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SUPPLEMENTAL RESTRAINT SYSTEM (3R5).

1. se n PREVIOUS w e se as CRUISE GAUGE TWS LIGHT LIGHTS SHIFT LEVER LIGHT 1 4W 3 0Wx2 POSITION INDICATOR 1 4W DIMMING CIRCUIT FROM PREVIOUS PAGE ANTI LOCK BRAKE SYSTEM 1 BLK BLU BLK RED BLUWHT CONTROL UNIT GRN RED BLU I i I GRN RED CRUISE DASHLIGHT TCS ECU CONTROL BRIGHTNESS CONTROL UNIT CONTROL UNIT UNIT I i KG KX KF GRN RED GRN RED 1 and KS models PARKING SWITCH BLK LHD 6401 6402 6403 6202 RHD 6402 6403 23 4 OIL PRESSURE SWITCH LOW OIL PRESSURE 9 INDICATOR LIGHT 1 4W C4 YEL RED YEL RED YEL RED OIL LEVEL UNIT European model AN REMINDER LIGHT C3 BLU YEL INTEGRATED CONTROL UNIT model TURN SIGNAL SWITCH HAZARD SRS UNIT gt SWITCH 1 1 I 1 I BLU GRN BLU GRN YEL ORN I B2 C9 B7 I C3 1 1 1 1 I H SRS en s 1 LEFT TURN RIGHT TURN CIRCUIT OL INDICATOR 3 i INDICATOR 1 HNI SRS INDICATOR T p BLK LHD G401 G402 G403 RHD G402 G403 I 1 1 AZARD 1 INDICATOR 1 I 1 E 23 b Gauge Assembly Bulb Location GAUGE LIGHTS 1 4 W x 2 HIGH BEAM INDICATOR LIGHT 1 4 W HAZARD INDICATOR LIGHT 1 4 W European model or LOW OIL PRESSURE INDICATOR LIGHT 1 4 W
2. SRS REFER TO SERVICE SHOP MANUAL FOR DETAILED INSTRUCTIONS H NVISNIG TILL SHOP MANUAL FOR DETALJERADE ANIVISNINGAR KATSO KORJAAMOKASIKIRJAST TARKAT OHJEET Log yo 2252 Lo E e jl cont d 1 5 Warning Caution Label Locations cont d B DRIVER MODULE DANGER KF KG KX DANGER EXPLOSIVE FLAMMABLE POISON REFER TO THE SHOP MANUAL DANGER EXPLOSIF ET INFLAMMABLE POISON SE REPORTER AU MANUEL D ATELIER e GEFAHR EXPLOSIV ENTZUNDBAR GIFT WERKSTATTHANDBUCH LESEN GEVAAR EXPLOSIEGEVAAR BRANDBAAR GIFTIG LEES HET WERKPLAATSHANDBOEK KU A DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO THE HONDA SERVICE SHOP MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EVERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN A DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU OU DES METAUX LOURDS COMME LE CUIVRE LE OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS O
3. psi at idle 70 0 7 10 0 min at 3 000 min rpm 350 3 5 50 min 3 3 Standards and Service Limits Cooling Section 10 MEASUREMENT STANDARD NEW Radiator Coolant capacity 0 US gal Imp gal M T 8 8 2 32 1 94 for overhaul Including engine heater cooling 7 7 2 03 1 69 for coolant change line and reservoir 8 7 2 30 1 91 for overhaul Reservoir capacity 0 65 2 0 172 US gal 0 143 Imp gal 7 6 2 01 1 67 for coolant change Opening pressure kPa kg cm psi 95 125 0 95 1 25 13 5 18 Thermostat Start to open F 169 176 76 80 Fully open F C 194 90 Valve lift at fully open 10 0 4 min Radiator fan Radiator fan control sensor ON temperature LOW F C 183 84 Radiator fan control sensor OFF temperature LOW F C 172 78 Radiator fan control sensor ON temperature HIGH F C 194 90 Radiator fan control sensor OFF temperature HIGH F C 183 84 Fuel and Emissions Section 11 MEASUREMENT STANDARD NEW Pressure Pressure with regulator vacuum hose 270 320 2 7 3 2 38 46 regulator disconnected kPa kg cm2 psi Capacity 0 US gal Imp gal 68 180 15 0 Fast idle speed min rpm at 77 F 25 1 500 200 Idle speed rpm with headlight and 6504 50 neutral cooling fan off A T 600 50 position Idle CO 96 With CATA O 1 max Without
4. NOTE From page 19 55 Since there is a capacitor inside the TCS control unit the battery voltage can be measured if the fail safe relay system is functioning Battery voltage Measure the voltage between 165 MD the TCS control unit 26 HARNESS SIDE connector terminal 13A and body ground EN EIEI PACA anpra ro n ono nonus View from terminal side BRN WHT WIRE ls there battery voltage Turn the ignition switch OFF VP Disconnect the 26P connector from the TCS control unit JUMPER WIRE Remove the fail safe relay No 2 TERMINAL from under hood relay box C FAIL SAFE RELAY CONNECTOR Connect the No 2 and No 4 No 4 TERMINAL terminals of the fail safe relay connector with a jumper wire Battery voltage TCS CONTROL UNIT Measure the voltage between 26P CONNECTOR the 26P connector terminal 13 HARNESS SIDE and body ground inp C as vs 9s ox Ten pon on mn nn poen View from terminal side BRN WHT WIRE VP NO Is there battery voltage YES Repair open in the BRN WHT wire between the fail safe relay and TCS control unit Substitute a known good TCS control unit and recheck To page 19 57 19 56 fe From page 19 56 TCS CONTROL UNIT 26 CONNECTOR BLU YEL WIRE Turn the ignition switch OFF HARNESS SIDE Disconnect the 2P connector from the TC
5. DO NOT USE ELECTRICAL TEST EQUIPEMENT OR PROBING DEVICES THEY CAN CAUSE ACCIDENTAL DEPLOYMENT NO SERVICEABLE PARTS INSIDE DO NOT DISASSEMBLE e PLACE AIRBAG UPRIGHT WHEN REMOVED e FOLLOW SERVICE SHOP MANUAL INSTRUCTIONS CAREFULLY DANGER EXPLOSIBLE INFLAMMABLE TOUT CONTACT AVEC L ACIDE L EAU OU DES METAUX LOURDS COMME LE CUIVRE LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS OU DES COMPOSES EXPLOSIFTS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLEMENT SRS DU MANUEL D ENTRIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS SI LE CONTENU EST ABSORBE INDUIRE UN VOMISSEMENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LE CAS OBTENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS ATTENTION LE GONFLEUR COUSSIN D AIR EST EXPLOSIBLE ET S IL SE DEPLOIE ACCIDENTELLEMENT IL RISOUE DE PROVOQUER DES BLESSURES GRAVES OU DE TUER NE PAS UTILISER DE MATERIEL D ESSAI ELECTRIQUE Ni DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR e IL N Y A PAS DE PIECES REPARABLES A L INTERIEUR NE PAS DEMONTER e QUAND ON RETIRE LE COUSSIN D AIR LE TENIR A LA VERT
6. onn uA pen po View from terminal side EU rain 19 70 19 70 Check the ABS B2 15A fuse in the under hood fuse relay box and the No 22 20A fuse in the under dash fuse relay box NO Are they normal YES Measure the voltage between the 26 connector terminal 1 and body ground Is there battery voltage YES Measure the voltage between the 16P connector terminal 10 NO B and body ground there battery voltage YES To page 19 72 NO ABS B2 15A FUSE No 22 20A FUSE UNDER HOOD FUSE RELAY BOX UNDER DASH FUSE RELAY BOX NOTE The standard wheel speeds initial offset memory in the control unit is erased when the ABS B2 15A fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see 19 11 Replace the ABS 2 15A fuse and or No 22 20 fuse and rechek TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE P aa sk 4 7 n ox A 7 il rane pon map fn pon pss pr View from terminal side WHT WIRE VB Battery voltage Repair open in the WHT wire between the TCS control unit id under hood fuse relay TCS CONTROL UNIT OX 16P CONNECTOR HARNESS SIDE Faas a bs es ez ose View from terminal side Repair open in the BLK YEL wire between the TCS control unit and und
7. ORN GRN ORN BRAKE 1 BRAKE BRAKE LIGHT LIGHT LIGHT 32CP 32 32 LEFTTAILLIGHT Se RIGHT TAILLIGHT BLK BLK 6551 6405 23 12 Brake Light Failure Sensor Test Except KY model First make sure the brake lights come on when the brake pedal is pressed if all brake lights come on go to step 2 e if one of the brake lights does not come on check whether the bulb is blown If the bulb is OK go to step 2 if none of the brake lights come on check the brake light circuit see page 23 15 Open the trunk lid and remove the access panel to the left taillight Watch the BRAKE LAMP light in the safety indicator when the A RHD or B LHD WHT GRN wire of the 6 P connector is grounded and the ignition switch is turned from OFF to ON 11 View from wire side ACCESS PANEL e f the BRAKE LAMP light comes on and stays on check for an open in the A RHD or B LHD WHT GRN wire between the safety indicator and the failure sensor e If the BRAKE light does not stay go to step 3 6 P CONNECTOR 3 Watch the BRAKE LAMP light as you turn the igni tion switch from OFF to ON Il with the B RHD or A LHD wire of the 6 connector ground ed and the brake pedal pressed f the BRAKE LAMP light comes on and stays on check for an open in the B RHD or A LHD BLK wire between failure sensor and
8. Release fork Manual transmission Urea Grease UM264 P N 41211 PY5 305 Steering boots Throttle cable end Steering ball joints Select lever Automatic transmission Pedal linkage Intermediate shaft Brake master cylinder pushrod Trunk hinges Door hinges upper and lower Door opening detents Fuel fill lid Hood hinges and hood latch Clutch master cylinder pushrod Manual transmission Change rod joint Manual transmission 22 Caliper Piston seal Dust seal Silicone grease Caliper pin Piston 24 Differential Differential oil Hypoid gear oil classified GL4 or GL5 Viscosity SAE90 above 18 F SAE 80 W90 below 18 C 0 F 25 Air conditioning compressor Compressor oil ND OIL8 P N 38899 7 003 For Refrigerant HFC 134a R 134a Recommended Engine Oil Service Grade SF SG or SH fuel efficient oil Multi purpose grease Select the oil for the car according to this chart mamana 15w 40 15W 50 CAUTION Used engine oil may causes skin cancer if repeatedly left in 30 2 46 0 10 20 30 40 contact with the skin for prolonged periods Although this is 20 8 20 40 6 80 100 unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil 1 For cars with cat
9. Substitute a known good TCS control unit and recheck 4 5V gt OV repeatedly View from terminal side STEERING ANGLE SENSOR CONNECTOR HARNESS SIDE GRY WIRE WHT WIRE STR B STR A More than 4 5V Check for a poor connection TCS CONTROL UNIT M the connection is 16P CONNECTOR replace the steering angle HARNESS SIDE sensor see page 19 75 View from terminal side WHT WIRE STR A Repair open in the wire between the TCS control unit and steering angle sensor GRY STR B GRY WIRE STR B More than 4 5V 19 28 From page 19 28 Turn the ignition switch OFF Disconnect the 16P connector from the TCS control unit TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side GRY WIRE STR WHT WIRE STR A Check for continuity between the 16P connector terminals and body ground No 15B STR No 11B STRA Continuity Repair short in wire between YES the TCS control unit and steering angle sensor STR B NO WHT STRA Check for poor connec tions or loose wires Substitute a known good TCS control unit and recheck 19 29 Troubleshooting TCS Lateral Acceleration Lg Sensor Problem Code 2 3 Lateral acceleration Lg sensor Turn the ignition switch ON Mesure the voltage between the No 1 terminal of the Lg sensor connector and body
10. 2nd clutch pressure at 2 000 min rpm 750 7 5 107 1 or 2 position Reverse clutch pressure at 2 000 min 1 190 1 270 11 9 12 7 1 150 11 5 164 R position 169 181 Throttle B pressure Throttle fully closed 15 0 15 2 1 Throttle fully open 590 640 5 9 6 4 84 91 Stall speed Check with car on level ground 2 000 1 850 2 150 rpm Clutch Clutch initial clearance 1st hold 0 70 0 90 0 028 0 035 1st 0 65 0 85 0 026 0 033 2nd 3rd 0 60 0 80 0 024 0 031 4th 0 50 0 70 0 020 0 028 Reverse 0 75 0 95 0 030 0 037 Clutch return spring free length 1st hold 1st 2nd 3rd 4th 33 70 1 327 Reverse 30 30 1 193 Clutch disc thickness 1st hold 1st 2nd Reverse 1 88 2 00 0 074 0 079 3rd 4th 2 28 2 40 0 090 0 094 Clutch plate thickness 1st hold 1st 2nd Reverse 1 95 2 05 0 077 0 081 3rd Ath 2 55 2 65 0 100 0 104 Clutch end plate thickness Mark 1 2 05 2 10 0 081 0 083 1st 2nd 3rd 4th Mark 2 2 15 2 20 0 085 0 087 Mark 2 25 2 30 0 089 0 091 Mark 4 2 35 2 40 0 093 0 094 Mark 5 2 45 2 50 0 096 0 098 Mark 6 2 55 2 60 0 100 0 102 Mark 7 2 65 2 70 0 104 0 106 Mark 8 2 75 2 80 0 108 0 110 Mark 9 2 85 2 90 0 112 0 114 Clutch end plate thickness Mark L1 2 05 2 10 0 081 0 083 1st hold Mark L2 2 15 2 20 0 085 0 087 MarkL3 2 25
11. NO ACTUATOR CONNECTOR cos DRAIN TUBE gt RS 77 LOWER gt 8 x 1 25 BOLT BRACKET 22 N m 2 2 kg m 16 lb ft installation install the TCS control valve onto the mounting rubber and tighten the nuts Temporarily install the TCS control valve brackets Tighten the upper bracket bolt first then tighten the lower bracket bolts Install the removed parts in the reverse order of removal NOTE Align the cutout in the air intake duct with the aligning mark on the TCS control valve body 19 78 22 2 2 kgm 16 lb ft Rear Emblems Installation 20 3 Sunroof Inde zzy suy 20 2 Outline of Model Changes The rear emblems have been changed The sunroof construction has been changed Sunroof Index FRAME SEAL CABLE SLIDER REAR DRAIN TUBE F FRONT DRAIN TUBE SLIDE SWITCH ASSEMBLY OUTER CABLE ASSEMBLY DRAIN CHANNEL ROD 3 GE XS 6c BRACKET GLASS SLIDING GLASS SUNROOF FRAME BRACKET COVER SUNSHADE DRAIN CHANNEL tc D lt LN ow lt lt tc 20 2 Rear Emblems Installation Apply the rear emblems where shown NOTE Before applying clean the trunk lid surface with a sponge dampened in alcohol e After cleaning keep oil grease and water from get ting on the surface e When applying make sure there no wrinkles in
12. WHEEL SENSORS DRIVE WHEELS DRIVEN WHEELS STEERING ANGLE SENSOR Left wheel kiya E TWS CONTROL UNIT Speed defference in the Actual yaw rate left and right wheels Drive wheels F E Speed defference inthe Actual yaw rate 555 differences left and right wheels Driven wheels Driving wheel Driven wheel speed speed Vehicle speed offset Deflation 4 ITWS acceleration Lg offset judgment pm ofset ITJ THROTTLE estimated offset Yaw rate Sensor offset identification ANGLE Initial offset memory SENSOR TT ees er TCS off switch Self diagnosis Function When the TWS is faulty it turns the TWS indicator light on Also the TCS indicator light is turned on simultaneously Therefore the problem can be checked by the TCS code Reset of TWS For Proper Operation of TWS The standard wheel speeds memorized in the TWS control unit must be initialized and new standard wheel speeds must be inputted into the control unit after the following tire air pressure adjustment tire change tire rotation other occasions when the wheel speeds change Reset the standard wheel speeds as follows 1 Shift the transmission into N neutral or P parking and set the parking brake 2
13. Second indication Problem code 2 Main Code 2 Sub code none Third indication Problem code 4 2 Main Code 4 Sub code 2 First indication Problem code 2 1 Main Code 2 Sub code 1 Engine start switch on f b 2nd cycle 2 0 sec c 1 2 sec 0 3 sec g 3 8 sec b 0 5 sec d 1 0 sec f 2 5 sec NOTE e The TCS control unit has three memory registers When a problem occurs the control unit stores the code in the first memory register If another problem occurs the control unit moves the first code to the next memory register and stores the second code in the first register If there s a third problem occurrence the two existing codes are moved up one register and the third code is stored in the first register If problems continue to occur the oldest code is moved out of the last register and lost and the most recent code is stored in the first register e The TCS indicator light will not come on again after the engine starts unless another prblem occurrence is detected However there will still be a code stored in the control unit s memory After the repair is completed disconnect the jumper wire from the Service Check connector and remove the ABS B2 15A fuse from the under hood fuse relay box for at least 3 seconds to erase the control unit s memory e The control unit s memory is erased if the connector is disconnected from the control unit or if the control unit is removed from the car e After re
14. grip of the tires on the road and signals the TCS control valve actuator and ECU to relax engine power if necessary thus improving grip WHEEL SENSORS DRIVE WHEELS DRIVEN WHEELS Lg SENSOR Right Wheel Left Wheel Right Wheel Left Wheel STEERING ANGLE SENSOR Driving Wheel Average speed speed of left and right wheels Speed difference in the left and right wheeles Actual Rotational yaw rate vibration Normative yaw rate Rough road detection Rough road control Handling control Acceleration control Target slip ratio Engine control block TCS control valve control TCS control valve actuator TCS control valve DC motor angle sensor es PES UR EP UN E rp ERR ZZ 9 19 6 Fail Safe Function the control unit detects an abnormality it shuts the traction control system off and causes the TCS indicator light to come on However if the abnormality is detected while the TCS is activated the control first establishes the appropriate wheel spin velocity then shuts the system down thus preventing excessive wheel spin Self Diagnosis Function If the control unit detects an abnormality it records Problem Code which can be used to diagnose the problem The code is shown at the TCS indicator light when the Service Check connector terminals are connected with a jumper wire Steering Angle Detection Steering angl
15. p GBNIDRN CONTROL UNIT 1 I 1 I HIGH 4 ANTI LOCK I I P MOUNT 1 BRAKE SYSTEM I I i I BRAKE 1 ABS l i lt i i s LIGHT CONTROLUNIT I FAILURE 1 FAILURE I ECU I SENSOR I SENSOR I li ii I i I 1 I 1 i I I BRAKE I I l 1 LIGHT i l I 21W 1 1 i I I 1 I 1 I I 1 I I i ET I I 1 l RIGHT 1 BLK I I LEFT TAILLIGHT 2 LEFT TAILLIGHT t TAILLIGHT eee ih T I I KF KG and KX models RHD and KS models BLK BLK I I I I 1 I 1 BLK i I I i E I 1 I i G551 6521 i i G522 and models 23 15 Brake Lights Circuit Diagram KY model BATTERY Q Z No 39 UNDER HOOD FUSE RELAY 20 BOX WHT GRN WHT GRN 1 WHT GRN HORN SYSTEM BRAKE SECURITY INDICATOR SWITCH SAFETY GRN WHT INDICATOR WHTIGRN GRN WHT GRN WHT GRN WHT GRN WHT CRUISE CONTROL UNIT ANTI LOC BRAKE SYSTEM ABS CONTROL UNIT ECU RIGHT FAILURE FAILURE SENSOR SENSOR ORN GRN ORN GRN ORN ORN SUNT 1 BRAKE es LIGHT BRAKE BRAKE BRAKE 45 LIGHT LIGHT LIGHT Qi LEFT TAILLIGHT RIGHT TAILLIGHT BLK BLK BLK BLK 6551 6405 23 16 Keyless Entry Syste
16. 1 01 0 Clutch Section 12 SERVICE LIMIT Pedal play 1 0 7 0 0 04 0 28 Clutch pedal Disengagement height to floor 90 3 5 min Clutch disc Rivet depth 1 5 0 06 min 0 5 0 02 Thickness 9 6 10 3 0 38 0 41 6 8 0 27 STANDARD NEW MEASUREMENT 193 0 7 60 139 0 5 47 Clutch pedal height to floor Stroke at pedal Total clutch pedal free play include the pedal play 9 0 15 0 0 35 0 59 Manual Transmission Section 13 MEASUREMENT STANDARD NEW Unit of length mm in SERVICE LIMIT Transmission oil Capacity 2 US qt Imp qt 2 6 2 7 2 3 for overhaul 2 3 2 4 2 0 for change Reverse gear shaft Mainshaft 3rd gear Mainshaft 4th gear Mainshaft 5th gear Distance collar 4th 5th gear Countershaft 1st gear Countershaft 2nd gear End play Diameter of bearing contact area Clutch housing side A Transmission housing side C Transmission cover side D 3rd gear B Runout Diameter of bearing contact area Clutch housing side A Transmission housing side B Transmission cover side C Runout Reverse drive Thickness 1 0 Thickness End play when tightening by specified torque 1 0 Thickness End play when tightening by specified torque I D Thickness End play when tightening by specified torque Diameter of needle bearing contact area Thickess of need
17. 19 37 Troubleshooting TCS PGM FI Signals cont d From page 19 37 TCS CONTROL UNIT 16 CONNECTOR HARNESS SIDE Repair open in the GRY BLK wire between the TCS control unit and ECU YES Is there more than 2 0V NO Turn the ignition switch OFF GRY BLK WIRE TC INH Disconnect the 12P connector from the ECU and the 16P connector from the TCS control unit Check for continuity between the 16P connector terminal 9B and body ground BRN BLK WIRE LGE 1 YES Repair short in the GRY BLK Is there continuity wire between the TCS TCS CONTROL UNIT control unit and ECU 16P CONNECTOR NO HARNESS SIDE TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE axl rom one sn noon n GRY BLK WIRE TC INH View from terminal side View from terminal side BRN BLK WIRE LGE 2 00 00 Reconnect the 16P connector to the TCS control unit Measure the resistance between the 16P connector terminal 9B and 26P connector terminal 20 or 16 connector terminal 5B of the TCS control unit YES Is there OQ Replace the TCS control unit and recheck NO e Check for poor con NOTE nections or loose wires The normal resistance is approx Substitute a known good 20 k Q for reference ECU and rechek 19 38 Engine Speed NEP Signal Problem Code 3 2 Engine speed NEP signal Remove the A
18. 87 OS b11813815 C1 C3 C3 C7 C Ct DI b DS D 08 Di 093 015 017 918 023 oooooococoooooolooooooooloooooojooooooooooQ0 A2 Ad AR AR ATE A20 A22 A24 26 B2 Bi 65 BS 812 BIA C C4 CG 8 CWCI 02 Ot OF 08 010 012 014 DIE 018 020 022 TERMINAL LOCATION 11 3 Troubleshooting Self diagnostic Procedures SELF DIAGNOSIS SYSTEM INDICATED PAGE INDICATOR BLINKS LEFT OXYGEN SENSOR With CATA model 2 RIGHT OXYGEN SENSOR With CATA model MANIFOLD ABSOLUTE PRESSURE MAP SENSOR MP 4 CRANK ANGLE 1 COOLANT TEMPERATURE TW SENSOR 7 THROTTLE ANGLE No 1 CYLINDER POSITION 1 CYL SENSOR INTAKE AIR TEMPERATURE TA SENSOR IDLE MIXTURE ADJUSTMENT IMA Without CATA model FP EXHAUST GAS RECIRCULATION SYSTEM EGR Except KO model o ATMOSPHERIC PRESSURE PA SENSOR ELECTRONIC CONTROL IGNITION OUTPUT SIGNAL o 13 7 1 IGNITION TIMING ADJUSTMENT po 5 2 O MICA RIGHT FUEL SUPPLY SYSTEM With CATA model CRANK ANGLE 2 59 No 1 CYLINDER POSITION 2 CYL SENSOR f codes other than those listed above are indicated verify the code If the code indicated is not listed above replace the ECU For reference pages not listed with the respective Self
19. Do not strike or drop it The sensing section of the steering angle sensor is covered with the extremely thin protection film Handle the steering angle sensor with care not to touch the sensing section with a hand and do not allow any parts and material to come in contact with the section 19 76 4 Set the adjustment shims on the steering angle sensor and install the steering angle sensor on the steering column with care not to drop the shims tighten the mounting bolts NOTE After installation check that the shims are installed properly and the steering angle sensor contacts with the bracket CAUTION Do not apply grease or adhesive agent to the adjustment shims with the intention of holding the shims in place or prevention of the shims from dropping ADJUSTMENT SHIMS SENSING SECTION MOUNTING BOLTS 10 N m 1 0 kg m 7 lb ft Connect the steering angle sensor connector 6 Install the column cover 7 Perform the steering angle sensor system check see page 19 26 to check that the steering angle sensor functions properly If there is a problem perform the troubleshooting for Problem Code 2 1 see page 19 26 Adjustment Shim Selection NOTE The steering shaft to steer ng angle sensor clearance is controlled to stabilize the output of the steering angle sensor Select the correct adjustment shims that match with the respective matching marks stamped on the steering column
20. S 8 1 25 22 2 2 kg m 16 Ib ft Cylinder Head Valve Train Cylinder Head Removal 6 2 Outline of Model Changes e The suction pipe of air conditioning system has been changed LHD model e The TCS has been adopted Cylinder Head Removal Refer to shop manual code No 62SP020 and 62SP021 for service procedures except following LHD model CAUTION Take care not to bend the suction pipe when removing and installing the cylinder heads 1 Remove the suction pipe clamps from the strut bar and throttle cable bracket see page 5 2 Cars equipped TCS NOTE Do the following also when removing the timing belt 1 Remove the air cleaner assembly and air flow tube AIR CLEANER ASSEMBLY 6x 1 0mm 10 1 0 kg m 7 lb ft AIR FLOW TUBE 2 Remove the TCS upper and lower bracket NOTE Refer to section 19 when installing the bracket TCS UPPER 6x 1 0 mm BRACKET 12 N m 1 2 kg m 9 Ib ft BRACKET 20 TCS LOWER e 2585 8 1 25 22 2 2 kg m 16 lb ft 3 Disconnect the TCS throttle sensor connector and TCS throttle actuator connector then remove the TCS control valve assembly TCS THROTTLE SENSOR CONNECTOR TCS THROTTLE TCS CONTROL VALVE ACTUATOR CONNECTOR ASSEMBLY Engine Lubrication Engine oil 8 2 Replacement 8 2 Outline of Model C
