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Honda Civic 2002 Si engine electrical

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Honda Civic 2002 Si engine electrical Powered By Docstoc
					     EngineElectrical

     EngineElectrical                                              -   +
      SpecialTools                                      4-2
                                                                   ENGINE
     StartingSystem
      Comoonent  Location Index ...............        4-J
      CircuitDiagram                                   4-4
      Starter    it
             Circu Troubleshooting                     4-5
                    SwitchTest
      ClutchInterlock                                  4-6
      StarterSolenoidTest ..............               4-7
      StarterPerformance Test                          4-8
      StarterReolacement   ...............             4-9
      StarterOverhaul .......................          4-10
     lgnition System
      Component         Index ...............
                 Location                              4-15
      CircuitDiagram                                   4-16
      lgnitionTimingInspection                         4-17
      lgnitionCoilRemoval/1nsta11ation                 4-18
                                      .......................
      Spark PlugInspection                             4-19
     ChargingSystem
      Component         Index ..................................
                 Location                                  4-2O
            Diagram
      Circuit                                              4-21
                                     ...........................
      Charging      Troubleshooting
              Circuit                                      4-22
                                        .......................
      DriveBeltInspection                                  4-26
                                           ...................
      DriveBeftReplacement                                 4-26
                                               ..............
      DriveBeftAuto-tensionerInspection                    4-27
                                            ..................
      DriveBeftAuto-tensionerReplacement                   4-28
                                               ..............
      AlternatorReolacement                                4-29
                                                .............
      Alternator
               Overhaul ................              .... 4-30
     CruiseControl
      Component Location                               4-36
                        Index ..................................
            Diagram
      Circuit                                          4-37
                                   ...........................
      Symptom                Index .......................
               Troubleshooting                         4-38
      Cruise      UnitlnDut
            Control                                    4-40
                           Test .............................
      MainSwitch TesVReolacement                       4-42
                                   ...........................
      SeVResume/Cancel SwitchTesVReplacement 4-42   ..
      Cruise      Actuator
            Control       Test                   ......4-43
      Cruise      Actuator/Cable
            Control             Replacement 4-44 ......
      ActuatorCableAdjustment                          4-45
                              ..................................
      ClutchPedal       Switch
                 Position                              4-45
                               Test .......................

\.
    EngineElectrical
     SpecialTools                                                           \ C
      Number             Tool Number                    Description   otv
          o    07746-0010400           Attachment,52 x 55 mm           1
          @    07749-0010000           Driver                          1




I




                                                                            \(a
    4-2
     Starting System
      ComponentLocationIndex


                                                                        UNDER-DASH
                                                                        FUSE/RELAYBOX
                                               - l - -
                                                        -i
                                              ar]]]ll             I



                                                  -_-
                                               -.      rt_.1
                                              _-- _. /

                                                          Itti:
                                                             i t
                                               : - l t . i t - t! -
                                               !t:!|-                        CLUTCH INTERLOCKSWITCH
                                                                             Test,page4-6
        STARTERCUTRELAY
            page
        Test,   22-51



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                \'\l I
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              , . \ \         /
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               \ \ /


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               t l        \




                                  STARTER
                                                              page4 5
                                  StanerCircuitTroubleshoot,ng,
                                  SolenoidTest,page 4-7
                                  PerformanceTest,page4-8
                                               page4-9
                                  Replacement, '10
                                  Overhaul,page4




                                                                                                      4-3
Starting System
 CircuitDiagram

                                                              -
                                                                  ilo.20lOA) :USA  motkl
                                                                  No.2!l50A) : C.nid. model
                  H@D
             UiIOEN  fUSE/REI.IY
                             BOX




                                       in
                                   STHOT STA8T
                                             illl




                                                            UNDEiOASTI
                                                            FUST/ifLAY
                                                            80x




                                                                                              Y.




                                                         [{Tr8LocK
                                                    cLuTot
                                                    swtlcH




                                                                                                   a

4-4
    StarterCircuitTroubleshooting
    NOTE:                                                              4. Checkthe batterycondition.Checkelectrical
    . Airtemperaturemust be between59'and 100'F(15'                       connections the battery,the negativebaftery
                                                                                       at
      and 38'C) during this procedure.                                    cableto body, the engine ground cablesand the
    . After this test, or any subsequent             repair,resetthe      starterfor loosenessand corrosion.Then try
      enginecontrolemodule (ECM) clear any diagnostlc
                                                  to                      startingthe engine again.
      trouble codes (DTCS)         {seepage 11-4).
    . The batterymust be in good conditionand fully                      Did the statter crank the engine?
      charged.
    . lf you disconnect       the baftery,do the ECM idle learn          YES Repairing the looseconnectionfixed the
      p r o c e d u r es e ep a g e1 1 - 1 3 9 ) .
                      (                                                  problem.The startingsystem is now OK.!

    Recommended    Procedure:                                            N O l f s t a r t e r w i l l o t c r a n k t h e e n g i n e t a l l ,g o t o
                                                                                                     n                               a
    . Use a startersystemtester.                                         step 5. lf it cranksthe engine erraticallyor too
    . Connectand operatethe equipmentin accordance                       slowly, go to step 7. lf it won't disengage                   from the
      with the manufacturer'sinstructions.                               flywheel ring gear when you releasethe key, check
                                                                         for the following until you find the cause.
    Alternate Procedure
                                                                          . Solenoidplungerand switch malfunction
     1. Hook up the following equipment:                                  . Dirty drive gear or damagedoverrunningclutch
        . Ammeter,0 400A
        . Voltmeter,0 20 V (accuratewithin 0.1 volt)                   5. Make sure the transmissionis in neutral,then
        . Tachometer,0 1200rpm                                            disconnect startersubharness connector(A)
                                                                                     the                   1P
                                                                                                      'lP
                                                                          from the enginewire harness connector(B).
                                                                          Connecta jumper wire from the batterypositive
                                                                                                           'l
                                                                          terminalto the startersubharness P connector.




      2 . Removethe No. 17 (15A)fuse from the under-dash
         fuse/relaybox.

      3 . With the clutch pedal pressed,
                                       turn the ignition
         switchto start (lll).

         Did the starter crank the enginenormally?
                                                                          Did the starter crank the engine?
         YES-The startingsystem is OK.I
                                                                          YES-Go to step 6.
         NO-Go to step 4.
                                                                          NO Checkthe BLK,ANHT    wire betweenthe starter
                                                                          subharness connectorand the starter.lf wire is
                                                                                     1P
                                                                          OK, removethe starter,and repairor replaceas
                                                                          necessary.

L
                                                                                                                                            (cont'd)



                                                                                                                                                   4-5
StartingSystem
 StarterCircuitTroubleshooting                                                      ClutchInterlockSwitch Test
 (cont'dl
  6. Checkthe following items in the order listeduntil
     you find the open circuit.
                                                                                    1. Disconnect clutchinterlock
                                                                                               the                    2P
                                                                                                                switch connector.
      . Checkthe BLIVWHT    wire and connectors
        betweenthe under-dash   fuse/relaybox and the
        ignition switch,and betweenthe under-dash
        fuse/relaybox and the starter.
      . Checkthe ignition switch {seepage 22-53).
      . Checkthe clutch interlockswitch and connector.
      . Checkthe startercut relay (seepage 22-51).
      . CheckLT GRNwire betweenthe startercut relayl
        under-dash  fuse/relaybox and the clutch
        interlockswitch.
      . Checkthe BLKwire betweenthe clutch interlock
        switch and G501.

  7, Checkthe crankingvoltageand currentdraw.

      ls ctanking voltagegreatet than or equal to 8.7 V
      and current draw less than or equal to 230 A?

      YES-Go to step8.

