General lnformation1-2 Codes ....................... Chassis Paint and 1-10 NumberLocations ......... ldentification 1-11 Warning/Caution LabelLocations ....... Under-hood Emissions Control . . . . . . . . . . . . . . 1.-.1.5 . . . . Label ......... . Lift and SupportPoints 1-19 LiftandSafety Stands....................... Floor ....................... 1-20 Jack .........1-21 Towing Service Precautions ..,................. 1-22 PaftsMarkingLocations for 4WD Precautions Real-time (Four-wheel Drivel......... ................. 1-23

Chassis and PaintCodesU.S. 1997ModelVehicleldentificationNumberJHLRD184*VC000001

JHL: HONDAMOTOR CO.,LTD HONDA, Multipurpose Passenger Vehicle(MPV) line, Body and Engine Type RDl: CR V/82084 Body Type and TransmissionType 8: 5-door/4-soeed Automatic Vehicle Grade (Series) 4: LX 5: LX (with ABS) CheckDigit Model Year Vt 1997 C: Saitama Factory Japan(Sayama) in

B-84P NH-552M NH-592P R-94

Supermarine Blue Pearl Cypress GreenPearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

(o

Vehicleldentification Number and FederalMotor Vehicle

COLOR LABEL

INT. COLOR

WPEF B-84P

EXT. COLOR KA S2BA1 C

to1-2

U.S.1998Model

JHLRD174*WC000001

JHL: HONDAMOTOR CO.,LTD HONDA. Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RD1:CR-V/82084 RD2:CR'V/82084 Body Type and TransmissionType 7: 5-door/s-soeed Manual 8; 5-door/4-soeed Automatic

Multiport B20B4t 2.01 DOHC Sequential Fuel-injected engine

MDLA: 4-speedAutomatic M4TA: 4-speed Automatic S B X M : s - s p e eM a n u a l d MDLA,SBXM:1000001 M4TA: 3000001in C: SaitamaFactory Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

Blue Pearl Supermarine CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

VehicleldentificationNumber and CanadianMotor Vehicle

LABEL COLOR

INT. COLOR

TYPE F8.84P

EXT. COLORKA S2BA1 C

1-3

Chassis and PaintCodesU.S. 1999ModelVehicle ldentification NumberJHLRDIT4*XC000001

JHL: HONDAMOTOR CO.,LTD HONDA. Multipurpose

B2OZ2:2.0 DOHC | Sequential Multiport Fuel-injected engine

RDlt CR-vlB20Z2 RD2t CR-V1B2OZ2 Body Type and TransmissionType 7: 5-door/5-speed Manual 8: 5-door/4-spsed Automatic 4: LX MDLA: 4-speedAutomatic MDMA:4-speed Automatic SBXM: s-speed Manual

6:ExChock Digit Model Year X: 1999 C: Saitama Factory Japan(Sayama) in

MDLA:2000001MDMA: 1000001SBXM:2000001-

B-84P B-92P G.95P NH-578 NH-552M R,81

Supermarine Blue Pearl Nighthawk BlackPearl CloverGreenPearl TaffetaWhite SebringSilverMetallic MilanoRed

Vehicle ldentification Number and CanadianMotor Vehicle

COLOR LABEL

INT. COLOR

TYPE F B.84P

EXT. COLOR KA S2BA1 C

1-4

Model U.S.2000

Y JHLRD174* C000001

CO.,LTD JHL: HONDAMOTOR HONDA, Multipurpose Vehicle(MPV) Passenger Line. Body and EngineType RDlt CR-V/82022 RD2iCR-v/BzOz2 Body Type and TransmissionType Manual 7: 5-door/s-speed 8: 5 door/4-soeed Automatic

MultiDort 2.0 Seouential B20Z2t I DOHC Fuel-injected engine

Automatic MDLA; 4-speed Automatic MDMA:4-speed SBXM: s-speedManual

MDLA:3000001MDHA: 2000001SBXM:2000001in CrSaitamaFactory Japan(Sayama)

B-92P B-95P G-95P NH-578 NH-552M R-81

Nighthawk BlackPearl BluePearl Electron CloverGreenPearl Taffeta White SebringSilverMetallic Milano ed R

LABEL COLOR

Safety Standard Certification. lrl ..V

INT. COLOR

F TYPE 8.92P

EXT, COLOR KA S2BA1 C

1-5

and PaintCodes ChassisCanada1997Model

J H L R D 1 8 5 *V C 8 0 0 0 0 1

HONDAMOTOR CO.,LTD HONDA, Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDl: CR-V/B2084 Body Typ and TransmissionTyp Automatic 8: s-door/4-soeed

2.0 MultiDort B20g4t | DOHC Seouential Fuel-injected engine

MDMA- 1000001

MDMA:4-speed Automatic Automatic SDMA: 4-speed Factory Japan(Sayama) in C: Saitama

B-84P G-82P NH-552M NH-592P R-94

Supermarine BluePearl CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

Vehicle ldentification Number and Canadian Motor Vehicle Safety Standard Certification.

LABEL COLOR

INT. COLOR

F TYPEB-84P

EXT. COLOR

KCS2BC2 C

1-6

Canada1998Model

J H LR D 1 4 * W C 8 0 0 0 0 1 7

CO.,LTD JHL:HONDAMOTOR HONDA, Multipurpose Vehicle(MPV) Passenger Lino, Body and EngineType RD1:CR-V/82084 Body Type and TransmissionType Manual 7: 5-door/s-speed Automatic 8: 5-door/4-speed

Multiport Sequential | 8208 4:2.0 DOHC engine Fuel-injected

Automatic M4TA: 4-speed Manual SBXM:5-speed SBXM:1000001M4TA: 3000001* in C: SaitamaFactory Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

BIuePearl Supermarine CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

LABEL COLOR

INT. COLOR

TYPE F8.84P

EXT. COLOR

KCS2BC2 C

1-7

Chassis and PaintCodesCanada1999ModelVehicle ldentification NumberJ H LR D l T 4 * X C 8 0 0 0 0 1

JHL:HONDAMOTOR CO.,LTD HONDA, Multipurpose Passen0er Vehicle{MPV) Line, Body and Engin6Type RD1:CB-Y/B2OZ2 Eody Typ6 and Transmi$ion Type 7: 5-door/5-speed Manual 8: s-door/4-speed Automatic 4: LX 5: EX ChockDigit Model Yeal X: 1999 C: SaitamaFactory Japan{Sayama) in

B20Z2i I DOHC 2.0 Sequential Multiport Fuel-injected engine

MDMA:4-speed Automatic SBXM: s-speed Manual

B-84P a-92P G.95P NH.552M R-81

Supermarine BluePearl Nighthawk BlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed

VehicloldentificationNumber and Canadian Motor Vehicle Safety Standard Certification.

LABEL COLOR

INT. COLOR

TYPE F B-84P

EXT. COLOR KCS2BC2 C

1-8

J H LR D l7 4 * Y C8 0 0 0 0 1 Manulacturer, Make and Type of Vehicle CO.,LTD JHL:HONDAMOTOR Multipurpose HONDA, Passenger Vehicle(MPV) Line, Body and EngineType RDlt CR-VlB2oZ2 Body Type and TransmissionType Manual 7: 5-door/s-soeed Automatic 8: 5-door/4-sDeed Vehicle Grade (Seriesl 4: LX 5: EX Check Digit Model Year Yr 2000 FactoryCode in C: SaitamaFactory Japan(Sayama) Serial Number B-96P B-92P G-95P NH-552M R-81 YR-524M Blue Pearl Eternal BlackPearl Nighthawk CloverGreenPearl SebringSilverMetallic MilanoRed NaplesGold lVetallic

Multiport | Sequential 8 2022:2.0 DOHC engine Fuel-injected

Automatic MDMA:4-speed Manual SBXM: s-speed

Vohicle ldentification Number and Canadian Motor Vohicle

LABEL OOLOR

tNrcoL0R

F TYPE B-92P

COLOR EXT. KCS2BC2 C

1-9

ldentification NumberLocations

VehicleldentificationNumber lVlNl

Vehiclldentific.tion Number tvtNl

-

TransmissionNumb6r lManudl)

TransmissionNumbor {Aulomaticl

EngineNumbel

1-10

LabelLocations Warning/Caution

A: CABLEREELCAUTION

MODULEWARNING C: DRIVER A WARNING A I T H E A I R E A GI N F L A T O R S E X P L O S I V E N D , I F HURT CAN SERIOUSLY DEPLOYED, ACCIDENTALLY OR KILLYOU. OR TEST EOUIPMENT . DO NOT USE ELECTRICAL DEVICES. PROBING DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . N O S E R V T C E A B LP A R T S l N S l D E . D O N O T E DISASSEMBLE. WHEN REMOVED . PLACE AIRBAGUPRIGHT M . F O L L O WS E R V I C E A N U A L I N S T R U C T I O N S CAREFULLY.

OF TNSTALLATION THE SRSCABLEREELIS CRITICAL OF OPERATION THE SRS SYSTEM. TO THE PBOPER MANUAL FOR DETAILED TO REFER THE SERVICE INSTRUCTIONS. INSTALLATION MODULEDANGER B: DRIVER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALS S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y GASESOR HARMFULAND IRRITATING PRODUCE STOMGE TEMPERATURES COMPOUNDS. EXPLOSIVE F 2 { M U S T N O T E X C E E D O O " F1 O O ' C } . O R P R O P E R PROCEDURES. AND DISPOSAL HANDUNG,STORAGE, MANUAI- SRSSUPPI.EMENT, REFER SERVICE TO POTSON C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D NITRATE. POTASSIUM AID FIRST tF CONTENTS ARE SWALLOWED, INDUCE VOMITING.FOR EYE CONTACT,FLUSH EYESWITH WATERFOR 15 MINUTES.IF GASES IFROMACID OR WATER CONTACTIARE INHALED,SEEK FRESH A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L ATTENTION. OF KEEP OUT OF REACH CHILDREN

(cont'd)

1-11

Warning/Caution LabelLocations(cont'dl

(U.S.A. modelonlyl modolonlyl {U.S.A.

o: SRSWARNING{HOOD} SUPPLEMENTAL RESTRAINT SYSTEM{SRSI THIS VEHICLE EOUIPPED IS WITH DRIVER AND FRONT SEATPASSENGER AIRBAGS, ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE COLORED YELLOW. T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G ELECTRICAL TEST EOUIPMENT THE SRS WIRINGCAN ON MAKETHESYSTEMINOPERATIVE CAUSEACCIDENTAL OR FIRING THEINFLATOR. OF A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F ACCIDENTALLY DEPLOYED, CAN SEBIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.

E: STEERING COLUMNNOTTCE tHOODI NOTICE TO PREVENTSRS DAMAGE, REMOVESTEERING WHEEL BEFORE REMOVING STEERING SHAFTCONNECTING BOLT. F: MONITORNOTICE NOTICE . NO SERVICEABLE PARTStNStoE. . REFER TO SERVICEMANUAL FoR DETAILED

rNsrRucTtoNs.

1-12

AIRBAGMODULEDANGEN SEATPASSENGER G: FRONT A DANGER EXPLOSIVE/FLAMMABLE WITH ACID,WATER.OR I{EAVY METALSSUCH CONTACT HARMFUL MAY PRODUCE T.EAD. MERCURY OR AS COPPER. COMPOUNDS. GASESOR EXPLOSIVE AND IRRITATING MUST NOT EXCEED2OO"F TEMPERATURES STORAGE I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D MANUAL, TO REFER THESERVICE PROCEDURES DISPOSAL SRSSUPPLEMENT. POTSON SODIUM AZIDEANO POTASSIUM CONTAINSPOTSONOUS NITRATE. AID FIRST INDUCEVOMITING.FOR ARE SWALLOWED, IF CONTENTS E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5 MINUTES. IF GASES (FROM ACID OR WATEN CONTACT) SEEKFRESHAIR. IN EVERYCASE,GET ARE INHALEO. ATTENTION. PROMPT MEDICAL OF KEEP OUTOF REACH CHILDREN. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F HURT OR CAN SERIOUSLY DEPLOYED, ACCIDENTALLY YOU. KILL O L . D O N O T U S E E L E C T R I C AT E S T E O U I P M E N T R DEVICES, PROBING DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . NO SERVICEABI-E PARTSlNSlDE.DO NOT DISASSEMBII. WHENREMOVEO. . PLACE AIRBAGUPRIGHT CAREFULLY . FOLLOWSERVICMANUAL INSTRUCTIONS INFORMATION S.A. modell lU H: PASSENGER model} {U.S.A.'97 SIDE, AIEBAGSEEOTHER {U.S.A.'98 00 modelsl AIRBAGWARNING FLIPVISOROVER. l: SRSINFORMATION

lU.S.A.'98 00 models) WARNING INJURYCAN OCCUR' DEATHOR SERIOUS 12 . CHILDREN ANO UNDERCAN BE KILLEDBY THE AIRBAG. FORCHILDREN. PLACE . THE BACKSEATlS THESAFEST C . N E V E RP U T A R E A R - F A C I N G H I L DS E A T l N T H E FRONT. FROMTHEAIRBAG o SIT AS FARBACKAS POSSIBLE . ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS. TEN . THE SRSMUST BE TNSPECTED YEAnS AFTERlT lS INSTALLED. l . T H E O A T EO F I N S T A L L A T I O NS S H O W N O N T H E DOORJAMB. DRIVER'S AIRBAGWARNING PASSENGER J: FRONT lU.S.A.'98 00 models) WARNING C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E AIRBAG. PASSENGER 12 PLACEFORCI{ILDREN THE BACKSEAT IS THE SAFEST AND UNDER. USE SEAT BELTSOR CHILD MAKE SURE ALL CHILDREN SEATS. WARNING TENSIONER K: FRONTSEATBELT WABNING INSIDE MATERIAL EXPLOSIVE HURTOR BURNED, YOU CAN BE SERIOUSLY . DO NOT TAMPER DISASSEMBLE OR PARTSINSIDE. NO SERVICEABLE MANUAL FORCOMPLETE . REFER SERVICE TO INSTRUCTIONS.