21. TH2 signal xps rupe peu ee Fe fe 19 48 L I I j 4 4 Rightrearwheelsensor E dol j IO OI O IO O O 4 9 All wheel sensors 194511 j a JO 6156 actuator and or TCS control valve assembl e normally due to low voltage 53 Abnormalback upvoltage VB 1 ____ 16 6 1 electronic control unit ECU 3981 1 J TO TOO 19 16 c TCS Lights Do Not Come On The TCS indicator light TCS activation light and TCS switch indicator light do not come on for two seconds when the ignition switch is first turned on no bulb check NOTE The TCS indicator light stays on until the engine is started Turn the ignition switch ON Do the other indicator lights ABS Check Engin Light SRS No 13 7 5A FUSE Ap 07 Turn the ignition switch OFF Check the No 13 7 5A fuse in etc come on the under dash fuse relay box NO YES UNDER DASH FUSE RELAY BOX Replace the fuse and recheck Repair open in the YEL wire between the under dash fuse GRY RED WIRE frelay box and gauge assemb ly Turn the ignition switch OFF Disconnect the 26P and 16P RED GRN WIRE connectors from the TCS control unit Turn the ignition switch ON
22. ala zn ts sn View for terminal side BLU RED WIRE Ground the following terminals individually to the body ground and check the lights TCS indicator light 26P connector terminal 23A or 16 P connector terminal 7B TCS activation light 26P connector terminal 10A TCS switch indicator light 26 P connector terminal 6A NO Do all the lights come on YES To page 19 18 TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE Replace the defective bulb Repair open in the wire between the TCS control unit and gauge assembly or TCS switch TCS indicator light BLU RED wire TCS activation light RED GRN wire TCS switch indicator light GRY RED wire BLU RED WIRE 18 2 36 58 68 78 118128 138 148158168 View for terminal side 19 17 Troubleshooting TCS TCS Lights Do Not Come On cont d ABS B2 15A FUSE No 22 20A FUSE From page 19 17 Check the ABS B2 15A fuse in the under hood fuse relay box and the No 22 20A fuse in the under dash fuse relay box f r I im UNDER DASH FUSE RELAY BOX UNDER HOOD FUSE RELAY BOX NOTE NO Replace the ABS B2 15A The standard wheel speeds fuse and or No 22 20A fuse initial offset memory in the and recheck control unit is erased when the YES ABS B2 15A fuse is discon ne
23. ground a Is there approx 5V Measure the voltage between the TCS control unit 26P conector terminal 14 and Lg SENSOR 3P CONNECTOR HARNESS SIDE Approx 5V View from terminal side TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE YES body ground DEDOTTA a cs on o View from terminal side RED WHT WIRE Approx 5V GSEN VCC YES Repair open in RED WHT wire between the TCS control unit and Lg sensor NO Turn the ignition switch OFF Disconnect the 26P connector from the TCS control unit and the 3P connector from the Lg sensor TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Check for continuity between the terminal 14A and body ground C aa e o os 77 n n7 on n pnr on on so oon on RED WHT WIRE View from terminal side GSEN VCC Continuity Q Is there continuity YES NO Repair short in RED WHT wire between the TCS control unit and Lg sensor Substitute known good TCS control unit and recheck Check for poor connec tions or loose wires To page 19 31 19 30 Lg SENSOR CONNECTOR From page 19 30 HARNESS SIDE Turn the ignition switch OFF Check for continuity between View from terminal side BLK WIRE the Lg sensor 3P connector No 3 terminal and body ground Con
24. 2 30 0 089 0 091 14 2 35 2 40 0 093 0 094 Mark L5 2 45 2 50 0 096 0 098 31 70 1 248 28 30 1 114 Until grooves worn out Until grooves worn out Discoloration Discoloration cont d 3 7 Standards and Service Limits Automatic Transmission cont d Section 14 MEASUREMENT STANDARD NEW SERVICE LIMIT 2 55 2 60 0 100 0 102 2 65 2 70 0 104 0 106 2 75 2 80 0 108 0 110 2 85 2 90 0 112 0 114 4 05 4 10 0 159 0 161 4 15 4 20 0 163 0 165 4 25 4 30 0 167 0 169 4 35 4 40 0 171 0 173 4 45 4 50 0 175 0 177 4 55 4 60 0 179 0 181 4 65 4 70 0 183 0 185 4 75 4 80 0 187 0 189 4 85 4 90 0 191 0 193 Discoloration Discoloration 28 000 28 021 1 1024 1 1032 Wear or damage 31 000 31 013 1 2205 1 2210 14 016 14 034 0 5518 0 5525 13 980 13 990 0 5504 0 5508 0 03 0 05 0 001 0 002 Wear or damage Wear or damage 0 07 0 003 Clutch Clutch end plate thickness Mark L6 1st hold Mark L7 Mark L8 Mark L9 Clutch end plate thickness Mark R1 Reverse Mark R2 Mark R4 Mark R5 Mark R6 Mark R7 Mark R8 Mark 9 Valve body Stator shaft needle bearing contact 1 0 torq
25. 38 975 38 991 1 5344 1 5351 33 975 33 991 1 3376 1 3382 13 990 14 000 0 5508 0 5512 Unit of length mm in SERVICE LIMIT Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage Wear or damage 7 045 0 2774 11 53 0 454 1 80 0 071 1 80 0 071 2 08 0 082 2 08 0 082 Wear or damage Wear or damage cont d 3 9 Standards and Service Limits Automatic Transmission cont d Sectoin 14 MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission I D cont d Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 1st gear Countershaft 3rd gear Countershaft 2nd gear Countershaft 1st gear Countershaft reverse gear Reverse idler gear 59 000 59 016 2 3228 2 3235 40 000 40 016 1 5748 1 5754 39 000 39 016 1 5354 1 5361 54 000 54 016 2 1260 2 1266 44 020 44 036 1 7331 1 7337 44 000 44 016 1 7323 1 7329 39 000 39 016 1 5354 1 5361 18 007 18 020 0 7089 0 7094 Wear or damage Wear or damage 3 10 End play Mainshaft 4th gear 1st 4th clutch Mainshaft 2nd gear Mainshaft 1st gear Countershaft 3rd gear Countershaft 4th gear Countershaft 2nd gear Countershaft reverse gear Reverse idler gear Secondary gear shaft taper roller bearing preload starting torque N m kg m Ib ft Thrust washer 90 mm thickness torque converter housing side Thrust shim 75 mm thickness 0 03 0 18 0 00
26. 5 GRN WHT CRUISE CONTROL UNIT GRN WHT ANTI LOCK BRAKE SYSTEM ABS CONTROL UNIT From page ee 5 23 10 f I 1 1 WHT GRN GRN WHT 1 GRN WHT i E mee m emi 1 a 4 ae gt 1 1 1 1 1 I J 1 I I i I GRN ORN i 1 I HIGH I I MOUNT l 1 i 1 I LIGHT 1 FAILURE I FAILURE 45CP 1 SENSOR i SENSOR I I BRAKE i 1 LIGHT I I 1 1 1 21W 1 I 1 I 1 1 I I i ee 1 1 o G M I wa sasa 1 LEFT TAILLIGHT LEFT TAILLIGHT HT BLK i gt w w x s ee wee j s eee sv s eee s 1 1 KG and KX models RHD and KS models BLK BLK 1 I I BLK 1 l 54 1 1 2 I G551 i G521 and models cont d 23 11 Safety Indicator Circuit Diagram cont d KY models From page WHT GRN 23 10 WHT GRN WHT GRN BRAKE LIGHT SWITCH HORN SYSTEM SECURITY INDICATOR GRN WHT GRN WHT GRN WHT CRUISE CONTROL UNIT ECU ANTI LOCK BRAKE SYSTEM ABS CONTROL UNIT From page B 23 10 WHT GRN GRN WHT GRN GRN WHT GRN WHT as i MOUNT LIGHT LEFT RIGHT 45CP FAILURE 1 FAILURE SENSOR SENSOR
27. An open in the wire CAUTION To prevent damage to the motor apply battery voltage only momentarily European model RHD 23 22 Keyless Entry System Test CAUTION All SRS wiring harnesses are covered with yellow outer insulation Before disconnecting any part of the SRS wire har ness install the short connectors Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring SRS MAIN HARNESS Covered with yellow outer insulation NOTE Before proceeding to testing make sure that the door lock system is functioning properly 1 Adjust the voltage select switch according to local requirements then connect the Keyless Entry Check er to an AC power outlet and check that the power indicator light goes on 2 Place the ignition key transmitter within 500 mm 19 7 in from the front of the infrared ray window and press the transmit button on the ignition key transmitter Check that the ray indicator light goes on If the ray indicator light goes on go to step 3 KEYLESS ENTRY CHECKER O7MAJ SP00200 INFRARED RAY WINDOW IGNITION KEY TRANSMITTER SELECT SWITCH RAY INDICATOR LIGHT POWER INDICATOR LIGHT If the ray indicator light does not go on insert the ignition key into the keyless entry checker the charge indicator light goes on then check again NOTE If the short circuit indicator light goes on pull out the i
28. CAUTION It is necessary to select the shims only when the steering column assembly without the steering angle sensor has been replaced Use the original adjustment shims when the steering angle sensor is replaced The matching marks numerical letter 1 through 8 are stamped on the steering column as shown MATCHING MARKS Select the adjustment shims according to the following tables Adjustment Shim WHITE 19 77 TCS Control Valve Assembly Removal Installation CAUTION Be careful not to damage the TCS control valve when handling the TCS control valve assembly Removal Disconnect the vacuum tube breather pipe and air hose from the intake air duct Loosen the intake air duct band screws and remove the intake air duct BREATHER PIPE VACUUM TUBE ALIGNING MARK RES S Ph CUTOUT OSS Silent AIR HOSE EX D Pd FH INTAKE AIR DUCT Disconnect the TCS control valve angle sensor connector and actuator connector Remove the drain tube from the clamp on the TCS control valve lower bracket Disconnect the water hoses and breather tube from the TCS control valve body Remove the TCS control valve brackets Remove the four nuts and the TCS control valve assembly from the mounting rubber MOUNTING RUBBER UPPER BRACKET 6 x 1 0 mm BOLT 12 N m 1 2 kg m 9 lb ft ANGLE SENSOR CONNECTOR BREATHER TUBE WATER HOSES 8 x 1 25 mm NUT
29. Start the engine 3 Push the TCS switch and hold it until the TWS indicator light turns on for more than 5 seconds then release it The TWS indicator light should go off Input new standard wheel speeds as follows 1 Connect the two terminals of the Service Check Connector with a jumper wire see page 19 14 and make sure that the TWS indicator light comes on 2 Drive the car at more than 10 mph 16 km h until the TWS indicator light goes off for 1 10 minutes Input of the standard wheel speeds completes 3 Remove the jumper wire 19 11 Circuit Diagram FUSE FUSE NAME BACK UP LIGHTS TURN SIGNALS FUELPUMP 22 FUELPUMP T UNDER DASH FUSE RELAY BOX YEL UNDER HOOD FUSE RELAY BOX GAUGE ASSEMBLY BATTERY 120 IGNITION SWITCH IG SW 50 A BATTERY ML S w o BLKYEL STOP HORN 20 A GRN RED GRN RED BLK YEL BRAKE FLUID PARKING LEVEL BRAKE NEUTRAL SWITCH SWITCH SWITCH only WHT WHT GRN WHT RED BLK BRNWHT BLKWEL ke _ GRN RED 6101 6202 2 16 1 22 13 108 9 NTSW VB STOP FSR VP 161 PARK M T only TCS CONTROL UNIT only SEALED M LGE1 LGE2 TCFC TCSTB PA NEP VREF TC SP 12A 24A 26A 25 5 20A 18 38 19 SB 14B 18A 1A 128 5A O TY iY O BLK BLK BLU YEL BLU BLK BRN BLK BRN BLK BLU GRN RED BLU GRY BL
30. Throttle Angle TH1 Sensor Problem Code 3 6 Throttle angle 9 TH1 sensor NOTE If the Check Engine Light indicator code 7 or indicator light indicates code 3 refer to the appropriate troubleshooting flowchart NOTE Remove the ABS B2 15A fuse in the under hood fuse relay box for more than 3 seconds to reset the TCS The standard wheel speeds initial offset memory in the control unit is erased when the ABS B2 15A fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see page 19 11 control unit Start the engine Confirm the TCS code see page 19 14 NO Intermittent failure Check for poor connections or loose wires 15 code 3 6 indicated YES Turn the ignition switch OFF RED BLE WIRE 8 TH1 TCS CONTROL UNIT 16P CONNECTOR Disconnect the 16P connector HARNESS SIDE from the TCS control unit Measure the voltage between the TCS control unit 16P Turn the ignition switch ON connector terminal 3B and body ground View from terminal side Is voltage O 5 V at fully closed throttle and approx 4 5V at fully open throttle NOTE There should be a smooth transition from O 5 V to approx 4 5 V as the throttle is depressed Check for poor connec YES tions or loose wires Substitute a known good TCS control unit and recheck Repair open in the RED BLU wire between the TC
31. added ABS Anti lock Brake System Operation After Disconnecting ABS B2 15A Fuse The TWS s standard wheel speeds is erased when the ABS B2 15A fuse is disconnected Be sure to input the standard wheel speeds initial offset memory again after disconnecting the ABS B2 15A fuse in the under hood fuse relay box When the ALB checker is used after disconnecting the ABS B2 15A fuse disconnect the ABS B2 fuse again and input the new standard wheel speeds The incorrect standard wheel speeds can be inputted when the ALB checker is used before input of the correct standard wheel speeds 19 2 TCS Traction Control System TWS Tire pressure Watching System Component Location 19 4 System Description TCS OUTS ous u n metti 19 5 Construction and Function 19 6 System Description TWS TISSU 19 10 Construction and Function 19 11 Circuit 19 12 Troubleshooting TCS 19 14 Troubleshooting TW S 19 68 Electronic Components TES Test Saa 19 74 Fail safe Relay 19 74 Lateral Acceleration Lg Sensor Test 19 75 TCS Control Unit Replacement 19 75 Steering Angle Sensor Replacement 19 76 TCS Control Valve Assembly Remo
32. ron oen son anos on Confirm the TCS code see page 19 14 View from terminal side GRN WHT WIRE STOP NO Battery voltage Are codes 4 1 4 2 4 4 and or Turn the ignition switch OFF 4 8 indicated YES Disconect the 26P connector from the TCS control unit Measure the voltage between the 26P connector terminal 22 A and body ground with the brake pedal depressed YES Intermittent failure Is there battery voltage Check for poor connections NO or loose wires Repair open or short in the GRN WHT wire between the TCS control unit and brake switch Confirm the ABS code see ABS section Repair according to the ABS troubleshooting chart see ABS section Are codes 4 1 4 2 4 4 and or 4 8 indicated NO To page 19 49 19 48 From page 19 48 Measure the voltage between the TCS control unit 16P connector terminals and body ground No 8B Right front No 6B Left front No 4B Right rear No 2B Left rear Is there 0 V when the wheel is V YES stopped and approx 2 V when the wheel is rotated by hand NO Turn the ignition switch OFF Disconnect the 14P connector from the ABS control unit Turn the ignition switch ON Measure the voltage between the TCS control unit 16P connector terminals and body ground No 8B Right front No 6B Left front No 4B Right rear No 2B Left rear NO Is t
33. 0 218 5 55 0 219 Installed height IN and EX 15 75 16 25 0 620 0 640 Rocker arm Arm to shaft clearance 0 018 0 054 0 0007 0 0021 0 08 0 003 Except KY KT 2 KY KT 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring Unit of length mm in Engine Block Section 7 MEASUREMENT STANDARD NEW SERVICE LIMIT Cylinder block Warpage of deck surface 0 07 0 003 max 0 10 0 004 Bore diameter 90 00 90 02 3 543 3 544 90 07 3 546 Bore taper 0 05 0 002 Reboring limit 0 5 0 02 Skirt O D at 17 0 mm 0 67in from bottom of skirt No Letter 89 980 89 990 3 5425 3 5429 89 970 3 5421 B 89 970 89 980 3 5421 3 5425 89 960 3 5417 Clearance in cylinder 0 02 0 04 0 001 0 002 0 08 0 003 Groove width for ring Top 1 220 1 230 0 0480 0 0484 1 250 0 0492 Second 1 220 1 230 0 0480 0 0484 1 250 0 0492 Oil 2 805 2 820 0 1104 0 1110 2 85 0 112 Piston ring Ring to groove clearance Top 0 035 0 060 0 0014 0 0024 0 13 0 005 Second 0 030 0 055 0 0012 0 0022 0 13 0 005 Ring end gap 0 25 0 40 0 010 0 016 0 70 0 028 0 40 0 55 0 016 0 022 0 85 0 033 0 20 0 70 0 008 0 028 0 80 0 031 0 20 0 50 0 008 0 020 0 80 0 031 O D 21 994 22 000 0 8659 0 8
34. 12 V 45 CP 12 V 5 W 12 V 5 W 12 V 21 W 12 V 45 12 V 21 5 W 12 V 32 2 CP 12 V 5 W 12 V 3 CP 12 V 21 W 12 V 32 CP 12 V 21 W 12 V 45 CP 12 V 5 W 12 V 8 W 12 V 3 0 W 1 4 W 12 V 1 12 W 1 4 W 12 V 5 W 12 V 3 4 W 12 V 3 4 W 12 V 3 4 W 12 V 1 6 W 2 12 V 1 4 W 4 Except European type and KU ENGLISH Independent double wishbone coil spring with Out 0 04 in In 0 08 in 8 99 sq in 4 34 7 60 sq in Mechanical expanding drums rear two wheels See tyre information label on driver s door jamb W 0 84 W Parking brake 3 17 Body Specifications Maintenance Lubrication Points 4 2 Maintenance Schedule 4 4 the details of lubrication points and types of lubricants to be applied refer to the Illustrated Index and various work procedures such as Assembly Reassembly Replacement Overhaul Installation etc contained in each section Ne LUBRICATION POINTS LUBRICANT API Service Grade SF SG or SH fuel efficient oil SAE Viscosity See chart below Transmission API Service Grade SF or SG SAE Viscosity 10 30 or 10 W 40 Automatic transmission fluid ATF ee s manavase erase van movien
35. CONNECTOR HARNESS SIDE Measure the voltage between the No 1 terminal and body ground BLK YEL WIRE IG1 NO Is there battery voltage YES Replace the steering angle sensor see page 19 75 View from terminal side Battery voltage Repair open or short in the BLK YEL wire between the under dash fuse relay box and steering angle sensor cont d 19 27 Troubleshooting TCS Steering Angle Sensor cont d From page 19 27 Connect the voltmeter be tween the steering angle sensor terminals No 21 and No 5 STR B 4 and No 5 STRA Turn the steering wheel slowly one revolution YES Does the needle pulse 4 5V 0 V4 5V 0V repeatedly NO Turn the ignition switch OFF Disconnect the 5P connector from the steering angle sensor Turn the ignition switch ON Measure the voltage between the steering angle sensor connector terminals and body ground No 2 STR B No 4 STRA YES Is there more than 4 5V NO Measure the voltage between the TCS control unit terminals and body ground No 15B STR B No 11B STRA is there more than 4 5V To page 19 29 WHT STRA 4 5V gt OV repeatedly GRY WIRE STR B LT GRN BLK WIRE STR GND MEMOD WHT WIRE STR A STEERING ANGLE SENSOR 5P CONNECTOR HARNESS SIDE View from terminal side Check for poor connec tions or loose wires
36. Diagnosis Indicator Blinks refer to base Shop Manuals The Check Engine Light may come on indicating a system problem when in fact there is a poor or intermittent electrical connection First check the electrical connections clean or repair connections if necessary The Check Engine Light and indicator light may come on simultaneously when the self diagnosis indicator blinks 6 7or 17 Check the PGM FI system according to the PGM FI control system troubleshooting then recheck the indicator light e The Check Engine Light and TCS indicator light may come on simultaneously when the code blinks 3 5 6 13 15 17 35 and 36 Check the PGM FI system according to the PGM FI system troubleshooting then recheck the TCS indicator light If it comes on see page 19 16 11 4 Brakes ABS Anti lock Brake System 19 1 TCS Traction Control System TWS Tire pressure Watching System 19 3 Outline of Model Change e The system of the TCS Traction Control System with the TWS Tire pressure Watching System is additionally equipped on the KG KS KX and KF models Outline of Model Change ABS Anti lock Brake System Operation After Disconnecting ABS B2 USB 19 2 e Owing to the addition of the TCS Traction Control System with the TWS Tire pressure Watching System to the KG KS KX and KF models the operational procedure after disconnecting the ABS B2 15A fuse is
37. LABEL KF KG KX e DANGER EXPLOSIVE FLAMMABLE POISON WARNING REFER TO THE SHOP MANUAL e DANGER EXPLOSIF ET INFLAMMABLE POISON ATTENTION SE REPORTER AU MANUEL D ATELIER GEFAHR EXPLOSIV ENTZ NDBAR GIFT WARNUNG WERKSTATTHANDBUCH LESEN GEVAAR EXPLOSIEGEVAAR BRANDBAAR GIFTIG WAARSCHUWING LEES HET WERKPLAATSHANDBOEK KS KY e DANGER EXPLOSIVE FLAMMABLE POISON REFER TO THE SHOP MANUAL e FARLIGT EXPLOIVT LATTANTANDLIGT GIFTIGT SE VERKSTADBOKEN ATTENTION SE VERKSTADBOKEN VAARA HELPOSTI RAJAHTAVA SYTTYVA MYRKKY KATSO LIIKEOHJETTA dug uda T gt PASSENGER MODULE DANGER LABEL KE KT KU A DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURE REFER TO SERVICE SHOP MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EVERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN AWaRrNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU
38. NO Turn the ignition switch OFF Disconnect the 26P connector from A T side of the ECU and the 26P connector from the TCS control unit Check for continuity between the TCS control unit 26P connector terminal 5A and body ground YES NO To page 19 64 NOTE Modify the test harness O7LAJ PT3010A connector by removing the bars from both ends of the A 26P male connector block A11 TC SP Approx 5 V TEST HARNESS Repair open in the ORN BLU wire between the TCS control unit and ECU ORN BLU WIRE TC SP Continuity View from terminal side Repair short in the ORN BLU wire between the TCS control unit and ECU 0000000000000 00000000 00000000000 0009000000000 00000000 me COENEN SENECA ENESCO ra web un onn nono sn oo TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE cont d 19 63 Troubleshooting TCS A T Gear Position Signal cont d From page 19 63 Reconnect the 26P connector to the TCS control unit Measure the resistance between the 26P connector terminals 5A and 20A or the 16p connector terminal 5B of the TCS control unit ORN BLU WIRE 009 00 C aa sn x 5 n 7 on 9x pon sal a jen pon 24 23 2eAjas 2 View from terminal side BRN BLK WIRE LGE 2 TCS CONTROL UNIT TCS CONTROL UNIT 26P CONNECTOR 16P CONNECTOR HARNESS SID
39. RED GRN BLU View from wire side 22 P CONNECTOR 23 8 Test condition Under all conditions Ignition switch ON ll Shift lever in P GRN RED Shift lever in Shift lever in GRN BLU Shift lever in GRN YEL Shift lever in GRN ORN Shift lever in Ignition switch ON and shift lever in 4 YEL RED Ignition switch ON II and shift lever in any position except Lighting switch ON and dash lights brightness control dial on full bright RED BLK and RED Test Desired result Possible cause if result is not obtained Check for continuity to ground Poor ground 6401 6402 G403 There should be continuity LHD or G402 G403 RHD n open in the wire Blown No 13 LHD or No 17 RHD 7 5 A fuse An open in the wire Check for voltage to ground There should be battery voltage Check for continuity to ground Faulty shift position console switch There should be continuity Poor ground G601 or G402 G403 LHD or G521 G522 RHD An open in the wire Check for voltage to ground Faulty shift position console switch There should be battery voltage Faulty ECU Poor ground G601 or G402 G403 LHD or G521 G522 RHD open in the wire Check for voltage to ground Faulty ECU should be less than 1 V for two open in the wire seconds after the ignition switch is turned ON and more than battery voltage two se conds later Faulty dash lig
40. Service Publication Office General Info Special Tools Specifications Maintenance 522 77 diram pad Cooling Fuel and Emissions Transaxle 2 nei dei Eaa N ass Steering gt QNI CADO NUR GM MUR Suspension t L Air Conditioning V NIRE i precautions are required when Outline of Model Changes MODELS REFERENCE SECTION ITEM DESCRIPTION LEGEND COUPE added Changed Engine mounts brackets and Transmission mounts brackets General Changed Suction pipe of air conditioning system LHD model Dipstick Recommended oil and Intake manifold Truction Control System TCS adopted KG KS KX KF Changed Component locations and Fuel tank Electronic Control Unit ECU modified lol TCS control system added KG KS KX KF ECU modified Changed Electrical connections and Self diagnostic procedures Fuel and Emissions Changed Gearshift points and Torque value of locknuts Modified Gearshift selector Hydraulic flow circuit A T speed sensor Valve bodies and Rear cover Suspension 16 inch aluminum wheel added European type Turning angle specifications changed Brake ABS ABS control unit changed TCS with TWS