      NO Replace starter.or remove and
                  the
                 it,
      disassemble and checkthese items until you find                               2. Removethe clutch interlockswitch (A).
      thecause.
                                                                                      Checkfor continuitybetweenthe terminals
      . Starterarmaturedragging                                                       accordingto the table.
      . Shortedarmature winding
      . E x c e s s i vd r a g i n e n g i n e
                       e                                                              . lf the continuityis not as specified,replacethe
                                                                                        clutch interlockswitch.
  8 . C h e c k h e e n g i n e p e e dw h i l ec r a n k i n g h e e n g i n e .
              t                s                              t                       . lf OK, installclutch interlockswitch and adjust
                                                                                        the pedal height (seepage 12-4l..
      ls the engine speed above 100 tpm?
                                                                                      \                   Terminal
      YES Go to step 9.                                                                                                        2
                                                                                       Cl","f ri"t.tf ."tS""*Jrl
      NO-Replace the starter,or remove and                                                  PRESSED                  o--   - --o
      disassemble and checkfor the following until
                          it,                                                               RELEASED
      y o u f i n dt h e c a u s e .

      . Excessively       worn starterbrushes
      . Open circuit in commutator brushes
      . Open circuit in starterarmaturecommutator
        segments
      . D i r t yo r d a m a g e d e l i c as p l i n e s r d r i v eg e a r
                                  h         l           o
      . Faultydrive gear clutch

  9. Removethe starter,and inspectits drive gear and
     the flywheel ring gear for damage.Replaceany
               p
     damaged ans.I




4-6
     StarterSolenoidTest
                                   from thestarter
     1. Disconnect S andlvlconnectors
                 the
        solenoid.




     2. Checkthe hold-incoil for continuitybetweenthe S
        terminal and the armaturehousing(ground).There
        should be continuity.

         . lf there is continuity,goto step 3.
         . lf there is no continuity,replacethe solenoid,

     3. Checkthe pull-incoil for continuitybetwee the S               n
et      t e r m i n a a n d M t e r m i n a l T h e r es h o u l db e
                      l                       .
        continuity,

         . lf there is continuity,the solenoidis OK.
         . lf there is no continuity,replacethe solenoid,




                                                                          4-7
StartingSystem
 Starter Performance
                   Test
  1 , Disconnect wires from the S terminal and the M
                the                                           5. Disconnect batteryfrom the starterbody. lfthe
                                                                             the
      termrnal.                                                  pinion retractsimmediately,it is working properly.

      Make a connectionas describedbelow using as
      heavya wire as possible(preterably equivalentto
      the wire used for the vehicle). avoid damaging
                                    To
      the starter,never leavethe batteryconnectedfor
      more than 10 seconds,

      Connectthe batteryas shown. Be sure to
      disconnect   the startermotor wire from the solenoid.
      lf the starterpinion moves out, it is working
      propefly.




                                                              6 . Clampthe starterfirmly in a vise.

                                                              7 . Connect  the starterto the batteryas describedin
                                                                  the diagram below,and confirm that the motor
                                                                  starts and keepsrotating.




      Disconnect batteryfrom the M terminal.lf the
                 the
      pinion does not retract,the hold-incoil of the
      solenoidis working properly.




                                                                lf the eiectriccurrent and motor speedmeet the
                                                                specifications  when the batteryvoltage is at 11.5V,
                                                                the staner is working properly,

                                                                Specifications:

                                                                   1.1 kw    90 A or less (Electric
                                                                                                  current),
                                                                                        ot more




                                                                                                                       L




4-8
    Starter Replacement
    1. Make sure you havethe anti-theftcode for the radio.   5. Disconnect startercable (A)from the B terminal
                                                                           the
       then write down the frequencies the radio's
                                      for                                                     the BLK,/WHT
                                                                on the solenoid,then disconnect           wire
       presetbuttons.                                           { B )f r o mt h eS t e r m i n a l .
                                                                         mm
                                                                  10x 1.25
    2. Disconnect negativecablefrom the batteryfirst,
                 the                                              44N.m{a.5kgf.m,33lblft)
                     the positivecable.
       then disconnect

    3. Disconnect knocksensorconnector.
                the

    4. Removethe bolt (A) securingthe harnessbracket,
       then removethe intakemanifold bracket(B).

    A
    6x1,0mm
    12 N.m {1.2kgf.m,
    8.7 tbt.ft)


                                                                8 x 1 . 2 5m m
                                                                9Nm
                                                                10.9 kgf.m,7 lbl ft)             2
                                                                                             S'-12x12smm
                                                                                                       6ilNm
                                                                                                       { 6 . 5k g l m , 4 7 l b f f t )


                                                                Removethe two bolts holdingthe starter,then
                                                                removethe starter.

                                                             7 . lnstallthe starterin the reverseorder of removal.
     8 x 1.25mm
               kgt.m,
     22 N,m 12.2                                                 Make sure the crimped side of the ring terminal (A)
     16rbf.ftl                                                   is facing out.




                                                                                           I

                                                                Connectthe positivecable and negativecableto
                                                                the batterY.

                                                              9 . Start the engineto make sure the starteroperates
                                                                 propeny.

                                                             '10.Enterthe anti-theftcode for the radio,then enter
                                                                 the customer'sradio stationpresets.

                                                             1 1 .Set the clock.
                                                             ' t 2 .Performthe enginecontrol module (EcM) idle learn
L                                                                procedure(seepage 1'1- ).
                                                                                      139




                                                                                                                                          4-9
StartingSystem
 Starter Overhaul                                                                              f
 Disassembly/Reassembly




                                                     STARTERSOLENOID
                                @
                                @

                                                  ----_2<-
                       ,--\
                                                                   G
                   rw.h
               ;   ,/ 1(-\
                                                                             SOLENOID
                                                                                    LEVER


                    \:!@a                 - @-A
                   q                       -z\hsc6
                   b-.-                ,"
                                    OVERRUNNING
                                    CLUTCHASSEMBLY

                                                                                            7:- o

                          o*"lu*.                     S#o
                                              V*rN*
                              \#.                                  A*@
                                    \                   c^)* -#""Jli[X:""

                                                     -v
                                                     a<-4 t^ fr/ /           ffiA
                                                               9\:-/ lW
                                                             ,..  D
                                                                       ffitr'!4/
                                                     END COVER         t/
                                                                   BRUSHHOLDER




                                                                                            \ r
4-10
\


      Armature Inspection and Test                                                        5. Checkthe commutatordiameter.lf the diameteris
                                                                                             below the servicelimit, replacethe armature.
       1. Removethe starter(seepage 4-9).
                                                                                            Commutator Diameter
       2 . D i s a s s e m b lte e s t a r t e r s s h o w na t t h e b e g i n n i n g
                               h               a                                            Standard(Newl: 28.0mm (1.10in.l
           of this procedure.                                                               ServiceLimit: 27.0 mm (1.06in.)

       3. Inspectthe armaturefor wear or damagefrom
          contactwith the permanentmagnet.lf there is wear
          or damage,replacethe armature.




                                                                                          6 . Measurethe commutator (A) runout.

                                                                                             . lf the commutator runout is within the service
                                                                                               limit, checkthe commutatorfor carbondust or
?.-        Checkthe commutator(A) surface.lf the surfaceis                                     brasschips betweenthe segments.
                                   with emery cloth or a lathe
           dirty or burnt, resurface                                                         . lf the commutator runout is not within the service
           within the specifications step 5, or recondition
                                     in                                                        limit, reolacethe armature.
           with # 500 or # 600 sandpaper(B).
                                                                                            Commutator Runout
                                                                                                                       in.)
                                                                                            StandardlNew): 0.02mm 10.001 max.
                                                                                            ServiceLimit: 0.05mm (0.002in.)