model lU.s.A.'97i '97 00modls I lcanadaCAUTION INJURY: TO AVOIDSERIOUS lN . FORMAXIMUM SAFEW PROTECTION ALL TYPESOF YOU MUST ALWAYS WEAR YOUR SAFETY CRASHES, 8ELT. CHILOSEATSlN o OO NOT INSTALLREARWARD-FACING SEATPOSITION. ANY FRONTPASSENGER CLOSETO THE . DO NOT SIT OR LEAN UNNECESSARILY AIRBAG. OVERTHE AIRBAGOR . DO NOT PLACE ANY OBJECTS THEAIRBAGAND YOURSELF. BETWEEN . SEE THE OWNER'S MANUAL FOR FURTHER AND EXPLANATIONS INFORMATION TEN YEARSAFTERlT lS . THE SRS MUST BE INSPECTED INSTALLED. l . T H E D A T E O F I N S T A L L A T I O NS S H O W N O N T H E DOORJAMB. DRIVER'S

(cont'd)

1-13

Warning/Caution LabelLocations(cont'd)

VACUUM HOSEROUTING DIAGRAMlUndor-hood EmissionsControl Lrb6ll ENGINE COOLANT INFORMATION

SERVICE INFORMANON {Under-hood Emission3 Control l.rbell STEERING COLUMNNOTICE (sepage 1-12)

(Canadamodel)

RAOIATORCAP CAUTION

AIR CONDITIONING INFORMATION

1-14

ControlLabel Emissions Under-hoodGroupldentification Emission (1997 modellExample: DIAGRAM VACUUMHOSEROUTING

Families and Evaporative EngineF Engine amily: l v H N 2 . oJ G K E

Year Model v:1s97

T_fTi I

INFORIMATION VEHICLE Ii/PORTANTVHN2 ENGINE FAMILY OIJCrcK OLITER DISPIACEMENT'2 VNNl0778YMBP VE f EVAPORATAM]LY

NFORMATON. REfERTOSEBVICEMANUALfORAODITIONAL I-]P TUNT CONDITIONS TEMPERATURE, AT OPERATNG ENGINE NORI\,!AL FAN TL]RNED COOLING OIF OFF ES ALLACCESSOR NNEUTRAL TRANSM1SSION ADJUSTMENIS NEEDED NO OTHEB

CATALYST

ap'

| \6( Zror '.

ND\. 61F r L

TO TNISVENICLE CONFORMS U.S EPAREGUI.ATIONS TRACKS NWL GNI DUTY TO YEAR APPICASLE I99] MODET

Manufaqturer H N :H o n d a Displacement Class 1: Light DutyVehicle Fuol Systom ,nd Numbr of valves Multiport Sequential J: Electronic (threeor more valvesper Injection cylinder) Fuel Type G: Gasoline Standard F: 49 or 50 StatesTier 1 K: 49 or 50 StatesTier 1 Tier 1 1: California TLEV 2: California LEV 3: California ULEV 4: California Catalyst E, F, G, H: ThreeWay Catalyst

I I | L

@

OBDK - T: OBDEquipped VHNlOTTBYMBP T|

ON OSVE TRACT CONTROL'EOLJIPPED OR fOUB OF LOADED TEST]NG PERMANENT WHEEL IM ZED SYNCHRON ON VEHTCLES MUST BE CONDUCTED A IOUR WHEELDRVE SPEEO ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO

Evaporative Family:"r0", "*,

50ST (50 Statesl: OF TO CONFOBMS U.S.EPAAND STATE THISVEHICLE E S C A L I F O R N I R E G U L A T I O NA P P L I C A B LT O 1 9 9 7 A DUTYTRUCKS. YEARNEWLIGHT MODEL 49ST{49 Statos/Federall: TO CONFORMS U.S.EPA REGULATIONS THISVEHICLE YEARNEW LIGHTDUTY TO APPLICABLE 1997IVIODEL TRUCKS. CAL (Calitornial: OF TO CONFORMS U.S.EPAAND STATE THISVEHICLE T '1997 A IA REGULATIONS PPLICABLE O CALIFORN M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S IS THAT THISVEHICLE ONLY INTRODUCED PROVIDED F I N T O C O M M E R C E O R S A L E I N T H E S T A T EO F CALIFORNIA.

V: 1997 Manufacturer HN: Honda Storago System 1: Canister CanistorWorking Capacity (gramsl CanisterConfigulation Bottom) Housing(Closed A: Plastic Bottom) Housing(OPen B: Plastic Fusl System Y: FuelInjection FuelTank M: Metal Standard A: CurrentEvap Evap B: Enhanced Wild C.rd

5 1-1

Under-hood Emissions ControlLabelEmission Groupldentification (1998 modellExample:DwlF\AIo|NG cha\Gtftc+ cootr\r -smsoru1or or FoNoA-IEaoTTxD-ibl oB I a\D M oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN' wATfB. w r or_ut-ir coolqNt, ENGINE BE MAY SEflIOUSLYSIONTENEO. DSEPLACI CoOTANT 85 itNlgsloF@ MILIS AnEs l@0 rnl, wHrcHEvEs coMEs TNEREAFTR, EvEny REPLACE fmAFSlm m M[Esi@ kml, wHcHrvEB coMEs DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX.iAD]ATOR. NOTTHE DFOR FUFTNEfr INFO8MATION COOT]NC NEAD OWNEN'S ON IN SYSIEM THE MANUAL, . CHECK YOUR OEALEF. W|TH NONDA

Engineand Evaporative FamiliesEngineFamily:Modl Year W: 1998 ManufacturerSubcods HNX:HONDA W HNX T O2.O UF1

Family Typo V: LDV T: LDTDisplacomsnt SoquncoCharaciors

IMPORTANT VEHICLE INFORMATIONTHIS VEHICLE CONFOEMS I], S.EPA TO FEGIJLAIIONSAPPLICASLE MOOEL TO1993 YAF NEW LIGHT DUIYTNUCXS.

Evaporative Fami Family:Model Yeat W:1998 Manufastu16rSubcode HNX:HONDA Family Type E: EVAP R; EVAP/ORVR CanisterWork Capacity SgquoncoCharaqtsrs

W HNXEOOSOAAB

rwqHozst2l/sFt/osD l cERI|FtEOvAlvttAsH lrr0.l010.02nm icolo) EX:01310.02mm SPAS( PIUG GAP I.O IINM 686,13G96 lDLlSPTED 750 50rym I PROCEOURESI 2.0 L TlNt UPCoND/ToNS: ATNOiM ENGINE IEMPETAIURT,ALLACCESSORIESTUNNI fANOFf. TRAI1SMISSON INNEUTMI NO OIIIER AOJUSTI\TFIIS IIEEOED.

CATALYST

GD

@

50ST {50 States}: THISVEHICLE CONFORMS U.S.EPAAND STATEOF TO CALIFORNIA EGULATIONS PPLICABLE O 1998 R A T MODEL YEARNEWLIGHT DUTYTRUCKS, /$ST (itg Statos/Fodsrsll: THISVEHICLE CONFORMS U.S.EPA REGULATIONS TO APPLICABLE 1998MODELYEARNEW LIGHTDUTY TO TRUCKS. CAL {California}: THISVEHICLE CONFORMS U.S.EPAAND STATEOF TO C A L I F O R N I A E G U L A T T O NA P P L I C A B L E O 1 9 9 8 R S T M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S PROVIDED THATTHIS VEHICLE ONLY INTRODUCED IS I N T O C O M M E R C E O R S A L E I N T H E S T A T EO F F CALIFORNIA.

1-16

Groupldentification Emission (1999 model)Example:U-ECo-q.NOEDI Of USE THE COOLANT. @SOLU I ON FONOA '.WNEN NG CNANGINC AOO OR 0F LIFE oILLJTE CooLANT,0RTHE TNE mcrtniuvcoourr mo wlttt NEVEF THE

Families Engineand EvaporativeEngineFamily:Model Year X:1999 Manutao{urerSubcode HNX:HONDA

UA2 X HNXT02,O

wNrcHEVEn coMEs LEs ffi'"R "Eifil:$o""niii?i,THffi @ M lmo rhl,^,r*a, rurr"* i'lrt^t orrrr, os @ coMEs wNICHEVER MLEs 1@ kmrIHE TAN( ATTHE }CNECK ADD OR COOLANT RESER!'E NOT NADIATOS MANUAL' READ OWNER'S NC ON COOL SYSTEM THE DFOfi fWTHEF NFORMATION THE ' CHECK YOUS HONOA OEALER. WIIH

Type Family V: LDV T: LDTDisplacoment SaquenceCharactors X HNXEOO8OAAB

INFORMATION VEHICLE IMPORTANTS EPA VEHICLE CONFOAMSTOU. NLEV THIS TO MODL APPLICCBLI 1999 FEGULANONS ]nUCKSAND DUTY TIEVLIGHT YEA8NEW IO APPLICASLE 19S9 REGULATIONS CALIFORNIA DUTY IFIJCKS, TLEV LIGHT YEAR NEW MOOEL

Family: Evaporative,|F

CATALYSTmm IASN lN:010r0.02 VALVE E X0 1 3 1 0 0m m 2 lCoLDj PLUG SPA8K GAP 10- l l nm 130 5{ rPm t IDLE SPEED 201

OBDIICERT]ATD

Ll:.-.-,1 I rFrll \=#_H*JL

--'-

Model Yoal X:1999 ManutacturarSubcode

HNX:HONDAFamily Typo E: EVAP R: EVAP/ORVR Canbter Work Capacity SquonceChartsters

NOB I]PCONDIIIONS INGINEAT TUNE ES TLJRN ATL ACCESSOS TEI\'PERATUR NNEL]TML FAN IRANSMSSION OFf NEEOEO. ADJUSTMTNTS NO OINER

SPEED MUsTcoMoufitooNArounwNEElDslvE Iooro nr tist rc orn svtncrE BE rEsr ouRE sT Pf D sE iitriunor mo ovuvo uenn orr Enw aNoN.loaDE PRoCE MU 8E Rr-

GD50 state TLEV + NLEV {Unrestricted} T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V E R E G U L A T I O N A P P L I C A B L T O 1 9 9 9 M O D E LY E A R S A N E W T L E V L I G H TD U T Y T R U C K S N O C A L I F O R N I A A P P L I C A B L T O 1 9 9 9 M O D E LY E A R E REGULATIONS DUTYTRUCKS. NEWLIGHT

1-17

Under-hood Emissions ControlLabelEmission Groupldentification (2000 model)Example:DWFEN r,tc ChA\CtN! cooraN.ust MsoLU- oNor fioNpA aDD 0R q-af6MrNp-ol rlt DREpf coolaNrAFTEBt3tlomistoR@MtLEs cE r@km),wH ctlEvrscoMEs T|E8EAFTER, EVEny BEprAcE ErdFstoB@ MttEs lmr,t, ffitcHEVER coMEsDCIIICXOF ADDCOOLA\ I'-FE I

Engineand Evaporative FamiliesEngineFamily:Model Yar Y: 2000 ManufaqturerSubcodo HNX:HONDA Y HNX TO2.OUA2

\rvEn coo|-d',r os-Fiiiiifi-' lfi ;!,."5:P!$t:1t9ffilf u u'r+-E 1AISIRVI TAI{I\. NOI THEMDIAIOR

":3lliJ#fl

s,5TEMTrE sMA\u.r. "lj,9lx6L;T&Iji(0or|]\G 8r!D owrEp IMPORTANT VEHICLE INFORMATION

Family Type V: LDV T: LDT DisplacementSaquencoCharasters

IHIS\/IHICLE CONFONMS U.S.EPA TO NLEV SEGULATIONS APPIJCq3LE 2OOO TO IVOOEL YEAF NEW T!!V LIGHT DUTY TBUCKS AND CALIFONNIA SEGULATIONS APPLICASLE 2OOO TO MOOL YIAA NEW TLEV LIGHT.OUTY TFIJCKS.

Evaporative Family:Modol Yea. Y: 2000 ManufacturerSubcode HNX:HONDA Family Type E: EVAP R: EVAP/ORVR CanisterWork Capacity SoquencaCharactet3

Y HNXEOOSOAAB

CATALYSTvALvt LA5h tN:0,10r0.02 mm {C0t0l E l : 0 . 1 3 ! 0 0 2h m S P A n ( P L U G G A1 . 0 - 1 1 m m O8OCENTFIED P lDlE PEEo S 734150lpm ?.0 t TUNIUP CoNDIToNS: ENGINE NORM AT TTMPERAIURE ATLACCESSORIES fu BNI TAN TiANSMISS INNUTRAL OFF ON NO OTHER AD.ILJSTMENIS NEEDEO.