41. and driver s door An open in the wire key cylinder switch in LOCK model ke 4 BLT Passenger s door lock Check for voltage to ground Faulty passenger s door lock switch switch in LOCK There should be 1 V or less BLK RED Passenger s door lock switch in UNLOCK 4 Check for voltage to ground There should be 1 V or less Poor ground G401 G402 G403 G402 G403 An open in the wire Faulty driver s door lock actuator Poor ground G401 G402 G403 16402 64031 open the wire Check for voltage to ground There should be 1 V or less 56 7 5 A fuse the ignition switch GRN BLU Passenger s door key cylinder in UNLOCK BLU WHT Driver s door lock knob in LOCK GRN BLK Driver s door lock knob in UNLOCK GRN BLU Driver s door opened IGRN RED GRN RED Passenger s door opened GRN BLU BLU WHT Ignition key is inserted into Passenger s door key Ree in LOCK Check for voltage to ground There should be 1 V or less Check for voltage to ground Switch is turned Connect the YEL RED terminal to the WHT GRN WHT RED and YEL RED momentarily terminal and the WHT RED terminal to the BLK terminal Check door lock operation All doors should unlock as the battery is connected momentarily Connect the WHT RED terminal to the WHT GRN momentar
42. between the TCS ground e Repair poor ground G101 Check for poor con nections or loose wires Subst tute a known good TCS control unit and recheck 19 19 Troubleshooting TCS TCS Switch and Activation Lights Do Not Go Off The TCS switch indicator light and the TCS activation light do not go off two seconds after the ignition switch is turned on GRY RED WIRE RED GRN WIRE Turn the ignition switch OFF From TCS SWITCH INDICATOR LIGHT From TCS ACTIVATION LIGHT Disconnect the 26P connector from the TCS control unit Turn the ignition switch ON eS un n 0x p np ha warn pun mn pn mn osa o View from terminal side TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Repair short in the RED GRN wire between the TCS control unit and gauge assembly and in the GRY RED wire between the TCS control unit and TCS switch NO Do the lights go off Substitute a known good TCS control unit and recheck 19 20 TCS Indicator Light Does Not Go Off The TCS indicator light does not go off after the engine starts NOTE When the engine is started a system check is performed The TCS indicator light will go off if the system is normal e If the back up power supply is less than 8V to the TCS control unit 26 connector terminal 1A the system check is stopped and TCS indicator light comes on Turn the ignition switch ON D
43. check Confirm the A T system code see section 14 YES Repair according to the PGM 15 a code indicated FIAT Electronic Control Unit ECU system troubleshooting NO guide see section 14 Raise the car and support it with safety stands see section 1 ORN BLE WIRE TC SP Approx 5 V TCS CONTROL UNIT HARNESS SIDE EN Ga ax us of o x x r7 pon wa eran erts oor oo View from terminal side Shift the transmission into P N or 2 Measure the voltage between the TCS control unti 26P connector terminal and body ground NO ls there approx 5 V To page 19 63 ORN BLE WIRE YES TC SP Sift the transmission into 1 No voltage TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Measure the voltage between the TCS control unit 26 connector terminal and body ground EE 7 ws Por onn alaaa sa 204 ze eco View from terminal side cont d page 19 62 19 61 Troubleshooting TCS A T Gear Position Signal cont d From page 19 61 Is there no voltage Turn the ignition switch OFF Disconnect the 26P connector from the A T side of the ECU Turn the ignition switch ON No voltage Ea C ax sve 54 ox se ox rs npn hu pen ran ro ma zn on oo p View from terminal side ORN BLU WIRE TC SP TCS CONTROL UNIT 26P CONNECTO
44. connector Turn the ignition switch ON Repair short in the BLU WHT wire between the gauge assembly and TCS control unit NO Does the light go off YES Substitute known good TCS contro unit and recheck C os S n So 6n 7 8A 9A pon Taal pen mean ronan 7 ron oo ps penu View from terminal side TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE 19 73 Electronic Components TCS Switch Test Remove the TCS switch assembly from the dashboard lower cover TCS SWITCH ASSEMBLY There should be continuity between the A and B terminals when the switch is pushed and there should be no continuity when the switch is released There should be continuity between the C and D terminals and between the E and F terminals at all time A B Switch C D indicator light E F Illumination light 19 74 Fail Safe Relay Test Remove the fail safe relay from under hood relay box C FAIL SAFE RELAY UNDER HOOD RELAY BOX C There should be continuity between the No 2 and No 4 terminals when the battery is connected to the No 1 and No 3 terminals There should be no continuity between the No 2 and No 4 terminals when the battery is disconnected No 2 NO 3 Lateral acceleration Lg Sensor Test CAUTION Be careful not to drop or bump the Lg sen sor The Lg sensor may be damaged if dropped or bumped hard Remove the rear seat back see section 20 Remove the Lg sens
45. each oil change 4 Fill the engine with oil up to the specified level run the engine for more then three minutes then check for oil leakage and oil level Intake Manifold Exhaust System Intake Manifold Replacement 9 2 Outline of Model Changes ntake manifold has been changed e The TCS has been adopted Intake Manifold Replacement NOTE f e Use new gaskets and O rings when reassembling Refer to section 19 when installing the TCS upper and lower brackets car s equipped TCS INTAKE MANIFOLD AIR SUCTION VALVE Replace if cracked or Except KY KQ KT models if mating surfaces are damaged 6 x 1 0 mm 12 Nem 1 2 kg m 9 Ib ft 8 x 1 25 mm 22 2 2 kg m 16 Ib ft AIR INLET PIPE FAST IDLE VALVE VACUUM PIPES 12 N m 1 2 kg m 9 ib ft O RING Replace WATER PASSAGE INTAKE AIR THROTTLE BYPASS VALVE BODY BASE O RING BODY ASSEMBLY GASKET Replace Replace EGR PIPE THROTTLE BODY 6 x 1 0 mm 12 N m 1 2 kg m 9 Ib ft GASKETS Replace INTAKE MANIFOLD 8 x 1 25 mm CHAMBER 22 Nem 2 2 kg m 8 x 1 25 mm 16 ib ft 22 2 2 kg m 16 lb ft INTAKE MANIFOLD B ful GASKETS e careful not TCS CONTROL to damage Replace SUCTION PIPE Car s equipped TCS Except KY KT models 8x 1 25 mm 25 4 0 kg m 29 lb ft AIR BOOST VALVE Apply engine oil Be careful not when installing to dam
46. ground poor ground at G551 an open in the E GRN ORN wire between failure sensor and right brake light an open in the BLK wire between right brake light and ground if the BRAKE LAMP light comes on and stays on replace the failure sensor 23 13 Safety Indicator Brake Light Failure Sensor Test KY model First make sure the brake lights come on when the brake pedal is pressed all brake lights come on go to step 2 If one of the brake lights does not come on check whether the bulb is blown If the bulb is OK go to step 2 if none of the brake lights come on check the brake light circuit see page 23 16 Open the trunk lid and remove the access panel to the left taillight Watch the light in the safety indicator when the A WHT GRN wire of the 6 connector is grounded and the ignition switch is turned from OFF to ON Il View from wire side ACCESS PANEL the BRAKE LAMP light comes and stays on check for an open in the A WHT GRN wire between the safety indicator and the left failure sensor e if the BRAKE LAMP light does not stay on go to step 3 Watch the BRAKE LAMP light as you turn the igni tion switch from OFF to ON ll with the B GRN wire of the 6 P connector grounded and the brake pedal pressed if the BRAKE LAMP light comes on and stays on replace the left failure sensor e if the BRAKE LAMP light does not
47. input new standard wheel speeds into the control unit again seconds to reset the TCS after inspection see page 19 11 control unit and ABS control unit Start the engine Confirm the TCS code see page 19 14 or loose wires Check the ABS indicator light ts the ABS indicator ight ON s Repair according to the ABS Is the ABS indicator light ON troubleshooting guide see ABS section TCS CONTROL UNIT 16P CONNECTOR NO HARNESS SIDE NO Intermittent failure Is code 4 9 indicated Check for poor connections E YES Y Measure the voltage between the TCS control unit 16P connector terminals and body ground with the wheels stopped Approx 5 V No 8B Right front No 6B Left front No 4B Right rear No 2B Left rear View from terminal side GRN WIRE FRP LT GRN WIRE RLP GRN ORN WIRE GRN BRN WIRE RRP FLP Check for poor connec NO tions or loose wires Is there approx 5 V Substitute known good control unit and YES recheck To page 19 52 cont d 19 51 Troubleshooting TCS All Wheel Sensors cont d From page 19 51 ABS CONTROL UNIT GRN BRN WIRE 14P CONNECTOR IFLP HARNESS SIDE Approx 5 V Measure the voltage between the ABS control unit 14P connector terminals and body ground with the wheels stopped No 6 Right front No 5 Left front No 13 Right rear No 14 Left rear n GR
48. of the four tires is low 2 0 This code may be detected when there is excessive wear difference between the left and right front tires NOTE The detected code memorized in the TWS control unit can be erased by disconnecting the ABS B2 15 A fuse 19 10 ke Construction and Function TWS Control Unit The TWS control unit is integrated in the TCS control unit and shares the wheel speed signal steering angle signal and lateral acceleration signa with the TCS control unit measures the difference of the actual rotation speed between the left and right wheels while estimating the normal difference of the rotation speeds between the wheels on both sides from the vehicle speed and steering wheel angle If the system senses a difference between the values measured and estimated which commonly indicates a low pressure it diagnoses a possibility of a flat tire NOTE The TWS monitors the imbalance of the speed between the wheels Therefore the system does not blink the indicator light when the tire air pressure of the four wheels decreased simultaneously TWS may blinks indicator light when the tire chains are installed on the wheels when being towed with a trailer or under other conditions when there are the significant differences in speed between the wheels Return the car to the original condition restart the engine and test drive the car The tire air pressure is normal if the TWS indicator light does not blink
49. stay on go to step 4 23 14 6 P CONNECTOR 4 RIGHT FAILURE SENSOR Remove the access panel to the right taillight Watch the BRAKE LAMP light as you turn the ignition switch from OFF to ON 11 with the B GRN wire of the 6 P connector grounded and the brake pedal pressed View from wire side ACCESS PANEL e if the BRAKE LAMP light comes on and stays on there is an open in the B GRN wire between the left failure sensor and the right failure sensor If the BRAKE LAMP light does not stay on go to step 5 Watch the BRAKE LAMP light as you turn the igni tion switch from OFF to ON H with the A BLK wire of the 6 P connector grounded and the brake pedal pressed if the BRAKE LAMP light comes on and stays on replace the right failure sensor e If the BRAKE LAMP light does not stay on check for an open in the A BLK wire between the right failure sensor and ground and check for a poor ground at G551 Brake Lights Circuit Diagram Except KY model BATTERY UNDER HOOD FUSE RELAY BOX WHT GRN WHT GRN WHT GRN BRAKE HORN SYSTEM SWITCH gt INTERLOCK SYSTEM model SECURITY INDICATOR IKT and KG models GRN WHT SAFETY INDICATOR P 1 WHT GRN 2 GRN WHT GRN WHT I GRN WHT I r y Be Oe I S cM I 1 i I i T I I 1 I I I i i i PFR i 1 CRUISE l I i
50. the ignition switch OFF Lg SENSOR 3P CONNECTOR HARNESS SIDE Disconnect the 26P connector from the TCS control unit and the 3P connector from the Lg sensor View from terminal side Check for continuity between the No 2 terminal and body ground RED BLU WIRE Continuity Repair short in RED BLU wire between the TCS control unit and Lg sensor YES NO Replace the Lg sensor Repair open in RED BLU wire between the TCS control unit and Lg sensor Substitute a known good TCS control unit and recheck Check for poor con nections or loose wires amp PGM FI Signals Problem Code 3 1 TC STB FC and TC INH signals NOTE The ECU outputs the TC INH signal to the TCS control unit when the correct TC STB and TC FC signals have been inputted to the ECU from the TCS control unit Remove the No 15 7 5A fuse in the under hood fuse relay box for more than 10 seconds to reset the ECU Confirm the PGM FI system code see section 11 Are codes 35 TC STB open or short circuit and or 36 TC FC open or short circuit indicated Check the TC INH signal if no code is indicated see page 19 37 Perform the PGM FI system troubleshooting procedure if 168 codes other than 35 and 36 HARNESS SIDE Check the TC STB signal are indicated see section 11 when PGN FI system code 35 is indicated s
51. thus enhancing cornering For any given driving situation the control unit will determine the amount of wheel spin best suited to the driver s needs and if necessary will then signal the TCS control valve actuator and engine ECU to reduce engine power The system is automatically ready whenever the engine is started but be manually canceled with the TCS switch However once activated the system cannot be canceled until it is once again in the ready state ABS CONTROL UNIT REAR RIGHT TCS CONTROL UNIT WHEEL SENSOR Lg SENSOR ECU FRONT RIGHT WHEEL SENSOR TCS SWITCH REAR LEFT WHEEL SENSOR STEERING ANGLE SENSOR TCS CONTROL VALVE ASSEMBLY FRONT LEFT WHEEL SENSOR Components Wheel sensors The TCS shares the wheel sensors with the anti lock brake system ABS The wheel sensors trans mit the wheel speed signals to the TCS contro unit through the ABS control unit Steering angle sensor The steering angle sensor signals the TCS control unit about the amount of steering angle Lg sensor The Lg sensor detects the lateral acceleration of the vehicle and signals the TCS control unit TCS control valve actuator The actuator gets signals from the TCS control unit and closes the TCS contro valve accordingly TCS control unit The control unit gets driving condition signals from the sensors and if necessary signals the TCS control valve actuator to close the TCS control v
52. with the engine idling and warmed up e Confirm that the analog tester needle swings to approx 6 V j TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE GA an vx o 7 3e Taqa perpe Bonon ons po View from terminal side 6 Measure the voltage between the TCS control unit 26P connector terminal 17 A and body ground BLU WIRE Repair open the BLU wire between the TCS control unit and ECU Is there approx 6 V NO YES Check for poor connec tions or loose wires Substitute known good TCS control unit and recheck 19 40 Reference Voltage VREF Signal Problem Code 3 4 The 5 V standard voltage VREF Remove the ABS B2 15 fuse in the under hood fuse relay box for more than 3 seconds to reset the TCS control unit Measure the voltage between Start the engine Confirm the TCS code see page 19 14 Is code 3 4 indicated bos the TCS control unit 16P connector terminal 12B and body ground Is there approx b V YES NO Turn the ignition switch OFF Disconnect the 16P connector from the TCS control unit Turn the ignition switch ON Measure the voltage between the 16P connector terminal 12 B and body ground YES ts there approx 5V NO To page 19 42 NOTE The standard wheel speeds initial offset memory in the control unit is eras
53. 000000 018 Repair open the BLU wire Is there approx 5V between the TCS control unit Approx 5 V and ECU NO e Check for poor tions or loose wires Substitute a known good ECU and recheck 19 42 Atmospheric Pressure PA Sensor Problem Code 3 5 The atmospheric pressure PA sensor Remove the ABS B2 15A fuse and No 15 7 5 A fuse in the under hood fuse relay box for more than 10 seconds to reset the TCS control unit and ECU Start the engine Confirm the TCS code see page 19 14 5 code 3 5 indicated YES Confirm the PGM FI system code see section 11 Is code 13 indicated 2 Turn the ignition switch OFF Disconnect the 26P connector from the TCS control unit Turn the ignition switch ON Measure the voltage between the 26P connector No 18A terminal and body ground ls there approx 2 V to 3 V NO To page 19 44 NO YES YES NOTE The standard wheel speeds initial offset memory in the control unit is erased when the ABS B2 15 A fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see page 19 11 intermittent failure Check for poor connections or loose wires Repair according to the PGM Fl system troubleshooting guide see section 11 ORN RED WIRE PA Check for poor connec tions o
54. 1 0 007 0 0 08 0 003 0 06 0 16 0 002 0 006 0 10 0 25 0 004 0 010 0 02 0 12 0 001 0 005 0 0 08 0 003 0 07 0 15 0 003 0 006 0 05 0 16 0 002 0 006 0 03 0 30 0 001 0 012 3 5 4 5 0 35 0 45 2 5 3 3 0 99 1 01 0 039 0 040 1 56 1 58 0 061 0 062 1 590 1 610 0 0626 0 0634 1 62 1 64 0 064 0 065 1 65 1 67 0 065 0 066 1 68 1 70 0 066 0 067 1 71 1 73 0 067 0 068 1 740 1 760 0 0685 0 0693 1 770 1 790 0 0697 0 0705 1 80 1 82 0 071 0 072 1 83 1 85 0 072 0 073 1 86 1 88 0 073 0 074 1 89 1 91 0 074 0 075 1 920 1 940 0 0756 0 0764 1 95 1 97 0 077 0 078 1 98 2 00 0 078 0 079 2 01 2 03 0 079 0 080 2 04 2 06 0 080 0 081 2 07 2 09 0 081 0 082 2 100 2 120 0 0827 0 0835 2 13 2 15 0 084 0 085 2 16 2 18 0 085 0 086 2 19 2 21 0 086 0 087 2 22 2 24 0 087 0 088 2 250 2 270 0 0886 0 0894 2 28 2 30 0 090 0 091 2 31 2 33 0 091 0 092 2 34 2 36 0 092 0 093 2 37 2 39 0 093 0 094 2 40 2 42 0 094 0 095 2 430 2 450 0 0957 0 0965 Adjust with washer Adjust with a washer Adjust with a washer Wear or damage Automatic Transmission Section 14 MEASUREMENT One way ball spring Secondary spring 4 3
55. 3 2 Keyless Entry System Except KU model 23 17 Safety Indicator S 23 10 Shift Lever Position Indicator 2327 Read SRS precautions on 23 41 of the 93 Legend Coupe Shop Manual Supplement 625 121 then install the short connectors on the airbags before working in these areas Outline of Model Changes Brake Light The failure sensors of all models have been changed Gauge Assembly The TCS and Tire Pressure Watching System TWS lights have been added to the KG KX KF and KS models Keyless Power Door Locks A trunk receiver unit has been added and the system has been renamed to Keyless Entry System Safety Indicator The failure sensors of all models have been changed Shift Lever Position Indicator The circuit has been partly changed Special Tool Ref No Tool Number Description Qty Page Reference O7MAJ SP00200 Keyless Entry Checker 1 23 23 Gauge Assembly Circuit Diagram UNDER DASH FUSE BOX UNDER HOOD IGNITION FUSE RELAY BOX SWITCH BATTERY MEA 5 LHD 7 5 RHD No 31 120A No 35 50A BLK YEL YEL YEL BLK YEL No 46 20 FUSE BLK YEL YEL RED YEL HIGH Bate WASHER BEAM CHARGE FLUID LEVEL INDICATOR SYSTEM INDICATOR ACTIVATION SYSTEM A Y INDICATOR LIGHT LIGHT LIGHT COOLANT 1 4W a Ww 1 4
56. 5 1 337 30 05 30 10 1 183 1 185 9 67 9 70 0 381 0 382 9 72 9 75 0 383 0 384 9 77 9 80 0 385 0 386 9 82 9 85 0 387 0 388 9 87 9 90 0 389 0 390 9 92 9 95 0 391 0 392 9 97 10 00 0 393 0 394 35 95 36 00 1 415 1 417 27 95 28 05 1 100 1 104 23 50 23 55 0 925 0 927 2 97 3 00 0 117 0 118 3 02 3 05 0 119 0 120 3 07 3 10 0 121 0 122 3 12 3 15 0 123 0 124 3 17 3 20 0 125 0 126 3 22 3 25 0 127 0 128 3 27 3 30 0 129 0 130 3 32 3 35 0 131 0 132 3 37 3 40 0 133 0 134 3 42 3 45 0 135 0 136 3 47 3 50 0 137 0 138 68 95 69 05 2 715 2 718 28 95 29 05 1 140 1 144 24 02 24 05 0 946 0 947 95 764 95 790 3 7702 3 7713 86 487 86 513 3 4050 3 4060 79 107 79 120 3 1144 3 1150 69 833 69 846 2 7493 2 7498 6 97 6 98 0 274 0 275 11 47 11 48 0 452 0 452 7 018 7 030 0 2763 0 2768 11 500 11 518 0 4528 0 4535 1 980 1 995 0 0780 0 0785 1 980 1 995 0 0780 0 0785 2 025 2 060 0 0797 0 081 1 2 025 2 060 0 0797 0 0811 24 980 24 993 0 9835 0 9840 53 968 53 984 2 1247 2 1254 34 975 34 991 1 3770 1 3776 34 975 34 991 1 3770 1 3776 34 975 34 991 1 3770 1 3776 38 505 38 515 1 5159 1 5163 47 975 47 991 1 8888 1 8894 38 975 38 991 1 5344 1 5351
57. 60 0 260 6 80 0 268 14 00 0 551 21 099 0 8307 51 30 2 020 86 50 3 406 43 00 1 693 30 30 1 193 30 60 1 205 33 00 1 299 41 80 1 646 56 50 2 224 46 80 1 843 49 60 1 953 28 30 1 114 55 50 2 185 42 10 1 657 35 00 1 378 75 50 2 972 80 80 3 181 96 70 3 807 80 00 3 150 68 40 2 693 78 40 3 087 115 50 4 547 73 70 2 902 61 20 2 409 36 30 1 429 37 50 1 476 38 50 1 516 34 30 1 350 sss 3 11 Standards and Service Limits Differential Section 15 MEASUREMENT STANDARD NEW SERVICE LIMIT Differential oil Capacity 2 US qt imp qt 1 10 1 16 0 97 for overhaul 1 05 1 11 0 92 for oil change Differential Pinion shaft contact area l D 20 000 20 021 0 7874 0 7882 Carrier to pinion shaft clearance 0 013 0 050 0 0005 0 0020 0 10 0 004 Drivershaft and intermediate shaft 32 025 32 045 1 2608 1 2616 contact area l D Carrier to driveshaft clearance 0 045 0 086 0 0018 0 0034 0 120 0 0047 Carrier to intermediate shaft clearance 0 080 0 116 0 0031 0 0046 0 120 0 0047 Differential Backlash 0 05 0 15 0 002 0 006 0 30 0 012 pinion gear I D 20 042 20 066 0 7891 0 7900 Pinion gear to shaft clearance 0 055 0 095 0 0022 0 0037 0 15 0 006 Drive pinion gear
58. 661 Pin to piston clearance 0 012 0 024 0 0005 0 0009 Connecting rod Pin to rod interference 0 013 0 032 0 0005 0 0013 Small end bore diameter 21 968 21 981 0 8649 0 8654 Large end bore diameter Nominal 57 0 2 24 End play installed on crankshaft 0 15 0 30 0 006 0 012 67 967 68 000 2 6759 2 6772 53 970 53 994 2 1248 2 1257 Crankshaft Main journal diameter Rod journal diameter Taper 0 005 0 0002 max 0 010 0 0004 Out of round 0 004 0 0002 max 0 010 0 0004 End play 0 10 0 29 0 004 0 01 1 0 45 0 018 Total runout 0 020 0 0008 max 0 030 0 0012 Bearings Main bearing to journal oil clearance 0 020 0 044 0 0008 0 0017 0 05 0 002 Rod bearing to journal oil clearance 0 022 0 046 0 0009 0 0018 0 05 0 002 1 RIKEN manufactured piston ring 2 TEIKOKU PISTON RING manufactured piston ring Engine Lubrication Section 8 MEASUREMENT STANDARD NEW SERVICE LIMIT Capacity 2 US qt Imp at 5 3 5 6 4 7 for engine overhaul 4 5 4 8 4 0 for oil change including filter 4 0 4 2 3 5 for oil change except filter Inner to outer rotor radial clearance 0 04 0 16 0 002 0 006 20 0 008 0 Housing to outer rotor radial clearance 0 10 0 18 0 004 0 007 0 Housing to rotor axial clearance 0 02 0 07 0 001 0 003 0 Relief valve Pressure setting at oil temperature 176 F 80 C kPa
