INDEX

NDEX -
INTAKE MANIFOLD,
TIGHTENING TORQUE .-’

HYDRAULIC LASH ADJUSTER (HLA) 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
INSPECTION, PAGE Bl-7

r “Y7 ENGINE COOLANT/

SECTION E

EXHAUST MANIFOLD
TIGHTENING TORQUE
16-23 N.m (1.6-2.3 m-kg,
12-17 ft-lb\

DEFLECTION AT (98 N, 10 kc 19 22 lb) mm (in)

11 DRIVE BELT NEW USED LIMIT

COMPRESSION INSPECTION PAGE 61-10 kPa (kg/cm*, psi)-rpm

y-1, Sta,,dar‘-j , ,238;;;;;;$))-3(J() ,,,97;;2~;;&)0

IIA/C
8.0-9.
(0.31-0.35) I (0.35-0.39) I (0.45) 11 Minimum 883 (8.8, 125)-300 834 (8.5, 121)-300
23UOBl-00:

1. Timing belt 6. Engine

Removal / installation . . . . . . . . . . . .. . . . page 61-l 2 Removal ................................... page Bl-28
2. Cylinder head gasket Engine stand mounting.. .......... page 81-35
Rep!acement . .. . . . . . . . . . . . . . . . . .. .. . . . . . page Bl-16 Disassembly ............................. page Bl-38
3. HLA Inspection / Repair .................... page Bl-54
Removal / Installation . . . . .. .. . . . . . . . page 81-20 Assembly.. ................................ page 81-66
4. Front oil seal Engine stand dismounting.. ..... page 81-92
Replacement . . . . . . . . . . . . . . . .. .. . . . . . . . . . page Bl -23 Installation ................................. page 81-94 .+-
5. Rear oil seal
Replacement . . , . . ,.. . . . . . . .. . . . . . . . . . . . page Bl-25

81-2
 REMOVAL
Step 6
Separate the engine and transaxle in the order shown in the figure.

MTX
BP SOHC

ATX
BP SOHC

--
03UOB1-060

1. Intake manifold bracket 5. Integrated stiffener (B6 engine)

2. Starter and bracket 6. Torque converter nuts (ATX)
3. Throttle cable (ATX) 7. Transaxle mounting bolts
4. No.2 engine mount rubber and bracket 8. Transaxle

01-34
Bl ASSEMBLY

ASSEMBLY
PREPARATION
SST

49 LO1 1 OAO 49 LO11 001 For

removal and
Piston pin setting Support block installation of
tool set body piston pins
(Part of
49 LO11 OAO)

49 LO1 1 004 I For 49 LO1 1 005 For

removal and removal and
Screw installation of Stopper bolt installation of
(Part of piston pins (Part of piston pins
49 LO1 1 OAO) 49 LO1 1 OAO)

49 LO1 1 006 49 LO1 1 007

Puller & installer

49 LO1 1 OAO)

Centering tool

49 LO1 1 OAO)

49 HO11 OOlA

Support block

49 EOll 103

49 EOll 104
installation of
Collar

49 LO12 001
installation of
Bl INSTALLATION
Tie-rod end
1. Install the tie-rod end to the knuckle.

Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
2. Install the new split pin.

03UOBl.183
Stabilizer
1. Install and adjust the stabilizer.

Dimension @: 17-19mm (0.67-0.75 in)

Extension bar (MTX)

1. Install the extension bar to the transaxle.

Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
Shift control rod (MTX)
1. Install the shift control rod to the transaxle.

Tightening torque:
16-23 N.m (I .6-2.3 m-kg, 12-l 7 ft-lb)
\ ,I /

03UOBl-18
Clutch release cylinder (MTX)
1. Install the clutch release cylinder.

Tightening torque:
16-23 N#m (I .6-2.3 m-kg, 12-17 ft-lb)
2. Set the pipe bracket in position.

Tightening torque
@: 6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
@: 16-23 N.m (I .6-2.3 m-kg, 12-17 ft-lb)

Shift control cable (ATX)

1. Install the shift control cable to the transaxle.

Tightening torque:
6.9-l I N-m (70-l IO cm-kg, 61-95 in-lb)

81-98
B2 ON-VEHICLE MAINTENANCE
REAR OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to Removal Note.
3. install in the reverse order of removal, referring to Installation Note.
t I 1
ITX
16-26 (1.6-2.7, 13-20)
\

\TX

N.m (m-kg, ft-It 0

L
23UOBZ-027

1. Transaxle 4. Drive plate (ATX)

MTX Removal Note ..,........................ page B2-29
Service . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . Section J2 Installation Note . . . . . . . . . . . . . . . . . .. . . . . . page 62-30
ATX 5. Oil seal
Service . . . , . . . . ,.......................... Section K Removal Note .,......................... page 52-29
2. Clutch cover, clutch disc (MTX) Installation Note . . . .. . . . . . . . . . . . . . . . . . . . page B2-29
Service . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
3. Flywheel (MTX)
Removal Note . . . . .. . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . below
Installation Note .,.....,..,............. page 82-29

Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.

23UOB2-05 il
82-28
B2 INSPECTION / REPAIR
(8) Measure the oil clearances.

Oil clearance:
0.035-0.081 mm (0.0014-0.0032 in)
Maximum: 0.15mm (0.006 in)
(9) If the oil clearance exceeds specification, replace the
cylinder head.

r-- 7. Measure the camshaft end play. If the end play exceeds
specification, replace the camshaft and/or the cylinder head.

End play : 0.07-0.19mm (0.0028-0.0075 in)

Maximum: 0.20mm (0.008 in)

HLA

Caution
l Do not attempt to repair the HLA.
1, Inspect the HLA friction surfaces for wear or damage. Re-
place the HLA if necessary.
2. Hold the bucket body and press the plunger by hand. If
the plunger moves, replace the HLA.

1
05UOBX-14

I - CYLINDER BLOCK
1. Inspect the cylinder block for the following. Repair or re-
place the cylinder block as necessary.
(1) ‘Leakage damage.
(2) Cracks.
(3j Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in the figure.

Distortion: 0.15mm (0.006 in) max.

3. If the distortion exceeds specification, repair by grinding’or

replace the cylinder block.

Height : 221 Smm (8.720 in)

Grinding: 0.20mm (0.008 in) max.

L
05UOBX-149

82-60
92 ENGINE STAND DISMOUNTING
Water Inlet Pipe
1. Remove all foreign material from the water inlet pipe mount-
ing surface.
2. Install a new gasket and the water inlet pipe. -

Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)

Water Bypass Pipe

1. Apply a small amount of engine coolant to the new O-ring.
2. install the water bypass pipe.

03UOB2 122
A/C Compressor Bracket (If equipped)
1. Install the A/C compressor bracket.

Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb) v

-l!----- -
0311082-70
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.

Tightening torque:
38-46 N*m (3.9-4.7 m-kg, 28-34 ft-lb)

__._.__ -- _...-- 05UOEX-25

Exhaust Manifold insulator
1. Install the exhaust manifold insulator.

Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)

_____II-___p--.-

051JOBX-25
82-92
E RADIATOR
RADIATOR
REMOVAL / INSTALLATION
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.

1. Disconnect the negative battery cable.

2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.

7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)

-...__--- --- i

771 InFu.nnc;
cvyILII ..,.,..

1. Resonance chamber 6. Oil cooler hose (ATX)

2. Cooling fan connector 7. Radiator bracket i
Y’
3. Radiator thermoswitch connector (BP ATX) 8. Radiator
4. Coolant reservoir hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. . page E-9
5. Radiator hose 9. Cooling fan and radiator cowling assembly

E-8
F TROUBLESHOOTING GUIDE
Output Devices and Engine Conditions

Note
. The data in this chart is for reference only.
INJECTOR
THREE-WAY
SOLENOID SOLENOID
AIR ISC VALVE VALVE AK
INJECTION “AL”E VALVE (PURGE (PRESSURE RELAY
INJECTION TlMlNG
CONTROL) REGULATOR
CONTROL)‘3
CONDITIONS
A A 1, c
All
CRANKING
cylinders
-COLD ENGINE
Zero each
l COLD AIR
ignition
l COLD COOLANT
pulse OFF
(Purge
1
COLD START cut)
Large 1
-FAST IDLE One ,
Rich Open: amount or
l COLD AIR mrnute
coolant bypass air
l COLD COOLANT
tem-
perature:
COLD DRIVEAWAY Below
-PART THROTTLE Two 40%
l COLD AIR minutes (104OF)
l COLD COOLANT
,
I/
WARM DRIVEAWAY
-PART THROTTLE Three
. WARM AIR minutes
OFF
l WARM COOLANT
(Vacuum
Rich and 2-group” 1’
/I to
I lean l-group”
pressure
HOT CRUISE regulator)
l WARM AIR
l WARM COOLANT
,
i

HOT ACCELERATION
-60% THROTTLE

-lOT ACCELERATION
-WIDE OPEN
THROTTLE

Closed

After start-
rng: ON dur-
ing hot start
only (Vacu-
um cut)

OFF

l 2 SOHC, *’ BP

F-22
F TROUBLESHOOTING GUIDE

15 ENGINE STALLS ON DECELERATION

DESCRIP- l Engine unexpectedly stops running while decelerating or after deceleration
TION l Idle condition normal
[TROUBLESHOOTING HINTS]
Engine speed drops too much when releasing accelerator or poor connector connection disconnected by deceleration
force
3 Idle speed control malfunction @ Idle speed misadjustment
3 Fuel cut control malfunction
TEP INSPECTION ACTION
1 Check if idle condition is normal Yes Go to next step

No Adjust or perform troubleshooting

Nos. 8-11 “ROUGH IDLE” v page F-42
F-48
--
2 Check if “00” is displayed on Self-Diagnosis Yes Go to next step
Checker with ignition switch ON
W page F-82 No Service Code No. displayed
SYSTEM SELECT: 1 Check for cause (Refer to specified
check sequence) w page F-83

“88” flashes
Check ECU terminal IF voltage LIT= page F-150

Specification: Battery voltage

(Ignition switch ON)

W: SELF TEST + If OK, replace ECU w page F-149

Q If not OK, check wiring between
ECU and Self-Diagnosis Checker
3 Check switches for correct operation with Self- Yes Go to next step
Diagnosis Checker Monitor Lamp with ignition
switch ON No Lamp not ON or OFF with specified
w page F-105 switch
Check for cause (Refer to specified
check sequence) CT page F-106

Lamp always ON
-,-y/
,’ Check wiring between ECU terminal 1D
and Self-Diagnosis Checker

W: SELF TEST

4 Check if ECU terminal voltages are OK Yes Go to next step

MTX...Especially IV, 2D, 20, 2U, 2V and 2Q
ATX... Especially 28, 2E, 30, 3U, and 3V w page F-151
No Check for cause
w page F-150
5 Check for poor connection of following parts Yes Repair or replace
. Ignition coil
l Igniter
l Distributor --
l High-tension lead No Go to next step
l Injector
l Circuit opening relay
l ECU