                                                                                                                                         (cont'd)



                                                                                                                                           4-11
StartingSystem
 StarterOverhaul(cont'dl
  7. Checkthe mica depth (A).lf the mica is too high {B),    9. Placethe armature(A) on an armaturetester (B).
     undercutthe mica with a hacksawbladeto the                 Hold a hacksawblade (C)on the armaturecore. lf
     properdepth.Cut away allthe mica (C)between                the blade is attracted the core or vibrateswhile
                                                                                                 to
     the commutatorsegments.   The undercutshould               t h e c o r ei s t u r n e d , h e a r m a t u r e s s h o n e d .R e p l a c e
                                                                                             t                   i
     not be too shallow,too narrow,or V-shaped(D).              thearmature.

    Commutator Mica Depth
    Standard(New):0.50-0.80 mm {0.020-0.031in.)
    ServiceLimit: 0.20 mm (0.008in.)




                                                            1 0 ,Checkwith an ohmmeterthat no continuityexists
                                                                betweenthe commutator(A) and armaturecoll
                                                                core (B),and betweenthe commutatorand
                                                                armatureshaft (C).lf continuityexists,replacethe
    Checkfor continuitybetweenthe segmentsof the                armature.
    commutator.lf an open circuitexists betweenany
    segments,replacethe armature.




          M

                                                                                                                                                  \




4-12
Starter Brush Inspection                              Starter Brush Holder Test

11. lvleasure brush length.lf it is not within the
             the                                      14, Checkthat there is no continuitybetweenthe (+ )
    servicelimit, replacethe brush holder assembly.       b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e
                                                          is continuity,replacethe brush holder assembly.
    Brush Length
    Standard{New): 14.0-14.5 mm (0.55-0.57 in.)
    Service Limit: 9.0 mm {0.35 in.)




                                                      Brush Spring Inspection
Starter Field Winding Test
                                                      15. Insen the brush (A) into the brush holder,and bring
12. Checkfor continuitybetweenthe brushes(A).lf           the brush into contactwith the commutator,then
    there is no continuity.replacethe armature            attacha spring scale(B)to the spring (C).Measure
    housing B).
              (                                           the spring tensionat the moment the spring lifts off
                                                          the brush.lf the springtension is not within
                                                          specification, replacethe spring.

                                                            Spring Tension: 13.7-17.7 N {1.40-1.80 kgf,
                                                                            3.09 3.97lbf)




 1 3 .Checkfor continuitybetweeneach brush (A) and
    the armaturehousing(B).li there is continuity,
    replacethe armaturehousing.




                                                                                                                             (cont'd)



                                                                                                                                4-13
StartingSystem
 StarterOverhaul(cont'dl
 Planetary Gear Inspection                                                        Starter Reassembly

 1 6 . C h e c k h e p l a n e t a r y e a r s( A )a n d r i n g g e a r{ B ) .
               t                     g                                            20, Pry backeach brush spring with a screwdriver,                 then
       Replace    them if they are worn or damaged.                                   positionthe brush about halfwayout of its holder,
                                                                                      a n d r e l e a s eh e s p r i n gt o h o l d i t t h e r e .
                                                                                                        t

                                                                                        NOTE:To seatthe new brushes.slip a strip of #5OO
                                                                                        or # 600 sandpaper.with the grit side out, be&veen
                                                                                        the commutatorand each brush,and smoothly
                                                                                        rotatethe armature.The contactsurfaceof the
                                                                                        brusheswill be sandedto the same contouras the
                                                                                        commutator.




 OverrunningCluich Inspection

 17. Slidethe overrunningclutchalong the shaft.
     Replaceit if it does not slide smoothly.

 18. Rotatethe overrunningclutch(A) both ways.                                    21 l n s t a l l t h e r m a t u r en t h e h o u s i n ga n d i n s t a l l t h e
                                                                                                        a            i                     ,
     Doesit lock in one directionand rotatesmoothly in                               brush holder.Next, pry backeach brush spring
     reverse? it does not lock in eitherdirectionor it
              lf                                                                     a g a i n , n d p u s ht h e b r u s hd o w n u n t i li t s e a t s
                                                                                                 a
     locksin both directions,replaceit.                                              againstthe commutator,then release                       the spring
                                                                                     againstthe end of the brush.




 1 9 .lf the starterdrive gear (B) is worn or damaged,
                                                                                                                s
     replacethe overrunningclutch assembly;     the gear                               Installthe starterend cover to retainthe brush
     is not availableseparately.                                                       holder.
     Checkthe conditionof the flywheel ring gear.
     Replaceit if the starterdrive gear teeth are
     oamageo.

                                                                                                                                                                       i.-




4-14
lgnition System
 ComponentLocationIndex




      SPARKPLUG
               page
      Inspection, 4-'19   IGNITION COIL
                                 Timing
                          lgnition              page
                                       Inspection, 4-17
                                           page
                          Removal/lnstallation, 4-18




                                                          4-15
lgnition System
 Gircuit
       Diagram                                                              (



                                                     'No.20lOA)
                                                               :USAmo&l
           UNDEB  FUST/8TIAY
               HOOD       M)(                         No.A          model
                                                          l50A):Cmrda




                                lG1tioT in 0N {ll)
                                rd SIARIilll)




4-16
    lgnition Timing Inspection
    1 . Connectthe Honda PGM Testerto the data link                 6. Pointthe light toward the pointer (A) on the cam
        connector(DTC),and checkfor DTC'S. a DTCis
                                          lf                                                                        t
                                                                       c h a i nc a s e . h e c k h e i g n i t i o n i m i n g u n d e rn o l o a d
                                                                                        C       t
        present,diagnoseand repairthe causebefore                      conditions:headlights,           blower fan. rearwindow
        inspectinthe ignitioniming.
                  g         t                                          defogger,and air conditionerare not operaling.lf
                                                                       the ignitiontiming differsfrom the specification,
      Startthe engine.Holdthe engine at 3,000rpm with                  and there are no enginecontrol module {ECM)DTcs,
      no load (in Neutral)until the radiatorfan comes on,              r e p l a c eh e E C M( s e ep a g e1 1 - 4 )
                                                                                   t
      then let it idle.
                                                                        lgnition Timing:
      C h e c k h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) .
              t                                                         8"+2" BTDC{REDmark {B))during idling in neutral

                                                      "SCS" menu                                       A
    4. Follow the tester'sprompts in the
      {seethe testeroperator'smanual),

    5 . Connectthe timing light to the serviceloop.




o                                                                   7. Turn the ignition switch OFF.

                                                                                                                       a
                                                                        D i s c o n n e c t t hH o n d aP G MT e s t e r n dt h e t i m i n g
                                                                                               e
                                                                        light.




                                                                                                                                          4-17
lgnition System
 lgnitionCoilRemoval/lnstallation
  1. Removethe ignition coil cover (A),then removethe
     i g n i t i o n o i l s( B ) .
                    c

  6x1.0mm
  9.8 N.m (1.0kgf.m,7.2lbf ftl




  2. Installthe ignition coils in the reverseorder of



                                                        ---
     removal.


                                                          a




4-18
    SparkPlug Inspection
    1 . Inspectthe electrodes
                            and ceramicinsulator.             3. Replace  the plug at the specifiedinterval,or if the
                                                                 centerelectrodeis rounded{A). Use onlVthe spark
      Burned or worn electrodes may be caused by:                plugs listedbelow.
      . Advancedignitiontiming
      . Loosespark plug                                         Spark Plugs: lZFR6Kl1(NGK)
      . Plug heat rangetoo hot                                               SKJ2ODR-M11(DENSO)
      .Insufficientcooling

      Fouledplug may be causedby:
      . Retardedignitiontiming
      . Oilin combustionhamber    c
      . Incorrect    spark plug gap
      . Plug heat rangetoo cold
      . Excessive     idling/lowspeed running
      . C l o g g e d i rc l e a n e r l e m e n t
                    a                e
      . Deteriorated      ignitioncoils
             Worn or deformed
             electrodes
                                      f .lmproper gap
                                 I    J.Oil-touling
                                        . Cs6on deposits
                                 'r- 1I . Crackedcenter
                                      \ electrode insulator   4 . Apply a small quantityof anti-seize
                                                                                                    compoundto
                                                                the plug threads,and screwthe plugs into the
                                                                cylinder headfinger-tight.             Then torque them to
                                                                1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .
L


      Do not adjustthe gap of iridium tip plugs (A);
      replacethe spark plug if the gap is out of
      specification.

