Haynes Honda Accord & Crosstour Automotive Repair Manual 1620920638, 9781620920633

Citation preview

Honda Accord

& Crosstour

‘Honda Accord © 2003 thru 2012 Honda Crosstour 5 2010 thru 2012

Haynes Repair Manual | Base d on a complete teardown and rebuild

ant ED 7) Yy

%S gC 7a ED ray

Includes essential information for today’s more complex vehicles

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/nondaaccordcrossO000madd

Honda Accord & Crosstour Automotive Repair Manual by Robert Maddox and John H Haynes Member of the Guild of Motoring Writers

Models covered: Honda Accord - 2003 through 2012 Honda Crosstour - 2010 through 2012 Meee Does not includeeee information Maespecific CEEto DLLor All-Wheel RINE erDrive Raebe models

(42015-5R6-3)

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MEMBER

Haynes Publishing Group THISig sialtHDRAWN FROM THE RECORDSOF THE | Sparkford Nr Yeovil MAR 3 1 2021 Somerset BA22 7JJ England Haynes North America, Inc

861 Lawrence Drive

—=—"MID-CONTINENT PUBL LsKARY

Newbury Park

|

California91320 USA

|

Acknowledgements Technical writers who contributed to this project include Tim Imhoff, Joe L. Hamilton, John Wegmann

and Mike Stubble-

field. Wiring diagrams originated exclusively for Haynes North

America, Inc. by Solution Builders.

;

© Haynes North America, Inc. 2005, 2008, 2012, 2013 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 10: 1-62092-063-8 ISBN 13: 978-1-62092-063-3 Library of Congress Control Number: 2013940361 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. 13-320

D-CONTINENT PUBLIC LIBRARY - QU

TMUN

Contents Introductory pages About this manual Introduction to the Honda Accord Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants Conversion factors Fraction/decimal/millimeter equivalents Safety first! Troubleshooting

Chapter 1 Tune-up and routine maintenance

Chapter 2 PartA Four-cylinder engine

2A-1

Chapter 2 Part B V6 engine

2B-1

Chapter 2 Part C General engine overhaul procedures

Chapter 3 Cooling, heating and air conditioning systems

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions and engine control systems

Chapter 7 PartA Manual transaxle

Chapter 7 Part B Automatic transaxle

Chapter 8 Clutch and driveaxles

8-1

Chapter 9 Brakes

9-1

Chapter 10 Suspension and steering systems

Chapter 11 Body

Mid-Continent Public Library 15616 East US Highway 24 Independence, MO 64050

Chapter 12 Chassis electrical system

Wiring diagrams Index

10-1

pO

Haynes mechanic and photographer with a 2003 Honda Accord

About this manual Its purpose The purpose of this manual is to help you

get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and

servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs,

doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must Pass on to you to cover its labor and overhead

costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Sec-

tion 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward.

Even though we have prepared

this

manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Honda Accord and Crosstour Accord models are available in twodoor coupe and four-door sedan body styles. Crosstour models are available only as a fourdoor hatchback.

The transversely mounted inline four-cylinder or V6 engines used in these models are equipped with electronic fuel injection.

The engine drives the front wheels through either a five-speed manual or a fourspeed automatic transaxle via independent driveaxles. Independent suspension, featuring coil

spring/shock absorber units, is used on all four wheels. The power-assisted rack-and-

pinion steering unit is mounted

behind the

engine. The brakes are disc at the front and either disc or drum at the rear, with power assist standard. Some models are equipped with Anti-lock Braking Systems (ABS).

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.

VIN Engine and model year codes

Engine codes

Vehicle identification number

Two particularly important pieces of information found in the VIN are the engine code and model year code. Counting from the left, the engine code designation is the sixth digit, and the model year code is the first digit after the star symbol at the center of

the VIN.

The engine code number is commonly needed when ordering engine parts. Besides being a component of the VIN, this code can also be found near the right (passenger side) end of the engine, near the exhaust manifold on four-cylinder models (see illustration) or on a pad near the left end of the front cylinder head on V6 models. The engine code is the first five digits of the number. The engines covered by this manual are:

(VIN) This very important number is stamped on the firewall in the engine compartment

Model year codes

and on a plate attached to the dashboard inside the windshield on the driver’s side of

K24A4, K24A8......... 2.4L DOHC i-VTEC four-cylinder J30A4, J30A5.......... 3.0L SOHC VTEC V6 K24Z2, K24Z3.......... i-VTEC four-cylinder JBSZ2 nei see resteee i-VTEC, Variable Cylinder Management V6 J30Z3 inoseere ECO

the vehicle. The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was manufactured, the

model year and the body style (see illustration).

Transaxle number

The Vehicle Safety Certification label is affixed to the bottom of the driver’s door pillar

The Vehicle Identification Number (VIN) is stamped into a metal plate fastened to the dashboard on the driver’s side - it is visible through the windshield

The transaxle number is commonly needed when ordering transaxle parts. On manual transaxles it’s located on the bellhousing, near the starter motor. On automatic transaxles, it’s located on the front of the transaxle case, above the dipstick.

The four-cylinder engine code number is located near the exhaust manifold

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is

as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on

an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to

buy materials and parts needed for general! vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far

from home. Authorized dealer parts department: This is the best source for parts which are

unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty information: \f the vehicle is still covered under warranty, be sure that any replacement parts purchased regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will

be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

Fasteners Fasteners are nuts, bolts, studs and screws

used

to hold

two

or more

parts

together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, _ either a lockwasher,

locknut,

locking

tab

or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and

must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust penetrant,

let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric bolt is sized in millimeters

0-8

Maintenance techniques, tools and working facilities

a

SS

(the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped

into one side, while metric nuts are marked with a number. The greater the number of

SS

SS

dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch_or compare it to a known fastener of the same size. Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different

Grade 1 or 2

Grade 5

strength ratings, be sure to reinstall any bolts,

studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original.

Tightening sequences and procedures Most threaded fasteners should be tightened to a specific torque value (torque is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters, have specific torque values, many of which are Specifications at the beginning of ter. Be sure to follow the torque dations closely. For fasteners not

Grade 8

Bolt strength marking (standard/SAE/USS; bottom - metric)

Grade

Identification

Grade

Identification

Hex Nut Property Class 9 Arabic 9

Hex Nut Property Class 10

Hex Nut Grade 8

6 Dots Standard hex nut

strength markings

Arabic 10 Metric hex nut strength markings

Class 10.9

Class 9.8

Class 8.8

Metric stud strength markings

noted in the each Chaprecommenassigned a

0-9

Maintenance techniques, tools and working facilities specific torque, a general torque value chart

is presented here as a guide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out in a pattern, such as

cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tightened in sequence to avoid warping the component. This sequence will normally be shown in the appropriate Chapter. If a specific pattern is not given, the following procedures can

be used to prevent warping. Initially, the bolts or nuts should be assembled finger-tight only. Next, they should be tightened one full turn each, in a crisscross or diagonal pattern. After each one has

Metric thread sizes WAG ea ary cts arena ae eens emer fy ER Se RE RES “RN Roni Scat LM15.) SCR ae ep res Dy cre Nisei oe oot eh ecseluak Sone cd Nia tak ote ee on oe fl ae

Ft-Ibs 6 to9 14 to 21 28 to 40 50 to 71 80 to 140

been tightened one full turn, return to the first one and tighten them all one-half turn, following the same pattern. Finally, tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

Component disassembly Component disassembly should be done with care and purpose to help ensure that

Nm

9 to 12 19 to 28

38 to 54 68 to 96 109 to 154

Pipe thread sizes CT eee Ce SR SRE SEL | GARE Oo ede Py ree Ss re 2 ee eile Ge Chnae RR int Oa Ce PEEL in eats (Pe kOe ee, 2. Bene eee per tents Fert

5 to 8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44

U.S. thread sizes BA eOO AOS 5 plete skh ee ge BikG cali eese kB tae sk ee LACT SY Re TRU Teor, Us ote 1 een set 8 Seeiaate OAR AD te 0. Me Reh oth Cakes TUNG) Ri SI ORaRrO ee ShO RE steer ant tea ea AEE Gt A eas oes Pees ae ete tee FTA Bie OOO u Ah 6) ee rein) ee OL os DAO a hs, pecs ho tee ss ae

6 to 9 12 to 18 14 to 20 22 to 32 27 to 38 40 to 55 40 to 60 55 to 80

9 to 12 17 to 24 19 to 27 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108

34 to 47

00-2 HAYNES

Standard (SAE and USS) bolt dimensions/grade marks

G_ L__ T D

Grade marks (bolt strength) Length (in inches) Thread pitch (number of threads per inch) Nominal diameter (in inches)

Metric bolt dimensions/grade marks Property class (bolt strength) Length (in millimeters) Thread pitch (distance between threads in millimeters) 1i ee] Diameter

0-10

Maintenance techniques, tools and working facilities

Dial indicator set

Micrometer set

the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such as a grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of components before removal. When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for this purpose, since each cavity can hold the bolts and nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior dash and trim pieces. The cavities can be marked with paint or tape to identify the contents. Whenever wiring looms, harnesses or connectors are separated, it is a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

Gasket sealing surfaces Throughout any vehicle, gaskets are used to seal the mating surfaces between two parts and keep lubricants, fluids, vacuum or pressure contained in an assembly. Many times these gaskets are coated with a liquid or paste-type gasket sealing compound before assembly. Age, heat and pressure can sometimes cause the two parts

to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do

not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed. Avoid using a screwdriver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften

it so it can be easily scraped off. Caution: Never use gasket removal solutions or caustic chemicals on plastic or other composite components. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason

the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gasket sealer should be used.

Hose removal tips Warning: /f the vehicle is equipped with air conditioning, do not disconnect any of the A/C hoses without first having the system depressurized by a dealer service department or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may leak. This is especially true for radiator hoses. Because

of various chemical

reactions, the

rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove

a hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it

around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled from the spigot. If this must be done, be careful that the metal connection is not damaged. If a hhose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few tools, the initial investment might seem high, but when compared to the spiraling costs of professional auto maintenance and repair, it is a wise one. To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics should start off with the maintenance and

minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer will assemble a tool set complete enough for most repair and overhaul procedures and will add tools from the special category when it is felt that the expense is justified by the frequency of use.

Maintenance techniques, tools and working facilities

Dial caliper

Hand-operated vacuum pump

Compression gauge with spark plug hole adapter

0-11

Fuel pressure gauge set

General purpose puller

Hydraulic lifter removal tool

Valve spring compressor

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removal/installation tool

Maintenance techniques, tools and working facilities

Ring compressor

Cylinder hone

Brake hold-down spring tool

Torque angle gauge

Clutch plate alignment tool

Tap and die set

Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

Standard screwdriver (stubby 5/16-inch) Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch) Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4mm to 10 mm) A selection of files Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type) Note: Another tool which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits.

Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (box-end and openend combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench. Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver (5/16-inch x 6 inch) Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan

Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and are in addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2-inch drive

over the 3/8-inch drive. Although the larger drive is bulky and more expensive, it has the capacity of accepting a very wide range of large sockets. Ideally, however, the mechanic should have a 3/8-inch drive set and a 1/2-

inch drive set. Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch)

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition,

Maintenance techniques, tools and working facilities most of these tools can be obtained from a tool rental shop on a temporary basis. This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump

Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are a number of options available when purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one of the large retail chain stores. A set can usually be bought at a substantial savings over the individual tool

prices, and they often come with a tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be purchased to expand the tool selection. Build-

ing a tool set gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be

used. Tool stores will often be the only source of some of the special tools that are needed,

but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Care and maintenance of tools Good tools are expensive, so it makes sense to treat them with respect. Keep them clean and in usable condition and store them properly when not in use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won’t get lost during a test drive. Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung on a panel mounted on the garage or workshop wall, while others should be kept in a tool box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

How to repair damaged threads Sometimes, the internal threads of a nut or bolt hole can become stripped, usually from overtightening. Stripping threads is an all-toocommon occurrence, especially when working with aluminum parts, because aluminum is so soft that it easily strips out. Usually, external or internal threads are only partially stripped. After they've been cleaned up with a tap or die, they’il still work.