F-54
F SELF-DIAGNOSIS FUNCTION
Troubleshooting
If a service code number is show on the SST, check for the cause by using the chart related to the code
number shown.
.-I

rc:ODE
-
No.
I
02 (DISTRIBUTOR Ne-SIGNAL) I
iTEl INSPECTION ACTION 1
1 Check distributor circuit for poor connection Yes Repair or replace connector
1 I I
No SOHC
Go to Step 3
DOHC
Go to next step
2 Check if Code No.03 is also present Yes Go to next step
I

No Go to Step 5

-5- Check terminal-wire for continuity Yes Go to next step

I I I

4 Check if battery voltage exists at distributor

I I No

Yes
Repair or replace

Go to next step
terminal-wire
No Check for open circuit in wiring from
distributor to main relay (FUEL INJ
relay)
-i-- Check terminal-wire between distributor and Yes Go to next step
ECU terminal 2E (MTX) 2A (ATX) for continuity
and ground No Repair or replace

6 Cl$c; ,if$CU terminal 2E (MTX) 2A (ATX) volt- Yes Replace ECU w page F-149 4

w page F-152 . No Go to next step

I I

7 Check if OV or 45V--55V exists at distributor 1 Yes 1 Reolace distributor I

terminal-wire (W)
No Go to next step

8 Check if 4.5V-5.5V exists at ECU terminal 2E Yes Check for short circuit in wiring from
(MTX) 2A (ATX) (With distributor connector dis- distributor to ECU
connected)
No Replace ECU CT page F-149
-

F-86
 VARIABLE INERTIA CHARGING SYSTEM (VICS)
SYSTEM OPERATION
DIAGNOSIS 1. Connect the tachometer to the IG- terminal of the diagno-
CONNECTOR sis connector.
2. Start the engine and run it at idle.
- 3. Verify that the rod of the shutter valve actuator has pulled
inward.
4. increase the engine speed gradually and verify that the rod
is extended when the engine speed reaches 5,000 rpm.

OSUOFX-I 19
SHUTTER VALVE ACTUATOR
Inspection
1. Remove the vacuum hose from the actuator.
2. Verify that the rod can move in and out smoothly.

i-..

1” \

03UOFX-I 2
3. Start the engine and run it at idle.
4. Place a finger over the end of vacuum hose and verify that
there is vacuum.
5. Install the vacuum hose and verify that the rod is pulled
inward.

23UOFX-1 C
SOLENOID VALVE (VICS)
Inspection
1. Remove the three-way solenoid valve.
2. Verify that air flows between each port as below.
Port Air flow
@--@ - - No
@-0 No
@ --- (g Yes

23UOFX-1 C
3. Connect battery voltage and a ground to the terminals of
the solenoid valve.
4. Verify that air flows between each port as below.
Port Air flow
-_I
-I_
@- 03 Yes
@l-o No
@--0 No

23UOFX-IC
F-118
 CONTROL SYSTEM
Terminal voltage (MTX)
VB: Battery voltage

wminal Input Output Connection to Test condition Correct voltage Remark

V’

1A - - Battery Constant VB For backup

1B 0 Main relay OFF OV

Ignition switch ._-
(FUEL INJ relay) VB
ON
1c 0 Ignition switch While cranking Approx. 10V -
(START) Ignition switch ON ov
10 0 Self-Diagnosis Test switch at “SELF-TEST” With Self-
Checker Lamp illuminated for 3 sec. after ignition 4.5--5.5v Diagnosis Check-
(Monitor lamp) switch OFF+ON er and System
Lamp not illuminated after 3 sec. VEI Selector

Test switch at “02 MONITOR” at idle 4.5-5.5v

Monitor lamp illuminated
Test switch at “02 MONITOR” at idle
Va
Monitor lamp not illuminated
1E 0 Malfunction indica- Lamp illuminated for 3 sec. after ignition With System
Below 2.5V
tor lamp (MIL) switch OFF-ON Selector test
switch at
Lamp not illuminated after 3 sec. VB
“SELF-TEST”
Lamp illuminated Below 2.5V
Lamp not illuminated VR
1F 0 Self-Diagnosis Buzzer sounded for 3 sec. after ignition l With Self-
Below 2.5V
Checker switch OFF+ON Diagnosis
(Code Number) - Checker and
Buzzer not sounded after 3 sec. VE
System Selector
Buzzer sounded Below 2.5V l With System
Buzzer not sounded VB Selector test
switch at
“SELF-TEST”
1G 0 Igniter Ignition switch ON ov -
Idle Approx. 0.2V
1H - - - - - -
_-
II - - - - - -
1J 0 AIC relay Ignition switch ON VB

A/C switch ON at idle Below 2.5V

A/C switch OFF at idle VB -

1K 0 Diagnosis System Selector test switch at Ignition switch

VB
connector “02 MONITOR” ON
(TEN terminal) System Selector test switch at ov
“SELF-TEST”

1L 0 DRL relay Parking brake pulled with ignition switch l DRL.: Daytime
Ve
(Canada) ON (DRL OFF) Running Lights
Idle (DRL ON) Below 2.5V

F-l 50
G CHARGING SYSTEM

INDICATOR BATTERY
Inspection
Indicator sign (If equipped)
1. Check that the indicator is blue.
2. If the indicator is not blue, check if the electrolyte level lies
between the upper and lower lines.
3. If low, add distilled water, being careful not to overfill.
4. If the electrolyte level is acceptable and yet the indicator
is not blue, the battery must be recharged.

Specific gravity of electrolyte

Measure the specific gravity with a hydrometer.

NG POINT Specification: 1.27-l .29 (at 20°C [66OF])

Note
l If the battery charge indicator is not blue when the
specific gravity is normal, the indicator could be
defective.

OSUOGX-Ol!

Battery discharge test

I I

Measure open circuit voltage of battery with a digital voltmeter capable of

reading O.OlV

II
I 1
Below i 2.4V Abo”;t 12.4V

I 1 I
Quick charge for 2 hours
and recheck voltage

c
Below 12.4V Above 12.4V
Test load
l Apply test load (see test load chart) to the battery Battery ] Load (A)
using a battery load tester 55D23L 180
l Record battery voltage at the end of 15 seconds; is
voltage more than specification?
Battery voltage with load
Approximate Minimum
YES battery temp. voltage (V)
21 OC (70°F) 9.6
15OC (60%) 9.5
Measure open circuit 10°C (50°F) 9.4
4% (40°F) 9.3
-1 ‘C (30°F) 9.1
-7OC (20°F) 8.9
-12OC (lOoF) 8.7
Below 12.4V Above 12.4V -18% ( 0“F) 8.5

Charge battery J
23UOGX-003 L_,* /

G-8
H CLUTCH MASTER CYLINDER
Removal Note
Clutch pipe
1, Disconnect the clutch pipe with the SST.

\ \\ I
03UOHX-016
7
2. Disconnect the clutch hose from the reservoir.
3. Plug the outlet of the reservoir.

Installation Note
Clutch pipe
1. Tighten the clutch pipe with the SST.

Tightening torque:
13-22 N.m (1.3-2.2 m-kg, 9-16 ft-lb)

Air Bleeding
I. After installation, bleed the clutch system.
(Refer to page below.)

23UOHX-Ot ,a Inspection and Adjustment

Clutch pedal height and free play
(Refer to page H-5.)

AIR BLEEDING
The clutch hydraulic system must be bled to remove air in-
troduced whenever a hydraulic line is disconnected.

Note
l The fluid in the reservoir must be maintained at the
3/4 level or higher during air bleeding.
Caution
l Clutch fluid will damage a painted surface. If fluid
does get on a painted surface, wipe it off im- __,
mediately.
l Do not mix different brands of clutch fluid.
I l Do not reuse the clutch fluid that was drained.
03UOHX-014
Jl TRANSAXLE
Primary Shaft Assembly
1. Measure the thrust clearances of all gears before disassembly, referring to Preinspection.
2. Disassemble in the order shown in the figure, referring to Disassembly Note.

REPLACE

. . /’

1. Bearing 7. 3rd gear

Disassembly Note.. . . . . . . .. . .. . . . . page Jl-23 Disassembly Note.. . . . . . . . . . . . page J l-23
Inspection.. . . .., . . . . . . . . . . .. . . . . . . . . . page J l-28 Inspection.. ... ... . . . . page J 1-28
2.4th gear 8. Bearing
Disassembly Note . . . . .. .. . . . . . . . . . . . . . page Jl-23 Disassembly Note.. . ., . . . page J l-23
Inspection.. . . . . . . . . . . . . . . ........ page J l-28 9. Primary shaft
3. Synchronizer ring (4th) Inspection., ... . .. .. ... page J 1-27
Inspection.. . . . . . . . . . . .. . . . . . . . . . page J l-27 10. Synchronizer spring
4. Retaining ring 11. Clutch hub sleeve
5. Clutch hub assembly (3rd/4th) 12. Synchronizer key
Disassembly Note .. . . . . . . . . . . . . . . page Jl-23 13. Clutch hub
inspection.. . . . . . . . . . . . . . . . . . . . . . . page J l-29
6. Synchronizer ring (3rd)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Jl-23
Inspection.. . . . .., . . . .. . ,.. . . . . . . . . page J l-27

Jl-22
Jl DIFFERENTIAL
4. If the backlash exceeds specification, adjust by selecting
and installing thrust washers between the case and the side
gears.
-.
Caution
l Use thrust washers with the same thickness on each
side.
Thrust washer thickness: mm (in)

1 2.0 (0.079) 2.1 (0.083) 2.2 (0.087)

23UOJl-012

Disassembly Note
Side bearing inner race (Side opposite ring gear)
Caution
l Hold the gear case with one hand so that it does
not fall.

1. Remove the bearing inner race with the SST.

03UOJ2-10
Side bearing inner race (Ring gear side)
Note
l Use pads in the vise.
1. Remove the bearing inner race with the SST.

03UOJ2-104
Inspection
Inspect all parts and repair or replace as necessary.

Ring gear and ring case

Note
l If the gear case is replaced, adjust the bearing
preload.
1. Inspect the ring gear for wear and cracks.

03UOJl-13 6
Bearing inner race
Note
l When replacing the bearing inner race, replace the
bearing outer race and inner race as a set.
l If the bearing is replaced, adjust the bearing
preload.
--
1. Inspect for wear and rough rotation.

03UOJl-1:

Jl-54
J2 TRANSAXLE
Bearing inner race (primary shaft end)
1. install the new bearing inner race with the SST.

I
23UOJ2-OC
i 3rd gear, synchronizer ring (3rd) and clutch hub
assembly (3rd/4th)
Note
l The size of the lst, 2nd, 3rd, and 4th synchronizer
W-W rings are the same. Be careful when installing them.
The 2nd ring has the larger cut-out as shown in the
illustration.
l Align the synchronizer ring groove and clutch hous-
ing hub key when installing.
W-U (REVERSE)
I
03UOJ2-054
1, Install the 3rd gear, synchronizer ring (3rd), and clutch hub
assembly (3rd/4th) with the SST.

(FOUR PLACES)!
23UOJ2-00 7

r Synchronizer ring (4th), 4th gear and bearing inner race

1. Install the synchronizer ring (4th), 4th gear, and bearing
ner race with the SST.
in-

2. Measure the clearance between the 3rd gear and 2nd gear.

Clearance: 0.05-0.20mm (0.002-0.008 in)

Maximum : 0.25mm (0.010 in)

52-m
03UOJ2-O!
1
57
M REAR AXLE
Removal note
Brake pipe
Caution
l After disconnecting the brake pipe, plug it to avoid
fluid leakage.