      Electrode Gap:
      Standard(New):        1.0 1.1 mm
                            {0.039-0.0€ in.)
      ServiceLimit:         1.3 mm {0.051in.l




                                                                                                                         4-19
Gharging
       System
 ComponentLocationIndex



                                   CHARGING    SYSTEMINDICATOR
                                   (ln the gaugeassembly)




                                                                          q*o




                                                          BATTERY
                                                              page22-50
                                                          Test,


                                                 ALTEBNATOR
                                                               page
                                                 Troubleshooting, 4-22
               DRIVEBELT                                    page
                                                 Replacement, 4-29
                        page4 26
               Inspection,                               page4-30
                                                 Overhaul,
                           page
               Replacement, 4 26




4-20
\   CircuitDiagram

                                                    'flo.
                                                           {l0Al :uSAhod.l
               UNDTR
                   XOOD
                      FUSI/RILAY
                              MX                      ilo.20l50Al:C.n.d.mod.l




                                          +--,
                                          I fmlil*t"t'
                                          T-

                                   +ilt
L                                  = l




                                                                                4-21
       System
Gharging
        CircuitTroubleshooting
 Charging
 lf the chargingsystem indicatordoes not come on or                   6. Measurethe voltageat the No. 3 terminal of the
 does not go off, or the batteryis dead or low, test these                          w                  6                  r
                                                                         e n g i n e i r e h a r n e s s P c o n n e c t ow i t h t h e i g n i t i o n
 items in the order listedbelow:                                         s w i t c hO N {l l ) .

 Battery(seepage 22-50)                                                           ENGINEWIREHARNESS CONNECTOR
                                                                                                  6P
 Chargingsystem indicator
 Alternatorand regulatorcircuit
 Alternatorcontrol system
                                                                                                                                IBLK/YEL}
        SystemIndicator
 Charging             Test
  1 . T u r nt h e i g n i t i o n w i t c hO N { l l ) .
                                  s

      Does the chatging system indicator come on?

      YES Go to step 2.                                                                                   terminals
                                                                                          Wiresideof female

      NO Go to step 3.
                                                                          ls there battery voltage?
  2. Startthe engine.
                                                                          YES-Go to step 7.
      Does the charging system indicator go off?
                                                                                                                          f
                                                                          N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A ) u s e i n t h e
      YES-Charging system indicatorcircuitis OK. Go                       under-dash     fuse/relaybox. lf the fuse is OK, repair
                                   circuitTest.t
      to the Alternatorand Regulator                                      open in the wire betweenthe alternatorand the
                                                                          under-dash     fuse/relaybox.I                                                  ?
      NO-Go to step 3.
                                                                      7 . Turn the ignition switch OFF.
  3. Turn the ignitionswitch OFF.
                                                                                   enginecontrol module (ECM)connector
                                                                      8 . Disconnect
  4. Troubleshoot multiplexcontrol system (see
                  the                                                     B (24P).
     page 22 172).
                                                                      9 . Checkcontinuitybetweenthe ECMconnector
      ls the multiplex control system OK?                                                                       w
                                                                          t e r m i n a lB ' 1 0 n d e n g i n e i r e h a r n e s s Pc o n n e c t o r
                                                                                               a                                   6
                                                                          t e r m i n a lN o . 6 .
      YES Go to step 5.
                                                                                                 ECM CONNECTOB A (24P)

      NO Checkthe multiplexcontrol system as
      indicatedby the diagnostic            trouble code (DTC) (see
      s t e p8 o n p a g e2 2 - 1 7 2 ) . 1
                                                                                                         ACGL WHT/BLU)
                                                                                                             {
                the
  5. Disconnect enginewire harness6P connector
     from the startersub harness6P connector.
                                                                                           W
                                                                                      ENGINE IBE
                                                                                      HARNESS
                                                                                      6P
                                                                                                                                    L (WHT/BLUI
                                                                                             W i r e s i d eo f f e m a l e t e r m i n a
                                                                                                                                        s


                                                                          ls there continuity?

                                                                          YES Go to step 10.

                                                                          NO-Repair open in the wire betweenthe
                                                                          a l t e r n a t oa n dt h e E C N 4 . I
                                                                                           r
                                                                                                                                                          \"4
4-22
'10.
   Checkcontinuitybetweenthe ECMconnector             Alternator and RegulatorCircuitTest
   t e r m i n a l8 1 0 a n d b o d y g r o u n d .
                                                       1. Be sure the batteryis sufficientlychargedand in
                    ECMCONNECTOR I24PI
                               S                          good condition{seepage 22-50),    and the
                                                                       at
                                                          connections the fuse box and alternatorare
                                                          clean and tight.
                     2 3 t 4t 5       6 7
                 8 I 10 ,/1,/ 3       15               2. Raisethe hoist to full height.
                 1 1 8 ,N nt,/ 21      23
                         ACGL(WHT/BLUI                 3. Hook up the ammeter,0     400 A, to the starter
                       t1'                                subharness.



                 Wire side ol femaleterminals



       ls there continuity?

   YES- Repairshort to ground in the wire between
   the ECMand the enginewire harness6P connector.
   t

   NO-Go to alternatorand regulatortest.


                                                         Lower the hoist.

                                                         Hook up the voltmeter,0     20 V (accurate
                                                                                                  within
                                                         0.1V),toT101.




                                                                                                      (cont'd)




                                                                                                        4-23
GhargingSystem
 Charging                    (cont'd)
        CircuitTroubleshooting
 6. Startthe engine.Hold the engineat 3,000rpm with       Alternator Control SystemTest
    no load (in Neutral)until the radiatorfan comes on,
    then let it idle.                                     NOTE:After troubleshooting, performthe engine
                                                          control module (ECM)idle learn procedure(seepage
 7. Raisethe engine speedto 2,000rpm, and hold it         11-139).
    there.
                                                           1. Checkfor proper operationof the electricalload
 8. Turn the headlights(high beam)on, and measure             detector(ELD)by checkingthe malfunction
    voltageat the under-hoodfuse/relaybox terminal.           i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s
                                                              present,diagnoseand repairthe causebefore
    ls the voltagebetween 13.9and 15.1v?                      continuingwith this test.

   YES-Go to step 9.                                                     the
                                                           2. Disconnect enginewire harness6P connector
                                                              from the startersub harness6P connector.
   NO Repairor replacethe alternatorcomponents
   (seepage 4-30).1                                        3. Start the engine,and turn the headlights(high
                                                              b e a m )O N ,
                          '13.5
                              V.
 9. Readthe amperageat
                                                           4. Measurevoltage betweenthe enginewire harness
    NOTE:Adjust the voltage by turning the blower             6P connectorterminal No. 2 and the positive
    motor, rearwindow defogger,brakelights.etc.ON.            terminal of lhe battery.

    ls the amperage604 ot morc?                                                              BATTERY

                          operationis OK.I
   YES-Alternator/regulator

    NO Repairor replacethe alternatorcomponents
    (seepage 4-30).1                                                                                  C {WHT/GRN)




                                                                             WIRE
                                                                        ENGINE        6P
                                                                                HARNESS CONNECTOR
                                                                                               terminals
                                                                               Wiresideof female


                                                               ls there 1 V or less?