59. 7 003 For Refrigerant HFC 134a R 134a system Lubricant capacity Condenser 30 0 1 01 1 06 m2 fl oz Imp oz Evaporator 60 0 2 03 2 11 Line or hose 10 0 1 3 0 35 Reservoir 10 0 1 3 0 35 Compressor Lubricant type ND OIL8 P N38899 PR7 003 For Refrigerant HFC 134a R 134a Lubricant capacity m2 fl oz Imp oz 140 4 2 3 4 9 Coil resistance at 68 F 20 C Q 3 4 3 8 Pulley to pressure plate clearance 0 5 0 02 0 15 0 006 Compressor Deflection with 100 10 22 Ibs 8 0 10 0 0 31 0 39 with used belt belt between pulleys 5 0 6 5 0 20 0 26 with new belt Belt tension N kg Ibs 400 600 40 60 88 132 with used belt Measured with belt tension gauge 800 1 000 80 100 176 220 with new belt When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values Electrical Section 23 MEASUREMENT STANDARD NEW SERVICE LIMIT lgnition coil Rated voltage V Primary winding resistance at 77 F 25 C Q Spark Plug Type Refer to section 23 Base manual Code 625 Electrode gap 1 00 1 10 0 039 0 043 1 3 0 05 TNNT s Alternator Deflection with 100 N 10 kg 22165 9 5 11 5 0 37 0 45 with used belt beit between pulleys 5 5 7 5 0 22 0 30 with new belt Belt tension kg lbs 350 550 35 55 77 121 with used belt Measured with b
60. 8 For European models Engine oil and oil filter element converter Fvey20000kminaqoomisnortamon Der Fonwakedicomdcaiee 1 00004 6000mio Sone DEF 1 Evey2DG00km 12000 menor rente porera __ Bey 004m 00 momen For cars without catalytic converter 4 6 Engine Removal Installation Engine Removal Installation 5 2 Outline of Model Changes The suction pipe of air conditioning system has been changed LHD model e The TCS has been adopted Engine Removal Installation Refer to shop manual code No 62SP020 and 62SP021 for service procedures except following LHD model CAUTION Take care not to bend the suction pipe when removing and installing the cylinder heads 1 Remove the suction pipe clamp from the strut bar 8 x 1 25 mm 22 2 2 kg m 16 Ib ft SUCTION PIPE SUCTION PIPE 2 Remove the suction pipe clamp from the throttle cable bracket SUCTION PIPE CLAMP NES 6 x 1 0 mm 10 N m 1 0 kg m 7 lb ft Cars equipped TCS 1 Remove the air cleaner assembly and air flow tube AIR CLEANER ASSEMBLY 6 x 1 0 mm 10 N m 1 0 kg m 7 Ib ft AIR FLOW TUBE Remove the TCS lower bracket from the power steering bracket and TCS control valve assembly NOTE Refer to section 19 when installing the bracket TCS LOWER BRACKET Oe
61. 8 000 9 000 80 90 1 138 1 280 Power steering Fluid capacity Reservoir 0 5 0 5 0 4 fluid 0 US qt Imp qt System 1 7 1 8 1 5 Deflection with 100 10 kg 22 Ibs between pulleys 11 5 13 5 0 45 0 53 with used belt Power steering 7 5 9 5 0 30 0 37 with new belt belt Belt tension kg Ibs 350 550 35 55 77 121 with used belt Measured with belt tension gauge 700 900 70 90 154 198 with new belt When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 12 Unit of length mm in Suspension Section 18 SERVICE LIMIT Side slip Front Out 1 0 0 04 2 0 0 08 HI Wheel Rim runout Axial 0 0 7 0 0 03 2 0 0 08 Radial 0 0 7 0 0 03 1 5 0 06 Wheel bearing End play Front 0 0 05 0 0 002 0 0 05 0 0 002 1 KY only 2 KF KG KX KE KS MEASUREMENT STANDARD NEW Wheel Camber Front 0 00 1 0 15 1 alignment Rear 0920 19 0 5 1 Caster Front 3945 1 3 30 1 Total toe Front Out 1 0 0 04 2 0 0 08 Rear 2 0 0 08 2 0 0 08 Front wheel turning angle Inward wheel 44 2 40 2 2 Outward wheel 35 33 2 Brake Section 19 MEASUREMENT STANDARD NEW SERVICE LIMIT Parking brake Play in
62. 80 1 7354 29 32 1 154 0 30 0 012 31 050 1 2224 37 940 1 4937 29 54 1 163 53 081 2 0898 35 85 1 411 Adjust 53 081 2 0898 35 85 1 411 Adjust 19 93 0 785 25 078 0 9873 26 38 1 039 3 5 Standards and Service Limits Manual Transmission cont d Sectoin 13 MEASUREMENT STANDARD NEW SERVICE LIMIT Spacer collar D 37 950 37 960 1 4941 1 4945 38 008 1 4964 countershaft 46 989 47 000 1 8500 1 8504 46 940 1 8480 2nd gear Thickness 36 07 36 09 1 420 1 421 Adjust 36 03 36 05 1 419 1 419 Adjust Countershaft O D bearing contact area 46 989 47 000 1 8500 1 8504 46 94 1 848 reverse gear Thickness 50 45 50 55 1 986 1 990 50 38 1 983 Synchro ring Ring to gear clearance 0 85 1 10 0 033 0 043 0 4 0 02 ring pushed against gear Double cone synchro ring Clearance ring pushed against gear Outer synchro ring to gear Synchro cone to gear Outer synchro ring to synchro cone 0 6 0 02 0 3 0 01 0 3 0 01 0 95 1 68 0 037 0 066 0 5 1 0 0 02 0 04 0 5 1 0 0 02 0 04 Shift fork 1st 2nd 3rd 4th and bth 7 4 7 6 0 29 0 30 0 35 0 65 0 014 0 026 1 00 0 039 Finger thickness Finger to synchro sleeve clearance 6 4 6 6 0 25 0 26 0 35 0 65 0 014 0 026 1 00 0 039 Revers
63. ABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT S R S A SHI 8 Sal gi S R S 36551 exa S alas SMG gt lt i EP Ja3 54 dine La UAI Sos H LABEL 1 10 DRIVER INFORMATION LABEL SUNVISOR KF KG KX 585 ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S e IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT e IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER ATTACHEZ TOUJOURS VOTRE CEITURE CE VEHICULE EST EQUIPE D UN COUSSIN D AIR POUR LE PASSAGER AVANT QUI CONSTITUENT UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S e CE COUSSIN D AIR COMPLETE LA FONCTION DE LA CEINTURE DE CECURITE SI LE TEMOIN SRS S ALLUME PENDANT LA CONDUITE ADRESSEZ VOUS A VOTRE CONSSIONNARIE HONDA OFFICIEL SRS SICHERHEITSUGRTE JEDER FAHRT ANLEGEN DIESES FAHRZEUG BESITZT JE EINEN AIRBAG F R FAHRER UND BEIFAHRER ALS ZUSATZLICHES R CKHAL TESYSTEM S R S e DAS R CKHALTESYSTEM IST EINE ERGANZUNG ZUM SICHERHEITSGURT eSOLLTE WAHREND DER FAHRT DIE SRS KONTROLLEUCHTE AUFLEUCHTEN SUCHEN SIE BITTE UNGEHEND EINEN HONDA HANDLER SUF DRAAG ALTIJD UW VEILIGHEIDSGORDEL DIT VOERTUIG IS UITGERUST MET AIRBAG SRS AAN BESTUURDERSZIJDE EN PASSAGIERSZIJDE VOOR EXT
64. AINA TURVAVY T AUTO OM VARUSTETTU AJAJAN ILMATYYNYLL JA ETUMATKUSTAJAN ILMATYYNYLL JOTKA TOIMIVAT YLIMAARAISENA TUKIJ JESTELM M e SE ON SUUNNITELTU T YDENT M N TURVAVY T e JOS SRS MERKKIVALO SYTTYY AJON AIKANA OTTAKAA YHTEYS VALTUUTETTUUN HONDA MYYJ N al gt Lails S R S 235 adigi 9 aSa 3jLauall aba ad e 5 5 3021 amp o 9l Solas 3292 941 Anal sual Jas cont d 1 11 Warning Caution Label Locations cont d J INFLATOR BAM LABEL KF KG KX only AIRBAG GAS GENERATOR UT 11873 MORTON INTERNATIONAL OGDEN USA HERSTELLUNG JAHR EINF HRER HONDA DEUTSCHLAND GMBH 6050 OFFENBACH BAM PT 0437 DER GASGENERATOR DARF NUR F R INSASSEN R CKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAF R GESCHULTEM PERSONAL VORGENOMMEN WERDEN CAUTION THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED FLAMMABLE WITH THE AIRBAG SYSTEM THE GAS SOLIDS GENERATOR IS TO BE INSTALLED AND OR DISASSEMBLED ONLY BY TRAINED PERSONNEL ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE CONTENT DE INSTALLE QUE SUR DES VEHICULES SOLIDES EQUIPES D UN SYSTEME AIRBAG LE FLAMMABLES MONTAGE ET LE DEMONTAGE DU GENERATEUR DE GAZ NE PEUT ETRE EFFECTUE QUE PAR UN PERSONNEL QUALIFIE 1 12 PASSENGER MODULE DANGER
65. BS 82 15 A fuse in the under hood fuse relay box for more than 3 seconds to reset the TCS control unit Start the engine Confirm the TCS code see page 19 14 ls code 3 2 indicated NO YES Start the engine Check that the tachometer operates properly Does the tachometer operate properly To page 19 40 NOTE The standard wheel speeds initial offset memory in the control unit is erased when the ABS B2 15 A fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see page 19 11 Intermittent failure Check for poor connections or loose wires Turn the ignition switch OFF Connect the test harness to the ECU see section 11 NOTE Use the 10 V range or a similar range in the analog tester Check with the engine idling e Confirm that the analog tester needle swings to approx 6 V JUL Measure the voltage between the C4 terminal of the test harness and body ground NO is there approx 6 V Check the PGM FI system NES TEST HARNESS 000000 00000000000 9000000000000 900000006 QP 0000 IF Approx 6 V C4 NEP cont d 19 39 Troubleshooting TCS Engine Speed NEP Signal cont d From page 19 39 NOTE Use the 10 V range or a similar range in the analog tester Check
66. Backlash At inspection hole 0 06 0 14 0 002 0 006 Adjust and ring gear At ring gear circumference 0 08 0 18 0 003 0 007 Adjust Drive pinion Preload starting toque Adjust N m kg m New bearing 0 93 1 57 0 093 0 157 0 7 1 1 Reused bearing 0 72 1 21 0 072 0 121 0 5 0 9 A T New bearing 1 86 2 54 0 186 0 254 1 3 1 8 Reused bearing 1 45 1 95 0 145 0 195 1 0 1 4 Drive pinion and Total preload starting torque Adjust differential unit N m kg m lb ft MTO Tp 0 55 0 78 0 055 0 078 0 4 0 6 2 Tp 0 55 0 78 0 055 0 078 0 4 0 6 3 0 65 0 79 0 065 0 079 0 5 0 6 0 65 0 79 0 065 0 079 0 5 0 6 1 06 1 28 0 106 0 128 0 8 0 9 Tp 1 06 1 28 0 106 0 128 0 8 0 9 Tp 0 96 1 09 0 096 0 109 0 7 0 8 0 96 1 09 0 096 0 109 0 7 0 8 D Pinion and ring gear bearings are new 2 Ring gear bearing is new Pinion bearing is new Pinion and ring gear bearings are reused Tp Actual measurement of drive pinion preload Tp should be within the standard spec Steering Section 17 MEASUREMENT STANDARD NEW Steering wheel Play at steering wheel circumference 10 0 4 Starting load at steering wheel circumference kg 165 Engine stopped 200 20 44 max Engine running 30 3 6 6 max Pump pressure with shut off valve closed kPa psi
67. E HARNESS SIDE Replace the TCS control unit and recheck YES Is there Q Substitute known good ECU and recheck NOTE The normal resistance is approx 12 5k Q for reference 19 64 TC SP BRN BLK WIRE LGE 1 TCS Function Test Traction Control System Function Test Raise the car and support it with safety stands see section 1 Turn the ignition switch ON NOTE Check the TCS indicator lights The TCS activation light and TCS switch indicator light come on for about 2 TCS activation light and TCS seconds after the ignition switch is turned on then go off The TCS indicator switch indicator light light stays on NO Perform the troubleshooting Are the lights come on on page 19 17 YES Start the engine NOTE Check the TCS indicator light The TCS indicator light stays on and the system is not ready when the coolant temperature is below O C 32 F NO Perform the troubleshooting Does the light go off on page 19 21 YES Check the TCS switch indicator light YES NO Does the fight come on Replace the TCS control unit and recheck Shift the transmission into 2nd or 2 A T Press the accelerator pedal about 1 3 down Make sure that the speedometer indicates at 12 20 mph 20 30 km h and the engine speed is at 1 000 2 000 rpm NO Confirm the TCS code see according to the trouble YES shooting gui
68. ELAY NO 15 it normal Replace the TCS 15A fuse and recheck YES _ Check the fail safe relay see page 19 74 NO UNDER HOOD RELAY BOX C Is it normal Replace the fail safe relay and recheck YES Turn the ignition switch ON To page 19 54 cont d 19 53 Troubleshooting TCS Fail safe Relay TCS Control Valve Actuator cont d Battery voltage From page 19 53 No 1 TERMINAL From No 22 20 fuse Measure the voltage between the No 1 terminal of the fail safe relay connector and body ground FAIL SAFE RELAY CONNECTOR NO Repair open in the BLK YEL wire between the fail safe relay under dash fuse YES relay box Is there battery voltage Measure the voltage between the No 2 terminal of the fail safe relay connector and body ground Measure the voltage between YES NO Repair open in the GRN RED wire between the fail safe relay and under hood fuse relay box Battery voltage Is there bettery voltage No 2 TERMINAL From TCS 15A fuse Turn the ignition switch OFF Install the fail safe relay FAIL SAFE RELAY CONNECTOR Disconnect the 26P connector from the TCS control unit Battery voltage RED BLK WIRE FSR ee TCS CONTROL UNIT Turn the ignition switch ON 26P CONNECTOR HARNESS SIDE C n 34 v 9 amp ox 5 ox pos on nance To page 19 55 View from terminal side the 26 conn
69. EN LUFTKUDDE FORARSATET SOM ETT KOMPLETTERANDE SKYDDSSYSTEM SRS SAMTLIGA ELLEDNINGAR OCH KONTAKTER SRS SYSTEMET AR GULFARGADE ANVAND INTE ELEKTRISK PROVUTRUSTNING F R DESSA KRETSAR OM DU ANDRAR ELLER LOSSAR EN SRS LEDNING KAN DET RESULTERA 1 EN OAVSIKTLIG UTLOSNING AV TRYCKPUMPEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA DA KAN EN ALLVARLIG OLYCKA UPPSTA VAROITUS sns mE TASSA AUTOSSA ON YLIMAARAISENA TUKWARJESTELMANA AJAJAN ILMATYYNY SRS KAIKKI SRS SA HK JOHDOT JA LIITTIMET OVAT KELTAISET ALA SAHKOKOELAITTEITA NAISSA VIRTAPIIREISAA SRS JOHTOJEN TUKKEAMINEN IRROTTAMINEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TAI TEHDA JARJESTELMAN KAYTTOKELVOTTOMAKSI TASTA TAAS SAATTAA AIHEUTUA VAKAVIA VAURIOITA S R S TS AUIS GU ils tadi odd o3 5 S R S 365 S R S guey 15 AiL 611 Juyi gt CX uglls 91 daal 1 9201 el SII lasa Y 520 239 S R S 32 ea Sl uu food J TRES Loo post e ala Jalas 4 4 5 gt jM poi 92 gt SUNVISOR 1 9 Warning Caution Label Locations cont d G STEERING COLUMN CAUTION LABEL KE KO KT KU KF KG KX CAUTION 585 TO AVOID DAMAGING THE S R S CABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT ATTENTION POUR NE PAS RI
70. ENT BRAKE SYSTEM ELECTRICAL 1 KY only Type Shock Absorber Camber Caster Toe Type Pad and Lining Surface Area Parking Brake Battery Starter Alternator METRIC Front Rear Front and Rear Type Fuses In The Under dash Fuse Box In The Under hood Relay Fuse Box Headlights Low High Front Turn Signal Lights Front Position Lights Side Turn Signal Lights Rear Turn Signal Lights Brake Taillights Side Marker Lights Back up Lights Rear Fog Light High Mount Brake Light License Plate Lights Gauge Lights Indicator Lights Warning Lights Interior Light Boot Light Door Courtesy Lights Vanity Mirror Lights Illumination and Pilot Lights 2 Except KY Heater Illumination Light Manual Front 3 European type and KU Out 1 0 mm In 2 0 mm Power assisted self adjusting ventilated disc Power assisted self adjusting solid disc with 58 0 cm 28 0 49 0 cm 12 V 1 4 W 1 1 12 V 0 91 W 0 56 W LED stabilizer Independent double wishbone coil spring with stabilizer Telescopic hydraulic nitrogen gas filled 0 00 0 15 0 20 095 3 45 3 30 parking brake drum 12 V 72 AH 20 HR 12 V 2 0 kW 12 V 110 7 5 A 10 A 15 20 30A 7 5 A 10 A 15 A 20 A 30 A 40 A 50 A 120 A 12 V 55 60 W 12 V 55 65 W 12 V 21 W
71. ER GASGENERATOR DARF NUR F R INSASSEN R CKHALTESYSTEME MIT GURSTRAFFEREINHELTEN IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAF R GESCHULTEM PERSONAL VORGENOMMEN WERDEN 1 14 O MONITOR NOTICE KF KG KX KE KO KT KU NOTICE NO SERVICEABLE PARTS INSIDE e REFER TO SERVICE SHOP MANUAL FOR DETAILED INSTRUCTIONS BEV KAW emmy RRR Z 7 Y REMARQUE AUCUNE PIECE REPARABLE A L INTERIEUR POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS LET UP e ONDERDELEN BINNEN DEZE UNIT WAARAAN WERKZAAMHEDEN KUNNEN WORDEN VERRICHT RAADPLEEG HET WERKPLAATSHANDBOEX VOOR NADERE AANWIJZINGEN ACHTUNG DIE INNENTILE BED RFEN KEINER WARTUNG e AUSF HRLICHE ANWEISUNGEN SIND DEM WERKSTATTHANDBUCH ZU ENTNEHMEN KS KY NOTICE NO SERVICEABLE PARTS INSIDE e REFER TO SERVICE SHOP MANUAL FOR DETAILED INSTRUCTIONS HAV e OLOT PEAVY e REY HER s lt OBERVERA e INGA REPARERBARA DELAR INVANDIGT e HANVISNING TILL SHOP MANUAL FOR DETAIJERADE ANVISNINGAR HUOM SISALL El OLE HUOLLETTAVISSA OLEVIA OSIA KATSO KORJAAMOK SIKIRJASTA OHJEET ab SL Jd Se sijal Special Tools Individual tool lists are located at the front of each section Specifications Standards and Service L
72. ERKPLAATSHANDBOEK KS KY WARNING eREFER TO THE SHOP MANUAL eSE VERKSTADSHANDBOKEN eKATSO TYOKASIKIRJAA ala iis gt 9 25 Slagle sli 25911 INFLATOR BAM LABEL KF KG KX only TRW Safety Systems manufactured inflator AIRBAG GAS GENERATOR 150028 TRW SAFETY SYSTEMS MESA HERSTELLUNGSJAHR 1989 EINF HRER HONDA DEUTSCHLAND GMBH OFFENBACH BAM PT 0358 DER GASGENERATOR DART NUR F R INSASSEN R CKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAF R GESCHULTEM PERSONAL VORGENOMMEN WERDEN CAUTION THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED FLAMMABLE WITH THE AIRBAG SYSTEM THE GAS SOLIDS US GENERATOR 1 TO BE INSTALLED AND DOT E 8236 OR DISASSEMBLED ONLY BY TRAINED PERSONNEL ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE CONTENT DE INSTALLE QUE SUR DES VEHICULES SOLIDES EQUIPES D UN SYSTEME AIRBAG LE FLAMMABLES MONTAGE ET LE DEMONTAGE DU US GENERATEUR DE GAZ NE PEUT ETRE DOT E B8236 EFFECTUE QUE PAR UN PERSONNEL QUALIFIE NIPPON KOKI manufactured inflator AIRBAG GAS GENERATOR NK8 NIPPON KOKI SHIRAKAWA JAPAN HERSTELLUNGSJAHR 1991 EINF HRER HONDA DEUTSCHLAND GMBH OFFENBACH BAM PT 0379 DER GASGENERATOR DART NUR F R INSASSEN R CKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAF R
73. GESCHULTEM PERSONAL VORGENOMMEN WERDEN CAUTION THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED FLAMMABLE WITH THE AIRBAG SYSTEM THE GAS GENERATOR IS TO BE INSTALLED AND OR DISASSEMBLED ONLY BY TRAINED PERSONNEL ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE CONTENT DE INSTALLE QUE SUR DES VEHICULES SOLIDES EQUIPES D UN SYSTEME AIRBAG LE FLAMMABLES MONTAGE ET LE DEMONTAGE DU GENERATEUR GAZ PEUT ETRE EFFECTUE QUE PAR UN PERSONNEL QUALIFIE Warning Caution Label Locations cont d HOOD WARNING LABEL KF KG KX KE KT KU WARNING THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE S R S WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY lt 5 VEHICULE EST EQUIPE D UN COUSSIN D AIR DU COTE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE S R S TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYSTEME DE RETENUE COMPLEMENTAIRE S R S SONT DE COULELUR JAUNE N UTILISEZ PAS UN EQUIPEMENT D ESSAIS ELECTRIQUES SUR CES CIRCUITS NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME S R S CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHEMENT ACCIDENTEL DU GONFLEU
74. ICALE e SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN cont d 1 13 Warning Caution Label Locations 1 PRETENSIONER ELR CAUTION LABEL WARNING EXPROSIVE MATERIAL INSIDE YOU CAN BE SERIOUSLY HURT OR BURNED e INSTALL RED SHORT CONNECTOR WHEN WIRE HARNESS 1 DISCONNECTED e DO NOT TAMPER OR DISASSEMBLE NO SERVICEABLE PARTS INSIDE e USE ONLY APPROVED ELECTRICAL TESTERS FOR CIRCUIT DIAGNOSIS REFER TO SERVICE SHOP MANUAL FOR COMPLETE INSTRUCTIONS A ATTENTION MATERIEL EXPROSIF A L INTERIEUR VOUS POUVEZ SUBIR DES BLESSURES OU DES BRULURES GRAVES LE CONNECTEUR ROUGE COURT EN PLACE QUAND LE FAISCEAU DE FILS EST DEBRANCHE e NE PAS MODIFIER OU DEMONTER NE COMPREND AUCUNE PLECE INTERNE A ENTRETENIR e N UTILISER QUE DES APPAREILS DE VERIFICATION APPROUVES POUR LE DIAGNOSTIC DU CIRCUIT CONSULTER LE MANUEL D ENTRETIEN POUR LES DIRECTIVES COMPLETES M PRETENSIONER POWER SOURCE CAUTION LABEL PUFvyvat Cav a7rBROR SEAT BELT DO NOT TAMPER REFER TO TENSIONER SERVICE SHOP MANUAL FOR COMPLETE INSTRUCTIONS ENROULEUR DE CEINTURE DE SECURITE NE PAS MODIFIER CONSULTER LE MANUEL D ENTRETIEN POUR LES DIRECTIVES COMPLETES N PRETENSIONER POWER SOURCE BAM LABEL Except KY P T PWR SOURCE BGO NIPPON KOKI SHIRAKAWA JAPAN HERSTELLUNGSJAHR 1991 EINFUHRER HONDA DEUTSCHLAND GMBH OFFENBACH BAM 0380 D
75. N WIRE FRP Te popa ps e View from terminal side GRN ORN WIRE RRP Repair open wire between the TCS control unit and ABS control unit GRN Right front GRN BRN Left front GRN ORN Right rear LT GRN Left rear LT GRN WIRE RLP NO 13 there approx 5 V YES Check for poor connec tions or loose wires Substitute a known good ABS control unit and recheck 19 52 fo Fail safe Relay TCS Control Valve Actuator Problem Code 5 1 Fail safe relay system and TCS control valve actuator system NOTE The TCS control unit closes the TCS control valve once after the engine is started to check that the TCS control valve actuator operates properly NOTE Remove the ABS B2 15A The standard wheel speeds initial offset memory in the control unit is fuse in the under hood fuse erased when the ABS B2 15 A fuse is disconnected relay box for more than 3 Be sure to input new standard wheel speeds into the control unit again seconds to reset the TCS after inspection see page 19 11 control unit UNDER HOOD FUSE RELAY BOX Start the engine and run it for more than 3 seconds Confirm the TCS code see page 19 14 z Intermittent failure Check for poor connections or loose wires Is code 5 1 indicated YES Turn the ignition switch OFF TCS 15A FUSE Check the TCS 15A fuse in the under hood fuse relay box FAIL SAFE R
76. OOO C8 TC FC Approx Repair open in the GRY BLU wire between the TCS control unit and ECU 19 36 e TC INH signal check Continued from page 19 33 if PGM FI system codes are indicated Measure the voltage between the TCS control unit 16P connector terminal 9B and body ground Is there more than 2 0 V NO Turn the ignition switch OFF Connect the test harness to the ECU see section 11 Start the engine Measure the voltage between the test harness C6 terminal and body ground To page 19 38 YES NOTE e Use the 10V range or a similar range in the analog tester Confirm that the analog tester needle swings to more than 2 0V TCS CONTROL UNIT 16 HARNESS SIDE View from terminal side GRY BLK WIRE TC INH More than 2 Check for poor con nections or loose wires Substitute a known good TCS control unit and recheck NOTE Use the 10V range or a similar range in the analog tester e Confirm that the analog tester needle swings to more than 2 0V ii JUUUUL TEST HARNESS View from terminal side C6 TC INH More than 2 cont d
77. R HARNESS SIDE Shift the transmission into and slowly increase the speed up to 30 mph km h Measure the voltage between the TCS control unit 26P connector terminal 5A and body ground Measure the voltage between the TCS control unit 26 connector terminal and body ground Is there no voltage YES Substitute a known good ECU and recheck NOTE Check with the engine warmed up Use the 10 V range or similar range in the analog tester e Confirm that the analog tester needle swings to approx 2 5 V ORN BLU WIRE TC SP Substitute a known good TCS control unit and recheck Substitute a known good ECU and recheck NO ls there approx 2 5 V Approx 2 5 V TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE _ an S sx 7 os wn pon wr pn rn son on oe oos ool View from terminal side Check for poor connec tions or loose wires Substitute a known goog TCS control unit and recheck m 2 A 19 62 From 19 62 Turn the ignition switch OFF Connect the test harness with the adaptor to the A T side of the ECU see section 14 Start the engine Shift the transmission into P N or 2 Measure the voltage between the test harness No A 11 terminal and body ground YES Is there approx 5 V
78. R OU RENDRE LE SYSTEME INOPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES WARNUNG DIESES FAHRZEUG IST MIT EINEM FAHRER AIRBAG SRS ALS ZUSATZLICHEM RUCKHALTESYSTEM AUSGERUSTET ALLE ELEKTRISCHEN KABEL SOWIE DIE ZUGEHORIGEN STECKVERBINDER DES S R S SYSTEMS SIND IN GELBER FARBE AUSGEFUHRT KEINE ELEKTRISCHEN PRUFGERATE AN DIE S R S VERKABELUNG ANSCHLIEBEN VERANDERN ODER UNTERBRECHEN DER S R S VERKABELUNG KANN UNKONTROLLIERTES Z NDEN DES GASGENERATORS AUSL SEN ODER DAS SYSTEM AUBER FUNKTION SETZEN WAS ZU ERNSTHAFTEN VERLETZUNGEN F HREN KANN WAARSCHUWING sns DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMING SRS ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITINGEN VAN DE S R S ZIJN GEEL GEKLEURD GEBRUIK GEEN ELEKTRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS OF LOSKOPPELEN VAN S R S LEIDINGEN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKELEN VAN HET SYSTEEM DIT KAN TOT ERNSTIGE ONGELUKKEN LEIDEN 1 8 KS WARNING sns THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL S R S ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCONNECTING THE 8 5 WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY VARNING 585 DETTA FORDON HAR