1. Disconnect the brake pipe with the SST.

!O
lnstallatlon note
Brake pipe
1. Tighten the brake pipe with the SST.

Tightening torque:
13-22 N*m (1.3-2.2 m-kg, 9.4-16 ft-lb)

03UOMX-01 0
Locknut
0.5mm 1. Install a new locknut and stake it, as shown.

Tightening torque:
177-236 Narn (16-24 m-kg, 130-l 74 ft-lb)

19

M-12
N MANUAL STEERIN
Disassembly note
Steering gear and linkage
1, Secure the mounting part of the removed gear and linkage
in a vise.

Caution
l Be sure to insert a soft, protective material between
the part and the jaws of the vise.

93GONX-007
Tie rod end
1. Make a matching mark on the tie rod threads for proper
reassembly.

23UONX-01 I
Tie rod
1. Uncrimp the locking washer.

c-7
23UONX-01
2. After wrapping the rack in a rag and securing it in a vise,
remove the tie rod from the rack.

63U 1OX-089
Pinion protector
1. Hit the rim of pinion protector with a plastic hammer gently
from under to remove it.

I m- I
93GONX-067
N-16
P CONVENTIONAL BRAKE SYSTEM
AIR BLEEDING
1. Jack up the vehicle and support it with safety stands.

Caution
l The brake fluid reservoir must be 314 full during air
bleeding.

2. Remove the bleeder cap and attach a vinyl hose to the

bleeder plug.
03UOPX-006 3. Place the other end of the vinyl tube in a clear container.
4. One person should depress the brake pedal a few times,
and then hold it in the depressed position.
5. A second person should loosen the bleeder screw, drain
out the fluid, and retighten the screw with the SST.

Caution
l The two persons should stay in voice contact with
each other.
l Be sure the pedal remains depressed until the air
bleed screw is tightened.

03UOPX-00 6. Repeat steps 4 and 5 until no air bubbles are seen.

7. Check for correct brake operation.
8. Verify that there is no fluid leakage. Clean away any spilled
fluid with rags.
9. After bleeding the air, add brake fluid to the reservoir up
to the specified level.

Tightening torque:
5.9-8.8 N-m (0.8-0.9 m-kg, 4.3-8.5 ft-lb)

Note
l Air bleeding must be done from the bleeder screw
03UOPX-00 farthest from the disassembled parts to the nearest.
BRAKE HYDRAULIC LINE

03UOPX-00

1. Brake pipe 2. Flexible hose

Inspection / Removal / Inspection / Removal /
Installation . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . page P-7 Installation . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . page P-7

P-6
 WHEELS AND TIRES
Tire Wear
1. Check the remaining tread.

Remaining tread ’ _,I’

Standard tires: 1.6mm (0.063 in) min.
Snow tires: 50% of tread

2. The tire should be replaced if the wear indicators are

WEAR IbiDICATOR
exposed.
WEAR INDICATOR

13UOQX-00s
Inspection (Tire and Wheel)
The wheel or tire should be replaced if any crack, damage,
deformation or other problem is found.

13UOQX-011 0
Wheel and Tire Runout
1. Jack up the vehicle and place it on safety stands.
2. Set the probe of a dial indicator against the wheel, and meas-
ure the runout through one full revolution.

Runout: _..’
Horizontal Aluminum wheel: 2.0 (0.079), Steel wheel: 2.5 (0.098)
Vertical 1.5 (0.059)

3. Replace the wheel if necessary.

23UOQX-004
Caution
l Adjust wheel balance after replacement of a wheel
or tire.

Lug Nut
1. Verify that the lug nuts are tightened to the specified torque.

Tightening torque:
66-l 16 N*m (9-12 m-kg, 65-67 ft-lb)

Q-4
S POWER WINDOW SYSTEM
POWER WINDOW SUB-SWITCH
Inspection
00
CD
Check for continuity between terminals of the switch with an
ohmmeter. -,
Passenger side

UP 0 0
0 0 -
--- -c
L I 0
23UOSX-014
IOWN

o---O: indicates continuity

Rear

03uosx-04
H: Indicates continuity

POWER WINDOW MOTOR (In power window regulator)

Inspection
1. Disconnect the power window motor connector.
2. Connect battery voltage to terminal (a) and ground termi-
nal (b) of the motor connector, and verify that the motor -I
operates.
3. Reverse the above connections and check for reverse oper-
ation of the motor.

REAR

23UOSX-015
S-32
S REAR WINDOW GLASS

HATCHBACK

1 J

03UOSX-106

1. Rear wiper arm and blade 4. Seaming welt

Removal / Installation . . . . . . . . . . . . . . . . . . page S-78 5. Rear window glass
2. Rear window molding Removal Note ..,.,,,.......,.............. page S-64 ‘.-
Removal. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . page S-44 Installation Note . . . . . . . .. . . . . . . . . . . . . . . . . . page S-65
Installation . . . . .,...,........................ page S-45 6. Spacer
3. Rear hatch lower trim
Removal / Installation . . . . . . . . . . . . . . .. page S-98

Removal Note
PROTECTIVE TAPE Rear window glass
1. Apply protective tape along the edge of the body to pro-
tect it from damage.
2. Using an awl, make a hole through the sealant from the in-
side of the vehicle.
3. Pass piano wire through the hole.

4. Wind each end of the wire around a bar.

5. Working with another person, saw through the sealant
around the edge of the glass. Then remove the glass.

Caution
l Use a long sawing action to spread the work over
the whole length of wire to prevent it from breaking.
l Be careful that the wire does not rub on the body.

SMUOSX-139
S DASHBOARD
Installation Note
Dashboard
After installing the dashboard, adjust the control wires of the
heater and blower units.

Mode control wire

1. Set the control lever to the position shown.
2. Set the mode control link to the extreme stop position.
Install the wire loop onto the link.
3. Clamp the wire into position with the clip.

Caution
l Move the Mode lever to verify that it moves the full
stroke between DEF and VENT.

Ret-Fresh selector control wire

1. Set the control lever to the position shown.
2. Set the air-mix control link to the extreme stop position.
Install the wire loop onto the link.
3. Clamp the wire into position with the clip.

Caution
l Move the Ret-Fresh lever to verify that it moves the
03UOSX-182
full stroke between REC and FRESH.

Temperature control
Temperature control wire
1. Set the control lever to the position shown.
2. Set the temperature control link to the extreme stop posi-
tion. Install the wire loop onto the link.
3. Clamp the wire into position with the clip.

Caution
l Move the Temperature control lever to verify that
it moves the full stroke between HOT and COLD.
03uosx-18 '3

S-96
T INDEX
OTHER

23UOTX-OOf

1, Joint box (including CPU) 4. Main fuse

Removal / Installation . . . . . . . . . . . . . . . .. . page T-l 5 Removal I Installation . . . . . . . . . . . . . . . . . . page T-14
Inspection . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. . page T-58 5. Rear window defroster (Filament)
2. Circuit breaker Troubleshooting ,..........,,...,........, page T-75
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. .. .. .. .. . page T-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-77
3. Horn Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . page T-77
Removal I Installation . . . . . . . . . . . . . . . . . . page T-88

T-8
 I

EXTERIOR LIGHTING SYSTEM

Both stoplights do not operate when brake pedal is

depressed

i
Check stop 20A fuse Short circuit
I

Confirm battery voltage on G/W wire of the stoplight Repair harness (Fuse - Stoplight switch)
switch
I
OK

Check the voltage with the brake pedal depressed

I
BD c
Confirm battery voltage on G Replace the stoplight switch

8) OK

Confirm battery voltage on G Repair harness (Stoplight switch - Stoplight)

(B
Confirm continuity on B wir Repair harness (Stoplight - Body ground)
I I I

I
Replace the bulb
I
23UOTX-023

One stoplight does not come on Burnt out bulb or faulty grounding
03UOTX-058

T-40
T INSTRUMENT CLUSTER
Water temperature gauge
1. Remove the instrument cluster. (Refer to page T-69.)
2. Apply battery voltage to terminal 2L and ground terminal 2E.
3. Connect the red lead of the SST to terminal 3L and the black ____,
lead to a negative battery terminal.

I
23UOTX-045
4. Set the SST to the resistance values shown in the figure.
W/ TACHO WI0 TACHO 5. Turn the ignition switch ON, and verify that the needle indi-
cates the correct values.
Cautlon
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.

QMUOTX-08!
Speed sensor
1. Remove the instrument cluster.
2. Check continuity between terminals 2A and 2F while rotat-
ing the speedometer cable shaft.
3. If there are not four pulses per shaft rotation, replace the
speed sensor.

03UOTX- 11,
WATER THERMOSENSOR
Removal / Installation
1. Remove the connector.
2. Remove the thermosensor.
3. Install in the reverse order of removal.

03UOTX.11
Inspection
1. Remove the sensor.
2. Place the sensor in water.
3. Heat the water gradually, and check the resistance of the
sensor with an ohmmeter.
4. If the resistance is not as specified, replace the sensor.

Resistance: 190-2603 at 5O*C (122OF)

OBUOTX-
T-72
C
l HEATER 6 AIR CONDITIONER 1 G
b
MAIN
I3 Fl
AD FAN

JB-06 4
B/R (F) 1, 1 I
G-07 REAR WIPER
IOA
t -L/G (F) _fcoJI)
a-07
63 A/C SWITCH 6 BLOWER SWITCH ILLUMINATION
LAMPS’REFER T O SECTION I-4
ENGINE

r CONTROL
(SECTION
UNIT
6-1~. 2bl

BjG L)B
RESISTOR ASSEMBLY L/B
(AC9 (AC)
-1

-L/B

4NT

;~~l-bJG
6 33
FAN
(SECTION B-3. 4)

A/C SWITCH

-03 DIODE (AC) G-04 REFRIGERANT G-05 REFRIGERANT G-06 MAGNETIC CLUTCH (AC) G-07 IE) - (AC) CONNECTOR
i-01 CONDENSER FAN (AC)
PRESSURE SWITCH NO.2 (AC) PRESSURE SWITCH NO. 1 (AC)

I I I I
s-10 A/C SWITCH(ACl G-12 BLOWER MOTOR (F) G-13 RESISTOR ASSEMBLY (II
I

I
j-14 BLOWER SWITCH (I)
U AIR CONDITIONER
Performance test
After finishing repairs, conduct a performance test of the air
DRY AND WET THERMOMETER conditioning system as follows.
1. Connect the manifold gauge set. (Refer to page U-32.)
2. Start the engine and keep the engine speed at 1,500 rpm.
3. Operate the air conditioner at maximum cooling.
4. Open all windows and doors.
5. Place a dry-bulb thermometer in the center ventilator outlet.
6. Place a dry and wet thermometer close to the blower inlet.

13uoux-014
7. Wait until the air conditioner outlet temperature stabilizes.