                                                               YES Go to step 8.

                                                               N O - G o t o s t e p5 .

                                                                                              s                    s
                                                           5 . T u r nt h e h e a d l i g h t a n d i g n i t i o n w i t c hO F F .

                                                                        ECMconnectorB (24P).
                                                           6 . Disconnect




                                                                                                                                         \,




4-24
\

    7, Checkfor continuitybetweenECMconnector                 10. Checkfor continuitybetweenECMconnector
       t e r m i n a l8 1 8 a n d b o d y g r o u n d .           t e r m i n a l8 1 8 a n d e n g i n e i r e h a r n e s s Pc o n n e c t o r
                                                                                                        w                  6
                                                                  t e r m i n a lN o . 2 .
                     ECM CONNECTOR {24PI
                                  B
                                                                                                   B
                                                                                      ECM CONNECTOR l2,lPI

                  1 2 3 t 4t 5          6 1                                       1 2 3 1 4 l 5 l l6l 7
                  8 9 10 ,/1,/ 3         5                                        8 9 10    t.)    15
                 11o          nt,/21    23                                        11o          n
                                                                                            21 23
                         ACGC{WHT/GRN}                           (WHT/GRN)
                                                              ACGC
                                                                                             o          C (WHT/GRN)
                     o
                                                                                                    2    3
                                                                                                    5     6
                  Wire side ot femaleterminals
                                                                           ENGINE          6P
                                                                                 WIREHARNESS CONNECTOR
                                                                                  Wire side oI lemale terminals
       ls there continuity?
                                                                   ls therc continuity?
      YES-Repair short to ground in the wire between
      the alternatorand the ECM.I                                  YES Repairor replacethe startersubharness
                                                                                                           or
                                                                   the alternator(seepage 4-30).I
      NO-Check that the terminalsare firmly seatedat
      the ECMconnectorB. lf OK, substitutea known-                 NO Repairopen in the wire betweenthe
      good ECM,and recheck(seepage 11-6).                                           r
                                                                   a l t e r n a t oa n d t h e E C M . I
      lf prescribed
L                  l
                        voltage is now available.replacethe
      o r i g i n aE C M , I

      Turn the headlightsand ignition switch OFF.

                 ECMconnectorB (24P).
    9 . Disconnect




                                                                                                                                     4-25
       System
Charging
 DriveBelt Inspection                              DriveBelt Replacement
      that
 Check the auto-tensioner        (A)
                         indicator is withinthe                                (A)
                                                   1, Move the auto-tensioner to relievetensionfrom
 standard     (B)        lf
         range asshown. it is out of thestandard      the drive belt (B).and removethe drive belt.
 range,replace drivebelt(see
             the            page4-26).




                                                   2. Installthe new belt in the reverseorder of removal.




4-26
\
    DriveBelt Auto-tensioner
                           Inspection
    1 . Checkwhether there is a changein the positionof                                                              (seepage 4-28).
                                                                                              Removethe auto-tensioner
      the auto-tensioner         indicatorbeforestartingthe
      engineand after startingthe engine.lf there is a                                        I n s t a ltlh e t e n s i o n e p u l l e y .
                                                                                                                               r
                                         ,
      c h a n g e n t h e p o s i t i o nr e p l a c eh e a u t o - t e n s i o n e r .
                 i                                   t
                                                                                                                        (A)
                                                                                          7 . Clampthe auto-tensioner by using two 8 mm
                                                                                              bolts (B)and a vise (C)as shown. Do not clamp the
                                                                                              auto-tensioner itself.




      C h e c k o r a b n o r m a n o i s ef r o m t h e t e n s i o n e p u l l e y .
                f                    l                                      r
                        l
      l f a b n o r m a n o i s ei s h e a r d ,r e p l a c eh e t e n s i o n e r
                                                            t
      pulley.

    3 . Removethe drive belt (seepage 4-26).
                                                                                          8 . Set the torque wrench (D)on the pulley bolt.
      lMove  the auto-tensioner within its limit with the
      belt tension releasetool in the directionshown.                                     9 . Align the indicator{E)on the tensionerbasewith
      Checkthat the tensionermoves smoothly and                                               c e n t e rm a r k( F )o n t h e t e n s i o n e a r m b y u s i n gt h e
                                                                                                                                               r
      without any abnormal noise.lf the tensionerdoes                                         torque wrench, and measurethe torque. lf the
      not move smoothly or there is abnormal noise,                                           torque value is out of specification,                replacethe
      replacethe auto-tensioner.                                                              auto-tensioner,
                                                                                              NOTE;lf the indicatorexceeds                  the centermark,
                                                                                                          the
                                                                                              recheck torque.

                                                                                              Auto-tensioner spring torque:
                                                                                              26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)




                                                                                                                                                                 4-27
       System
Charging
                        Replacement
 DriveBelt Auto-tensioner
  1. Removethe drive belt (seepage 4'26).                               4. Removethe auto-tensioner,

 2 . R e m o v e h e i d l e rp u l l e y .
               t

                                                          6xl.0mm
                                                          9.8 N.m
                                                          (1,0kgl.m,
                                                          7.2 tbf.ft)




   d

 I
 6x1,0mm
 12 N.m
 ('1.2
     kgt.m.8.7lbt.ft)
                                               x 1.25mm
                                              22 N.m
                                              {2.2 kgt m, 16 lbf ft}


  3. Removethe tensionerpulley.                                         8 x 1.25mm
                                                                        22 N.m (2.2kgf.m, 16lbt.ft)


                                                                        5. lnstall in the reverse order of removal.

                                                                                                                      \-a




4-28
l\-   AlternatorReplacement
      1. Make sure you havethe anti-theft
                                        code for the radio,      9 . Removethe alternator.
         then write down the frequencies the radio's
                                       for
         preset buttons,                                        1 0 . Installthe alternatorand drive belt in the reverse
                                                                      order of removal.
      2. Disconnect negativecablefrom the batteryfirst,
                   the
                       the positivecable.
         then disconnect                                        'I
                                                                  1 . Connectthe positivecable and negativecableto
                                                                      the battery.
      3. Removethe front bumper (seepage 20-85).
                                                                tt.   Enterthe anti-theft
                                                                                        code for the radio,then enter
      4. Removethe right side headlight(seepage 22-79).               the customer'sradio station presets.

      5. Removethe reservetank from the bracket.                1 3 .Set the clock.

      6. Removethe drive belt (seepage 4-26).                   1 4 . Performthe enginecontrol module {ECM)idle learn
                                                                                      (
                                                                      p r o c e d u r es e ep a g e1 1 - 1 3 9 ) .
      7. Removethe three bolts securingthe alternator.

                                            8 x 1 . 2 5m m
                                            22 N.n 12.2kgl.m,




        Disconnect alternatorconnector(A) and BLK
                   the
        wire (B)from the alternator.

                                 8 N.m
                                 10.8kgf.m,6lbf.ft)


                                    \
                                        6




                                                                                                                     4-29
ChargingSystem
 AlternatorOverhaul
 ExplodedView



           -
       .oy."             ROTOR
   W|UF.,    REARBEARING
                          /
       \        \                    /
                    \   ,/          ./           B
                                             FRoNr
                                                 BEARING


               @b.J.y{=RE+LN'"'
                vVFko"-% \  I
                           /
                        qtr*njlv
                                           " )
                                         V ( rV ,                    PULLEY

                        BRUSH                 \11
                                                -\\
                                                                 /        PULLEY
           BRUSH
               HOLOER   HOLDER                                            LOCKNUT
           TNSULATOR      \                       \l             \   /
                \           \  VOLTAGE
                               REGULATOR
                                                   }
                                                  (-             /@
                \-
                           -\:
                        @*F,
                             \



                                 v_re*^i                                            \-a
                                          \gP^@'I


                        TERMINAL
                                     *ffilw9
                        INSULATOR



                                                            REARHOUSING
                                                            ASSEMBLY
                                                INSULATOR
                                                BUSHING




4-30
L
    Special Tools Required                                5 . R e m o v e h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .
                                                                        t
    . Driver07749-0010000
    . Attachment,52x 55 mm 07746-0010400

    NOTE:Referto the ExplodedView as neededduring
    this procedure.

