD. of

play

End

Length '02

model {}

Length '02

model

'03

model

Reverse Reverse

end

clutch

bearing

needle

of

gears

of

washer thickness

length

collar

gear

collar

ring thickness

nng

pipe

O.D.

piPe

bushing

bearing

needle

o{

gears

of

o{ collars

1000001

of collars,

selector

and

($

1021248 ),

(#

2000001 )

hub

plate

thickness

contact

flange from

groove

I D

contact

1021247)

cotter thickness

and

width

o.D

Oualitication

11

N4ark

12

Mark

13

Mark

14

Mark

15

Mark

16

Mark

17

Mark

fl"'trIT

19

Mark At stator At sth At

sth

4th

5ih 4th

shaft gear 51.915-51-991 gear

4th

gear

gear gear

1

No.

No.2

No.3 No.4

No.5

No.6

i-

nousrng

gear

4th

At

reverse

At

collal

gear

4th

gear

Reverse

gear

sth

gear

4th

gear 0.10

Reverse

gear

4th

Distance collar Collar

x

35x47

Collar

x 57.8

37x41

j

Cotterthickness

collar

gear

collar

7.8 mm

mm

g.t

3.2

3.3

3.4

3.5

3.6

3.7

3.8 mm

3.9 mm

22.984

33.975-33.991

57.000

12.2441

40.000 (1.5748

0.03

0.1

6.35

6.40

6.45

q!ryr19!:91!l

6.55

6.60

66 3

19.15

1 91

,.OrU

(0.0797

1.97 7.98 mm

8.OOO {0.3150

36.005 {1.4175

37.980 (1.4953

43.000 (1.6929

46.000

0.'10

o:a

]

I 24.00

14.25

7.2

57.75

2.00

25.45

55.87

m;

mm

mm mm mm mm mm

0.31 mm

0.212 mm mm

mm

mm mm

66.4

-1.97

7.3

mm

Standard

(olt

ir,J

(0.126

in.)

(0.130

in.)

(0.134

in.)

(0.138

in.)

(0.142

il.)

(0.146

in.)

(0.150

in.)

(0.154

4n.)

23.000

57.019

2.24lain.l

40.016

1.5754

mm (0.250 (0.252

(0.254

(0.258 (0.260

mm

19.30

mm

-rn

,.OaO

0.0811

mm

8.015

0.3156

36.015

1.4179

37.994

1.4959

43.016

1.6935

46.016

mm

0.42

-Illioo

o.rl

mm

0.25

24.05

4.30 mm

7

mm

.AO mm

57

10.078

25.65

55.90

New

or

(0.905

(2

046

(1.3376

0 012

0.008

0 906

2.047

mm mm mm

mm

in.)

(0.001 {0.004

in.) in.)

in.)

-

in.) in.)

(2.610

(0.0752

in.)

10.3138 0 3142

mm

(0.004

mm

(0.28

mm

(0.754

in.)

(1.5740

in.)

(1

{0.945

12923

0.29

21

\2

in.)

{1.002 {2.200

614

2

0.760in)

0.0776

8110

0 017

9.oqa

0 010

0.947

2.925in)

in.)

4 2.216

1 010ln )

2.201

Servic€

discolored

when

w!g! !,"9919199

When discolored

discolored

ivhen

discglored

When

discolored

When

worn ordamaged

When

in

)

worn or damaged

When

in.)

1.3382

in.)

in

)

-

in.)

worn ordamaged

When

I

worn or damaged

When

t--.'

When worn

j

'=-

f__.

whenworn

worn or

When

lw!{*9!gq9ryq"!

q!qry.",r!''"!se9'-

q!!I'd9Mldirnlgql

-.1ry!""I9ry1d4999q

in )

When worn

(0

in.)

In

r

staa-" rl-wt

1.86

2.080 mm {0.0819

I

t

8 030

Whenwornordamaqed

i--.

Whenworn

".r"t"

whrn

l

18116in)

in.)

in

t

in.)

in

When

]

)

:.

In.)

Whenwornordamageo

Limit

ordamaged

or0amageo

damaged

0r oamageq

in

0732

in

)

(0

3161

mm

ordamaqed

ot

*ot o,

worn or

)

-

in

)

a"ffi

a"t-o"a

damaged

(confd)

2-11

Standards

and

Service

Limits

Aulomatic

Item

I U."""r"-J

37

I

4u x

Jrd

Length end Sealing wrorn

urutch

ATF guide

Transmission

erdrrerer area

End

or neeote

play

ofgears

x 58

mmthrustwasherthickness

51,5

mm

gear

cotlar length

ot

3rd

ring

thickness

or

seattng .rng groove

pipe

teed

of

sealing

Deanng

thrust

washerthickness

gear

collar

bushing

ring

contact

flange

from

O.D.

contact

l.D.

and

Ouelificetion

At 1st

At 2nd gear

At

3rd

lst

2nd

3rd

gear

1st

2nd

3rd

No. 1

No.2 No.3

No.

No.5 No.6

No.7

No.I No.9

No.

10

No. 11

No.

12

No. 13

No. 14

No.

15

No.

16

No.

17

\o.

18

\o.

19

\o.20

No. 1

No.2

No.3

No.

4

No.5

No.6

3rd

clutch

pipe 1st

clutch

prpe

3rd

clutch feed

pipe

'lst

clutch

pipe

gear

4

Differential lconf'd

gear

feed

39.986-

39.986

collar

36.975

47.000

11.8504 1.8510

46.000 (1.8110-

43.000-43.016

0.04

0.0a

0.10

3.90

3.925

3.95

3.975

4.00

4.025

4.os

4.075

410

4.125

4.15

4.175

4.20

4.225

4.25

4.275

4.30

I

4.325

4.35

4.375

I

4.80

4.85

4.90

4.95

5.00

5.05

43.9

5.25-5.40

lj91

2.025-2.060

11.47

(0.4516

6.97

11-500-

{0.4528

7.018 (0.2763-0.2768

29.000

11.1417

(1

.51

mm mm mm

42 - 1

0.12

0.22 mm

mm

10.189

mm

{0.191 in.)

mm

{0.193 (0.195

{0.197

10.199 in.)

44.0

1.97

-

11.48

0.4520

6.98

11.518

0.4553

7.030

29.021

1.1426

39.999

36.991

47.0'16

46.016

1.8116

mm mm

(0.154

(0.155

(0.156

{0.156

(0.157

(0.158

r0.ts9

(0.160

(0161

10.162

(0.163

{0.164 in.)

{0.165 in.)

(0.'t66

(0.167

10.168In.)

{0.169 in.}

(0.170

(0.171

(0.172

mm mm

mm

Standard

.57 48

or

N6w

mm

in.)

mm

fi.5'ttZ t.Si$,i

mm

{1.4557 i.4563

mm

in.)

mm

in.)

mm

{1.6929- 1.6935

(0.002

0.005

-O.O0S

{0.002

(0.004-0.009

in.)

in.r

in.)

in)

- I

in.)

jn_)

in.)

jn_) in.)

{1.728- 1.732 (0.207

0.213 in.)

{0.0752

mm

(0.2744

mm

in.)

mm

in.l

0.0776in.)

10.0797 O.OB11

in.)

0.2748

-

in

in.) in.) in.)

)

in.)

Service

Whenwornordamaged

When

worn

in.

Whenwornordamaocd When

worn

When

worn

in.)

When

worn

When

worn

When

worn

Whenwornordamaged

When

worn

When

worn

When

worn

d;;;" ", r*;",

When

worn

wtren

worn

When

worn

When

worn

When

worn

Wh"n *orn

]

When

worn

When

worn

When

worn

When

worn

Whcn wdrn ^r n2m.^.,1

When

When When When

Whenwornordamaqed

When When

Whenwornordamaged

When

1.86

in.)

2.080

11.45

(0.4508

{0.2736

11.530

{0.4539 in.)

7.045 10-2714in.1

29.05

- :::jj]:t

worn

worn worn worn

worn worn

worn

(0.0732

mm

in.)

mm

(1.144

mm

Limit

or damaged

or

damaged

or damaged

or damaged ordamaged

or

damaged

or

damaged

ordamaged

or

damaged

or aamaged or

damaged

or

damaged ordamaged o, a"r**a

or damaged

or darnagpd or

damaqed

or damaged

:9:1

or damaged

or

damaged

or damaged

or

damaged

or

damaged

61

66rnrn"6

in.)

10.0819 in.)

in.)

lo

z

a

2-12

Item

gear

ldler

Reverse

shaft

idler

gear

pump ATF

ATF

shaft

Stator

shift

Reverse

fork

gear

Park

and

Diameter of

needle area Thickness Reverse

ofcotters

gear

idler

needle bearing

LD.

l.D. ot reverse area on

l.D. of

pump pump

ATF

pump

ATF

pump

ATF Ne€dle

Sealing

{inger thickness

Fork

idler

transmission

idler

reverse

thrust gear-to_body

driven driven

bearing

ring contact

bearing contact

shaft diameter

area

contact

gear

shaft

housing

gear

shaft

clearance

gear

l.D.

gear

shaft O.D.

I D.

contact

l-D.

area

at

contact

holder

Ourlilic3tion

End cover

gear

Drive

gear 0.070

Driven

convener

Torque

side

pump

ATF

side

Strnd..d

mm

32.013

32.003

1.42 mm

1.39

14.99

20.007 (0.7877

14.800- 14.818

14.800-

0.03 0.05

0.210-0.265

(0.08-0.010

14.016- 14.034

13.980

21.000-2"1.021

29.000-29.021 (1.1417-

29.000 {1.1417

5.90 6.00

{0.0547-0.0559

15.00 mm

20.020

0.78a2

14.824 mm

mm

in.)

-0.125

mm

13.990

1.1426 in.)

29.021

1.1426 mm

mm

in.)

mm

(0.001

mm mm mm

mm

{0.232-0.236

New

or

(1.2600

10.5902

(0.5827

0 5906

0.002

1.2604

0 5834

0.5836in) in

(0.003-0.005

{0.5518-0.5525 (0.5504-0.5508

1.064 in.)

11.063

in.)

in

Servica

in.) When

in.)

in )Whenwom

When

in.

When worn or

mm

)

0.07

in-)

in.l When

When worn

in

l

When

29.05 mm

)

5.40

When

Limrt

worn or damaged

or damagod

worn or damaged

damaged

in.)

{0.003

worn or damaged

or damaged

worn or damaged

(1.144

in.)

mm

in.)

10.213

wom or damagod

shaft bore

shaft

ring contact

A spring

valve

valve I spring

valve C

body

Shiftlork

Sealing

Shift

,

Servo body

Regulator

Item

Main valve

(see

spflngs page

14-201)

valve

Shift

Reliel valve

Lock up controlvalve

check

Cooler

LD.

valve bore

LD.

Measuremefi

spring

sprang

sPring

valve sPring

I D.

Oualifi6tion

'02

model

(#

1000001

1006166i

'02

model

(#

1006167

'03

model

and {#2000001

valve spring

control

Servo

E spring

valve

Shift

14.000(0.5512

37.000-37.039

29.000

wire Diameter

0.8 mm (0.031

mm

0.8

10.031

1.0 mm (0.039

0.65 mm (0.026

(0.024

mm

0.9

10.035

),

)

(0.028

mm

0.8 (0.031

0.5516

29.021

in.)

an.)

in.l

in.)

(1.4567

mm

(l-1417

mm

5.6 mm {0.220

5.6 mm (0.220

5.6

10.220

9.6 mm (0.378

7.1 mm (0.280

5.8

(0.228

6.6 (0.260

6.6 {0.260

5.6 (0.220

-

Standard

o.D.

in.)

mm

in.)

mm

in.)

mm

in.)

mm

in.)

mm

in.)

1 4582

1.1426

New

or

Fre€ Length

28.1 mm (1.106

28. t mm (1.106

28.1 (1.106

34.1 mm (1.343

23.1 mm (0.909

14.5 (0.571

(1.043

{1.406

28.1 (1.106

in.)37.045 in.)29.05

mm

in.)

mm

in.)

in.l

in.)

mm

in.)

mm

in.)

mm

(1.4585

(1.144

of Coil

No.

15.9

r5.9

15.9

10.2

12.1

6.8

12.6

11.2

15.9

in.)

mm

14.010

(cont'd)

2-13

Standards

Au

Item

Hegulalor oooy spnngs

(see page

203)

Servo body spflngs page

14

valve

14

{see

2O4l

and

tomatic

Stator

L

Reguialor

Hegurator

r

orque

Lock up

gtd

"""r.rLtor.

r

1$ accumutator

1st accumulator

Shift valve

4th

accumulator

4th

*"rnrt"r.l.

I

,"d r""-r,rbt"I'

Znd sccumulator

&l'|a"*,-rl"t"r

Service

Transmission

Measurement

reaction

spring

valve

spring

vatve

spring

converter

shift valve

D

spring

check valve

"pti"g

spring

spring B

rpri""

Wil"S

spring

"pr|

A

B

spring

A

B

A

B

A

"S

Limits

and

spring

Oualification

]

Differential {cont'd

Wire Diameter

4.5 mm (0.177

1.9 mm (0.075

1.6 mm

(0.063

1.2

mm

(0.047

1.0

mm

(0.039

2.5

mm

{0.098

2.4 mm {0.094

2.3

mm

10.091

0.8 mm (0.031

in.)

2.3

mm

(0.091

in.)

2.4mm (0.094

in.)

2.0

mm

(0.079

in.)

2.2 mm (0.087

in.)

2.5 mm (0.098

in.)

in.i

in.)

35.4

mm

(1.394

14.7

mm

10.579

(0.362

8.6 mm (0.339

6.6 mm

(0.260

14.6

mm

(0.575

18.6

mm

(0.732

12.2.nm

{0.480

5.6 mm /.0.22O

12.2mm (0.480

'18.6

mm

(0.732

10.6

mm

(0.417

16.6 mm

(0.654

14.6

mm

(0.575

Standard

o.D.

in.)

in.i

in.)

or New

Fres

30.3 mm {1.193

80.6 {3.173

44.0 /.t.132

33.8 (1.331

35.5

mm

(1.398

29.9 mm (1.177

49.0

mm

(1.929

(1.240

28.1

mm

{1.106

31.5

mm

{1.240

49.0

mm

(1.929

34.0 mm (1.339

48.2

mm

(1.898

29.9 mm (1.177

Length

in.}

mm

in.)

mm

in.)

mm

in.)