Stabilized condition
Blower inlet temperature: 25-35*C (77-95*F)
High-pressure side:
1,177-1,619 kPa (12.0-16.6 kg/cm’, 171-235 psi)
Note
l If the high-pressure side becomes too high, pour
cool water on the condenser. If It is too low, cover
the front of the condenser.

8. After the air conditioner stabilizes, read the dry and wet ther-
mometer at the air inlet.
9. Calculate the relative humidity from the chart below by com-
paring the wet- and dry-bulb readings.
05uoux-051

‘C ‘F
IO. Read the dry thermometer at the air outlet, and calculate
the difference between the inlet dry-bulb and outlet dry-bulb
26
24 temperatures.
22 11. Verify that the intersection of the relative humidity and tem-
20
18 perature difference is in the shaded zone.
16
14
12
10

U
--k----
RELATIVE HUMIDITY ‘%’
I

96U16X.103
U-36
 AIR CONDITIONER
Adjustment
Drive belt
Vehicle with power steering
1. Loosen bolt A and nuts B and C.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.

Belt Deflection: When applying moderate pressure

98 N (IO kg, 22 lb)
New 8-9mm (0.31-0.35 in)
Used 9-l Omm (0.35-0.39 in)
23UOUX-045
3. Tighten bolt A and nuts B and C.

Tightening torque
Bolt A: 36-54 N-m (3.7-U m-kg, 27-40 ft-lb)
Nut B : 36-51 N-m (3.8-5.3 m-kg, 28-38 ft-lb)
Nut C : 32-46 N-m (3.2-4.7 m-kg, 24-34 ft-lb)

Vehicle without power steering

1. Loosen nut A.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.

Belt Deflection: When applying moderate pressure

98 N (10 kg, 22 lb) .-,
New 8-9mm (0.31-0.35 in)
Used 9-l Omm (0.35-0.39 in)

DEFLECTION
3 *Tighten nut A.
03uoux-087
Tightening torque:
32-34 N*m (3.2-3.5 m-kg, 24-25 Mb)

u-50
 TECHNICAL DATA
D. LUBRICATION SYSTEM

Item
Engine B6 SOHC BP SOHC BP DOHC 1
I I bhricatinn mothnd Force-fed

Requlated pressure kPa (kg/Cm”, p

Inner rotor tooth tip to outer rotor Standard I-‘---- -.----,
clearance mm (in) Maximum 0.20 (0.0078)
Standard 0.09-0.18 (0.0035-0.0071)
Outer rotor to body clearance mm (in)
Maximum 0.22 (0.0087)
Standard 0.03-0.11 (O.pniq n nnn=’
“” I r-“.““+..I,
Side clearance mm (in)
“.n4rlI ‘t (U.0055)
Maximum ‘-
I I 1
Oil filter
_ Type Full-flow, paper element
Relief pressure differential kPa (kg/cm’, psi) 1 78-l 18 (0.8-I .2, 1 l-l 7)
Engine oil
Tntal /An, nnr*inol 3.4 (3.6, 3.0) 1 4.0 (4.2, 3.5)

I Capacity
liters (US qt, Imp qt)
VII 111Lb1
3.0 (3.2, 2.6) 1 3.6 (3.8, 3.2)
0.17 (0.18, 0.15)
API Service SG Energy Conserving II (ECQ
Grade
I Viscosity 1~Above -25% (-13OF 1 I I
SA!f _ InW-Xl
.-.. --

number 1 Below O’C (32OF) SAE 5W-30 1

E. COOLING SYSTEM

EnginelTransaxle B6 SOHC BP SOHC BP DOHC

MTX ] ATX 1 MTXl , ATX 1 MTX ) ATX
Cooling method Water-cooled, forced circulation J

LThermostat
Type Wax, two-stage
Opening temperature “C (OF) Sub: 83.5-86.5 (182--188), Main: 86.5-89.5 (188-193)
Full-open temperature OC (OF) 100 (212)
Full-open lift mm (in) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min.
Radiator
_ Type Corrugated fin
Cap valve opening pressure kPa (kg/cm2, psi) 74-103 (0.75-1.05, 11-15)
Cooling circuit checking pressure kPa (kg/cm’, psi) 103 (1.05, 15) ~..
Cooling fan .-
Type Electric
Number of blades 4_.---- _I___-
Outer diameter mm (in) 320 (12.6) --_ ~~-
Capacity w-v 80-12 - 160-12 80-l 2 160-12
Hi : 13.3 Hi : 13.3
Current A 6.6 6.6
_------ ._____ Low : 8.8 Low : 8.8
Water thermoswitch
OFF-ON “c (OF) 1 I--. 97 (207)
Radiator thermoswitch __-I____-
OFF+ON “C (OF) 1 1105 (221)( - (105 (221)

TD-8
TD TECHNICAL DATA

Outer diameter Free length Wire diameter

Spring name No. of coil mm (in)
mm (in) mm (in)
BP DOHC 11.6 (0.457) 59.7 (2.350) 16.9 1.8 (0.071)
2-3 accumulator
small spring 56
BP SOHC
SOHC 10.0 (0.394) 71.8 (2.827) 24.2 1.4 (0.055)
2-3 accumulator BP DOHC 15.0 (0.591) 71.8 (2.827) 9.8 1.2 (0.047)
large spring B6
BP SOHC
SOHC 15.0 (0.591) 71.8 (2.827) 15.8 2.0 (0.079)
l-2 accumulator small spring 11.2 (0.441) 84.7 (3.335) 25.5 1.5 (0.059)
BP DOHC - - - -
l-2 accumulator
large spring B6
BP SOHC
SOHC 16.0 (0.630) 84.7 (3.335) 19.5 1.9 (0.075)
Accumulator
B6 SOHC 10.8 (0.425) 101.2 (3.984) 28.2 1.2 (0.047)
N-D Accumulator
BP
BP SOHC
DOHC 10.8 (0.425) 101.2 (3.984) 28.2
small spring 1.2 (0.047)
B6 SOHC 15.0 (0.591) 94.2 (3.709) 16.5 1.6 (0.063)
N-D Accumulator
large spring BP
BP SOHC
DOHC 15.0 (0.591) 94.2 (3.709) 16.5 1.6 (0.063)
N-R Accumulator small spring 9.8 (0.386) 93.2 (3.669) 31.5 1.3 (0.051)
N-R Accumulator large spring 14.0 (0.551) 106.5 (4.193) 23.0 1.7 (0.067)
3-4 clutch Return spring 74.4 (2.929) 40.5 (1.594) 1 .o 5.0 (0.197)
Coasting clutch Return spring 7.3 (0.287) 20.45 (0.805) 10.0 1 .o (0.039)
Low
brake and reverse Return spring 5.55 (0.219) 14.3 (0.563) 12.0 0.75 (0.030)
Servo Return spring 27.7 (1.091) 43.25 (1.703) 4.5 3.2 (0.126)

Vehicle Speed at Shift point Table

- -
Throttlecondition
lode angc (Throttlesensor
- - voltage)
Fully opened
(4.0 volt)

Half throttle
(1.6-2.2 volt) / &%L) j1 3850-2,500 2,100-2,650 2,300-3,000 74-100 (46-62) 91-116 (56-72) 93-120 (58-74
D Lock-up [1,850-2,20011,950-2.550(2,300-2,700/74-88 (46--55)185-110 (53-68)(93-108 (58-67)1

OD -+ DI 1,05U
Kir.kdnwn

%lly opened s2 -+ 5,000-5,45c

s3
i4.0 volt) s3 2,900
-+ s2
S2 -+ ST 2,300-2,6OC
Half throttle SI * 52 2.500-3.35C
(1.6-2.2 volt) s2 -+ s3 v, v...

Fully opened Ll + L2 5,150-5,75(

w-dt\ I7w-ln

nlf throttle
6-7 7 vnltl I Ll + L2 (2.500-3.350(2,850-3,8OOj3.300-4.300125-34 (16-21$1-41 (19-25)j33-43 (20-27)1

TD-16
ST SPECIAL TOOLS

GENERAL INFORMATION
The letters A and B in the priority column indicate the degree of importance of each tool.
A.. . Indispensable
The tools ranked A in this list are indispensable for performing operations satisfactorily, easily, safely, and
efficiently. It is, therefore advisable that all service shops have these tools.
B.....Selective
The tools in this list are not as necessary as tools ranked A, but all service shops should have these tools
to perform repairs more easily and more efficiently.
23USTX-002

ST-2
ST SPECIAL TOOLS
FRONT AND REAR SUSPENSIONS

TOOL NUMBER TOOL NUMBER PRIORITY ILLUSTRATION

PRIORITY ILLUSTRATION
& DESCRIPTION 81 DESCRIPTION

49 8034 2A0 49 GO34 1AO

Replacer set, A Compressor, coil A

rubber bush spring

49 1243 785 49 0208 701A

Installer, dust A Air-out tool, boot B

boot

HEATER AND AIR CONDITIONER SYSTEMS

TOOL NUMBER TOOL NUMBER

PRIORITY ILLUSTRATION PRIORITY ILLUSTRATION
i? DESCRIPTION & DESCRIPTION

49 BO61 005 0000-41-0809-06

Replacer, seal A Remover &

plate installer, seal

CHECKER AND OTHER EQUIPMENT

TOOL NUMBER PRIORITY ILLUSTRATION

81 DESCRIPTION

49 0839 285 49 GO19 901

Checker, fuel & A EC-AT tester

thermometer

49 GO19 901A 49 HO19 902

EC-AT tester A
(EC-AT tester)

49 BO19 904 49 BO19 905

Panel
(EC-AT tester)

ST-10
 01 LAMP.., ., ,..... . . . . . . 9..a.. .. . 9.e... . . . . . . . . . . . . . T-5233
ARTER .,,.,..,..,..,,....,..,......,........................ G-25
RTER INTERLOCK SWITCH .,............... G-31
ERING GEAR AND LINKAGE .. .. . . . . . . N-13,30
ERING KNUCKLE . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. .. . . . M-5
TEERING WHEEL AND COLUMN . .. . . . .,.. N-8,26
WITCH . . . . . . .. . . . . ..I..................... T-47

THERMOSTAT . . . . . ,.,..,......,.. . . . . . . . . . . . . . . .. .. . ..a..... . E-9

THROTTLE BODY . . . . . . . . . . . . . . . . . ..s............. .. . . . F-l 12
THROTTLE SENSOR .., . . . . . . . . . s............. . . . . . . . . F-l 69
TNS RELAY . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .. . . . . . . . T-18
TRIM . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-97
TRUNK COMPARTMENT LAMP . . . . . . . .. ...a..... T-54
TRUNK LID ,,.,...........,................................... S-33
TRUNK LID LOCK AND OPENER a.............. S-35

VACUUM CHAMBER (VICS) . . . . . . . . . . . . .. ..s..... F-l 19

AND INDICATOR LAMP . ..a........ T-60

BUZZER AND TIMER . . . . . . . . . . . . . . . . . T-58
MP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . E-l 1
THERMOSENSOR s..........,.. F-l 68, T-72
THERMOSWITCH ..,,....................... E-l 6
ALIGNMENT . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .. . . R-7
HEEL CYLINDER ,.............,..,.................... P-30
HEEL HUB .r,....,......................................... M-5
HEELS AND TIRES . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . Q-3
INDSHIELD WIPER AND WASHER . . . . . . . . . . S-67
WASHER MOTOR ,.......,..,...................... S-71
WINDSHIELD WIPER
AND WASHER SWITCH s............,......... S-71
WIPER MOTOR ,....,,............................... S-70
INDSHIELD .,.......,.....,..,....,,....................... S-58
 VEHICLE IDENTIFICATION NUMBERS(VIN)
(CHASSIS NUMBER)

4 DOOR PROTEGE
JMl 80223 *NO 400001-
JMl BG224*NO 400001-
JMl BG225*NO 400001-
JMl BG226 *NO 400001-

3 DOOR HATCHBACK
JMl BG231 *NO 400001-
JMl BG232*NO 400001-
JMl BG233*NO 400001-
JMl BG234*NO 400001-

WIRING COLOR CODE

Color Code Color Code

Blue L Natural N
Black B Orange 0
Brown BR Pink P
Dark Blue DL Red R
Dark Green DG Purple PU
Green G Tan T
Gray GY White W
Light Blue LB Yellow Y
Light Green LG Violet V
Z-Gl-4 Reading Wiring Diagrams -

System circuit diagram/connector diagram

l These show the circuits for each system, from the power supply to the ground. The power supply side
is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with
the ignition switch off. -
Below is an explanation of the various points in the diagram.
-
IGNITION SYSTEM l ENGINE CONTROL -
‘“G:
si-
P
7:’

) Indicates operating conditions for switches.