     1, Testthe alternatorand regulatorbeforeyou
        remove them (see page 4-22l,.

     2. Removethe alternator(seepage 4-29).

     3. lf the front bearingneedsreplacing,removethe
        pulley locknutwith a 10 mm wrench (A) and a
        22 mm wrench (B).lf necessary, use an impact
        wrencn.




                                                          6 . Removethe brush holder (A),voltage regulator(B),
                                                             a n dt h e r u b b e rs e a l{ C } .


                      , (( , t tI
                       ; r _l L t
                                                                                             L1i.21---^
                                                                                             tqLJ

       Removethe harnessbracket(A),insulator(B).three                       B-"--|.
       flange nuts (C),and the screw (D),then removethe
       p l a t et e r m i n a l( E ) .




                                                                                         1!q[-dr,:l



                                                                                                                             (cont'd)



                                                                                                                                 4-31
ChargingSystem
 AlternatorOverhaul(cont'dl
 7. Removethe four screws,then removethe rectifier    9. lf you arenot replacing frontbearing
                                                                               the          and/or
    ( A )a n d f o u r i n s u l a t o r ( B ) .                      go        '16.
                                         s                                              the
                                                         rearbearing, to step Remove rotorfrom
                                                         the statordriveendhousing.




                                                     1 0 .Inspectthe rotor shaftfor scoring,and inspectthe
                                                             bearingjournal surfacein the statorhousingfor
                                                                    m
                                                             setzure arks.
   Removethe four flange nuts,then removethe rear
   h o u s i n g A )a n dw a s h e r( B ) .
                (                                             . l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g d a m a g e d ,
                                                                                                                           is
                                                                replacethe alternator,
                                                              . lf both the rotor and the stator housingare OK,
                                                                g o t o s t e p1 1 .
                                                                                                                                               \"
             o\                                      'l
                                                          1 . R e m o v e h e r e a rb e a r i n g s i n ga p u l l e ra s s h o w n .
                                                                        t                         u




                                                                                                                                               f.r,e

4-32
\-

     1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a v a i l a b l eo o l s
                                                            y               t          14. Supportthe stator housingin a vise, and drive out
           shown, installa new rear bearingon the rotor shaft.                             the front bearingwith a brassdrift and hammer.
           NOTE:Installthe bearingusing the inner race.




                                                                                       1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si , s t a l a n e w
                                                                                                                                                       n         l
                                                                                             front bearingin the stator housing.
     13. Removethe front bearingretainerplate.

                                     s
                                     H
                                               q
                                               E
                                     6           e
                                     u           s                                               07749-0010000

                                    f-\
                                      \r-:1
                                    \s---'^/

                                                                                                                                             07746-0010400




                                                                                                                                                              (cont'd
                                                                                                                                                                    )



                                                                                                                                                                 4-33
ChargingSystem
 AlternatorOverhaul(cont'd)
 Rectitier Test                                                              Alternator Brush Inspection

 16. Checkfor continuityin each direction,betweenthe                                                                                   (
                                                                             1 7 . M e a s u r eh e l e n g t ho f b o t h b r u s h e s A ) w i t ha
                                                                                               t
     B terminal and P terminals,and betweenthe E                                   vernier aliper B).
                                                                                            c          {
     t e r m i n a a n d P t e r m i n a l s f e a c hd i o d ep a i r .
                    l                      o
     A l l d i o d e ss h o u l dh a v ec o n t i n u i t yn o n l y o n e
                                                          i                        . l f e i t h e rb r u s hi s s h o r t e r t h a n t h e e r v i c e i m i t ,
                                                                                                                                           s           l
     direction.Because            the rectifierdiodes are designed                   r e p l a c eh e b r u s ha s s e m b l y .
                                                                                                   t
     to allow currentto pass in one direction,and the                              . lf brush length is OK, go to step '18.
     rectifieris made up of eight diodes (four pairs).you
     musttest each diode in both directionsfor                                    Alternator Brush Length:
     continuitywith an ohmmeterthat has diode                                     Standard(New): 10.5mm (0.41in.)
     checkingcapability: total of 16 checks.
                                    a                                             ServiceLimit: 1.5 mm (0.06in.)

      . lf any diode is faulty. replacethe rectifier
        assembly.{Diodesare not availableseparately.)
      ' lf all the diodes are OK, go to step 17.




                                 /--:',t-     -L   . --
                             -          -o \--       l'-=
                                                                                                                                                                     \"
                                                                             Rotor Slip Bing Test

                                                                             18. Checkthat there is continuitybetweenthe slip rings
                                                                                 {A).

                                             B P "                                 . lf there is continuity,go to step 19.
                                                                                   . lf there is no continuity,replacethealternator.




                                                            P,

                                                            P.

                                                            P,
                                                            P.




                                                                             1 9 . Checkthat there is no continuitybetweeneach slip
                                                                                   ring and the rotor (B) and the rotor shaft (C).

                                                                                   . lf there is no continuity,goto step 20.
                                                                                   . lf there is continuity,replacethe alternator.
                                                                                                                                                                     \r'a

4-34
Stator Test

20. Checkthatthereis continuitybetweeneach pair of
    leads(A).

      lf there is continuity,go to step 21.
      lf there is no continuity,replacethe alternator.




                         '--l-- --i


2 1 .Checkfor no continuitybetweeneach lead and the
    coil core (B).

    . lf there is no continuity,goto step 22.
    . lfthere is continuity,replacethe alternator.

22. Assemblethe alternatorin reverseorder of
               and note these items:
    disassembly,

    . Be carefulnot to get any greaseor oil on lhe slip
      nn g s .
    . lf you removedlhe pulley,tighten its locknutto
      1 1 1N . m ( 1 1 . 3 g f m , 8 1 . 7l b f . f t ) w h e n y o u n s t a l l
                          k                                          i
      it.




                                                                                    4-35
GruiseControl
 ComponentLocationIndex

                                                                          CRUISE  CONTROL  INDICATOR
                                                                          (Builtinto gaug6assembly)




  CLUTCH PEDAL POSITION                 CRUISE CONTROL UNIT
  swtTcH                                         page
                                        lnputTest,   4-40
      page
  Test,   4-45
  Clutch    Adjustment,
        Pedal
  page12-4                        BRAKE PEDAL        SWITCH
                                              POSITION
                                  Test,page22-84
                                  PedalHeight         page'19-6
                                             Adjustment,



                                                              -   l   l
                          t.-   _,-    _




  CRUISECONTROL
  ACTUATOR
      page
  Test,   4'43                                                               ACTUATORCABLE
             page
  Replacement, 4-44                                                          Adjustment,page4-45



                                                                                                       \-a
4-36
CircuitDiagram

                                                                                           '
                                                                                               No.aloAl    USAnod.l
                                                                                               No.20
                                                                                                   itoAl   C.md! modrl
                 fUS'/iILAY IOX
        UISEF NOOD


                                          -to         ots     BU/YIL

                                           lcl H0Tii0llilll
                                           mdSTARTlllll




                                                    1 Honilsffroi




                                  2   6                    1        1          1      3
                                                           uNtT
                                                cnu6EcoNTnoL                          l0