.l-L

|oAoEDr/MTESTNG oFTHsvtHrctE gt couolorooN,{raua.wxEtt uLrst onuspreo syNoiRoN DvNAMoMETER. ANoN.LoAoEopBocEounr sr pair zEo olrEiwsE. rEsr uust

m

1

50 State TLEV + NLEV (Unrestricied, T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V R E G U L A T I O N A P P L I C A B L T O 2 O O O O D E LY E A R S E M N E W T L E V L I G H TD U T Y T R U C K S N D C A L I F O R N I A A R E G U L A T I O N A P P L I C A B L T O 2 O O O O D E LY E A R S E M NEWLIGHT DUTYTRUCKS.

1-18

Lift and SupportPointsLift and SafetyStandsplace ffi When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to b lemoved, vehicle, the !iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the center of gravity may change and can causethe vehicle to tip fotward on the hoist' 30 weighsapproximately lbs (14 kg),placingthe front wheelsin the cargoareacan assembly NOTE:Sinceeachtire/wheel with weight distribution. assist 1. Place lift blocksas shown. the and the 2. Raise hoista few inches(centimeters), rockthe vehicleto be sure it is firmly supported. the lift pointsfor solidsupport' the 3. Raise hoistto full height,and inspect NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'

POINT FRONT SUPPORT

LIFTBLOCKS

POIMT REARSUPPORT

1-19

Lift and SupportPointsFloorJack1 . Blockthe rear wheelswhen raisingthe front of the vehicle; blockthe front wheelswhen raisingthe rear of the vehicle. Place blocksbehindand aheadof the wheels, the Raisethe vehicle high enough to insert the safety stanos. Adjust and place the safety stands so the vehicle will be approximately level,then lower the vehicle onto them. Always usg safety standg when working on or under any vehicle that is supported by only a iack. Nevor attempt to use a bumper jack for tifting or supporting ths vehicl.

Front:

Center the jack

bracketin the middle of the jack lift platform.

JACK LIFTPLATFORM

Rsar:

Centerthe iack in bracket the middle of the iack lift platform.

JACK LIFT PLATFORM

1-20

Towing

l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l towing service.Never tow the vehicle behind another vehjclewith just a rope or chain.lt is very dangerous. EmergencyTowing Thereare three popularmethodsof towing a vehicle. Flat-bedEquipment- The operator loads the vehicle on the Thisis the bestway of transporting the backof a truck. vehicle. Wheel Lift Equipment- The tow truck usestlvo pivoting armsthat go underthe tires lfront or rear)and liftsthem o f f t h e g r o u n d .T h e o t h e r t w o t i r e s r e m a i no n t h e a g r o u n d . T h e v e h i c l e ' ss u s p e n s i o n n d b o d y c a n b e seriously damagedif this methodof towing is attempted. Equipment The tow truck usesmetalcables Sling-type with hookson the ends.Thesehooksgo aroundpartsof and the cableslift that end of the frame or suspension and suspension the vehicleoff the ground.The vehicle's damagedif thjs methodof towing body can be seriously T i s a t t e m p t e d . h i s m e t h e d o f t o w i n g t h e C R - Vi s unaccePtable. way of towing the CR-Vis on a The onlv recommended f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e towed with all four wheelson the ground.

Front:

lOwlNG HOOKS.nd TIE DOWN BRACKETS

Rear:

Towing the four-wheel dlive CR-v with only two wheels on the ground will damage parts of the 4wD system. It this vehicle is damaged, it should be towed on a flat-bed truck ol trailel. It the 2 wheel drive CR-v is towed wiih all tour wheels on the ground, do the following: Manual Transmission . Release parkingbrake. the . Shiftthe transmission Neutral in Automatic Transmission . Release parkingbrake. the . Start the engine. . Shiftto lD.lposition. then E position. . Turn off the engine. BRACKET TIEDOWN lmproper towing preparation will damage the transmission.Follow the above procedure exactly. lf you cannot shift the transmission or start the engine, the vehicle must be transported on a flat-bed truck. lf the vchicle is towed with four wheels on the ground, il is best to tow the vehicle no larther than 50 miles (80 km), and keep the speed below 35 mph {55 km/h). Trying to lift or tow the vehicle by ihe bumpers will cause serious damage. The bumpers ale not dosigned to support the vehicle's weight.

1-21

ServicePrecautionsPartsMarkingLocationsTo deter vehicletheft, cenain major components are markedwith the vehicleidentification number{VlN).Originalparts will have self-adhesive labelsor labelsattachedwith a break-offbolt. Replacement body parts will have self-adhesive labels, and replacement engineand transmission partswill be stampedwith a codetor spareparts. NOTE: . Be carefulnottodamagethe partsmarkinglabelsduringbody repairs. Maskthe labelsbeforerepainting. ' Labellocation letters without parenthesis indicate originalparts.Letters with parenthesis indicate replacement pans. A, (A): Engine B, (B): Transmission C, (C): FrontBumoer D, (D); Hood E, (E): Tailgate F, (F): RearBumper (Lefrand Right) G, (G):FrontFenders H, {H): FrontDoors(Leftand Right} l, (l): RearDoors(Leftand Right) J, (J): OuterSide Panel(Leftand Right)

1-22

Drivel 4WD(Four-wheel for Precautions Real-timel , U n d e r n o r m a l c o n d i t i o n s t h e v e h i c l ei s i n 2 W D ( f r o n t - w h e ed r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t on drivingforceto the rearwheels{depending the drivingforceof the front wheelsand the road conditons) appropriate Pump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice 4WD-Dual The Real-time the front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels spinning work requires are off the ground (seepage1-19).

1-23

SpecificationsLimits............... 2-2 Standards Service and .......... Design Specifications .................. 2-12 ..........2-14 BodySpecifications

Standardsand ServiceLimitsEngineElectrical Section4MEASUREMENT lgnitioncoillgnition wire R a t e dv o l t a g e V P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )

STANDAFDINEWI 12 0.63 0.77 25 max. 1 3 4-2See Section 4 1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )

SERVICE LIMIT

Besistance 68"F(20 C) ktl at Firingorder Type Gap At idle

Sparkplugl g n i t i o nt i m i n g Alternator belt*r

BTDC

D e f l e c t i o nw i t h 9 8 N { 1 0 k g f , 2 2 l b f )

Alternator

Belttension N {kgf,lbt) gauge Measured with bek tension rpm OutputA (at 13.5V, hot and 6,000 alternator Brushlength

AII M/I A/f Mfi

1 6 12 { R e d ) 8 . 5 1 1 . 5 1 0 . 3 3 . 4 5 ) w i t h s e db e l t 0 u 5.5- 8.0 (0.22 0.31) with new belt 340- 490{35- 50,77 110) with usedbelt 690 880(70 90, 150- 200iwith new belt 95 90 ( 10.50.41) 1.5(0.06i 1.1 1.0 0.5- 0.8{0.02 0.03) 0,0.02 (0 0.0008) ( 2 7 . 9 2 8 . 0 1 . 0 9 8 41 . 1 0 2 4 ) 14.0 14.5(0.55 0.57) (1.40 1.80,3.093.97) 13.7 17.7

Staningmotor

Output kW Micadepth Commutator runout Commutator O.D. Brushlength Brushspringtension N (kgf,lbf)

0.2 (0.008) 0.0s(0.002) ( 27.0 1.06) 9.0 (0.35)

' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .

CylinderHead/Valve Train - Section6MEASUREMENT Compression 250rpm and wide openthrottle , kPa(kgflcm' psi) Warpage Height E n dp l a yCamshaft to hoider oil clearance

STANDARD {NEW}

SERVICE LIMIT

Nominal 1,230i'12 , 11Al .5 Minimum 930(9.s,135) Maximumvariation 20012.0,2al 1 3 1 . 9-5 1 3 2 . 0{ 5 . 1 9 - 5 . 1 9 9 ) 5 5 0.05 0.1s(0.002 0.006) (0.0012 0.0027) 0.030 0.069 0.03 0.001)max. { 33.204\1.30721 33.528 {1.3200) 16 33.1 \1.321 4) 33.528 {'1.3200) 0.08- 0.12(0.003 0.005) 0.16 0.20(0.006 0.008) (0.2591 0.2594) 6.580 6.590 (0.2579 0.2s83) 6.550 6.560 0.02- 0.05{0.00t 0.002) 0.05- 0.08(0.002 0.003) 1.25 1.55(0.049 0.061) ( 9 1 . 2 5 1 . 5 5 0 . 0 4- 0 . 0 6 1 ) 40.765 41.235 {1.6049 1.6234) 42.765 43.235i'1.6837 1.70221 (1.668i 42.36 44.32t1.1451 6.61 6.6310.260 0.261) 6.61 6.63{0.260 0.261i 1 3 . 7 - 1 4 . 2 5 0 . 5 4 10 . 5 6 1 i 5 1 15.75 16.25 {0.620 0.640i 0.05{0.002) 0.5(0.02) 0.15(0.006) 0.04(0.002)

Cylinder head Camshaft

Totalrunout Cam lobe height

'97,'98models '99,'00models

(Cold)* Valveclearance ValvestemO.D. Stem'to-guide clearance width height SteminstalledValve spring Valve guide Freelength

lN EX lN EX lN EX lN EX lN EX tN EX lN EXlN EX

u* to.rutt6.52lO.257l 0.08{0.003i 0.'1t(0.004) 2.0 (0.08) 2.0 (0.08) 41.485 {1.6333} 43.485 {1.7120i

I,D, Installed height

IN EX tN EX

6.6510.2621 6.65(0.262i

*: Measured between camshaft the and rocker arm,

2-2

o

EngineBlock- Section7MEASUREMENTCylinder block

Unit of length: mm (in)

(NEWI STANDARD max. 0.07(0.003) (3.307 3.308) 84.00 84.02 (3.306 3.307) 83.98 83.99 0.01- 0.04(0.0004 0.00161 1.240 1.250 {0.0488 0.0492) 1.220 1.230 {0.0480 0.0484) - 0 2.805 2.825 0.1104 .1112) 1 (0.0022 0.0031) 0.055 0.080 (0.0014 0.0024) 0.035 0.060 0.20 0.30(0.008 0.012) 0.40- 0.55(0.016 0.022) 0.20- 0.50(0.008 0.020) (0.8266 0.8268i 20.996 21.000 (0.0004 0.0007) 0.010 0.017 (0.0006 0.0013) 0.015 0.032 -20.98110.8255 -0.8260) 20.968 48.0(1.89) 0.15- 0.30{0.006 0.012i (2.' 54.976 55.000 l644 2.1654) (2.1642 2.1651) 54.970 54.994 44.976 45.000/.1.1707 1.71111 (0.0002)max. 0.005 (0.0002) max. 0.005 0.10- 0.35(0.004 0.0r 4) 0.03(0.001)max.

Piston

Warpageof deck surface Borediameter Boretaper bottomof skart SkirtO.D.*1trom in Clearance cylinder Groove width {Forringi

Piston ring

clearance Ring-to'groove Ringend gap

Top Second oil ToP Second ToP Second oil

SERVICE LIMIT 0.10(0.004) (3.310) 84.07 0.05(0.002) (3.306) 83.97 0.05{0.002) 1.26(0.0s0) 1.25(0.049) 2.44lo.112l 0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.70(0.028)

PistonPin rod Connecting

o.D.

o

Pin-to-piston clearance Pin-to-rodinterference Smallend borediameter Nominal Large end borediameter Endplayinstalled crankshaft on Mainjournaldiameter Crankshaft N o .1 , 2 , 4 a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out ol round Endplay Bunout Main bearing-to-iournal clearance oil Bearing N o .1 ,2 , 4 a n d 5 i o u r n a l s No.3 journal oil Rodbearing-to-,ournal clearance *1: '97,'98models15 mm (0.6in) '99,'00models20 mm (0.8ini

oroto.oroi

(0.00041 0.010 (0.0004) 0.010 0.45(0.0r8) 0.04(0.002)

0.0017) 0.024 0.042 10.0009 (0.00120.0019) 0.030 0.048 (0.0008 0.0015) 0.020 0.038

(0.002) 0.06 (0.002) 0.06 (0.002) 0.05

o2-3

Standards andServiceLimitsEngineLubricationEngine oil

Section8MEASUREMENT STANDARO {NEWI SERVICE LIMIT 4.6(4.9, 4.0)Iorengineoverhaul 3 . 8{ 4 . 0 , 3 . 3 ) f o ri l c h a n g e n c l u d i nfg l t e r o i, i 3.5 (3.7, 3.1)for oil change, withoutIilter 0.04- 0.16(0.002 0.006) 0.20(0.008) 4 0 . 1 0 0 . 1 9 ( 0 . 0 0- 0 . 0 0 7 ) 0.20(0.008) 0.02-0.07 (0.001 0.003i 0.15(0.006) 70 (0.7,10)min. 3 4 0{ 3 . 5 , 5 0m i n . )

Capacity f (US qt, lmp qt)

Oilpump

R e l i e fv a l v e

Inner-to-outer rotorclearance Pumphousing-to-outer clearance rotor Pumphousing-to rotoraxialclearance Pressure setting engineoil temp. 176'F(80'C) at kPa(kgt/cm,,psi) At ldle At 3,000rpm

CoolingRadiator

Section 10MEASUREMENT Coolant capacity , (USq1,lmp qt) engine, heater,I llncluding line Lcooling and reservoirl Reservoir capacity: q 0 . 6 1( 0 . 6 3 S q t , 0 . 5 3 l m p t ) U pressure kPa(kgf/cm?, psi) Opening Startsto open 'F 1"C) Fullyopen 'F ("C) Valvelift at tully open "ON" temperature "F Thermoswitch {'C) "OFF"temperature 'F ('C) Thermoswitch STANDARO INEW} 5.9{6.2, 5.2}toroverhaul 3.9(4.1, 3.4ifor coolant change 6.0(6.3, 5.3ifor overhaul 4.0(4.2, 3.5)for coolant change 9 3 - 1 2 3( 0 . 9 5 1 . 2 5 1 4 1 8 ) , - 176(76- 80) 169 194(90) 8 . 0( 0 . 3 1 i m i n . 196- 203 (91- 95) Subtract - 14 (3 - 8) trom actual"ON" temperature 5

M/T

Radiator cap Thermostat

Cooling fan

Fueland Emissions

Section 11MEASUREMENT STANDARD INEW} 260- 31012.7 3.2,38- 46) 270-32012.8 3.3,40- 471 , 5 8 ( 1 5 . 31 2 . 8 ) MT AT {E or E position)

Pressure regulator Pressure with regulatorvacuum hose disconnected '97,'98models , kPa(kgflcm' psi) '99, '00 rnodels Fueltank (USgal,lmp gal) Capacity / En g i n e ldle speed with headlights coolingfan off rpm and '97 model '98 model '99,'00 models Fastidle rpm '97 model '98 model '99,'00 models

750 50 r 7301 501,5001200 1,600 200 r 0.1max.