79. R WHT RED ACTUATOR PASSENGER S BLK BLK BLK BLK SWITCH European model BLK BLK 1 b LHD G401 G402 G403 LHD 6401 6402 6403 LHD 6401 6402 64043 LHD 6401 6402 6403 RHD 6402 6403 RHD 5402 6403 RHD 6402 6403 RHD 6402 6403 23 19 Keyless Entry System Except KU model Troubleshooting NOTE The numbers in the table show the troubleshooting sequence Item to be inspected Power door lock system doesn t operate at all Blown No 44 20 A fuse in the under hood fuse relay box Disconnected or obstructed door lock rod linkage Driver s door lock knob switch in the door lock actuator Doors don t lock or unlock with the driver s door lock switch Doors don t lock or unlock with the pas senger s door lock switch Doors don t lock or unlock with the driver s door lock knob Doors don t lock or unlock with the pas senger s door key cylinder Switch The door is not supposed to be locked but it is locked Remains locked after the ignition key is inserted and the door is opened The power door lock sys tem operates properly but the keyless entry system doesn t operate Trunk doesn t unlock with the keyless entry System European model RHD 23 20 Passenger s door key cylinder switch Passenger s door switch Ignition key switch Poor ground G401 G402 G403 G402 G403 Open
80. RA VEILIGHEID ONTWORPEN ALS EXTRA BESCHERMING NAAST DE VEILIGHEIDSGORDELS e ALS HE SRS WAARSCHUWINGSLAMPJE GAAT BRANDEN ONDER HET RIJDEN NEEM DAN KONTAKT OP MET EEN HONDA DEALER KE KQ KT srs ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S IS DESIGNED TO SUPPLEMENT THE SEAT BELT e YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER KU ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S T IS DESIGNED TO SUPPLEMENT THE SEAT BELT IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED ACURA DEALER KS KY ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM S R S e IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT e IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER SRS ANV ND ALLTID BILBALTET e FORDOM F RSETTMED EN LUFTKUDDE F RARS TET OCH EN LUFKUDDE F R PASSAGERAS TET FRAM SOM ETT KOMPLETTERANCE SKYDDSSYSTEM S R S e DET ATT KOMPLETTERA BILB LTET e SRS INDIKATORN T NDS UNDER K RNING SKALL DU KONTAKTA EN AUKTORISERAD HONDA ATERF RS LJARE K YT
81. RAGE REFER TO THE HONDA SERVICE SHOP MANUAL DISPOSE OF THE ENTIRE UNIT AS DIRECTED KU WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLY DEPLOYED CAN SERIOUSLY HURT OR KILL YOU NOT USE ELECTRICAL TEST EQUIPEMENT OR PROBING DEVICES THEY CAN CAUSE ACCIDENTAL DEPLOY MENT eNO SERVICEABLE PARTS INSIDE DO DISASSEMBLE PLACE AIRBAG UPRIGHT WHEN REMOVED FOLLOW SERVICE SHOP MANUAL INSTRUCTIONS CAREFULLY ATTENTION LE GONFLEUR DE COUSSIN D AIR EST EXPLOSIBLE S LL SE DEPLOIE ACCIDENTELLEMENT IL RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE TUER NE PAS UTILISER DE MATERIEL D ESSAI ELECTRIQUE NI DE SONDE ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSSIN D AIR iL N Y A PAS DE PIECES REPARABLES A L INTERIEUR NE PAS DEMONTER e QUAND RETIRE LE COUSSIN D AIR LE TENIR A LA VERTICALE e SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D ENTRETIEN KF KG KX WARNING eREFER TO THE SHOP MANUAL eSE REPORTER AU MANUEL D ATELIER eWERKSTATTHANDBUCH LESEN eLEES HET WERKPLAATSHANDBOEK KS KY WARNING eREFER TO THE SHOP MANUAL eSE VERKSTADSHANDBOKEN eKATSO TYOKASIKIRJAA 3 Jala ais Ax gt Glaglall e D STEERING WHEEL WARNING KG KX KE KT KU WARNING eREFER TO THE SHOP MANUAL e SE REPORTER AU MANUEL D ATELIER eWERKSTATTHANDBUCH LESEN eLEES HET W
82. S contro unit and throttle position sensor Codes are indicated by the Check Engine Light and the Da indicator light if there is a short 19 45 Troubleshooting TCS TCS Control Valve Angle 0 TH2 Sensor Problem Code 3 7 TCS control valve angle 8 TH2 sensor NOTE Remove the ABS B2 15A The standard wheel speeds initial offset memory is erased when the ABS B fuse in the under hood fuse 2 15A fuse is disconnected relay box for more than 3 Be sure to input new standard wheel speeds again after inspection see page seconds to reset the TCS 19 11 control unit Start the engine Confirm the TCS code see page 19 14 NO Intermittent failure Is code 3 7 indicated Check for poor connections or loose wires YES Approx 5V Turn the ignition switch OFF ES 2149 Disconnect the connector from the TCS control valve angle sensor View from terminal side V Turn the ignition switch ON YEL WHT WIRE gt GRN WHT WIRE TCS CONTROL VALVE Measure the voltage between TCS CONTROL VALVE the No 1 and No 3 HARNESS SIDE ANGLE SENSOR terminals i 3P CONNECTOR HARNESS SIDE YEL WHT WIRE NO Measure the voltage between Is there approx 5V the No 3 terminal and body ground YES Turn the ignition switch OFF Approx 5V Connect the 3P connector to View from terminal side the TCS contr
83. S control valve actuator and the 26P CIENCIA CNA rs pena dn ron ma za oon ps os connector from the TCS View from terminal side control unit BLU BLK WIRE M 1 1 Check for continuity between Continuity the 26P connector terminals ontinuity and body ground No 25 BLU BLK No 26 BLU YEL i YES Repair short in the BLU BLK wire and or BLU YEL wire between the TCS control unit NO and actuator Connect the side 2 TCS CONTROL UNIT connector No and No 2 2P CONNECTOR 26P CONNECTOR terminals with a jumper wire HARNESS SIDE HARNESS SIDE View from terminal side Check for continuity between BLU YEL WIRE the 26P connector terminals 2 26 Ca zn us o 7 s os Tg wal un enn za 294 View from terminal side NO Repair open in the BLU BLK between the TCS control unit YES and actuator JUMPER WIRE BLU BLK WIRE M Continuity Measure the resistance TCS CONTROL VALVE ACTUATOR between the No 1 and No 2 2P CONNECTOR terminals of the TCS control HARNESS SIDE valve actuator 2P connector View from terminal side Check for poor connec YES tions or loose wires Is the resistance less than 2 50 Substitute a known good TCS control unit and NO recheck To page 19 58 Less than 2 50 cont d 19 57 From page 19 57 Connect the battery termi
84. SEAT BELT REMINDER LIGHT 1 4 W KY model LEFT TURN SIGNAL INDICATOR LIGHT 1 4 W RIGHT TURN SIGNAL INDICATOR LIGHT 1 4 W BRAKE SYSTEM LIGHT 1 4 W CHARGE SYSTEM LIGHT 1 4 W SRS INDICATOR LIGHT 1 4 W CHECK ENGINE LIGHT 1 4 W CRUISE LIGHT 1 4 W ANTI LOCK BRAKE SYSTEM ABS INDICATOR TIRE PRESSURE LIGHT 1 4 W WATCHING SYSTEM WASHER FLUID LEVEL LIGHT 1 4 W European model LOW FUEL INDICATOR LIGHT 1 4 W GAUGE LIGHTS 3 0 W x 3 GAUGE LIGHT 3 0 W TCS ACTIVATION TCS INDICATOR LIGHT 1 12 W LIGHT 1 12 W 23 6 Shift Lever Position Indicator Circuit Diagram UNDER DASH IGNITION UNDER HOOD FUSE RELAY BOX SWITCH FUSE BOX BATTERY No 13 7 5A LHD No 31 120A No 35 50A No 17 7 5A RHD O O O O WHT O BLK YEL No 49 15A FUSE ECU YEL RED BLK YEL RED A1 A4 A16 Ab BLK RED TCS CONTROL UNIT LHD of except KY model LT GRN In the gauge assembly 1 O O O Q I 6 amp LI i 1 1294 a w 0 12w wa 12w l 0 12w l 1 120 A10 eee INTERLOCK A18 17 14 A13 A12 A11 CONTROL UNIT model GRN WHT GRN GRN BLU GRN ORN GRN RED GRN YEL GRN WHT GRN RED GRN BLK GRN BLU GRN YEL GRN ORN No 49 15A FUSE RED BLK GRN RED GRN WHT SHIFT POSITION SED gl CONSOLE SWITCH DASHLIGHT 6402 0403 Without security system BRIGHTNESS G601 With
85. SQUER D ENDOMMAGER LE CABLE OU L ENROULEUR DU S R S DE RENDRE AINST LE SYSTEME INOPERANT RETIREZ LE VOLANT AVANT DE DEVINSSER LE BOULON D ACCOUPLEMENT D ARBRE DE DIRECTION ACHTUNG sns UM BESCHADIGUNGEN DER S R S KABELROLLE ODER DES KABELS WELCHE DAS S R S SYSTEM AUBER FUNKTION SETZEN W RDEN ZU VERMEIREN VOR ARBEITEN AN DER LENKSPINDEL DAS LENKRAD AUSBAUEN WAARSCHUWING sRs TE VOORKOMEN DAT DE S R S KABEL OF HASPEL BESCHADIGD WORDEN HETGEEN ERTOE ZOU LEIDEN DAT HET SYSTEEM UITVALT DIENT U HET STUUR TE VERWIJDEREN VOORDAT U DE STUURSCHACHT CONNECTORBOUT VERWIJDERT CAUTION TO AVOID DAMAGING THE S R S CABLE OR REEL WHICH COULD MAKE THE SYSTEM INOPERATIVE REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT 58 POUR NE PAS RISQUER D ENDOMMAGER LE CABLE OU L ENROULEUR DU S R S ET DE RENDRE AINST LE SYSTEME INOPERANT RETIREZ LE VOLANT AVANT DE DEVISSER LE BOULON D ACCOUPLEMENT D ARBRE DE DIRECTION KS OBSERVERA 585 F R ATT UNDVIKA SKADOOR PA SRS SYSTEMETS KABEL ELLER TRUMMA NAGOT SOM KAN G RA ATT SYSTEMET INTE FUNGERAR SKALL RATTEN TAS BORT INNAN RATTAXELNS BULT TAS BORT VAROITIUS 585 SRS KAAPELIN JA RULLAN VAHINGOITTUMISEN EST MISEKSI JOTTS J RJESTELM El MENISI K YTT KELVOTTOMAKSI IRROTETAAN OHJAUSPY R ENNE KUIN IRROTETAAN OHJAUSVARREN LIITTIMEN PULTTI CAUTION sRs TO AVOID DAMAGING THE S R S C
86. SUPPLEMENTAL RESTRAINT SYSTEM SRS The Legend Coupe Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located i in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in the 93 Legend Coupe Shop Manual Supplement 62SP121 Items marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits Firat Edition 11 93 INTRODUCTION How to Use This Manual This supplement contains informat
87. Tire pressure Watching System added KG KS KX KF Changed Dashboard Doors Exterior molding Panels Frame repair chart Interior trim Mirrors Quater glass Front seat belt and Rear seat Trunk spoiler added Front seats modified Rear seat access switch Front passenger s seat added Changed Rear emblems and Sunroof construction Changed Rear emblems and Sunroof construction lol 20 System for refrigerant HFC 134a R 134a changed fof Suction pipe of air conditioning system changed LHD model Automatic Transmission Body Air Conditioning MODELS DESCRIPTION REFERENCE Electrical Changed Power supply circuit Rear side marker lights Taillights KY Locks Keyless Power door locks and Stereo sound system Added Power door closer Seat belt presenters Power and Seat belt pretensioner SRS Rear ashtray illumination deleted Power supply circuit changed Added Interlock system Key in reminder system KY Rear seat access switch Front pas senger s seat and Spark plugs for models without catalytic converter Em Brake light failure sensors Safety indicator failure sensor and Shift lever position indicator circuit Added TCS light TWS light KG KF KS KX and Keyless entry system trunk receiver Except KU KM Supplemental SRS unit changed Restraint Troubleshooting procedure modified System SRS F
88. U DES COMPOSES EXPLOSIFS LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 200 F 100 C POUR LES PROCEDURES DE MANIPULATION DE RANGEMENT ET DE MISE AU REBUT VOIR LE SUPPLEMENT SRS DU MANUEL D ENTRETIEN POISON RENFERME DE L ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES PREMIERS SECOURS 1 LE CONTENU EST ABSORBE INDUIRE UN VOMISSEMENT EN CAS DE CONTACT AVEC LES YEUX LAVER A GRANDE EAU PENDANT UN QUART D HEURE EN CAS D INHALATION DES GAZ PAR CONTACT AVEC L ACIDE OU L EAU ALLER A L AIR FRAIS DANS TOUS LES CAS OBTENIR PROMPTEMENT DES SOINS MEDICAUX TENIR HORS DE PORTEE DES ENFANTS KS KY e DANGER EXPLOSIVE FLAMMABLE POISON REFER TO THE SHOP MANUAL FARLIGT EXPLOIVT LATTANTANDLIGT GIFTIGT SE VERKSTADSHANDBOKEN VAARA HELPOSTI RAJAHTAVA SYTTYVA MYRKKY GIFT KATSO TYOKASIKIRJAA 8 a gt sa e AL 5 aie dale Aslan dle 9l 3 Jats iS Ax g gt 5 Lagi adl ys wh C DRIVER MODULE WARNING KE KO KT WARNING sns TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY ALWAYS INSTALL THE PROTECTIVE SHORT CONNECTOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS IS DISCONNECTED UNDER NO CIRCUMSTANCES SHOULD DIAGNOSIS BE PERFORMED USING ELECTRICAL TEST EQUIPEMENT OR PROBING DEVICES NO SERVICEABLE PARTS INSIDE DO NOT DISASSEMBLE OR TAMPER STORE THE REMOVED AIRBAG ASSEMBLY WITH THE PAD SURFACE UP FOR SPECIAL HANDLING OR STO
89. U GRY BLK GRY YEL ORN RED BLU BLU ORN BLU i 1 1 1 I l BRN BLK PGM FIECU BRN BLK TCS CONTROL VALVE ACTUATOR DC MOTOR G404 6101 19 12 LIGHTING SWITCH GEAR POSITION BLK YEL RED BLK GAUGE ASSEMBLY INDICATOR A T only DIMMING CIRCUIT TCS SWITCH ACTIVATION INDICATOR LIGHT INDICATOR LIGHT BLU RED GRN ILLUMINATION LIGHT E INDICATOR LIGHT GEAR 9 SENSOR POSITION DASH LIGHT SWITCH Y y BRIGHTNESS AT only CONTROL UNIT BLK BLU RED BLU RED RED GRN BLUAVHT BRN RED GRY RED LTGRN RED WHT BLK RED BLU G601 Q 23A 7B 10 138 168 2 TC TC TC BUSY TIRE TCSW TCSW NP SW GSEN GSEN GSEN WARN2 WARN1 LAMP AIR LAMP GND IN 65 RRP FLP STRA STRB STRGND 4A 28 4B 68 88 11 158 16 2 2 WHT LT GRN GRN ORN GRN BRN GRN WHT GRY ITGRN BLK BLKYEL mE WHT e WHT STEERING ANGLE SENSOR SERVICE CHECK CONNECTOR BLK G403 WHEEL SENSORS 26P CONNECTOR 16P CONNECTOR sa 2A 1a TCS CONTROL UNIT CONNECTORS View from terminal side 19 13 Troubleshooting TCS TCS Indicator Light NOTE After the engine is started the TCS indicator light goes off and TCS switch indicator light comes on to indicate that the system is ready If there i
90. UNIT 99 0 A C CLUTCH RELAY T AIC PRESSURE SWITCH A 11 2 IGNITER UNIT IGNITION A B D19 VCC1 IG No 1 A21 1 E o 0 O OD20 VCC2 2 dene _ IG No4 B6 9 0 5 SENS 5 OD17PB IG No 5 0 0 OOS 00 O sensor sow THROTTLE 22221 IG No 6 0 0 oe if O 00 O R ij AME 5 4 2 TACHOMETER SENSOR IGNITION ADJUSTER s With TCS model gt can 18 mm ILL NUES mereces I 141 jievect 1 21 IG No 3 B8 SENSOR Without C TCINH 7 v CONTROL ithout CATA qu model y TCSTB C129 VREF D 18 O Le E E P S OIL PRESSURE SWITCH O EGR CONTROL BRAKE SWITCH SOLENOID VALVE TA SENSOR Q ASA ALTERNATOR UM Q PURGE CONTROL SOLENOID VALVE o 00 O BYPASS LOW CONTROL p QD9ACGF BPS1A14 Q SOLENOID VALVE Q BYPASS HIGH CONTROL sagaro Lu 11 pom asnaq 08 FUEL PRESSURE REGULATOR With CATA CONTROL SOLENOID VALVE 7 Pesang ae 2016 RVS 417 0 RIGHT HEATED 4 AIR SUCTION CONTROL O SENSOR SOLENOID VALVE With wA d in T 1 Except KO model 2 Except KT model 3 Except KY KT model AT AD AS A8 AY413315 4112 414 421423 25 1 81 B
91. UNIT BATTERY TRANSMITTER GANIRED 2 GRN WHT WHT BLU GRN BLK GRN BLK WHT BLU GRN YEL WHT GRN WHT GRN A A A A A TRUNK KEYLESS ENTRY CONTROL UNIT stock SWITCH O O O O O O WHT RED 2 TRUNK OPENER SWITCH WHT BLK WHT BLK GRN RED GRN WHT BLK WHT BLU WHT 2 WHT RED YEL RED CONTROL UNIT 1 GRN RED BLK RED CONTROL UN CONTROL UNIT KY model WHT BLK GRN RED GRN RED BLU WHT 2 OPENER KEY IGNITION SOLENOID SATIS LOCK S LOCK LOCK G LOCK KEY SWITCH DRIVER S DOOR DRIVER S DOOR PASSENGER S KEY CYLINDER LOCK SWITCH DOOR LOCK SWITCH SWITCH KE model BLK BLK BLK BLK BLK 6551 6551 LHD 6401 6402 6403 LHD 6401 6402 6403 1 6401 6402 6403 1 401 6402 6403 RHD 6402 6403 RHD 6402 6403 RHD 6402 6403 RHD 6402 6403 23 18 UNDER DASH FUSE BOX YEL BLK IGNITION RHD KEY GRN BLK 2 GRN RED 2 IGRN BLU INTEGRATED n BLU WHT CONTROL UNIT GRNAWHT GRN RED4 GRN BLU 2 POWER DOOR CLOSE CONTROL ae ee GRN BLK SECURITY GRN RED 2 CONTROL GRN BLU UNIT GRN RED With GRN RED 4 system GRN BLU RN BLU GRN RED GRN RED GRN RED 2 IGRN BLU3 GRN WHT4 pm GRN BLU 5 GRN BLU DOOR GRN RED IGRN RED4 LOCK YEL RED BLU RED KNOB GRN WHT YEL RED DOOR KEY GRN BLU GRN RED DRIVER S PASSENGER S DOOR LOCK DOOR LOCK WHT RED ACTUATO
92. W TEMPERATURE th ow European model GE C10 C8 018 D3 016 08 07 1 RED BLU WHT BLU BLU RED RED GRN BLU RED GRN BLK YEL GRN I 1 BLU RED I BLU RED BLU RED BLU RED 1 1 l DIMMER VOLTAGE T i RELAY REGULATOR CONTROL WASHER FLUID COOLANT UNIT i LOCK LEVEL SWITCH TEMPERATURE European model SENDING UNIT KG KX KF and KS models I SYSTEM 5 E RHD LHD G301 RHD G201 23 2 TO NEXT PAGE 49 15 ECU FUSE pulse RED BLK BLU YEL 022 9 5 22 ie PAGE FAILURE TACHOMETER SPEEDOMETER LOW FUEL DEC GAUGE DRIVE CIRCUIT DRIVE CIRCUIT 3 0Wx2 HI 1 4W 1 0 91W TACHOMETER SPEEDO RET Z A Ti mr CR ECU CRUISE CONTROL UNIT AUTOMATIC CLIMATE CONTROL UNIT BLK RED BLK YEL POWER SEAT CONTROL UNIT YEL WHT GRN RED SPEED ALARM UNIT KY model YEL RED a FUEL LOW YEL RED aie FUEL UNIT SENSOR Q C DASHLIGHT BRIGHTNESS SPEED SENSOR BLK BLK CONTROL UNIT FUEL GAUGE UNIT GRN WHT BLK ECU 7 ground gt LHD G401 6402 6403 LHD G406 RHD 6402 6403 RHD 6405 6406 cont d 23 3 Gauge Assembly Circuit Diagram cont d FROM PREVIOUS PAGE No 14 7 5A FUSE ST signal No 49 15A 60 FUSE KY models RED BLK BLK WHT YEL F o gt
93. age BREATHER PIPE GASKETS Replace Fuel and Emissions System Description Electrical Connections 11 2 Troubleshooting Self diagnostic Procedures 11 4 Outline of Model Changes The TCS control system has been added e The Electronic Control Unit ECU has been modified and changed following Electrical Connections Self diagnostic Procedures System Description Electrical Connections PGM FI MAIN RELAY IGNITION SWITCH FUEL PUMP im IGP1 DT FLR1A7 O i o i A T GEAR POSITION CONSOLE SWITCH A T FUSES No 15 7 5 A LHD UP 7 5 RHD STOP amp HORN 20 MAIN FUSE BATTERY 120 MAIN FUSE IG SW 50 MAIN FUSE FUSE BOX 50 BNo 5 20 A No 25 IG COIL 30 A 8No 22 FUEL PUMP 20 A No 13 BACK UP LT 7 5 A 9No 3 RR DEF 15 A No 14 EFI STS 7 5A In the under hood fuse relay box B11 CYL B12 CYL 1M B13 CRNK 2P B14 CRNK 2M B15 1P O B16 CRNK 1M B9 CYL 2P 9 B10 CYL 2M m gt lt I O SPEED SENSOR s O io o 79 i To GEAR POSITION 4 7 NP SW A T oe CLUTCH 7N SW WIT SWITCH M T c7 MrTCLS SERVICE NEUTRAL 5 SWITCH CONNECTOR COOLING AUTOA C FAN CONTROL CONTROL UNIT
94. alve and the ECU to cut the fuel and retard the ignition timing 19 5 System Description TCS Construction and Function TCS Control Unit Acceleration Control The TCS control unit gets signals from the wheel sensors about the rotational speed of each wheel Traction control is activated when the rotational speed of the driving wheels differs from the rotational speed of the driven wheels i e vehicle speed Handling Control Based on signals about the left and right driven wheel rotational speeds the control unit calculates the car s yaw rate the turn rate of the car s body Based on signals from the steering angle sensor and driven wheel sensors the control unit also calculates the yaw rate expected by the driver If the difference between actual and expected yaw rates is substantial that is if the direction of the car s body will exceed the driver s expected line the control unit signals the TCS control valve actuator and ECU thus reducing engine power and maintaining the expected line Rough Road Control Based on signals from the wheel sensors the control unit detects a rough road based on frequency of wheel rotational vibration The control unit then signals the TCS control valve actuator and ECU to relax engine power thus improving acceleration efficiency Grip Control Based on signals about wheel speed and from lateral acceleration Lg sensor the control unit determines the efficiency of the
95. alytic converter 2 For cars without catalytic converter Ambient temperature ranges 4 2 4 3 Maintenance Schedule R Replace I lnspect After inspection clean adjust fill up repair or replace if necessary ova o ve koe va a so ee eo vro Deme npn m s a o se ef For European models Replace every 10 000 km 6 000 miles or 12 months Service at the interval listed x 1 000 km or miles or after that number of months whichever comes first e Engine oil and oil filter For other than European models Replace every 10 000 km 6 000 miles or 6 months Foreuropeanmodes R R n For other than European models r r R rR For European modes R R r For other than European models R R R R R Belt tension and conditions Alternator Power steering A C compressor e Transmission oil Front differential oil Water pump Cooling system hoses and connections E e Engine coolant R m Spark plugs For cars with catalytic converter cars without catalytic converter timing For other than European modes if pof rj 1 1 Air cleaner element Forcarswitheatahticconverter a R R R n n Tank fuel lines and connectio
96. and TCS switch Shift the transmission into 2nd or 2 A T Press the accelerator pedal about 1 3 down Make sure that the traction contro does not operate and the TCS activation light and TCS indicator light do not flash NO Is it normal Replace the TCS control unit YES NOTE Depress the brake pedal and Stop the front wheels slowly to prevent damage to the suspension stop the front wheels Shift the transmission into neutral N A T Perform the steering angle sensor system check see page 19 26 NO YES Test drive and return the car to the customer 19 67 Troubleshooting TWS TWS Indicator Light Blinks The TWS indicator light blinks during driving NOTE The TWS blinks the TWS indicator light when it detects the abnormal tire air pressure during driving The TWS indicator light goes off when the ignition switch is turned OFF and it blinks when the system detects the abnormality again Check the four tire air pressures NOTE The TWS may blinks indicator light during driving under the following conditions e when one or more different tires are installed e when the tire chains are installed when there are the significant differences in speed between the wheels such as being towed with a trailer NO Are tire air pressure normal Adjust the tire air pressure s YES NOTE Check the tire for wear Reset the standard wheel speeds see pa
97. apa aaa aane heahzaheajioajzoa 122A View from terminal side Replace the parking brake switch Parking brake switch stuck OFF 19 69 Troubleshooting TWS TWS Indicator Light Do Not Come On TWS indicator light do not come on for two seconds when the ignition switch is first turned on no bulb check NOTE The TWS indicator light stays on until the engine is started Turn the ignition switch ON Do the other indicator lights NO ABS Check Engine Light SRS etc come on Turn the ignition switch OFF Check the No 13 7 5 A fuse YES in the under dash fuse relay box NO Is it normal Repair open in the YEL wire between the under dash fuse relay box and gauge assembly Turn the ignition switch OFF TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Disconnect the 26P connector from the TCS control unit Turn the ignition switch ON Ground the 26P connector terminal 7A to the body ground and check the light Replace the defective bulb Repair open in the BLU WHT wire between the gauge assembly and TCS contro unit Do the light come on To page 19 71 3A 4 16 No 13 7 5A FUSE Te eT jii b 18 MINI mi TIU 4 a D Ni ua Es UNDER DASH FUSE RELAY BOX Replace the fuse and recheck BLU WHT WIRE za 6n 9s ox oA on
98. circuit in wires loose or disconnected terminals WHT GRN G401 G402 G403 G402 64031 GRN RED or GRN WHT G401 G402 G403 16402 64031 BLK RED or BLK WHT G401 G402 G403 G402 G403 G401 G402 G403 G402 G403 G401 G402 G403 G402 G403 G401 G402 G403 G402 G403 G401 G402 G403 6402 64031 BLU WHT or GRN BLK GRN BLU or GRN WHT BLU WHT WHT BLU GRN WHT GRN BLK GRN YEL GRN BLK WHT BLU Control Unit Input Test CAUTION All SRS wiring harnesses are covered with yellow out er insulation Before disconnecting any part of the SRS wire har ness install the short connectors Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring Remove the dashboard lower panel then disconnect the 14 P and 10 connector from the control unit Inspect the connector and socket terminals to be sure they are all making good contact f the terminals are bent loose or corroded repair them as necessary and recheck the system e f the terminals look OK make the following input tests at the connector f any test indicates a problem find and correct the cause then recheck the system the input tests prove OK the control unit must be faulty replace it NOTE Several different wires have the same color They have been given a number suffix to distingu