4n.)

in.)

No.

1.92

16.I

12.2

14.2

4.9

1.1

6.6

7.1

8.0

8.s

4.9

ofCoil

differential

A/T carner

Pinion

Er'ie,

Carrier

^

Lari,er

shaft contact

beafing

area

ro-pinion

lo rntermeoiale

shafi ctearance

shafr

stdrl ng

roroue

l.D.

ctearance

Fo' new

bearing

18.000

(0.709

0.710 in.)

0.013

0.054

(0.001

0.002 in.)

28.015 (1.103

1.104

0.035 0.086

28.015

fOoOS

O-;i.-

2.7 3.9 t\.m

40 kgf

{28

37 kgf

125

0.087

0.146

0.05

0.15 mm

18.042 (0.7103

(0.0022

18.025

mm

28.045 mm in.)

mm

28.045

mm

cm,24

cm, 22

mm

(0.002

18.066

mm

0.7'113 in.)

0.0037

in.)

{0.001 0.003 in.)

(1.103

1.104

fo OO

35lbf.in)

32 tbf.in)

(0.003

0.006 in.)

in.)

.f

0.1 mm

0.12 mm

0.2

mm

0.12

mm

(0.004

10.005 in.l

{0.008

(0.005

in.)

in.i

2-14

f,

Item

Steering

Gearbox

wheel

Pump

Power steering fluid

M€asurem€nt I Rotational edge Initialturning outside edge

Angle of from locked

Output

play

with engine

load

with engine

guide

rack

position

pressure

closeo

Capacity Use Honda

power

measured

running

measured

running

screw loosened

shut-off

with

steering

at outsade

at

valve

fluid

Oualification

K20A2 engine

K20A3 engine

K20A2 engine K20A3 engine Fluid change System overhaul

model

M/T

on

overhaul

System

Standard

10 mm

0

38.2 N

37.2 N

15'Max.

{0

(3.9

kst,8.6lbf)

(3.8

kgI,8.4lb{)

7,200-7,800

7,300

6,600

0.2 0 {0.21

0.7 0

0.8

tJS

(0.74

t,S

010.85 US

0.39

kPa kPa

qt) qt)

qt)

or New

in.)

(73

80 kgflcm',

(67

T4kgtcm',950-1,100psi)

1,000

Servica

1,100

Limit

psi)

Drive belt

Item

Wheelalignment

bearing

Wheel

Camber

Caster

TotalToe

Frontwhegl

Aluminum

Steelwheel

End

wheel runout

play

Measurement

turning angle

runout

Oualification Front Rear

lnside wheel

wheel

Outside

Axial

Badial

Front

Rear

Auto adiust

Standerd

0"00'r45'

0"45'J4s'

1"30'41

0+3 mm

(010.12

lN 2 ' , mm

10.08

in.)

'"

35'00'12"

28"00'(Referonce)

(0

mm

mm mm

0.03 (0-0.03 (0

0.04 in.)

-0.04

{0

(0

0.002

(0

0.002

0.7 mm

0

0 0.7

1.0 mm

0

-

1.0

0 0"0.05 0 0.05

or New

in.)

,.

in.) in.)

in.)

in.) in.)

Service

mm

2.0

1.5 mm mm

2.0

1.5 mm

Limil

(0.08

in.)

(0.06in.)

in.)

10.08 (0.06

in.)

2-15

Standards

and

Brakes

Item

Parking

brake

lever

pedal

Brake

Master

cvlinder

Brake disc

Distance

with

Pedal

Thickness

Measurement

traveled

196

N

{20 kgf, 44lbs)

height

Service

when

(carpet

removed)

lever

of force

pulled

Limits

Oualitication

7

I

clicks

180 mm '183

mm

0.4 3.0

0 0.4

mm

Standard

(7

1/16

(7

3/16 in.)

(0.016

mm

(0

or New

in.)

0.118in.)

0.02 in.)

23.0

Service

(0.91

mm

Limit

in.)

Brake

pads

t^

Parallelism

Thickness

-

^Startercoil

Pulley

Tension

-

to-pressure plat"

resistance

r]99lryn

lf""t

Oualification

=-:nr::tvaporato d5

99llp,esso,

i lltoe.f

I

fzacf

10.0

mm

7.5

mm

HFC 134

500

550

'"

"'l

l1:_ '1

m0

r30

1s0

l:-os

3J5,r

0.35

0.6 mm

I ^ .

Auto

tensioner

(0.39

in.)

(0.30

in.)

(B-13a

a

(17.6

g

j1v:ll!qy:L

1 2

fi 07 1.6lmp

(4

m0

1/3

(0.014

(needs

a)

19.4

oz)

5 ft oz, 4.6

0

Or4 i.r)

no

_

oz)

s.3 imp

adiustrnent)

19.00

8.0 mm

To.ro

0.10 0

015 mm

1.6 mm

ozt

mm

{0.31

.n-

mm

(0.06 (0.06

(0.75

in.)

i..r

ib.oor

(0.004

in.)

10.0006 in.) in.i in.)

2-16

Design

Specifications

hem

NSIONS

DIME

WEIGHT

WEIGHT {CANADA)

ENG

(U.S.A,)

INE

STARTER

CLUTCH

W2[T5 MANUAL TRANSMISSION

Measurement Overalllength Overallwidth

Overallheight

Track

clearance

Ground

capacity

Seating

Weight

Vehicle

Gross (GVWR)

Weight

Vehicle

Gross

Type

Cylinder

arrang

Bore and

Compression

Valve Lubrication

Oil

Water

Fuel

Type

Normaloutput

Nominalvoltage Hour rating Direction Clutch

Clutch

stroke

ratio

train

svstem

pump

displacement

pump

displacement

required

rotation

oJ

type

friction

Final reduction

Rating

material surtace

area

Oualification

Front

Rear Type S

Premium

RSX,

RSX

Type S

RSX

Type S

engine

K20,A2

engine

K20A3

At 6,000

engine

rpm

6,000 engine

At

rpm

engine

K20A2

engine

K20A3

K20A2 engine K20A3 engine

Mfi

w2M5

1st 2nd 3rd

4th

5th

Tvpe

ratio

Gear

mm {101.2 mm

15.87

mm

(4)

tbs

kg kg

cooled,

mm

drive,

wet sumP,

q

{87

reduction

seconds

plate

174 cm'

1:1

1.880

1.212

0.921

0.738

3.583 helical

Single

4.388

(173.0

(67.9

in.)

(55.1

in.)

(58.3

in.)

(58.3

in.)

(5.98

in.)

4-stroke

(3.39

(122

cu

DOHC VTEC

qt}/minute

US

qti/minute

US

gasoline gasoline

viewed

as

dry,

torque

(26.97

sq 5-speed

gear

4,395 mm

1,725 mm 1,400 mm 2,570

1,482 1,481 mm 149 mm

'152

four

3,700

3690lbs

'r,670 1,675

1,670 kg

Water Inline 4-cylinder, 86 x 86

1,998 cm'

11.0

9.8 chain Forced,

54.3 0 {57.4

82

UNLEADED UNLEADED Gear

1.2kW 12V

30 Clockwise Sinqle

3-element

Svnchronized, Direct

Specification

in.)

DOHC

transverse

in.)

x 3.39

in.)

4 valves

trochoid

with

with with

from

diaphragm

converter

in.)

{orward,

VTEC engine

per

PumP

pump

91

pump

86

gear

end

sPting

with lock-up

1 reverse

cylinder

octane octane

clutch

number numbet

or higher or higher

-

(cont'd)

2-17

Design

(

cont'd

X2M5 TRANSIVISSION

AUTOMATIC TRANSMISSION

STEERING

SUSPENSION

WHEEL ALIGNMENT

BRAKES

TIBES (U.S.

model)

Specifications

Item

MANUAL

TIBES {Canada

model)

Measurement Type Primary

reduction

Gear ratio

Final

reduction

Type Primary

reduction

Gear

ratio

Finalreduction

Type Overall ratio Turns,lock-to-lock Steering Tvpe

Shock

Camber

Caster Totaltoe

Type

Pad

Shoe Size

Size of

Size of tront

Size of

wheel

absorber

ofservice

parking

of

friction

ot tront

spare

diameter

brake

braks

surface

and rear

tire

and rear

tire

area

area tires

tires

Ouelification

X2M5

tst

2nd

3rd

4th

5th

6th Reverse

type

Gear ratio

tst

2nd 3rd 4th

5th

Reverse

Type Gear ratio

Front R€ar

Front

Rear Front

fiear

Front Front Rear

Rear

Front Rear Rear RSX

Type

S RSX Type

S RSX Premium

Type

S RSX

Premium Type

S

Synchronized,6 Direct 1:1

2.130

1.147

o.921

0.738

3.583 Single helicalgear

4.388 Electronically Diroct 1r1

2.07

4

1.159

0.796

o.773

0.511

2.000

Single

4.563 Power.assisted

15.06

2.64

360

mm Independent Double

Telescopic, Telescopic,

0'_

0'45'

1"30'

0 mm In

2 mm

Power.assisted Power-assisted

M€chanical

42 cm?

tl

"rn'

controlled

helicalgear

ini

{14.2

strut wjth

wishbone

hydraulic, hydraulic,

in.i

{0

(1/16

in.)

actuating,

(6.5sq

in.)x2

;r "n.'"

{3

l9{r!1'lfi9:uf4

P205l55

R16

89H

P205l55

B t6

89V

T135/70

D15

99M

T125r0

D16

96M

P]95/65

R15

89H

P205ls5

F 16 89V

P205l55

R16 89V

T135/70

D15

99M

T135/70

D15

99t\4

T125r0

D16

96M

Specificstion

speed forward,

automatic,

rack

self-adjusting

self

i

pinion

and

stabilizer,

nhrogen gas nitrogen gasJilled

-ad,ustrng

rear

wheels

^2

1 reverse

5.speed

coil spring

filted

ventitated sotid

disc

forward,

disc

2-18

ra

hem AIR CONDITIONING

ELECTRICAL RATINGS

Moesuremont

Compressor

Condenser

Evaporator Blowea

Temperature Compressor

ReJrigerant

8attery Start€r

Alternator

Fuses

Light bulbs

control

clutch

Oualification

Number of

Maximum Lubncant

Lubricant

Tvpe Type

Motor type Speed

Maximum

Electrical consumptron

68'F

Type

Capacity

Under-hood relay oox Under'dash relay

Headlight

cylinder

soeed capacity type

control

capacity

power

(20'C)

fuse/

luse/

box

high

at

85.7 12-000

m0

130

SP-10

_

corruqated

Corruqated Sirocco

Wl12V

220 Infinite 480

Dry, single 42 W

HFC-'134a 500 12V

12 V' 12V 1ooA,

20A, 15A,

12V

(5.23

in.l/rev.

mq

m'

cu

rom

'll3

fl oz)

{4

(P/N

38897-P13-A01AH

fin fin

fan

variable (16.900

cu ft)/h

plate,

PolY

maximum

550

36 AH/5

1.1 kW,

gsA,90A

50A,

55W

al

1F-134a)

q (17.6

hours

1.2 kW

40A, 30A,

10A,7.5A

SPecification

V belt

12 V

19.4 oz)

20A,

38899-Pl3

or

drive

15A,7.sA

A01)

Headlight

Frontturn lights Front

Rearturn lights Rear side lights

Brake/taillights High mount lisht Back

License

Ceiling

Cargo Spotlights

Gauge

Indicator

low

signal

parking lights

signal

marker

brake

lights

up

plate light

light

area

lights

1'V 55

-21W

12 V

12V 12V - 21W

1'V-5W

12V

12V 21W

12V

12V-5W 12V 8W LED LED

\V

5W

'115W

21W

8W

Body

Specifications

2-20

'i.

i

Maintenance

Lubricants

Maintenance

and

Schedule

Conditions

Distance/Time

Listed

Maintenance

by

Schedule

Conditions

Listed

by Distance/Time

Maintenance

Conditions

Listed by

Maintenance

Conditions

Listed

by Maintenance

Fluids

for

for Severe

Schedule

for

ltem ...........'................'..........'

for

ltem

".......'.'.....

3-2

Normal

.........'...........

..'..........'.......

3-4

3-6

Normal

3-8

Severe

....................'............'.......

3-9

Lubricants

and Fluids

For details

lubrication

of

NO.

I

Engine

2 Transmission

3 Brake

4

5

o

7

system Clutch line Power

steerinq

Throttle

Shift

and select transmission) Throttle

8

9

Release fork

10

Brake

booster

11

Clutch booster

12

Shift lever

13

Pedal

't4 15

to

17

18

20 Air

linkage

Battery

Fuel

fill door

Hood hinges

Tailgate

Caliper Power

steering

conditioning

points

as

LUBRICATION

(includes

qearbox

cable

end

cable

cable end

(manual

clevis

terminals

and hood latch

hinges

piston

boot, caliper

system

compressor

and

type of lubricants

POINTS

Manual Automatic Transmission

ABS

line)

(throttle

(dashboard

link)

(manual

ends

lower

transmission)

Dins

Danel hole)

and

boots

to be applied. refer

Overha

Honda

Motor Cenification Gasoline Engines." Honda

MTF''

Honda

ATF-Z1

Honda

DOT 3 Brake

Honda

DOT Steering Super High Silicone

grease

Temp

grease

Multi-purpose

Honda

Caliper

Honda Power

Compressor or 38899-P13-A01) For refriqeranl:

to the illustrated

etc.)conta

LUBRICANT

(P/N

Oil

seal shown

08798-9023).

below. Make

(ATF)"

Fluid'"

3 Brake Fluid"3

(08733-8070E)

P/N

Urea Grease

grease

Grease

Steering Fluid"

oil: SANDEN:

HFC-134

08C30-80234M}

{P/N

SP-10

a {R-134 a)

index

and vaflous

Look for

(P/N

08798-9002)

(P/N

work

section,

the API

sure it savs

,,For

38897-P13-AO1AH

L,,

*1:

Always not contain

*2:

Always

*3:

Always

the

*4:

Always fluid

API CERNIICATION

use

Honda Manual

proper

the

use

Honda ATF-ZI

use

Honda

additives.

DOT 3 Brake

system.

use Honda

Power

can cause increased

SEAT

!.cgmmlnFd

En9rne

For

RSX .nd Pr.rnlum

no

Transmission

(ATF).

Using a non-Honda

Fluid.