.I
I
I
\
.i
-

The prefix letter indicates the system in which

:he connector is used.

JB: Joint box connections

X : Common connectors
A : Charging system/starting
connectors
system

B : Engine control system connectors

C : Gauge control system connectors
\\‘\ -
-
f
9
Tiii
zs
LL
<Gii
D : Wiper system connectors Y
a
E : Lighting system connectors EE
-
F : Signal system connectors
G : Air-conditioning system connectors
H : Transmission control system
connectors
I : Interior lamp system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors 9 harness ground is represented differently
L : Remote control mirror system :han a unit ground.
connectors
M : Sliding sunroof system connectors Types of grounds Symbol
N : Power steering/4-wheel steering Harness I
system connectors
0 : Anti-lock brake system connectors
P : Power seat/seat heater system
connectors
Cl : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/air bag
system connectors
T : Others
Y : Ground connector
1
- .
Z-Gl-8 Reading Wiring Diagrams
SvmbolsI

Symbol Meaning Symbol Meaning

(I, Generates electricity through Resistance l A resistor with a constant value
Battery l Mainly used to protect electrical
chemical reaction
l Supplies direct current to circuits components in circuits by maintaining
rated voltage

l Reading resistance values

<Colored type>
Ground (1) l Connecting point to vehicle body or No.1 Cobr band
other ground wire where current flows -No.2 Cobr band
from positive to negative terminal of -No.3 Cobr band
No.4 Cobr band
battery
Flnt color. Rerkrancs
-A-
1 l Ground (1) indicates a ground point to
body through wire harness
l Gound (2) indicates point where
Ground (2) component is grounded directly to body

Remark
oCurrent wilt not flow through a circuit if
ground is faulty

Fuse (1) l Melts when current flow exceeds that

specified for circuit, stopping current
flow

Precautions
o Do not replace with fuses exceeding
(box)
specified capacity
Fuse (2) <Box type>. <Cartridge type>

(Cartridge)
vlain fuse/Fusible <Main fuse> <Fusible links

Transistor (1) l Electrical switching component Motor 0 Converts electrical energy into
a Turns on when voltage is applied to mechanical energy

Transistor (2) l Pulls in and expels gases and liquids

l Reading code
coiibmr(Cl

Number of terminals O:Low- frequency NPN

Lamp l Emits light and generates heat when Cigarette lighter a Electrical coil that generates heat
current flows through filament
Z-GI-12 Troubleshooting
Handling connectors
Caution
l Be sure to grasp the connectors, not the wires, when disconnecting them.

<CPU connector>

1 .Open the rear cover.

2.Lift the tab with a
small screwdriver
and remove the

improperly engaged A loose terminal will

connectors will cause cause poor terminal
poor terminal contact.
Lift the tab with a

remove the terminal.

<Round connectors>

1 .Open the cover.

2.Lift the terminal to
Using a matching male Verify that terminals are
3.Verify that the
is no looseness in the connector when engaged. terminal IS securely
female terminal. mounted in the
connector when

3.Lift the tab with a

small screwdriver
and remove the

Lightly pull each wire to

verify that the terminal
does not pull out of the
II-GM6 Troubleshooting
Finding short circuits
Shorts occur between the power(positive) and ground(negative) sides of a circuit.
Therefore, finding a shdit circuit requires determining how the circuit is routed.

Circuits not connected to control unit

Examples
Finding short circuit
Battery Short location Indication
0 Fuse melts. 1. Remove the fuse and
main fuse of the circurt.
Short (A) 2. Disconnect all connectors
of electrical components
in the circuit.
0 3. Attach a voltmeter or test
l Main fuse melts.
Test lamp lamp to the fuse box and
reconnect each
Short(B)
connector, beginning
L* nearest the power
source.
The motor operates regardless
0 4. Check the voltmeter or
of whether thermoswitch ON see if the test lamp lights
Short (C) or OFF when the ignition as the connectors are
The- switch is ON. connected.
lotor M tmo- *The fuse is not melted.
switc @The main fuse melts when the
P ignition switch and thermo-
Short (D)
switch are ON and the relay is
operating.

Circuits connected to control unit

Examples -T Finding short circuit
Short locatior I Indication
l Fuse melts. - 1. Remove the fuse and main
ignition switch fuse of the circuit.

Fuse R-l
I
Short (A) ,,{:““o /
2. Disconnect all connectors of
electrical components in the
circuit.

;<
J+L--l
9enold m
A) u a(B) ’
Short (A)

rfr solenok Short (6)

l Solenoid A operates normally
when the ignition switch is
ON.
Test lamp
3. Attach a voltmeter or test
lamp to the fuse box and
reconnect each connector,
beginning nearest the power

4. Check the voltmeter or see

if the test lamp lights as the
l The CPU transistor burns out connectors are connected.
when the ignition switch is
Short (C) turned ON.

l The CPU thinks the switch is Sensor/switch 1. Attach the test lamp or
Short (0) ON because the same voltmeter to the CPU
conditions exist as when the connector.
Swltcl1
ml switch is ON.
*The CPU senses the sensor
to be 0 R because the
2. Connect to the swrtch/
sensor connector.
3. Check the voltmeter or see
if the test lamp lights.
conditions exist as when
Short (E) resistance value is 0 R
*The CPU equipped with the A short has occurred where voltmeter
self-diagnosis function output reads OV or the test lamp goes out,
the malfunctron code. -

Z-16
This page left intentionally blank
 I ww *. ..l.W Y.#WY”W-&m

aCHARGING SYSTEM A-2

ALTERNATOR

-04 ALTERNATOR (El A-05 ALTERNATOR (E)

Z-24
 . ” . ..S1.” Yrne-aU. .-m

EGI MT = ENGINE CONTROL SYSTEM (2/3)

1 1

OISTRIBUTOR W/R (EM)

Ez %P

MAIN RELAY (FUEL INJ)

(SECTION B-la)

*
w

11-O: ENGINE CONTROL UNIT (EM) Bi-09 DISTRIBUTOR (EM) Bl-10 POWER STEERING
2" IS 1Q 10 1M IK 11 1G IE 1C IA 2Y 2W 2U 25 20 20 3-l 2K 21 26 2E 2C 2A PRESSURE SW ITCH (F)

* L/O Y yy L/W R

ll-11 ISC VALVE(EM)

31-18 WATER THERMOS:~;;j;Bl-25 SOLENOID VALVE

(~1123 (INJ)

2-28
.
mnina Input &PJ connectkfl to T.&condition collect vdtaQe ReRlar* Connection to Test condition
1A - - -t ve For backup Stoplight swtch Bake pedal released
IEI 0 Main relay Off ov Brake pedal depressed
(FUEL INJ relay) IQ”&” switch -
ON V% P/S Qrc?ss"re lQ”ih0” switch ON
switch ___--
IC 0 Ignition switch Whik cranking Approx. tov P/S ON at idle
(START)
lgnitlon switch ON ov P/S OFF at idle
1D 0 .self-mag”osls Test switch at “SELF-TEST” With Self-
4 5--5.5v A!C switch A/C switch ON
Checker Lamp illuminated for 3 sec. after ignition D&Q”& Check-
(Monitor lamp) SwiIch OFF-KIN er and system A/C switch OFF
st?lt?ctor
Lamp not illuminated after 3 sec. Vi3 coohng fan swtctl Cwlng fan operatng (Engine coolant tem-
Test switch at “02 MONITOR” at idle perature over 97°C (207°F) or dlagnosls
Monitor lamp ilfummated connector terminal TFA grounded) (IG ON)

Test switch at “02 MONITOR” at idle Fan not ooeralmg (Idle)

Monitor lamp not illuminated VB
Blower Control Blower control switch OFF or 1 st posihon
1E swttch
0 Malfunction indicator Lamp illuminated for 3 sec. after ignition With System Blower control swtch 2nd or htgher
lamp switch OFF&N Below 2.w
Selector test position
NJ swtch at
Lamp not illuminated after 3 ser. VB Rear wmdow
“SELF-TEST” Rear window defroster swtch OFF
Lamp illuminated Eelow 2.5v defroster switch
Rear window defroster Switch ON
Lamp not #lluminated VS

-2-A - I
Headkght switch tieadlghts ON
0 Self- Diaanosis Buzzer sounded for 3 sec. after ignition Wiih Self-
l
Headlights OFF
Checke; switch OFF-ON 6&w 2.5v DkQnosls I

(Cede Number) Checker and NeulraliClutch Neutral positton or clutch pedal Ignition swtch
Buzzer not sounded after 3 set V8 switches ov
Svstem Selector depressed ON
Buzzer sou”ded 1 Below 2.5V 1 ‘.&h System
.
OlhWS VB
Selector test
Buzzer not sounded I VE I switch at Ground (Injector) constant ov -
“SELF-TEST”
0 lgnller lgnlti swtch ON ov
Ground (OUtQUt) Constant ov -

klk Ap~rox O.2V

- Ground (CPU) Co”stant ov -

1H - - - - -
Grou”d (Input) Constant ov -

II - - - - I - - D&ribulor
(Ne-sIgnal)
Igntho” swdch ON APprox. ov
or 4 5-5 5v -
1J 0 A/C relay fgnition switch ON VB Idle Approx. 2V
AX switch ON al idle 5&w 2.w - - - - -
NC switch OFF at Idle Vi3 Distributor Ignition swtch ON AQWOX. Ov
1K (G-stgnal) [DOHC] or 4 5-5 5v
0 3ignosis System Selector lest switch at Ignition switch -
x”“ec1or “0-z MONITOR” VB ON Idle APQ~OX 1.5V
,TEN terminal) -L
System Selector test swatch at
“SELF-TEST” ov

