Page 1426 of 1681

- G503 (Hatchback), G751
NOTE: Wires shown without color codes are black.
LEFT RIGHTBRAKE BRAKE
LEFT LIGHT/ RIGHT LIGHT/
REAR LEFT TAIL. REAB RIGHT TAIL-
TURN neln LIGHT TURN REAR LIGHT
SIGNAL PARKING LEFT Paqes SIGNAL PARKING RIGHT PAgCS
LIGHT LIGHT BAcK-uP 110-6 LIGHT LIGHT BACK.UP 110-6
Paqe Paoe LIGHT and Page Page LIGHT andtto*-s ttd-tz Paoe 110 110'12 110-3 110'12 Page 110 110-12
1-) 1- (-) r--r 1- 1-) f-) t--t(_r \_r \-/ r---' \-,, \-,, \.'/
LLIJ L-L.I
REARwtNDowWIPERMOTORPage 92
tl
PHOTO 108PHOTO 148
HATCHLATCHPage 114-3
t. I
lltl
cnv I
1 g c52a
HATCHOPENERSWITCHPage 134
HATCHOPENERACTUATORPage 134
HIGHMOUNTBRAKELIGHTPage 110'6
tl
tl
1 g c756
| ':::2"'
I (GS andI GS-R)
.l .rl' t- GS
: 'YF/o% :*^I a 1lz
I
IL
ALU
1
atu/
1
REO
c527PHOfO 106
HATCH KEYCYLINDERswtrcHPage 130
c530PHA|O 137
BLU
1c529
I
! cTsl
c525
POWERANTENNAMOTOR LICENSEPaoe 151 PLATEpu6rctos LIGHTS
|.--1 Page 110-12
| | l-t r-t
I | \-., \-,,
T;,. U
I iHi'$t"" I
I :3:.:ll: I
I ^ -:-"^ I
tt*l
tll
I I
' l e:3?.,,,
ltl-ll-
14-7
Page 1544 of 1681
POWEBDOOR LOCKCONTROL UNITPHO|O 82
;"-"str-_
YEL/FEDWHT/FEOalU/YEUFED
YEUBEO
SECURITY SYSTEMcoNNECTOR (OPTION)
o"n-"! [ ;c,fo?uo ,,,
t | 9,o""1"""
"""-ii*r*"
___LL "",9t9,,(Not Used)
LOCK
ry"
'r
I
_L__
c506
BLU/BLU/FEO
YEUAED
DRIVER'SDOOR LOCKACTUATOR
f) BrK
ll
IKEYc511
WHT/FED
WHT/RED
c610PHOTO 85
YEUFED
6
YEL/BED
1
YEURED
WHT/FEO
WHT/RED
11
WHT/REO
WHT/FEO
"a,-rro [l
#:,L," f, ,"ru_1,i" "onn"",o,,
9:::. ," "" "'o I lSY.Jnt'l?,, ""...r
F,%t3* ,'"n^J" fi "t"%',3 '*
FRONTPASSENGER'SDOOR LOCKACTUATOR
ffi*l-i"'JJ.r, Ui3!
2
BLKFED
DRIVER'SDOORKEYCYLINDERswtTcH
BLK,l
BLK
L--L---,-
c633inoroed sYi,::f.,"6",*
c4o1 WHIFED ! 13s
PHoraTe
C516
c421 wnrneo ! f][f[eoffl!n"cto''p4oto56 ! pre'sent 'n all carst
a
I
Ia
c506#{':l
",.,
ALK
l::t-'^^.
130-1
Page 1545 of 1681
Power Door Locks (cont'd)
- Sedan
10
!. -T----'t UNDER.DASH
i IHP'* ![[]:':'*'LJ----J
n "r,n"tn tr t"%% u,
"";f F,x9B^
rc I ceoa
LT GFI{
4
LT GRN
-"4{"*
--'
;;:*,*uu
n"","..