Using a non-Honda

Steering

wear and

Fluid.

poor

€Drim

oI vrscos y ror 3 mbrent

.20 -ro

Fluid

orl

mod.l.

o

ro 20

(MTF).

Using motoroil

ATF can

Using any

steering

other type

in cold

t€mporature rang6s

!o roc

-t

affect shift

brake fluid

power

of

weather

-s

-ro

cancause

qualiw.

can cause

steering fluid

stiffer

shifting because itdoes

corrosion

and decrease

or automatic

life

the

of

transmission

L.

3-2

@@@@

oo

oooo

o

oo

@

3-3

Maintenance

Schedule

Listed

Service at maintenance. For

_Lq9

120,000

by Distance/Time

indicat6d

the

Canada models,

lnspect

D

E

Ll

E

valve clearance.

Exha!st:

0.013 in.) Replace SK22PR-lrl 1, SK22PR-M1

Inspect

Replace

mi/

0.25 - 0.29 mm

spark

adle speed.'

manual transmission

ilems in '192,000

distance or time, whichever

plugs.

A,8,C,

years,

km/

6

use the [/laintenance

(cold) (see

-

(0.010

0.01 1 in.l,K20A3

lZFR6Kl

Use

Should be K20A2

and D.

then every 90,000 mi/ 144.000

l

1S

lDENSO)

fluid. use Honda

for Normal

comes first. This

Schedule tor

page

6-37), otherwise

engine: Intake:

(NGK)

or SKJ2ODR-N41

for

K20A2 enoine.

engine 700+ 50 rpm, K20A3

MTF

Conditions

two-page Maintenance

Severe conditions.

adjust onty it

'l

{DENSO}

(see

page't3-4).

years

km/ S

noisy. K2OA2

0.21 - 0.25 mm for K20A3

engine 650J50

Schedule outlines

engine: Intake:

i

(O.OO8

0.010 in.) Exhaust:

engine, and uso IFRTG-'1 1K,

rpm in neutral

the minimum r€quired

0.2.t 0.25 mm o.2B - 0.32 mm

{Automatic

1O.OO8

|FRTG-t 1KS

transmission

{NcKt

0.010 an.)

(O.o

1

or

E

-

According emissions warranties. reliabilitv.

to stato and tederal

regulations, failure

However,

Honda recommends

to do tho maintenance

that all maintenance

atems rnarked

seryices

with an

be done at

(*)wjll

asterisk

recommended

tha

not void

interval

L.,J

the custom6r,s

to ensure rong-rcrrn

3-4

L,

Do the

items in

parts

A, B, C,

O, and

E as required

for mileage/tim€

interval

listed

A

t'

B

'1,

qt)

(4

0

8 US

u

iJ

tl

tr

U

C

n

fl

tr tr tr

D

tr n

D

n

iiiesifort"w

Coiar.

Rep|aceengineoiIfiker(seepage8T)'capacitywithfi|terchange:K20A2engine4.74(5'oUsqt),K20A3engine4'20(4'4LJsqt} lnsoectfront

.

Check

.

Check calipers

Check

lnsoecitie-rod

.

aheck

.

Check

'

Check fluid

Inspect suspension

.

Check

.

Check condition tnspeci d rivesh aft lnsoect brake and ch€ck brake lnsoect exhaust engine i".ii""1r,r"r damage

Inspect and

.

Look for

Replace

-{"pri*

.

Beplace

pads

parking

rack boots

boks

leakage.

all fluid

{lLtid, and

page

{see

ii"E" -o

pans

adjust drive

cracks and

the dust and

ir'"

air cleaner

and

and discs

grease

line

fortightness.

hoses and

paiern

tte

rear brakes

for

damage,

brake adjusament

steering

ends, for damage

levels and

windshield

{see

Jr"t ""a

steering

and

fot damage

comPonents.

ballioint

of

b h eck

boots.

lines

condition

svstem*.

check

and for

9-14i,

".nnections*.

11-157).

Page

belt.

damage,

pollen

element

and leaking

(see page

oil

enqine

Reorace

Capacity

8-6).

lsee

wear

washer{luid

filter

every

in ttre Owner,s

strown

page

19-4)

{thickness),

leaks, and

Should

gearbox,

and leaks.

{including

and boots

linkage.

grease

lor deterioration

boots

boots fo r cracks

ol tluads;

catatytrc

K2OA3 engine

checi

inspect auto

and

(see

page

whenever;irflow

30,000

tightness

be fully

ABal

check

converter

to;loo."

21-47).

miles

filter change:

withoul

Manuat

damage and

o{ mount

within 7 to

applied

(see page

and

boot

and

lCheckthe

for leaks.

heat shield,

(see page

9-15)

"inn""tion".

tensioner

the climate

trom

(48,000

km){independent

damage'

be nds fo

K2OA2 engine

Checktire

cracks

bolts'

9 clicks

17'8)'

r tightness

mastercyiinder,

It necessary,

pipe

exhaust

and

"ru"ks

(needs

no adiustment)'

control

4 5

information

(see

proportio=ning controlvalve'

ATF

add

and muffler deteriorstion;

system

o{tim€}'

and condition.

page

1 6-3)

(so6

page

{or damage,

less than normal'

is

K20A3 engine

14-138) or

retightsn

MTF

l€aks, and tightness

loose conn€ctions

4 0 0

-

andABS

(see page

modulator

qt)

2 US

14

for damag€

13'41, engin6

K20A2

for

replace

and

coolant'

E

Replace brake

tr

According emissions

reliability.

fluid every and federal

to state warranties.

years

3

regulations,Iailureto

However,

nonoa reco-mm;n;;that

(independent

o{ mileage).

perform

tho

maintenance

all

mainlenance

se

marked with asterisk{+ }will

items

ics be don€

recommended

at the

void customer's

not

interval to ensure

long-term

3-5

Maintenance

Listed

Service atthe indicated tollowing Seve.o

.

Driving less than

.

Driving in

'

Extensive

'

Trailer

.

Driving on muddy,

60,000 mi/96,000

by Distance/Time

conditions; if

Driving Conditions

towing, driving with

mi/

0

96,000 km/

Replace

!

Do items

E

5 miles extremelv hot idling or long

manuai

in A, B,

km/ 3

Schedule

distance ortime, whichever

only OCCASIONALLY driven in

(8

km)

(over

periods

a car-top carrier,

dusty,

or de-iced roads

3 vear

transmission lluid.

C, and D.

years,

then

per

trip or, in freezing

90.F/32"C) of

conditions

stop-and-go driving

or driving in mountainous

Use Honda MTF

for

Severe

comes Iirst.

these

Gonditions

Use this schedule ilthe

conditions, use the Normal

temperatures,

lse€

driving lessthan 1O miles

conditions.

page

13,4).

vehicls is

Conditions schedule

driven ltlAlNLy in

km)per

{16

{see

trip

page

Canada or in any

3-4}.

ofthe

90,000 mi/ 1

Replace

!

110,000

mi/ 176,000 km/

lnspectvalve

Ll

Exhaust:0.25

0.013 in.) Replace

!

SK22PR-tul11,

Replace transmission

D

Replace

I

Antilreeze/coolant

automatic

spark

transmission fluid. Honda

cloarance-

0.29mm(0.010

plugs.Use

SK22PR-lr411S

D

years,

10

(see

coolant

Type

(cold)

|ZFR6K11

{DENSO)

tluid.

Use Honde MTF

th6n

page

10-6).

2.

(see

page

6-1'l), otherwise

0.01 1 in.), K2OA3 {NGK)or

every

Capacity:

SKJ2ODB-M11

for K20A2

{see

mi/96,000

K20A2

(ATF)

ATF-Z1

engin€i Intake:

enoine.

page

13-4)

km/ 5

engine: 4.7 0

page

{see

adiustonly ifnoisy.

(DENSO)to.

or Honda AIF-21

years

l4-139).

0.21 - 0.2S mm K2OA3 engine.

(5.0

qt),

US

K20A3

K2OA2

engine: Intak6:0.21-0.25

-

O.O tO in.) Exhausr

10.008 and use tFR7c,11K.

(s€e

page

4.2

14-139).

(4.5

0

IATFI

engine:

mm

0.28 O.32mm(0.011 |FRTG-11KS

q0

US

Use Honda A

(O.OO8

(NGK)or

Soason

'a-.J

0.010in.)

3-6

L1

t1'

Do the

items

in

parts

A, B, C,

D, g F, and

G as

required

for mileage/time

interval

listed

A

u

B

U D

tr tr

I

U

n

c

!

tr

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bolts condition

aii"""r,"rt

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lsee

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ii"ii i.l-;;;;;ri.;;;.

t".J

parts

right.. Ch;rcffunction

adiust

tor"r""ta und

air cleaner

page

oil(see

rear brakes

discsforwear{thickness),

lor damage,

latches

locks,

vehicte

steering

€nds,

for damage

brake

{see

i"f",nderbody.

steering

and

comPonents

of ballioint

ooots.

adjustment.

tines.

"nd

19-24)

Page

windshield

svstem*.

9-14), and

l1 161).

Page

belt

drivs

damage,

potten

anO

"*icies; atso

element

-

Capacity

8-6)

leaks, and

and hinges

has been

check

condition

Check

orrven

gearbox,

linkage

and leaking

leaks

and

bootslor

for cracks

boots

Should

(inctuaing

fluids;

of

washerfluid.

catalytic

K2oA3 engine

for

ah""i

interior

of a

Check thg

inspect

and

titter, everiii,ooo-

every

reptace

15,000

t'he dust

tilter

without

of mount

white lithium

(see page

and

and boor

for leaks.lf

heat shield,

page

lsee

damag6,

ii uerri"r".is

mire.

pollen

and

(24,000

km)

and

ri"La. folroiu

the

9'15)'

damage,

tightness

Honda

with

the ii"t"n""

and boots

grease

deterioration

lully appliedwithin

be nbS). iheck

check

conveft€r

for roose connections,

rnd exterior

paintfor

auto tensioner lneeds

miles

K2OA2

change:

cracks'

bolts'

grgase'

pattern

the

17-8)

damage

for tightness {see

bands

7 to 9clicks

cvlinder,

masler

nec€ssarv,

pipe

exhaust

cracks

and the

lights,

scratches,

anytime

(ind€pendent

stone

no adiustment)

mostly

Oriven

airftow

of

0

4 5

engine

shown

page

proponioning controlvalve,

(see

ATF

add

muffler

and

and deterioration; position

of the

chipping'

where

is tess than

(see

time)

page

q0'

14-138)or

retishten

dents

has high

(see

page

11-179,.

K20A

loose connections

concentration

8 US

14

in the Owner's

16-3).

page

for damage,leaks'

headlights {see

and

air

usual

engine

Manual-Check

and

MTF

page

47).

21

(4

0

4 0

ABS modulatorfor

(see

page

tightnesstor

and

22-70)'

o{

qt)

2 US

inflation

tirs

13-4)' engine

replace

and

trom industry

soot

K20A2

and

damage

coolant'

and

..1

fl Reolace

G

tr

According omissions

reliability.

air cleaner

.

l;duswconditions,

brake

Reolace

to state

warranties.

element

reDlaceevery

fluid every and federal

However,

miles

3O,O0O

every

15,000miles{24,000km}

(independent

years

3

regulattons,

Honda recommenda

tailure to

(48,000

km)

of mileage)'

perform

the maintenance

maintenance

that all

(independent

seruices

of time)

atems

b€

(see page

marked

done

11 179)'

with asrerisk 1*)will

atthe recommended

void customer's

not

intervalto

€nsure

long-term

L

3-7

Maintenance

Schedule

Listed

Follow

the Normal not apply, Followthe

,*o*t

Check Visually

. .

Inspect Replace Replace

Service Replace Replace

Inspect

Inspect Replace

Replace

and if

Severe

56rvice

at the indicated

whichevor

Replace

engine

Rotate

tires

(Check

tire inflation

Beplace

enqine

tro",

parking

inspect

.

Tie-rod

. . . .

ends, Suspension Driveshaft Brake hoses Allfluid levels Exhaust

systemr

Fuel

lines

and adjust

dust transmission

the tollowing

air cl€aner spark

valve

idle speed*

engine

brake fluid

by Maintenance

schedule

only OCCASIONALLY

Conditions

comes Iirst.

oil

oil filtei

""0j"*

brake

the following

steering

components

boots

and lines

and condrtion

and connections*

drive

pollen

and

plugs

clearance

coolant

ifthe severe

schedule ifthe

distance

and

condition

altt

adjustment

items:

gearbox

{including ABS}

belt

tilter

tluid

items

at tho rgcommerded

element

ortime,

and boots

of fluids

ltem

driving conditions

driven in

at least

once

for

severe

vehicle

AN

driving

is driven-MAlNLy

miles

x 1,000 km x 1,000 months

per

montn)

Mfi

intervals

Normal

specified in

conditions.

At 120,000 years

Evory

the Maintenance

an

Canada.

10

20

32 48

12

a

o

At 120,000 years

Every Every 110,000 Inspect Every

miles

30,000 miles

every 110,000

160,000

miles

years

3

Conditions

schedule for

30 40

21

o

a

{192,000

(48,000

mrles

1176,000

miles

i256,000

{192,000

miles

50

64 80

a a

o

km)

or 6

km)

1176,000 km),

km)or

km)

or 10

yeals,

7

years,

sev€re

60 10 96 112

o

a o

o

a

then every

otherwise adjust

years

then

every 60,000

conditions

80

128

48

a

o

90,000

miles

only if

mites

on the next

90 100

144 r60

60

a

a a

o

{144,000

noisy.

{96,000

page

110 120

km)

or 5

km)

or 5

do

192

72

o

a

o

';"{

a

*:

emlsslons reliability-

3-8

According

warranties.

to state

and tederal

However,

Honda recommends

regulations,

failure

perform

to that all maintenance

the maintenance

service

items

marked

be done

with an

at

recommended

the

asterisk

intervals

not vord

{*)will

ii-ensure long+erm

the customer's

€-J

Severe

Maintenance

Listed

use conditions, Severe

.Drivinoless-than5miles{8km)pertripor,intree?ingtemperatures'drivinglessthanl0miles(16km)pertrip'

.

Drivin;

.

Extenslve

.

Trailer towing.

Driving on Service

whichever

Beplace

Rotatetires lCheck

Beplace

'nr*o,,o^lo

Lubricate Visually

. . .

Check oarkinq Visuallv

. .