1L c 3RL relay (canada) ParkIng brake pulled wth lgndlon swtch ON l DRL: oaytime
VB
(DRL OFF) Running tigms
Idle (DFtL ON) Below 2.5v
1M - - - - -
1N 0 rhr0ttte sensor Accelerator pedal released ov Ignition switch
‘Idle switch) ON
Accelerafor pedal depressed VB
 WIRINQ MAQRAM o...DoHc
EGI EC-AT mENGINE CONTROL SYSTEM &i EC-AT CONTROL SYSTEM(2/3)

~II;~CONTROL
@+...-BR/w IF) ~BR/W (EM) 1 ~~~~j @--- Y/B (F) s Y/B (EM) 1
(SECTION E-3)

3F ENGINE CONTROL UNIT 1E

CANADA DOHC
3M 3u 3V 2E IL 10 IH 1P 1Q
2A IN 3Q 20 31
_._----.-. ------~---
2-01y==---- --~--

I
L/Y I I I I
I I [FM\ x?
G/O
(EM) GM,
Y/B
(EM)

I
82-11

EC
VALVE

82-11

26
1 b
REAR
WINDOW
(SECTION DEFROSTER
Gl SWITCH
(SECTION
i 25 I-l)
A/C RELAY ILL~l lMIl \IATIONSTOPLIGHT
MAIN RELAY (FUEL INJ) (SECTION LA& ‘S SWITCH
(SECTION B-2a) G) :TII 3N (SECTION
I-4) F-2)

82-09 DISTRIBUTOR (EM)

2-01 ENGINE CONTROL UNITCEM)
11: ,S 113 10 IM IK 11 1G 1E 1~ 1A -I 20 2M 2K 21 2G 2E
2C 2A 3~ 3w 3” 3s 3~ 30 3M 3K 31 36 3~ 3C 7A
1 I I I , __ , ,, .,- ,, f 1 I _ I, ,“I 11 1 ,^ 1 1 I ,” I ., I: B/R 1 v I,., I v lb ,I c
* W W/L W/L R/BFG/qW/UIL/WIH/Li W
k”,, -L_ .A _ ,, I_ ,^ , _
L L/1 ‘,tl,, * , * , x , * , * , m ,‘,“, * IF’“” ‘,“‘V
* R/W B/L O/L~L/Y[L/BIB/LIR/BIW/B(IYY/YIU(/R R/YY/LI * (-‘;--pH/kpqwb( H 1
2P 2N 2L 2J 2H 2F 20 28 32 3x 3V 37 3R
~~ 3P
~- 39
--’ 3L
-’ zw
-‘ 311
-” Jr
7r JY
=” _I”
=(1
3” IT IR IP ,N IL IJ 1H IF 3D lF?
62-13 SOLENOID VALVE ~2-14 INJECTOR No.t(INJ) 82-15 INJECTOR N0.3(INJ) 82-16 INJECTOR N0.2(INJ)
z-10 POWER STEERING
PRESSURE SWITCH (Fl (PRESSURE REGULATO
I

12-25 SOLENOID VALVE

wrcs) (INJ)
 Terminal voltage v‘s: Battery vottage
Terminal vdt e (ATX) ve: aattefy voltage
I I 1
comcl voltage Remark
wminal lrput Connected
to I Test wndition ~cwrect rc4t.gej F&W* 1 Terminal input Output Connected to Test condition

For backt@ 10 A/C swatch AIC switch ON Befow25V ignition switch

1A - 3attery Constant V% 0
ON and blower I
ov A/C switch OFF VB motor ON
1B 0 Uain r&y OFF
:FUEL INJ relay) tgnition swdch
ON
- V6 IP Blower control Blower control swtch OFF or 1 St poSItion VB tgnibon switch
- 3 ii
switch ON
1C 0 Ignition swtch White crankii npprox 1ov Blower control switch 2nd or higher ov
(START) position
fgnition switch ON ov
1Q Stopltght switch Brake pedal released Below 1 ov
1D Self-Diagnosis Test swtch at “SELF-TEST’ With Self- 0 -
Checker Lamp illuminated for 3 sec. after igmtmn 4.5-5.w Diagnosis Check- VE
Brake pedal depressed
[monitor lamp) switch OFF-+ON er and System
Selector lnhtbitor switch N or P range ov Ignition switch
Lamp net illuminated after 3 Sec. VS ON
(P N range)
Other ranges VB
Test swtch at “02 MONITOR” at idle 4.5-55v lgmhon swtch
i Monitor lamp illuminated Cruise control man Set or Resume swtch ON or vehicle speed
switch 8kmih &mph) lower than preset speed &tow 1 5~ ON
Test switch at “02 MONtTOR” at idfe (Drwng vehcfe crwse cantrol OperatiOn)
Monitor lamp not illuminated
Normal conditions “8
Malfunction indicator lamp illuminated for 3 sec. after ignition With System
Below 2 5v selector test Bebw 1 ov lgnihon swatch
lalllp switch OFF+ON IT <; Throttle Sensor Accelerator pedal released
switch at (Idle switch) ON
WLI Accelerator pedal depressed VS
Lamp not luminated after 3 sec. VE “SELF-TEST”
I
lamp ifluminated BelOW 2.w Fk - - - - -
Lamp not illuminated VS 1v -- - - - -
Self-Diagnosis Buzzer sounded for 3 sec. after ignrtion l With Self- z 3A ’ D&rib&r lgmtion swtch ON Approx. OV
Below 2.5V or 5v
Checker switch OFF-+ON Diagm!3s -‘. / b / / (Ne-signal) / ,,,, -
(code number) Checker and
._. Approx 2v
Buzzer not sounded after 3 set VB system Select0 I /
l With System 28 1 ., AdlOw meter lgmhon switch ON Approx 3 BV
Buzzer sou&?d Below 2 5v
Selector test -

I Buzzer not sounded

2c j r:
\’
oxygen sensor
Idle
fgmtson switch ON
Approx

ov
3 3V

ov I 1
tgmter Ignition switch ON
Idle (cold englIIei ov
Idle Appror 0 2v - -
Idle (after warn-up) O-l ov
Headlight switch Headlights ON VB
f - lncreasma _ enwe- speed (after warm-up) 0 w-1 .ov
,
! ov
, Headlbhts OFF
Deceleration o-o 4v
Diagnosis System Selector test switch at Ignition witch
VS 20 Coolmg fan swtch Fan operahng (engine coolant temperature
connector “02 MONITOR” ON
over 97°C (207’F) or diagnosis connector DV
(TEN terminal) -
System Selector tesf switch at termmat TFA grounded)
QV
“SELF-TEST”
Fan not operatmg (idle)
Rear window Rear window defroster watch OFF ov lgmhon switch
Water thermosensor Engine codant temperature L” %, I”” I , ‘Y”8’.“” . . . ...-1.
defroster switch __ ON
Rear window de!roster watch ON VO
After warm-up
I
Ground Icalifornia) ConSlant ov
- .._..._--..--
Thrnttb SP”SOi 1 Accelerator pedal released Approx 0.5V
-
Main relay (canadal fgmtion switch ON VB
- Accelerator pedal fully depressed Approx. 4 OV
0 AC relay Ignitiin switch ON VB
2G ATF thermosensor -XPC (-2o”~)--1x1~c (302°F) aprxox as5-~m lgmhon swtch
0
A/C switch ON at Idle Below 2.5% - ON
ATF temp 20°C (68°F) Approx. 4.6V
A/C switch OFF at Gle 13OOC (266°F) Aporox 1.54V
I I I I I I
Vehicle speed / Vehicle stopped
2H / i, I / Hold switch Hold mode Below 2V Ingbhon switch

- Normal mode
P/S pressure lgmhon switch ON
switch
P/S ON at idle Iturnino) I.
I
P/S OFF at idle VB
-
: WIRINQ DIAQRAM \

PROTEGE EC-AT aCOOLING FAN SYSTEM

MAT?., BATTEI

.B (F)

GNITION
WITCH

MAIN RELAY
(SECTION B-2al

JB-04
@

(E) I

COOLING FAN NI ?
RELAY NO.2 ?EL .AY

Y (El
,-,
COOLING FAN

84-05
3 : 54-02

ENGINE
UNIT
CONTROL
B/G’ (F)

04

COOLING FAN (SECTION E3-2a)

NO. 3

DOHC -

Q
84-06 DXAGNOSIS DOHC
I CONNECTOR (3c451 +
WATER
‘TTCH (SECTION u) - F I
THERMOSW I

84-06
B ci) THERMOSWITCH

34-01 COOLING FAN 34-02 COOLING FAN 84-03 WATER THERMO- 84-04 COOLING FAN
RELAY NO. 1 (E) MOTOR (F) SW ITCH (EM) RELAY NO 2 (F)

34-05 COOLING FAN B4-06 WATER THERMO- 54-07 SHORT CONNECT0

RELAY NO. 3 (F1 SWITCH (F) (EM
j Z WlRiNQ MAQRAM
A.. .EC-AT 0 .CANACA
/ l NSTRUMENT CLUSTER & WARNING LAMPS *...WITH PASSIVE SHOULDER BELT
c

BATTERY MAIN
0 01 BOA
0 0, B (E) 0 (F)

.-I

FLASHER UNIT HEADLIGHTS

INSTRUMENT CLUSTER
SECTION F-l (SECTION E-2)
(SECTION E-3) ILLUMINATION LAMP
;REFER T O SECTION I-4 k,
JR-06 @

METER
15A
STARTING SYSTEM
(SECTION n-i) E J&O4 0
WY
Fl
I
INSTRUMENT CLUSTER

SEYSOR
OOHC
&

:-04 PARKING BRAKE C-07 WATER THERMOSENSOR

SWITCH (I?) (EMI
(INJI

DOHC
 w IT\IIWU uwbunnm
;JITHOUT WINDSHIELD D-l
XllJISE CONTROL’WIPER 6; WASHER
MAIN Q

l-01 WINDSHIELD WIPER 6, WASHER SWITCH(F) D-02 WINDSHIELD WIPEdD-03 WINDSHIELD

MOTOR (F) WASHER MOTOR (F)
-
L/Y L/O L

L/W B R *
‘

Z-48
 WIRINQ DIAQRAM
‘1Tt-i WINDSHIELD II.. . PROTEGE
D-2
RUISE CONTROL ‘WIPER 6; WASHER
MAIN
BOA \\
B (El
&fJq

L (F)

j---W (F)

-----j-ER (F) -//LI

01:

WINDSHIELD
[
01:

L/( i (F)
WINDSHIELD (5
I
I -

;;;;;“I”‘”

MOTOR
I
f3iF)

6 (F)

v (
-01 WINDSHIELD WIPER E; WASHER SWITCH (F) D-02 WINDSHIEt-“oT~~~~~ I-03 WINDSHIELD

w
(ASHER MOTOR (F)

L/O

-04 WINDSHIELD WIPER RELAY (F)

f3 L/Y G/Y L/W R

BR L/O L w G/W 1.