750t 50 750r 50 7301 0 51,5001 00 2 1,5001 00 2 1,600 200 r

ldle CO %

2-4

ClutchClutchpedal

Section 12MEASUREMENT height Pedal Stroke Freeplay play Pedal Disengagement height runout ClutchsurfaceRivet head depth Thickness

Unitof length:mm lin) STANDARD INEWI 183(7.20) - 5 135-14515.31 .71) 7 - 2210.24 0.41J 1-9 (0.04-0.35) m 7212.83)in. SERVICE LIMIT

to floor

to floor

(0.002) max. 0.051 . 2 1 . 7 1 0 . 0 5 -. 0 7 ) 0 8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 ) ( 0.03 0.001)max. 0.6 (0.02) max.

0.r5(0.006)0.2(0.01) 6.0i0.24) 0.15(0.006) 0.8 (0.03)

Clutchdisc plate Pressure

Warpage Diaphragm springfingeralignment

ManualTransmission Section 13Transmission fluidMainshaft

MEASUREMNT Capacity f (USqt, lmp qti Endplay contact area(clutch side) Diameter ball bearing of Diameter needle of bearing contact area Diameterof ball bearingcontactarea (transmission housing side) Runout LD. Endplay Thickness LD. Endplay Thickness Diameterol needlebearingcontactarea Diameter ball bearing oI and needle bearing contact Diametero{ 1st gear contactarea Runout

STANDARD INEW}1 . 71 1 . 8 1 . 4 ) f o ro i l c h a n g e , 2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l

I

SERVICE I-IMIT

0.'11 0.18(0.004 0.007) (1.1015 1.1020) 27.977 27.990 (1.4954-1.4961) 37.984 38.000 (1.1018 1.1024) 27.987 28.000 0.02(0.0011max. 43.009- 43.02511.6933 1.6939) 0.06- 0.21 (0.002- 0.008) 34.92 34.97 11.375 1.377) , 31.42- 31.4'7 11.237 1.2391

Adjust ( 2 7 . 9 41 . 1 0 0 ) (1.493) 37.93

Mainshatt and 3rd 4th gears

3rd gear 4th gear

Mainshaftsth gear Countershaft

(1.100) 27.94 0.05{0.002) 43.08011.6961) 0.3 (0.01) 34.811.37) 31.311.23) 1.6939) 43.08011.6961) 43.00943.02511.6933 (0.0020.008) 0 . 3( 0 . 0 1 ) 0.06 0.21 ( 30.8 1.21) 30.92 30.97 {1.217 1.219) - 1.4179) 3s.95 - 36.015 (1.415) 36.000 {1.4173 (0.982) 24.94 24.987- 25.000(0.9837 0.9843) -1.4567) 36.984 37.00011.4561 0.02(0.001)max.

(1.4s4) 36.93 (0.002) 0.0s(1.696) 43.08 0.2310.009) 47.08 {1.854) 0.18(0.007) ( 3 1 . 0 61 . 2 2 3 ) (1.494) 37.94 26.01t1.0241

1st countershatt gear Countershaft 2nd gear collar Spacer (Mainshaft 4th and 5th gears) Reverse idlergear ring Synchro Dualcone

LD. Endplay Thickness t.D. Endplay Thickness

(1.69331.6939) 43.00943.025 (0.0020.007i 0.06 0.18 (1.061 1.063) 26.9s,27.00 (1.85071.8514) 47.00947.025 ,0.006) 0.07 0.14 10.003 l 2As2 2a.971.139-1.1411A

t.D. o.D.Length

l le ' s

I

t.D. gear Gear-to-reverse shaftclearanceR i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )

31.002- 31.O12 .2205, 1.2205) 11 (1.4956 1.4961) 37.989 38.000 56.45- 56.55Q.222- 2.2261 26.03,26.08(1.025 1.027) - 20.043 (0.7880,0.7891) 20.01 6 (0.0014 0.0033) 0.036 0.084

(0.7909) 20.09 0.16010.0063)0.4 (0.02)

0.85 r.10(0.0330.043) 0.5 1.0(0.02 0.04) 0.5- 1.0(0.02 0.04) (0.0370.066) 0.95 1.68 7.4- 7.6(0.29 0.30) 6.2- 6.4(0.240.2s) (0.0't40.026) 0.35 0.65

Shift fork

(ringpushed gear) against Clearance ring to synchro cone Outersynchro Synchrocone-to-gear Outersynchro ring-to-gear Finger thickness 3rdl4th shiftlork Exceptabove Fork-to-synchro sleeveclearance

0.3(0.01) 0 . 3( 0 . 0 1 ) 0.6(0.02)

't, torag)

Standards and ServiceLimitsManualTransmission {cont'd}- Section 13MEASUREMENT Raverse shift Iork Pawl groove width Fork-to-reverse idler gear clearance width*l Groove Fork-to-5th/reverse shaft clearance*' shift at B' Shift arm A Shiftarm C Select armSelectlever Shift lever Shift fork diameter at contact area Shift arm A-to-shitt tork shaft clearance

at A atB

STANDARO INEW) '13.0 13.3(0.5' - 0.52) j 0.5- 1.1(0.02 0.04) 7.O5 7.25 i.0.21 - 0.2451 4 7.4-7.7 t0.29 0.301 0.05- 0.35(0.002 0.014) 0.4,0.8 (0.02 0.03) 12.9 13.0(0.508 0.512) 0.2- 0.5 (0.008-0.020) 0.05 0.25(0.002 0.01) r2.9- 13.0(0.508 0.512) 0.05- 0.25(0.002 0.01) 1 7 . 9- 8 . 0( 0 . 3 1- 0 . 3 1 s ) (0.6276 0.6287) 15.94r 15.968 (0.0013 0.0034) 0.032 0.086 (0.6276 0.6287) r5.941 15.968 (0.0013 0.0050) 0.032 0.127 (0.7091 0.7098) 18.010 18.028 (0.0011 0.0022) 0.027 0.057 (1.1026,1.1033) 28.005 28.025 (0.0010,0.0026) 0.025 0.066 0.055- 0.09110.0022 0.0036)

SERVICE LIMIT

18 (0.07)

0.5{0.02) (0.04) 1.00.6{0.024i

Shiftarm C'to-shift arm B clearance Diameterof shift arm B contactarea Selectarm'to-shift arm A clearance Diameter shiftarm A contact of area

o.D.Transmission housing clearance

o.D.Shift arm cover clearance

Differential carner

Pinion shaftcontact areaLD. Carrier-to-pinion clearance shaft Driveshaft,intermediateshatt contact area LD, Carrier-to-driveshaft clearance Carrierto-interrnediate shaft clearance

0.1 (0.004) 0.12 0.005i { ( 0.15 0.006i

Differential piniongear

Backlash t.D. gearto-pinion clearance Pinion shaft

0.05-0.r5 {0.0020.006) (0.71030.7113) 18.04218.066 0.059 0.095 10.00230.0037)1.4 2.5i'14 26,12-231

oru ro.ooorAdjust

Ditferential taperedrollrbesringpreloac Staningtorque N.m (kgf.cm, lbl.ini Transter Diameter rollerbearing of contact area Translershaft {driven gear side} Translorshaft {middle of shaft) Transterdrive gear gearside) Translor drivengearshaft{driven Transter drivengearshaft(splined side) Trans{ergear backlash Totalstarting torqueN.m (kgicm,lbiin)

(1.337 1.339) 33.984 34.000 21.977 27.99011.101 1.1021 - 1.576) 40.002 40.01811.575 - 1.379) 35.002 35.01811.378 (1.062 1.063) 26.975,26.988 0.06- 0.16{0.002 0.006) 2.64 3.41 \21.3,35.4,23.1 30.t|

(1.336) 33.93 27.92 (1.O99) (1.573) 39.95 (1.376) 34.95 (1.060) 26.92 Adjust Adjust

11:fuleasuring points

A

*2: Measuring points

A'

A 'Ay"

_{-P)

-l-...

2-6

Automatic Transmission Section 14MEASUREMENT Transmission fluid Capacity I {US qt, lmp q0 4WD 2WD Hydraulic pressure kPa (kgflcm', psi) Linepressure 2,000 at rpm in LII or El position 1slclutchpressure 2,000 at rpm in Da position 1st-hold rpm In l position clutchpressure 2,000 at STANDARO INEW} 6.8(7.2, 6.0)for overhaul 2.6)for fluid change 2.9(3.1, 5.2)foroverhaul 5.9{6.2, 2.4}forfluid change 2.7{2.9, 830- 880(8.5- 9.0,120 130)

U n i t o f l e n g t h :m m ( i n )

SERVICE LIMIT

780(8.0,1' t0)

2nd clutchpressure 2,000 at rpm in El position ('97, 3rd clutchpressure 2,000 at rpm in E position '98 models), or E position with O/DOFFindicator light ON ('99,'00models) ('97, 4th clutchpressure 2,000 at rpm in gl position '98 models), with O/DOFFindicator or E position lightoFF ('99,'00models) rpm (Check with vehicle levelground) on Stallspeed 1st Clutchinitialclearance 2nd,3rd,4th 'lst-hold Clutchreturnspringfree length discthickness Clutch Clutchplatethickness Clutchend platethickness (lsti 1st,2nd,3rd,4th '1st-hold 2nd,3rd, 4th 1st,1st-hold Mark1 Mark2 Mark3 Mark4 Mark5 Mark6 Mark7 Mark8 MarkI Mark 10 Mark6 Mark7 Mark8 Mark9 M a r k1 0 M a r k1 1 lvlark 12 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 Mark17 Mark8 MarkI M a r k1 0 M a r k1 1 M a r k1 2 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 M a r k1 7 Mark1 M a r k2 Mark3 No mark Mark6 Mark7

800- 850(8.2 4.7,120 1241

760t7.7,1101

end platethickness Clutch {2nd,4th)

Clutch end platethickness {3rdi

Clutch end platethickness ( 1 s th o l d )

2,550 -0.033) 0.65- 0.85(0.026 0.40- 0.60(0.016 0.024) 0.5- 0.8(0.020 0.031) 31.1 11 .22) ( 34.6 1.36) 1.88 2.00(0.074 0.079) 'r.95 2.05 {0.077 0.081) '1.55-1.65(0.061 0.065) 2.05- 2.r0 (0.081 0.083) 2.15 2.20(0.085 0.0871 2.25 2.30(0.089,0.091) 2.35 2.40{0.093 0.094} 2.45- 2.50{0.096-0.098} 2.55- 2.60(0.100 0.102) 2.65- 2.70(0.104 0.106) 2.75 2.80i0.108 0.110) . 2 . 8 5 2 . 9 0 1 0 1r2 0 . 1 1 4 ) 2.95 3.0010.116 .118) 0 2.55 2.6010.100 0.102) 2.65 2.70(0.104,0.106) 2.75- 2.80(0.108 0.110) ( 2 2 . 8 5 2 . 9 0 0 . 1 1- 0 . r r 4 ) ( 2.95 3.00 0.116-0.118) ( 0 3 . 0 5 3 . 1 0 0 . 1 2- 0 . 1 2 2 ) ( 3.15 3.20 0.124-0.126) 3.25- 3.30(0.128 0.130) 3.35- 3.40(0.r32- 0.134) 3.45- 3.50(0.136 0.138) ( 0 3 . 5 5 3 . 6 0 0 . 1 4- 0 . 1 4 2 ) 3.65- 3.70(0.144 0.146) ( 2 . 7 5 2 . 8 0 0 . 1 0 80 . 1 1 0 ) ( 2 2 . 8 5 -2 . 9 0 0 . 1 1- 0 . 1 1 4 ) ( 6 2 . 9 5 3 . 0 0 0 . 1 1- 0 . 1 ' j 8 ) 3.05 3.10(0.120 0.122) 3 . 1 5 - 3 . 2 00 . 1 2 4 0 . 1 2 6 ) { 3.25- 3.30(0.128 0.r30) 3.35- 3.40(0.132 0.r34i 3.45- 3.50(0.136 0.138) 3.55- 3.60{0.140 0.142) 3.65- 3.70{0.144 0.r46) 2.05 2.10(0.081 0.0831 2.r5 2.20(0.085 0.087) 2.25- 2.30{0.089 0.091} 2.35- 2.4010.093 0.094i 2.45- 2.50(0.096-0.098i 2.55- 2.60(0.r00- 0.102) 2.65- 2.70(0.r04- 0.106)