Inspect Beplace Replace

by

rhe schedule

Driving Conditions

Tie rod ends,

Suspensaon Oriveshaft

Brake hoses and

Alllluid

.

Exhaust

.

Fuel

.

Lights

if the

Normal

use the

In extremely

idling, or

driving

muddv.

indicated

at the

comes

oil

enqine

inflation

tjre

oil

engine

alllocks.

inspect the

steering

comPonents

boots

brake adiustment

the

inspect

levelsand

system*

lines and connections*

controls,

and

adjust drive

and

dust and transmission

is driven

vehicle

Conditions

over 95

hol

petiods of stop_and

long

with a car_top

dustY.

first.

and condition

filter

iced

or de

distance

'""'1,**-

lalches

and

hinges.

following

lines

Pollen

atems:

gearbox

items:

(includinq

condition

underbody

vehicle

belt lilteflo*'

f luid

"F

or

offluids

ltem

MAINLy

schedule.

'Cl

conditions

{32

carrier,

roads

time,

once

at least

and boots

ABS)

for

in canada

go_driving

driving

or

1,000

x

miles

km x 1,000 months

per

month)

Mfi

in any

or

mountainous

in

Conditions

following

of the

condrtrons

10 20 16

12

every

Replace

a

miles

At 60,000

30

18

24

5.000

a

(96,000

rrrles

conditions;

40

64

o

if only

50 80 96

36

18.000 km) or

o

years,

3

km)or

occAsloNALLY

70

60

112

{8

6 monlhs

a

o

a

every 30,000

then

80 90

144

128

O

a

miles

driven

60

a

(48,000

in these

100

160 176

a

110

a a

km)or

12

years

2

120

192

a

o

a

t-

th€ tollowing

Service Clean and

Replace spark Inspect Inspect

Replace

*

: According

"ai".tn"

reliability. NOTE 1:

concentrations

replace

plugs valve clearance idle speed*

engine

brake

to state

*Zronti"..

Replace

of

ilems

cleaner

air

coolant

fluid

and

ffo*"uer,

the dust

in the air

soot

at the

element

federal

pollen

and

from

recommended

regulatons,

,""orn.ends

Ho;da

filter as

industry

intervals

perform

failLrre to

that all

(at

often

15,000

and diesefpowered

the

maintenance

miles/24,000

15,000

Clean at conditions,

Every Inspect every Every

At

Every 3

otherwise

110,000

160,000

miles

120,000

years

maintenance

service

km) ;l the

vehicle

miles

i24,000

usenormal

(176,000

miles

110,000

miles

{256,000

(192,m0

items marked

done atthe

be

vehicle

replace

km),

schedule.

km)

(176,000

km)or 7

years,

lO

km)or

with an asterisk {*)

recommended

driven

is

everY 30,000

then

adiust

every

in urban

km), otherwise

Years

mostly

(48,000

miles

if noisy'

only

miles

60,000

not void

will

intervalto

areas

dustY

km)in

(96,000

km)or5

the customer's

long-term

ensure

have high

that

3-9

Engine

Special

Starting

Component Circuit Starter

Clutch Starter Starter Starter

Starter

lgnition

ComDonent Circuit

lgnition lgnition Spark

Gharging

Component Circuit

Charging Drive Drive

Alternator

Gruise

Electrical

Tools

SYstem

Location

Diagram

Circuit

Interlock

Solenoid

Performance

Replacement'....'...'.....

Overhaul

Troubleshooting

Switch

Test

System

Location

Diagram

Timing Coil

Plug

Inspection

Removal/lnstallation

InsPection

System

Location

Diagram

Circuit

Inspection

Belt

Replacement

Belt

Auto-tensioner

Belt

Drive

Auto-tensioner

Drive Alternator

Belt

RePlacement Overhaul

Control

Comoonent Circuit Symptom Cruise

TroubleshootinS

Cruise

Switch

Main SeVResume/Cancel Cruise Cruise Actuator

Clutch

Location

Diagram

Troubleshooting

Control Control

Pedal

Communication

Unit

TesVReplacement

Actuator

Actuator/Cable

Cable

Adiustment

Position

4-2

Index

Test

....'......'......'....

Index

Index'.....,.....'..

Troubleshooting

.............."

Index

(A/Tl'..........................'....."...'

Input

Switch

..'.....'...'..

Test

.....'..........

...'.........'.

.......'....."""""

Inspection Replacement

................"""'..""""'

'..'.......'......'."""'

lndex

Test

TesVReplacement

Test

............'........

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Circuit

......'........."....'..."'

.........'.........."""'

Replacement

.......'...........""

Test

.......-.."'

4-3 4-5

4-6 4-8

" 4-54 """ .""

4-4

4-7 4-10

4-12 4-20

4-21

4-22 4-23 4-24

4-25 4-26 4-27

4-32 4-32

4-33

4-34 4-35 4-36

4-47

4-48

4-49 4-51

4-52

4-54

4-55

4-56

4-57

4-58

Engine

SpecialTools

Electrical

t

Attachment,

52 x

55

mm

1-2

Starting

System

Component

STABTER Test,

CUT

page

22-55

Location

RELAY

Index

UNDER-DASH FUSE/RELAY

BOX

CLUTCH

page

Test,

INTERLOCK

4-6

SWITCH {M/TI

i-

STANTER Siarter Circuit Solenoid Performance

Replacement, Overhaul,

Test,

Tesl,

Page

TRANSMISSION

swrrcH

Test. oaqe Repla;eirent,

Troubleshooting,

4-7

Page

4-12

Page

4-10

4'8

'rrl

(A/Tl

14-168

page

4'5

RANGE

Page

14-170

4-3

$tarting

System

Circuit

Diagram

UNOER.H@o

FUsEniuY

8ox

IGNITION

SWITCH

'

N0.20 (a0A) No

20 (50

: USA

nbet

).Canid.md.l

o

4-4

F;;;,;**-;l

j.*''*Y__-l

+

\2

Starter

NOTE:

.

Air temperature and 38"C)

.

After

Engine Control Module

(DTCS)

.

The battery charged.

.

you

lf

learn

Recommended

.

use a starter

.

Connect with the

Alternate

1. Hook

Gircuit

during

this test,

(PCM)

{see

disconnect

procedure

and manuf

Procedure

up the

.

Ammeter,0-400

.

Voltmeter,

.

Tachometer,0

Troubleshooting

be

must

this

Procedure.

anY subsequent

or

Module

to clear

page must

Proc€dul€: system operate

acturer's

following

any

11-4).

in

be the battery.

(see page

tester'

the

A

V

20

O

'1200

and

between

(ECM)/Powenrain

good

equipment

instructions.

equiPment:

(accurate

rpm

59'

repair, reset

Diagnostic

condition

ECM/PCM

the

do

11-149).

in accordance

within 0.1

Trouble

and

100"F

the

Control

Codes

fully

idle

volt)

(15'

4. Check

5.

the batterY

connections

to body,

cable

tor looseness

starter starting

Did the

YES-Repairing

problem.

NOstep slowly, flywheel

release

find the

. .

Make disconnect solenoid battery

the

startet

lf starter

lf it cranks

5. go

or

the

cause.

Solenoid

drive

Dirty

sure the

positive

at the

the

engine

crank

the loose

staning

The

will

to step

torque

check

kev,

plunger

gear

transmission

BLK,ryVHT

the

(B).

Connect

terminal

condition.

battery,

engine

and corrosion.

again

no1

the

7. lf it converter

and

or damaged

Check

the

ground

the engine?

connection

system

the engine

crank

engine

won't disengage

Jor the

switch

is in

wire

jumper

a

the solenoid

to

electrical

negative

cables

Then

tixed

now OK.l

is

erratically

gear

ring

following

overrunning

(A)

when

malfunction

neutral,

from

wire from

battery

the

and

try

the

go

all,

at or too

from the

you

unlil

clutch

then

the starter

the

terminal'

to

Remove

tuse/relay

With the

pressed Did the YES NO

the

box.

shift

(M/T),

starter

The

Go to

17

No.

lever

turn the

ctank

starting

step

system

4.

(15A)

or

in

[8

ignition

the

from the

fuse

(A'lT)

E

switch

engine

OK.l

is

under-dash

clutch

or

start

to

normally?

pedal

(lll)'

engine:

K20A3

engine:

K20A2

the stattet

Did

YES- Go

Remove

NO necessary.

crcnk

to step

the

the engine?

6. starter,

and

repair

replace

or

as

(cont'd)

4-5

Starting

System

Starter (cont'dl

6. Check

7.

230

YES-Go

NO disassemble you

.

8.

Check ls

YES

the

you

find

.

Check between ignition

fuse/relay

.

Check

.

Check connector connector

.

Check

.

Check

switch

Check

the

ls

cranking

(K20Ag draw

less

(K20A2

A

-

Replace

find

Starter Shorted Excessive

the

engine

Go to

Circuit

following

the

the BLKMHT

the

switch,

the ignition

the

the the

and

cranking

voltage greater

engine)/A.7

than

to step

the

cause.

armature

drag

engine

step

Troubleshootin

open

circuit.

under-dash

and

box

and

transmission

(4,/T)

or

(M/T).

staner

BLK

wire

G101(AvlT)

voltage

or equal

engine)?

8.

the

starter,

it,

and check

dragging

in

engine

speed

above

9.

items

in

the order

wire

and

fuse/relay

between

the

starter.

(see

switch

range

the

clutch interlock

cut relay.

between

or

c402(M/T).

and current

than

(K2OA2

V

to

S5O

or remove

for

the

winding

while

cranking

100 rpm?

g

listed

until

connectors

box

and

the under_dash

page

22_93).

switch

and

switch

the

clutch

interlock

draw.

or

equal

to B.S

engine)

A ( K2OAT

and

following

the engine.

current

engine)/

until

the

and

Clutch

1. Disconnect

V

Remove

Check

according

.

\

Clutch

Interlock

the

clutch

for

continuity

to the

lf

the continuity

clutch

interlock

lf

OK,

install

the

pedat

clutch

l.rterlock

PRESSED RELEASED

clutch

interlock

table.

is not

switch.

clutch

height

Teiminal

Switch \

Switch

interlock

switch

between

interlock

the terminals

as

specified.

(see

o--

Test

switch

(A).

switch page

12-4).

----o

2p

connector.

replace

and adjust

the

?

9. Remove

4-6

-

NO

Replace

disassemble

you

find

the

.

Excessively

.

Open

.

. .

the flywheel damage.

circuit

Open

circuit segments Dirty

or damaged

Faulty

drive

the starter,

Replace

the

starter,

it,

and

cause.

worn

in

commutator

in

starter

gear

clutch

and

or

torque

any

or remove

check

for

starter

brushes

armature

helical

splines

inspect

converter

damaged

and

the following

brushes

commutator

or drive

its

ring

parts.l

drive

gear

for

until

gear

and

Starter

Solenoid

Test

K20A2

engine

1.Disconnect

solenoid.

the

Check terminal

be continuity.

should

.

lf there

.

lf there

S and

the

hold-in

and

is continuity, is

coil

armature

the

no continuity,

M connectors

continuity

for

housing

go

to step

3

replacethe

from the

between

(ground)

solenoid

starter

S

the

There

the

Check

lf

there

lf there

and

iscontinuity.thesolenoid

is

terminal conlrnurry.

. .

pull-in

M terminal

no continuity,

for continuity

coil

. There

should

replacethe

between

be

is OK'

solenoid

the

S

4-7

Starting

System

Starter

K20A3

2.

3.

engine

1.

Disconnect Make

the

heavy

a wire

the

wire

the

staner,

more

than

Connectthe moves

Performance

the

wire

from

the

connectjons

as

used

for

never

10

seconds.

battery

out,

it is

as described

possible (preferably

the vehicle).

leave

the

as

shown.

working properly.

Test

S terminal.

To

avoid

battery

lf the

IGROUND)

below

using

equivalenito

damaging

connected

pinion

staner

AODY

for

as

5.

Clamp

the

6. Connect the

diagram

sta rts

and keeps

7.

lf

the electric

specifications

the

starter

firmly

in

a vise.

the

starter

to the

banery

below.

current

is working properly.

rotating.

when

and

the

confirm

motor

battery

as described

that

the

motor

speed

meet

voltage

is

in

the

at 11.5

V,

4.

Disconnect

retracts

the

battery

immediately,

from

js

it

working

the body.

properly.

BODY

IGROUND)

lf

the

pinion

Specifications: Electric Motor

currenti

speed:

80 A 2,600

or less

rpm

or

more

4-8

K20M

engine

1. Disconnect terminal.

Make the

2,

a wire as

heavy

wire

the the starter,

more than

3. Connect disconnect

starter

lf the

properly.

from the S

wires

the

connections

possible

vehicle).

for the

used

leave

never

10 seconds.

battery

the

pinion moves out.

as

starter

terminal

as described

(preferably

To avoid

wire

is working

it

connected

sure

from the

the battery

shown.Be

motor

s

and

using

below

equivalent

damaging

to

solenoid

the

to

for

as

M

5. Disconnectthe retracts

Clamp

immediately,

the starter

battery

it

firmlY

Irom the

is working

vise,

in a

body.

properly'

lfthe

pinion

Disconnect

pinion

does

propefly.

the

not

battery

retract,

from

the

hold-in

.\

BODY (GROUND}

\/

terminal.

the M

coil

lf the

is working

1.

Connect the diagram

rts and

sta

lf the electric sDecifications the starter

Specifications: Electric

speed:

Motor

starter

the

below,

keePs

current

when

is working

current:

the battery

to

and confirm

rotating

and

the battery

ProPerlY.

A or

90

ipm or

3,000

that

s

-."-*

"(-)'

STARTERJ

t

motor

voltage

less

more

described

as

the

speed

motor

meet

is at

in

the

1 1.5

V.

4-9

Starting

System

Starter

1.

Make

then write preset

2. Disconnect then

3. Disconnect

4,

Disconnect

(K20A3

Replacement

sure

buttons.

disconnect

engine).

you

have

the

down

the frequencies

the negative

positive

the

knock

the

bolt

securing

anti-theft

cable

sensor

code for

for

the radio,s

from

the

batterv

cable.

connector.

the harness

6x1,0mm

12

N.m

kgf.m.8.?