99. cording the main and sub code if applicable refer to the Troubleshooting Guide 19 15 Troubleshooting TCS Troubleshooting Guide Related Components 1 Josues JoJ3u09 621 Josuas 64 193 Id INDd 123 LV I3 INDd System indicated 1 9J8S Ie J 81M yun j043u02 621 VGL SOL esnj VGL cH SAV 9 VOZ CC ON uu 1s s 043u09 210 y yms Burjeg Josues aj6ue 13304 L Josues aj6ue Bur1991S 043409 SIL 103 043409 5 The TCS indicator light TCS activation light and TCS switch indicator light do not come on when the ignition switch is turned ON The TCS switch indicator light and the TCS activation light do not go off two seconds 19 20 after the ignition switch is turned ON FEET The TCS indicator light does not go off after 19 21 Eee Weds SERS the engine starts _ 1 2 TCScontroluit 7 19 24 2 Parking brake 19 25 1 um 2 1 Steering angle sensor 1 1926 23 gsensr A 19 301 pz 2 3 2 speed __ 19 39 _ ee p T IOO n TELLUS signal 3 6 Abnormal throttle ange 0 1 sensor signall 19 45 Tol T Toro ET en BR NN EN
100. cted Measure the voltage between Be sure to input new standard the 26P connector terminal 1A wheel speeds into the control and body ground unit again after inspection see WHT WIRE VB page 19 11 8A toa 124 134 9A 20 22A 23A 24A 26A 26A View from terminal side Battery voltage ne repel open TCS CONTROLUNIT TCS CONTROL UNIT Is there battery voltage ue ush ne 26P CONNECTOR 16P CONNECTOR HARNESS SIDE HARNESS SIDE box Measure the voltage between the 16P connector terminal 10 B and body ground Repair open in the BLK YEL wire between the TCS control unit and under dash fuse relay box ls there battery voltage To page 19 19 Battery voltage BLK YEL WIRE IG1 19 18 From page 19 18 Turn the ignition switch OFF Check for continuity between the 16P connector terminal 58 and body ground and between the 26P connector terminal 20 A and body ground Continuity BRN BLK WIRE LGE1 lt s 9220130 eral en View from terminal side TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE ERES 1 2a 3A 4A ea f 9A SA 108 2A 13A saj ATA 9A 22A 298 24AJ25A View from terminal side Continuity BRN BLK WIRE LGE2 Repair open in the BRN NO BLK wire
101. d TCS control unit and recheck Repair short in wire between the TCS control unit and ABS control unit GRN Right front GRN BRN Left front GRN ORN Right rear LT GRN Left rear GRN WIRE FRP Approx 5 V GRN BRN WIRE FLP Measure the voltage between the ABS control unit 14P connector terminals and body ground No 5 Left front No 6 Right front No 13 Right rear No 14 Left rear YES Is there approx 5 V Repair open in wire between the TCS control unit and ABS control unit GRN Right front GRN BRN Left front GRN ORN Right rear LT GRN Left rear ABS CONTROL UNIT 14P CONNECTOR HARNESS SIDE View from terminal side 2 3 10 91 12113 GRN ORN WIRE LT GRN WIRE Check for poor tions or loose wires e Substitute known good ABS control unit and recheck 19 50 f All Wheel Sensors Problem Code 4 9 A l wheel sensors NOTE The TCS indicator light comes on if all wheel speed signals from the ABS control unit stop for more than five seconds while the engine is running NOTE Remove the ABS B2 15A The standard wheel speeds initial offset memory in the control unit is fuse in the under hood fuse erased when the ABS B2 15 A fuse is disconnected relay box for more than 3 Be sure to
102. d body ground NO Is there V TCS in operation YES Check for poor con nections or loose wires Substitute known good TCS control unit and recheck Check for poor con nections or loose wires Substitute known good ECU and recheck 19 34 Turn the ignition switch Measure the voltage between the TCS control unit 16P connector termonal 14B and body ground Is there more than 4 0V NO Turn the ignition switch OFF Disconnect the 16P connector from the TCS control unit Check for continuity between the 16P connector terminal 14B and body ground NO eCheck for poor con nections or loose wires Substitute a known good TCS control unit and recheck TC FC signal check Turn the ignition switch ON Measure the voltage between the TCS control unit 26P connector terminal 19A and body ground To page 19 36 Repair short in the GRY YEL wire between the TCS control unit and ECU YES c TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE From page 19 33 View from terminal side GRY YEL WIRE TC STB Replace the ECU and recheck More than 4 0 TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side Continuity 1 0 NOTE Use the 10V range or a similar range in the analog tester e Confirm that the analog tester needle swi
103. d ends gear box and boots fete che Power steering function hoses and connections Pa Nish al ae Wloka a All fluid levels Inspect every 10 000 km 6 000 miles or 12 months Sr cond EAEE Inspect every 10 000 km 6 000 miles or 12 months Tires condition wear and pressure Including spare Lights operation and headlight beam Inspect every 10 000 km 6 000 miles or 12 months ir eas tod won Test drive Noise stability dashboard operations Cleanliness of controls door handles etc Inspect after every service Supplemental Restraint System Inspect system 10 years after first registration cont d Maintenance Schedule cont d Severe Driving Conditions The following items must be serviced more frequently on cars normally used under severe driving conditions Refer to the chart below for the appropriate maintenance intervals Severe driving conditions include Repeated short distance driving Driving in dusty conditions Driving in severe cold weather Driving in areas using road salt or other corrosive materials Driving on rough and or muddy roads Towing a trailer l Inspect After inspection clean adjust fill up repair or replace if necessary pra _ 100 ms re Ro Bem 20000 2000 ior mah Air cleaner For cars with catalytic 0
104. de Check that the TCS activation light green flash at the same time To page 19 66 cont d 19 65 Troubleshooting TCS TCS Function Test cont d From page 19 65 NO Do the lights flash Replace the TCS control unit and recheck YES Depress the brake pedal and NOTE stop the front wheels Stop the front wheels slowly to prevent damage to the suspension TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE Push the TCS switch one time Check that the TCS indicator light comes on and TCS switch indicator light goes off NO Do the lights operate properly Turn the ignition switch OFF Disconnect the 16P connector from the TCS control unit Turn the ignition switch Measure the voltage between the TCS control unit 16P View from terminal side BRN RED WIRE TC SW YES connector terminal 13B and body ground with the TCS switch released NO 15 there V Replace the TCS switch and recheck YES Measure the voltage between the TCS control unit 16P connector terminal 13B and body ground with the TCS switch pushed YES 15 there battery voltage Replace the TCS control unit and recheck NO To page 19 67 To page 19 67 19 66 From 19 66 From page 19 66 Check the TCS switch see page 19 74 15 it normal Replace the TCS switch Repair open in the BRN RED BRN wire between the TCS control unit
105. e is detected by the steering angle sensor located on the steering column The sensor uses two magnetoresistor elements to determine steering angle and direction of rotation When the driver turns the steering wheel a magnet in the steering shaft generates waves in the MR elements These waves are amplified and converted into signals which the control unit can interpret as angle and direction of turn lt MR ELEMENT a CER GND Vehicle Speed Detection Wheel rotation speed is detected by the wheel sensors located at each wheel The signals are sent to the control unit which compares each wheel s speed and determines whether traction control is required WHEEL SENSOR 19 7 System Description TCS Construction and Function Lateral Acceleration Detection Lateral acceleration is detected by the lateral acceleration BRACKET Lg SENSOR Lg sensor located behind the rear seat back The Lg sensor varies the output voltage in accordance with the left or right side acceleration and sends it to the TCS control unit as a lateral acceleration signal 90 degrees RIGHT SIDE ACCELERATION OUTPUT CHARACTERISTIC lt LATERAL ACCELERATION LEFT SIDE RIGHT SIDE JDVLIOA LNd LNO 19 8 Engine Output Control When the TCS is activated the TCS control unit signals the TCS control valve actuator and ECU The actuator is linked to the TCS control valve which
106. e shift fork Finger thichness Finger to reverse synchro sleeve clearance Groove width 13 20 13 30 0 520 0 524 Fork to reverse shift holder clearance 0 20 0 50 0 008 0 020 0 8 0 03 Shift fork shaft Fork to shift piece clearance 0 25 0 55 0 010 0 022 0 85 0 033 Groove width of the shift piece contact point 12 20 12 40 0 480 0 488 Shift arm Diameter at the contact point with the 7 90 8 00 0 311 0 315 change piece Arm to change piece clearance Diameter at the contact point with the shift piece Arm to shift piece clearance 0 10 0 30 0 004 0 012 0 55 0 022 Groove width of the shift arm contact point 8 10 8 20 0 319 0 323 Shift piece Diameter at the contact point with the 11 85 11 95 0 467 0 470 shift fork shaft Reverse shift Diameter at the contact point with the 12 80 13 00 0 504 0 512 holder reverse shift fork Diameter at the contact point with the 12 80 13 00 0 504 0 512 5th reverse shift fork shaft Holder to 5th reverse shift fork clearance 0 20 0 60 0 008 0 024 0 8 0 03 Holder to reverse shift fork clearance 0 20 0 50 0 008 0 020 0 8 0 03 0 10 0 30 0 004 0 01 2 7 90 8 00 0 311 0 315 0 55 0 022 Secondary gear Backlash 0 061 0 121 0 0024 0 0048 Preload starting torque Nem kg m lb ft 1 4 2 6 0 14 0 26 1 0 1 9 Diameter of bearing contact are Clu
107. e turn 4 seconds NOTE e Restart the check from the beginning if the steering wheel is turned counterclockwise e Turn the steering wheel slowly no faster than one turn in 4 seconds The tire pressures are incorrect or the wrong diameter tires are installed The steering angle sensor is OK Does the light flash properly 1 time M T 4 times TCS INDICATOR LIGHT FLASH PATTERN ON 1 2 3 4 OFF Begin to flash Turn the ignition switch OFF Remove the steering column lower cover page 19 27 STEERING ANGLE SENSOR 5P CONNECTOR 19 26 From 19 26 Turn the ignition switch Measure the voltage between the No 1 4 and No 5l terminals of the steering angle sensor Is there battery voltage YES To page 19 28 NO STEERING ANGLE SENSOR CONNECTOR HARNESS SIDE BLK YEL WIRE 161 Battery voltage Turn the ignition switch OFF Disconnect the 5P connector from the steering angle sensor Check for continuity between the No 5 terminal and body ground NO YES Turn the ignition switch ON View from terminal side View from terminal side LT GRN BLK WIRE STR GND STEERING ANGLE SENSOR 5P CONNECTOR HARNESS SIDE Continuity LT GRN BLK WIRE STR GND Repair open in the LT GRN BLK wire between the steering angle sensor and TCS control unit NGLE SENSOR 5P
108. eajrrA nea 20A 22A zu 24A 26A 26A GRY BLK WIRE TC INH View from terminal side View from terminal side BRN BLK WIRE LGE 2 00 00 Measure the resistance between the TCS control unit 16P connector terminal 9B and 26P connector terminal 20A or 16P connector terminal 5B YES Is there OQ Replace the TCS control unit and recheck NO Check for poor connection NOTE or loose wire The normal resistance is approx e Substitute known good 20 kQ for reference ECU and recheck 19 23 Troubleshooting TCS TCS Control Unit Problem Code 1 2 or the TCS indicator light stays on TCS control unit NOTE e If the indicator light indicates Problem Code 1 2 replace the TCS control unit e f the TCS indicator light stays on check for a short to body ground in the BLU RED wire between the TCS control unit and the TCS indicator light If the wire is OK replace the TCS control unit 19 24 Parking Brake Signal Problem Code 2 Parking brake signal NOTE lo e Before proceeding to the troubleshooting procedure be sure to perform a running test and check whether the TCS indicator light comes on or not If the TCS indicator light does not come on the system is working properly If the TCS indicator light comes on make sure the parking brake lever is released e When both of the rear wheels are running at 6 mph 10 km h or over and the parking brake is applied for more than 30 seconds c
109. ector terminal 8 and body ground 19 54 From page 19 54 NO Is there bettery voltage YES Turn the ignition switch OFF Connect the 26P connector to the TCS control unit Turn the ignition switch ON Measure the voltage between the 26P connector terminal 8A and body ground Start the engine When the TCS indicator light remains on s there battery voltage After the TCS indicator light goes off ls there no voltage YES page 19 56 Turn the ignition switch OFF Check for continuity between RED BLK WIRE FSR the 26P connector terminal 8A and body ground Continuity TENER Ga ao sn n 9s 7 rna eap en en on ro ors o View from terminal side TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Repair open in the RED BLK wire between the fail safe relay and TCS control unit Is there continuity Repair short in the RED BLK wire between the fail safe relay and TCS control unit RED BLK WIRE FSR TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE ha erra un ro oon aaa anneal View from terminal side Check for poor connec tions or loose wires Substitute a known good TCS control unit and recheck cont d 19 55 Troubleshooting TCS Fail safe Relay TCS Control Valve Actuator cont d
110. ed when the ABS B2 15 fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see page 19 11 Intermittent failure Check for poor connections or loose wires Check for poor connec tions or loose wires Substitute a known good TCS control unit and recheck Replace the TCS control unit and recheck TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side Approx 5 V BLU WIRE VREF TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side Approx 5 V BLU WIRE VREF cont d 19 41 Troubleshooting TCS Reference Voltage VREF Signal From page 19 41 Turn the ignition switch OFF Disconnect the 22P connector from the ECU TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE fa s s s o ss oa nla View from terminal side Check for continuity between the TCS control unit 16P connector terminal 12B and body ground NO Measure the voltage between Gs s 5 BLU WIRE VREF Continuity Repair short in the BLU wire YES between the TCS controi unit and ECU Is there continuity Connect the test harness to the ECU see section 11 Turn the ignition switch ON the test harness D18 terminal TEST HARNESS and bady ground 0000000000000 00000000 0000000000000 00000000
111. ee below Check the TC FC signal when PGM FI system code 36 is indicated see page 19 35 TC STB signal check Turn the ignition switch ON View from terminal side GRY YEL WIRE Measure the voltage between More than 4 0V TC STB the TCS control unit 16P connector terminal 14B I and body ground Disconnect the 12P connector from the ECU To page 19 34 To page 19 35 cont d 19 33 Troubleshooting TCS Signals cont d From page 19 33 Turn the ignition switch OFF Connect the test harness to the ECU see section 11 OOOOOOOOOOO OOOOOOOOOOO 00000000 OOOOOO TEST HARNESS 2 More than 4 0 Measure the voltage between the test harness C12 terminal and body ground Repair open in the GRY YEL Is there more than 4 0V wire between the TCS control unit and ECU YES TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE Raise the car and support it with safety stands see section 1 Start the engine Shift the transmission into 2nd and depress the accelerator pedal slowly until a vehicle speed more than 12 mph 20 km h is reached View from the terminal side GRY YEL WIRE TC STB OV Measure the voltage between the TCS control unit 16P connector terminal 14B an
112. eeds Initial Offset Memory Even the new tires of the same brand have approximately 1 of difference in diameter which affects directly to the wheel speed Therefore it is necessary for the TWS control unit to memorize each wheel speed previously by actual driving This wheel speed memorized in the control unit is the standard wheel speeds initial offset memory Blinking of TWS Indicator Light When the TWS detects the abnormal tire pressure during driving it blinks the TWS indicator light to warn the driver When the TWS indicator light warns of the abnormal tire pressure the detected code can be shown with the TWS indicator light by connecting the two terminals of the Service Check Connector with the jumper wire see page 19 14 The abnormal pressure tire can be determined by the blinking frequency of the TWS indicator light Detected Code Probable Cause The pressure of either the left or right front tire is low The pressure of either the left or right rear tire is low The pressures of either the two front tires or two rear tires are low This code may be detected under the following conditions When the tire rotation is not performed and the front tires are worn excessively after the standard wheel speeds initial offset memory is inputted in the control unit When the car is driven at high speed with the low speed range tires installed When the car is driven at high speed with the trailer towed The pressure of one
113. eering Angle Sensor Problem Code 2 1 Steering angle sensor NOTE The TCS control unit performs the self diagnosis for the steering angle sensor when the average speed of the two rear wheels exceeds 10 mph 16 km h The TCS indicator light comes on if a yaw rate is generated and the steering angle signal that corresponds to this yaw rate is not inputted when the steering wheel is turned while there is no input from the STOP brake light signal and PARK parking brake signal Start the engine Push the TCS switch 3 times within 3 seconds Turn the steering wheel slowly clockwise more than 1 5 turn Push the TCS switch 2 times within 3 seconds Return the steering wheel counterclockwise slowly check the number of times the TCS indicator light flashes after the wheel has moved approximately one turn NOTE e Steps 1 through 4 are the steering angle sensor check procedures for actual vehicle operating conditions This will be called the steering angle sensor system check in the following sections e The standard wheel speeds initial offset memory is erased when the TCS switch is pushed for more than 5 seconds If the standard wheel speeds value is erased be sure to input it again after inspection see page 19 11 NOTE e Restart the check from the beginning if the steering wheel is turned counterclokwise e Turn the steering wheel slowly no faster than on
114. elt tension gauge 750 900 75 90 165 198 with new belt Alternator Output A at 13 5 V hot and 110 6 000 alternator min rpm Brush length 10 5 0 41 i 3 5 0 14 Starting motor Type Output kW Reduction Permanent magnet 2 0 Commutator mica depth 0 5 0 8 0 02 0 03 0 20 0 008 Commutator runout 0 0 05 0 002 0 10 0 004 Commutator D 31 90 32 10 1 256 1 264 31 5 1 24 Brush length 18 0 0 71 11 0 0 43 Brush spring tension kg Ibs 29 7 36 3 2 97 3 63 6 55 8 00 1 not adjust the electrode gap replace spark plug if it is out of spec 2 When using a new belt adjust deflection or tension to new values Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt values 3 14 Design Specifications DIMENSIONS Overall Length Except KY 4 885 mm 192 3 in KY 4 890 mm 192 5 in Overall Width 1 810 mm 71 3 in Overall Height Except KY 1 370 mm 53 9 in KY 1 375 mm 54 1 in Wheelbase 2 830 mm 111 4 in Track Front Rear Except KY 1 550 1 540 mm 61 0 60 6 in KY 1 545 1 535 mm 60 8 60 4 in Seating Capacity Five WEIGHT Curb Weight M T 1 580 kg 3 483 Ibs A T European type 1 600 kg 3 527 5 1 585 3 494 Ibs KY 1 595 kg 3 516 Ibs KU 1 560 kg 3 439 Ibs Weight Distribution M T 960 620 kg 2 116 1 367 Ibs Front Rear A T Europea
115. er dash fuse relay box BLK YEL WIRE IG1 Battery voltage i cont d 19 71 Troubleshooting TWS TWS Indicator Light Do Not Come On cont d Continuity From page 19 71 BRN BLK WIRE LGE 1 TCS CONTROL UNIT 16P CONNECTOR Turn the ignition switch OFF HARNESS SIDE N 18 aB 58 68 108 118 128 38 148 158168 View from terminal side Check for continuity between the 16P connector terminal 5B and body ground and between the 26P connector terminal 20 A and body ground TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE EA un S 6 7 oA o ATED ear aos pon pos rn sn po View from terminal side BRN BLK WIRE LGE 2 Continuity Repair open in the BRN BLK wire between the TCS control unit and body ground Repair poor ground G101 NO Is there continuity YES e Check for poor connec tions or loose wires Substitute known good TCS control unit and recheck 19 72 TWS Indicator Light Does Not Go The TWS indicator light does not go off after the engine is started NOTE If the TWS indicator light and TCS indicator light come on after the engine is started or during driving confirm the TCS code and repair according to the TCS troubleshooting guide BLU WHT WIRE From TWS INDICATOR LIGHT Turn the ignition switch OFF Disconnect the TCS control unit 26P
116. ge 19 11 test drive the car and make sure that the TWS indicator light does not blink NO Equalize the tread depthes of the tires as possible by the tire rotation or change ls all tires worn evenly YES Turn the ignition switch OFF NOTE It is important to equalize the tread depthes of the left and right front tires Disconnect the TCS control TCS CONTROL UNIT unit 26P connector 26P CONNECTOR i HARNESS SIDE Measure the voltage between 26P connector terminal 22A ICA TED IAJIA I8A 19A 204 22234 240 26A 26 View from terminal side and body ground with the brake pedal pressed 5 GRN WHT WIRE NO Repair open in the GRN WHT Battery voltage STOP wire between the TCS control unit and brake switch Is there battery voltage YES Measure the voltage between 26P connector terminal 22A and body ground with the brake pedal released YES Replace the brake switch Brake switch stuck ON 5 there voltage To page 19 69 19 68 From page 19 68 Pull up the parking brake lever Measure the voltage between 26P connector terminal 9A and body ground NO The system is OK at this time Reset the standard wheel speeds see page 19 11 and recheck YES ls there voltage TCS CONTROL UNIT 26P CONNECTOR GRN RED WIRE HARNESS SIDE PARK Battery a
117. gnition key once and reinsert f the ray indicator light goes on go to step 4 f it does not go on check for contaminated or deformed ignition key tip If the key tip is not contaminated or deformed the ignition key transmitter itself is faulty KEYLESS ENTRY CHECKER 07MAJ SP00200 IGNITION KEY TRANSMITTER CHARGE INDICATOR LIGHT SHORT CIRCUIT INDICATOR LIGHT 23 23 Keyless Entry System Except KU model Keyless Entry System Test cont d 3 Remove the driver s door trim panel and trunk lid in IGNITION KEY ner trim and check that the receiver output levels TRANSMITTER change when the transmit button on the transmit ter is pressed Driver s door receiver unit TRUNK LID Connect the positive probe of the digital mul timeter to the GRN WHT terminal and the nega 3 P tive probe to the GRN BLK terminal CONNECTOR Trunk receiver unit Connect the positive probe of the digital mul timeter to the GRN YEL terminal and the negative probe to the GRN BLK terminal NOTE Keep the 4 3 P connector connected Use a digital multimeter DC range If the output voltage momentarily changes to 4 Insert the ignition key transmitter into the ignition the range of approx 3 5 mV 1 V go to step 4 switch and turn to ON Then check whether there is charged voltage of 8 10 V between the key If there is no voltage check for contaminated terminal