I secunrrvI SYSTEMi CONNECTOR
I (oPloil)
!"'-!x',}*
19
!T GRN
BLU/AED
14
LT BT]U
Ic611PHOTO 85c634PHOTO 86
2
BLKBEOFRONTPASSEN.GER'SoooRKEYCYLINDERSWITCH
L-t--*J-
DRIVER'SDOORKEYCYLINOERSWITCHPHOfO A5
FRONTPASSEN-GER'SDOORLOCKSwlTCH
DRIVER'SDOORLOCKswtTcH
8LK
1
ALX
I-"a
2
at(
ALK
2c634 "noto tt
PHO|O 86c611PHOfO 85
BLK
130-2
Page 1610 of 1681

Connector ldentification and Wire Harness Routing (cont'd)
Connector
ol
Terminal
Number of
Cavities/
Color
LocationConnects toNotes
Rear Wire Harness (Hatchback)
c421
c422
cs03
c504
c505
UCUO
c507
c508
c509
c510
c511
c512
cs13
c514
c515
ucto
c518
c519
c520
c521
c522
c523
uczc
c526
c527
c528
c529
c530
c531
1 6-GRY
14-GRY
8-GRN
16-GRN
14-BLU
25.GRY
2.GRY/BRN
1-WHT
1-WHT
8-GRY
3-BRN
1-WHT
2-GRY
2-GRY
2-GRY
20-cAVtry
3-GRY
2.GRY
6-GRY
6-GRY
2-GRY
6-GRY
2-BRN
4.GRY
2.GRY
6-GRY
3-GRY
2-GRY
4-BRN
Behind left kick panel
Behind left kick panel
Behind dashboard lower cover
Behind dashboard lower cover
Behind dashboard lower cover
Driver's door
Center floor
Center floor
Left quarter panel
Top of tuel tank
Top of fuel tank
Right quarter panel
Right quarter panel
Left quarter panel
Left quarter panel
Lett quaner panel
Left side corner of cargo area
Left side corner of cargo area
Left side corner of cargo area
Left side corner of cargo area
Center of cargo area bulkhead
Right rear corner of cargo area
Right side of cargo area
Right side of cargo area
Right side of cargo area
Center of cargo area bulkhead
Center of cargo area bulkhead
Center of cargo area bulkhead
Left side corner of cargo area
Main wire harness
Main wire harness
Under-dash fuse/relay box
Under-dash fuse/relay box
Dashboard wire harness
Driver's door wire harness
Driver's seat belt switch
Parking brake switch
Driver's door switch
Fuel pump sub-harness
Fuel tank unit
Passenger's door switch
Right rear speaker
Left rear speaker
Noise condenser
Rear wire harness
Power antenna motor
Cargo area light
Trailer lighting connector
Lett taillight
License plate lights
Right taillight
Hatch wire harness
Hatch wire harness
Hatch wire harness
Hatch latch
Hatch key cylinder switch
Hatch opener actuator
Hatch opener relay
G502
\,CUJ
Lett side of floor
Center ot cargo area bulkhead
Body ground, via rear wire hamess
Body ground, via rear wire hamess
. = Inline connector: mav not be oresent in all cars.
203-14
Page 1616 of 1681
Connector ldentification and Wire Harness Routing (cont'd)
Connector
or
Terminal
Number ot
Cavities/
Color
LocationConnects toNotes
Driver's Door Wire Harness
c506
c602
c603
c604
c605
c605
UOUO
vou/
c608
c609
c609
c610
c611
c612
25.BLK
2-GRY
4-GRY
14-GRY
8-BLK,^/VHT
3-GRY
2-GRY
3.GRY
1O-GRN
1O-GRY
16-GRY
6-GRY
2-GRY
1-BRN
Driver's door
Driver's door
Driver's door
Driver's door
Behind mirror control panel
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Driver's door
Rear door wire harness
Driver's door speaker
Driver's power window motor
Power door lock control unit
Left power mirror
Left power mirror
Left hveeter
Driver's door lock switch
Power mirror switch
Power window master switch
Power window master switch
Driver's door lock actuator
assemDly
Driver's key cylinder switch
Power window master switch
Hatchback
Sedan
Hatchback
Sedan
Sedan
rl-
Page 1618 of 1681
Connector ldentification and Wire Harness Routing (cont,d)
Connector
or
Terminal
Numbea ot
Cavities,l
Color
LocationConnects toNotes
Front Passenger's Door Wire Harness
c401
c627
c628
vozv
c629
lJOOU
c631
uo.tz
c633
uo.tz+
25-BLK
2-GRY
2-GRY
8.BLK/VVHT
3.GRY
2-GRY
.t-
h T
5.GRY
Z-I'FI T
3-GRY
Front passenger's door
Front passenger's door
F[ont passengefs door
Behind cover panel
Front passenger's door
Front passenger's door
Front passenger's door
Front passenger's door
Front passenger's door
Front passenger's door
Main wire harness
Front passenger's door speaker
Front passengefs power window
motor
Right power mirror
Right power mirror
Right tweeter
Front passenger's door lock
switch
Front passenger's power window
switch
Front passenger's door lock
actuator
Front passenger's door key
cylinder switch
Hatchback
Sedan
I
203-22
Page 1644 of 1681

I
I
Standards and Service Limits
Cylinder Head/Valve Train (B18Bl engine)Section 6
*: Measured between the camshaft and rocker arm.