Sometimes, however, threads are badly damaged. When this happens, you’ve got three choices: 1) Drill and tap the hole to the next suitable oversize and install a larger diarneter bolt, screw or stud. 2) Drill and tap the hole to accept a threaded plug, then drill and tap the plug to the original screw size. You can also buy a plug already threaded to the original size. Then you simply drill a hole to the specified size, then run the threaded plug into the hole with a bolt and jam nut. Once the plug is fully seated, remove the jam nut and bolt.

3) The third method uses a patented thread repair kit like Heli-Coil or Slimsert. These

0-13,

easy-to-use kits are designed to repair damaged threads in straight-through holes and blind holes. Both are available as kits which can handle a variety of sizes and thread patterns. Drill the hole, then tap it with the special included tap. Install the Heli-Coil and the hole is back to its original diameter and thread pitch. Regardless of which method you use, be sure to proceed calmly and carefully. A little impatience or carelessness during one of these relatively simple procedures can ruin your whole day’s work and cost you a bundle if you wreck an expensive part.

Working facilities Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out,

some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents, etc. which soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fluids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal for this purpose. Always keep a supply of old newspapers and clean rags available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it with an old blanket or bedspread to protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

0-14

Jacking and towing Jacking Warning: The jack supplied with the vehicle should only be used for changing a tire or placing jackstands under the frame. Never work under the vehicle or start the engine while this jack is being used as the only means of support. The vehicle should be on level ground. Place the shift lever in Park, if you have an automatic, or Reverse if you have a manual transaxle. Block the wheel diagonally opposite the wheel being changed. Set the parking brake. Remove the spare tire and jack from stowage. Remove the wheel cover and trim ring (if so equipped) with the tapered end of the lug nut wrench by inserting and twisting the handle and then prying against the back of the wheel cover. Caution: On some models the wheel cover can’t be removed by prying; the wheel nuts must be removed first. Loosen, but do not remove, the lug nuts (onehalf turn is sufficient).

Place the scissors-type jack under the side of the vehicle and adjust the jack height until the slot in the jack head engages with the raised portion of the ridge on the vertical rocker panel flange nearest the wheel to be changed. There is a front and rear jacking point on each side of the vehicle (see illustration). Turn the jack handle clockwise until the tire clears the ground. Remove the lug nuts and pull the wheel off. Replace it with the

spare. Install the lug nuts with the beveled edges facing in. Tighten them snugly. Don’t attempt to tighten them completely until the vehicle is lowered or it could slip off the jack. Turn the jack handle counterclockwise to lower the vehicle. Remove the jack and tighten the lug nuts in a criss-cross pattern. Install the cover (and trim ring, if used)

and be sure it’s snapped into place all the way around. Stow the tire, jack and wrench. Unblock the wheels.

Towing As a general rule, the vehicle should be towed with the front (drive) wheels off the ground (the best method is to have the vehicle placed on a flat-bed tow truck). If they can’t be raised, place them on a dolly. The ignition key must be in the OFF position, since the steering lock mechanism isn’t strong enough to hold the front wheels straight while towing. Vehicles equipped with an automatic transaxle can be towed from the front with all four wheels on the ground, provided that speeds don’t exceed 35 mph and the distance is not over 50 miles. Before towing, check the

transmission fluid level (see Chapter 1). If the level is below the HOT line on the dipstick, add fluid or use a towing dolly. Additionally, perform the following steps:

a) Release the parking brake b) Start the engine c) Move the transaxle gear selector into D, then to Neutral d) Turn off the engine e) Place the ignition key in the OFF (not

the LOCK position).

The jacking points are located near the front and rear wheel on each side of the vehicle

Caution: Never tow a vehicle with an automatic transaxle from the rear with the front wheels on the ground. When towing a vehicle equipped with a manual transaxle with all four wheels on the ground, be sure to place the shift lever in neutral and release the parking brake. Equipment specifically designed for towing should be used. It should be attached to the main structural members of the vehicle, not the bumpers or brackets. Safety is a major consideration when towing and all applicable state and local laws must be obeyed. A safety chain system must be used at all times. Remember that power steering and power brakes will not work with the engine off.

0-15

Booster battery (jump) starting Seta

these precautions when using a booster battery to start a

a) Before connecting the booster battery, make sure the ignition Switch is in the Off position. b) Tum off the lights, heater and other electrical loads. c) Your eyes should be shielded. Safety goggles are a good idea. d) Make sure the booster battery is the same voltage as the dead one in the vehicle. e) The two vehicles MUST NOT TOUCH each other! f) Make sure the transaxle is in Neutral (manual) or Park (automatic). g) If the booster battery is not a maintenance-free type, remove the vent caps and lay a cloth over the vent holes. Connect the red jumper cable to the positive (+) terminals of each battery (see illustration). Connect one end of the black jumper cable to the negative (-) terminal of the booster battery. The other end of this cable should be connected to a good ground on the vehicle to be started, such as a bolt or bracket on the body. Start the engine using the booster battery, then, with the engine

running at idle speed, disconnect the jumper cables in the reverse order

Dead

battery

Booster battery

OQOO0000

eae

eae,

4

=

of connection.

Make the booster battery cable connections in the numerical order shown (note that the negative cable of the booster battery is NOT attached to the negative terminal of the dead battery)

0-16

Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

Cleaners Carburetor cleaner and choke cleaner is a strong solvent for gum, varnish and carbon. Most carburetor cleaners leave a dry-type lubricant film which will not harden or gum up. Because of this film it is not recommended for use on electrical components. Brake system cleaner is used to remove brake dust, grease and brake fluid from the brake system, where clean surfaces are absolutely necessary. It leaves no residue and often eliminates brake squeal caused by contaminants. Electrical cleaner removes oxidation, corrosion and carbon deposits from electrical contacts, restoring full current flow. It can also be used to clean spark plugs, carburetor jets, voltage regulators and other parts where an

oil-free surface is desired. Demoisturants remove water and moisture from electrical components such as alternators, voltage regulators, electrical connectors and fuse blocks. They are non-conductive and non-corrosive. Degreasers are heavy-duty solvents used to remove grease from the outside of the engine and from chassis components. They can be sprayed or brushed on and, depending on the type, are rinsed off either with water or solvent.

Lubricants Motor oil is the lubricant formulated for use in engines. It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) from 0 to 50. The recommended weight of the oil depends on the season, temperature and the demands on the engine. Light oil is used in cold climates

and under light load conditions. Heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights

from OW-20 to 20W-50. Gear oil is designed to be used in differentials, manual transmissions and other areas where high-temperature lubrication is required. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered, such as for wheel bearings, balljoints, tie-rod ends and universal joints. High-temperature wheel bearing grease is designed to withstand the extreme temperatures encountered by wheel bearings in disc

brake equipped vehicles. It usually contains molybdenum disulfide (moly), which is a drytype lubricant. White grease is a heavy grease for metal-to-metal applications where water is a problem. White grease stays soft under both low and high temperatures (usually from -100 to +190-degrees F), and will not wash off or dilute in the presence of water. Assembly lube is a special extreme pressure lubricant, usually containing moly, used to lubricate high-load parts (such as main and rod bearings and cam lobes) for initial start-up of a new engine. The assembly lube lubricates the parts without being squeezed out or washed away until the engine oiling system begins to function. Silicone lubricants are used to protect rubber, plastic, vinyl and nylon parts. Graphite lubricants are used where oils cannot be used due to contamination problems, such as in locks. The dry graphite will lubricate metal parts while remaining uncontaminated by dirt, water, oil or acids. It is electrically conductive and will not foul electrical contacts in locks such as the ignition switch. Moly penetrants loosen and lubricate frozen, rusted and corroded fasteners and prevent future rusting or freezing. Heat-sink grease is a special electrically non-conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module.

Sealants RTV sealant is one of the most widely used gasket compounds. Made from silicone, RTV is air curing, it seals, bonds, waterproofs, fills surface irregularities, remains flexible, doesn’t shrink, is relatively easy to remove, and is used as a supplementary sealer with almost all low and medium temperature gaskets. Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself. It remains flexible, is solvent resistant and fills surface imperfections. The difference between an anaerobic sealant and an RTV-type sealant is in the cur-

ing. RTV cures when exposed to air, while an anaerobic sealant cures only in the absence of air. This means that an anaerobic sealant cures only after the assembly of parts, sealing them together. Thread and pipe sealant is used for sealing hydraulic and pneumatic fittings and vacuum lines. It is usually made from a Teflon compound, and comes in a spray, a paint-on liquid and as a wrap-around tape.

Chemicals Anti-seize compound prevents seizing, galling, cold welding, rust and corrosion

in fasteners. High-temperature ant-seize, usually made with copper and graphite lubricants, is used for exhaust system and exhaust manifold bolts. Anaerobic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation, in the absence of air. Medium strength locking compound is used for small nuts, bolts and screws that may be removed later. Highstrength locking compound is for large nuts, bolts and studs which aren’t removed on a regular basis. Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction. It should be noted that most oil manufacturers caution against using additives with their oils. Gas additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburetor, fuel injection and intake parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings, and others contain chemicals to remove con-

densation from the gas tank.

Miscellaneous Brake fluid is specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems. Care must be taken so this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to prevent contamination by water or dirt. Weatherstrip adhesive is used to bond weatherstripping around doors, windows and trunk lids. It is sometimes used to attach trim pieces.

Undercoating is a petroleum-based, tar-like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion. It also acts as a sound-deadening agent by insulating the bottom of the vehicle. Waxes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of different types of wax and polish. Some polishes utilize a chemical or abrasive cleaner to help remove the top layer of oxidized (dull) paint on older vehicles. In recent years many non-wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.

0-17

Conversion

factors

Length (distance) Inches (in) Feet (ft) Miles

X X X

25.4 0.305 1.609

=Millimeters (mm) = Meters (m) = Kilometers (km)

X X X

0.0394 3.281 0.621

=Inches (in) =Feet (ft) =Miles

Cubic inches (cu in; in’) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt)

X 16.387 = Cubic centimeters (cc; cm’) X 0.568 = Liters (I) X 1.137 = Liters (I) X 1.201 =US quarts (US qt)

X x m4 X

0.061 1.76 0.88 0.833

US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal)

X X X

0.946 4.546 1.201

= Liters (I) = Liters (I) =US gallons (US gal)

1.057 0.22 0.833

US gallons (US gal)

X

3.785

= Liters (I)

X Xx X X

0.264

=Cubic inches (cu in; in’) =Imperial pints (Imp pt) = Imperial quarts (Imp qt) =Imperial quarts (Imp qt) =US quarts (US qt) = Imperial gallons (Imp gal) =Imperial gallons (Imp gal) =US gallons (US gal)

X X

28.35 0.454

=Grams (g) =Kilograms (kg)

X X

0.035 2.205

= Ounces (oz) =Pounds (Ib)

X X X

0.278 4.448 0.1.