118. hanges e The dipstick has been changed e Recommended oil has been changed Engine Oil Inspection 1 Check engine oil with the engine off and the car parked on level ground 2 certain that the oil level indicated on the dipstick is between the upper and lower marks 3 If the level has dropped close to the lower mark add oil until it reaches the upper mark CAUTION Insert the dipstick carefully to avoid bending it DIPSTICK UPPER MARK LOWER MARK Replacement CAUTION Remove the drain bolt carefully Hot oil may cause scalding 1 Warm up the engine 2 Drain the engine oil DRAIN BOLT 45 Nem 4 5 kg m 33 Ib ft 3 Reinstall the drain bolt with a new washer and refill with the recommended oil CAUTION Do not overtighten the drain bolt API Service Grade SF SG or SH Every 10 000 km 6 000 miles or 6 1272 months 8 European models 4 5 0 4 8 US qt 4 0 Imp at at oil change including filter 4 0 0 4 2 US qt 3 5 Imp at at oil change without filter 5 3 0 5 6 US qt 4 7 Imp qt at engine overhaul Capacity Engine Oil SAE Viscosity for Outside Temperature Ranges 30 20W 40 20W 50 15W 40 15W 50 30 20 10 0 10 20 30 40 L zl ku 20 0 20 40 60 80 100 Ambient temperature ranges 1 For cars with catalytic converter 2 For cars without catalytic converter NOTE Oil filter should be replaced at
119. heel speeds initial offset memory in the control unit is fuse in the under hood fuse erased when the ABS B2 15 A fuse is disconnected relay box for more than 3 Be sure to input new standard wheel speeds into the control unit again seconds to reset the TCS after inspection see page 19 11 control unit Start the engine Confirm the TCS code see page 19 14 NO Intermittent failure Check for poor connections or loose wires Is the code 5 2 indicated YES Turn the ignition switch OFF TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE WHT WIRE VB Disconnect the 26P connector from the TCS control unit Turn the ignition switch ON More than 12 5 V EN 14 2A 3A sa sa 6A Jroa fra 134 160 20A 22A 23A 24A 25A 2 the 26 connector terminal 1 View from terminal side and body ground Measure the voltage between NO Check the battery terminals for looseness and charging system see section 23 ls there more than 12 5 V YES Check for poor connec tions or loose wires e Substitute a known good TCS control unit and recheck 19 59 Troubleshooting TCS Back up Voltage VB Problem Code 5 3 Abnormal VB back up voltage Remove the ABS B2 15A fuse in the under hood fuse relay box for more than 3 seconds to reset the TCS control unit Start the engine and run it at more than 1 000 rpm for more tha
120. here approx 5 V Turn the ignition switch OFF YES To page 19 50 NOTE e Use the 10V range or a similar range in the analog tester e Confirm that the analog tester needle swings to approx 2V Aud ul TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE mm GRN BRN WIRE FLP View from terminal side Check for poor connec tions or loose wires LT GRN WIRE e Substitute known good RLP Le unit and GRN ORN WIRE GRN WIRE recheck RRP FRP TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE Approx 5 V LT GRN WIRE GRN BRN WIRE RLP FLP GRN ORN WIRE GRN WIRE RRP FRP Turn the ignition switch OFF Disconnect the 16P connector from the TCS control unit To page 19 50 cont d 19 49 Troubleshooting TCS Individual Wheel Sensors cont d From page 19 49 Fram page 19 49 TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side 18 48 58 68 78 108 16 126138148 158168 LT GRN WIRE GRN BRN WIRE Check for continuity between RLP FLP the 16P connector terminal GRN ORN WIRE GNN WIRE and body ground No 8B Right front No 6B Left front No 4B Right rear No 2B Left rear Is there continuity YES RRP FRP Check for poor connec tions or loose wires Substitute a known goo
121. hts brightness con trol system An open in the wire Check for voltage between RED BLK and RED terminals should be battery voltage Ignition switcn ON 11 With security system Check for voltage to ground should be about 5 V Faulty ECU An open in the wire 23 9 Safety Indicator Circuit Diagram UNDER HOOD FUSE RELAY BOX No 39 20A To page 23 11 Except KY model IGNITION SWITCH To page 23 12 No 311120A No 35 50A ene WHT O O re BLK YEL CHT M No 49 15A Ku KY KW FUSE and KH models No 13 7 5 LHD No 17 7 5 RHD UNDER DASH WHT BLU GRN RED 2 FUSE BOX YEL RED BLK WHT BLU WHT BLU 9 9 3 0 91 1 12W SAFETY INDICATOR CIRCUIT WHT GRN To page 23 11 Except KT 23 12 model GRN BLK GRN BLK GRN BLU GRN RED BLK RED WHT GRN 2 LEFT COURTESY LIGHT INTEGRATED DOOR 5 RIGHT DASHLIGHT INTEGRATED RIGHT COURTESY LIGHT CONTROL UNIT 000 0008 BRIGHTNESS CONTROL UNIT FRONT DOME LIGHT KG KX KF SWITCH SWITCH CONTROL KS KX KF REAR DOME LIGHT nd KS models UNIT and KS models GRN BLK TRUNK LATCH SWITCH BLK Exclusive use of safety indicator G551 LHD G401 G402 G403 RHD 6402 6403 23 10 Except KY model From page WHT GRN 23 10 WHT GRN WHT GRN BRAKE LIGHT SWITCH INTERLOCK SYSTEM model HORN SYSTEM SECURITY INDICATOR GRN WHT and KG models
122. ily Connect the WHT BLK terminal to the WHT GRN terminal momentarily WHT BLK Trunk key cylinder in UNLOCK Under all conditions Under all conditions terminal and the YEL RED terminal to the BLK terminal Check door lock operation is connected momentarily Check trunk opener solenoid operation Trunk lid should unlock as the battery is connected momentarily NOTE Before testing remove No There should be 1 V or less as the All doors should lock as the battery Faulty driver s or front passenger s door switch Poor ground G401 G402 G403 6402 G403 open in the wire Faulty ignition key switch Poor ground G401 G402 G403 G402 G403 An open in the wire Faulty door key cylinder Poor ground G401 G402 G403 G402 G403 open in the wire Faulty actuator open in the wire Faulty trunk opener solenoid Poor ground G401 G402 G403 G402 G403 An open in the wire Check for voltage to ground There should be 1 V or less Check for voltage to ground There should be battery voltage Faulty trunk key cylinder switch Poor ground 5551 An open in the wire Faulty security control unit An open in the wire Check for voltage to ground There should be battery voltage Faulty security control unit
123. imits 3 2 Design Specifications 3 15 Body Specifications 3 18 Standards and Service Limits Cylinder Head Valve Train Section 6 MEASUREMENT STANDARD NEW SERVICE LIMIT Compression 200 min rpm and Nominal 1 400 kPa 14 0 kg cm 199 psi wide open throttle Minimum 1 000 kPa 10 0 kg cm2 142 psi Maximum variation 200 kPa 2 0 kg cm 28 psi Cylinder head Warpage 0 05 0 002 Height 99 95 100 05 3 935 3 939 ai Camshaft End play 0 05 0 15 0 002 0 006 Camshaft to holder oil clearance 0 050 0 089 0 0020 0 0035 Total runout 0 03 0 001 Cam lobe height 40 118 1 5794 37 766 1 4868 40 005 1 5750 37 766 1 4868 Hydraulic tappets Auto adjuster type Hydraulic tappets Auto adjuster type 5 48 5 49 0 2157 0 2161 5 45 5 46 0 2146 0 2150 0 02 0 05 0 001 0 002 0 05 0 08 0 002 0 003 Valve seat Width IN 1 25 1 55 0 049 0 061 Valve clearance Valve stem O D 0 215 Stem to guide clearance 0 004 EX 1 25 1 55 0 049 0 061 Stem installed height IN 46 935 47 425 1 8478 1 8671 EX 47 885 48 375 1 8852 1 9045 Valve spring Free length IN 50 16 1 9748 1 50 17 1 9752 2 50 36 1 9827 Valve guide 1 0 IN and 5 51 5 53 0 217
124. in the BLU GRN control unit and TCS control NO valve angle sensor Check for open in the BLU GRN wire between the TCS control unit and TCS control valve angle sensor If the wire is OK replace the TCS control valve assembly faulty TCS control valve angle sensor and recheck 19 47 Troubleshooting TCS Individual Wheel Sensors Problem Code 4 1 Right front wheel sensor 4 4 Right rear wheel sensor 4 2 Left front wheel sensor 4 8 Left rear wheel sensor NOTE e The TCS indicator light comes on if any wheel speed signal from the ABS control unit stops for more than three seconds when either the left or right rear wheel speed is 10 mph 16 km h or more e If the wheel speed signals from the ABS control unit are abnormal the TCS control unit makes the TC FC signal to ECU The ECU then indicates PGM FI system code 36 After the repair is completed reset the ECU see section 11 NOTE Remove the ABS B2 15 The standard wheel speeds initial offset memory the control unit is erased fuse in the under hood fuse when the ABS B2 15A fuse is disconnected relay box for more than 3 Be sure to input new standard wheel speeds into the control unit again after seconds to reset the TCS inspection see page 19 11 control unit and ABS control unit TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE Test drive for approx 6 seconds at more than 10 mph 16 km h C ox 9x s 5 95 7 9 on oon ee ra an
125. ion for the 1994 LEGEND COUPE Refer to following shop manuals for service procedures end datanot included in this minas REPAIR AND CONSTRUCTION 91 LEGEND COUPE SUPPLEMENT 91 LEGEND COUPE SUPPLEMENT 92 LEGEND COUPE SUPPLEMENT 93 The first page of each section ia sucka with a task teb thet Snes up with one of the thumb index tabs on this page You can quickly find the first page of each section without looking through a full ta ble of contents The symbols printed at the top corner of each page can also be used quick reference system NOTE Gives helpful information CAUTION M a vehicle or make it unsafe ud cous PERSONAL INJURY damage cannot cover conceivable ways in which service whether or not gas ad ditt or of the possible eae eae ee dee Allinformation containes in this manual is based on the latest product information available at the time of printing We reserve the right tomake changes at any time without notice No part of this publica tion may be reproduced stored in retrieval system or transmitted inany form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the This includes text and tables 180 pages All Rights Reserved HONDA MOTOR CO LTD
126. ir short in the BLU RED Is the TCS indicator light on wire between the TCS control unit and gauge NO assembly Substitute a known good TCS control unit and recheck NOTE Use the 10V range or a similar range in the analog tester e Confirm that the analog tester needle swings to more than 2 0V Turn the ignition switch OFF Connect the test harness to the ECU see section 11 TEST HARNESS ooooooooooooo ooooooooloooooolooooooooooo 0000000000000 00000000 J 099000 00000000000 the test harness C6 terminal and body ground 6 TC INH Start the engine Ec i Measure the voltage between More than 2 0V YES Repair open in the GRY BLK wire between the TCS control unit and ECU 15 there more than 2 0V NO Turn the ignition switch OFF To page 19 23 19 22 19 22 From page 19 22 TCS CONTROL UNIT 16P CONNECTOR IHARNESS SIDE Disconnect the 12P connector from the ECU and the 16P connector from the TCS control unit GRY BLK WIRE TC INH View from terminal side Check for continuity between the 16P connector terminal 9B and body ground Continuity ontinulty YES Repair short in the GRY BLK control unit and ECU NO to the TCS control unit BRN BLK WIRE LGE 1 TCS CONTROL UNIT TCS CONTROL UNIT 26P CONNECTOR 16P CONNECTOR HARNESS SIDE HARNESS SIDE NEN 2A 3A sa sa 108 12 14a
127. is normally returned to fully open position by the two return springs Although the throttle valve is still within the driver s control the engine output is relaxed by the TCS control valve and ECU to achieve optimum traction TCS CONTROL VALVE ANGLE SENSOR TCS CONTROL VALVE RETURN SPRINGS TCS CONTROL VALVE TCS CONTROL VALVE ACTUATOR DC MOTOR DURING NORMAL DRIVING DURING TCS ACTUATION TCS CONTROL VALVE TCS CONTROL VALVE RETURN SPRINGS TCS CONTROL VALVE ACTUATOR DC MOTOR TCS ACTUATION SIGNAL FROM TCS CONTROL UNIT 19 9 System Description TWS Outline Role of System The tire air pressure is very important for safety driving and should be properly adjusted to maintain proper steering control and low fuel consumption Also driving with low air pressure tires will adversely affect the tires and may damage them The Tire Pressure Watching System TWS is designed to make the driver check the tires immediately by warning with the TWS indicator light when the air pressure of one or more tires is abnormal TWS INDICATOR LIGHT Operating Principle The lower air pressure tires rotates faster than the normal pressure tires during driving because its diameter is smaller than the one of the normal pressure tires Noting this fact the TWS detects the drop of tire air pressure by means of the various sensor signals such as the wheel speed signal of the anti lock brake system Standard Wheel Sp
128. ish them for example GRN RED and GRN RED are not the same The illustration shows the LHD type LHD 1 GRN BLK BLK RHD KE model 14 P CONNECTOR GRN BLK BLK WHT GRN GRN BLU GRN RED WHT RED 2 GRN BLK BLU WHT GRN WHT WHT GRN 2 GRN BLU GRN RED WHT RED BLU WHT SRS MAIN HARNESS Covered with yellow outer insulation KEYLESS ENTRY CONTROL UNIT 10 P CONNECTOR BLK WHT WHT BLK BLK RED BLU WHT GRN RED3 BLU WHT BLU BLK WHT WHT BLK GRN GRN RED GRN WHT YEL RED GRN BLU BLU GRN WHT WHT BLU GRN RED2 23 21 Keyless Entry System Except KU model Control Unit Input Test cont d Test condition Under all conditions Test desired result Check for continuity to ground There should be continuity Possible cause if result is not obtained Poor ground 6401 G402 G403 G402 6403 An open the wire WHT GRN Under all conditions Check for voltage to ground Blown No 44 20 A fuse There should be battery voltage An open in the wire 3 GRN WHT LOCK Driver s door lock switch in Check for voltage to ground There should be 1 V or less Faulty driver s door lock switch Poor ground G401 G402 G403 G402 G403 GRN RED Driver s door lock switch in UNLOCK
129. kick down valve spring Regulator valve spring A Regulator valve spring B Stator reacting spring Modulator valve spring Torque converter check valve spring Relief valve spring Cooler relief valve spring 3 4 orifice control valve spring Throttle valve spring 1 2 shift valve spring 2 3 3 4 shift valve spring 4 3 shift timing valve apring 1st accumulator spring 4th accumulator spring 2nd accumulator spring A 2nd accumulator spring B 1st hold accumulator spring 3rd accumulator spring Reverse accumulator spring Lock up shift valve spring Lock up timing valve spring Lock up control valve spring CPC valve spring 0 29 0 011 2 30 0 091 1 10 0 043 1 80 0 071 1 70 0 067 6 50 0 256 1 50 0 059 1 40 0 055 1 00 O 039 1 00 0 039 0 90 0 035 0 80 0 031 0 70 0 028 2 90 0 114 2 80 0 110 3 60 0 142 2 00 0 079 4 00 0 157 3 20 0 126 3 50 0 138 0 90 0 035 0 80 0 031 0 70 0 028 0 70 0 028 0 70 0 028 1 00 0 039 Unit of length mm STANDARD NEW 4 00 0 157 20 20 0 795 7 10 0 280 14 70 0 579 6 00 0 236 26 40 1 039 9 40 0 370 9 40 0 370 8 40 0 331 8 40 0 331 8 40 0 331 6 60 0 260 7 60 0 299 7 60 0 299 6 60 0 260 7 10 0 280 18 00 0 709 16 50 0 650 22 0 0 87 6 60 0 260 25 00 0 984 19 00 0 748 18 60 0 732 7 60 0 299 6 60 0 260 6 60 0 260 6 60 0 260 6
130. le bearing contact area 1 0 Thickness End play when tightening by specified torque 1 0 Thickness End play when tightening by specified torque 0 183 0 375 0 0072 0 0148 27 977 27 990 1 1015 1 1020 30 987 31 000 1 2200 1 2205 27 987 28 000 1 1018 1 1024 37 989 38 000 1 4956 1 4961 0 02 0 001 max 33 000 33 015 1 2992 1 2998 31 975 31 988 1 2589 1 2594 27 987 28 000 1 1018 1 1024 0 02 0 001 max 25 007 25 020 0 9845 0 9850 26 45 26 50 1 041 1 043 44 009 44 025 1 7326 1 7333 31 39 31 47 1 236 1 239 0 06 0 19 0 002 0 007 44 009 44 025 1 7326 1 7333 29 39 29 47 1 157 1 160 0 06 0 19 0 002 0 007 44 009 44 025 1 7326 1 7333 29 39 29 47 1 157 1 160 0 06 0 19 0 002 0 007 30 992 31 002 1 2202 1 2205 37 989 38 000 1 4956 1 4961 29 56 29 61 1 164 1 166 53 010 53 029 2 0870 2 0878 35 92 36 00 1 414 1 417 0 04 0 10 0 002 0 004 53 010 53 029 2 0870 2 0878 35 92 36 00 1 414 1 417 0 04 0 10 0 002 0 004 0 525 0 0207 27 930 1 0996 30 940 1 2181 27 937 1 0999 37 935 1 4935 0 05 0 002 32 950 1 2972 31 928 1 2570 27 937 1 0999 0 05 0 002 44 080 1 7354 31 32 1 233 0 30 0 012 44 080 1 7354 29 32 1 154 0 30 0 012 44 0
131. m Except KU model Component Location Index CAUTION All SRS wiring harnesses are covered with yellow out er insulation Before disconnecting any part of the SRS wire har ness install the short connectors Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring NOTE RHD type is symmetrical to LHD type For tests and replacements not mentioned here refer to the 91 Legend Coupe Shop Manual With security system SRS WAIN HARNESS Covered with yellow outer insulation KEYLESS CHARGING UNIT Test page 23 24 IGNITION KEY SWITCH PASSENGER S DOOR LOCK SWITCH KEYLESS ENTRY TRUNK OPENER CONTROL UNIT MAIN SWITCH Input test page 23 21 PASSENGER S DOOR LOCK ACTUATOR ASSEMBLY and LOCK KNOB SWITCH DRIVER S DOOR LOCK SWITCH PASSENGER S KEY CYLINDER SWITCH and PASSENGER S DOOR SWITCH DRIVER S DOOR RECEIVER UNIT Test page 23 23 TRUNK RECEIVER UNIT Test page 23 24 TRUNK OPENER e wee DRIVER S DOOR LOCK ACTUATOR NI ASSEMBLY and LOCK KNOB SWITCH TRUNK OPENER SOLENOID and DBIVEH DOON KEY TRUNK KEY CYLINDER CYLINDER SWITCH and SUCH DRIVER S DOOR SWITCH 23 17 Keyless Entry System Except KU model Circuit Diagram UNDER HOOD FUSE RELAY BOX IGNITION SWITCH No 31 120A No 35 50A C O O O WHT O O BLK YEL SECURITY CONTROL wa With Nith security systemi system WHT GRN GRN RED 3 DRIVER DOOR RECEIVER
132. n 10 seconds Confirm the TCS code see page 19 14 1 the code 5 3 indicated YES Turn the ignition switch OFF Disconnect the 26P connector from the TCS control unit Measure the voltage between Turn the ignition switch ON the 26P connector terminal 1A and body ground Is there more than 7 V YES Check for poor connec tions or loose wires Substitute a known good TCS control unit and recheck 19 60 NO NO NOTE The standard wheel speeds initial offset memory in the control unit is erased when the ABS B2 15 A fuse is disconnected Be sure to input new standard wheel speeds into the control unit again after inspection see page 19 11 intermittent failure Check for poor connections or loose wires TGS CONTROL UNIT 26P CONNECTOR HARNESS SIDE WHT WIRE VB More than 7 V REN C an ux sn ss 77 n x Tenn re on za oen o View from terminal side Check the battery terminals for looseness and charging system see section 23 fo A T Gear Position Signal Problem Code 6 1 A T gear position signal NOTE When the back up voltage is disconnected from the TCS control unit the TCS control unit on an A T model goes into the M T mode Once the engine is started however the TC SP signal switches the TCS control unit back to the A T mode The system mode be confirmed by performing the steering angle sensor system
133. n type 975 625 kg 2 149 1 378 Ibs KQ 960 625 kg 2 116 1 378 ibs KY 965 630 kg 2 127 1 389 165 Max Permissible Weight for European 2 150 kg 4 740 Ibs Permissible Axle Weight for European Front Rear 1 100 1 090 kg 2 425 2 403 Ibs Max Loaded Vehicle Weight ADR 1 998 kg 4 405 Ibs ENGINE Type Water cooled 4 stroke SOHC gasoline engine Cylinder Arrangement 90 V6 cylinder Bore and Stroke 90 0 x 84 0 mm 3 54 x 3 31 in Displacement 3 206 cm mf 195 6 cu in Compression Ratio 9 6 1 9 0 1 Except European type and KU Valve Train Belt driven SOHC Lubrication System Forced and wet sump trochoid pump Oil Pump Displacement 42 3 min 44 7 US qt min at 6 000 pump At oil temp 120 C 248 F 37 2 Imp qt min rpm Fuel Required C32A2 Engine PREMIUM UNLEADED gasoline with European type research octane number of 95 or higher and KU C32A3 Engine UNLEADED gasoline with research octane number KO i of 91 or higher C32A4 C32A5 Engines LEADED gasoline with research octane number of KY KT 91 or higher Unleaded gaso line with R O N of 91 or higher may also be used Water Pump Displacement 178 min 188 US qt min at 5 760 pump At coolant temp 25 C 77 F 157 Imp qt min rpm STARTER Type Make Gear reduction permanent magnet MITSUBISHI Normal Output Nominal Voltage Hour Rating Direction of Rotation Weight CLUTCH Type Facing Area 2 0 kW 12 30 seconds Clockwise as viewed from gea
134. nal to the No 1 terminal of the actuator 2P connector and the terminal to the No 2 terminal for 1 2 seconds to operate the TCS control valve actuator Does the TCS control valve click YES Operate the TCS control valve actuator with the battery 10 times Measure the resistance between the No 1 and No 2 terminals of the TCS control valve actuator 2P connector 15 the resistance less than 2 50 YES Check for poor tions or loose wires e Substitute a known good TCS control unit and recheck 19 58 Troubleshooting TCS Fail safe Relay TCS Control Valve Actuator cont d NO NO CAUTION e Be careful not to short the terminals Disconnect the terminal from the actuator immediately after the TCS control valve clicks is fully closed TCS CONTORL VALVE ACTUATOR 2P CONNECTOR ACTUATOR SIDE View from terminal side Remove the intake air duct and recheck the TCS control valve operation If it is defective replace the TCS control valve assembly see page 19 78 TCS CONTORL VALVE ACTUATOR 2P CONNECTOR ACTUATOR SIDE View from terminal side The TCS control valve actuator is faulty Replace the TCS control valve assembly see page 19 78 Less than 2 50 X TCS Control Valve Actuator Problem Code 5 2 TCS control valve actuator does not operate normally due to low voltage NOTE Remove the ABS B2 15 The standard w
135. ngs to approx 3 V TCS CONTROL UNIT OV HARNESS SIDE 26P CONNECTOR BE 9A 10 12A 9A aL aaa sn dedu View from terminal side GRY BLU WIRE TC FC Approx 3 V 19 35 Troubleshooting TCS Signals cont d 19 35 YES Is there approx 3V NO Turn the ignition switch OFF Disconnect the 26P connector from the TCS control unit and the 12P connector from the ECU Check for continuity between the 26P connector terminal 19 A and body ground YES NO Reconnect the 26P connector for the TCS control unit Connect the test harness to the ECU Wire harness side only see section 11 Turn the ignition switch ON Measure the voltage between the C8 terminal of the test harness and body ground NO Is there approx 5V YES Check for poor con nections or loose wires Substitute a known good TCS control unit and recheck If symptom does not go away substitute a known good ECU and recheck Substitute known good ECU TCS CONTROL UNIT and recheck 16P CONNECTOR HARNESS SIDE WE Ga ze 9x o se os 7n s 7 oos o View from the terminal side GRY BLU WIRE TC FC Continuity Repair short in the GRY BUL wire between the TCS control unit and ECU TEST HARNESS OOOOOOOOOOO0O0O0 OOOOOOOO OOOOCOO OOOOOOOOOOO OOOOOOOOOOOOO OOOOO
136. ns Lee ga las Tal Oe meme _ nj a n _ Positive j hj ws ESR system For cars without cataticconverte if 1 11 1 EGR fitar For cars without cataiyie converte For cars without catalytic converter Evaporative emission control system For other than European models Day to day care engine oil ATF and coolant level should be done practically according to the owner s manual by the customer Replace every 6 years or 100 000 km 60 000 miles whichever comes first For KS model recommended by manufacturer only except for KS model it is required 1 2 R Replace l Inspect After inspection clean adjust fill up repair or replace if necessary Service at the interval listed x 1 000 km or x1 000km 20 40 100 120 140 160 180 200 miles or after that number of months whichever comes first x 1 000 mites 12 24 36 48 60 72 84 96 108 120 rons pm e0 72 asss sr 1 rp 1 wis Brake fluid Including ABS n n R er Brake hoses and lines ENEREEESESEESERESES Anti lock brake system operation X BE IE E deis Anti lock brake system high pressure hose Exhaust system and condition i EET Catalytic converter heat shield For cars with catalytic converter Suspension components jaa Steering function tie ro