2,400,2,700

( 29.1 1.15) 32.6(r.28) worn out Untilgrooves Discoloration DiscolorationDiscoloration

Discoloration Discoloration

Discoloration

Discoloration

Discoloration

(cont'd)

2-7

Standards and ServiceLimitsAutomatic Transmission (cont'd)- Section 14MEASUBEMENT Transmission Diameter needle of bearing contact area statorshaftbearing On mainshaft 2nd gear On mainshaft 4th On mainshaft gearcollar On mainshaft gearcollar 1st (torque converter housing side) On countershatt On countershaft gear 3rd 4th On countershaft gear gearcollar On countershaft reverse 1st On countershaft gearcollar housing sidei On sub-shaft {transmission On sub shaft4th gearcollar idlergearshaft On reverse Inside diameter needle of bearing contact area 1st On mainshaft gear On mainshaft 2nd gear On mainshaft gear 4th 1st On countershaft gear 3rd On countershaft gear 4th On countershaft gear gear reverse On countershaft 4th On sub-shaft gear On reverse idlergear fleverse idlergearshaftholderl.D. Endplay Mainshaft gear 1st Mainshaft 2nd gear Mainshaft gear 4th Countershaft gear 1st Countershaft gear 3rd Countershaft gear 4th Sub-shaft4th gear Reverse idlergear Countershaftreversegear hub O.D. Selector Mainshaft gearcollarlength 4th Mainshaft gearcollarflange 4th thickness Mainshaft gearcollarlength 1st Countershaft distance collarlength STANDARD {NEW} SERVICE LIMIT (0.9441 0.9446) Wearor damage 23.980-23.993 (1.4163 1.4169) 35.975 35.99'! ( 3 1 . 9 7 5 3 1 . 9 9 11 . 2 5 8 91 . 2 5 9 5 i 30.975 30.99111.2195 1.2201l' (1.4175 1.4180) 36.004 36.017 (1.4165 1.4172) 35.980 35.996 ( 2 7 . 9 8- 2 7 . 9 9 31 . 1 0 1-61 . 1 0 2 1 i 0 ' ( 3 1 . 9 7 5 - 1 . 9 9 11 . 2 5 8-9 j . 2 5 9 5 i 3 ( 3 1 . 9 7 5 3 1 . 9 9 11 . 2 5 8-91 . 2 5 9 5 ) (1.0233 1.0236) 25.991 26.000 (0.9053 0.9058) 22.9935 23.006s 13.990 r4.000(0.5508 0.5512) Wearor damage (1.3780 1.3786) 35.000 35.016 4 1 . 0 0- 4 1 . 0 1 ( 1 . 6 1 4-21 . 6 1 4 8 ) 0 6 -' (1.4961 1.4967) 38.000 38.016 (1.496'1 1.4967) 38.000 38.016 4 1 . 0 0 0 4 1 . 0 1 ( 1 . 6 1 4 21 . 6 1 4 8 ) 6 (1.2992 1.2998) 33.000 33.016 (1.4961 1.4967) 38.000 38.016 (1.2598 1.2605) 32.000 32.016 (0.7089 0.7094) 18.007 18.020 (0.5676 0.5683) 14.416 14.434 0.05- 0.16{0.002 0.006) 0.05- 0.13(0.002 0.005) (0.002 0.006) 0.05,0.'16 0.1 0.5(0.004 0.020) 0.05 0.17{0.002 0.007) 0.10 0.18(0.004 0.007) 0.0s 0.17(0.002 0.007) 0.05- 0.18(0.002 0.007) 0.10,0.25(0.004 .010) 0 (2.042 2.043) 51.87 51.90 (1.9488 |.9508) 49.50 49.55 ( 4 . 4 3 5 4 . 5 2 50 . 1 7 4 6 - 0 . 1 7 8 1 ) 2 7 . 0 0 , 2 7 . 0{5 . 0 6 3 ' 1 . 0 6 5 i 1 (1.534 1.535) 38.97 39.00 (1.536, 1.537) 39.02 39.05 (1.538 1.539) 39.07 39.10 ( 0 3 9 . 1 2 3 9 . 1 5 1 . 5 4- 1 . 5 4 1 ) * (1.542 1.543) 39.17 39.20 39.22 39.25 11.544 1.545) 39.27 39.30 1'1.5461.547i 38.87 38.90 {1.530 1.531) (1.s32 1.533) 38.92 38.95 21.15- 21.20rc.4327 0.4346) , (0.57't 0.575) 14.5, 14.6 2.4- 2.6(0.094 0.102) 14.5 14.6(0.571 0.575) 2.4- 2.6(0.094 0.102) 24.0 24.1(0.945 0.949) ( 6 2 . 9 5 3 . 1 0 0 . 1 1- 0 . 1 2 2 ) Wearor damage

Wearor damage

il*=lo'. d"'.n"n"Wearor damage

Countershaft gearcollarlength 3rd gearcollarlength reverse Countershaft gearcollarflange Countershaft reverse thickness 1st Countershaft gearcollarlength lst Countershaft gearcollarflangethickness Sub-shaft gearcollarlength 4th Sub shatt4th gearcollarflangethickness

Wearor damage Wearor damage Wearor damage

2-8

Automatic Transmission - Section 14MEASUREMENT TransmissionMainshaft 2nd gear thrust washer thickness

Unit of length: mm (in)

(NEWI STANDARD3.974.024.07 4.12 4.17 4.224.274.32 4.374.422.95 2.434.9s2.93 4.0010.156 0.157) 4.05{0.158 0.159) 4.1010.160 .161) ( 2 4 . 1 5 0 . 1 6- 0 . 1 6 3 ) 4.20(0.164 0.165) 4.2510.166 0.167 ) 4.30(0.168 0.169) ( 4.35 0.170-0.171) 4.40(0.172 0.173) 4.45(0.174 0.r75) ( 3 . 0 5 0 . 1 1 60 . 1 2 0 ) 2.50(0.096 0.098) 5.00(0.195 0.197) ( 5 3 . 0 0 0 . 1 1- 0 . 1 1 8 1

SERVICE LIMIT

IWearor damage Wearor damage

It

I

Thrustwasher thickness l'rainshaft bearingleftside ball Mainshaft gear 1st Countershaft gearsplinedwasher 3rd Sub-shaft4th gear thrust washer One-way clutchcontact areaLD. 1st Countershaft gear gear Parking Mainshaft feed pipeA, O.D.(at 15 mm trom end) Mainshaft feed pipe B, O.D.(at 30 mm from end) teed Countershaft pipeO.D.lat 15 mm from end) Sub-shaft feed pipeO.D.(at 15 mm from end) ring thickness Mainshatt sealing (29mm and 35 mm) I.D. Mainshaft bushing Mainshaft bushingl.D. Countershaft bushing l.D. Sub shattbushingLD. Mainshaft sealingring groovewidth ATFpump gearsideclearance ATFpump gear'tobody clearance Drive Driven ATFpump drivengearLD. ATFpump drivengearshaftO.D.Sealing ring contact area l.D,

I Wear damage orWearor damage Wearor damage 8.95(0.352) 5.95(0.234) 7.95(0.313) 7.95{0.313) 1.42$.O72) (0.2380) 5.045 9.03(0.356) 8.03(0.316) 8.03(0.316) (0.082) 2.095 0.0710.003) Wearor damage Wearor damage (1.3799) 35.050

(3.2810 3.2821) 83.339 83.365 (2.6254 2.6259) 66.685 66.698 8.97- 8.98 (0.353- 0.354) 5.97 5.98{0.2350 0.2354) 7.97- 7.98(0.3138 0.3142) 7.97,7.98 (0.3138 0.3142) 1.87 1.97(0.074-0.078) (0.2369 0.2374) 6.018 6.030 (0.3543 0.3549) 9.000 9.015 (0.3150-0.3158) 8.000 8.022 (0.3150 0.3158) 8.000 8.022 (0.0797 0.0811) 2.025 2.075 0.03- 0.05(0.001 0.002) (0.004,0.005) 0.1050 0.1325 0.0350 0.0625 10.001 0.002) (0.5518 0.5525) 14.016*14.034 13.980 13.990 {0.5504 0.5508) 35.000 35.025 {1.3780 1.3782) 2't.o00 27.021I '1 .063, 1.064) 2 9 . 0 0- 2 9 . 0 1 3 1 1 . r 4 11 . 1 4 2 2 ) 0 7

o

ATFpump

Regulator valve body Stator shaft

deviceand Shifting parking brake con' trol Servo bodyDifferential carrier

Inside diameter bearing of oI contact area On torqueconvener side On ATFpump side Reverse shittfork fingerthickness Parkingbrakepawl gear Parking Shiftfork shattborel.D. Shiftfork shattvalvebore l.D. Pinionshaftcontact areaLD. Carrierto-pinion shaftclearance Driveshafvintermediate contact l.D. shaft are Carrier driveshalt to clearance Carrier-to-intermediate clearance shaft

5.90 6.00 {0.232,0.236)(0.55' l2 0.5516) 14.000 14.010 (1.4567 1.4582) 37.000 37.039 '18.010 18.028 - 0.710) 10.709 0.023 0.057 {0.001 0.002} (1.0246 1.0254) 26.025 26.045 (1.103 1.104) 28.025 28.045 0.045 0.08610.002 0.003) 0.075 0.111 0.004) 10.003-

Wearor damage Wearor damage 5.40(0.213) lWear or otherdefect

(1.4585) 37.045 0.r {0.004) 0.12(0.005) 0.15(0.006)

2WD 4WD

Differential prnron gear

Backlash t.D. gear'to-pinion clearance Pinion shaftDiameter rollerbearing of contact area gearside) Transfer shaft(transfer Transfer shaft(middle shaft) of Transferdrive gear gearside) Transfer drivengearshaft{driven Transfer drivengearshaft{splined side) gearbacklash Transfer Totalstarting lbf.in) torqueN.m (kgf.cm,

(0.0020.006) 0.05 0.15 (0.71030.7113) 18.06218.066 otu to.oout 0.055 0.095 10.00220.0037)0 0.15(0- 0.006) (1.515 1.516) 38.485 38.500 27.917- 21.990 |.1.101 1.102) (1.575 1.576) 40.002 40.018 (1.378 1.379) 35.002 35.018 -' (1.062 l.063) 26.975 26.988 (0.002 0.006) 0.060 0.160 2.64- 3.41 127.3 35.4,23.1 30.71 Adjust ( 3 8 . 4 31 . 5 1 3 ) (1.099) 27.92 (1.573) 39.95 (1.376) 34.95 (1.060) 26.92 Adiust Adiust

S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e

Transfer

o

(cont'd)

2-9

Standards and ServiceLimits(cont'dl - Section 14 Automatic TransmissionSTANDARO INEWI MEASUREMENT Wire Dia. Springs Regulator valvespringA Regulator valvespringB Statorreaction spring Modulator valvespring Torque convener valvespring check '97 model '98 - 00 models reliefvalvespring Cooler Relief valvespring 2nd orilicecontrolvalvespring 1-2shittvalvespring 2 3 shiftvalvespring 3-4shiftvalvespring 1staccumulator spring 4th accumulator springB 4th accumulator springA 2nd accumulator springA 3rd accumulator springA 2nd accumulator springB 3rd accumulator springI 3rd sub accumulator spring 2nd accumulator springC Lock-up shiftvalvespring Lock-up timing valvespring Lock'up controlvalvespring 3'4 orifice controlvalvespring Servocontrolvalvespring CPBvalvespring 4th exhaust valvespring 1 . 81 0 . 0 7 1 ) 1 . 8i 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.4{0.055) 1.1(0.043) 1.2(0.047) 1.0(0.039) 1 . 1( 0 . 0 4 3 ) 0.7 (0.028) 0.9 (0.035) 0.9 (0.035) 0.9 (0.03s1 2.1 (0.083) 2.3 (0.091) 2.6 (0.102) 2.410.094) 2 . 8( 0 . 1 1 0 ) 1.6(0.063) 2.1(0.083) 2.7{0.r06) 2.2lO.OA7) 0.9 (0.035) 0.9 (0.035) 0.7 (0.028) 0.6 (0.024) 1.0(0.039) 0.9 (0.035) 0.9 (0.035)

o.D.14.7(0.579) 9.6 (0.378) 35.4{1.394} 9.4 (0.370) 8.4 (0.331) 8.4 (0.331) 8.4 (0.331) 8.6(0.3391 6.6(0.260i 7.6{0.299} 7.6{0.299) 7.6{0.299) 16.0(0.630) 10.2to.402l 17.0(0.669) 29.0\1.1421 'r7.510.689) 9.0 (0.354) ( 31.0 1.220) 17.0(0.669) 14.510.571) 7.610.299i 8 . 1{ 0 . 3 1 9 } 6.6(0.260) 6.6(0.260i 8.1(0.319) 8.1{0.319) 6.t (0.240)