                                                                              PEDAL
                                                                        CTuICII
                                                                            swtrct
                                                                        P0sm0




                                                                                                                         4-37
CruiseControl
 Symptom TroubleshootingIndex
 NOTE:
 ' The numbersin the table showthetroubleshootingsequence.
 . Beforetroubleshooting.
   - checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A)fuse in the
     under-hoodfuse/relaybox,
   - checkthat the horn sounds.
   - checkthe tachometerto see if it works properly.
   - checkthe speedometer see if it works properly.
                           lo

              Symptom                                         Diagnostic procedure                         Also check for
  Cruisecontrol cannot be                 1. Checkmain switch (seepage 4-42)                             . Poorground:
  set                                     2. CheckSET/RESUME/CANCEL        switch (seepage 4-42)           G501
                                          3. Test brakepedal positionswitch (seepage 22-84)and check     . Opencircuit,
                                             its adjustment{seepage 19,6)                                  loose    or
                                          4. Test clutch pedal positionswitch (seepage 4-45)and check      disconnected
                                             its adjustment(seepage 12-41                                         i
                                                                                                           t e r mn a l s :
                                          5. Checkcruisecontrol unit {seepage 4-40}                        L TG R N ,
                                          6. Checkvehiclespeed sensor(VSS)(seepage 22-65)                  BLI(ORN.
                                                                                                           GRY/RED,      BLU.
                                                                                                           LTBLU,
                                                                                                           BLUAA/HT
  Cruisecontrol can be set                1. Check cruise               bulbin gauge
                                                         controlindicator           assembly
                                                                                           {see          . Poor ground:
  but indicatorlight does                    page 22-631                                                   G501
  not go on                               2. Check cruisecontrolunit(seepage4-40)                        . Open circuit,
                                                                                                           looseor
                                                                                                           disconnected
                                                                                                           termrnats:
                                                                                                           YEL,BLUA/EL
  ar, 'i.a   c^aa.l   ic                  1. Checkvehiclespeed sensor(VSS){seepage 22-65)
                    y
  n o t i c e a b l h i g h e ro r           Checkcruisecontrol actuator{seepage 4-43)
  lower than what was set                 2. Checkcruisecontrol unit (seepage 4-40)

  Excessive  overshooting                 1. Checkcruisecontrol actuator(seepage 4-43)
  or undershooting  when                  2. Checkvehiclespeed sensor(VSS)(seepage 22-65)
  trying to set speed                        Checkcruisecontrol unit (seepage 4-40)
                                          3.
  Speedfluctuationon a                    1. Checkvehiclespeedsensor(VSS)(seepage22-65)
  flat road with cruise                      Checkcruisecontrol actuator(seepage 4-43)
  control set                             2. Checkcruisecontrol unit (seepage 4-40)

  Vehicledoes not                         1. CheckSET/RESU ME/CANCEL     switch (seepage 4-42)          Open circuit,loose
  decelerate accelerate
                  or                      2. Checkcruisecontrol unit {seepage 4-40)                     or disconnected
  accordingly      when SET/                                                                            terminals:
  RESUME/CANCEL                button                                                                   GRY/RED,
  is pushed                                                                                             LT GRN/BLK
  Set speed does not                      1. Testclutch pedal positionswitch (seepage 4-45)and check    Shortto groundin
  cancel(enginerpm stays                     its adjustment(see page 12-4)                              the LTBLUwire
  h i g h )w h e n c l u t c hp e d a l   2. Checkcruisecontrol unit (seepage 4-40)
  is pushed
                                          '1.
  Set speeddoes not                             Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose
  cancelwhen brakepedal                         its adjustment(seepage 19-6)                            or disconnected
  is pushed                               2.    Checkcruisecontrol unit (seepage 4-40)                  terminals:
                                                                                                        WHT/BLK
                                                                                                                                g ,



4-38
        svmptom                                 Diagnosticprocedure                     Also check for
Set speeddoes not              1. Checkmain switch (seepage 4-42)                     Short to power in
cancelwhen main switch         2. Checkcruisecontrol unit (seepage 4-40)              the LT GRNwire.
is oushed FF O
Set speeddoes not              1. CheckSET/RESU ME/CANCEL     switch (seepage 4-42)   Open         loose
                                                                                            circuit,
c a n c ew h e n C A N C E L
         l                     2. Checkcruisecontrol unit (seepage 4-40)              or disconnected
button is pushed                                                                      terminals:
                                                                                      GRYiRED,
                                                                                      LTGRN/BLK
Set speedwill not              1. CheckSET/RESU ME/CANCEL     switch (seepage 4-42)   Open circuit,loose
resume henRESUME
        w                      2. Checkcruisecontrol unit {seepage 4-40)              or disconnected
button is pushed(with                                                                 terminals:
main switch on, and set                                                               L TG R N / B L K
speedtemporarily
cancelledby pressingthe
brakeDedal)




                                                                                                      4-39
CruiseGontrol
 CruiseControl Unit Input Test
 SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)
                                                                                    and precautions
                                                                                                  and
 procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.

  1. Disconnect 14Pconnectorfrom the control unit.
              the

  2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.

     . lf the terminalsare bent, loose,orcorroded, repairthem as necessary,
                                                                          and recheckthesystem.
     . lf the terminalslook OK, go to step 3.




                   Wire sideof
                   femaleterminals




  3. With the 14Pconnectordisconnected,
                                      make these inDuttests.

       Cavity    Wire     Test condition                      Test:Desiredresult                                      ifresuh
                                                                                                      Possiblecause is notobtained
                BRN/WHT Connectbattery                Checkthe operationof the                       ' Faultyactuator
                             power                    magneticclutch:Clutch                          . P o o rg r o u n d( G 3 0 1 )
                                                      s h o u l dc l i c ka n d o u t p u tl i n k   . An open in the wire
                                                      should be locked.                              . Shon to ground (arcswhen
                                                                                                       Doweris connected)
        2          BLU       lgnitionswitch ON        Checkfor voltageto ground;                     . Faultybrakepedal position
                             (ll),main swltch ON      There should be 0 V with lhe                     switch
                             and brakepedal           pedal pressedand battery                       . A n o p e ni n t h e w i r e
                             pressed, then            voltagewith the pedal                          . Open in cruisecontrol main
                             reteaseo                 released.                                        swrtcn
                                                                                                     . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
                                                                                                       under/dash       fuse/relavbox
        3          BLK  U n d e ra l l c o n d i t i o n s Checkfor continuityto                     . P o o rg r o u n d( G 5 0 1 )
                                                           grouno:                                   . An open in the wire
                                                           There should be continuitv
                BLIVORN l g n i t i o n w i t c hO N
                                       s                   Checkfor voltageto ground:                    B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
                        flr)                               Thereshould be battery                                        f
                                                                                                         under-dash use/relay            box
                                                           vottaqe.                                      An oDenin the wire
        5       WHT/BLK Brakepedal pressed, Checkfor voltageto ground:                                   B l o w nN o . 7 { 1 5A ) f u s ei n t h e
                        then released                      There should be battery                       under-hoodfuse/relaybox
                                                           voltagewith the pedal                         Faultybrakepedal position
                                                           pressed,and 0 V with the                      SWIICN
                                                           pedal released.                               A n o D e ni n t h e w i r e