{1.2

.--'

the

radio.

first.

bracket

lbt.ft)

6. Remove then remove

(K20A2

engine).

the bolt

the intake

8 x

1.25

22

N.m

{2.2

(A)

securingthe

mm

kgt.m,

manilold

16

tbt.ftl

harness

brackets

bracket,

(B)

5, Remove

(K20A2

engine).

the front

subframe

damoer

8 x 1,25 24 N'm

ksf.m,

l2.il

I

mm

17 lbt.ftl

1-10

7. Disconnect solenoid,

on the

(Bl

K20A3

8 x 9

10 x 1.25

44 N.m

kgf.m,

14.5 33 tbf.ft)

K20M

10 x 1.25

N m

44

from

1.25 mm

N.m

mm

(4.5

engine:

{0.9

the S

-------|ij^/

engine:

kgt.m,33lbf

starter

the

then

terminal.

kgf.m,

cable

disconnecl

ft)

7 lbf

12 x 1.25

64 N.m

ft)

,/

(A)

{6.5

from

mm

B terminal

the

BLK

the

kgf m,47lbf

/VHT

ft)

wire

Install

9. Make is facing

Connect

10. the

Start

11.

properly.

'12.

Enter the

Set the

starter

the

the crimped

sure

out.

positive cable

the

battery.

engine

the

anti-theft

the

customer's

clock.

in the

make

to

code

radio

reverse

of the

side

and

sure

for

station

order

ring terminal

negative

the starter

radio' then

the

presets.

removal'

of

cable

operates

(A)

to

enter

L-

I

8x

m

N.m

9N

.m,7

(0.9

ksf

Remove the

8. remove

lbf ft)

two

the starter.

bolts

<12

holding

1.25 mm

x

64Nm

kgl

5

{6

starter,

the

m' 47 lbf

then

ft)

Perform

14. powertrain procedure

control

the engine

control

(see

page

procedure

reset

unit

.on1to1

module

149), and

1 1

me6ule (PCM)

idle learn

power

(see

page

(ECM)/

window

22-139)'

4-11

Starting

System

Starter

Disassembly/Reassembly-K2OA3

Overhaul

GEAR

engine

HOLDER

i6R

u9

SWITCH

PLUNGER

\

t/

",,,

@.8 /

\@A

'qw

/

1r::i1:-.1

iir-/A

GEAR

COVER

I

ASSEMBLY

ARMATURE

HOUSING

6b-{(J-

g--@

\ t.*/-r'--

\

-

ARMATURE

ret

-

\

PLANETARY

a^.

#.!!E!s!ll] (Molybdenum

Disulfide)

(Molybdenum Disulfide)

SWITCH

----oRrvE

GEAR

SHAFT

PLATE

4-12

Disassembly/Reassembly-K20A2

engine

@

.@@,,

\

'''''":@

OVERRUNNING CLUTCH

ASSEMBLY

STARTER

SH,r.r r.l

f

SOLENOID

@._l

ffi

-qS.-..-

SOLENOID

GEAR

I

,\

e,

LEVER

HOUSING

r\

"\

--.N

A

.*uTl.

rA. ^Disurride)

*'-v

.$w

,,t D

ENDCOVER

Lrc@

_H

(lvlolybdenum

F;*;.

Disulfide)

ffi,i

/\Wy

//

ffi$

{cont'd)

4-13

Starting

System

Starter Overhaul

Armature

1. Remove the staner

2. Disassemble the starter as shown at the beginning

3.

Inspection

procedure.

of this

Inspect contact with the or damage,

the armature

replace

(cont'dl

and Test

(see

page

for wear

permanent

the armature.

4-10).

or damage

magnet. lf there is wear

from

/:%::

'75

5. Check the commutator below the service limit, replace the armature.

Commutator K20A3 engine: Standard

Service K2OA2 engine: Standard Service Limit: 27.0 mm

Diameter

lNew):

Limit: 27.5 mm

(New):28.0

diameter. lf

28.0 28.1 mm (1.102

mm

1.106 {1.083

{1.10 {1.06

the

in.)

in.l

in.) in.)

diameter is

Check the commutator

4. dirty or burnt, resurface with emery cloth or a lathe within the with # 500 or # 600 sandpaper

following

(A)

surface. lf the surface is

specifications, or recondition

(B).

Measure the commutator

'

lf the commutator runout is within the service limit,

check the commutator

brass chips between the segments.

.

lf

the commutator

limit, replace the armature.

Commutator Runout Standard Service

Limit:

{New):

0.02 mm

0.05

(A)

runout.

for

carbon dust or

runout is not within

(0.001

in.) max.

(0.002

mm

in-,

the service

4-14

I

7. Check undercut

proper

commutator

the

not be too

the mica

depth. Cut

shallow,

(A).

depth

with a hacksaw

away all the

segments.

lf the mica

The undercut

too narrow,

is too high

blade to

(C)

mica

or V-shaped

between

should

the

(D).

(B),

9. Place

the armature

Hold a hacksaw the blade the core the

is turned,

armature.

{A)

blade

is attracted

the armature

an armatu

on

(C)

on the

to the core

re tester

armature core

or vibrates

is shorted.

(B).

while

Replace

lf

Commutator

K20A3 engine: Standard Service Limit: K2oA2 engine: Standard Service

for continuity

Check

8.

commutator. segments,

Mica Depth

(New):

0.40

0.15

(Newl:

0.50

Limit: 0.20

lf

open circuit

an

replace

the armature.

0.50 mm

mm

10.006

0.80 mm

mm

{0.008

between

{0.016

in.)

(0.020

in.)

segments

the

exists

in.)

0.020

in.)

0.031

of the

between any

10.

Check

between

core

armature armalure.

with an ohmmeter

commutator

the

(B),

and between

(C).

lf

shaft

continuity

no continuity

that

(A)

the commutator

armature coil

and

exists,

exists

and

replace the

M

(cont'd)

4-15

Starting

System

Starter

'1

Brush Inspection

1.

Measure

service limit, Brush

Length

K20A3 Standard Service K20A2 Standard Service

Overhaul

the brush

engine:

(New):

Limit:

engine:

(New):

Limit:

length.

replace

11.1

4.3

14.0 14.5

9.0

mm

the

mm

L

(cont'd)

lf it is

not within

brush holder

mm

in.)

mm

in.l

(0.44

(0.55-

11.5 {0.17

{0.35

the

assemblv.

0.45 in.)

0.57 in.l

Starter

14.

Check brush is

K20A3

K20M

Brush

Holder Test

that there is

holder

continuity,

engine:

no

(A)

and

replace

continuity

(-)

brush

the

brush holder

between

(B).

holder

assemblv.

(

the

lfthere

+

I

)

Starter Field

12.

Check for there

is no

housing

Check

for

the

armature

replace

the

Winding

continuity

continuity,

(B).

continuily

housing

armature

(K2OA2

Test

between

replace

-'-..->4-:..-:

.-'.

between

(B).

housing.

engine)

the brushes

the

-,"./

each brush

lf

there is

(A).

armature

(A)

continuiW,

lf

and

4-16

Brush Spring

lnspection

(K20M

enginel

Overrunning

Clutch

Inspection

(l(20A3

enqine)

15. Insenthe brush the brush attach a spring the spring tension the brush.

specification,

Spring

Planetary Gear

16. Check the Replace them if they are

into contact

scale

lf the spring

replace the spring.

Tension:

Inspection

planetary

(A)

intothe brush

with the commutator,

(B)

the spring

to

moment the spring

at the

tension

13.7 17.7N(1.40

3.09 3.97

gears

is not within

lbf)

(A)

andringgear(B).

worn or

holder, and bring

then

Measure

{C).

lifts off

1.80 kgf,

damaged.

17. Holding the drive clockwise. the other smoothly,

18.

Holding counterclockwise. freely.

replace the

19.

lf the

replace the overrunning

is not available

Check

converter

gear

Check that

end. lf the drive

replace

the drive

gear

lf

the

gear

starter drive

separately.

the condition of

gear.

ring

teeth are

damaged.

(A),

gear

the drive

gear

the B

gear,

turn the

gear

The

shaft does

cover assemblY.

gear

is worn

the flywheel

Replace

the

turn

gear

does

cover

gear

shaft should

rotate

not

or damaged. assembly; the

clutch

it if the staner drive

gear

shaft comes out to not move

assembly.

shaft

rotate

smoothly,

or torque

{B)

gear

(cont'd)

4-17

Starting

System

Starter

Overrunning

20.

Slide

the

Replace

21. Rotate Does

it reverse? locks

in

lf

22.

the starter replace rs not

available

Check

the

Replace damaged.

Overhaul

Clutch

Inspection

overrunning

it if

it

does not

the overrunning

lock in

one

lf

it

does not

both directions,

drive

the

overrunning

separately.

condition

it if

the

starter

clutch

direction

lock

(B)

gear

of the flywheel

drive

(cont'd)

(K20A2

along the

slide

smoothly.

(A)

clutch

replace

is worn

clutch

both

and

rotate

in either

rt.

or damaged,

assembly;

gear

teeth

engine)

shaft.

ways.

smoothly

direction

the

gear.

ring

are

or it

gear

in

Starter

23. install

24.

Reassembly

armature NOTE:

or

# 600 sandpaper,

the

commutator rotate brushes

comm

Squeezing brush

this

for

the brush

(A)

To

sear

the

armature.

will be

uIaIor,

B

a spring

holder,

the other

(K20A3

into

in

the brush

the new

and

sanded

(C),

push

and

three

engine)

the

brush holder,

holder

brushes,

with

the

each

brush,

The

contact

to

the same

insert

it until

springs

{B).

slip

a strip

grit

side

up.

and smoothly

su rface

contour

it in

the hole

it bottoms.

(D,

E and

and

but*""n

of

the

\

on the

Repeat

F).

set the

of

F

as the

U

SOO

4-18

25

Installthe into

NOTE:

armature

the housing.

Make

sure

and

brush

the armature

holder

stays in

assembly

the

holder.

Starter

Reassembly

(K20A2

engine)

26. Pry

27.

back each brush

position and

NOTE: or # 600

the commutator

rotate the armature, brushes commulalor.

Installthe brush

the brush

release the

To

seat

sandpaper,

will be sanded

armature

holder. again, and against against

the commutator, the end of

spring to

the

Next,

push

and

the

with a screwdriver.

spring

halfway out

about

hold it there.

new brushes,

with the

each brush,

The contact surface

to the same

in the

pry

back

brush down

slip a strip

grit

side and smoothly

contour

houslng, and

each brush

until it seats

then release

the brush.

then

of its holder,

of ! 500

up, between

of the

as the

installthe

spring

the spring

24.

the starter

lnstall holder.

end cover

to retain the

brush

4-19

lgnition

System

Component

Location

i.li'N

'I

''i

rl

Index

4-24

SPARK PLUG

Inspection,

page

4-24

IGNITION lgnition tiemoval/lnstallation, page

COIL

Timing Inspeclion, page

4-23

4-22

Circuit

Diagram

UI{DEF HOOO

FUSAREUY

8OX

tGNtTtoltswtTcH

'

N0.20 N0.20

(l0l)

1504)

rUSA :

Cam&

nrodd

mod€l

lcM:10rfid1 contol

Modrb

4-21

lgnition

System

lgnition Timing

'1.

Connect the Honda

connector

present, inspecting

2. Start no load comes

3.

Check the idle Follow

(see

Connect the

5.

(DLC),

and check for DTC's. tf

diagnose

the ignition

the engine. Hold

(in

Park

on, then let it idle.

the tester's

the tester

and repair

or Neutral)

speed

prompts

operator's manual).

timing light

Inspection

PGM Tester

timing.

the engine

(see

to the service

to the

the cause before

at 3,000 rpm

until the radiator fan

page

1 1-148).

"SCS"

in

the

dala link

a DTC is

menu

loop.

with

6. Pointthe belt cover. Check

conditions:

defogger, and air

the ignition and there

powertrain

the ECM/PCM

lgnition M/T:

Nf:

lighttowardthe

are no engine

Timing:

8"+2'BTDC

in neutral

8"a2'BTDC

inEorE

pointers(A)

the ignition

headlights,

timing

control module

(see

blower fan, rear window

conditioner

differs from the

control module

page

11-4).

{RED (RED

onthetiming

timing under no

are not operating. lf

specification,

(ECM)/

(PCM)

DTC's,

replace

(Bll

mark mark

during idling

(B))during

Ul

load

idting

7.

Turn the ignition

8.

Disconnect light.

switch

the Honda

OFF.

PGM Tester

I

and the timing

4-22

t

lgnition

Removal/lnstallation

Coil

1. Remove the ignition ignition coils

6x1.0mm

(1.2

N m

12

(B).

kgf.m,8,7 lbf.ftl

\c

6x1.0mm 12Nm

kgf.m,

{1.2

tbf.ftl

8.7

Installthe ignition coils removar.

coil cover(A),then

in the reverse order

remove the

of

4-23

lgnition System

c]

Spark

1.2.Inspect the electrodes and ceramic insulator.

Plug Inspection

Burned or

.

Advanced ignition timing

.

Loose spark

.

PIug

.

Insufficient cooling

Fouled

.

Retarded

.

Oil

.

Incorrect spark

.

PIug heat

.

Excessive idling/low

.

Clogged air cleaner element

'

Deteriorated ignition coils

worn

electrodes

plug

heat range

plug

may be caused by:

ignition

in combustion chamber

range

wom or detormed electrodes

hot

too

timing

plug gap

too cold

speed

may be caused by:

running

.lmproper .

Oil-fouling

'

Carbon deposits

.

Cracked center 6lecirode insulatol

96p

3. Replace the

plug

at the specified

center electrode is rounded

plugs

listed below.

Spark Plugs:

K20A3 engine:

IZFROKll SKJ2ODR-M11

K20M

engine:

IFRTG-11K IFRTG-11KS SK22PR-M11 SK22PR-M11S

(A).

(NGKI

(DENSO)

INGK)

{NGK)

(DENSO)

interval, or if the

onlv the spark

Use

Do not adjustthe replace the spark specification.

Electrode Gap: Standard {New); 1.0

Service Limit:

gap

of

plug

(0.039

1.3 mm

iridium tip

gap

if

the

1.1

mm

..

0.0€ {0.051

plugs

is out of

in.)

in.l

(A);

Apply a small

4.

plug

the cylinder

Specified torque:

IFRTG-1

25N.m

Except IFRTG-11KS {DENSO): 18N.m

quantity

threads, and screw head finger-tight. Then torque them.

(NGK}.