Fiee Length

No. of Coils

87.8(3.457) 44.011.1321 30.31r.193) 35.0{1.378) 36.4{1.433) 32.4tl.216J 33.8 r.331) { ( 37.1 1.461) 34.8(1.370) 41.3(1.626) 57.0 (2.2441 57.0 12.2441 89.1(3.508) ( 51.6 2.031) 88.4(3.480) 39.011.s35) 94.313.713) 20.710.8r5) 38.2(1.504) 39.0(1.535) 68.0(2.677) 73.7 12.902) 8 r . 4( 3 . 2 0 5 ) 38.0fl.496) 37.9(1.492) ( 52.1 2.051) 41.2 t\ .A5Al 36.4(1.4331

r 1.0 1.9 10.9 12.O 12.7 8.2 13.4 22.0 26.4 26.8 13.8 14.2 2.9 15.9 2.6 6.3 32.0 47.A 20.8 '18.3 '19.5

Differential (4WDl * Section 15MEASUREMENTCapacity f (US qt, lmp ql)

STANOABD {NEW' , a 1 . 2( 1 . 3 1 . 1 ) t o v e r h a u l , a 1 . 0( 1 . 10 . 9 1 t f l u i dc h a n g e

SteeringSteering wheel

Section 17MEASUREMENT playat steering Rotational wheelcircumference Staningloadat steering wheelcircumference N {kgf,lbl) Engine running Angleof rack$uide-screw loosened lrom lockedposition '97, '98 models '99, '00 models Pumppressure with shut off valveclosed kPa (kgvcm,,psi) Recommended tluid Fluidcapacity I {USqt, lmp q0 Deflection with 98 N {1O kgl,22lht) pulleys between Belttension N {kgt,lbf} Measured with belttensiongauge 0 - 1 0( 0- 0 . 3 9 ) 29 (3.0,6.6) 10"1 5" 20" MAX. (70 80,995 1,138) 6,900 7,800

STANDARD INEWI

Gearbox

Pump Powersteering fluid Powersteering belt*

Hondapowersteering fluid. For overhaul 0.85(0.90,0.75) For reservoir 0.4{0.42,0.35) 11.0 14.5(0.43 0.57)withusedbelt 7.5- 10.0(0.30 0.40) with new belt 390- 540(40- 55,88 - 121) with usedbelt 740-880 (75 90, 165 198)withnew belt

* When usinga new belt,adjustdeflection tension new values. Runthe enginefor 5 minutes or to then turn it off. Readjust dellection tension usedbeltvalues. or to

2-10

Suspension Section18MEASUREMENT Wheelalignment Camber Caster Totaltoe Frontwheelturningangle Wheelbearing E n dp l a y Front Rear Front Front near Inwardwheel wheel Outward Front Rear Aluminumwheel Steelwheel Axial Badial Axial Radial 0"00'1 1' - 1"00' 1' 1 2"10'! 1" 0J3(011/8) r N2 r i ( 1 / 1 6 1 / r 6 ) 1 37"00'! 2 31'30'(Referencei 0 - 0.05{0- 0.002} 0 - 0.05(0 0.002i (NEW) STANOARD 0 - 0.7 (0 0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 0.03) 0.03) 0.04) 0.04)

Unit of length:mm {in) STANDARD {NEW)

Rim runout

LIMIT SERVICE 2.0(0.08) 'r.5 {0.06) 2.0{0.08) 1.s(0.06)

Brakes Sec'tion 19MEASUREMENT Parking brake lever Footbrakepedal Playin stroke 196N (20kgf,44lbf) at leverforce Pedal height(withtloor mat removed) NT Freeplay Mastercylinder Discbrake Piston-to-pushrod clearance Discthickness Discrunout Discparallelism Padthickness Rearbrakedrum LD. Liningthickness Front '97,'98 models '99,'00 models Front Front Front STANDARD INEWI when Dulled: - 6 notches 2 To be locked 155(6 1/8) 1 6 1( 6 5 / 1 6 ) 1 5 (1/16 3/16) 0 - 0.4(0- 0.02) STANDARD {NEW' 22.9- 23.1(0.902 0.909) 23.6 23.8(0.929 0.937) 10.5 11.5(0.4' t 0.45) (8.657 8.661) 2r9.9 220.0 3 . 9- 4 . 5( 0 . 1 5 0 . 1 8 )SERVICE LIMIT

t o l

21.0(0.83) 21.0(0.83) 0.10{0.004) (0.0006) 0.015 1.6(0.06) 221.O 8.7011 2.0(0.08)

Air ConditioningAir conditioning

Section 22MEASUREMENT

STANDARD {NEWI

Lubricant type: KEIHIN 10 (P/N38897 Pl3 - A01AHor 38899 SP P l 3- A 0 1 ) Condenser Lubricant capacity Evaporator mf {floz, lmp oz) Lineor hose Receiver Lubricant type:SP 10 Lubricant capacity ml ({l 02,lmp oz} at Stator coil resistance 68'F (20"C)O plate clearance Pulley-to-pressuae Deflection with 98 N (10kgl,22lbli pulleys between Belttension N (kgf,lbf) with belttensiongauge Measured

25 (5/6,0.9) 40 {1 1/3,1.4) 1 0{ 1 / 3 , 0 . 4 ) 10(.]/3,0.4) 1fi'3o, 4.6;"} 130'3'{4 3.05- 3.35 1 0.51 0.15(0.02 0.006) with usedbelt 7.5- 10.5{0.30 0.41) with new belt 5.0- 7.0(0.20 0.28) 3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t 740- 880 {75 90, 170- 200)with new belt

Compressor (KEIHIN)

Compressor belt*

* When usinga new belt,adjustdeflection tensionto new values. for then turn it off. Runthe engine 5 minutes or to Readjust deflection tension usedbeltvalues. or

o2-11

DesignSpecificationsITEM DIMENSIONS Overall length Overallwidth Overall height Wheelbase Track Seating capacity Grossvehicle weightrating(GVWR) Grossvehicle weightrating(GVWR) Type Cylinder arrangement Bore and stroke Displacement Compression ratio Valvetrain Lubricationsystem Oil pump displacement 6,000 at enginerpm Waterpump displacement 7,600 at enginerpm Fuelrequired STARTER Type Normaloutput Nominalvohage Hourrating Direction rotation of Weight CLUTCH Clutchtype Clutch lacingarea Transmission type PrimaryredLrction Type Gearratio 1st 2nd 3rd 4th 5th Reverse Geartype Gearratao MIT MIT MIT METRIC 4,510 m m 1,750 mm 1,608 mm 2,622mrn 1,533 mm 1,534 mm 5lf 4 , 1 6 5b s t | 1,900 kg Water-cooled, 4-strokeDOHC gasoline engine Inline4-cylinder, transverse 84.0x 89.0mm 3.31x 3.50in .1,973 (m{) cm3 120 u-in c 9.2 9.6 Beltdriven, DOHC 4 valvesper cylinder pump Forced wet sump, and trochoid 501 (53 US qt,44 lmp qt)/minute 1401(148US qt, 123lmp qt)/minute gasoljne UNLEADED with 86 PumpOctane Numberor Higher gearreduction Planetary A/T:1.1kW M/T: 1.0kW 12V 30 seconds Clockwise viewedfrom gearend as 3.7kg 8.2 lbs Singleplatedry, diaphragm spring Torqueconverter 203cm, 31.5sq-in Synchronized s-speedtorward, 1 reverse Electronically controlled 4-speedautomatic,1 reverse Direct I : 1 Manualtransmission 3.500 1.956 1.344 1.071 0.812 3.000*,. 3.461*'Single helicalgear 4.562

ENGLISH 1 7 7 . 6n i 68.9in 63.3in 1 0 3 . 2n i 60.4in 60.4in

NOTES

Front Rear

(USA) WEIGHT (CANADA) WEIGHT ENGINE

'97,'98mooers '99,'00 models

Approx.

TRANSMISSION

*1: '97- 99 models *2: '00 model

Finalreduction TransferReardifferential

0.434 2.533 Automatic transmission 2.722 1.079 0.711 1.955 gear Singlehelical 4.357

Type Gearratio 1st 2nd 3rd 4th Reverse Geartype Gearratio

Finalreduction Transfer

0.393

2-12

ITEMAIR CONDITIONING Cooling capacity

METRIC Type/manutacturer No. of cylinder CaPacity Max.speed Lubricant capacity Lubricant type Type Type Type Motor input Speedcontrol Max.capacity

ENGLISH

NOTES

Compressor

j Kcal/h 14,000 BTU/h 3,520 Scroll/KElHlN 85.7mf/rev | 5.23cu'in/rev 10,000 rpm algIloz 130mf 1 sP-10 fin Corrugated Corrugated finSiroccofan

-Condenser

-

Evaporator Blower

200w 112 v4-Speeo 440 m3/h 15,500 cu fvh

Temperature control Compressor clutch Befrigerant STEERING SYSTEM Type ratio Overall Turns, lock to lock Steering wheeldiameter SUSPENSION Type Front Bear Shock absorber WHEEL ALIGNMENT Camber Caster Totaltoe Frontand Rear Front hear Front Front Rear Front Rear Front Rear Tvpe Type Powerconsumption Type Ouantity Dry,singleplate,poly-V-belt drive 40 W max./12 V HFC-134a 1R-134a) 24j anoz zoo o' g rackand pinion Powerassisted, At 68'F (20 C)

Independent doublewishbone, spring coil with stabilizer Independent coil doublewishbone, spring with stabilizer gas tilled hydraulic nitrogen Telescopic,

0' - r"00'2.10' 0mm 0in l n 1 / 1 6n i ln2mm Power-assisted selt-ad,usting ventilateddisc Power assisted self-adiusting drum 49 cm, x 2 7.6sq-inx 2 7 3 c m ,x 2 11.3 q-in 2 s x rear Mechanical actuating, two wheelbrakes label. Seetire inlormation 12V, 36 AH/sHR 1 2 V 1 . 0 , . 1k W 1 12V 100A 7.5A, 10A, 15A, 20 A 7.5A, 10A, 15A, 20 A, 30 A, 40 A '100 A 7 . 54 , 2 0 A . 4 0A 12V 60/55 W 12V- 21 W ('97model), 1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s ) 12V 5 W {'97model),3 ('98- 00 models) CP 12V-8W 1 2V , 3 C P 12V-21W 12V 2115 W 1 2 V 2 1C P( 1 8 ) W 12V-8W 12V-8W 12V-5W 1 2 V- 2 1 W 1 2V - 1 . 4 W 12V 1.4 W 1 2V 1 . 4 , 3 W , 3 . 4 W W W W 1 2 V - 0 . 8 4 W ,1 . 1 2 , 1 . 4 , 3 W , L E D 12V - 0.84W, 1.4W, LED 1 2V , 1 . 4W

BRAKE SYSTEM

TvpePad surface area Lining surfacearea P a r k i n gb r a k e

Drum brake

TIRE ELECTRICAL

Sizeand pressure Baftery Starter Alternator In under-dash fuse/relay box In under hood fuse/relaybox In underhoodABSfuse/relay box Headlights Frontturn signallights lights Frontparking Frontsidemarkerlights Rearsidemarkerlights Rear turn signallights Erake/parking lights Back-up lights Ceiling lights{fronvrear) platelight License Spotlights Highmountbrakelight lgnitionkey light Ashtraylight Gaugelights Indicator lights lllLrmination pilotIights and Heater illumination lights

2-13

Body SpecificationsU n i t :m m ( i n )

2-14

Maintenance............3-2 Points Lubrication for Schedule 1997Model Maintenance (NormalConditions) ...".3-4 Model for Schedule 1997 Maintenance (Severe ."...3-6 Conditions) for Schedule 1998 2000Models Maintenance (NormalConditionsl ..'."3-8 for Schedule 1998 2000Models Maintenance (severe '....'3-10 Conditionsl

I

Lubrication Points

pointsand type of lubricants be applied.referto the illustrated Forthe detailsof lubrication to indexand variouswork pro(suchas Assembly/Reassembly, cedures Replacement, Overhaul, Installation, etc.)contained eachsection. inNO. Engine LUBRICATION POINTS LUBRICANT gradeoil.The oil APIService Grade: UseSJ "EnergyConserving" container may alsodisplay APICertitication shown the seal "For Gasoline below.Makesure it says Engines." SAEvjscosity: Seechartbelow. Genuine HondaMTF*1 Genuine HondaPremium Formula Automatic Transmission Fluid (ATF)*' Genuine HondaCVTFluid Genuine HondaDOT3 Brake Fluid*3 Brake fluid DOT3 or DOT4*3 with molybdenum Grease disultide LJrea Grease UM264P/N4'1211 PYs- 305 SteeringgreaseP/N 08733- B070E grease Silicone

Transmission 2

Manual

Automatic Reardifferential Brake line(includes ABS line) ClutchLineShift lever pivots (Manual transmission)

34 5 61 I

Release (Manual fork transmission)Power steeringgearbox T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l