137. o the TCS switch indicator NO and TCS activation lights stay See page 19 17 on after 2 seconds YES Start the engine Check the Check Engine Light YES Perform the PGM FI system troubleshooting procedure see section 11 and recheck Is the light on Confirm the PGM FI system Problem Code see section 11 z YES Are codes 35 and or 36 Perform the troubleshooting indicated procedures for Problem Code 3 1 see page 19 33 NO NOTE e Problem Code A short or open circuit in the GRY YEL wire between the TCS control unit 16P connector terminal 14B TC STB and ECU Problem Code 36 A short or open circuit in the GRY BLU wire between the TCS control unit 26P connector terminal 19A TC FC and ECU Start the engine Measure the voltage between the TCS control unit 16P connector terminal 9B and body ground NOTE e Use the 10V range or a similar range the analog tester Confirm that the analog tester needle swings to more than 2 0V TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE View from terminal side More than 2 0V GRY BLK WIRE TC INH cont d To page 19 22 19 21 Troubleshooting TCS TCS Indicator Light Does Not Go Off cont d From page 19 21 YES Is there more than 2 0V Turn the ignition switch OFF NO Disconnect the 26P and 16P connectors from the TCS control unit Turn the ignition switch ON YES Repa
138. ol valve angle sensor Check for open or short the NO YEL WHT wire between the TCS control valve angle sensor and ECU wire is OK YES substitute a known good ECU and recheck Repair open in the GRN WHT wire between the TCS control valve angle sensor To page 19 47 and ECU 19 46 From page 19 46 Remove the intake air duct see page 19 78 TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE BLU GRN WIRE 0 2 E 18 38 48 68 78 98 108 11 12 13 14 15 16 View from terminal side Disconnect the 16P connector from the TCS control unit Turn the ignition switch ON Measure the voltage between the TCS control unit 16 connector terminal 1B and body ground 5 voltage approx 4 5 V at fully open TCS control valve and 0 5 V at fully closed TCS control valve NOTE There should be a smooth transition from approx 4 5 V and 0 5 V at the TCS control valve is closed see page 19 58 Check for poor connec YES tions or loose wires e Substitute a known good TCS control unit and recheck NO TCS CONTROL UNIT 16P CONNECTOR HARNESS SIDE Turn the ignition switch OFF BLU GRN WIRE 8 2 Disconnect the 3P connector from the TCS control valve angle sensor Continuity Check for continuity between View from terminal side the 16P connector terminal 1B and body ground YES Repair short
139. ontinuously the TCS control unit will cause the TCS indicator light to come on Release the parking brake lever and turn the ignition switch ON Check the brake system light YES Does the light come on Check the brake fluid level NO NO Pull up the parking brake lever Is the level low YES Check the brake pad wear and fluid leakage Check the brake system light Release the parking brake lever Does the light come on YES Measure the voltage between the parking brake switch connector terminal and body ground Release the parking brake lever Measure the voltage between NO Is there battery voltage the TCS control unit terminal YES 9A and body ground Check the parking brake switch NO Is there battery voltage YES TCS 26 HARNESS SIDE eer WIRE Substitute known good TCS control unit and recheck e Check for poor con nections or loose wires Con onn n on 77 n n n 7 7 ra B Ao a Check the parking brake switch and brake fluid level Switch If they are OK repair short in GRN RED wire Check the brake system light bulb If it is OK repair open in the GRN RED wire between the parking brake switch and gauge assembly Repair open in the GRN RED wire between the TCS control unit and gauge assembly Battery voltagre View from terminal side 19 25 Troubleshooting TCS St
140. or with its bracket from the body NOTE Do not remove the Lg sensor from the bracket unless necessary Lg SENSOR EB EG Turn the ignition switch ON Measure the voltage between the No 2 and No 3 terminals with the connector connected There should be approx 2 5 V when the Lg sensor is vertical There should be approx 1 5 V when the Lg sensor is horizontal with the left bracket side facing down There should be approx 3 5 V when the Lg sensor is horizontal with the right connector side facing down No 2 No 1 View from wire side RIGHT SIDE LEFT SIDE BOLTS TCS Control Unit Replacement Remove the rear seat back see section 20 Disconnect the connectors from the TCS control unit Remove the three bolts and the TCS control unit TCS CONTROL UNIT gt CONNECTORS Install the TCS control unit in the reverse order of removal 19 75 Electronic Components Steering Angle Sensor Replacement 1 Remove the column covers 2 Disconnect the steering angle sensor connector 3 Remove the steering angle sensor mounting bolts NOTE There may be adjustment shims between the steering angle sensor and bracket Take care not to drop or lose them A ADJUSTMENT SHIMS gt m 4 EN Du STEERING ANGLE SENSOR MOUNTING BOLTS 10 Nm 1 0 kg m 7 Ib ft CAUTION The steering angle sensor is the precision instrument
141. r end 11 5 Ibs M T Single plate dry diaphragm spring AIT Torque converter M T 39 sq in 3 15 Design Specifications METRIC ENGLISH TRANSMISSION Type Synchronized 5 speed forward 1 reverse Electronically controlled 4 speed automatic 1 reverse Primary Reduction Direct 1 1 Gear Ratio 16 2 937 2 458 2 476 2nd 1 692 1 454 1 451 1 1 1 151 0 973 0 948 2 2 European 4th 0 868 0 630 0 688 type and KU 5th 0 682 Reverse 3 186 1 826 1 809 1 Secondary Reduction Gear Single helical gear 1 433 1 394 1 333 Final Reduction Gear Spiral bevel gear 3 133 3 133 AIR Cooling Capacity 4 900 Kcal h CONDITIONING Compressor Swash plate NIPPONDENSO No of Cylinder 10 Capacity 207 4 cm rev 12 7 cu in rev Speed 7 600 1 rpm Lubricant Type ND OIL8 Lubricant Capacity 140 4 2 3 fl oz 4 9 Imp oz Condenser Corrugated fin type Evaporator Type Corrugated fin type Sirocco fan Motor Input 200 W 12 V Speed Control Infinite variable Max Capacity 480 3 16 954 cu ft h Compressor Type Dry single plate poly V beit drive Clutch Power Consumption 40 W 12 V Refrigerant Type HFC 134a R 134a Quantity 700 EA g STEERING Type Power assisted rack and pinion SYSTEM Overall Ratio 16 7 Turns Lock to Lock 3 64 Steering Wheel Diameter 330 mm 3 16 SUSPENSION WHEEL ALIGNM
142. r loose wires Substitute known good TCS control unit and recheck 2 3A sa sa a oa A pan 160 174180 194 204 22 23 24 25 TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE View from terminal side Approx 2V to 3 V cont d 19 43 Troubleshooting TCS Atmospheric Pressure PA Sensor cont d From page 19 43 Turn the ignition switch OFF Disconnect the 22P connector from the ECU Check for continuity between the TCS control unit 26P connector terminal 18A and body ground p CUENENNCACIPACSEN CATE ral on nla onn TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE View from terminal side NO Connect the test harness to the ECU see section 11 Turn the ignition switch ON Measure the voltage between the test harness D5 terminal and body ground Is thre approx 2 V to 3 V YES NO Check for poor connec tions or loose wires Substitute a known good ECU and recheck 19 44 ORN RED WIRE e Continuity Repair short in the ORN RED wire between the TCS control unit and ECU Approx 2V to 3V D5 PA 000200000000 0000000000000 00000000 TEST HARNESS Repair open in the ORN RED wire between the TCS control unit and ECU fc
143. rical work the The Legend Coupe Supplemental Restraint System SRS includes a driver s airbag located in the steering wheel hub a front passenger s airbag located in the dashboard above the glove box and seat belt pretensioners located in the seat belt retractors Information necessary to safely service the SRS is included in the 93 Legend Coupe Shop Manual Supplement 62SP121 ltems marked with an asterisk on the contents page include or are located near SRS components Servicing disassembling or replacing these items will require special precautions and tools and should therefore be done only by an authorized Honda dealer A WARNING To avoid rendering the SRS inoperative which could lead to personal injury or death in the event of a severe frontal collision all SRS testing and repair must be done by an authorized Honda dealer Improper procedures including incorrect removal and installation of the SRS components could lead to per sonal injury caused by unintentional activation of the airbags and seat belt pretensioners All SRS electrical wiring harnesses are covered with yellow outer insulation Related components are located in the steering column center console and armrest dashboard lower panel and in the dashboard above the glove box Do not use electrical test equipment on these circuits Electrical Brake Lights m m 23 15 Gauge Assembly 2
144. ront seat passenger s airbag added General Information Chassis and Engine Numbers 1 2 Identification Number Locations 1 3 Warning Caution Label Locations 1 5 Chassis and Engine Numbers Vehicle Identification Number JHMKA81500C300001 Manufacturer Make and Type of Vehicle JHM HONDA MOTOR CO LTD HONDA Passenger car for except KU HONDA MOTOR CO LTD ACURA Passenger car for KU Line Body and Engine Type KA8 LEGEND COUPE C32A2 C32A3 C32A4 2 Body Type and Transmission Type 1 2 door Coupe 5 speed Manual 2 2 door Coupe 4 speed Automatic Vehicle Grade Series 5 L Fixed Code Auxiliary Number Factory Code C Saitama Factory in Japan Sayama _ Model Year 3 1994 Serial Number 1 2 Engine Number C32A2 4000001 Engine Type C32A2 C32A3 V 6 3 2 SOHC Sequential Multi port Fuel injected engine with catalytic converter C32A4 2 5 V 6 3 2 SOHC Sequential Multi port Fuel injected engine without catalytic converter Serial Number C32A2 C32A4 C32A5 4000001 C32A3 4800001 Transmission Number K4E6 4000001 Transmission Type K4E6 Manual MPYA Automatic Serial Number identification Number Locations Transmission Number Vehicle Identification Number VIN Automatic Engine Number Transmission Number Manual cont d Identification Number Locations con
145. rshaft 2nd gear parking gear Wear or damage Automatic Transmission Section 14 Transmission cont d MEASUREMENT Mainshaft 1st gear thrust washer thickness Mainshaft 1st gear distance collar length Mainshaft 1st gear collar length A 4th clutch collar Countershaft 2nd gear collar length Countershaft 1st gear A B collar length Thrust washer 38 8 x 47 thickness 1st hold clutch front side 1st hold clutch distance collar length Countershaft 3rd gear A collar length Diameter of one way clutch contact area Countershaft 1st gear Countershaft 2nd gear D One way clutch hub O D Parking gear one way clutch contact area D Feed pipe O D Feed pipe B O D Mainshaft and countershaft bushings 7 0 1 0 Mainshaft and countershaft bushings 11 51 0 Mainshaft sealing ring 37 mm thickness Countershaft sealing ring 42 mm thickness Mainshaft sealing ring groove width Countershaft sealing ring groove width Diameter of needle bearing contact area Mainshaft stator shaft Mainshaft 3rd gear Mainshaft 1st gear collar Mainshaft 1st gear distance collar Mainshaft 2nd gear collar Countershaft torque converter housing Countershaft 3rd gear collar Countershaft 1st gear collar Countershaft 2nd gear collar Countershaft reverse gear collar Reverse idler gear shaft STANDARD NEW 3 45 3 55 0 136 0 140 34 05 34 08 1 341 1 342 33 90 33 97 1 33
146. s sensor on the receiver and external damage If the sensor is not contaminated and there is NOTE Take care not to short circuit between the no external damage the receiver is faulty key terminals or between the terminals and vehicle body during voltage measurement If there is proper voltage check for contamina ted sensor on the receiver and external damage 4 P CONNECTOR If the voltage level is out of the proper range the charging unit is faulty IGNITION KEY TRANSMITTER DRIVER S DOOR RECEIVER IGNITION KEY LHD type is symmetrical to RHD type 23 24
147. s any abnormality in the system the TCS indicator light stays on Once the TCS switch is pushed however the TCS indicator light comes on and TCS switch indicator light goes off to indicate that the system is off Temporary Driving Conditions 1 The TCS indicator light will come on and the control unit memorizes the Problem Code under certain temporary conditions The spare tire is installed or a tire of the improper size is installed e The tire pressures are not correct 2 Ifthe TCS indicator light does not come back on after correcting the tire or tire pressure problem the system is NOTE Remove the ABS B2 15A fuse for at least three seconds to clear the code from the TCS control unit memory TCS Problem Code Indication 1 Stop the engine 2 Turn the ignition switch on and confirm that the TCS indicator light comes on 3 Turnthe ignition switch off 4 Connect the two terminals of the Service Check Connector with a jumper wire 5 Turnthe ignition switch on but do not start the engine 6 Recordthe blinking frequency of the TCS indicator light The blinking frequency indicates the code Long blinks indicate the main code short blinks indicate the sub code 7 Refer to the Troubleshooting Guide page 19 16 for repair information mi S V 5 SERVICE CHECK CONNECTOR 2P JUMPER WIRE TCS INDICATOR TCS ACTIVATION LIGHT LIGHT 19 14 First indication Problem code 2 1 Main Code 2 Sub code 1
148. security system CONTROL UNIT LHD RHD 6521 6522 DASHLIGHT BRIGHTNESS CONTROL UNIT LHD 6401 6402 6403 RHD G402 G403 23 7 Shift Lever Position Indicator Indicator Input Test CAUTION CONNECTOR Carries the SRS indicator signal All SRS wiring harnesses are covered with yellow outer insulation Before disconnecting any part of the SRS wire har ness install the short connectors see page 23 41 of the 93 Legend Coupe Shop Manual Supplement 625 1211 Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring After installing the gauge assembly recheck the oper ation of the SRS indicator light Remove the gauge assembly from the dashboard and dis connect the 22 P connector from the gauge assembly Inspect the connector terminals to be sure they are all making good contact SRS MAIN HARNESS inal i If the terminals are bent loose or corroded repair them Covered with yellow outer insulation as necessary and recheck the system If the terminals look OK make the following input tests at the connector f any test indicates a problem find and correct the cause then recheck the system all the input tests prove OK the indicator must be faulty replace printed circuit board A and the odo trip meter LT GRN RED RED BLK BLK 4 GRN ORN GRN RED GRN GRN YEL GRN WHT YEL
149. stroke at 200 20 kg 44 165 To be locked when pulled lever LHD lever force 8 12 notches Parking brake Play in stroke at 300 N 30 kg 66 lbs To be locked when pulled pedal RHD pedal force 6 8 notches LHD 213 8 39 RHD 210 8 27 Free play 1 5 1 16 13 64 Piston to pushrod clearance 0 0 2 O 0 008 fF Foot brake Pedal height with floor mat removed pedal Disc brake Disc thickness Front 23 0 0 91 21 0 0 83 28 0 1 10 26 0 1 02 Rear 9 0 0 35 7 5 0 30 Disc runout Front 0 10 0 004 Rear 0 10 0 004 Disc parallelism Front and rear 0 015 0 0006 Pad thickness Front 11 0 0 43 1 6 0 06 Rear 9 0 0 35 1 6 0 06 1 0 Lining thickness Rear Parking brake drum Brake booster 1 Dual pot caliper type 2 Rear disc brake with drum parking brake type 170 0 6 69 171 0 6 73 2 5 0 10 1 0 0 04 Line pressure kPa kg cm psi ia 700 7 0 100 min 820 8 2 117 min 6 230 62 3 886 min 6 190 61 9 880 min 9 920 99 2 1 411 min 9 780 97 8 1 391 min Characteristics at 200 20 kg 44 Ibs pedal force Vacuum O mm 0 in Hg 300 mm 11 8 in Hg 500 mm 19 7 in Hg 3 13 Standards and Service Limits Air Conditioning Section 22 MEASUREMENT STANDARD NEW Air conditioning Lubricant type ND OIL8 P N38899 PR
150. t d LEE rx Bie 2 gt N VIN and ENGINE No European type and KU VIN and ENGINE No KT BUILT DATE and VEHICLE TYPE CERTIFICATION PLATE 1 4 Warning Caution Label Locations A Refer to page 1 5 B Refer to page 1 5 6 C Refer to page 1 6 7 D E Refer to page 1 7 A CABLE REEL CAUTION A B DRIVER MODULE DANGER KG KX KE KU KE KQ KT DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 100 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO THE HONDA SERVICE SHOP MANUAL SRS SUPPLEMENT SRS REFER TO SERVICE MANUAL FOR DETAILED INSTRUCTIONS POUR LES INSTRUCTIONS DETAILL EES SE REPORTER AU MANUEL DE REPARATIONS Hike Z y v BB L C lt KA Wo POISON AUSF HRLICHE ANMEISUNGEN SIND DEM ZU ENTINEMEN CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE RAAD PLEEG HET WERKPLAATSHANDBOEK VOOR FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMITING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WATER CONTACT ARE INHALED SEEK FRESH AIR IN EVERY CASE GET PROMPT MEDICAL ATTENTION KEEP OUT OF REACH OF CHILDREN NADERE AANWIJZINGEN
151. tch housing side 55 002 55 021 2 1654 2 1662 Transmission housing side 45 002 45 018 1 7717 1 7724 Diameter of oil seal contact area Clutch housing side 54 894 54 940 2 1612 2 1630 Transmission housing side 44 911 44 950 1 7681 1 7697 Clutch housing to outer rotor clearance 0 03 0 13 0 001 0 005 0 18 0 007 Inner to outer rotor clearance 0 14 0 006 0 2 0 01 Clutch housing to rotor axial clearance 0 10 0 20 0 004 0 008 0 22 0 009 issi Unit of length i Automatic Transmission Section 14 nit of length mm MEASUREMENT STANDARD NEW SERVICE LIMIT Transmission oil Capacity 0 US qt Imp qt 8 7 9 2 7 7 for overhaul fluid 3 3 3 5 2 9 for oil change Hydraulic Line pressure at 2 000 min rpm 800 860 8 0 8 6 114 122 pressure N or P position kPa kg cm2 psi 1st clutch pressure at 2 000 min rpm D bs or 1 position 2nd clutch pressure at 2 000 rpm D position 3rd clutch pressure at 2 000 min rpm D position 750 7 5 107 380 3 8 54 throttle fully closed 400 4 0 57 throttle fully closed 860 8 6 122 750 7 5 107 Ath clutch pressure at 2 000 min rpm throttle more than throttle more than p position 1 4 opened 1 4 opened 1st hold clutch pressure at 2 000 min rpm 800 860 8 0 8 6 114 122 1 or 2 position
152. the rear emblems Attachment Points Reference Unit mm in ACURA or HONDA EMBLEM LEGEND EMBLEM ACURA or HONDA Emblem TRUNK LID LEGEND Emblem TRUNK LID 178 7 0 178 7 0 92 3 6 LOCK CYLINDER GUIDE FOAM 20 3 _ Automatic Climate Control Illustrated Index 22 2 System Service Performance Test 22 3 tll Outline of Model Changes e The suction pipe of air conditioning system has been changed LHD model Illustrated Index SUNLIGHT SENSOR BLOWER UNIT DISCHARGE LINE RECEIVER DRYER TRIPLE PRESSURE SWITCH CONDENSER OUTSIDE AIR TEMPERATURE SENSOR 22 2 AUTOMATIC CLIMATE CONTROL UNIT ASPIRATOR FAN MOT OR IN CAR TEMPERATURE NSOR HEARTER EVAPORATOR UNIT SUCTION LINE A C COMPRESSOR A C System Service Performance Test kPa kg cm psi 3000 30 427 2500 25 356 bea kg cm psi P 2000 400 30 20 4 86 284 57 DELIVERY ads PRESSURE 15 3 77 213 43 DELIVERY PRESSURE amp 10 6 142 28 PRESSURE 100 15 1 59 14 INTAKE PRESSURE P 30 0 10 7 50 m DELIVERY P d 5 41 DELIVERY TEMPERATURE SSS 25 30 30 40 G 77 86 95 104 F INTAKE AIR TEMPERATURE 22 3 Read this before you do any elect
153. tinuity NO Lg SENSOR 3P CONNECTOR Is there continuity HARNESS SIDE YES View from terminal side BLK WIRE TCS CONTROL UNIT 26P CONNECTOR HARNESS SIDE BLK WIRE GSEN GND ER EENAA AAA View from terminal side Continuity Disconnect the 26P connector from the TCS control unit and connector from the Lg sensor Check the BLK wire for continuity between the TCS control unit and Lg sensor NO Repair open in the BLK wire between the TCS control unit and Lg sensor YES Substitute known good TCS control unit and recheck e Check for poor con nections or loose wires page 19 32 cont d 19 31 Troubleshooting TCS Lateral Acceleration Lg Sensor cont d From page 19 31 Turn the ignition switch ON Measure the voltage between the No 2 terminal of the Lg sensor connector and body ground NO Is there approx 2 5V YES Turn the ignition switch OFF Disconnect the 26P connector from the TCS control unit and the 3P connector from the Lg sensor Check the RED BLU wire for continuity between the TCS control unit and the Lg sensor 15 there continuity YES Check the Lg sensor function see page 19 75 NO Replace the Lg sensor 19 32 YES Does it work properly Lg SENSOR 3P CONNECTOR HARNESS SIDE NC View from terminal side RED BLU WIRE Approx 2 5V Turn
154. ue converter side Startor shaft needle bearing contact D oil pump side Oil pump driven gear 1 0 Oil pump driven gear shaft O D Oil pump gear side clearance Oil pump gear to body clearance Drive 0 210 0 265 0 0083 0 0104 Driven 0 070 0 125 0 0028 0 0049 body Shifting device Parking brake cone Wear or other defect and parking Paring brake pawl brake control Parking gear Wear or other defect Mainshaft reverse gear distance collar length 25 95 26 05 1 022 1 026 Wear or damage 2nd clutch thrust washer 29 mm thickness 3 95 4 00 0 156 0 157 Mainshaft 2nd gear collar length A 35 00 35 05 1 378 1 380 B 31 06 31 09 1 223 1 224 Countershaft reverse gear thrust washer thickness Countershaft reverse gear collar length 3 95 4 05 0 156 0 159 26 95 27 05 1 061 1 065 23 05 23 09 0 907 0 909 35 45 35 55 1 396 1 400 1 27 1 30 0 050 0 051 1 32 1 35 0 052 0 053 1 37 1 40 0 054 0 055 1 42 1 45 0 056 0 057 1 47 1 50 0 058 0 059 1 52 1 55 0 060 0 061 1 57 1 60 0 062 0 063 1 62 1 65 0 064 0 065 1 67 1 70 0 066 0 067 1 72 1 75 0 068 0 069 1 77 1 80 0 070 0 071 1 82 1 85 0 072 0 073 1 87 1 90 0 074 0 075 Reverse clutch distance collar length Thrust washer 45 5 x 60 thickness counte
155. val Installation 19 78 Outline of Model Change The system of the TCS Traction Control System with the TWS Tire pressure Watching System is additionally equipped on the KG KS KX and KF models Component Location FAIL SAFE RELAY UNDER HOOD RELAY BOX C 26 5 qc X N 0270 22 UNDER HOOD FUSE RELAY BOX ELECTRONIC CONTROL UNIT ECU TCS CONTROL VALVE ANGLE SENSOR TCS CONTROL VALVE ASSEMBLY TCS CONTROL VALVE ACTUATOR 19 4 TCS CONTROL UNIT STEERING ANGLE SENSOR Lg SENSOR ABS CONTROL UNIT TCS SWITCH UNDER DASH FUSE RELAY BOX 65 System Description TCS Outline Role of System The traction control is variable system designed to enhance traction during acceleration and cornering It does so determining the optimum amount of wheel spin for any given driving situation then suppressing surplus engine power accordingly Construction and Function The TCS control unit gets signals about the vehicle s speed direction and road conditions from the wheel sensors steer ing angle sensor and lateral acceleration Lg sensor Based on these signals the control unit will determine the optimum amount of wheel spin Because the system is variable the control unit may determine depending on the driving condi tions that some wheel spin is beneficial thus enhancing straight line acceleration or that no wheel spin is beneficial

SUPPLEMENTAL RESTRAINT SYSTEM (3R5).

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