Et 0
I w 1rn1nu Y.#?Y”-WM

l 323 HATiCHBACK = REAR WIPER &WASHER D-3

MAIN

REAR WASHER

WITHOUT
 WlRlNQ DIMRAM
IITHOUT E-l
:RUISE CONTROL’ HEADL1GHTS

ILLUMINATION

BULB TRADE NUMBER

HEADLIGHT: 9004 (65/45W)

-01 COMBINATION E-02 COMBINATION E-03 HEADLIGHT LH (F) E-04 HEADLIGHT RH (F:
 WIUINW lJlAWnAm
JITH E-2
mJI:SE CONTROL l HEADLIGHTS

DRL CONTROL

DRL CONTROL

BULB TRADE NUMBER

qE-04 HEADLIGHT: 9004 (65/45W)

f t-02 COMBINATION E-03 HEADLIGHT LH(F) E-04 HEADLIGHT RH(F) E-05 HEADLIGHT RE;$
SWITCH (F)
”
R/W R W/R

B L/Y LG

E-06 TAILLIGHT REU&

Z-56
ZANADA l DAYTIME RUNNING LIGHTS E-3

DRL CONTROL UNIT

-07 DRL RELAY (F) E-08 DRL RESISTOR (F) E-09 DRL CONTROL UNIT (F)

a
! WIRINQ DIAQRAN
l TAILLIGHTS mREAR SIDE MARKER LIGHTS n POSITiON LIGHTS E-4
l LICENSE PLATE LIGHTS

ti;$ik;GHT

(SECTION E-l. 2)

BULB TRADE NUMBER BULB TRADE NUMBER

REAR SIDE MARKER: 194 (3.BW1 LICENSE PLATE: 89 (7.5W1
TAILLIGHT: 1157 (8W) POSITION. 1157 (8W)
-

I PROTFGF I PROTEGE IJ , PROTEGE

k
PROTEGE 1

I I

SIDE ION
-n TAILLIGHT Ll ‘-I LH
R a I i H“

-10 REAR SIDE MARKER E-II REAR SIDE MARKER E-12 TAILLIGHT LH (R) E-13 TAILLIGHT RH (R) E-14 LICENSE PLATE LI;li;E-I” LICENSE PLATE LK;:‘E-I” LICENSE PLATE L$j;
LIGHT LH (R) LIGHT RH (R)

-17 POSITION LIGHT c;r E-18 POSITION LIGHTRji

1 w ItuNu wnunnm

l TlJRN 6r HAZARD FLASHER LIGHTS F-l

BULB TRADE NUMBER

FRONT TURN: 1157 (27W)
REAR TURN : 1156 (27W)
FLASHER UNIT

____----_----

HAZARD SWITCH
ILLUMINATION LAMP:
REFEA TO SECTION I-4

--0 1 TURN SWITCH (F) F-02 FLASHER UNIT (F)

I=\ (++&(GIs/vl [ml

WITH CRUISE CONTROL
;;;aT;;l[ CRUISE

--05 HAZARD SWITCH (I) E-12 REAR TURN L$ti; E-13 REAR TU”N,‘R;;;;
 : WIRINQ DIAGRAM
. STOPLIGHTS F-2
BTN

z!zL
Y MAIN
+ 60A
BOA
B (E) m :> W/R (F)
IX-O l,j lx-0 11
JB-05 (B
STOP
--I 20A

Y JB-05 0

SHIFT-LOCK
UNIT
(SECTION HI

9
49
tr-~ (F) +@ ENGINE CONTROL UNIT
BULB TRADE NUMBER (SECTION 6-1~. 2b)
STOPLIGHT: 1157 (27W)
HIGH MOUNT t+G (F) -+@ CRUISE CONTROL UNIT
STOPLIGHT: 921 (18.4W) (SECTION Q)
(6,

WITH REAR SPOILER

3HB

12 STOPLIGHT

STOPLIGHT

12
STOPLIGH STOPLIGHT
B LH
PROTEGE

“-06 STOPLIGHT F-07 HIGH MOUNT STOP I-12 STOPLIGHT LH (R) c-13 STOPLIGHT RH (R)
SWITCH (F)

WITH 1 B 1 G 1 PROTI

REAR SPOILER- (R2

Z-64
! WIRINQ DIAQRAM
HN
ACK-UP LIGHTS F-3

B (F)
n
I_~
(F)
JB-05

STOP
X-

0
BTN
60A

EXCEPT
JB-06
GNITION
WITCH

@
BULB TRADE
BACK-UP: 1156
NUMBER
(27W1

EC-AT METER
20A 15A
JB-05 @ JB-07 @
\8 INHIBITOR
I
SWITCH
G/W Y:: (SECTION 8-2~)
(F) I

;/0
(F) %%E (F)
I ICONTROL
/
GjY

,.--
WITHOUT
CRUISE
CONTROL
5m
F-10

BACK-UP
SWITCH

F-10
LIGHT

BACK-UP LIGHTS
R/G
(?I

w
R B G/O Y G B/Y

.--lo BACK-UP LIGHT -02 HORN SWITCH (F) S-12 BACK-UP LIGHT Lt -13 BACK-UP LIGHT R’
SWITCH(F) F-3) (A
 JB-06

A/C SWITCH 6; BLOWER SWITCH ILLUMINATION

LAMPS:REFER T O SECTION I-4

ABOVE 57 ON
BELOW OC: nFF

SWITCH NO.2
5 WIRINQ DIAQRAM
6HIFT-LOCK SYSTEM H

MAIN

B 03

Sl GNITION
I WITCH
[

W/R (F1
JB-05 0 JB-06 @
STOP IETER
20A 15A
JB-05 @ JB-03 @
8 SHIFT-LOCK UNIT

i-0 1 SHIFT-LOCK
UNIT (f?)
 11.. . ..w-

HtAH WINDOW U&-H(.)S 1t+j

= DIGITAL CLOCK WXGARETTE LIGHTER I-.

REAR WINDOW
DEFROSTER

CONTROL UNIT
(SECTION
B-lc, 2b)
REAR WINDOW
DEFROSTER

LAMPS
(SECTION 1-4)

lFROSTER SWITCH (I)

 h ntnwJu lJlAUc(Arn

. INTERIOR LAMP l SOUND WARNING SYSTEM

QGNITION KEY CYLINDER LAMP
BTN

COURTESY LAMP
(SECTION I-3)

EECTION I-41

-05 IGNITION KEY I-06 BUCKLE SWITCH (R) I-07 INTERIOR 6 SPOT LAMPtIN) I-08 DOOR SWITCH FL (R)
: IEMINOER SWITCH(F)

SHOULDER BELT
YfOULCER BELT S%XlLOER BELT SHOULDER BELT
WITHOUT SUNROOF WITH SUNROOF
I -09 DOOR SWITCH FR (R) I-IO ODOR SWITCH RL(RI I-11 DOOR SWITCH RR(R) D-01 IGNITTON KEY CYLINDER LAMP(F) M-01 SPOT LAMP {IN)

WITH CRUISE CONTROL

SHOULDER BELT CRUISE CONTROL
M -02 SLIDING SUNROOF M-03 SLIDING SUNROOF
SWITCH MOTOR

z-74
-
 ! WIRING DIAQRAM
IHUNK C’OMPARff%?‘Jl LAMPS
= COURTESY LAMPS I-3
MAIN BTN
BOA 60A
B (El W/R (F)

,-W/R

JB-05 0
(F)
1 I

ROOM
IOA

1 \\ L/R (F) I I

PROTEGE

TESY
LH

(DRl)

34x-OS]
I-13
TRUNK COMPARTMENT R/W
LAMP (7)
I-13 I
1
R;/W
K-1

TRUNK COMPARTMENT
LAMP SWITCH

SWITCH
TION I-2)

:- 12 TRUNK COMPART- I-13 TRUNK COMPART- I-14 TRUNK COMPART- I-15 COURTESY LAMP
MENT LAMP (R3) MENT LAMP (R) MENT LAMP SWITCH(R) LH (~~11

I-16 COURTESY LAMP

RH (DR2)

R/W L/R

Z-76
 WlRlNa DIAGRAM
A .EC-AT

mILLiJMINATION LAMPS I-4

;;;i;;GHT

(SECTION E-l. 21

ENGINE CONTROL UNIT

- R/B [F) ----+@ (SECT ION B- IC. 2bl

I, -7

‘1::

:4JB-02 0 ?$JB-04 6 ?5JB-03 B

G-14 BLOWER

E L/V L/G R/B

: WIRINQ DIAQRAM
O...WITH POWER WINDOW
m AUDIO SYSTEM 1 J

B (F)

RADIO
15A
,I I
\\
JB-02

AUDIO ILLUMINATION LAMP:

REFER TO SECTION I-4

:J-01

AUDIO SYSTEM

J-01 AUDIO SYSTEM (I) J-02 AUDIO SYSTEM (I)

0 v R/B L/R L/B * * W/L

w L/O * * ++ * * x. L L/W * B/L

J-03 DOOR SPEAK:$$ J-04 DOOR SPEAKER RH J-05 REAR;SPEAKER(k; J-06 REAR SPEAKER I+
(R)

<

Z-80
 : WIRWQ MAORAY

aPOWERWINDOW K-l
MAIN
80A
8 (El 0 (F)

POWER WIND
30A
8/R (F)

c------ ------ -,,ROT,&--w--v-----,

POWER WlNDOW
MOTOR FL

:-01 POWER WINDOW MAIN SWITCH(DR1)

PROTEGE

G/Y W/R v/w L/W 8/W

RIG RIB 8 B/L G/W R/W

:-06 POWER WINDO;LI;l;OT;f K-07 POWER WINDOW SWITCH RR(DR4)

Z-82
, WIRINU VIAUI’IAM

l POWER DOOR LOCK K-2

,----PPROTEGf;----

:-09 POWER DOOR LOCK SWITCH(DR1) K-10 POWER DOOR LOCK K-11 POWER DOOR LOCK MOT’X#
RELAY (F)

(3HB) (PROTEGE) (3HB) (PROTEGE)

:-I2 POWER DOOR LOCK K-13 POWER DOOR LOCK

MOTOR RL (DR3) MOTOR RR (DR4)

Z-84
I . . ..I.. VW I.-.- . . . . m

l POWER OUTSIDE MIRROR L

RADIO

POWER OUTSIDE MIRROR SWITCH

_--------_------____

-RIGHT
-DOWN

MIRROR MOTOR
. WININU uwwanmm

GLIDING SUNROOF M

1-01 SLIDING SUNtWl; M-02 SLIDING S&tW~; M-03 SLIDING SU;;?;; M-04 SLIDING SUNROOF
RELAY

B mi r-r=
I wwtInu wmunnm
A. _ .EC-AT
l CRUISE CONTROL SYSTEM Q

CRUISE CONTROL MAIN SWITCH

ILLUMINATION LAMP:
REFER TO SECTION I-4

EC-AT CRUISE CONTROL UNIT

ACTUATOR

CRUISE CONTROL SWITCH (F) Q-O 1 STOPLIGHT Q-02 ACTUATOR (F)

SWITCH (F)

lm P G/Y
G B/Y v P
R 6 G/O Y
I G/L G/B
ffl

i CRUISE CONTROL UNIT (F) Q-04 CRUISE CONTROL

s 0 0 M G E C A MAIN SWITCH (I)
G/W * P G Y G/Y G/L
R/B GY

El x G/t3 R B/Y Y B
T R P N L J H F D 0
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 : WIRINQ MAQRAM
aPASSIVE SHOULDER BELT CONTROL SYSTEM S
TERY MAIN
BOA
0 (F) I I

BTN
GNITIoN
W/R IF) WITCH
INSTRUMENT
CLUSTER
(SECTION Cl
INSTRUMENl
C-1
- - I_IISTFR
(SECTION
-.
cl
f?PI
- -I
[SECTION I-21
rPI I
ERECTION I-21
1 ID-nl=
+““e-Y-

CONTROL UNIT
)

-01 PASSIVE SHOULDER BELT CONTROL UNIT(R)

” S 0 0 M I G E C A
BR Y/R * O/G B G/R B/Y * w Y/G
SHORT CORD
l/G L/Y Y/L P I3 LG Y Y/B L/B L/O w/0
” T R P N L J H F D B

-06 BUCKLE SWITCH (Al S-07 FRONT iF1 -INTERIOR

LAMP (IN)

7-94
7 nr
 . WIIWNU UIAUnA-

iDIAGNOSIS CONNECTOR U

ENGINE
CONTROL UN IT @-W/Y
(SECTION B-la. 2a) (SECTION B-la. 2al
ENGINE
CONTROL UNIT *W/B
(SECTION B-la, 2a) (SECTION B-la. 2a)

U-01 DIAGNOSIS CONNECTOR

IGNITION
COIL
(SECTION

J-01 DIAGNOSIS CONNECTOR (EM)

NOTE: TH-tS IS THE CONNECTOR AS ZEN FROM THE TERMINAL SIDE.