10 l1 12 14 16 17 18 19 20 21 22 23 24 25

Throttle link) cableend (Throttle pushrod Brake master cylinder Pedal linkage Battery terminals F u e l f i l ll i d pushrod Clutchmaster cylinder Hoodhinges and hood lock Tailgate hinges glasshinges Hatch Doorhinges, upperand lower Dooropeningdetent Caliper Piston seal,Dustseal, pin, Piston Caliper Shiltcableand select cable{Manual transmission) Brake line ioints(Front and rearwheelhouse) Powersteering system Air conditioning compressor

grease Multi purpose

Honda WhiteLithiumGrease

Silicone grease

Rustpreventives Genuine HondaPowerSteering Fluid-. Compressor SP 10 lP/N38897 P13- A0lAH or oil: 38899-P13-A01) For Refrigerant: 134a(R,134a) HFC

API SERVICE LABEL

SEAL API CERTIFICATION

E \ l l-;-1 5w-30/---l

/.'z-\e\ t / 6 A

/,.*-G\

10 20 30 40'c 0 r1: Always use GenuineHonda Manual Transmission Fluid {MTF).Using motor oil can causestiffer shifting becauseit does not containthe orooeradditives. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmission Fluid(ATF). Usinga non-Honda ATF can affect shift qualitv. +3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Honda brakefluid can causecorrosionand decrease the life of the system. *4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatic transmission fluid can causedincreased wear and poor steeringin cold weather.

w

ffi

Recomm6ndedEngine Oil Engine viscosity ambient oil for temperature ranges

-20

0

20

100'F

-30 -20 .10

3-2

and locksoncea year. all NOTE:Lubricate hinges,latches, is In corrosive areas,more frequentlubrication necessary. HondaWhite LithiumGrease. We recommend

3-3

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3-11

EngineElectrical4-2 ChargingSystem ............. Tools Speciaf 4-22 Location Index ............ Component Starting System 4-23 Diagram....................,........... 4-3 Circuit Index ............ Location Component 4-24 .............................. Troubleshooting 4-4 CircuitDiagram................................ 4-30 ..........,....... Replacement Alternator ........... 4-5 StarterTest 4-31 .......,,................ Alternator Overhaul 4'5 Test ...................... StarterSolenoid .........4-32 RectifierTest 4-7 ....................... StarterReplacement 4-32 Inspection ........... Alternator Brush 4-7 FieldWindingTest ........................... 4-33 4-8 RotorSlip RingTest ........................ StarterOverhaul............................,. 4-33 ............. Stator Test 4-9 ...........................,., BrushInspection Alternator Belt Inspectionand OverrunningGlutchInspection ......4-9 ........4-34 Adiustment and Test ........4-10 Armaturelnspection GruiseControl 4-12 BrushHolderTest ............................ 4-36 ComponentLocationIndex .,,,........ 4-1 2 ......................... StarterReassemb|y 4-37 CircuitDiagram................................ 4-13 Test ............................. Perf ormance 4-38 ControlUnit InputTest ................... lgnition System ..... Main Switch Test/Replacement 4-40 4-14 Index ............ Location Component Set/Resume Switch Test/ 4-15 CircuitDiagram................................ 4'40 .......................,........ Replacement lgnition Timing Inspectionand ....,,., 4-41 4-16 Setting .......................................... Actuator Test 4-42 Actuator Replacement...............,.... 4-17 ........,........ Distributor Replacement 4-43 Actuator CableAdiustment ............ 4-18 .............,,......... Distributor Overhaul 4-43 ClutchSwitchTest .......................... lgnition Control Module (lCM)Input .......... 4 .. . T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . .- 1.9 . . . . . . . .BrakeSwitchTest .................. 4-44 .. ...,. Test .............. 4-44 Actuator Solenoid 4-2O fgnitionCoilTest .............................. 4-45 ..................... ActuatorDisassembly lgnition Wire Inspectionand 4-20 Test ............................................... 4-21 SparkPlugInspection.....................

-

+

ENGINE

SpecialTools

Ref. No.

Tool Number A973X- 041 XXXXX 07JGG 001010A 07PAZ 0010100

Description

Oty

I

PageReference 4-41 434 4-16

VacuumPump/Gauge, 30 in.Hg. 0 BeltTensionGauge SCSService Connector * Included the BeltTensionGaugeSet,T/N 07JGG 0010004 in

o -o o

o

@

o4-2

StartingSystemLocationIndex Component

INTERLOCK CLUTCH

swtTcH {M/T)BATTERY Test,section23 Test,page 4-43 adiustment, Switchposition section12

I

SWITCH{A/T} A/T GEARPOSITION Test,section14 Reolacement. section14

Test,page4 5 Test,page4-6 Solenoid page 4-7 Replacement, page4 8 Overhaul, page4-12 Reassembly, Test,Page4-13 Performance

4-3

StartingSystemCircuitDiagramUNDER.HOOD FUSE/RELAY 8OX (100A) N0.41 (40A) N0.42 IGNTION SWITCH

-+o

/ BAI

\i7

cf-.|

\

BLKMHT

II

I Il

ELKMHT

t

t

BLK'WHT

l

-.1BLKREDIGNITION CONTROL MOoULECM) (

STARTEF CUl RELAY

GRY

I

GRN

IGEAR PosrroN! I A/T (A/T) | i swrTcH l \/ o N E o r N \ | l!-p . s i t o n/ : -_ --___J

f';--"-l I I TNTERLooK

fYl""yl, I

8LK

STARTEB (Field wndnglype)

Gl0l

4-4

StartingSystemStarter TestNOTE: The air temperaturemust be between 59 and '100'F and 38"C) (15 beforetesting. RecommendedProcedure: . . . Usea stanersystemtester. t i Connecand operatehe equipmentn accordance t instructions. with the manufacturer's Testand troubleshoot described. as Checkthe battery, battery positivecable, ground. for stanercut relay,and the wire connections loosenessand corrosion. Testagain. lf the staner still does not crank the engine,go to step 4. 4. Unplug the connector(BLK /VHTwire and solenoid from the starter. terminal) a 5 . Connect jumper wire from the bafterypositive(+) terminal. terminalto the solenoid The startershouldcrankthe engine.

Alte.nate Procedure: . Usethe followingequipment: - Ammeter,0 - 400A - Voltmeter, - 20 V (accurate within 0.1volt) 0 r T a c h o m e t e r ,-01 , 2 0 0 p m Hookup a voltmeterand ammeteras shown.

.

TERMINAL NEGATIVE

NOTE: After this test, or any subsequentrepair. reset the ECM/PCM clearany codes(seesection11). to Checkthe Starter Engagement: '1. Remove the No. 44 (15A) fuse from the under-hood fuse/relay box. 2. Turn the ignitionswitchto START(lll)with the shift lever in E or E position (A/T) or with the clutch pedaldepressed {M/T).The startershouldcrankthe e n gi n e . . . lf the starter does not crank the engine, go to step3. lf it cranksthe engineerratically too slowly,go or t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t page.

. .

l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e , its removeit, and diagnose internalproblem. the lf the startercranks engine,go to step6.

23). 6 . Check ignitionswitch(seesection the 7 . Check startercut relay{seesection23}. the 8. Checkthe IVT gear position switch (A/T)or the clutch switch (M[). interlock Checkfor an open in the wire betweenthe ignition switchand starter.

(cont'd)

4-5

StartingSystemStarterTest (cont'dlChecklor Wear and D8mage T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d s t e a d i l y l.f t h e s t a n e re n g a g e s b u t c r a n k s h e e n g i n e , t erratically, removeit, and inspectthe starterdrive gear and torque converterring gear or flywheelring gear for oamage. Checkthe drive gear overrunningclutchfor binding or s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e d r i v e gear held.lf damaged, replace gears. the CheckCrankingVoltage and Current Draw Cranking voltageshouldbe no lessthan 8.7 volts on Ay'T models, and 8.0volts on M/T moders. Currentdraw should be no more than 230 ampereson A,/T models, and 200amperes M/T models. on lf cranking voltageis too low, or currentdraw too high, checkfor: . deador low battery. a o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g , ments. . starterarmature dragging. . shortedarmature winding. . excessive drag in engine. CheckCrankingrpm Enginespeedduringcranking shouldbe above 100rpm. lf speedis too low, checkfor: a loosebafteryor starterterminals. . excesslvely worn stanerbrushes . opencircuitin commutatorsegments. . dirty or damagedhelicalsplinesor drivegear. a defective drive gearoverrunning clutch. CheckStarter Disengagement With the shift lever in @ or @ position(A,iT) with the or clutchpedaldepressed {M/T).turn the ignitionswitchto (lll).and release ON (ll). START to The starterdrive gear shoulddisengage from the torque c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u release key. the lf the drive gear hangs up on the torque converterring gearor flywheelring gear,checkfor . solenoid plungerand switchmalfunction. . dirty drive gear assemblyor damaged overrunning clutch.

Starter Solenoid Test1. Checkthe hold-incoil for continuitybetweenthe S . t e r m i n a la n d l h e a r m a t u r e o u s i n g( g r o u n d )T h e h coil is OK if thereis continuity.STARTER

B TERMINAL MOUNTINGNUT 9 N.m 10.9 kgtm, 7 tbtftl

TERMINAL

ARMATURE HOUSING (GROUND}

BLK/WHT WIRE 2. Checkthe pull in coil for continuitybetweenthe S and M terminals. The coil is OK if thereis continuity.

4-6

StarterReplacement1 . Disconnectthe battery negativecable. Disconnect startercablefrom the B terminalon the the solenoid. then disconnectthe BLK/WHTwire from the S terminal.B TERMINAL MOUNNNG NUT I N.m (0.9kgl.m, STARTER

Field Winding Testt. Checkfor continuitybetweenthe brushes. there's lf no continuity, replace armaturehousing, the Checkfor continuity between each brush and the a r m a t u r eh o u s i n g{ g r o u n d ) l f t h e r e i s c o n t i n u i t y . . replace armaturehousing. the

ERUSHES

7 rbtftl

RE

l0 x 1.25mm 4,1N.m {4.5 kgf.m, 33 tbt.ftl5.

R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r .t h e n remove the starter. I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e crimpedside ofthe ring terminal is facing out,Crimpedside of ring terminal

4.

TERMINAL

o

Connectthe batterypositivecableand negativecable to the batterv.

4-7

Starting SystemStarter OverhaulSTARTER SOLENOID

STARTER SOLENOID Test,page4 6 OVEBRUNNING CLUTCH

wARUSH

-6^lMOLYBDENUM DISULFIDE

SPRING CLIP Replace. BBUSH HOLDER Test,page4-12 GEAR HOUSING ARMATURE HOUSING

ARMATURE Inspection Test.page4-10 and ENDCOVER ..'...:|@{ MOLYBDENUM DISULFIDE

BAUSH page4-9 InsPeclon,

4-A

BrushInspectionMeasurethe brush length.lf it is not within the service limit, replace brush(or brushholderassembly). the Brush Lsngth Standard{Newl:14.0- I'1.5mm (0.55 0.57inl ServicoLimit: 9.0 mm (0.35in)

ClutchInspection Overrunning1.

2.

clutchalongthe shaft.Doesit Slidethe overrunning it. move freely?lf not, replace Rotatethe overrunningclutch both ways. Does it l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n reverse? it does not lock in either directionor it lf reDlace it. locksin both directions,

BRUSH

NOTE:To seat new brushes afterinstalling them in their with the holders. slip a strip of #500or #600sandpaper, grit side up, over the commutatorand smoothly rotate will be the armature. The contactsurfaceof the brushes sanded the samecontouras the commutator. to

3.

replace lf the starterdrive gear is worn or damaged, c t h e o v e r r u n n i n g l u t c ha s s e m b l yt;h e g e a r i s n o t available separately. ring gear Check condition the torqueconverter the of or the flywheel ring gear if the starter drive gear teethare damaged.

4-9

StartingSystemand Test ArmatureInspection1. f I n s p e c t h e a r m a t u r e o r w e a r o r d a m a g ed u e t o contact with the field winding. lf there is wear or damage. replace armature. the 3. C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e armalure. Commutator Diameter Standard(Newl:27.9- 28.0mm (1.09 1.10in) Limilr 27.0mm (1.06inl Service

lnspect damage. for

lf Check commutatorsurface. the surfaceis dirty the or burnt,resurface with emery cloth or a lathewithwith or in the tollowing specifications, recondition #500or #600sandDaoer.

4.

Measure commutatorrunout. the l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e limit, checkthe commutatorfor carbon dust or brasschipsbetween the segments. lf the commutator runout is not within the service limit, replace armature. the CommutatorRunout Standard(Newl:0 - 0.02mm (0 - 0.0008 in) Service Limit: 0.05mm {0,002 inl

4-10

I

5.

undercutthe Checkthe mica depth. lf necessary, properdepth. mica with a hacksaw bladeto achieve l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e the armature.

7.

Placethe armature on an armaturetester. Hold a hacksaw bladeon the armature core.

NOT GOOD

MICA DEPTI{

Commutator Mica Depth Standard (Nsw): 0.5 - 0.8 mm 10.02 0.03 inl mm (0.008in) ServicoLimit: 0.2 6. Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuit exists betweenany segments. replace armature. the

while lf the bladeis attracted the core or vibrates to the core is turned.the armatureis shorted.Replace the armature. 8. With an ohmmeter,checkthat no continuityexists betweenthe commutator and armature coil core, and between the commutatorand armatureshaft.lf there is continuity. replace armature, the

COMMUTATOR

cotLcoRE

4-11

StartingSystemBrush Holder Test1. the O and Check that there is no continuitybetween O brush holders.lf there is continuitv,replacethe brushholderassembly.