1 KS

(25kgf.m,

(1.8k9f.m,

of anti-seize compound to

plugs

the

SK22PR.M1 1S

18lbf.ft)

SK22PR-Ml

INGK).

1316lbf'ft)

(DENSO):

into the

lS

4-24

Charging

System

Component

Location

Index

CHARGING SYSTEM

g.ugo

{ln

the

assombly}

UNDER-HOOD FUSE/RELAY lHrs buih-in DETECTOR ELD Troubleshooting,

page

ELECTRICAL LOAD

IELDI

'l

l-100

INDICATOR

BOX

UNIT)

BATTERY

page

Test,

ALTERNATOR Troubleshooting,

Replacement, Overhaul

page

4-36

Overhaul

page

4-41

page

(K20A3 {K20A2

engine), engine),

22-54

page

4-35

4-27

4-25

Gharging

System

Circuit

Diagram

GAVRED

]l

/-A\

9^T

I I IGI ,I

\8-l

tGNtTtON

I

SWTCH

l5l!9li??1r,,')

UNDER,DASII FUSE,NELAY BOX

r

No.$ ilo.m

:US rnodol

{44)

: Can.d. modC

{504)

8LK

I

ALTEFNATOR

4-26

Charging Circuit

Troubleshooting

lf the charging system

go

not

does following

Battery Charging Alternator and Alternator

Gharging

off, or the battery

items in the order

(see

page

22-54)

system indicator

regulator circuit

control system

System

engine)

1. Turn the

Does

YES Go to step

NO Go to step

2. Start

Does the charging

YES Charging

the Alternator and

ignition switch ON

the charging system

2.

3.

the engine.

system

indicator

Indicator

system

Regulator Circuit

does not come

is dead or

listed below:

Test

(ll)

indicator

indicator circuit

on or

low. test the

(K20A3

come on?

go

olt?

is

OK.Go

Test,I

to

Disconnect

Measure

starter subharness

switch

ls there battery

YES Go to step

NO under-dash an open under-dash

the starter

the voltage at

ON ( ll).

STARTER SUB.HARNESS

IG

{BLK/YEL)

voltage?

7.

Check for a blown

fuse/relay box.

in the wire between

fuse/relay box.

subharness 8P

the No. 1 terminal

8P connector

CONNECTOR

8P

(10A)

No.4

lf

the

the alternator

!

connector.

of the

with the

fuse is OK,

ignition

fuse in the

repair

and the

NO-Go

3. Turn the

4. Troubleshootthe page

ls the multiplex contrcl

YES Go to step 5.

NO Check the

indicated by the DTC

to step 3.

ignition switch OFF.

22-1751.

multiplex control

system OK?

system as

(see

step 8 on

system

page

22-1751.a

(see

7. Turn the

8. Disconnect engine pow€nrain

\24P1. Check continuity

9. terminal terminal

ls there continuity? YES - Go

NOalternator

ignition switch

control

between the 810 and No. 5.

to step

Ropair an open

starter subharness

€CM/PCM

10.

and the

OFF.

control

module

ECM/PCl\il.f

module

(PCM)/

CONNECTOS

in the wire between

(ECM)/

connector

ECM/PCM connector

(2aP)

B

8P connector

the

(cont'd)

4-27

Gharging

System

Charging

10.

Check

continuity

terminal

Isthere

YES alternator

NO

Charging

engine)

1. Turn Does

YES

NO

2. Start Does

YES

NO

3. Turn

4. Troubleshoot page

ls

the YES NO

indicated

5. Disconnect

810

€CM/PCM

continuity?

Repair

and

-

Go

to alternator

System

the ignition

the

charging

Go

to step

Go

to step

the

engine.

the

charying

Charging

Go

to

step

the

ignition

22-1751.

multiplex

Go to

Check

the

by

the

Circuit

between

and

body

CONNECTOR

2

3 4

I

I 10

17

18

n

ACGL

Wire

side of

female

a short

the multiplex

step

the DTC

in

the

ECM/pCM.

and regulator

Indicator

switch

system

2.

3.

system

3. switch

control

5.

mulliplex

(see

starter

subharness

Troubleshooting (cont,d)

the

ECM/pCl\4

ground.

t5 6

13

2122

IWHT/BLU}

terminals

the wire

t

Test

ON l).

indicator

indicator go

indicator

OFF.

control

system

OK?

control

step

I on

B

I24P)

5

23 24

between

circuit

system

6p connector.

the

test.

(K20A2

come

oll?

is

OK.I

system

as

page

22_'tjSl.a

connector

on?

(see

6. Measure

7,

8.

9.

YES

NO alternator

starter

subharness

switch

ON

STARTER

IG

{BLK/YEL)

Is

there

battety

YES

Go to

NO

Check for

under-dash

an

open in

under-dash

Turn

the

ignition

Disconnect

Check

continuity terminal terminal

ls

there

810 No.4.

(WHT/BLU)

L

continuity?

Go to

Repair

and

the

voltage

(ll).

SUB-HARNESS

Wire

side

voltage?

step 7.

a

blown

fuse/relay

the wire

f use/relay

switch

EClvl

conneclor

between

and

starter

ECM

CONNECTOR

I

2ls

8 I 10

'ln

1

8

Wire

side

step 10.

an

open

the ECM.I

at

the No.

6P

connector

of female

No.4

box.

between

box.

OFF.

subharness

4

5l

21

CGL

{WHT/BLU}

STARTER

ARTER

6P CONNECIC

CONNECIOR

l

4

of femaleterminars

in

the wire

1terminal

with

6P

CONNECTOB

terminals

fuse

fi0A)

lf

the fuse

the alternator

I

(24p).

B

the ECM

(24PI

B

connector

6 1

3

tc

,/

23

SUB

SUB-HARNESS

2

3

5

between

6p connector

ofthe

the ignition

in

the

is

OK, repair

and

the

rne

U

4-28

'lO.

Check terminal

continuity

810 and body

between

ground.

the ECM connector

5. Hook

0.1 V), to

up the voltmeter,

T101.

0-20

(accurate

V

within

ECM

2 314

8 I

1 81,

Wire

ls therc continuity?

YES Repair

alternator and

NO Go to alternator

Alternator and

1. Be sure 22-541.

Raise the hoist to

2. Hook up the ammeter.0

3. suD-narness.

a short

the ECI\4.I

Regulator

the battery

CONNECTOR

5

U

n

to

21

10

ACGL IWHT/BLU}

a

temale terminals

side ol

in the wire between

regulator test

and

Circuit

is sufficiently

height.

full

400

B

{24PI

7

6

15 23

the

Test

charged

A. to the starter

(see

page

6. Start the no comes on,

Raise the engine

7. tnere.

Turn the headlights

8.

voltage at the

ls the

engine.

(in

load

Park

then let

vottage between

Hold the engine

or Neutral)

it idle.

to 2,000

speed

(high

beam) on,

under-hood

fuse/relay

13.9

at

until the

rpm and

15.1 V?

and

rpm with

3,000

radiator

hold it

measure

and

terminal.

box

fan

4. Lower the

:)

hoist,

.\

\

YES Go

NO-

Read the amperage

9. NOTE: Adjust

motor,

ls the amperage

YES Alternator/regulator NO Repair

to step 9.

Repair the alternator

. .

rear window

. .

engine

K20A3

engine

K20A2

at

the voltage

defogger.

60A

the alternator

engine

K20A3 K20A2 engine

components:

page

{see

(see

Page

13.5 V. by turning

or more?

operation

components:

(see

page

(see

page

4-36).1 4-41).1

the blower

lights, etc. ON.

brake

is OK.l

4-36).1 4-41).I

(cont'd)

4-29

Charging

System

Charging

Alternator engrnel

1.

Check for the MIL

2. Disconnect

3.

Start the beam)

4. Measure 8P terminal

Control

proper

(see

engine,

ON.

voltage

connector

of the

STARTER

Wire

Gircuit

System Test

operation

page

11-3).

the starter

and turn

between

terminal

batterv.

SUB.HARNESS

side

ol female

Troubleshooting

(cont,d)

(K20A3

of

the ELD

subharness

the headlights

the starter

No.

3 and the

BATTERY

C

{WHT/GRNI

8P

terminals

by checking

8p

connector.

(high

subharness

positive

CONNECTOR

7.

Check

terminal 818

lsthere

YES

alternator

NO

Substitute

recheck

prescribed

lf original

8. Turn

the headlights

for

continuity

and

ECM/PCM

1

2 3 4

8 9 10

'18

1l

Wire

continuity?

Repair

a shon

and

ECM/PCM.t

page

{see

voltage

ECM/PCM.

between

ground.

body

CONNECTOR

5

U

13

21

now

22 23

terminals

available,

f-t

ACGC

{WHT/GRN)

sade

of lemale

in the wire

a known-good

l1-6}.

is

t

and ignition

ECM/PCM

A I24P}

6

4 5

between

ECIM/PCM,

replace

switch OFF.

I

connector

the

and

the

t,

ls

there 1 YES-Go NO

Go to

5.

Turn

the headlights

o.

Disconnect

V or less?

to step

8.

step 5.

ECM/PCM

and ignition

connector

switch

(24p).

B

OFF.

9.

Disconnect

10.

Check for terminal terminal

(WHT/GRN)

ACGC

ls

there YES NO- Repair

alternator

ECN4/PCM

continuity 818 and No.

3.

ECM/PCM

B s 10

11 1Bl./

STARTER

Wire

continuity?

Repair

the alternator

an open in

and

connector

between

starter

subharness

CONNECTOR

2

3 4 5

'13

2122 23

n

\l

C

TI

5 6 7

SUB.HARNESS

side of female

the wire

ECM/PCM.

I

B

ECM/pCM

(24P}

B

U 6

J

24

(WHT

/GRNI

8P

CONNECTOR

terminats

(see

page

between

(24p).

connector

8p connector

4-36).1

the

4-30

Ahernator engine)

1. Check

2.

3. Startthe

for

MIL

the

Disconnect

ON.

beam)

Control

proper

(see

page

starter

the

engine,

System

operation

11-3).

subharness

and turn

the

(K20A2

Test

the ELD

of

6P

headlights

by checking

connector'

(high

7. Check terminal

for continuity

818 and

body

€CM CONNECTOR

314l5U

I ?

10

8 9

18

17

/tn

ACGC

between

ground.

3

21

{WHT/GRN}

ECM connector

B

{2,rP)

7

6

tc

Measure

4. 6P connector terminal

ls there

YES NO-Go Turn the

5.

6. Disconnect

voltage

of the

STARTER

1 V or

-

Go

to

headlights

between

terminal

battery

Wire side

to step

step 5.

ECM.onngglsr

No. 2 and

SUB.HARNESS

temale

of

less?

8.

and ignition

the starter

the

C

IWHT/GRN)

CONNECTOR

6P

terminals

switch

(24P).

B

subnarness

positive

OFF'

ls there YES

alternator

NO-Substitute

(see lf

original

Turn

8. Disconnect

9.

Check

10. terminal

terminal

continuitY?

Repair a

page

prescribed voltage

ECM.I

the

for

ACGC IWHT/GRN}

of female

side

Wire

in the

short

ECM.I

and

known-good

a

11-6).

headlights

ECM "onngglel B {24P).

continuity 818 No. 2.

and

starter

and

ECM

2l314l5 U

l

1ol./

8 9

l8

1

,/n

terminals

wire

now available,

is

ignition

between

subharness

3t/

zl./

C

{WHT/GRN}

between

ECM,

switch

connector

ECM

124Pl

1

6

5

the

recheck

and

replace

6P connector

the

OFF.

STARTER

continuitY?

there

Is

Repair

YES

-

Repair

NO alternator

and

4

SUA-HARNESS

of female

side

Wire

alternator

the

an open

ECM.I

2l3

s

l./

CONNECTOR

6P

lerminals

(see

wire bet\,/veen

in the

page

4-411

1

the

4-31

Charging

System

Drive

Check

that standard range,

replace

Belt

Inspection

the auto-tensioner

(B)

range

as shown.

the drive

belt

indicator

lf

it is

(see

page

out

(A)

is within

of the

4-32).

the

standard

Drive

1.

Unclip

2.

Move

the

drive

Belt

Replacement

power

the

auto-tensioner

belt

steering

(B),

and remove

-.

reservoir.

(A)to

relieve

the

drive

tension

belt.

I

from

3. Installthe

new

belt in

the reverse

order

of removal.

4-32

+

Drive

1.

Belt

whether

Check the auto-tensioner engine

change

and

in the

Auto-tensioner

is a change

there

before

engine.

the

replace

starting

after

position,

indicator

Inspection

in the

starting

auto-tensioner'

the

position

lf there

the

is a

of

Remove

Install

1.

Clamp bolts auto-tensioner

the

the auto-tensioner

(B)

and

auto-tensioner

tensioner

vise

a

PulleY.

(C)

itself

(A)

shown.

as

(see

page

4-34).

by using two

not clamp

Do

8

mm

the

for abnormal

Check

lf abnormal pu

lley,

Remove

lMove

tension

belt Check

without

move

not replace

noise

the drive

the auto-tensioner

the tensioner

that

any

smoothly

auto-tensioner.

the

noise heard.

is

belt

release

abnormal

tool

or there

from the

(see

within

in the

moves

noise

replace

page

tensioner

the

4-32).

its limit

direction

smoothly

lf the

is abnormal

with

tensioner

pulley'

the

shown'

and

does

nolse,

Set the

8. Align

9.

cenler torque torque

auto-tensroner.

torque

the

mark

wrench, value

lf the

NOTE: recheck

36.3

26.5

the

wrench

indicator

(F)

on

and

is out

indicator

torque.

(2.7

N.m

(D)

on the

(E)

the tensioner

on

tensioner

the

measure

specification,

of

exceeds

kg'm'

3.7

pulley

bolt'

arm with

by using

base

the torque.

replace

center

the

19.5-26.8lbl

the

lf the

the

mark,

ft)

4-33

Charging

System

Drive

1.

2. Remove

3. Remove

Belt

Remove

disconnecting

8 x 1.25

22 N.m

Auto-tensioner

the

drive power

the

mm

kgl.m,

12.2

the

tensioner pulley.

(see

belt

steering

p/S

hoses,

16lbf.frl

page

(p/S)

Replacement

4-32).

pump

without

4. Remove

8 x

1.25

N.m

mm

{2.2

22

the

auto-tensioner.

kgf.m,

i6

tbf.ft)

I

kgt.m,41

lbf.ft)

5. Install

in

the reverse

order

of removar.