=Newtons (N) = Newtons (N) =Kilograms-force (kgf; kg)

x X x

3.6 0.225 9.81

= Ounces-force (ozf; oz) =Pounds-force (Ibf; Ib) = Newtons (N)

Pounds-force per square inch

X

0.070

=Kilograms-force per square

X

14.223

= Pounds-force per square inch

Pounds-force per square inch

X

0.068

=Atmospheres

X

14.696

= Pounds-force per square inch

X

0.069

= Bars

x

14.5

= Pounds-force per square inch

Pounds-force per square inch

X

6.895

= Kilopascals (kPa)

xX

0.145

=Pounds-force per square inch

Kilopascals (kPa)

X

0.01

=Kilograms-force per square

x

98.1

X

1.152

= Kilograms-force centimeter

X

0.868

= Pounds-force inches

X

0.113

(kgf cm; kg cm) =Newton meters (Nm)

Xx

8.85

(Ibf in; Ib in) = Pounds-force inches (Ibf in; Ib in)

X

0.083

= Pounds-force feet (Ibf ft; Ib ft)

X

12

= Pounds-force inches

= oa a a meters (kgf m; kg m =Newton meters (Nm) = Kilograms-force meters . (kgf m; kg m)

X

7.233

= Pounds-force feet (Ibf ft; Ib ft)

X xX

0.738 9.804

= Pounds-force feet (Ibf ft; Ib ft) =Newton meters (Nm)

0.2961

Volume (capacity)

Mass (weight) Ounces (oz) Pounds (Ib)

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

Pressure (psi; Ibf/in?; Ib/in)

centimeter (kgf/cm?; kg/cm?) (atm)

:

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?; Ib/in?)

Pounds-force per square inch

(psi; Ibf/in?; Ib/in?)

(psi; Ibf/in?: Ib/in?)

(psi; Ibf/in?; Ib/in?)

centimeter (kgf/cm?; kg/cm?)

(psi; Ibf/in?; Ib/in?)

= Kilopascals (kPa)

Torque (moment of force) Pounds-force

inches

(Ibf in; Ib in) Pounds-force inches

(Ibf in; Ib in) Pounds-force inches

(Ibf in; Ib in)

(Ibf in; Ib in)

Pounds-force feet (Ibf ft; Ib ft)

xX 0.138

Pounds-force feet (Ibf ft; Ib ft) Newton meters (Nm)

X X

1.356 0.102

Vacuum Inches mercury (in. Hg)

X

3.377

Inches mercury (in. Hg)

X

25.4

= Kilopascals (kPa) = Millimeters mercury (mm Hg)

X X

0.0394

=Inches mercury =Inches mercury

X

745.7

=Watts

X

0.0013

=Horsepower

X

1.609

= Kilometers per hour (km/hr; kph) X

0.621

= Miles per hour (miles/hr; mph)

X X

0.354 0.425

= Kilometers per liter (km/I) =Kilometers per liter (km/1)

2.825 2.352

=Miles per gallon, Imperial (mpg) =Mlles per gallon, US (mpg)

Power Horsepower (hp)

(W)

(hp)

Velocity (speed) Miles per hour (miles/hr; mph)

Fuel consumption* Miles per gallon, Imperial (mpg) Miles per gallon, US (mpg)

Temperature

Degrees Fahrenheit

=

(°C x 1.8) + 32

X X

Degrees Celsius (Degrees Centigrade; °C)

*/t is common practice to convert from miles per gallon (mpg) to liters/100 kilometers (1/100km), where mpg (Imperial) x //100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

0-18 DECIMALS to MILLIMETERS Decimal

Decimal

0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.2540 0.5080 0.7620 1.0160 1.2700 1.5240 1.7780 2.0320 2.2860

2.5400 2.7940 3.0480 3.3020 3.5560 3.8100 4.0640 4.3180 4.5720 4.8260 5.0800 5.3340 5.5880 5.8420 6.0960 6.3500 6.6040 6.8580 7.1120 7.3660 7.6200 7.8740 8.1280 8.3820 8.6360 8.8900 9.1440 9.3980 9.6520 9.9060 10.1600 10.4140 10.6680 10.9220 11.1760 11.4300 11.6840 11.9380 12.1920 12.4460

12.7000 12.9540 13.2080 13.4620 13.7160 13.9700 14.2240 14.4780 14.7320 14.9860

15.2400 15.4940 15.7480 16.0020 16.2560 16.5100 16.7640 17.0180 17.2720 17.5260

17.7800 18.0340 18.2880 18.5420 18.7960 19.0500 19.3040 19.5580 19.8120 20.0660 20.3200 20.5740 21.8280 21.0820 21.3360 21.5900 21.8440 22.0980 22.3520 22.6060

FRACTIONS to DECIMALS to MILLIMETERS Fraction

Decimal

mm

Fraction

Decimal

1/64 1/32 3/64

0.0156 0.0312 0.0469

0.3969 0.7938 1.1906

33/64 17/32 35/64

0.5156 0.5312 0.5469

13.0969 13.4938 13.8906

1/16

0.0625

1.5875

9/16

0.5625

14.2875

5/64 3/32 7/64

0.0781 0.0938 0.1094

1.9844 2.3812 2.7781

37/64 19/32 39/64

0.5781 0.5938 0.6094

14.6844 15.0812 15.4781

1/8

0.1250

3.1750

5/8

0.6250

15.8750

9/64 5/32 11/64

0.1406 0.1562 0.1719

Sheil, 3.9688 4.3656

41/64 21/32 43/64

0.6406 0.6562 0.6719

16.2719 16.6688 17.0656

3/16

0.1875

4.7625

11/16

0.6875

17.4625

13/64 7/32 15/64

0.2031 0.2188 0.2344

5.1594 5.5562 5.9531

45/64 23/32 47/64

0.7031 0.7188 0.7344

17.8594 18.2562 18.6531

1/4

0.2500

6.3500

3/4

0.7500

19.0500

17/64 9/32 19/64

0.2656 0.2812 0.2969

6.7469 7.1438 7.5406

49/64 25/32 51/64

0.7656 0.7812 0.7969

19.4469 19.8438 20.2406

5/16

0.3125

T9315

13/16

0.8125

20.6375

21/64 11/32 23/64

0.3281 0.3438 0.3594

8.3344 8.7312 9.1281

53/64 27/32 55/64

0.8281 0.8438 0.8594

21.0344 21.4312 21.8281

3/8

0.3750

9.5250

7/8

0.8750

22.2250

25/64 13/32 27/64

0.3906 0.4062 0.4219

9.9219 10.3188 10.7156

57/64 29/32 59/64

0.8906 0.9062 0.9219

22.6219 23.0188 23.4156

76

0.4375

11.1125

15/16

0.9375

23.8125

29/64 15/32 31/64

0.4531 0.4688 0.4844

11.5094 11.9062 12.3031

0.9531 0.9688 0.9844

24.2094 24.6062 25.0031

1/2

0.5000

12.7000

1.0000

25.4000

0-19

Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your safety is not jeopardized. A moment's lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risks and to encourage a safety conscious approach to all work you carry out on your vehicle.

Essential DOs and DON’Ts DON’T rely on a jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON’T attempt to loosen extremely tight fasteners (i.e. wheel lug nuts) while the vehicle is on a jack - it may fall. DON’T start the engine without first making sure that the transmission is in Neutral (or Park where applicable) and the parking brake is set. DON’T remove the radiator cap from a hot cooling system - let it cool or cover it with a cloth and release the pressure gradually. DON’T attempt to drain the engine oil until you are sure it has cooled to the point that it

will not burn you. DON’T touch any part of the engine or exhaust system until it has cooled sufficiently to avoid burns. DON’T siphon toxic liquids such as gasoline, antifreeze and brake fluid by mouth, or allow them to remain on your skin. DON’T inhale brake lining dust - it is potentially hazardous (see Asbestos below). DON’T allow spilled oil or grease to remain on the floor - wipe it up before someone slips on it. DON’T use loose fitting wrenches or other tools which may slip and cause injury. DON’T push on wrenches when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls for pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip.

DON’T attempt to lift a heavy component alone - get someone to help you.

DON’T rush or take unsafe shortcuts to finish a job. DON’T allow children or animals in or around the vehicle while you are working on it. DO wear eye protection when using power tools such as a drill, sander, bench grinder, etc. and when working under a vehicle. DO keep loose clothing and long hair well out of the way of moving parts. DO make sure that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle.

DO carry out work in a logical sequence and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. DO remember that your vehicle’s safety affects that of yourself and others. If in doubt on any point, get professional advice.

When using cleaning fluids and solvents, read the instructions on the container carefully. Never use materials from unmarked containers. Never run the engine in an enclosed space, such as a garage. Exhaust fumes contain carbon monoxide, which is extremely poisonous. If you need to run the engine, always do so in the open air, or at least have the rear

of the vehicle outside the work area.

Steering, suspension and brakes These systems are essential to driving safety, so make sure you have a qualified shop or individual check your work. Also, compressed suspension springs can cause injury if released suddenly - be sure to use a

spring compressor.

Airbags Airbags are explosive devices that can CAUSE injury if they deploy while you’re working on the vehicle. Follow the manufacturer’s instructions to disable the airbag whenever you're working in the vicinity of airbag components.

Asbestos Certain friction, insulating, sealing, and other products - such as brake linings, brake

bands, clutch linings, torque converters, gaskets, etc. - may contain asbestos or other hazardous friction material. Extreme care must be taken to avoid inhalation of dust from such products, since it is hazardous to health. If in doubt, assume that they do contain asbestos.

Fire Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short circuit, by two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, can ignite gasoline vapors, which in a confined space are highly explosive. Do not, under any circumstances, use gasoline for cleaning parts. Use an approved safety solvent. Always disconnect the battery ground (-) cable at the battery before working on any part of the fuel system or electrical system. Never risk spilling fuel on a hot engine or exhaust component. It is strongly recommended that

a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or workshop at all times. Never try to extinguish a fuel or electrical fire with water.

Fumes Certain fumes are highly toxic and can quickly cause unconsciousness and even death if inhaled to any extent. Gasoline vapor falls into this category, as do the vapors from some cleaning solvents. Any draining or pouring of such volatile fluids should be done in a well ventilated area.

The battery Never create a spark or allow a bare light bulb near a battery. They normally give off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) cable at the battery before working on the fuel or electrical systems. If possible, loosen the filler caps or cover when charging the battery from an external source (this does not apply to sealed or maintenance-free batteries). Do not charge at an excessive rate or the battery may burst. Take care when adding water to a non maintenance-free battery and when carrying a battery. The electrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.

Household current When using an electric power tool, inspection light, etc., which operates on household current, always make sure that the tool is correctly connected to its plug and that, where necessary, it is properly grounded. Do not use such items in damp conditions and, again, do not create a spark or apply excessive heat in the vicinity of fuel or fuel vapor.

Secondary ignition system voltage A severe electric shock can result from touching certain parts of the ignition system (such as the spark plug wires) when the engine is running or being cranked, particularly if components are damp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is much higher and could prove fatal.

Hydrofluoric acid This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses, etc. are

exposed to temperatures above 750-degrees F (400-degrees C). The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned.

When dealing with a vehicle which has suffered a fire, or with components salvaged

from such a vehicle, wear protective gloves and discard them after use.