Z-96
” I
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f

> 13 FLOOR (FM -DOOR NO. 4 (DR41

) 17 FRONT iF) -ENGINE (E) X-18 ENGINE (El -EMISSION (EMI X-19 JOINT CONNECTOR (F) X-20 FRONT IF) -A/C (AC)
This page left intentionally blank
 *. .kC-AI
l COMMON CONNECTOR LIST b. .WITHOUT CRUISE CONTROt

X-21 FRONT (Fl -A/C (AC) X-22 JOINT CONNECTOR III X-24 FRONT (F1 -EMISSION (EM)

W (Fl .(EMl
(AC)

~1~~~

X-26 FRONT (F) -INSTRUMENT PANEL (1)

(0 (I)

z-101
l INTER CONNECTING DIAGRAM OF JOINT BOX gn
z-3
OJ cc

I-

i lIltlIt

I I Ill IIll
 ullslNu UlAUnAM 4

JB l JB CONNECTOR LOCATION l JOINT BOX

JE-01 ,I;;;::;” LAMP JB-02 INSTRUMENT PANEL HARNESS

J I G E C A

C I3 A

JB-03 REAR HARNESS

JB-04
JB-0 1

JB-06
JB-05
JB-02

JB-04 FRONT HARNESS JB-05 FRONT HARNESS

38-07

M J H F 0 B F 0 B

JB-06 FRONT HARNESS JB-07 FRONT HARNESS

JB-09 JB-08 -1 l’;& 0;; G;W l13;Yl x 1 : R;B L;R L;A

* (y) * Lp * * R/0
T R P N L J H F II B

J&O8 FRONT HARNESS

0 L/0
V B LG W * Ixl ,++] *
H G F E 0 C I3 A
JB-03

JB-09 CPU

PONMLKJIHGFEOCBA

A...WITH SUNQOOF t...WITH PASSIVE SHOULDER BELT

A.. .ECmAT 0 -CANADA I1 -PROTEGE

z-1 03
 NC RELAY 4
PL

SOlJSOlO VALVE
E%E”
MERMOSENSOR
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 DIAGRAM Z
-

PA ,KT-S INDEX
rl PARTS NAME SECTION T PARTS NAME SECTION

0 ACTUATOR ........................................................... Q IGNITER ........................................................ B-la,2a

A/C RELAY ........................................................... G IGNITION COIL .............................................. B-la.2a
t A/C SWITCH ......................................................... G IGNITION KEY CYLINDER LAMP ............................. l-2
t AIRFLOW METER .......................................... B-lc,Pc IGNITION KEY REMINDER SWITCH ........................ l-2
ALTERNATOR ..................................................... A-2 ILLUMINATION LAMP
t
I AUDIO SYSTEM ..................................................... J A/C SWITCH ..................................................... l-4
AT SELECT ....................................................... l-4
@BACK-UP LIGHT .................................................. F-3 AUDIO SYSTEM ................................................. l-4
BACK-UP LIGHT SWITCH ..................................... F-3 BLOWER SWITCH ............................................. l-4
I BLOWER MOTOR ................................................... G CIGARETTE LIGHTER ......................................... l-4
h BLOWER SWITCH .................................................. G CRUISE CONTROL MAIN SWITCH ....................... l-4
I BRAKE FLUID SWITCH ........................................... C HAZARD SWITCH ............................................. l-4
BUCKLE SWITCH ............................................. l-2, S INSTRUMENT CLUSTER ..................................... l-4
REAR WINDOW DEFROSTER SWITCH ................. l-4
CIGARETTE LIGHTER ............................................ I-1 INHIBITOR SWITCH .................................... A-l, B-2c
CIRCUIT OPENING RELAY .............................. B-l&Pa INJECTOR .................................................... B-1 b,2b
I CLUTCH SWITCH .............................................. B-lc INSTRUMENT CLUSTER .......................................... C
CONDENSER ................................................. B-la.2a INTERIOR & SPOT LAMP ....................................... l-2
CONDENSER FAN .................................................. G ISC VALVE ................................................... B-1 b,26
CONDENSER FAN RELAY ....................................... G
COMBINATION SWITCH .................................... E-l.2 @ LICENSE PLATE LIGHT ......................................... E-4
COOLING FAN MOTOR ..................................... B-3,4 LIMIT SWITCH ....................................................... S
COOLING FAN RELAY ........................................ B-3,4
COURTESY LAMP ................................................ l-3 481 MAGNETIC CLUTCH .............................................. G
CPU .................................................................... l-2 MAIN RELAY (FUEL INJ) ................................ B-la,Pa
CRUISE CONTROL MAIN SWITCH ........................... Q
CRUISE CONTROL SWITCH .................................... Q @ NEUTRAL SWITCH ............................................ B-lc
CRUISE CONTROL UNIT ......................................... Q
@ OIL PRESSURE SWITCH .......................................... C
@I DIAGNOSIS CONNECTOR ....................................... U OXYGEN SENSOR ......................................... B-la.2a
DIGITAL CLOCK ................................................... l-l
DIODE .................................................................. G @ PANEL LIGHT CONTROL ....................................... l-4
DISTRIBUTOR ............................................... B-l b,2b PARKING BRAKE SWITCH ...................................... C
DOOR CATCH SWITCH .......................................... S PASSIVE SHOULDER BELT CONTROL UNIT .............. S
DOOR SPEAKER ..................................................... J PASSIVE SHOULDER BELT MOTOR .......................... S
DOOR SWITCH .................................................... l-2 POSITION LIGHT ................................................. E-4
DRL CONTROL UNIT ............................................ E-3 POWER DOOR LOCK MOTOR ............................... K-2
DRL RELAY ......................................................... E-3 POWER DOOR LOCK RELAY ................................. K-2
ORL RESISTOR .................................................... E-3 POWER DOOR LOCK SWITCH .............................. K-2
POWER OUTSIDE MIRROR ...................................... L
ENGINE CONTROL UNIT .................................... B-1.2 POWER OUTSIDE MIRROR MOTOR .......................... L
POWER OUTSIDE MIRROR SWITCH ......................... L
i@ FLASHER UNIT .................................................... F-l POWER STEERING PRESSURE SWITCH ........... B-l b.2b
FRONT TURN LIGHT ............................................ F-l POWER WINDOW MAIN SWITCH ......................... K-l
FUEL METER ......................................................... C POWER WINDOW MOTOR ................................... K-l
FUEL TANK UNIT .......................................... B-la,2a POWER WINDOW SWITCH .................................. K-l

_ HAZARD SWITCH ............................................... F-l @ REAR TURN LIGHT .............................................. F-l

HEADLIGHT ..................................................... E-l.2 REAR SiDE MARKER LIGHT .................................. E-4
HEADLIGHT RELAY ............................................. E-2 REAR SPEAKER ...................................................... J
h HIGH MOUNT STOPLIGHT .................................... F-2 REAR WASHER MOTOR ...................................... D-3
h HOLD SWITCH .................................................. B-2c REAR WINDOW DEFROSTER ................................. I-1
4 HORN ................................................................. F-3 REAR WINDOW DEFROSTER SWITCH .................... I-1
HORN RELAY ...................................................... F-3 REAR WIPER MOTOR .......................................... D-3
! HORN SWITCH .................................................... F-3 REAR WIPER & WASHER SWITCH ........................ D-3
REFRIGERANT PRESSURE SWITCH .......................... G
0 IC REGULATOR .................................................. A-2 RESISTOR ASSEMBLY ............................................ G
-L
 PAWS INDEX

r~~~~~~
‘ARTS NAME SECTION 1 PARTS NAME SECTION

@ SHIFT-LOCK UNfT .................................................. H TRUNK COMPARTMENT LAMP .............................. l-3

SHORT CONNECTOR ........................................ B-3,4 TRUNK COMPARTMENT LAMP SWITCH ................. l-3
SLIDING SUNROOF ................................................ M TURN SWITCH .................................................... F-l
SLIDING SUNROOf MOTOR .............................. l-2. M
SLlDlNG SUNROOF RELAY ..................................... M @WARNING LAMP
SLIDING SUNROOF SWITCH ............................. l-2, M BEAM ................................................................ C
SOLENOID VALVE BELTS ............................................................... C
EC-AT ........................................................... 8-2~ BRAKE ............................................................... C
PRESSURE REGULATOR CONTROL .............. B-l b,2b CHARGE ............................................................ C
PURGE CONTROL ...................................... B-l b.2b CHECK .............................................................. C
VICS ........................................................ B-lb,Sb FUEL ................................................................. C
SPEED SENSOR ..................................................... C HAZARD ............................................................ C
SPOT LAMP ......................................................... l-2 HOLD ................................................................ C
STARTER ........................................................... A-l OIL .................................................................... C
STARTER INTERLOCK SWITCH ............................ A-l TURN ................................................................ C
STOPLIGHT SWITCH ....................................... F-2, Q WASHER ............................................................ C
STOPLIGHT ........................................................ F-2 WASHER LEVEL SENSOR ........................................ C
WATER THERMOSENSOR ........................... B-l b,2b,C
@ TACHOMETER.. ...................................................... C WATER THERMOSWITCH ................................. B-3.4
TAILLIGHT .......................................................... E-4 WINDSHIELD WASHER MOTOR ......................... D-l .2
TAILLIGHT RELAY ............................................... E-2 WINDSHIELD WIPER MOTOR ............................. D-l,2
TEMP METER ....................................................... c WINDSHIELD WIPER & WASHER SWITCH .......... D-1.2
THERMOSWITCH ................................................... G WINDSHIELD WIPER RELAY ................................. D-2
THROTTLE SENSOR ...................................... B-lc.2~