4-40
  Cavity    Wire     Test condition                                Test:Desiredresult                                               is
                                                                                                            Possible il result notobtained
                                                                                                                     cause
    6      GRYiRED Setbuttonpushed                          Checkfor voltageto ground:                       B l o w nN o . 7 ( 1 5A ) f u s e i n t h e
                                                            Thereshould be battery                           under-hoodfuse/relaybox
                                                            voltage,                                         Faultyhorn relay
                                                            W h e nt e s t i n g e r m i n a lN o . 6 ,
                                                                                  t                          Faultysevresume/cancel
                                                            there should be no voltageon                     swrtch
                                                            t e r m i n a lN o . 7 .                         Faultycable reel
    7      LT GRN/     Resumebutton                         Checkfor voltageto ground:                       An open in the wire
            BLK        pusneo                               Thereshould be battery                           Shon to ground (horn sounds
                                                            voltage.                                         when button is pressed)
                                                            W h e nt e s t i n g e r m i n a lN o . 7 ,
                                                                                  t
                                                            there should be no voltageon
                                                            t e r m i n a lN o . 6 .
             BRN       Connectbattery                       Checkthe operationof the                        . Faultyactuator
    11     BRNI/EL power to the BRN                         actuatormotor: You should                       . An open in the wire
                      t e r m i n a la n d g r o u n d      be ableto hear the motor.
                      to the BRNIVEL
                      termrnal
    10     BLUIVEL    lgnitionswitch ON                     Attachto groundi                                 Blown No. 10 (7.5A) fuse in
                       0r)                                  C r u i s e n d i c a t o l i g h ti n t h e
                                                                       i              r                      the under-dash        fuse/relaybox
                                                            g a u g ea s s e m b l y h o u l dc o m e
                                                                                       s                     Blown cruise indicatorbulfl
                                                            on.                                                         g
                                                                                                             F a u l t y a u g ea s s e m b l y
                                                                                                             An open in the wire
    12     BLU/VVHT lgnitionswitch ON                       Checkfor voltage between                         FaultyVSS
                       (ll) and main switch                 thE BLU/VVHT ANdBLK (+)                          An openin thewire
                       ON; raisethe front of                ( )terminals:                                    Shortto ground
                       the vehicle,and                      T h e r e s h o u l d b e 05 V o r
                       rotateone wheel                      more repeatedly.
                       s l o w l yw h i l e h o l d i n g
                       the other wheel
    13      LTGRN      lgnition    switchoN                 Check voltage ground:
                                                                 for       to                                B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
                       { l l )a n dm a i ns w i t c h       Thereshouldbe battery                            under-dash      fuse/relaybox
                       ON                                   voltage.                                         Faultymain switch
                                                                                                             An oDenin the wire
    14      LT BLU     C l u t c hp e d a l                 Checkfor continuityto                            Faultyclutch pedal position
                       reteaseo                             grouno:                                          swtlcn
                                                            T h e r es h o u l db e c o n t i n u i t y .    P o o rg r o u n d( G 5 0 1 )
                                                            N O T E : T h e r s h o u l db e n o
                                                                                e                            Incorrect    clutchswitch
                                                            continuitywhen the clutch                        adjustment
                                                            oedal is Dressed.                                An open in the wire

lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK,
the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works
properly,replacethe cruisecontrol unit.




                                                                                                                                                    4-41
CruiseControl
 Main Switch Test/Replacement                           Set/Resume/Cancel
                                                                       Switch Test/
                                                        Replacement
  1 . Removethe driver's dashboardlower cover (see
      page 20-59).
                                                        1. Removethe two screws.then removethe switch.
    Release clips of the main switch and push the
            the
    main switch 1A)out of the panel,then disconnect
    the 5P connector(B)from the main switch.




                                                          Checkfor continuitybetweenthe terminalsin each
                                                          switch positionaccordingto the table.

                                                          . lfthere is continuity,and it matchesthe table, but
    Checkfor continuitybetweenthe terminalsin each          switchfailure occurredon the cruisecontrol unit
    switch positionaccordingto the table. lf the            input test, checkand repairthe switch circult.
    continuityis not as specified,replaceillumination     . lf there is no continuityin one or both positions,
    bulbs (C)or the switch.                                 replacethe switch.

    \-------11v1                      1          4
                                                          \
                                                              ;"itl*
                                                                         Terminal
                                                                              '\               2
     Position
                                                                       sET(ONt      CF              --o
                OFF           (9             @                                              --o
                                                                RESUME
                                                                     ION)           o
                ON         o @ o \J          o                   CANCEL{ON}
                                                                                    o




                                                                                                                 r\--


4-42
CruiseControlActuatorTest
1. Disconnect 4P connector(A) from the cruise
              the                                                                     6. Checkthe operationof the actuatormotor in each
   control actuator(B).                                                                  output linkagepositionaccordingto the table.You
                                                                                         should be able to hear the motor.

                                                                                              Batterypower      Output linkageposition
                                                                                               Dolarities
                                                                                                            FULt MIDDLE  FUtL
                                                                                                            CLOSE PO$TIONOPEN
                                                                                          No,4     No.3     The    The   The
                                                                                          Terminal Terminal motor motor motor
                                                                                                            runs. runs. stoDs,
                                                                                          No.3     N o .4   The    The   The
                                                                                          Terminal Terminal motor motor motor
                                                                                                            sIoos. runs. runs.

                                                                                                                     OUTPUTLINKAGE
2. Removethe cover (A),and checkthe output linkage
   (B)for smooth movement.


                                                   ,to




                                                                                                       FULLCLOSE


                                                                                      1 . lf the actuatormotor does not operateas specified,
                                                                                          replacethe cruisecontrol actuatorassembly,




   Connectbatterypower to the No, 2 terminal and
   g r o u n dt o t h e N o . 1 t e r m i n a l .

                                                                      c
   C h e c k o r a c l i c k i n g o u n df r o m t h e m a g n e t i c l u t c h .
           f                     s
   The output linkageshould be locked.

 5 . lf the output linkageis not locked,replacethe
     cruisecontrol actuatorassembly,




                                                                                                                                       4-43
CruiseControl
 CruiseControlActuator/CableReplacement
  1 . Fully open the cruisecontrol link by hand,then   3 . Removethe actuatorcover (A),then removethe
      removethe cruisecontrol cable{A) from link.         actuatorcable (B)from the cruisecontrol actuator.
      Loosenthe locknut(B),and removethe cablefrom
      the bracket.




                                                       4 . Installin the reverseorder of removal,and adjust
                                                           the free play at the throttle linkageafter connecting
  2 . Disconnect 4P connector,and removethe three
               the                                         the actuatorcable.
    bolts securingthe cruisecontrol actuator.




               6x1,0mm
               12 N.m (1.2kgf.m,8.7lbf.ft)




                                                                                                                   \rla
4-44
ActuatorCableAdiustment                                    ClutchPedalPositionSwitch Test
1. Checkthat the actuatorcable{A) moves smoothly           1. Disconnect 2P connectorfrom the clutch pedal
                                                                        the
   with no binding or sticking.                               positionswitch (A),

                                                             CLUTCH               2P
                                                                             SWITCH CONNECTOR
                                                                      POSITION
                                                                  PEOAL
                                                                 T e r m i n a l s i do f
                                                                                      e
                                                                 m a l et e r m i n a l s




 2. Startthe engine.

 3. Measurethe amount of movementof the output
    linkage(B) until the engine speedstartsto increase.
    At first, the output linkageshould be locatedat the      Removethe clutch pedal positionswitch.
    fully closedposition(C).The free play (D)should be
    3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2n , ) .
                                         i                   Checkfor continuitybetweenthe terminals
                                                             accordingto the table.
 4. lf the free play is not within specs,loosenthe           . lf the continuityis not as specified,replacethe
    locknut(E).and turn the adjustingnut (F)untilthe           clutch pedal positionswitch.
    free play is as specified, then retightenthe locknut     . lf OK, installtheclutch pedal positionswitch and
                                                               adjustthe pedal height (seepage 12-4).

                                                                        Terminal
                                                                Cl"t"h P"d"l I              1         2
                                                                PositionSwitch
                                                                  PRESSED
                                                                  RELEASED                  o         o




                                                                                                           4-45

				
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