0-20

Troubleshooting Contents Section

Symptom 2

Engine CHECK ENGINESIGMI

aor arectetecnceteiete synoid snes oateeeres See Chapter 6

Section

Symptom

eeneuey sate) secrasneescaatceaeane sean Le aksilUbriCants.c diagnosis is being performed at sea level. As © elevation increases (or atmospheric pressure decreases), the reading will decrease. For every 1,000 foot increase in elevation above approximately 2,000 feet, the gauge readings

that the head gasket between them is blown. The appearance of coolant in the combustion chambers or the crankcase would verify this =

will decrease about one inch of mercury. 4 Connect the vacuum gauge directly to the intake manifold vacuum, not to ported é :

If the compression is unusually high, the combustion chambers are probably coated

wheels and set the parking brake. With the transaxle in Park, start the engine and allow it to run at normal idle speed. Warning: Keep

condition. 12 If one cylinder is slightly lower than the th d th eats light! h others, an e engine has a slightly roug idle, a worn lobe on the camshaft could be the eae

with carbon deposits. If that’s the case, the . cylinder head(s) should be removed and

|

| —

— | —

(throttle body) vacuum (see illustration). Be sure no hoses are left disconnected during : Z the test or false readings will result. 5 Before you begin the test, allow the engine to warm up completely. Block the

your hands and the vacuum gauge clear of

|

|

Section 2)

decarbonized.

the fans.

6

14 If compression is way down or varies greatly between cylinders, it would be a good

6 Read the vacuum gauge; an average, healthy engine should normally produce about

an automotive repair shop. This test will pin5 : ; point exactly where the leakage is occurring and how severe it is.

illustration). Refer to the following vacuum | y Baie gauge readings and what they indicate about. the engine’s condition: 7 A low steady reading usually indicates a ; | : ;

4

—and cylinder head(s) or throttle body, a leaky

Install a compression gauge in the spark

plug hole (see illustration).

7 Crank the engine over at least seven ; compression strokes and watch the gauge. : y ; ‘ THe Compression Should DUnCiUp GuiGiy I a healthy engine. Low compression on : the first ; stroke, followed by gradually increasing pressure on successive

strokes, indicates worn

piston rings. A low compression reading on

idea to have a leak-down test performed by

Vacuum gauge diagnostic checks

the first stroke, which doesn’t build up during

_—_17 to 22 in-Hg with a fairly steady needle (see

leaking gasket between the intake manifold

ae

aa

nese sey Addl Grning: eh incoreg,

successive strokes, indicates leaking valves

Refer to illustrations 4.4 and 4.6

a

or a blown head gasket (a cracked head could also be the cause). Deposits on the under-

1 A vacuum gauge provides inexpensive but valuable information about what is going

yallle Nel cine sp lan tg osner possibie) Cases Milage, teks pray ded tn tne

mang: Gases pee eet

will at

Chapter 2 Part C

General engine overhaul procedures

2C-5

Chapter before you remove the timing chain

cover to check the timing marks. 8

If the reading is three to eight inches

below normal and it fluctuates at that low reading, suspect an intake manifold gasket ak at an intake port or a faulty fuel injector. If the needle has regular drops of about vo-to-four inches at a steady rate, the valves

are probably leaking. Perform a compression ‘check or leak-down test to confirm this. 10 An irregular drop or down-flick of the edie can be caused by a sticking valve or in ignition misfire. Perform a compression check or leak-down test and read the spark plugs.

41:« nas SWITCH

el

Zaz orcs

|

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BLK

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BLK

———

interior lighting system - 2007 and earlier models

LIGHTS

Chapter 12

Chassis electrical system

12-23

HOT IN RUN OR START

INSTRUMENT CLUSTER

C5 |

POWER SUPPLY CIRCUIT/ CONTROLLER AREA NETWORK CONTROLLER

TL

nao arin ERNE

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12-24 Chapter 12 Chassis electrical system sore a ne SS Be ss

Bee ROWS TARE NOT AT ie

ALLIES:

5

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% a

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|

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igyron ItsySr

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Chapter 12

Chassis electrical system

12-25

a

HOTATAUINIMES res Seo) i)

|

suse

|

20A

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FUS|

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1

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yy =

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:

5 }-+@H RIGHT REAR POWER WINDOW MOTOR

i

12-26 ELAS Renee Sa RE etre

OT OTATALL AT ALL. TIMES TIMES

Chapter 12 Chassis electrical system UP ATG NC IER GMM SAU eli ak AE

TIMES HOT ATAT ALL ALLTIMES wm — HOT FUSE

reer 2 | FUSE/RELAY | BLOCK

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Lee

GRN/RED

Chapter 12 Chassis electrical system

HOT AT ALL TIMES

AiO

|

|

MIN NEAT ns

atge. (>SOT lo age 13

|

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Cruise control system - 2007 and earlier 4-cylinder models nn

UU EEIUEIEIIEEIIEIESESEEESSSESSED

12-28

Chapter 12 Chassis electrical system

SSS

HOT IN RUN eek OR START sg |

FUSE

|

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pas me Pale ||

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Air conditioning and engine cooling fan system (Auto A/C) - 2008 and later 2.4L models (1 of 3)

ai

|

Chapter 12

Chassis electrical system

HOT AT ALL TIMES (ea |

aan

HOT AT MES ALL TIMES

HOT AT __—_——_—sCALL TIMES

MULT

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Air conditioning and engine cooling fan system (Auto A/C) - 2008 and later 2.4L models (2 of 3)

12 13

Chapter 12

ILL+ } ILL- Je IG2

SCE

LT GRN

12-37

Chassis electrical system

> INTERIOR LIGHTS SYSTEM

DEF-LED SW OUT-4 SW OUT-3 SW IN-1 SW IN-2 SW IN-3 SW IN-4 REC-LED AUTO-LED RRDEF-LED

RED/WHT

GRN/BLK

ECT SENSOR 1

FRONT PASSENGER'S CLIMATE CONTROL SWITCH

ENGINE CONTROLS SYSTEM YEL/RED

RR DEF-LED AUTO-LED REC-LED SW IN-4 SW IN-3 SW IN-2

ECT SENSOR 2

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LIGHTS SYSTEM

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z 6

i:

a

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Air conditioning and engine cooling fan system (Auto A/C) - 2008 and later 2.4L models (3 of 3)

12-38

Chapter 12

HOT IN ON

Chassis electrical system

“7 DRIVER'S

NACA

| UNDER-DASH

SUB-DISPLAY

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UNIT

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|

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|

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C406

12-56

Chapter 12

Chassis electrical system

(1) W/O PADDLE SHIFTERS (2) W/ PADDLE SHIFTERS

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12-57

HOT AT ALL TIMES

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12-58

Chapter 12

Chassis electrical system

HOT AT HOT AT HOT AT HOT AT crAUSIUIMES Sais) QULTTIMES Sipe are serena ss anal A ALLITIMES Maeyaiacta MES TIMES a mate | FUSE 10 Fuse FUSE 20A

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Chassis electrical system

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6 7

10

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12-64

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Audio system - 2008 and later models (2 of 3)

RED | CEN

12-66

RIGHT TWEETER

Chapter 12

FRONT PASSENGER'S DOOR SPEAKER

DRIVER'S DOOR SPEAKER

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Audio system - 2008 and later models (3 of 3)

a

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ENE

IN

OO

IND-1

Index A

Balance shaft assembly and balance shafts, four-cylinder

About this manual, 0-5 Accelerator cable, removal, installation and adjustment, 4-12 Accelerator Pedal Position (APP) sensor, replacement, 6-9 Acknowledgements, 0-2 Air conditioning and heating system, check and maintenance, 3-11 compressor, removal and installation, 3-13 condenser, removal and installation, 3-14 pressure switch, replacement, 3-15 —

Balljoints, replacement, 10-6 Battery

engine, removal, inspection and installation, 2A-11

receiver-drier, removal and installation, 3-14

Air filter housing, removal and installation, 4-11 filter element, replacement, 1-19

Airbag system, general information, 12-18 Alternator, removal and installation, 5-7 Antenna, removal and installation, 12-10 Antifreeze, general information, 3-3

Anti-lock brake (ABS), traction control (TCS) and vehicle stability assist (VSA) systems, general information, 9-2 Automatic transaxle, 7B-1 diagnosis, general, 7B-1

fluid change, 1-22 level check, 1-10 removal and installation, 7B-5 shift cable, removal, installation and adjustment, 7B-2 interlock system, description and solenoid replacement, 7B-4 lever assembly, removal and installation, 7B-4 Automotive chemicals and lubricants, 0-16

Back-up light switch, manual transaxle, check and replacement, 7A-2

cables, check and replacement, 5-4 check and replacement, 5-3 check, maintenance and charging, 1-13 general information, precautions and disconnection, 5-2 Blower motor power transistor and blower motor, replacement, 3-9 Body repair major damage, 11-3 minor damage, 11-2 Body, 11-1 Body, maintenance, 11-1 Booster battery (jump) starting, 0-15 Brakes, 9-1 Anti-lock brake (ABS), traction control (TCS) and vehicle stability assist (VSA) systems, general information, 9-2 caliper, removal and installation, 9-5 disc, inspection, removal and installation, 9-6 fluid change, 1-21 level check, 1-9 general information, 9-2 hoses and lines, inspection and replacement, 9-11 hydraulic system, bleeding, 9-11 light switch/Brake Pedal Position switch, replacement, 9-13 master cylinder, removal and installation, 9-10 pads, replacement, 9-3 parking brake, adjustment, 9-13 pedal, adjustment, 9-13 power brake booster, check, removal and installation, 9-12 shoes, replacement, 9-7 system check, 1-16 wheel cylinder, removal and installation, 9-9 Bulb replacement, 12-13 Bumper covers, removal and installation, 11-7 Buying parts, 0-7

IND-2

Index Cruise control system, general information, 12-16

C

Cylinder compression check, 2C-4

Cable replacement accelerator, 4-12 battery, 5-4 fuel door, 11-10 hood release, 11-6 trunk release, 11-10 Caliper, disc brake, removal and installation, 9-5 Camshaft Position (CMP) sensor, replacement, 6-9 Camshafts, removal, inspection and installation

four-cylinder engine, 2A-8 V6 engine, 2B-12

Catalytic converter, general description, check and replacement, 6-18 Center console, removal and installation, 11-13

Charging system alternator, removal and installation, 5-7

check, 5-6 general information and precautions, 5-6 Chassis electrical system, 12-1 Chemicals and lubricants, 0-16 Circuit breakers, general information, 12-4 Climate control assembly, removal and installation, 3-9 Clutch components, removal, inspection and installation, 8-3 description and check, 8-2 fluid level check, 1-9 hydraulic system, bleeding, 8-3 master cylinder, removal and installation, 8-2 pedal adjustment, 8-5 release bearing and lever, removal, inspection and installation, 8-5 release cylinder, removal and installation, 8-3 start switch, check and replacement, 8-5 Clutch and driveline, 8-1 Coils, ignition, replacement, 5-5 Compressor, air conditioning, removal and installation, 3-13

Cylinder head, removal and installation

four-cylinder engine, 2A-9 V6 engine, 2B-14

D Dashboard switches, replacement, 12-6 trim panels, removal and installation, 11-14 Daytime Running Lights (DRL), general information, 12-18 Defogger, rear window, check and repair, 12-10

Diagnosis, 0-20 Diagnostic trouble codes, accessing, 6-2 Disc brake caliper, removal and installation, 9-5 disc, inspection, removal and installation, 9-6 pads, replacement, 9-3 Door latch, lock cylinder and handles, removal and installation, 11-12 removal and installation, 11-12 trim panels, removal and installation, 11-11

window glass regulator, removal and installation, 11-13 window glass, removal and installation, 11-13 Driveaxle boot check, 1-17 replacement, 8-7 intermediate shaft, removal and installation, 8-7 oil seals, replacement, 7A-1

removal and installation, 8-6 Drivebelt check and replacement, 1-20 tensioner, replacement, 1-21 Drum brake shoes, replacement, 9-7