Starter ReassemblyNOTE:Use the illustration page 4I as reference on for reassemDty. 1. Pry backeachbrushspringwith a screwdriver, then positionthe brush about halfwayout ol its holder, and release springto hold it there. the

O BRUSHHOLDER

@ BRUSHHOLDER

2. Insertthe brushinto the brushholder,and bring the then attach brush into contactwith the commutator, the a springscaleto the spring.Measure springtension at the momentthe spring liftsoff the brush.

Installthe armaturein the housing.Next, pry back each brush spring again,and push the brush down until it seatsagainstthe commutator,then release the springagainst end of the brush. the

-

al

F*4#-@ 6t tat ll lftla

E ^

SCALE SPRING

3.

I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .

SpringTension: 13.7- 17.7N (1.40 1.80kgf, 3.09- 4.00lbf)

4-12

,r

?

Test Performance1.

Disconnect wire from terminalN4. the M a k ea c o n n e c t i o n s d e s c r i b e d e l o w u s i n ga s a b heavy a wire as possible(preferably equivalentto the wire usedfor the vehicle).

5.

Disconnectthe battery also from the body. lf the pinion retractsimmediately, is working properly, it To avoiddamagingthe starter, not leavethe batdo for terv connected more than 10 seconds.

3.

Connect the batteryas shown. lf the starterpinion pops out. it is working properly. avoid damaging To the starter,do not leavethe batteryconnected for more than 10 seconds.

@

o6. 7. Clampthe starterfirmly in a vise. Connectthe starter to the battery as describedin t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r starts and keepsrotating.

12V BATTERY

ie

Disconnect the batteryfrom the M terminal. lf the pinion does not retract, the hold-in coil is working p r o p e r l y . o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t T leavethe batteryconnected for more than 10 sec onds.

8,

lf the electric current and motor soeed meet the when the batteryvoltageis at 11.5V, specifications the starteris workingproperly.

Specifications: Maker DENSO Electric current 90 A or less Motor speed 3,000rpm or more

4-13

lgnition SystemComponent LocationIndexIGNITIONTIMINGCONTROL SYSTEM . ldle speedInspection/Adjustment, section11 . Inspection and Sening.page4-16

SERVICECHECKCONNECTOR(2P) lwi.c colo6: BRNrnd BLKI

TEST TACHOMETER

SPARKPLUGS page4-21 Inspection, DISTRIBUTOR page4-17 Replacement, page4-18 Overhaul, lgnitionCoilTest, page4,20 lgnitionControl Module CM) InputTest,page4,19

WIRES Inspection Test,page4-20 and

4-14

CircuitDiagramUNDEF.HOOD FUSE/RELAY 8OXIGNIT ON SWTCH UNDEF,DASH FUSEi RELAY BOX

6\ l;;l i{Hr6-(-\9-'-'*'.--EII

Eci,.pcM

' i Vl

BLK/YEL

l^

IGNITION cotL

TDCTopdead cenler poslion CKP Cran[shan pro s r l o n C Y PC y l n d e TDC/CKP/CYP SENSOR

IGN]TION CONTROL MODULE (CM) buil-if\ / Has I no|se l

f

l-- r

IGNTION W]BES

i l' i--, l l i f rBLU

IJltfi--cMFcr,r II l: '99- 00models Gt01

SPARK PLUGS

l l / ' i| |I TACHOMETER

I

BLU BLU

I

resr

I I

tott"to*j

LTTCHoMEIEB '97-'98 models

4-15

lgnition Systemand Setting lgnition Timing Inspection1.

(see Checkthe idle speed,and adjustit if necessary section11). Pull out the servicecheckconnector2P (BRN and holderlocatedunder BLKwires)from the connector side,then connect the dash on the front passenger (P/N07PAz- 0010100) to the scs service connector it. Startthe engine.Holdthe engineat 3,000rpm with no load (A/T in N or E, Mff in neutral)until the fan radiator comeson, then let it idle. Connect the timing light to the No. I ignitionwire, then point the light towardthe pointeron the timing belt cover.

6.

2.

lf necessary, adjust the ignition timing as follows. Loosenthe distributormountingbolts,and turn the to distributorignition(Dl)housingcounterclockwise advancethe timing or clockwiseto retardthe timtn o ,To RETARD

5.

C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s : headlights, blower fan, rear window defogger,and air conditioner not operating. are lgnitionTiming: idling in neutral M/T: 16"12" BTDC(RED) (RED) idling in E or E AlTt'16" !2" BTDC

MOUNTING BOLTS 24 N.m{2.4kgfm, 17lbtft} 7 . Tightenthe distributormountingbolts,and recheck t h e i g n i t i o ni m i n g . t 8. connector from the serDisconnect SCSservice the vicecheckconnector.

CRANKSHAFT PULLEY

4-16

DistributorReplacementRemoval:e oI'

5.

Connect ignitionwires to the distributorignition the (Dl)cap as shown,

1. 2.

Disconnect connector the from the distributor. Disconnect the ignition wires from the distributor ( i g n i t i o n D l )c a p . R e m o v e h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r , t then remove distributor the from the cylinder head.CAMSHAFT END

3.

No. 1 CYLINDER MARK

6. 7. 8.

Connect connector the distributor. the to page). Setthe ignitiontiming (seeprevious After settingthe ignitiontiming, tightenthe mounting bolts.

BOLTS MOUNTING mm 8 x 1.25 17 2,1N.m {2.,1kgrf.m,lbfftl

lnstallation: 1. 2. 3. Bringthe No. 1 pistonto compression strokeTDC. Coata new O-ringwith engineoil, then installit. Align the lug on the end of the distributorand its mating grooves in the camshaftend, then slip the distributor into position. NOTE:The lug on the end of the distributorand its mating groovesin the camshaft end are both offset to eliminate the possibility installing of the distributor 180o of time. out 4. Installthemountingbolts,and tightenthem lightly.

4-17

lgnition SystemDistributor OverhaulLEAK COVEN

CAPSEAL for Check damage.

DISTRIBUTOR IGNITION IDII ROTOR IGNITION{DII CAP OISTRIBUTOR Checkfor cracks,wear, damage, and to!ling. or Clean replace.

O.RING Replace.

IGI{ITION HOUSING OISTBIBUTOR IDO for and Check cracks damage.

b

IGNITION COIL Test, page 4 20

@_IGNITION CONTROL MODULE{ICMI InputTest,page4-19

4-18.

lgnitionControlModule(lCMlInputTestNOTE: . See section11 when the malfunctionindicatorlamp ( M l L ) o m e so n . c . Performan input test for the ignitioncontrol module ( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atl e s t sf o r t h e ignitionsystemand the fuel and emissions systems. . '97 -'98 models:The tachometer shouldoperatenorm a l l yi f t h e I C Mi s O K . L Remove the distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover. Disconnect wiresfrom the lCM. the8LU WIRE '98 models} {'97 -

Turn the ignition switch ON {ll). Checkfor voltage betweenthe BLK,^/EL wire and body ground.There shouldbe batteryvoltage. . . lf there is no batteryvoltage,checkthe BLK/rEL wire betlveen ignitionswitchand the lclvl. the lf there is bafteryvoltage, go to step 4.

T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c k o r v o l t a g e f between WHT/BLU the wire and body ground.There shouldbe battery voltage. . lf thereis no batteryvoltage, check: - ignitioncoil. - WHT/BLU wire betweenthe ICM and ignition corl. . lf thereis batteryvoltage,go to step5, '97 model: Disconnect the ECM/PCM connectorA ( 3 2 P ) C h e c kf o r c o n t i n u i t yo n t h e Y E L / G R N i r e . w betweenthe ICM and ECM/PCM. There should be continuity. '98 - 00 models: Disconnect ECM,PCM the connector B (25P). Checkfor continuityon the YEUGRNwire betweenthe ICM and ECM/PCM. There should be continuity. Checkfor continuityon the YEUGRNwire to body ground.Thereshouldbe no continuity. 7 . Reconnect ECM/PClvl the connector. '97 -'98 models: Checkfor continuityon the BLU wire between test tachometer the connector and the lCM.Thereshouldbe continuity. 9. '97 -'98 models: heck or continuity n the BLU f C o wire to body ground.Thereshouldbe no continuity. '10. lf all the testsare normal,replace lCM. the

2.

4-19

lgnition SystemlgnitionCoilTestUsing an ohmmeter, measureresistancebetweenthe is terminals.lf the resistance not within sDecifications, replace ignitioncoil. the will vary with the coil temperature; NOTE: Resistance specifications at 68"F(20'C). are Plimary Winding Resistance {Betweenthe A and B terminals): 0.6it- 0.77 0 SecondaryWinding Resistance {Betweenthe A and secondarywinding terminals): 12.8- 19.2kO

lgnition Wire Inspectionand Test1 . C a r e f u l l y e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n r the rubber boots.Do not bendthe wires;you might breakthem inside. Check conditionof the ignitionwire terminals. the lf any terminalis corroded, cleanit, and if it is broken or distorted, replace ignitionwire. the

IGNITION WIRE

eTERMINAL {+l A

o

Connectthe ohmmeter probesand measureresistance. lgnition Wire Resistance: 25 kO max. at 68'F 120'Cl

IGNITION WIRE 4. lf the resistance exceeds 25 kO, replace the ignition wire.

4-20

SparkPlugInspectionfor: and ceramicinsulator the Inspect electrodes 2. gaP. the Check electrode . gappingtool. Adjustthe gap with a suitable

ElectrodeGap

I

. . . .

gap lmproper Oil-fouling deposits Carbon Cracked center insulator electrode

Standard

in) 1.1 3 ' mm (0.043Loo.

is the Replace plug if the centerelectrode rounded as shownbelow:ROUNDEO ELECTRODE

,--, (--/Burned or worn electrodesmay be causedby: . Advanced ignitiontiming . Loosesparkplug . Plugheat rangetoo hot . Insufficient cooling Fouledplug may be causedby: . Retarded ignitiontiming . O i li n c o m b u s t i oc h a m b e r n . Incorrect sparkplug gap . Plug heatrangetoo cold . Excessive idling/lowspeedrunnang . C l o g g e d i r c l e a n ee l e m e n t r a . Deteriorated ignitionwires

/r--'--'--r

-.-l-:=---:1 :Spark Plugs '97 - '98 modsls:

| |

(N ZFR5F-11 GK) (1 K J 1 6 C R - 1 1D E N S O ) '99 - 00 models; (N ZFR6F-11 GK) (DENSO) KJ2OCR-111 compound to Apply a small quantity of anti-seize and screwthe plugs into the cylinthe plug threads, Then torque them to 18 N'm der head finger-tight. (1.8kgf.m.13lbf.ft).

4-21

Charging SystemComponent LocationIndexCHARGING SYSTEMLIGHT (ln the gaugeassembly) Test, page 4-24

BATTERY

Test,

ALTERNATOR Troubleshooting, page4-24 Replacement, page4-30 Overhaul, page4-31 RectifjerTest,page 4,32

ALTERNATOR BELT Inspection Adjustment, and page4 34

4-22

CircuitDiagramBOX FUSUFtAY UNDES.HOOD BATTERY (1Cr0A) N0.41 ,-a\ (40A) N0.42 WHT/8tK

l.

( tot,o, )

Y

IGNITON SWITCH

8LI(YEL

GRN/RED

ECM/PCM

WHT/RED

V I

ALTERNATOR

4-23

Gharging SystemTroubleshootinglf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in the order listedbelow: (seesection23) 1. Battery 2. Charging systemlight 3. Voltage 4. Alternator controlsystem(U.S.A. model) 5. Alternator/regulator ChargingSystem Light TestChsrgingSystomLight Check: Turn the ignition switch ON {ll), and makesure the chargingsys tem lightcomeson.

Doesthe charging system lightcome on?

Check for a blown No. 15 17.5 Al fuse and a blown charging system light bulb. lf the tusa .nd bulb are OK, repair th open in th WHT/BLUwire.

Charging System Light Check {com'd}: Startthe engine.

II

I

Doesthe charging system light go offf

Perform the Alte.nator/Regulator Test lsee page +281.

ALTERNATOR CONNECTOR 4P modell {U.S,A.

Voltage Check: Measure the voltageat the No. I lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON

2(BLK/YEL)

3

Wiresade of femaleterminals

{ ).

ls there battery voltage?

Ropair the open in the BLK/YEL wiae betwoen the altemator and under-da3h luso/relay box.

ALTERNATOR CONNECTOR 3P lCanedamodel'

Iemale terminals

(To next page)

m [ ]:Canada odel

4-24

in

(Fromprevious page)

Ch6ckthe L circuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 4P [3P] connectorfrom the alternator. ON switch (ll). 3. Turnthe ignition

Doesthe charging system lightcomeon?

Repairthe short to ground in the WHT/BLUwire.

model [ ]: Canada

(cont'd)

4-25

Charging System(cont'dl Troubleshooting'97 modol: Alternator Control System Test {U.S.A.model) NOTE:Beforetesting, checkproperoperation