4-34

Alternator

you

1. Make

2.

3.

sure

down

write

then

buttons. Disconnect

disconnect

Remove

the

RePlacement

have

the

negative

Positive

belt

drive

anti-theft

the frequencies

cable,

cable

(see

code

for radio's

from

page 4-32).

radio.

the

preset

the battery

first'

Installthe

8. order

Connect

9. the

Enter

10. the

alternator

removal.

of

positive

the

battery.

anti-theft

the

customer's

radio

and drive

and

cable

ior the

code

station

in the

belt

negative

radio,

presets'

reverse

cable

then

to

enter

4. Remove

5. Remove

Disconnect

6.

wire

(B)

auto-tensioner

the

the three

from

bolts

alternator

the

alternator.

the

{see

securing

connector

N.m

8

(0.8

kst.m,

page

alternator'

the

(A)

6

4-34)'

mm

x 1.25

I 22 N.m

l2.2kgl.m,

rbt.ft)

16

BLK

and

lbl ft)

Set the

11.

Perform

12.

powertrain control page

reset Drocedure

clock.

the

1 l-149),

engine

the

and

(see page

control

(PCM)

module

learn

idle

power window

22-139)

(ECM)/

procedure

control

unlt

(see

7. Remove

alternator.

the

4-35

Charging

System

Alternator

K20A3 ExplodedView

enoine

Overhaut

BEARING

RETAINEN

t@,

a

PULLEY

n\) ,,'

'

tll

^<'

((@

I

REAR

HOUSING

ASSEMBLY

PULLEY

+-JO

v

Special

. .

Tools Required

07749-0010000

Driver Attachment,

52 x 55

mm 07746-0010400

Separate

5. housing by openings

the rear

inserting

prying

and

housing

a flat tip

them

from the drive-end

screwdriver

aPart.

into the

Refer to the

NOTE:

procedu

this

'1.

Test the alternator

remove

2. Remove

3. Remove

Heat the for about

re.

them

the alternator the four through

rear

Exploded

and

(see

page

bearing

5 minutes

View as

regulator

4-27).

(see

bolts

with a

seat

(129

needed during

before

page

4-35).

1,000

140"F, 50

you

w hair drier

60"C).

NOTE: Be careful tiD of the

6. Separate housing

screwdriver.

the

(B)

housing.

not

housing

rear

with the

damage

to

stator

the stator

(A)

anddrive-end

(C)

attached

with the

to the

rear

{cont'd)

4-37

Charging

System

Alternator

you

7. lf

8, Remove

are not replacing

rear

bearing,

soft-jawed

vise,

the

rotor

Overhaul

(cont'd)

the front

go

to step

1S. Clamp

then remove

using

puller

a

bearing

the

pulley

the

as snown.

and/or

rotor in

locknut.

10.

Remove

a

11.

Use a hand Apply damaging

the rear

press

pressure

the

bearing.

bearing

to install

only on

using

the

new rear

the inner

puller

race

as shown.

bearing.

to avoid

q

4-38

Inspect bearing seizure

.

the rotor

journal

marks.

lf eitherthe

damaged,

lf

both the

go

OK,

replace rotor

to

step 10.

shaft for

surface in

rotor

or drive-end

the

andthe

scoring,

the

drive-end

housino

alternator.

drive-end

and

inspect

housing

housino

the

for

is

are

12. Remove

bearing

front

the

##

retainer

Plate.

14. With front bearing

a hammer

in the

the

and

drive-end

special

housing

install a

tools,

07749-0010000

ir5-001

077

new

0400

Support

front bearing

the

out

the drive-end

with

housing

a brass

in a

drift

vise, and

hammer'

and

drive

Alternator

15. Measure

Brush

caliper.

'

lf either replace

.

lf brush

Alternator

Standard Service

InsPection

length of

the

brush

the

length

Brush

(New):

Limit:

step

in.)

with a

16

brushes

both

isshorterthantheservice

rear

is OK,

housing

Length:

19.0

5.0

goto

mm

assembly.

(0.75

(0.2

vernier

limit,

(cont'd)

4-39

Charging

System

Alternator

Rotor

Slip Ring

16. Check rings

.

lf

there

.

lf

there

assembly.

17.

Checkthatthere

ring

.

lf assembty, go

.

lfthere

Test

that

there

(A).

is

continuity,

is nocontinuity,

(A)

and

there is

is

continuity,

Overhaul

is continuity

goto

replacethe

is no

continu\ty

the

no

(B)

rotor

continuity,

to step

and

lg.

replace

(cont'd)

between

step

the rotor

the

17. rotor

between

shaft

the rear

slip

each

slip

(C).

housing

assembly.

11

Heat

the rear

for

about

22.

Put

the rear housing/rotor four

through

\;\

\N

23,

After

hand without

24. Install

bearing

5 minutes

housing

assembly

bolts

,?1f

assembling to make

the

sure the

noise.

alternator

seat with

(129

assembly

and

{C)

the alternator,

rotor

and

a

140"F,50

{A)

(B)

together,

pull

out the

rotates

drive

belt

'l,OOO

60"C).

and

tighten

turn

the

smoothly

(see

W hair

drier

drive-end

the

{D}.

pulley

and

page

4_3S).

I

K Er

by

Alternator

you

18.

lf

end

housing,

(1

1.3

kgf.m,

19.

Remove

20.

Push

the

(B)

(about

there.

Reassembly

removed

the

then

81.7 grease

any

brushes

1.8

mm

tbf.ft).

pulley,

put

tighten

(A)

(0.77

its locknut

or any

in,

then insen a pin

in.)diameter)

the rotor

oil from

in

to 1 11

the

slip

to hotd

the

N.m

rings.

or

drill bit

drive-

them

4-40

K20A2 Exploded

engine

View

WiXEt*

BEARING

covER

\

-%\ V@

BEARTNG

REAR

/

@o

-^ I

ROTOR

/

BEARING

/

RETAINER

\t

^ffi6

FRONT

4

SEAL

BEARTNG

STATOR BOLT

RING

THROUGH

//'?'1Y'E[I'

TERMINAL

'----'

TERMINAL

INSULATOR

PLATE

\q>

Y--{a\

we,fl

^rG(

ASSEMBLY

\

INSULATOR BUSHING

'_

l

HOUSING

REAR ASSEMBLY

(cont'd)

4-41

Gharging

System

Alternator

SpecialTools .

Driver

.

Attachment,

NOTE;

procedure.

this

1. Test remove

2.

Remove

3. lf

the front

pulley 22 mm

wrencn.

Required

07749-0010000

52

Refer

to the

the

alternator

them

the

bearing

locknut

wrench

Overhaul

x 55 mm

{see

alternator

with

07746-00t

Exploded

and

regulator

step 1

(see

needs

a 10

(B),

mm wrench

lf necessary,

View

on

replacing,

(cont'dl

O4OO

as needed

before

page

4-2g).

page

4-35).

remove

(A)

use

an impact

during

you

and

the a

5. Remove

Remove

the

and the rubber

end

(A)

cover

brush holder

seal{C).

anddustseal

(A),

voltage

regulator

(B).

(B)

4.

Remove

flange

plate

the harness

(C)

nuts

terminal

and

{E).

bracket

the screw

(A).

insulator

(D),

then remove

(B),

three

the

f[d I

:?

E

;"{ZA

ritili

-..-:rl

rl

Yo

E

4-42

7. Remove (A)

and

four

the

insulators

screws,

(B).

then

remove

the

rectifier

9.

you

lf

rear

the

not

are

bearing,

drive end

stator

replacing

go

step

to

housing.

the front

16. Remove

bearing

the

and/or

rolor

from

Remove housing

the four (A)

and

Ilange

washer

e

nuts,

(B).

then

e

remove

the

rear

10. lnspect bearing seizure

.

lf eitherthe replace

.

lf both go

to step

Remove

11.

rotor shaft

the

journal

marks.

rotoror

alternator.

the

rotor

the

11. rear bearing

the

for scoring,

surface

in the

statorhousing

and the

stator

using

and

housing

isdamaged.

housing

puller

a

inspect

the

for

OK,

are

as shown'

(cont'd)

4-43

Charging

System

Alternator

12. With

13. Remove

a hammer

shown, install

the front

Overhaul

and commercially

a new rear

bearing retainer

(cont'dl

bearing on

sg

available

rotor

the

plate.

tools

shaft.

14.

Suppon the

front

the

15.

With a hammer front

bearing in

stator housing in

bearing

with a

and

the special

the stator housing.

a vise,

and drive out

brass drift and hammer.

tools, install a new

I

6e

EB

,27\

((

\ -\___-./ ejj

<J'"

) I

07749-0010000

07746-0010400

4-44

Rectifier

16. Check

Test

B terminal terminal All diodes

direction.

to atlow

rectifier must continuity checking

for continuity

terminals,

and P

P terminals

and

should

Because

current

is made

test each

capability:

have

to

up

diode

with an

in each

the

pass

of eight

ohmmeter

a

direction'

and

of each

continuity

rectifier

in one

diodes

in both

total of

between

diode

in only one

diodes

direction,

directions

that

16 checks.

are designed

(four

has diode

the

pair'

and pairs),

for

E

the

you

Alternator

Measure

17. vernier

.

lf either

replace

.

lf brush

Alternator

Standard Service

Brush InsPection

the length

caliper

brush

the brush

length

Brush

{New):

Limit:

of

(B).

is shorterthan

assemblY

is

OK,

Length:

10.5 mm mm

1.5

both brushes

the

go

to steP

{0.41

(0.06

18.

in.)

(A)with

service

a

limit,

.

lf

diode

any

assembly.

.

lf all the

faulty,

is

are

.'/!

-t-

:--ilolf,ci

)

are

OK,

{Diodes

diodes

''

,': :-, /:\ \

\:

replace

available

not

go

to step

,

the rectifier

separately

17.

-\

P, P,

P, P.

)

Ring test

Slip

Rotor

rings

slip

18. Check (A).

.

lfthere

.

lf there

is continuity

there

that

is

continuity,

is no continuity,

go

to step

replace

between

the

19. alternator'

the

E

slip

Check

19. ring and the

.

lf

.

lf there

there

that

rotor

is no continuity,

there

is coniinuity,

is no continuity

rotor shaft

the

and

{B)

go

to

replace

the

between

step

each

(C).

20

alternator.

(cont'd)

4-45

Charging

System

Cr

Alternator

Stator

Test

20.

Check

that there

(A).

teads

.

lf there

.

lfthere

21.

Check for no coil core

is continuity, goto is no

(B),

Overhaul

is continuity

continuity,

continuity

replace

between

(cont'dl

between

step

each

21. the

alternator.

each lead

pair

and the

I

of

.

lf there

.

lf there

22.

Assemble disassembly,

.

Be

careful

nngs.

.

you

lf

111 N.m

it.

is no

continuity,

is continuity,

the

alternator

and note

get

not

to

removed

(11.3

the

kgf.m,

goto

step 22.

replace

these

any

pulley,

81.7 tbf.ft)whenyou

the alternator.

in

the reverse

items:

grease

tighten its

order

or oil on

locknutto

of

the slip

install

4-46

Cruise

Control

Component

Location

Index

CLUTCH swrlcH

Test. oaqe clutch

PEDAL (M/Tl

4-58

Adiustment,

P-edal

BBAKE PEDAL Test. Daqe Pedal

22-86

Height

POSITION

page

CRUISE Input

POSITION

Adiustment,

12-4

CONTROL

Test,

SWITCH

page 19-6

CRUISE CONTROL (Built

CRUISE SET/RESUME/CANCEL TesVReplacement,

page

CONTROL

UNIT

4-52

into

gsuge

Page

INDICATOR

assemblyl

SWITCH

4-54

CRUISE ACTUATOR Test,

CONTROL

gaqe

4-55

Repiacement,

page

4-56

TRANSMISSION

swrTcH

Test,

ACTUATOR

Adjustment,

CABLE

page

(A/T)

Page

4-57

RANGE

14-'l68

4-47

Gruise Control

Circuit Diagram

ciulst

COMINOL nESUirE/

cAlctL swtTol

'iha{o

iro 20

l50rl

USA nodel

1

C..rdr mod.l

t$r

N(

'l

52

6 712

cf,utsfco nol Ut{[

GNN

113

rnansussroN

iINGISWTCH

toN td t6t r I

crurorpro* P0sm0 swficli

[0N

BU 8U

tl

-1

P.d.rd.*.dl

10

8U

TL

G{01

I

| I

I I

I

Symptom

Troubleshooting

Index

NOTE:

.

The numbers

.

Before trou

-

checktheNo.'10(7.5A)

under-hood

-

check

-

check

Cruise

set

Cruise

indicator

but

go

not

Cruise noticeably lower Excessive or undershooting

trvind to

Speed

road with

flat control Vehicle does decelerate accordingly

RESUME/CANCEL is Dushed

speed

Set cancel

high) when

i- ^',-h6.1 /[r/T\

speed

Set cancel moved

position Set speed cancel

pushed

is

in the table

bleshooting.

fuse/relaY

horn sounds.

the

that the tachometer

Symptom

control

cannot

control

can be

Iighl

on

is

speed

higher or

was set

what

than

overshooting

qct

sneed

fluctuation

cruise

set

not

or accelerate

when

not

does

(engine

when shift

to Neutral

when

clutch

does not

(A/T)

does

brake

rpm stays

not

be

set

does

when

a

on

SET/

button

Pedal

Iever

_

pedal

the troubleshooting

show

(10

A) fuses

4

No

and

box

it works

see if

to

Check

1.

2. Check Test

3.

(see page

Test clutch

4. its adjustment Check

5. Check

6.

Check

Cire"k

1.

Check cruise

2.

Check

3.

1. Check

2. Check

3. Check i-. check

Check cruise

2. 2 aha^L.i'ica..jntrol ||nil {see oaoe 4-52}

r. cne"t

2. Check

fest

1. (see

Check

2.

Check

is

1.