Condenser, air conditioning, removal and installation, 3-14

Conversion factors, 0-17 Coolant level check, 1-8 reservoir, removal and installation, 3-6 temperature sending unit, 3-8 general information, 3-3 Cooling fans and switch, check and replacement, 3-4 Cooling system check, 1-15 servicing (draining, flushing and refilling), 1-21 Cooling, heating and air conditioning systems, 3-1 Cowl cover, removal and installation, 11-17 Crankshaft front oil seal, replacement four-cylinder engine, 2A-7 V6 engine, 2B-9

Crankshaft Position (CKP) sensor, replacement, 6-10 Crankshaft pulley, removal and installation four-cylinder engine, 2A-7 V6 engine, 2B-7 Crankshaft, removal and installation, 2C-14

E Electric side view mirrors, general information, 12-16 Electrical Load Detector (ELD) unit, replacement, 6-10 Electrical troubleshooting, general information, 12-1 Emissions and engine control systems, 6-1 Engine Coolant Temperature (ECT) sensor, replacement, 6-11 Engine coolant, level check, 1-8

Engine cooling fans and switch, check and replacement, 3-4 Engine electrical systems, 5-1

Engine front cover, four-cylinder engine, removal and installation, 2A-6 Engine, general overhaul procedures, 2C-1 crankshaft, removal and installation, 2C-14 cylinder compression check, 2C-4 engine overhaul disassembly sequence, 2C-9 reassembly sequence, 2C-17

IND-3

index Haare

ee

aE

STI

EE

TaD

engine rebuilding alternatives, 2C-5

engine removal, methods and precautions, 2C-5 engine, removal and installation, 2C-6 general information, 2C-2 initial start-up and break-in after overhaul, 2C-17 oil pressure check, 2C-3 pistons and connecting rods, removal and installation, 2C-9 vacuum gauge diagnostic checks, 2C-4 Engine, in-vehicle repair procedures Four-cylinder engine, 2A-1 balance shaft assembly and balance shafts, removal, inspection and installation, 2A-11 camshafts and rocker arms, removal, inspection and installation, 2A-8 crankshaft pulley and front oil seal, removal and installation, 2A-7 cylinder head, removal and installation, 2A-9 engine front cover, removal and installation, 2A-6 Engine Mount Control System, description and check, 2A-14

exhaust manifold, removal and installation, 2A-5 flywheel/driveplate, removal and installation, 2A-12

intake manifold and injector base, removal and installation, 2A-4 i-VTEC system, description and component checks, 2A-7 oil pan, removal and installation, 2A-10 oil pump, removal, inspection and installation, 2A-11 powertrain mounts, check and replacement, 2A-13 rear main oil seal, replacement, 2A-12 repair operations possible with the engine in the vehicle, 2A-3

timing chain and sprockets, removal, inspection and installation, 2A-6 Top Dead Center (TDC) for number 1 piston, locating, 2A-3

valve clearance check and adjustment, 2A-4 valve cover, removal and installation, 2A-3 water passage, removal and installation, 2A-12 V6 engine, 2B-1 camshafts, removal, inspection and installation, 2B-12

crankshaft front oil seal, replacement, 2B-9 cylinder heads, removal and installation, 2B-14 Engine Mount Control System, description and check, 2B-17 exhaust manifold, removal and installation, 2B-6 flywheel/driveplate, removal and installation, 2B-17 intake manifold, removal and installation, 2B-5 oil pan, removal and installation, 2B-15

oil pump, removal, inspection and installation, 2B-15 powertrain mounts, check and replacement, 2B-17 rear main oil seal, replacement, 2B-17

repair operations possible with the engine in the vehicle, 2B-3 rocker arm assembly, removal, inspection and installation, 2B-11 timing belt and sprockets, removal, inspection and installation, 2B-6 Top Dead Center (TDC) for number 1 piston, locating, 2B-3 valve clearance, check and adjustment, 2B-4 valve covers, removal and installation, 2B-4

EINE ISLE ENSSPE CDE EAL LE

TOE

IDO

ETE TEES

LINED

ALLE

OPER

ET LEONE

SEIS

TE EE IDEERIE

VTEC system, general description and component checks, 2B-10 Engine Mount Control System, description and check four-cylinder engine, 2A-14 V6 engine, 2B-17 Engine oil and oil filter change, 1-12 Engine oil, level check, 1-8 Engine overhaul disassembly sequence, 2C-9 reassembly sequence, 2C-17 Engine rebuilding alternatives, 2C-5 Engine removal, methods and precautions, 2C-5 Engine, removal and installation, 2C-6 Evaporative Emissions Control (EVAP) system, general description and component replacement, 6-19 Exhaust Gas Recirculation (EGR) system, general description and component replacement, 6-21 Exhaust manifold, removal and installation four-cylinder engine, 2A-5 V6 engine, 2B-6 Exhaust system check, 1-19 servicing, general information, 4-19

i Fans, engine cooling, check and replacement, 3-4 Fault finding, 0-20 Fender, front, removal and installation, 11-8 Filter replacement engine air, 1-19 engine oil, 1-12 fuel, 4-9 interior ventilation, 1-19 Fluid level checks automatic transaxle, 1-10 brake fluid, 1-9 clutch fluid, 1-9 engine coolant, 1-8 engine oil, 1-8

manual transaxle, 1-10 power steering, 1-9 windshield washer, 1-9 Fluids and lubricants capacities, 1-1 recommended, 1-1 Flywheel/driveplate, removal and installation four-cylinder engine, 2A-12 V6 engine, 2B-17 Four-cylinder engine, 2A-1 balance shaft assembly and balance shafts, removal, inspection and installation, 2A-11 camshafts and rocker arms, removal, inspection and installation, 2A-8 crankshaft pulley and front oil seal, removal and installation, 2A-7 cylinder head, removal and installation, 2A-9 engine front cover, removal and installation, 2A-6 Engine Mount Control System, description and check, 2A-14 exhaust manifold, removal and installation, 2A-5

IND-4

Index

flywheel/driveplate, removal and installation, 2A-12 intake manifold and injector base, removal and installation, 2A-4 i-VTEC system, description and component checks, 2A-7

Headlight

oil pan, removal and installation, 2A-10

oil pump, removal, inspection and installation, 2A-11 powertrain mounts, check and replacement, 2A-13 rear main oil seal, replacement, 2A-12 repair operations possible with the engine in the vehicle, 2A-3

Heater core, replacement, 3-9 Hinges and locks, maintenance, 11-3 Hood release latch and cable, removal and installation, 11-6 Hood, removal, installation and adjustment, 11-3 Horn, replacement, 12-13

timing chain and sprockets, removal, inspection and

Hub and wheel bearing assembly, removal and installation

adjustment, 12-12 bulb, replacement, 12-11

housing, replacement, 12-12

installation, 2A-6 Top Dead Center (TDC) for number 1 piston, locating, 2A-3 valve clearance check and adjustment, 2A-4

front, 10-6 rear, 10-8

valve cover, removal and installation, 2A-3

water passage, removal and installation, 2A-12 Fraction/decimal/millimeter equivalents, 0-18 Fuel

filter, replacement, 4-9 general information, 4-1

lines and fittings, general information, 4-3 pressure regulator, replacement, 4-8 pressure relief procedure, 4-2 Programmed Fuel Injection (PGM-FI) system check, 4-15 general information, 4-14 pulsation damper, removal and installation, 4-19 pump/fuel gauge sending unit removal and installation, 4-6 replacement, 4-7 pump/fuel pressure, check, 4-3 rail and injectors, removal and installation, 4-16 system check, 1-19 tank cleaning and repair, general information, 4-11 removal and installation, 4-10 Fuel and exhaust systems, 4-1 Fuses, general information, 12-3

G General engine overhaul procedures, 2C-1 crankshaft, removal and installation, 2C-14 cylinder compression check, 2C-4 engine overhaul disassembly sequence, 2C-9 reassembly sequence, 2C-17 engine rebuilding alternatives, 2C-5 engine removal, methods and precautions, 2C-5

engine, removal and installation, 2C-6 general information, 2C-2 initial start-up and break-in after overhaul, 2C-17 oil pressure check, 2C-3 pistons and connecting rods, removal and installation, 2C-9 vacuum gauge diagnostic checks, 2C-4

H Hazard flasher relay, check and replacement, 12-5

Idle Air Control (IAC) valve, replacement, 6-17 Ignition switch/key lock cylinder assembly, replacement, 12-6 Ignition system check, 5-5 coils, replacement, 5-5 general information, 5-4 Initial start-up and break-in after overhaul, 2C-17 Injector base, four-cylinder engine, removal and installation, 2A-4 Input shaft (mainshaft) and output shaft (countershaft) speed sensors, replacement, 6-12 Instrument cluster, removal and installation, 12-7 panel, removal and installation, 11-16 Intake air bypass control thermal valve, replacement, 6-17 Intake Air Temperature (IAT) sensor, replacement, 6-13 Intake Manifold Runner Control (IMRC) system, description and component replacement, 6-17 Intake manifold, removal and installation four-cylinder engine, 2A-4 V6 engine, 2B-5 Interior ventilation filter replacement, 1-19 Intermediate shaft, removal and installation, 8-7 Introduction to the Honda Accord, 0-5 i-VTEC system, four-cylinder engine, description and component checks, 2A-7

Jacking and towing, 0-14 Jump starting, 0-15

K Key lock cylinder, ignition, replacement, 12-6 Knock sensor, replacement, 6-13 Knuckle, rear, removal and installation, 10-8

L Lower control arm (front), removal and installation, 10-7 Lubricants and chemicals, 0-16

IND-5

index Lubricants and fluids capacities, 1-1 recommended, 1-1

Maintenance schedule, 1-6 Maintenance techniques, tools and working facilities, 0-7 Maintenance, routine, 1-1 Manifold Absolute Pressure (MAP) sensor, replacement, 6-13 Manual transaxle, 7A-1 back-up light switch, check and replacement, 7A-2 driveaxle oil seals, replacement, 7A-1 lubricant change, 1-23 level check, 1-10 overhaul, general information, 7A-3 removal and installation, 7A-2 shift cable, removal and installation, 7A-2 Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor, replacement, 6-14 Master cylinder, removal and installation brake, 9-10 clutch, 8-2 Mirrors electric side view, general information, 12-16 removal and installation, 11-13

Powertrain mounts, check and replacement four-cylinder engine, 2A-13 V6 engine, 2B-17 Pressure switch, air conditioning, replacement, 3-15 Programmed Fuel Injection (PGM-Fl) system check, 4-15 general information, 4-14

R Rack-and-pinion steering gear, removal and installation, 10-14 Radiator, removal and installation, 3-6 Radio and speakers, removal and installation, 12-8 Rear knuckle, removal and installation, 10-8 Rear main oil seal, replacement

four-cylinder engine, 2A-12 V6 engine, 2B-17 Rear suspension arms, removal and installation, 10-9

Rear window defogger, check and repair, 12-10 Receiver-drier, air conditioning, removal and installation, 3-14 Recommended lubricants and fluids, 1-1 Relays, general information and testing, 12-4 Release cylinder, clutch, removal and installation, 8-3

Repair operations possible with the engine in the vehicle four-cylinder engine, 2A-3 V6 engine, 2B-3 Rocker arms, removal, inspection and installation

four-cylinder engine, 2A-8 V6 engine, 2B-11

O Oil pan, removal and installation

four-cylinder engine, 2A-10 V6 engine, 2B-15 Oil pressure check, 2C-3 Oil pump, removal, inspection and installation

four-cylinder engine, 2A-11 V6 engine, 2B-15 Oil, engine, level check, 1-8 On Board Diagnostic (OBD) system and troubie codes, 6-2 Oxygen sensors, replacement, 6-14

p Pads, disc brake, replacement, 9-3 Parking brake, adjustment, 9-13 Pistons and connecting rods, removal and installation, 2C-9

Positive Crankcase Ventilation (PCV) system, general description, check and component replacement, 6-22 Power brake booster, removal and installation, 9-12 Power door lock system, general information, 12-17 Power steering fluid level check, 1-9 pump, removal and installation, 10-16

system, bleeding, 10-16 Power Steering Pressure (PSP) switch, replacement, 6-15 Power window system, general information, 12-17 Powertrain Control Module (PCM), removal and installation, 6-17

Rotor, brake, inspection, removal and installation, 9-6 Routine maintenance schedule, 1-6 Routine maintenance, 1-1

S Safety first!, 0-19 Scheduled maintenance, 1-1 Seat belt check, 1-15 Seats, removal and installation, 11-17 Shift cable, removal and installation automatic transaxle, 7B-2 manual transaxle, 7A-2 Shift interlock system, description and solenoid replacement, 7B-4 Shift lever assembly, automatic transaxle, removal and installation, 7B-4 Shock absorber or coil spring, component replacement, 10-4

Shock absorber/coil spring assembly, removal and installation front, 10-4 rear, 10-8 Shoes, drum brake, replacement, 9-7 Spare tire, installing, 0-14

Spark plug check and replacement, 1-22 torque, 1-2 type and gap, 1-2 Speakers, removal and installation, 12-8

IND-6 ESR

Index SS

EE EE

A

IS

RA

RG

Stabilizer bar and bushings, removal and installation front, 10-6 rear, 10-9 Starter motor and circuit, check, 5-8 removal and installation, 5-9

Starting system, general information and precautions, 5-8 Steering column covers, removal and installation, 11-15

IEE

SSIS SIRES TSS

TE

A

SE SS

5TT

SID

interlock system, description and solenoid replacement, 7B-4

lever assembly, removal and installation, 7B-4 Transaxle, manual, 7A-1 back-up light switch, check and replacement, 7A-2 driveaxle oil seals, replacement, 7A-1 lubricant

change, 1-23

gear boots, replacement, 10-14 gear, removal and installation, 10-14

level check, 1-10 overhaul, general information, 7A-3 removal and installation, 7A-2 shift cable, removal and installation, 7A-2 Transmission range switch, replacement and

knuckle and hub, removal and installation, 10-5 wheel, removal and installation, 10-11

Trim panels, dashboard, removal and installation, 11-14

column switches, replacement, 12-5 column, removal and installation, 10-13

Steering, suspension and driveaxle boot check, 1-17 Subframe (front), removal and installation, 10-17 Suspension and steering systems, 10-1 Suspension arms, rear, removal and installation, 10-9

+ Tailgate components (Crosstour models), removal, installation and adjustment, 11-9 Tensioner, drivebelt, replacement, 1-21 Thermostat, check and replacement, 3-4 Throttle body, removal and installation, 4-15 Throttle Position (TP) sensor, replacement, 6-16 Tie-rod ends, removal and installation, 10-11

Timing belt and sprockets, V6 engine, removal, inspection and installation, 2B-6 Timing chain and sprockets, four-cylinder engine,

removal, inspection and installation, 2A-6 Tire and tire pressure checks, 1-10 Tire rotation, 1-15 Tire, spare, installing, 0-14 Tools and working facilities, 0-7 Top Dead Center (TDC) for number 1 piston, locating four-cylinder engine, 2A-3 V6 engine, 2B-3 Torque specifications brake caliper mounting bolts, 9-1 cylinder head bolts four-cylinder engine, 2A-2 V6 engine, 2B-2 sparks plugs, 1-2 thermostat bolts, 3-1 water pump bolts, 3-1 wheel lug nuts, 1-2 Other torque specifications can be found at the front of the Chapter that deals with the component being serviced Towing, 0-14 Transaxle, automatic, 7B-1 diagnosis, general, 7B-1 fluid change, 1-22 level check, 1-10 removal and installation, 7B-5 shift cable, removal, installation and adjustment, 7B-2

adjustment, 6-16 Trouble codes, accessing, 6-2 Troubleshooting, 0-20 Trunk lid latch and lock cylinder, removal and installation, 11-8 lid, removal and installation, 11-9 release and fuel door cable, removal and installation, 11-10 Tune-up and routine maintenance, 1-1 Tune-up general information, 1-8 Turn signal and hazard flasher relay, check and replacement, 12-5

U Underhood hose check and replacement, 1-18 Upholstery and carpets, maintenance, 11-2

Upper control arm (front), removal and installation, 10-7

V V6 engine, 2B-1 camshafts, removal, inspection and installation, 2B-12 crankshaft front oil seal, replacement, 2B-9

cylinder heads, removal and installation, 2B-14 Engine Mount Control System, description and check, 2B-17 exhaust manifold, removal and installation, 2B-6 flywheel/driveplate, removal and installation, 2B-16 intake manifold, removal and installation, 2B-5 oil pan, removal and installation, 2B-15 oil pump, removal, inspection and installation, 2B-15 powertrain mounts, check and replacement, 2B-17 rear main oil seal, replacement, 2B-17 repair operations possible with the engine in the vehicle, 2B-3 rocker arm assembly, removal, inspection and installation, 2B-11 timing belt and sprockets, removal, inspection and installation, 2B-6 Top Dead Center (TDC) for number 1 piston, locating, 2B-3 valve clearance, check and adjustment, 2B-4 valve covers, removal and installation, 2B-4 VTEC system, general description and component checks, 2B-10 Vacuum gauge diagnostic checks, 2C-4

TS

IND-7

Index SS

ETAT

ST

EE EE ESSE

STI

SELLE

LIES EPA LELP

Valve clearance, check and adjustment four-cylinder engine, 2A-4 V6 engine, 2B-4 Valve cover, removal and installation four-cylinder engine, 2A-3 V6 engine, 2B-4 Variable Valve Timing and Lift Electronic Control (VTEC) systems, description and component replacement, 6-23 Vehicle identification numbers, 0-6 Vinyl trim, maintenance, 11-2 VTEC system, V6 engine, general description and component checks, 2B-10

ETE SLRLGEEIE

BIE EG IEEE

EE ES

IEEE FEET

PLIOCENE

Water pump check, 3-7 replacement, 3-8

Wheel alignment, general information, 10-17 Wheel cylinder, removal and installation, 9-9 ‘Wheels and tires, general information, 10-16 Window glass, removal and installation, 11-13 regulator, removal and installation, 11-13 Windshield

and fixed glass, replacement, 11-3 washer fluid, level check, 1-9

wiper blade inspection and replacement, 1-13 Wiper motor, check and replacement, 12-7

Wiring diagrams, general information, 12-18 Working facilities, 0-7

W Water passage, four-cylinder engine, removal and installation, 2A-12

TEA EET,

Haynes Automotive

Manuals

NOTE: If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information. 30023 30025 Integra '86 thru 89 & Legend ’86 thru 90 Integra '90 thru '93 & Legend '91 thru '95

Integra '94 thru '00 - see HONDA Civic (42025) MDX '01 thru '07 - see HONDA Pilot (42037) Acura TL all models '99 thru '08 deep CJ - see JEEP (50020) Concord/Homet/Gremlin/Spirit '70 thru '83 (Renault) Alliance & Encore '83 thru 87 4000 5000 5000 Audi

15030 AUSTIN

all all all A4

models models models '96 thru

'80 thru '77 thru '84 thru '01 - see

Audi A4 ‘02 thru ‘08

’87 ’83 ’88 VW Passat (96023)

Buick Century '97 thru '05 Century (front-wheel drive) - see GM (38005) Buick, Oldsmobile & Pontiac Full-size iene wheel drive) ’85 thru '05 uick, Oldsmobile & Pontiac Full-size (Rear wheel drive) '70 thru ‘90 Mid-size Regal & Century '74 thru '87 Regal - see GENERAL MOTORS (38010) Skyhawk - see GM (38030) Skylark - see GM (38020, 38025) Somerset - see GENERAL MOTORS (38025)

19025 19030

CADILLAC 21015 21030

CTS & CTS-V ‘03 thru ‘12 Cadillac Rear Wheel Drive '70 thru '93 Cimarron, Eldorado & Seville - see

GM (38015, 38030, 38031)

CHEVROLET 10305 24010 24015 24016

Chevrolet Engine Overhaul Manual Astro & GMC Safari Mini-vans '85 thru '05 Camaro V8 all models ’70 thru '81 Camaro all models '82 thru '92 Cavalier - see GM (38075) Celebrity - see GM (38005) Camaro & Firebird '93 thru '02 Chevelle, Malibu, El Camino '69 thru '87 Chevette & Pontiac T1000 '76 thru ’87 Citation - see GENERAL MOTORS (38020) Colorado & GMC Canyon ’04 thru 10 Corsica/Beretta all models '87 thru '96 Corvette all V8 models ’68 thru '82 Corvette all models '84 thru 96 Full-size Sedans Caprice, Impala, Biscayne, Bel Air & Wagons’69 thru '90 Impala SS & Caprice and Buick Roadmaster ‘91 thru '96 impala '00 thru '05 - see LUMINA (24048) Impala & Monte Carlo all models '06 thru 11 Lumina ’90 thru '94 - see GM (38010) Lumina & Monte Carlo ’95 thru '05 Lumina APV - see GM (38035) Luv Pick-up all 2WD & 4WD ’72 thru '82 Malibu - see GM (38026) Monte Carlo all models ’70 thru '88 Monte Carlo '95 thru ’01 - see LUMINA Nova all V8 models ’69 thru ’79 Nova/Geo Prizm ’85 thru ’92 Pick-ups '67 thru '87 - Chevrolet & GMC Pick-ups '88 thru ’98 - Chevrolet & GMC Pick-ups '99 thru '06 - Chevrolet & GMC Chevy Silverado & GMC Sierra ‘07 thru ‘12 S-10 & GMC S-15 Pick-ups ’82 thru '93 S-10, Sonoma & Jimmy '94 thru '04 Chevrolet TrailBlazer, GMC Envoy & Oldsmobile Bravada '02 thru 09 Sprint ’85 thru ’88, Geo Metro ’89 thru ’01 Vans - Chevrolet & GMC ’68 thru '96 Full-size Vans ’96 thru ’10

24017 24020 24024 24027 24032 24040 24041 24045 24046 24047 24048 24050 24055 24059 24060 24064 24065 24066 24067 24070 24071 24072 24075 24080 24081

CHRYSLER 10310 25015

25025 25026 25027 25030 25038 25040

DATSUN

28025

30008 30010 30011 30012 30013 30016 30020 30021 30022

EAGLE 34010 34025

FORD 10320 10355 11500 36004

36006

36008 36012 36016 36020

36022 36024 36025 36028 36030 36032 36034 36036 36044 36045 36048 36049 36050 36051 36052 36054 36058 36059 36060 36061 36062 36066

36070 36071 36074 36075 36078 36082 36086 36090 36094 36097

200SxX all models '80 thru ’83 B-210 all models '73 thru '78 210 all models '78 thru '82 2402, 260Z & 280Z Coupe ’70 thru ’'78 280ZX Coupe & 2+2 '79 thru '83 300ZX - see NISSAN (72010) 510 & PL521 Pick-up ’68 thru 73 510 all models '78 thru ’81 620 Series Pick-up all models '73 thru '79 720 Series Pick-up - see NISSAN (72030) 810/Maxima all gas models '77 thru '84

400 & 600 - see CHRYSLER (25030) Aries & Plymouth Reliant '81 thru '89 Caravan & Ply. Voyager ’84 thru ’95 Caravan & Ply. Voyager ’96 thru '02

Challenger/Plymouth Saporro ’78 thru ’83 Challenger ’67-’76 - see DART (30025) Caravan, Chrysler Voyager, Town &

Country '03 thru '07 Colt/Plymouth Champ ’78 thru '87 Dakota Pick-ups all models '87 thru 96

Durango '98 &'99, Dakota 97 thru '99 Durango ’00 thru '03, Dakota ’00 thru 04

Talon - see MITSUBISHI (68030, 68031) Vision - see CHRYSLER (25025) 124 Sport Coupe & Spider '68 thru '78 X1/9 all models '74 thru '’80 Ford Engine Overhaul Manual Ford Automatic Transmission Overhaul Mustang '64-1/2 thru '70 Restoration Guide Aerostar Mini-vans '86 thru ’97 Aspire - see FORD Festiva (36030) Contour/Mercury Mystique '95 thru ’00 Courier Pick-up all models ’72 thru '82 Crown Victoria & Mercu Grand Marquis ’88 thru '1 Escort/Mercury Lynx ’81 thru ’90 Escort/Mercury Tracer '91 thru ’02 Expedition - see FORD Pick-up (36059) Escape & Mazda Tribute '01 thru '11 Explorer & Mazda Navajo ’91 thru '01 Explorer/Mercury Mountaineer ’02 thru ’10 Fairmont & Mercury Zephyr '78 thru ’83 Festiva & Aspire ’88 thru '97 Fiesta all models '77 thru ‘80 Focus all models '00 thru ‘11 Ford & Mercury Full-size ‘75 thru '’87 Ford & Mercury Mid-size '75 thru '86 Ford Fusion & Mercury Milan ’06 thru 10 Mustang V8 all models '64-1/2 thru '73

Mustang II 4 cyl, V6 & V8 '74 thru '78 Mustang & Mercury Capri '79 thru '93 Mustang all models '94 thru ’04 Mustang '05 thru '10 Pick-ups and Bronco '73 thru '79 Pick-ups and Bronco '80 thru 96 Pick-ups & Expedition '97 thru ’09 Super Duty Pick-up, Excursion ’99 thru '10 F-150 full-size '04 thru '10 Pinto & Mercury Bobcat '75 thru ’80 Probe all models '89 thru '92

Probe '93 thru '97 - see MAZDA 626 (61042) Ranger/Bronco Il gas models '83 thru ’92 Ford Ranger '93 thru '10 & Mazda Pick-ups '94 thru '09 Taurus & Mercury Sable ’86 thru 95 Taurus & Mercury Sable '96 thru ’01 Tempo & Mercury Topaz ’84 thru 94 Thunderbird/Mercury Cougar '83 thru '88

Thunderbird/Mercury Cougar ’89 thru '97 Vans all V8 Econoline models ’69 thru ’91 Vans full size '92 thru '10 Windstar Mini-van '95 thru ’07

GENERAL 10360 38005

38010 38015 38016 38017 38020 38025 38026

Chrysler Engine Overhaul Manual Chrysler Cirrus, Dodge Stratus, Plymouth Breeze, ‘95 thru ‘00 Full-size Front-Wheel Drive ’88 thru ’93 K-Cars - see DODGE Aries (30008) Laser - see DODGE Daytona (30030) Chrysler LHS, Concorde & New Yorker, Dodge Intrepid, Eagle Vision, '93 thru '97 Chrysler LHS, Concorde, 300M, Dodge Intrepid ’98 thru '04 Chrysler 300, Dodge Charger & Magnum ’05 thru ’09 Chrysler/Plym. Mid-size '82 thru 95 Rear-wheel Drive - see DODGE (30050) PT Cruiser all models '01 thru '10 Chrysler Sebring ’95 thru '06, Dodge Stratus ‘01 thru '06, Dodge Avenger ’95 thru 00

25020

DODGE

30050 30055 30060 30065

FIAT 3/5 Series '82 thru ’92 3 Series including Z3 models '92 thru '98 3-Series incl. Z4 models '99 thru '05 3-Series ‘06 thru ‘10 320i all 4 cyl models ’75 thru ’83 1500 thru 2002 except Turbo '59 thru ’77

19020

28018 28020 28022

30034 30035 30036 30040 30041 30042 30045

Healey Sprite - see MG Midget (66015)

BMW 18020 18021 18022 18023 18025 18050 BUICK 19010

28005 28007 28009 28012 28014

30030

Durango '04 thru ’09, Dakota ’05 thru ’11 Dart, Challenger/Plymouth Barracuda & Valiant 6 cyl models ’67 thru ’76 Daytona & Chrysler Laser '84 thru ’89 Intrepid - see Chrysler (25025, 25026) Dodge & Plymouth Neon '95 thru ’99 Omni & Plymouth Horizon '78 thru ’90 Dodge and Plymouth Neon '00 thru ’05 Pick-ups all full-size models '74 thru 93 Pick-ups all full-size models ’94 thru '01 Pick-ups full-size models ’02 thru '08 Ram 50/D50 Pick-ups & Raider and Plymouth Arrow Pick-ups ’79 thru '93 Dodge/Ply./Chrysler RWD ’71 thru '89 Shadow/Plymouth Sundance '87 thru '94 Spirit & Plymouth Acclaim ’89 thru '95 Vans - Dodge & Plymouth '71 thru 03

38027 38030 38031

38032 38035 38036 38040

38070 GEO 40030 GMC

MOTORS

GM Automatic Transmission Overhaul Buick Century, Chevrolet Celebrity, Olds Cutlass Ciera & Pontiac 6000 '82 thru '96 Buick Regal, Chevrolet Lumina Oldsmobile Cutlass Supreme & Pontiac Grand Prix front wheel drive ’88 thru '07 Buick Skyhawk, Cadillac Cimarron, Chevrolet Cavalier, Oldsmobile Firenza

Pontiac J-2000 & Sunbird '82 thru ’94

ISUZU

JAGUAR

TOYOTA (92036)

Storm all models '90 thru '93 Tracker - see SUZUKI Samurai (90010)

Accord CVCC all models '76 thru ’83 Accord all models '84 thru '89 Accord all models '90 thru '93 Accord all models '94 thru '97 Accord all models '98 thru '02 Accord '03 thru ’07 Civic 1200 all models '73 thru '79 Civic 1300 & 1500 CVCC '80 thru '83 Civic 1500 CVCC all models ’75 thru '79 Civic all models '84 thru '91 Civic & del Sol '92 thru '95 Civic '96 thru ’00, CR-V '97 thru '01, Acura Integra '94 thru '00 Civic '01 thru 10, CR-V '02 thru ’09 Odyssey models '99 thru 10 Passport - see ISUZU Rodeo (47017)

XdJ6 all 6 cyl models ’68 thru '86 XdJ6 all models '88 thru '94 XJ12 & XJS all 12 cyl models '72 thru '85 Cherokee,

Comanche & Wagoneer

Limited all models '84 thru '01

50020 50025 50026 50029 50030 50035

CJ all models '49 thru '86 Grand Cherokee all models '93 thru ’04 Grand Cherokee '05 thru '09 Grand Wagoneer & Pick-up '72 thru ’91 Wrangler all models '87 thru 11 Liberty ’02 thru '07

KIA 54050 54070

Optima ‘01 thru ‘10 Sephia '94 thru '01, Spectra ’00 thru ’09, Sportage '05 thru '10

LEXUS

ES 300/330 - see TOYOTA Camry (92007)

(92008)

:

RX 330 - see TOYOTA Highlander (92095)

LINCOLN

Navigator - see FORD Pick-up (36059) Rear Wheel Drive all models ’70 thru 10

59010

MAZDA 61010 61011 61012 61015 61016 61020 61030 61035 61036 61040 61041 61042 61043

GLC (rear wheel drive) '77 thru '83 GLC (front wheel drive) '81 thru ’85 Mazda3 ‘04 thru ‘11

323 & Protegé '90 thru '03 MX-5 Miata ’90 thru '09 MPV all models '89 thru '98 Navajo - see FORD Explorer (36024) Pick-ups '72 thru '93 Pick-ups '94 on - see Ford (36071) RX-7 all models '79 thru '85

RX-7 all models '86 thru '91

626 (rear wheel drive) ’79 thru '82

626 & MX-6 (front wheel drive) '83 thru '92 626 '93 thru '01, & MX-6/Ford Probe ’93 thru 02 Mazda6 ‘03 thru ‘11

MERCEDES-BENZ 63012

123 Series Diesel '76 thru '85

63015

89002 89003 89100 89101

190 Series 4-cyl gas models, ’84 thru ’88

1100, 1300, 1400 & 1600 '71 thru ’79 1600 & 1800 2WD & 4WD ’80 thru '94 Legacy models ’90 thru ’99 Legacy & Forester ’00 thru ’06

90010

Samurai/Sidekick/Geo Tracker '86 thru '01

TOYOTA 92005 92006 92007 92008

92009 92015 92020 92025 92030 92032 92035 92036 92037 92040 92045 92050 92055 92056 92060 92065 92070 92075 92076 92077 92078 92079 92080 92081 92082 92085 92090 92095

Camry all models ’83 thru ’91

Camry all models '92 thru '96 Camry/Avalon/Solara/Lexus ES 300 '97 thru '01 Toyota coy Avalon and Solara & Lexus ES 300/330 all models '02 thru '06 Camry ‘07 thru ‘11 Celica Rear Wheel Drive '71 thru 85 Celica Front Wheel Drive ’86 thru '99 Celica Supra all models '79 thru '92 Corolla all models ’75 thru '79 Corolla rear wheel drive models '80 thru ’87 Corolla front wheel drive models ’84 thru ’92 Corolla & Geo Prizm '93 thru ’02 Corolia models '03 thru '11 Corolla Tercel all models '80 thru '82 Corona all models '74 thru '82 Cressida all models '78 thru '82 Land Cruiser FJ40/43/45/55 '68 thru '82 Land Cruiser FJ60/62/80/FZJ80 '80 thru '96 Matrix & Pontiac Vibe '03 thru ’11 MR2 all models ’85 thru '87 Pick-up all models '69 thru ’78 Pick-up all models ’79 thru 95 Tacoma, 4Runner & T100 ’93 thru 04 Tacoma all models '05 thru ’09 Tundra '00 thru ’06, Sequoia ’01 thru ’07 — 4Runner all models 03 thru '09 Previa all models '91 thru ’95 Prius '01 thru ’08 RAV4 all models '96 thru 10 Tercel all models '87 thru '94 Sienna all models '98 thru '09 Highlander & Lexus RX-330 '99 thru ’07 |

TRIUMPH 94007 94010

Spitfire all models '62 thru '81 TR7 all models '75 thru '81

Vw 96008 96009 96016 96017 96018 96019 96020 96023 96030 96035 96040 96045

Beetle & Karmann Ghia '54 thru '79 New Beetle '98 thru 11 Rabbit, Jetta, Scirocco, & ee ae models '75 thru ’92 & Convertible '80 "92 Golf, GTI & Jetta '93 thru '98, Cabrio '95 thru 02 Golf, GTI & Jetta '98 thru '05

Jetta, Rabbit, GTI & Golf ‘05 thru ‘11

Rabbit, Jetta, Pick-up diesel '77 thru 84 Passat '98 thru ’05, Audi A4 '96 thru '01

Transporter 1600 all models ’68 thru ’79 Transporter 1700, 1800, 2000 '72 thru’79 Type 3 1500 & 1600 '63 thru '73 Vanagon air-cooled models ’80 thru '83

63020 230, 250 & 280 6 cyl sohc '68 thru '72 63025 280 123 Series gas models '77 thru ’81 63030 350 & 450 all models '71 thru '80 63040 C-Class: C230/C240/C280/C320/C350 '01 thru ’07 MERCURY

VOLVO

MG

TECHBOOK MANUALS

64200

66010 66015

Villager & Nissan Quest '93 thru ’01 All other titles, see FORD listing.

MGB Roadster & GT Coupe ’62 thru ’80 MG Midget & Austin Healey Sprite Roadster '58 thru '80

MINI

67020 Mini ‘02 thru ‘11 MITSUBISHI 68020 Cordia, Tredia, Galant, Precis & Mirage 83 thru '93 68030 Eclipse, Eagle Talon & Plymouth Laser '90 thru '94 Eclipse '95 thru '05, Eagle Talon '95 thru ’98

Galant '94 thru '10 Pick-up '83 thru '96, Montero '83 thru '93

72010 72011 72015 72016 72020 72021 72025 72030

300ZX all models incl, Turbo '84 thru '89 350Z & Infiniti G35 all models '03 thru 08 Altima all models ’93 thru '06 Altima ‘07 thru ‘10 Maxima all models ’85 thru '92 Maxima all models '93 thru '01 Murano ‘03 thru ‘10 Pick-ups '80 thru '97, Pathfinder '87 thru '95

72031 72032 72040: 72050 72051 72060 72070

Frontier Pick-up, Xterra, Pathfinder '96 thru '04 Frontier & Xterra '05 thru '11 Pulsar all models '83 thru '86 Sentra all models '82 thru '94 Sentra & 200SX all models '95 thru '06 Stanza all models '82 thru '90 Titan pick-ups ‘04 thru ‘10, Armada ‘05 thru ‘10

OLDSMOBILE 73015

Cutlass ’74 thru '88 For other OLDSMOBILE titles, see

BUICK, CHEVROLET or GM listings.

Chevrolet HHR ‘06 thru ‘11 Metro - see CHEVROLET Sprint (24075) Prizm - see CHEVROLET (24060) or

Hombre - see CHEVROLET S-10 (24071) Rodeo, Amigo & Honda Passport ’89 thru '02 Trooper ’84 thru '91, Pick-up ’81 thru ’93

47017 47020

JEEP 50010

Saturn all L-series models ’00 thu ’04 Saturn VUE ’02 thru '07

SUZUKI G35 '03 thru '08 - see NISSAN 350Z (72011)

NISSAN

Chevrolet Equinox ‘05 thru ‘09 Pontiac Torrent ‘06 thru ‘09

Elantra all models ’96 thru 10 Excel & Accent all models ’86 thru ’09 Santa Fe all models '01 thru ’06 Sonata all models '99 thru '08

49010 49011 49015

87020 87040

SUBARU

INFINITI

Olds Omega, Pontiac Phoenix ’80 thru '85 Buick lark & Somerset, Olds Achieva, Calais & Pontiac Grand Am ‘85 thru '98 Chevrolet Malibu, Olds Alero & Cutlass, Pontiac Grand Am ’97 thru '03 Chevrolet Malibu ’04 thru 10 Cadillac Eldorado & Oldsmobile Toronado '71 thru '85, Seville ’80 thru ’85,

Vans & Pick-ups - see CHEVROLET

42026 42035

43010 43015 43050 43055

68031 68035 68040

Buick Riviera '79 thru '85 Cadillac Eldorado & Seville '86 thru '91, DeVille & Buick Riviera '86 thru ’93, Fleetwood & Olds Toronado '86 thru '92 DeVille '94 thru ’05, Seville ’92 thru '04 Cadillac DTS 06 thru 10 Chevrolet Lumina APV, Olds Silhouette & Pontiac Trans Sport ’90 thru 96 Chevrolet Venture, Olds Silhouette, Trans Sport & Montana ’97 thru 05 GM Full-size RWD - see BUICK (19025)

Honda Pilot '03 thru '07, Acura MDX ’01 thru 07 Prelude CVCC all models '79 thru ’89

HYUNDAI

Chevrolet Cavalier/Pontiac Sunfire '95 thru '05 Chevrolet Cobalt & Pontiac G5 '05 thru '11 Buick Skylark, Chevrolet Citation,

HONDA 42010 42011 42012 42013 42014 42015 42020 42021 42022 42023 42024 42025

42037 42040

PLYMOUTH For PLYMOUTH titles, see DODGE.

PONTIAC 79008 79018 79019 79025 79040

Fiero all models '84 thru '88 Firebird V8 models except Turbo '70 thru '81 Firebird all models '82 thru '92 Gé6 all models ‘05 thru ‘09 Mid-size Rear-wheel Drive '70 thru '87 Vibe '03 thru '11 - see TOYOTA Matrix (92060) For other PONTIAC titles, see BUICK, CHEVROLET or GM listings.

PORSCHE 80020 80025 80030

911 Coupe & Targa models '65 thru '89 914 all 4 cyl models '69 thru '76 924 all models incl. Turbo ’76 thru '82

80035 944 all models incl. Turbo ’83 thru '89 RENAULT Alliance, Encore - see AMC (14020)

SAAB 84010

900 including Turbo '79 thru '88

SATURN 87010

87011

Saturn all S-series models '91 thru ’02

Saturn lon '03 thru 07

97010 97015 97020 97040 10205 10206 10210 10215 10220 10225 10230 10240 10305 10310 10320 10330 10333 10340 10345 10355 10360 10405 10410 10415 10420 10425 10430 10435 10440 10445 10450 10452

120, 140 240 740

130 Series& 1800 Sports '61 thru 73 Series all models '66 thru '74 Series all models '76 thru '93 & 760 Series all models ’82 thru '88

Automotive Computer Codes OBD-II & Electronic Engine Management Automotive Emissions Control Manual Fuel Injection Manual, '78 thru ’85

Fuel Injection Manual, '86 thru 99

Holley Carburetor Manual Rochester Carburetor Manual Weber/Zenith/Stromberg/SU Carburetor Chevrolet Engine Overhaul Manual Chrysler Engine Overhaul Manual Ford Engine Overhaul Manual GM and Ford Diesel Engine Repair Engine Performance Manual Small Engine Repair Manual Suspension, Steering & Driveline

Ford Automatic Transmission Overhaul GM Automatic Transmission Overhaul Automotive Automotive Automotive Automotive

Body Repair & Painting Brake Manual Detaiing Manual Electrical Manual

Automotive Heating & Air Conditioning Automotive Reference Dictionary t

Automotive Tools Manual Used Car Buying Guide Welding Manual ATV Basics Scooters 50cc to 250cc

SPANISH MANUALS 98903 98904

98905 98906 98910 98913 98915 99040 99041 99042 99043 99048 99055 99075 99076 99077 99088 99089 99091 99095 99100 99106 99110 99118 99125

Reparacién de Carrocerfa & Pintura Manual de Carburador Modelos Holley & Rochester Cédigos Automotrices de la Computadora OBD-II & Sistemas de Control Electrénico del Motor Frenos Automotriz Electricidad Automotriz Inyeccién de Combustible '86 al '99 Chevrolet & GMC Camionetas ’67 al '87 Chevrolet & GMC Camionetas ’88 al '98 Chevrolet Camionetas Cerradas ‘68 al ‘95 Chevrolet/GMC Camionetas ‘94 al ‘04 Chevrolet/GMC Camionetas ‘99 al ‘06 Dodge Caravan/Ply. Voyager ’84 al '95 Ford Camionetas y Bronco ’80 al'94__ Ford F-150 ‘97 al ‘09 Ford Camionetas Cerradas ‘69 al ‘91 Ford Modelos de Tamafio Mediano ‘75 al ‘86 Ford Camionetas Ranger ‘93 al ‘10 Ford Taurus & Mercury Sable ‘86 al ‘95 GM Modelos de Tamafio Grande ‘70 al ‘90 GM Modelos de Tamafio Mediano ‘70 al ‘88 Jeep Cherokee, Wagoneer & Comanche '84 al '00

Nissan Camionetas & Pathfinder ‘80 al ‘96

Nissan Sentra '82 al '94 Toyota Camionetas y 4-Runner '79 al '95

Over 100 Haynes motorcycle manuals also available

Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320 e (805) 498-6703 © http://www.haynes.com

7-12

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Common

spark plug conditions NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.

TOO HOT

WORN Symptoms: Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy. Recommendation: Plugs have been left in the engine too long. Replace with new plugs of the same heat range. Follow the recommended maintenance schedule.

CARBON

ASH DEPOSITS Symptoms: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration. Recommendation: lf excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage of oil into the combustion chambers. Also try changing gasoline brands.

OIL DEPOSITS Symptoms: Oily coating caused by poor oil control. Oil is leaking valve guides or piston

rings into the cambhustion

correct

plug

heat

range,

over-

advanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

PREIGNITION

DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. Causes misfiring, hard starting and hesitation. Recommendation: Make sure the plug has the correct heat range. Check for a clogged air filter or problem in the fuel system or engine management system. Also check for ignition system problems.

past worn

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life. Recommendation: Check for the

chamber.

misfiring and Correct the with necesnew plugs.

Symptoms: Melted electrodes. Insulators are white, but may be dirty due to misfiring or flying debris in the combustion chamber. Can lead to engine damage. Recommendation: Check for the correct plug heat range, overadvanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

HIGH SPEED GLAZING Symptoms: \nsulator has yellowish, glazed appearance. Indicates that combustion chamber temper-

atures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds. Recommendation: _ Install new

plugs. Consider using a colder plug if driving habits warrant.

DETONATION Symptoms: Insulators may be cracked or chipped. Improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston damage. Recommendation: Make sure the fuel anti-knock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.

MECHANICAL DAMAGE

on deposits electrodes. nulate and p. The plug } in a dead -ocate the ne deposits oe

eeerruur

wie SreTctrodes.

Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage. Recommendation: Repair the mechanical damage. Remove the foreign object from the engine and/ or install the correct reach plug.

Ki Titi

Inside this manual: ‘& Routine maintenance m@ Tune-up procedures

m@ Engine repair

m Cooling and heating @ Air conditioning ‘lm Fuel and exhaust m= Emissions control

& Ignition m= Brakes

m= Suspension and steering = Electrical systems

= Wiring diagrams Chapter 2 PartB

wore

3.0L V6 engine

oe

Step-by-step procedures linked to hundreds of easy-to-follow photos and illustrations

e Complete troubleshooting section helps identify specific problems e Written from hands-on experience based ona vehicle teardown using commonly available tools e Haynes tips give valuable short cuts to make the job

easier and eliminate the need for special tools Notes, Cautions and Warnings for the home mechanic

Color spark plug diagnosis Easy to use index

_ Models covered by this manual:

Honda Accord - 2008 thru 2012

:

|

Honda Crosstour - 2010 thru 2012

:

Does not include information specific to hybrid models or All-Wheel Drive modele

ABCDEFGHIJ

Raies Goon

799-2996

Visit www.haynes.com for. FREE videos, tips and details

on our salle cess Haynes line

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ISBN13 97812002060. .

0 58545'42085!

: v1

3

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