NH: NIHON HATSUJO manufactured valve spring
CH: CHUO HATSUJO manufactured valve spring
MEASUREMENTSTANDARD (NEW) I SERVICE LIMIT
Compression250 rpm and wide open throttle Minimum
kPa (kgf/cm' , psi) Maximum variation930 (9.5, 135)200 Q.0,281
Cylinder headWarpageHeightta,|* - 132.05 (5.195 - 5.199)0.05 (0.002)
CamshaftEnd playCamshaft-to-holder oil clearanceTotal runoutCam lobe height lNEX
0.05 - 0.15 (0.002 - 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 (0.001) max.33.7 16 11.327 4l33.528 ( 1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
ValveValve clearance (Cold)" lNEX
Valve stem O.D. lNEX
Stem-to-guide clearance lNEX
0.08 - 0.12 (0.003 - 0.005)0.16 - 0.20 (0.006 - 0.00816.580 - 6.590 (0.2591 - 0.2594)6.550 - 6.560 (0.2579 - 0.2583)
0.02 - 0.05 (0.001 - 0.002)0.05 - 0.08 (0.002 - 0.003)
ouu to.rutt6.52 rc.2571.0.08 (0.003)
0.1 1 (0.004)
Valve seatwidth lNEX
stem installed height lNEX
1 .25 - 1.55 (0.049 - 0.061 )1.25 - 1 .55 (0.049 - 0.061 )40.765 - 41.235 (1.6049 - 1.6234142J65 - 43.235 (1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 (1.6333)
43.485 (1.71201
Valve springFree length (Reference)IN NHCHEX
41.27 (1.6251
41.28 (1.625)
44.32 t1-7 451
Valve guidet.D. lNEX
Installed height lNEX
6.61 - 6.63 (0.260 - 0.261)6.61 - 6.63 (0.260 - 0.261)13.7 5 - 1 4.25 (0.541 - 0.561 )15.75 - 16.25 (0.620 - 0.640)
6.6s (0.262)
6.65 (0.262)
Page 1645 of 1681

Engine Block (81881 engine)Section 7Unit of length: mm (in)
3-3
\
Yl
R: RIKEN manufactured piston ringT: TEIKOKU PISTON RING manufactured piston ring
E' - Declror
MEASUREMENTSTANDARD (NEW}SERVICE LIMITCylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
0.07 (0.003) max.81.00 - 81.02 (3.189 - 3.190)0.10 (0.004)
81.07(3.192)0.05 (0.002)
0.25 (0.010)PistonSkirt O.D. at 15 mm (0.6 in) from bottom of skirtClearance in cylinderGroove width (For ring) TopSecondoil
80.98 - 80.99 (3. 1 88 - 3. 1 89)0.01 - 0.04 (0.0004 - 0.0016)1 .030 - 1.040 (0.0406 - 0.0409)1.230 - 1.240 (0.0484 - 0.0488)2.805 - 2.820 (0.1 104 - 0. 1 1 10)
80.97 (3.188)
0.05 (0.002)1.06 (0.042)
1.26 (0.050)
2.84 (0.112!.Piston ringRing-to-groove clearance TopSecond RT
0.045 - 0.070 (0.0018 - 0.0028)0.040 - 0.065 (0.0016 - 0.0026)0.045 - 0.070 (0.0018 - 0.0028)
0.13 (0.0051
0.13 (0.005)
0.13 (0.005)
Ring end gap Top
Secondoil
HT
RT
0.20 - 0.35 (0.008 - 0.014)0.20 - 0.30 (0.008 - 0.012)0.40 - 0.55 (0.016 - 0.022)0.20 - 0.50 (0.008 - 0.020)0.20 - 0.45 (0.008 - 0.018)
0.60 (0.024)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
0.70 (0.028)Piston Pino.D.Pin-to-piston clearance20.994 - 21.000 (0.8265 - 0.8268)0.010 - 0.022 (0.0004 - 0.0009)Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.013 - 0.032 (0.0005 - 0.0013)20.968 - 20.981 (0.8255 - 0.8260)48.0 (1 .89)0.15 - 0.30 (0.006 - 0.012)0.40 (0.016)CrankshaftMain journal diameterNo. 1, 2, 4 and 5 journalsNo. 3 journalRod journal diameterTaperOut-of-roundEnd playRunout
54.976 - 55.000 (2.1644 - 2.1654)54.970 - 54-994 (2.1642 - 2.1651144.976- 45.000 (1.7707 - 1.771710.005 (0.00021 max.0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.014)0.03 (0.001) max.
0.010 (0.0004)0.010 (0.0004)
0.45 (0.018)
0.05 (0.002)Bea ringMain bearing-to-journal oil crearanceNo. 1, 2, 4 and 5 journalsNo. 3 journalRod bearing-to-journal oil crearance
0.024 - 0.042 (0.0009 - 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.020 - 0.038 (0.0008 - 0.0015)
0.050 (0.0020)
0.060 (0.0024)0.0s0 (0.0020)
L rlllllllllrltruE