2.

properly

main switch SET/RESUME/CANCEL

pedal position

brake

19-6)

pedal

transmission cruise

control

cruise

uehi"le

cruise cruise vehicle speed cruise vehicle

stlnesUMEicANCEL

cruise

ctutcn page

4-58)

cruise

transmission cruise

Check

Trst brake

(see

page

19-6)

Test cruise

sequence'

in the under-dash

Diagnostic

(see

page

switch

position

(lvl/T)

control

unit

spe"d control control control

control

spss6

control

oedal

control

position

pedal

control

position

switch

(see

page

rangeswitch

(see

unit

(see

page

sensor actuator

unit

{see actuator sensor unit

{see 5gn5er actuator {see

(see page

unit

switch

(see

unit

range

(see page

unit

switch

(see

unit

proc€dure

4-54)

switch

page

(VSS)

(VSS) (VSS)

switch

page

fuse/relay

(see

check

and

(see

12-4)

(Ay'T)

4-52)

(see

page

4-52}

(see

page {see

page

4-521

\see page

switch

4-52)

and check

page

4-52)

(see

4-52)

and

4-52)

box'

,

page

its adjustment

page

4-58)

(see

page

22-67)

4-55)

page

22-67)

page

22-671

4-55)

(see

page

its adjustment

page

14-168)

its adjustment

check

and the

4-54)

and check

14-'168)

4-54)

(15

T

No

Also

.

Poor G101(A"/T), G4o2(M/T).

'

OPen loose or disconnected terminals:

LT GRN, BLVORN, GRY/RED, LT BLU/VVHT

.

Poor G401

.

Open loose or disconnected termrnals: YEL,

Open

disconnected

or terminals:

GRY/RED. LT GRN/BLK

Short thE

Short the

Open or disconnected

terminals:

WHT/BLK

fuse in the

A)

check ground:

circuit,

BLU,

ground:

circuit,

BLUf/EL

circuit.

ground

to

LT BLU

ground

to

BLU wire

LT

circuit.

for

G401

BLU,

loose

in

WiTE

In

loose

(cont'd)

4-49

Cruise

Control

Symptom

-- ::-.,

>eI

cancelwhen

rs

Set cancel button

Set resume

button main speed

cancelled

oraKe

The

down when going the

DYrnpIom

speed

does

Dusned uFt-

speed

switch

temporarily

transmission

slower

cruise

main

does

when

CANCEL

pushed

is

will

when

pushed (with

is

on, and

pressing

by

than

up

control

Troubleshooting

not

switch

not

RESUME

set

shifts

normal

a hill

with

on

the

1.

Check

2.

Check

1.

Check

2.

Check

1.

Check

2.

Check

1.

Troubleshoot page

4-51)

main cruise

SET/RESU cruise

SET/RESUVe/CaruCel

cruise

Index

Diaqnostic

switch

control

ME/CANCEL

control

tne

cruise

(cont,d)

(see

page

a5a)

(see

unit

page

switct

page

{see

s*itctr

(see

page

cont-rot

4-52)

page

tsee

4_52)

(-see

4

52)

co;;unicationiircuit (see

p"Se

+Ei

4_54)

Also

check for

Shon

the Open

or

Iermrnats:

GRY/RED,

LTG Open or orsconnected

terminals:

LT

power

to

LT

GRN wire.

circuit,

otsconnected

circuit,

GRN/BLK

loose

in

4-50

+

Cruise

Control Communication

Circuit

Troubleshooting

(A/Tl

1.

2. Turn on the cruise

3.

4. Disconnect PCM connector

5, Check

the engine.

Start

control main switch.

vehicle to speeds over

the the cruise control.

Does the cruise control

YES Go to step 3. NO Check the cruise

or cruise Turn the ignition switch

control unit

terminal D12 and

control actuator.l

14P

ior

continuity

PCM CONNECTOR D {17P)

control unit(see

connector.

between

body

operate?

OFF.

ground.

25 mph

(40

(17P)

D

and cruise

PCM connector

then drive

km/h)with

page

4-52)

7. Connect a 14P connector

Test-drive the

(40 voltmeter.

voltmeter between cruise

terminal

vehicle at speeds over

km/h) with the cruise control

CONTROL UNIT

CRUISE

2 3 4 5

8 I t011

BLU,/OBN

Wire side of female terminals

ls therc about

YES - Go to step 8.

NO Replace the

Connect a voltmeter between

terminal

speeds over

control set,

1 V?

cruise control unit.l

D12 and body

25 mph

and watch the

(40

control unit

No. I and body

25 mph

set, and

14P CONNECTOR

6 7

1)

1213

PCM connector

ground.

km/h)

Drive the

with the cruise

voltmeter.

ground.

watch the

vehicle at

Wire

ls there

YES Repair a shortto PCM connector terminal unit

NO Go to step 6. Reconnect PCM connector

control unit 14P connector.

continuity?

'l4P

connector terminal

of female terminals

side

ground

D12 and the

No. 8.I

(17P)

D

in

wire between

the

cruise control

and the cruise

PCM CONNECTOR D I17P}

Wire side of Iemale terminels

ls there about

YES Check for

replace the PCM and

NO Repair an open connectorterminal connector

1 V?

loose

terminal

connectors.

recheck

in the wire between D12 and the No. 8.1

lf necessary

(see

page

control unit

11-4).1

PCM

14P

4-51

Cruise

Control

Cruise

SRS procedures (see

1.

2.

Control

components

Disconnect

Inspectthe

.

lf

the terminals

.

lf

the terminals

connectorand

Unit

are located

page

23-1

the 14P

connecto

are bent, look

in

1) in

OK,

socket

go

Input

this^area.

the SRS

r

loose,

Test

section

from

th e

terminals

orcorroded,

to

step

Review

before

cruise

to

3

the

SRS

component

performing

control be suretheyareall

unit.

repairthem

reparrs

as necessary,

"),-.

locations

or servrce.

making

good

and recheckthe

(see

contact.

page

23_j 1)

system.

precautions

and

I

and

3.

With

Cavity

the 14P

2

3

4

5

connector

Wire

BRN/VVHT

BLU

BLK

BLVORN

WHT/BLK

disconnected,

Test

conditign

Connect Power

lgnition (ll),

and pressed,

released

Under

lgnition

t)

Brake then

battery

switch

main

sw

pedal

brake

then

all

conditions

switch

pedal

released

tch

pressed,

make

ON

these inDUt

Ctrect

magnetic should shguld Cn-[toivoftage

There

pedal

voltage released.

Check g

rou

TIere

Check

There

lvoltage.

Check

There

i

vottage

pressed,

I

edal

tests.

Test: Desired

ttre ope-tion

click be locked.

should

pressed

with

for

nd:

should

for voltage

should

for

should

with

and

released.

result

clutch;

Clutch

and

output link

to

be

O V with

and battery

pedal

the

c-ntinuity

be continulty.

to

be battery

voltage

to

be bafiery

pedal

the

0 V with

ot tne

ground:

the

to

grouid:

ground

the

Possible

Faulty Poor

An

open

.

Faulty switch

.

An

open in

Poor

An open Blown

under-dash

An

open in

.

Blown under-hood

.

Faulty

switch

-

An open

cause if

resuh

actuator

ground

in the

brake

the

ground

in

the wire

(10

No.4

fuse/relay

the wire

(15

No.

7

f use/relay

pedal

brake

in

the wire

is not

(G451)

wire

p6dal

position

wire

{G401)

Alfuse

A) fuse

position

obtained

in

the

box

in

the

box

4-52

Cavity

6

1 LT GRN/

Wire

GRY/RED

BLK

9

11

10

BRN Connect

BR NI/E L

BLUI/EL

12 BLUMHT

13

14

8

LT GRN

LT BLU

BLU/ORN

Test condition

Set button

pushed

Resume button pusneo

battery

power

terminal tO

the BRN

to

ground

and

thE BRNryEL

termrnal

lgnition switch (

)

lgnition (ll)

ON; raise the the vehicle,

slowly the other

main switch

and

rotate one

while

lgnition switch (ll)

ON

main switch

and

ON

switch ON

front of

and

wheel

holding

wheel

ON

A,/T: Shift lever

orE

Clutch

pedal

M/T:

released

Reconnect

control

connector, engine, switch

the

over 25 mph

h) with the cruise

control set.

the cruise

14P

unit

start the

turn the

ON and

vehicle to speeds

(40

in

LO

main

drive

km/

Desired

Tesl:

for voltage

Check There should voltage.

testing terminal

When

should be

there terminal

Check

There should

voltage.

When

there terminal

Check actuator be

Attach to Cruise

gauge

on. Check

the BLUA/VHT

(

There should

more

Check for There

No.7.

voltage to

for

testing

should be

No. 6.

the operation

motor:

able to

ground:

indicator

assembly

for vollage

)terminals:

repeatedly.

voltage to

should be

to

be battery

no voltage on

be battery terminal

no voltage

You should

hear the

light in the

should

between

{+ )

be 0

battery

and

-5

voltage.

Check for continuity grounq:

when

be about

continuity.

the clutch

or

to

There should be

There should

NOTE: continuity pedal shift Check There should

pressed

is

lever is in other

for voltage

result

ground:

No.6,

_

ground:

-

No. 7,

of the

motor.

come

BLK

V or

ground:

to

no

be

when the

positions.

ground:

1V

on

. .

Possible cause

Blown No. 7 under-hood Faulty horn Faulty switch Faulty cable An open

Faulty actuator An open

Blown No.

the

Faulty

An open

if rasult

(15

A) fuse

fuse/relay

relay

set/resumelcancel

reel

wire

in the

wire

in the

(7.5

10

under-dash

gauge

fuse/relay

assemblY

iq the wire

Faulty ECM/PCM

wire

An open

Blown under-dash Faulty

An oDen

Faulty transmission switch Faulty clutch switch Poor (M/T:

An open Faulty cruise control Short

in the

(10

No. 4

fuse/relay box

main switch

in the

pedal position

grou

nd

A,rT: G 101)

G402,

in the

ground

to

A) fuse in the

wire

is not obtained

in

the

box

fuse in

A)

box

_

range

unit

4. lfanytest the cruise

indicatesa control

unit must be

problem,

find and

replace it.

faulty;

co rrect the

ca use, then

recheckthe

system.

lf all the

input tests

prove

OK,

4-53

Cruise

Control

Main

1.

Gently release

Release

of

the

from

Switch

pry

up on

the

hooks

the

clips,

panel,

then

the main

switch.

Test/Replacement

the

driver,s

(B),

and

disconnect

then

push

pull

the

Terminal

male

panel (A)to

switch

out

the

main

switch

Sp connector

side of

terminals

panel.

(A)

(B)

out

Set/Resume/Cancel

Switch

Replacement

1.

Remove

./,,

\

.\

\

./

Check switch

.

lf switch input

the switch

.

lfthere replace

the

for

continuity

position

there is

failure

test,

is no

the switch.

two

screws,

between

according

continuity,

occurred

check

and repair

circuit.

conlinuity

then remove

the terminals

to the

and it matchesthe

on the

the wire

in

one

Terminal

male

terminals

table.

cruise

harness

or both

Test/

the switch.

side of

in

table,

but

control

unit on

positions.

c

a

3.

4-54

Check

for

continuity

position

switch

continuity

illumination

\

__lTr1

Position

is not

OFF

ON

according

as

specified,

(C)

bulbs

between

to the

or

the switch

o o

@

the

terminals

table. lf

replace

5 1

o

oo

the

o @

o @l

in

each

4

o

Cruise

Control

1 . Disconnect the

control

actuator

Actuator

4P connector

{B).

(A)

Terminal male terminals

Test

Jrom the cruise

side of

6. Check output should

Battery

(+)

4

No. Terminal

No.3

Terminal

the operation

linkage

be able

position

to hear the

power

oolarities

No.3 Terminal

No.4 Terminal

actualor

of the

according

motor.

Output

FULI-

ct0sE

The

motor runs,

The

molor

stoDS.

in each

motor

table.

to the

linkage

OUTPUT LINKAGE

position

MIODLE PosfioN The molor runs.

The

molor runs.

FULt OPEN

The

motor $oos.

The

motor runs.

You

Remove the cover (B)

for smooth

Connect and

Check for a clicking The output

lf the output

cruise control

the

ground

(A),

movement.

battery

No. 1 terminal

to the

linkage should

linkage

actuator

check the output

and

power

to the

from the

sound

be locked.

locked, replace

is not

assembly.

linkage

.A

No 2 terminal

magnetic

clutch.

the

FULL CLOSE

4-55

Cruise Control

Cruise Gontrol Actuator/Cable

1.K20A3

the cruise

K20A2 engine:

hand,

link.

from

engine: Remove

open the cruise

control cable

locknut

(C),

and remove

Fully open

then remove

Loosen

the bracket.

the locknut

the

throttle cover

control link by hand,

(B)

from link. Loosen

the cable from

the cruise

(B),

and remove the

6x 1.0

mm 12Nm ('1.2

kgt.m,

control cable

then remove

control link by

Replacement

(Al.

the bracket.

8.7 lbf.ft)

(A)from

cable

fully

the

Remove

Disconnect bolts securing

Remove

actuator cable

the cowl

the

the actuator

(see

cover

4P

connector,

the cruise control

cover

(Bl

from

page

and remove the

then remove

{A),

the cruise

20-98).

two

actuator.

6x1.0mm 12 N.m

(1.2

kgf m.

8.7 rbf.ft)

the

control actuator.

',,,

o

4-56

Aetuator

Gable

Adiustment

6. Remove the actuator.

in the reverse order

Install

7. play

free

the

actuator cable.

the

bracket

from the cruise

throttle

at the

control

of removal,

and adjust

linkage after connecting

1.

that the

Check with no binding

Measure the amount linkage At fully closed

3.7510.5

lf the locknut, and

play

(B)

until

first, the output

position

mm

play

free

turn the adjusting

is as specified,

actuator cable

or sticking.

of movement

the engine

linkage should

(0.15

t

is not

then retighten

speed starts

(C).

The free

in.).

0.02

within specs,

(A)

moves

be located

play

loosen the

nut until

the locknut.

smoothly

of the output

to increase.

at the

(D)

should

the tree

be

4-57

Cruise

Gontrol

Clutch

1.

CLUTCH PEDAL POSITION

Pedal

Disconnect position

Remove

switch

Terminalside of

male

the clutch

the 2P connector from

terminals

Position

(A).

SWITCH 2P CONNECTOR

pedal position

Switch Test

the clutch Dedal

switch.

Check for according to the

.

lf the clutch

.

lf OK. install adjustthe

continuity between

continuity is not as

pedal position

theclutch

pedal

Terminal

Clutch Pedal Position Switch

PRESSED RELEASED

table.

height

\

the terminals

specified, replacethe

switch.

pedal

(see

1

position

page

switch and

12-4).

2

4-58

Acura RSX 2004 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual